Aerosol-generating items
The planar aerosol-generating article with susceptor materials heated by a magnetic field addresses the heating inefficiencies of conventional designs, ensuring uniform heating and cost-effective aerosol production.
Patent Information
- Application Number
- JP2025531985
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-12-23
- Filing Date
- 2023-12-21
- Publication Date
- 2025-12-11
AI Technical Summary
A significant portion of the aerosol-forming substrate in conventional aerosol-generating articles does not get sufficiently heated during use, leading to wasted material and increased manufacturing costs without contributing to aerosol delivery.
An aerosol-generating article with a planar design and susceptor materials in thermal communication, heated by a varying magnetic field, ensures uniform and efficient heating of the aerosol-forming substrate, utilizing materials like aluminum, iron alloys, and graphite.
The solution provides rapid and uniform heating of the aerosol-forming substrate, minimizing waste and reducing manufacturing costs while enhancing aerosol delivery efficiency.
Smart Images

Figure 2025540147000001_ABST
Abstract
Description
[Technical Field]
[0001] The present disclosure relates to an aerosol-generating article that includes an aerosol-forming substrate. [Background technology]
[0002] A typical aerosol-generating article may appear similar to a conventional cigarette. For example, such an aerosol-generating article may be a substantially cylindrical article comprising an aerosol-forming substrate and other components, such as a mouthpiece filter element, all wrapped in cigarette paper. The dimensions of a typical aerosol-generating article are often similar to those of a conventional cigarette.
[0003] Studies have shown that in such typical aerosol-generating articles that include a plug of aerosol-forming substrate, a significant portion of the plug of aerosol-forming substrate may not be heated sufficiently to form an aerosol during use. This is undesirable because this portion of the plug of aerosol-forming substrate contributes to the costs of manufacturing and shipping the aerosol-generating article but does not contribute to the aerosol delivered to the end user. This can be true regardless of the method by which the aerosol-forming substrate is heated, for example, whether a resistance heater or an induction heater is used, and regardless of whether the plug of aerosol-forming substrate is heated from the inside or the outside.
[0004] It is an object of the present disclosure to provide an aerosol-generating article in which a larger portion of the aerosol-forming substrate of the aerosol-generating article is heated sufficiently to form an aerosol during use. Summary of the Invention
[0005] According to the present disclosure, there may be provided an aerosol-generating article comprising an aerosol-forming substrate for generating an aerosol, the aerosol-generating article being a planar aerosol-generating article having a base defined by a length extending in the x-direction, a width extending in the y-direction, and a height extending in the z-direction, and the aerosol-generating article also further comprises one or more susceptor materials disposed in thermal communication with the aerosol-forming substrate.
[0006] According to the present disclosure, there may be provided an aerosol-generating article comprising an aerosol-forming substrate for generating an aerosol, the aerosol-generating article comprising a substantially planar upper surface defined by a length extending in the x-direction and a width extending in the y-direction, and a substantially planar lower surface defined by a length extending in the x-direction and a width extending in the y-direction. The substantially planar upper surface and the substantially planar lower surface may be spaced apart vertically from each other by a height defined in the z-direction. The aerosol-generating article also further comprises one or more susceptor materials disposed in thermal communication with the aerosol-forming substrate.
[0007] According to the present disclosure, an aerosol-generating article for use in an aerosol-generating device may be provided. By way of example, the aerosol-generating article may be as described in any of the preceding paragraphs. The aerosol-generating article may have a substantially planar upper surface and a substantially planar lower surface. The upper and lower surfaces may be vertically spaced apart from each other by a height defined in the z-direction. The aerosol-generating article may further include an aerosol-forming substrate and one or more susceptor materials. The one or more susceptor materials may be disposed in thermal communication with the aerosol-forming substrate.
[0008] The substantially planar top surface may be defined by a length extending in the x-direction and a width extending in the y-direction.
[0009] The substantially planar lower surface may be defined by a length extending in the x-direction and a width extending in the y-direction.
[0010] The one or more susceptor materials function as heaters to provide heat to the aerosol-generating article. Heating of the one or more susceptor materials can occur when the aerosol-generating article is placed in a varying magnetic field, which results in heating of the susceptor materials by one or both of eddy current heating and magnetic hysteresis. Such a varying magnetic field can be generated by supplying an alternating current to an inductor coil. Preferably, the inductor coil forms a component part of an aerosol-generating device to which the aerosol-generating article is coupled.
[0011] The aerosol-generating article of the present disclosure is generally flat and thin. In combination with one or more susceptor materials disposed in thermal communication with the aerosol-forming substrate, a generally flat and thin aerosol-generating article is provided, thereby providing rapid and efficient heating of the aerosol-forming substrate and improved uniformity in heating through its thickness. The aerosol-forming substrate is preferably porous and / or low-density, thereby reducing resistance to airflow through the aerosol-forming substrate (e.g., when the aerosol-generating article has an airflow path extending through the aerosol-generating article). The aerosol-generating article preferably does not contain any single-use plastic, thereby providing an aerosol-generating article with improved sustainability.
[0012] Preferably, the one or more susceptor materials are in direct contact with the aerosol-forming substrate.
[0013] Advantageously, one or more susceptor materials may be incorporated into the aerosol-forming substrate. Particles of the susceptor material may be dispersed within the aerosol-forming substrate.
[0014] The one or more susceptor materials may be incorporated into the aerosol-generating article as one or more strips, threads, or wires of susceptor material. The one or more strips, threads, or wires of susceptor material may be disposed in the airflow path of the aerosol-generating article.
[0015] The one or more susceptor materials may be incorporated into the aerosol-generating article as one or more sheets or layers of susceptor material. The one or more sheets or layers of susceptor material may be disposed within the airflow path of the aerosol-generating article or at least partially define the airflow path of the aerosol-generating article. The one or more sheets or layers of susceptor material may cover an outer portion of the aerosol-generating article. The one or more sheets or layers of susceptor material may form a structural component of the aerosol-generating article. At least one of the one or more susceptor materials or layers may be formed as a mesh of susceptor material.
[0016] Advantageously, the aerosol-generating article may include multiple susceptor regions spaced apart from one another and arranged in thermal communication with the aerosol-forming substrate, the multiple susceptor regions comprising or consisting of one or more susceptor materials. Spaced apart from one another, the different susceptor regions allow selective heating of different regions or portions of the aerosol-forming substrate by the different susceptor regions. Conveniently, the multiple susceptor regions may be spaced apart from one another in the X direction. The multiple susceptor regions may comprise one or more susceptor materials overlaid on or incorporated into the paper-based substrate or aerosol-forming substrate.
[0017] The susceptor material may include one or more materials selected from the list consisting of aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.
[0018] The upper and lower surfaces may be parallel to one another.
[0019] The aerosol-generating article may extend over its length between a distal end and a proximal end. The aerosol-forming substrate may extend over at least a portion of the length of the aerosol-generating article. The aerosol-forming substrate may extend over a portion of the length of the aerosol-generating article and may be positioned closer to the distal end than to the proximal end. In another embodiment, the aerosol-forming substrate may extend over the entire length of the aerosol-generating article. The aerosol-forming substrate may extend to the distal end. The proximal end may be the oral end of the aerosol-generating article.
[0020] Aerosol-generating articles according to the present disclosure may preferably be substantially flat or substantially planar. Such articles have a large base area relative to the volume of the article. Advantageously, a larger base area may provide a larger surface area for heating by the planar heater of the aerosol-generating device. Advantageously, a smaller height may result in a smaller temperature gradient or difference across the height of the aerosol-generating article during heating. For example, if the base of the aerosol-generating article is heated in contact with the planar heater, a smaller distance or height between the base and the top surface may result in a smaller temperature difference between the base and the top surface opposite the base. Advantageously, this may allow a greater proportion of the aerosol-forming substrate of the aerosol-generating article to be heated to a temperature at which an aerosol is emitted, while minimizing the risk of burning the hottest portion of the substrate closest to the heater. Alternatively, or additionally, this may reduce the time required to heat the aerosol-forming substrate sufficiently to emit an aerosol.
[0021] An aerosol-generating article according to any of the embodiments disclosed herein may have an airflow path through the aerosol-generating article. The aerosol-generating article may have an airflow path defined through the aerosol-generating article in the x / y plane, from one side of the aerosol-generating article to the other side of the aerosol-generating article. The aerosol-generating article preferably has a resistance to draw (RTD) in the direction of the airflow path of less than 20 millimeters of HO, for example less than 10 millimeters of HO. The aerosol-generating article preferably has an RTD of less than 20 millimeters of HO, for example less than 10 millimeters of HO, in at least one direction in the x / y plane of the aerosol-generating article. An aerosol-generating article with a low resistance airflow path may enable superior airflow management, allowing aerosol to be more efficiently drawn from the aerosol-generating article and directed to the user.
[0022] Unless otherwise specified, resistance to draw (RTD) is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through the entire length of a component, such as an aerosol-generating article. The terms "pressure drop" or "draw resistance" of a component or article can also refer to "resistance to draw." These terms generally refer to measurements made in accordance with ISO 6565-2015 and typically performed under test at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr), and a relative humidity of about 60%, with a volumetric flow rate of about 17.5 milliliters per second at the output or downstream end of the component being measured.
[0023] An aerosol-generating article according to any of the embodiments disclosed herein may include substantially planar upper and lower surfaces. The vertical separation between the substantially planar upper and lower surfaces may define the height (e.g., z-dimension) of the aerosol-generating article. An airflow channel may be defined between the substantially planar upper and lower surfaces. The height of the aerosol-generating article may be less than 5 millimeters, for example, between 1.5 millimeters and 5 millimeters, for example, between 1.5 millimeters and 4 millimeters, for example, between 1.5 millimeters and 3 millimeters, for example, between 1.5 millimeters and 2 millimeters. One or both of the substantially planar upper and lower surfaces may comprise an aerosol-forming substrate. The aerosol-generating article may comprise an upper layer and a lower layer, at least one of which comprises or consists of an aerosol-forming substrate, the upper layer forming the substantially planar upper surface and the lower layer forming the substantially planar lower surface.
[0024] The aerosol-generating article may further comprise an intermediate layer disposed between the upper and lower layers. The upper surface may define an outer surface of the upper layer, and the lower surface may define an outer surface of the lower layer. An airflow path may be defined through the aerosol-generating article in the x / y plane between the distal and proximal ends of the aerosol-generating article.
[0025] The resistance to draw (RTD) of the aerosol-generating article along the airflow path may be less than 20 millimeters H2O.
[0026] Preferably, at least one of the top layer, middle layer and bottom layer comprises or consists of one or more susceptor materials.
[0027] At least one of the upper layer, the middle layer, and the lower layer may include multiple susceptor regions spaced apart from one another, each of which may comprise or consist of one or more susceptor materials. The spaced apart susceptor regions allow selective heating of different regions or portions of the aerosol-forming substrate by the different susceptor regions. The multiple susceptor regions may be spaced apart from one another in the x-direction.
[0028] One or both of the upper and lower layers may comprise or consist of an aerosol-forming substrate, and the middle layer may comprise or consist of one or more susceptor materials.
[0029] One or both of the upper and lower layers may comprise or consist of one or more susceptor materials, and the middle layer may comprise or consist of an aerosol-forming substrate.
[0030] One or both of the upper and lower layers may comprise or consist of an aerosol-forming substrate and one or more susceptor materials. One or more susceptor materials may be dispersed in one or both of the upper and lower layers.
[0031] One or both of the upper and lower layers may comprise a sub-layer of an aerosol-forming substrate overlaid with one or more sub-layers of susceptor material, the sub-layer of the aerosol-forming substrate defining an inward-facing surface of the respective upper or lower layer.
[0032] The intermediate layer may comprise or consist of a paper-based substrate.
[0033] The intermediate layer may not include an aerosol-forming substrate.
[0034] The intermediate layer may comprise or consist of an aerosol-forming substrate. The intermediate layer may further comprise one or more susceptor materials.
[0035] The intermediate layer may not include a susceptor material.
[0036] One or more strips, threads, or wires of susceptor material may be positioned within the airflow path defined by the intermediate layer.
[0037] A plurality of longitudinally extending channels can be defined by corrugations between the upper and middle layers and between the middle and lower layers. The longitudinally extending channels can extend along the x / y plane between the distal and proximal ends. One or more strips, threads, or wires of susceptor material can be arranged in one or more corrugations.
[0038] In instances where one or more strips, threads, or wires of susceptor material are positioned within the airflow path formed by the intermediate layer, or arranged in one or more corrugations, the intermediate layer may comprise or consist of an aerosol-forming substrate.
[0039] The middle layer can be secured to at least one of the upper and lower layers by an adhesive. For example, the adhesive can include guar gum. The adhesive can include an aerosol-forming material, such as a homogenized tobacco slurry.
[0040] The middle layer may comprise corrugated elements.
[0041] The intermediate layer may include a plurality of corrugated elements. Two or more of the plurality of corrugated elements may be disposed between the upper and lower layers in a mutually perpendicular relationship. One or more of the plurality of corrugated elements may include one or more susceptor materials, and one or more other of the plurality of corrugated elements may include an aerosol-forming substrate. The intermediate layer may further include a planar element positioned between two of the plurality of corrugated elements. The planar element may include or consist of one or more susceptor materials.
[0042] According to the present disclosure, an aerosol-generating article may be provided, comprising a first planar layer, a second planar layer, and a corrugated layer disposed between the first and second planar layers. At least one of the first planar layer, the second planar layer, and the corrugated layer may comprise or consist of an aerosol-forming substrate. The aerosol-generating article also further comprises one or more susceptor materials disposed in thermal communication with the aerosol-forming substrate. The susceptor materials may be as described in any of the preceding paragraphs.
[0043] The use of a corrugated structure in an aerosol-generating article may advantageously enable the production of an aerosol-generating article that has a very low RTD, yet is rigid enough for a user to handle. Furthermore, the use of a corrugated structure may enable the production of a low-density, low-RTD aerosol-generating article using high-speed manufacturing methods similar to those used to manufacture corrugated cardboard.
[0044] The aerosol-generating article may further include a planar frame positioned between the upper and lower layers. The upper surface may define an outer surface of the upper layer, and the lower surface may define an outer surface of the lower layer. The planar frame may define a cavity. An airflow path may be defined through the aerosol-generating article in the x / y plane, the airflow path passing through the cavity.
[0045] The upper and lower layers may be bonded to opposite surfaces of the frame so as to cover opposite ends of the cavity.
[0046] One or both of the upper and lower layers may include or consist of one or more susceptor materials.
[0047] Advantageously, at least one of the upper and lower layers may include a plurality of susceptor regions spaced apart from one another, the plurality of susceptor regions comprising or consisting of one or more susceptor materials. The plurality of susceptor regions may be spaced apart from one another in the x-direction.
[0048] One or both of the upper and lower layers may comprise or consist of an aerosol-forming substrate and one or more susceptor materials.
[0049] One or more susceptor materials may be dispersed in one or both of the upper and lower layers.
[0050] One or both of the upper and lower layers may comprise a sub-layer of an aerosol-forming substrate overlaid with one or more sub-layers of susceptor material, the sub-layer of the aerosol-forming substrate defining an inward-facing surface of the respective upper or lower layer.
[0051] The aerosol-generating article may further comprise one or more particles, pieces, or sheets of an aerosol-forming substrate disposed within the cavity between the upper and lower layers. The upper and lower layers may be free of an aerosol-forming substrate.
[0052] The corrugated elements may be disposed within the cavity between the upper and lower layers. A plurality of longitudinally extending channels may be defined by the corrugations between the upper layer and the corrugated elements and between the corrugated elements and the lower layer. The longitudinally extending channels may extend along the x / y plane between opposite ends of the frame. One or more strips, threads, or wires of susceptor material are disposed in one or more corrugations. The corrugated elements may include or consist of an aerosol-forming substrate. The outer and inner layers may not include an aerosol-forming substrate.
[0053] The airflow path may be at least partially defined by the frame. The frame may include an inlet airflow channel and an outlet airflow channel, the inlet airflow channel configured to allow air flow into the cavity and the outlet airflow channel configured to allow air flow out of the cavity. The inlet airflow channel and the outlet airflow channel may be defined on opposite ends of the frame. The inlet airflow channel may be defined at a first width edge of the frame and the outlet airflow channel may be defined at a second width edge of the frame.
[0054] According to the present disclosure, there may be provided an aerosol-generating article comprising: a first outer planar surface, a second outer planar surface, a cavity, a frame positioned between the first outer planar surface and the second outer planar surface, the frame at least partially defining the cavity, an aerosol-forming substrate positioned between the first outer planar surface and the second outer planar surface, an air inlet and an air outlet, and an airflow passage extending through the cavity between the air inlet and the air outlet. The aerosol-generating article also further comprises one or more susceptor materials disposed in thermal communication with the aerosol-forming substrate. The susceptor materials may be as described in any of the preceding paragraphs.
[0055] The frame may include a peripheral wall that at least partially surrounds or encloses the cavity. The frame may include a peripheral wall that completely surrounds or encloses the cavity.
[0056] The aerosol-generating article may include a first planar outer layer and a second planar outer layer, the first planar outer layer forming a first planar outer surface and the second planar outer layer forming a second planar outer surface. Optionally, at least one of the first planar outer layer, the second planar outer layer, and the frame may comprise or consist of an aerosol-forming substrate.
[0057] The cavity may be substantially empty.
[0058] The aerosol-forming substrate may be positioned within the cavity.
[0059] The corrugated layer may be positioned within the cavity.
[0060] An aerosol-generating article according to any embodiment of the present disclosure may have a length (e.g., x-dimension) of, for example, 10 mm to 100 mm, or 10 mm to 50 mm, for example, 12 mm to 30 mm, for example, 14 mm to 26 mm, for example, 16 mm to 24 mm, for example, 18 mm to 22 mm, for example, about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.
[0061] The aerosol-generating article may have a width (e.g., y dimension) of from 5 mm to 20 mm, such as from 8 mm to 18 mm, for example from 10 mm to 16 mm, for example from 11 mm to 15 mm, for example from 12 mm to 14 mm, for example about 13 mm.
[0062] The aerosol-generating article may have a height (e.g., z-dimension) of from 1 mm to 10 mm, such as from 1.2 mm to 8 mm, for example from 1.4 mm to 7 mm, for example from 1.6 mm to 6 mm, for example from 1.7 mm to 5 mm, for example about 1.7 mm, or about 4.5 mm, or about 2 mm, or about 3 mm, or about 4 mm.
[0063] An aerosol-generating article according to any embodiment of the present disclosure, when viewed in a plan view, may have a shape that defines a polygon, a quadrilateral (e.g., a rectangle or square), an ellipse, or a circle, or a combination thereof. When an aerosol-generating article includes substantially planar upper and lower surfaces, one or both of the upper and lower surfaces, when viewed in a plan view, may have a shape that defines a polygon, a quadrilateral (e.g., a rectangle or square), an ellipse, a circle, or a combination thereof. When an aerosol-generating article includes substantially planar upper and lower surfaces, the perimeter of one or both of the upper and lower surfaces, when viewed in a plan view, may have a shape that defines a polygon, a quadrilateral (e.g., a rectangle or square), an ellipse, a circle, or a combination thereof.
[0064] The aerosol-forming substrate may comprise nicotine, which may be present in the form of tobacco material or may be in the form of a nicotine extract.
[0065] The aerosol-forming substrate preferably comprises or consists of a homogenized tobacco material, such as a reconstituted tobacco material or a cast leaf tobacco material.
[0066] The aerosol-forming substrate may comprise or consist of a solid aerosol-forming material. The aerosol-forming substrate may comprise a liquid aerosol-forming substrate material, for example a liquid aerosol-forming material held within a porous matrix. The aerosol-forming substrate may comprise a gel aerosol-forming material.
[0067] The aerosol-forming substrate may comprise one or more aerosol formers. Suitable aerosol formers are well known in the art and include, but are not limited to, one or more aerosol formers selected from polyhydric alcohols (such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (such as dimethyl dodecanedioate and dimethyl tetradecanedioate). It may be particularly preferred that the aerosol former is or comprises glycerin.
[0068] The aerosol-forming substrate may comprise at least 1, 2, 5, 10, or 15 percent by weight of aerosol formers. The aerosol-forming substrate may comprise more than 15 percent by weight of aerosol formers, for example more than 20 percent, or more than 25 percent, or more than 30 percent, or more than 40 percent, or more than 50 percent by weight of aerosol formers.
[0069] The aerosol-forming substrate may comprise 30% or less by weight of aerosol formers, 25% or less by weight of aerosol formers, or 20% or less by weight of aerosol formers, i.e., the aerosol-forming substrate may have an aerosol-former content of 30% or less by weight, 25% or less by weight, or 20% or less by weight.
[0070] The aerosol-forming substrate can include from 1 weight percent to 30 weight percent aerosol former, from 1 weight percent to 25 weight percent aerosol former, or from 1 weight percent to 20 weight percent aerosol former.
[0071] The aerosol-forming substrate can include 5 to 30 percent by weight of aerosol formers, 5 to 25 percent by weight of aerosol formers, or 5 to 20 percent by weight of aerosol formers.
[0072] The aerosol-forming substrate can include 10 to 30 percent by weight of aerosol formers, 10 to 25 percent by weight of aerosol formers, or 10 to 20 percent by weight of aerosol formers.
[0073] The aerosol-forming substrate can include 15 to 30 percent by weight of aerosol formers, 15 to 25 percent by weight of aerosol formers, or 15 to 20 percent by weight of aerosol formers.
[0074] The aerosol-forming substrate may comprise at least 50 percent by weight of the aerosol former, at least 60 percent by weight of the aerosol former, or at least 70 percent by weight of the aerosol former.
[0075] The aerosol-forming substrate can include 85 weight percent or less of the aerosol former, 80 weight percent or less of the aerosol former, or 75 weight percent or less of the aerosol former.
[0076] The aerosol-forming substrate can comprise 50 to 85 percent by weight of aerosol formers, 50 to 80 percent by weight of aerosol formers, or 50 to 75 percent by weight of aerosol formers.
[0077] The aerosol-forming substrate can comprise 60 to 85 percent by weight of aerosol formers, 60 to 80 percent by weight of aerosol formers, or 60 to 75 percent by weight of aerosol formers.
[0078] The aerosol-forming substrate can comprise 70 to 85 percent by weight of aerosol formers, 70 to 80 percent by weight of aerosol formers, or 70 to 75 percent by weight of aerosol formers.
[0079] The aerosol-forming substrate may comprise nicotine. The aerosol-forming material may comprise natural nicotine, or synthetic nicotine, or a combination of natural and synthetic nicotine.
[0080] The aerosol-forming substrate may comprise at least 0.5 weight percent nicotine, at least 1 weight percent nicotine, at least 1.5 weight percent nicotine, or at least 2 weight percent nicotine, i.e., the aerosol-forming substrate may have a nicotine content of at least 0.5 weight percent, at least 1 weight percent, at least 1.5 weight percent, or at least 2 weight percent.
[0081] The aerosol-forming substrate may contain one or more cannabinoid compounds, such as one or more of tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannabivarin (CBV), cannabidivarin (CBDV), tetrahydrocannabivarin (THCV), cannabichromene (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), and cannabicitran (CBT). The cannabinoid compound may preferably be CBD or THC. The cannabinoid compound may particularly preferably be CBD.
[0082] The aerosol-forming substrate may contain one or more flavoring agents. The one or more flavoring agents may include one or more essential oils, such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and one or more herbaceous materials. Suitable herbaceous materials include herb leaves or other herbaceous materials from herbaceous plants, including, but not limited to, mint (such as peppermint and spearmint), lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavoring agents may include tobacco materials.
[0083] The aerosol-forming substrate may have a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state. For example, the aerosol-forming substrate may be a homogenized tobacco material having a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state.
[0084] The aerosol-forming substrate may comprise tobacco leaf; for example, a tobacco leaf blend incorporating about 15-45%, preferably about 20-35%, of at least one of the following tobacco types: bright tobacco, dark tobacco, and aromatic tobacco. The tobacco material, such as tobacco leaf, is preferably ground and graded to a particle size of about 100-380 mesh, preferably about 170-320 mesh.
[0085] "Tobacco type" means one of various types of tobacco, for example, based on different curing processes that are performed on the tobacco before it is further processed into tobacco products.
[0086] Examples of bright tobaccos include Brazilian Fulcure, Indian Fulcure, Chinese Fulcure, American Fulcure, e.g., Virginia tobacco, and Tanzanian Fulcure.
[0087] Examples of aromatic tobaccos include Turkish Oriental, Greek Oriental, and Semi-Oriental tobaccos, but also fire-cured, US Burley, and varieties such as Perique and Rustica.
[0088] Examples of dark tobaccos include dark-cured Brazilian Galpao, Burley Malawi or other African Burley, Sun-cured or air-cured Indonesian Kastri.
[0089] The aerosol-forming substrate may contain cellulose fibers. For example, the aerosol-forming substrate may contain about 1 to 15% cellulose fibers, preferably about 3 to 7% cellulose fibers. Preferably, the cellulose fibers have a length of about 10 to 250 μm, preferably about 10 to 120 μm.
[0090] The aerosol-forming substrate may contain organic fibers, such as non-tobacco fibers or tobacco fibers. For example, the aerosol-forming substrate may contain about 5 to 20%, preferably about 7 to 15%, tobacco fibers. The tobacco fibers are preferably derived from stems and / or petioles graded into fibers with lengths of about 10 to 350 μm, preferably about 10 to 180 μm. The aerosol-forming substrate may contain about 10 to 30%, preferably about 15 to 25%, non-tobacco organic fibers. For example, organic fibers may be obtained from cellulose, cotton, wood, or tea plant varieties as by-products or secondary processing waste products of the tea industry. The organic fibers preferably have lengths of about 10 to 400 μm, preferably about 10 to 200 μm.
[0091] The aerosol-forming substrate may contain a binder. For example, the aerosol-forming substrate may contain about 1 to 10%, preferably about 1 to 5%, of a binder such as any of the common gums or pectins used in the food and beverage (F&B) industry. Preferred binders may include natural pectins, such as fruit pectins, e.g., citrus pectins, or tobacco pectins; guar gum, land locust bean gum, e.g., hydroxyethyl and / or hydroxypropyl versions of these gums; starches, e.g., modified or derivatized starches; alginates; methylcellulose, ethylcellulose, ethylhydroxymethylcellulose, and carboxymethylcellulose; dextran; and xanthan gum. A preferred binder is guar.
[0092] The aerosol-forming substrate may include an organic vegetable glycerin preparation. For example, the aerosol-forming substrate may contain about 15-55%, preferably about 20-35%, of plants such as clove, echinacea species, fennel, ginger, hawthorn berry, elderberry, monarda, mullein leaf, nettle, plantain, turmeric, yarrow, and compounds thereof.
[0093] The aerosol-forming substrate may comprise an organic plant extract. For example, the aerosol-forming substrate may comprise about 1% to 15%, preferably 2% to 7%, of menthol (dl-menthol, C ) obtained from any of the aforementioned plants, as well as Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related plant varieties. 10 H 20 0, 2-isopropyl-5-methylcyclohexanol), and P-menthone-3-ol as an optional secondary alcohol as a diastereoisomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.
[0094] The aerosol-forming substrate may comprise a plant essential oil, for example about 0.5 to 5%, preferably about 1 to 3%, of a plant essential oil, such as palm oil, coconut oil, and wood-based essential oils.
[0095] The aerosol-forming substrate preferably comprises an aerosol former, e.g., about 5-35%, about 10-25%, of an aerosol former. Suitable aerosol formers known in the art include glycerin; monohydric alcohols such as menthol; polyhydric alcohols such as triethylene glycol; esters of polyhydric alcohols such as glycerol monoacetate, glycerol diacetate, or glycerol triacetate; and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids, e.g., their dimethyl esters.
[0096] As used herein, the term "aerosol-generating article" may refer to an article that is capable of generating or emitting an aerosol.
[0097] The term "aerosol-forming substrate" as used herein may refer to a substrate capable of emitting an aerosol or volatile compound capable of forming an aerosol. Such a volatile compound may be emitted by heating the aerosol-forming substrate. The aerosol-forming substrate may comprise an aerosol-forming material. The aerosol-forming substrate may be adsorbed, coated, impregnated, or loaded onto a carrier or support. The aerosol-forming substrate may conveniently be part of an aerosol-generating article or a smoking article.
[0098] As used herein, the term "aerosol-generating device" may refer to a device for use with an aerosol-generating article to enable the generation or emission of an aerosol.
[0099] As used herein, the term "aerosol generation system" refers to the combination of an aerosol generation device and one or more aerosol-forming articles for use with the device. The aerosol generation system may include additional components, such as an electrically operated aerosol generator or a charging unit for recharging an on-board power supply in an electric aerosol generator.
[0100] As used herein, the term "aerosol former" may refer to any suitable known compound or mixture of compounds that, upon use, facilitates the formation of an aerosol. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal decomposition at the operating temperature of the aerosol-forming substrate or aerosol-generating article.
[0101] As used herein in connection with the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salts.
[0102] As used herein with respect to the present invention, the terms "proximal," "distal," "upstream," and "downstream" are used to describe the relative locations of components or portions of components of an aerosol-generating article.
[0103] As used herein, the term "longitudinal" refers to a direction corresponding to the major longitudinal axis of the aerosol-generating article, extending between the upstream and downstream ends of the aerosol-generating article. During use, air is drawn longitudinally through the aerosol-generating article.
[0104] As used herein, the term "sheet" refers to a laminar element having a width and length substantially greater than its thickness. The width of the sheet may be greater than 10 mm, preferably greater than 20 mm or 30 mm. In certain embodiments, a sheet of material for use in forming an aerosol-forming substrate as described herein may have a thickness of from 10 μm to about 1000 μm, e.g., from 10 μm to about 300 μm.
[0105] As used herein, the term "homogenized tobacco material" encompasses any tobacco material formed by agglomeration of particles of tobacco material. A sheet or web of homogenized tobacco material is formed by agglomerating particulate tobacco obtained by grinding or otherwise pulverizing one or both of tobacco lamina and tobacco stems. In addition, the homogenized tobacco material may contain one or more small amounts of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during tobacco processing, handling, and shipping. Sheets of homogenized tobacco material may be produced by casting, extrusion, a papermaking process, or any other suitable process known in the art.
[0106] The term "cast leaf" refers to a product made by a casting process based on casting a slurry containing plant particles (e.g., clove particles, or a mixture of tobacco and clove particles) and a binder (e.g., guar gum) onto a support surface (e.g., a conveyor belt), drying the slurry, and removing the dried sheet from the support surface. Examples of cast or cast leaf processes are described, for example, in U.S. Pat. No. 5,724,998 for making cast leaf tobacco. In the cast leaf process, particulate plant material is produced by pulverizing, grinding, or comminuting plant parts. Particles produced from one or more plant bodies are mixed with a liquid component, typically water, to form a slurry. Other components in the slurry may include fibers, binders, and aerosol formers. The particulate plant material may be agglomerated in the presence of a binder. The slurry is cast onto a support surface and dried into a sheet of homogenized plant material. Preferably, the homogenized plant material used in the article according to the present invention is produced by casting. Such homogenized plant material may include agglomerated particulate plant material.
[0107] As used herein, withdrawal resistance may be expressed using the units of pressure "mmH2O" or "mmWG" or "millimeters of water column" and measured in accordance with ISO 6565:2002. [Brief explanation of the drawings]
[0108] [Figure 1] FIG. 1 is a perspective side view of an aerosol-generating article according to a first embodiment of the present disclosure. [Figure 2] FIG. 2 is a perspective view of an aerosol-generating article according to a second embodiment of the present disclosure. [Figure 3] FIG. 3 is a schematic end view of an aerosol-generating article according to a third embodiment of the present disclosure. [Figure 4] FIG. 4 is a schematic side view of the aerosol-generating article of FIG. [Figure 5] FIG. 5 is a schematic plan view of the aerosol-generating article of FIG. [Figure 6] FIG. 6 shows a schematic diagram of a corrugated element used in the aerosol-generating article of FIG. [Figure 7] FIG. 7 is a schematic end view of an aerosol-generating article according to a fourth embodiment of the present disclosure. [Figure 8] FIG. 8 is a schematic end view of an aerosol-generating article according to a fifth embodiment of the present disclosure. [Figure 9] FIG. 9 shows a perspective view of an aerosol-generating article according to a sixth embodiment of the present disclosure. [Figure 10] FIG. 10 shows an exploded perspective view of the aerosol-generating article of FIG. [Figure 11] FIG. 11 shows a further exploded perspective view of the aerosol-generating article of FIG. [Figure 12] FIG. 12 shows a schematic transverse cross-section of the aerosol-generating article of FIG. [Figure 13] FIG. 13 shows a schematic longitudinal cross-sectional view of the aerosol-generating article of FIG. [Figure 14] FIG. 14 shows an exploded perspective view of an aerosol-generating article according to a seventh embodiment of the present disclosure. [Figure 15] FIG. 15 shows a schematic transverse cross-section of the aerosol-generating article of FIG. [Figure 16] FIG. 16 shows a schematic cross-sectional side view of the aerosol-generating article of FIG. [Figure 17] FIG. 17 shows a schematic transverse cross-sectional view of an aerosol-generating article according to an eighth embodiment of the present disclosure, which is a variation of the aerosol-generating articles of FIGS. [Figure 18] 18A-18C are cross-sectional views of different composite structures containing one or more susceptor materials for use in aerosol-generating articles of the present disclosure, such as the aerosol-generating articles of FIGS. 1-17. [Figure 19] FIG. 19 is a perspective view of a composite structure incorporating spaced apart sheets of susceptor material for use in the aerosol-generating articles of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION
[0109] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features described above, for example, with any one or more features of other examples, embodiments, or aspects described herein.
[0110] Example 1: An aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article comprising a substantially planar upper surface and a substantially planar lower surface, the upper and lower surfaces being vertically spaced apart from each other by a height defined in the z-direction, the aerosol-generating article further comprising an aerosol-forming substrate and one or more susceptor materials, the one or more susceptor materials being disposed in thermal communication with the aerosol-forming substrate.
[0111] Example 2: An aerosol-generating article as described in Example 1, wherein the one or more susceptor materials are in direct contact with the aerosol-forming substrate.
[0112] Example 3: An aerosol-generating article according to any one of Examples 1 or 2, wherein the one or more susceptor materials are incorporated within the aerosol-forming substrate.
[0113] Example 4: An aerosol-generating article as described in Example 3, wherein particles of susceptor material are dispersed within the aerosol-forming substrate.
[0114] Example 5: An aerosol-generating article according to any one of Examples 1 to 4, wherein the one or more susceptor materials are incorporated into the aerosol-generating article as one or more strips, threads, or wires of susceptor material.
[0115] Example 6: 6. The aerosol-generating article of example 5, wherein one or more strips, threads, or wires of susceptor material are positioned within the airflow path of the aerosol-generating article.
[0116] Example 7: 7. An aerosol-generating article according to any one of Examples 1 to 6, wherein the one or more susceptor materials are incorporated within the aerosol-generating article as sheets or layers of one or more susceptor materials.
[0117] Example 8: 8. The aerosol-generating article of example 7, wherein one or more sheets or layers of susceptor material are located within or at least partially define the airflow path of the aerosol-generating article.
[0118] Example 9: An aerosol-generating article according to any one of Examples 7 or 8, wherein one or more sheets or layers of susceptor material cover an outer portion of the aerosol-generating article.
[0119] Example 10: An aerosol-generating article according to any one of Examples 7 to 9, wherein one or more sheets or layers of susceptor material form a structural component of the aerosol-generating article.
[0120] Example 11: 11. The aerosol-generating article of any of Examples 7-10, wherein at least one of the one or more sheets or layers of susceptor material is formed as a mesh of susceptor material.
[0121] Example 12: An aerosol-generating article according to any one of Examples 1 to 11, comprising a plurality of susceptor regions spaced apart from one another and arranged in thermal communication with the aerosol-forming substrate, the plurality of susceptor regions comprising or consisting of one or more susceptor materials.
[0122] Example 13: 13. The aerosol-generating article of example 12, wherein the susceptor regions are spaced apart from one another in the x-direction.
[0123] Example 14: 14. The aerosol-generating article of any one of Examples 12 to 13, wherein the plurality of susceptor regions comprises one or more susceptor materials layered on or incorporated within the paper-based substrate or aerosol-forming substrate.
[0124] Example 15: 15. An aerosol-generating article according to any one of Examples 1 to 14, wherein the susceptor material comprises one or more materials selected from the list consisting of aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.
[0125] Example 16: An aerosol-generating article according to any one of Examples 1 to 15, wherein the upper and lower surfaces are parallel to each other.
[0126] Example 17: An aerosol-generating article according to any one of Examples 1 to 16, wherein the aerosol-generating article extends over a length extending between a distal end and a proximal end, and the aerosol-forming substrate extends over at least a portion of the length of the aerosol-generating article, and optionally the aerosol-forming substrate extends over the entire length of the aerosol-generating article.
[0127] Example 18: An aerosol-generating article as described in Example 17, wherein the aerosol-forming substrate extends over a portion of the length of the aerosol-generating article and is positioned closer to the distal end than to the proximal end.
[0128] Example 19: 19. An aerosol-generating article according to any one of Examples 17 or 18, wherein the aerosol-forming substrate extends to a distal end.
[0129] Example 20: 20. An aerosol-generating article according to any one of Examples 17 to 19, wherein the proximal end is the mouth end of the aerosol-generating article.
[0130] Example 21: An aerosol-generating article described in any one of Examples 1 to 20, further comprising an intermediate layer disposed between the upper and lower layers, wherein the upper surface defines the outer surface of the upper layer and the lower surface defines the outer surface of the lower layer, and an airflow path is defined through the aerosol-generating article in the x / y plane between the distal and proximal ends of the aerosol-generating article.
[0131] Example 22: An aerosol-generating article as described in Example 21, wherein the resistance to draw (RTD) of the aerosol-generating article along the airflow path is less than 20 millimeters HO.
[0132] Example 23: 23. An aerosol-generating article according to any one of Examples 21 or 22, wherein at least one of the upper layer, the middle layer, and the lower layer comprises or consists of one or more susceptor materials.
[0133] Example 24: An aerosol-generating article as described in Example 23, wherein at least one of the upper layer, middle layer, and lower layer comprises a plurality of susceptor regions spaced apart from one another, and the plurality of susceptor regions comprises or consists of one or more susceptor materials.
[0134] Example 25: 25. The aerosol-generating article of Example 24, wherein the susceptor regions are spaced apart from one another in the x-direction.
[0135] Example 26: 26. An aerosol-generating article according to any one of Examples 23 to 25, wherein one or both of the upper and lower layers comprises or consists of an aerosol-forming substrate, and the middle layer comprises or consists of one or more susceptor materials.
[0136] Example 27: 26. An aerosol-generating article according to any one of Examples 23 to 25, wherein one or both of the upper and lower layers comprises or consists of one or more susceptor materials, and the middle layer comprises or consists of an aerosol-forming substrate.
[0137] Example 28: 28. The aerosol-generating article of any one of Examples 23-27, wherein one or both of the upper and lower layers comprises or consists of an aerosol-forming substrate and one or more susceptor materials.
[0138] Example 29: The aerosol-generating article of Example 28, wherein one or more susceptor materials are dispersed within the aerosol-forming substrate in one or both of the upper and lower layers.
[0139] Example 30: 30. An aerosol-generating article according to any one of Examples 28 or 29, wherein one or both of the upper and lower layers comprises a sublayer of an aerosol-forming substrate laminated with one or more sublayers of susceptor material.
[0140] Example 31: 31. The aerosol-generating article of Example 30, wherein a sub-layer of the aerosol-forming substrate defines an inward-facing surface of each upper or lower layer.
[0141] Example 32: 32. The aerosol-generating article of any one of Examples 28-31, wherein the intermediate layer comprises or consists of a paper-based substrate.
[0142] Example 33: 33. The aerosol-generating article of any one of Examples 28 to 32, wherein the intermediate layer does not comprise an aerosol-forming substrate.
[0143] Example 34: An aerosol-generating article according to any one of Examples 28 to 32, wherein the intermediate layer comprises or consists of an aerosol-forming substrate.
[0144] Example 35: The aerosol-generating article of Example 34, wherein the intermediate layer further comprises one or more susceptor materials.
[0145] Example 36: An aerosol-generating article according to any one of Examples 28 to 34, wherein the intermediate layer does not comprise a susceptor material.
[0146] Example 37: An aerosol-generating article according to any one of Examples 21 to 36, wherein one or more strips, threads, or wires of susceptor material are located within the airflow path defined by the intermediate layer.
[0147] Example 38: An aerosol-generating article described in any one of Examples 21 to 37, wherein a plurality of longitudinally extending channels are defined by corrugations between the upper layer and the middle layer, and between the middle layer and the lower layer.
[0148] Example 39: An aerosol-generating article as described in Example 38, wherein the longitudinally extending channels extend along the x / y plane between the distal end and the proximal end.
[0149] Example 40: An aerosol-generating article according to any one of Examples 38 or 39, wherein one or more strips, threads, or wires of susceptor material are arranged in one or more corrugated patterns.
[0150] Example 41: An aerosol-generating article according to any one of Examples 37 to 40, wherein the intermediate layer comprises or consists of an aerosol-forming substrate.
[0151] Example 42: An aerosol-generating article described in any one of Examples 21 to 41, wherein the intermediate layer is secured to at least one of the upper and lower layers by an adhesive, for example, the adhesive comprises guar gum, and optionally the adhesive comprises an aerosol-forming material such as a homogenized tobacco slurry.
[0152] Example 43: An aerosol-generating article according to any one of Examples 21 to 42, wherein the intermediate layer comprises corrugated elements.
[0153] Example 44: An aerosol-generating article as described in Example 43, wherein the intermediate layer comprises a plurality of corrugated elements, two or more of which are disposed between the upper and lower layers in a mutually perpendicular relationship.
[0154] Example 45: An aerosol-generating article as described in Example 44, wherein one or more of the plurality of corrugated elements comprises one or more susceptor materials and one or more other of the plurality of corrugated elements comprises an aerosol-forming substrate.
[0155] Example 46: An aerosol-generating article described in either Example 44 or 45, wherein the intermediate layer further comprises a planar element positioned between two of the plurality of corrugated elements.
[0156] Example 47: The aerosol-generating article of Example 46, wherein the planar element comprises or consists of one or more susceptor materials.
[0157] Example 48: An aerosol-generating article described in any one of Examples 1 to 20, further comprising a planar frame positioned between the upper layer and the lower layer, wherein the upper surface defines the outer surface of the upper layer and the lower surface defines the outer surface of the lower layer, the planar frame defining a cavity, and an airflow path defined through the aerosol-generating article in the x / y plane, the airflow path extending through the cavity.
[0158] Example 49: An aerosol-generating article as described in Example 48, wherein the upper and lower layers are bonded to opposite surfaces of the frame so as to cover opposite ends of the cavity.
[0159] Example 50: An aerosol-generating article according to any one of Examples 48 or 49, wherein one or both of the upper and lower layers comprises or consists of one or more susceptor materials.
[0160] Example 51: An aerosol-generating article described in Example 50, wherein at least one of the upper and lower layers comprises multiple susceptor regions spaced apart from one another, and the multiple susceptor regions comprise or consist of one or more susceptor materials.
[0161] Example 52: An aerosol-generating article as described in Example 51, wherein the multiple susceptor regions are spaced apart from one another in the x-direction.
[0162] Example 53: An aerosol-generating article according to any one of Examples 50 to 52, wherein one or both of the upper and lower layers comprises or consists of an aerosol-forming substrate and one or more susceptor materials.
[0163] Example 54: The aerosol-generating article of Example 53, wherein one or more susceptor materials are dispersed within the aerosol-forming substrate in one or both of the upper and lower layers. Example 55: An aerosol-generating article described in either Example 53 or 54, wherein one or both of the upper and lower layers comprises a sublayer of an aerosol-forming substrate laminated with one or more sublayers of susceptor material.
[0164] Example 56: 56. The aerosol-generating article of Example 55, wherein the sub-layer of the aerosol-forming substrate defines the inward-facing surface of each upper or lower layer.
[0165] Example 57: 57. The aerosol-generating article of any one of Examples 48 to 56, comprising one or more particles, pieces, or sheets of an aerosol-forming substrate disposed within the cavity between the upper and lower layers.
[0166] Example 58: The aerosol-generating article of Example 57, wherein the upper and lower layers do not comprise an aerosol-forming substrate.
[0167] Example 59: 59. The aerosol-generating article of any one of Examples 48 to 58, wherein the corrugated element is disposed within a cavity between the upper and lower layers.
[0168] Example 60: 60. An aerosol-generating article as described in Example 59, wherein a plurality of longitudinally extending channels are defined by corrugations between the upper layer and the corrugated element and between the corrugated element and the lower layer.
[0169] Example 61: An aerosol-generating article as described in Example 60, wherein the longitudinally extending channels extend along the x / y plane between opposing ends of the frame.
[0170] Example 62: 62. An aerosol-generating article according to any one of Examples 60 or 61, wherein one or more strips, threads, or wires of susceptor material are arranged in one or more corrugated patterns.
[0171] Example 63: The aerosol-generating article of any one of Examples 59-62, wherein the corrugated element comprises or consists of an aerosol-forming substrate.
[0172] Example 64: The aerosol-generating article of Example 63, wherein the outer layer and the inner layer do not comprise an aerosol-forming substrate.
[0173] Example 65: An aerosol-generating article according to any one of Examples 48 to 64, wherein the airflow path is at least partially defined by a frame.
[0174] Example 66: An aerosol-generating article as described in Example 65, wherein the frame has an inlet airflow channel and an outlet airflow channel, the inlet airflow channel configured to allow air to flow into the cavity and the outlet airflow channel configured to allow air to flow out of the cavity.
[0175] Example 67: 67. An aerosol-generating article as described in Example 66, wherein the inlet airflow channel and the outlet airflow channel are defined on opposite ends of the frame.
[0176] Example 68: 68. An aerosol-generating article described in either one of Examples 66 or 67, wherein the inlet airflow channel is defined in a first width edge of the frame and the outlet airflow channel is defined in a second width edge of the frame.
[0177] The embodiments will now be further described with reference to the figures.
[0178] 1 shows a perspective view of an aerosol-generating article 100 according to a first embodiment of the present disclosure. The aerosol-generating article 100 has an upper surface 110 and a lower surface 120 that are flat or planar.
[0179] The aerosol-generating article 100 includes an aerosol-forming substrate and one or more susceptor materials (not shown). In one embodiment, the aerosol-generating article 100 may consist essentially of the aerosol-forming substrate and one or more susceptor materials. In another embodiment, the aerosol-forming substrate and one or more susceptor materials may be a subset of the components of the aerosol-generating article 100. The aerosol-forming substrate may be enclosed within the interior of the aerosol-generating article 100. The aerosol-forming substrate may at least partially define the exterior of the aerosol-generating article 100; for example, one or both of the upper surface 110 and the lower surface 120 may comprise or consist of the aerosol-forming substrate. The one or more susceptor materials may be enclosed within the interior of the aerosol-generating article 100. One or more susceptor materials may at least partially define the exterior of the aerosol-generating article 100, for example, one or both of the upper surface 110 and the lower surface 120 may comprise or consist of one or more susceptor materials. In further embodiments, one or more susceptor materials may be combined with an aerosol-forming substrate to form a composite structure.
[0180] The susceptor material may be formed from stainless steel or aluminum.
[0181] A suitable aerosol-forming substrate may be homogenized tobacco.
[0182] The aerosol-generating article 100 has a length extending in the x-dimension of 80 millimeters, a width extending in the y-dimension of 15 millimeters, and a height extending in the z-dimension (which may also be referred to as thickness) of 3.6 millimeters.
[0183] FIG. 2 shows a side perspective view of an aerosol-generating article 200 according to a second embodiment of the present disclosure, which is a variation of the aerosol-generating article 100. Like the aerosol-generating article 100, the aerosol-generating article 200 also includes one or more susceptor materials. Features in common with the aerosol-generating article 100 are referred to by like reference numerals. An airflow path 230 is defined through the aerosol-generating article 200 between the upper surface 110 and the lower surface 120. The airflow path 230 extends between opposing first and second ends 201, 202 of the aerosol-generating article 200. The first end 201 may define the distal end of the aerosol-generating article 200, and the second end 202 may define the proximal end of the aerosol-generating article. The airflow path 230 may be directed toward a user's mouth to allow the user to inhale the aerosol generated as a result of heating the aerosol-forming substrate of the aerosol-generating article 200.
[0184] 3, 4, and 5 show end, side, and plan views, respectively, of an aerosol-generating article 300 according to a third embodiment of the present disclosure. The aerosol-generating article 300 includes a planar upper layer 310, a planar lower layer 320, and an intermediate or separating layer 340 disposed between the upper and lower layers 310, 320.
[0185] The planar upper layer 310 is formed from a 50 micron thick sheet of susceptor material (e.g., a stainless steel or aluminum sheet). The planar lower layer 320 is formed from a 50 micron thick sheet of susceptor material (e.g., a stainless steel or aluminum sheet). The middle layer 340 is a corrugated element formed from a corrugated sheet 345 of aerosol-forming substrate. A suitable aerosol-forming substrate may be homogenized tobacco. Thus, the middle layer 340 may be formed from a corrugated sheet 345 of homogenized tobacco material.
[0186] Figure 6 illustrates a corrugated sheet of aerosol-forming substrate 345. The corrugations have an amplitude 346 of 3 millimeters and a wavelength 347 of 3 millimeters. The sheet 345 of aerosol-forming substrate forming the intermediate layer 340 has a thickness of 150 micrometers.
[0187] The intersections 351 between the top layer 310 and the middle layer 340 and the intersections 352 between the bottom layer 320 and the middle layer 340 include adhesive bonding the respective layers together.
[0188] The aerosol-generating article 300 has a length extending in the x-dimension of 80 millimeters, a width extending in the y-dimension of 15 millimeters, and a height (or thickness) extending in the z-dimension of 3.6 millimeters.
[0189] The corrugations of the intermediate layer 340 form a first set of longitudinally extending channels 361 bounded by the top layer 310 and the intermediate layer 340, and a second set of longitudinally extending channels 362 bounded by the bottom layer 320 and the intermediate layer 340. The first and second sets of longitudinally extending channels 361, 362 extend through the length of the aerosol-forming substrate between the proximal end 371 of the substrate 345 and the distal end 372 of the substrate 345. The longitudinally extending channels 361, 362 define an airflow path through the substrate 345. Thus, the airflow path passes through both sides of the aerosol-forming substrate sheet 345. The porosity of the aerosol-generating article along the airflow path is approximately 90%. This provides a very low resistance to draw (RTD) of less than 5 mmH2O. In fact, the RTD is close to zero.
[0190] The aerosol-forming substrate 345 may be a sheet of any suitable aerosol-forming substrate.
[0191] During use, the aerosol-generating article 300 is placed in a time-varying magnetic field. The time-varying magnetic field heats the susceptor material of the planar upper layer 310 and the planar lower layer 320 (by one or both of eddy current heating and magnetic hysteresis). The time-varying magnetic field can be generated by supplying alternating current to inductor coils of an aerosol-generating device (not shown) to which the aerosol-generating article 300 can be connected. Heating the susceptor material of the planar upper layer 310 and the planar lower layer 320 results in heating of the corrugated sheet of the aerosol-forming substrate 345. Heating the aerosol-forming substrate 345 causes it to release volatile compounds, which are then entrained in air drawn into the channels 361, 362 via the distal end 372. The volatile compounds then cool and condense to form an aerosol, which can be drawn out of the channels 361, 362 of the aerosol-generating article 300 via the proximal end 371.
[0192] FIG. 7 shows an end view of an aerosol-generating article 400 according to a fourth embodiment of the present disclosure, which is a variation of aerosol-generating article 300. Features common to aerosol-generating article 300 are referred to by like reference numerals. In aerosol-generating article 400, planar upper layer 310 is formed from a sheet of aerosol-forming substrate having a thickness of 150 microns, planar lower layer 320 is formed from a sheet of aerosol-forming substrate having a thickness of 150 microns, and middle layer 340 is a corrugated susceptor element formed from a corrugated sheet of stainless steel or aluminum having a thickness of 50 microns. A suitable aerosol-forming substrate for planar upper and lower layers 310, 320 may be homogenized tobacco. Thus, planar upper layer 310 and planar lower layer 320 may be formed from homogenized tobacco material.
[0193] FIG. 8 shows an end view of an aerosol-generating article 500 according to a fifth embodiment of the present disclosure, which is a variation of the aerosol-generating articles 300 and 400. Features common to the aerosol-generating articles 300 and 400 are referred to by like reference numerals. In the aerosol-generating article 500, the planar upper layer 310 is formed from a sheet of paper having a thickness of 300 microns, the planar lower layer 320 is formed from a sheet of paper having a thickness of 300 microns, and the middle layer 340 is a corrugated element formed from a corrugated sheet of aerosol-forming substrate 345 having a thickness of 150 microns. A suitable aerosol-forming substrate for the middle layer 340 may be homogenized tobacco. Thus, the middle layer 340 may be formed from a corrugated sheet 345 of homogenized tobacco material. Longitudinal susceptor strips 570 are disposed within each longitudinally extending channel 361. The susceptor strips 570 may be formed from stainless steel or aluminum.
[0194] 9 shows an aerosol-generating article 600 according to a sixth embodiment of the present disclosure. The aerosol-generating article 600 comprises a first planar outer layer 624 forming a first planar outer surface 621, a second planar outer layer 625 forming a second planar outer surface 622, and a frame 650 positioned between the first planar outer layer 624 and the second planar outer layer 625. The second planar outer surface 622 is positioned parallel to the first planar outer surface 621.
[0195] Figures 10 and 11 show exploded views of the aerosol-generating article 600 of Figure 9. A frame 650 surrounds and at least partially defines a cavity 630. Figure 10 shows the cavity 630 in an empty state. Figure 11 shows the cavity 630 filled with an aerosol-forming substrate 640. Figures 12 and 13 show transverse and longitudinal cross-sectional views, respectively, of the aerosol-generating article 600 when the cavity 630 is filled with the aerosol-forming substrate 640.
[0196] First planar outer layer 624 and second planar outer layer 625 are made from a sheet of susceptor material (e.g., a sheet of stainless steel or aluminum) having a thickness of 35 micrometers and are in physical contact with and adhered to frame 650. First planar outer layer 624 overlies a first end of cavity 630 and forms first cavity end wall 631. Second planar outer layer 625 overlies a second end of cavity 630 and forms second cavity end wall 632, which is opposite first cavity end wall 631. That is, frame 650, first planar outer layer 624, and second planar outer layer 625 collectively define cavity 630.
[0197] The frame 650 has a hollow rectangular parallelepiped shape and is made from cardboard. The frame 650 defines an opening that extends through the height (also referred to as thickness) of the frame 650, and the opening at least partially forms the cavity 630 of the aerosol-generating article 600. The frame 650 includes a peripheral wall 651 that surrounds the cavity 630. The peripheral wall 651 includes a front wall 613 and a rear wall 614. More specifically, the peripheral wall 651 is defined by an inner transverse surface 652 of the frame 650 and an outer transverse surface 653 of the frame 650. The inner transverse surface 652 of the peripheral wall 651 at least partially defines the periphery of the cavity 630. The outer transverse surface 653 of the peripheral wall 651 at least partially defines the periphery of the aerosol-generating article 600. The peripheral wall 651 has a radial thickness measured between an inner transverse surface 652 of the frame 650 and an outer transverse surface 653 of the frame 650 of about 5 millimeters.
[0198] An air inlet 611 and an air outlet 612 are defined by and extend through a peripheral wall 651 of the frame 650. More specifically, the air inlet 611 extends through a front wall 613, and the air outlet 612 extends through a rear wall 614. The air inlet 611 and the air outlet 612 have an equivalent diameter of 5 millimeters. An airflow passage extends through the cavity 630 between the air inlet 611 and the air outlet 612. As shown in FIGS. 11-13 , an aerosol-forming substrate 640 is positioned within the cavity 630. The aerosol-forming substrate 640 includes an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 weight percent on a dry weight basis. As shown, the aerosol-forming substrate 640 fills the entire volume of the cavity 630.
[0199] The aerosol-generating article 600 has a cubic shape and has a height (or thickness) of 8 millimeters extending in the z-dimension, a width of 40 millimeters extending in the y-dimension, and a length of 60 millimeters extending in the x-dimension, measured between the first planar outer surface 621 and the second planar outer surface 622. The frame 650 has a height (or thickness) of 7.93 millimeters extending in the z-dimension, a width of 40 millimeters extending in the y-dimension, and a length of 60 millimeters extending in the x-dimension. The cavity 630 has a height (or thickness) of 7.93 millimeters extending in the z-dimension, a width of 39.93 millimeters extending in the y-dimension, and a length of 52 millimeters extending in the x-dimension.
[0200] Figure 14 shows an aerosol-generating article 700 according to a seventh embodiment of the present disclosure. Features in common with aerosol-generating article 600 are referred to by like reference numerals. Aerosol-generating article 700 differs from aerosol-generating article 600 in that the aerosol-forming substrate is in the form of a sheet 740 of aerosol-generating material, specifically a corrugated sheet of homogenized tobacco material. Figures 15 and 16 show cross-sectional and side views, respectively, of the aerosol-generating article 700 of Figure 14.
[0201] The corrugated sheet of homogenized tobacco material 740 comprises a plurality of parallel corrugations having a plurality of substantially parallel peaks 743 and valleys 744. The parallel corrugations are defined by a sinusoidal corrugation profile, as seen in FIG. 15 . The parallel corrugations have a corrugation wavelength of approximately 4.6 millimeters. The corrugation amplitude is approximately the same as the height (i.e., thickness) of the cavities 630, as indicated by the peaks 743 and valleys 744 coinciding with the first and second cavity end walls 631 and 632, respectively.
[0202] The parallel corrugations form a plurality of channels 745 between the sheet of aerosol-generating material 740 and the first cavity end wall 631, and a plurality of channels 746 between the sheet of aerosol-generating material 740 and the second cavity end wall 632. The channels 745, 746 extend longitudinally through the aerosol-generating article 700 and form at least a portion of the airflow passageway extending between the air inlet 611 and the air outlet 612.
[0203] During use, each aerosol-producing article 600, 700 is placed in a time-varying magnetic field. The time-varying magnetic field heats the susceptor material of the first planar outer layer 624 and the second planar outer layer 625 (by either eddy current heating or magnetic hysteresis, or both). The time-varying magnetic field can be generated by supplying alternating current to an inductor coil of an aerosol-generating device (not shown) to which the aerosol-generating article 600, 700 can be connected. Heating the susceptor material of the first planar outer layer 624 and the second planar outer layer 625, in turn, results in i) heating of the aerosol-forming substrate 640 disposed within the cavity 630 in the case of the aerosol-generating article 600, or ii) heating of the corrugated sheet of aerosol-generating material 740 in the case of the aerosol-generating article 700. Heating of the aerosol-forming substrate 640 / aerosol-generating material 740 causes the aerosol-forming substrate 740 / aerosol-generating material 640 to release volatile compounds, which are then entrained in the air drawn into the cavity 630 through the air inlet 611. The volatile compounds then cool and condense to form an aerosol, which can be drawn out of the aerosol-generating article 600, 700 through the air outlet 612.
[0204] FIG. 17 shows a transverse cross-sectional view of an aerosol-generating article 800 according to an eighth embodiment of the present disclosure, which is a variation on the aerosol-generating articles 600 and 700. Features common to the aerosol-generating articles 600 and 700 are referred to with like reference numerals. The aerosol-generating article 800 includes all the features of the aerosol-generating article 700 (such as the corrugated sheet of aerosol-generating material 740), but further includes longitudinal susceptor strips 870 positioned within each of the longitudinally extending channels 745 formed between the sheet of aerosol-generating material 740 and the first cavity end wall 631. The susceptor strips 870 may be formed from stainless steel or aluminum. In this variation of the aerosol-generating article 800 of FIG. 17, the first planar outer layer 624 and the second planar outer layer 625 may be formed from cigarette paper (rather than a sheet of susceptor material).
[0205] As shown in aerosol-generating articles 300, 400, 500, 600, 700, 800, different components of the aerosol-generating article may be formed from susceptor material, and the susceptor material may be positioned in a variety of different locations within the aerosol-generating article.
[0206] 18A-18C illustrate various alternative configurations in which susceptor materials are integrated or combined with other materials to form composite structures that include the susceptor material.
[0207] FIG. 18A shows an embodiment of a composite structure 1000 suitable for use in an aerosol-generating article (such as any of aerosol-generating articles 100, 200, 300, 400, 500, 600, 700, or 800). The composite structure 1000 has a laminated structure in which a first layer 1011 is layered on top of a second layer 1012. The first layer 1011 is formed from a sheet of susceptor material, such as a sheet of stainless steel or aluminum. The second layer 1012 is formed from a sheet of paper-based substrate. The paper-based substrate can be a substrate formed of paper or cardboard. In an alternative embodiment, an aerosol-forming substrate can be used in place of the paper-based substrate of the second layer 1012. For example, the composite structure 1000 can be used to form the planar upper layer 310 or the planar lower layer 320 of the aerosol-generating article 300 (see FIG. 3). In another example, the composite structure 1000 may be used to form the corrugated intermediate layer 340 of the aerosol-generating article 400 (see FIG. 7). In yet another example, the composite structure 1000 may be used to form the first planar outer layer 624 and the second planar outer layer 625 of the aerosol-generating article 600 (see FIGS. 9-13).
[0208] FIG. 18B illustrates a further embodiment of a composite structure 1000′ suitable for use in an aerosol-generating article (such as any of aerosol-generating articles 100, 200, 300, 400, 500, 600, 700, and 800). The composite structure 1000′ has a layer 1021 and particles or strips of susceptor material 1023 (e.g., stainless steel or aluminum particles or strips) applied onto a surface of the layer 1021. The layer 1021 is a sheet formed from a paper-based substrate. The paper-based substrate may be a substrate formed from paper or cardboard. An adhesive (not shown) may be used to facilitate adhesion of the particles or strips of susceptor material 1023 to the surface of the layer 1021. In an alternative embodiment, an aerosol-forming substrate may be used in place of the paper-based substrate of the layer 1021. Also, for example, the composite structure 1000' may be used to form the planar upper layer 310 or the planar lower layer 320 of the aerosol-generating article 300 (see FIG. 3). In another example, the composite structure 1000' may be used to form the corrugated middle layer 340 of the aerosol-generating article 400 (see FIG. 7). In yet another example, the composite structure 1000' may be used to form the first planar outer layer 624 and the second planar outer layer 625 of the aerosol-generating article 600 (see FIGS. 9-13).
[0209] FIG. 18C shows a further embodiment of a composite structure 1000″ suitable for use in an aerosol-generating article (such as any of aerosol-generating articles 100, 200, 300, 400, 500, 600, 700, or 800). The composite structure 1000″ has a layer 1031 containing a dispersion of particles or flakes 1033 of a susceptor material (e.g., stainless steel or aluminum particles or flakes). The layer 1031 is a sheet formed from a paper-based substrate. The paper-based substrate can be a substrate formed from paper or cardboard. In an alternative embodiment, an aerosol-forming substrate can be used in place of the paper-based substrate of the layer 1031. Also, for example, the composite structure 1000″ can be used to form the planar upper layer 310 or the planar lower layer 320 of the aerosol-generating article 300 (see FIG. 3 ). In another example, the composite structure 1000'' may be used to form the corrugated intermediate layer 340 of the aerosol-generating article 400 (see Figure 7). In yet another example, the composite structure 1000'' may be used to form the first planar outer layer 624 and the second planar outer layer 625 of the aerosol-generating article 600 (see Figures 9-13).
[0210] FIG. 19 shows a composite structure 2000 in the form of a sheet 2010 of paper-based substrate (e.g., a sheet of paper or cardboard) incorporating individual sheets 2020a-d of susceptor material (e.g., sheets of aluminum or stainless steel). Each of the sheets 2020a-d of susceptor material is spaced apart from one another by a distance "a" to define a spatially distinct susceptor region. When used in an aerosol-generating article (e.g., any of aerosol-generating articles 100, 200, 300, 400, 500, 600, 700, or 800), the composite structure 2000 is preferably arranged such that the individual sheets 2020a-d of susceptor material are spaced apart from one another along the airflow path or longitudinal axis (e.g., the x-direction) of the aerosol-generating article. For example, the composite structure 2000 can be used to form the planar upper layer 310 or the planar lower layer 320 of the aerosol-generating article 300 (see FIG. 3). In another example, the composite structure 2000 may be used to form the corrugated intermediate layer 340 of the aerosol-generating article 400 (see FIG. 7). In yet another example, the composite structure 2000 may be used to form the first planar outer layer 624 and the second planar outer layer 625 of the aerosol-generating article 600 (see FIGS. 9-13).
[0211] For illustrative purposes applicable to any of the above-described embodiments, the composition of a suitable aerosol-forming substrate may be as follows: Percentages are given in weight percent relative to the product in its final state. The aerosol-forming substrate may have a moisture content of about 5-25%, preferably about 7-15%, in the final product. The aerosol-forming substrate may further comprise: 1. Tobacco leaf; for example, a tobacco leaf blend containing about 15-45%, preferably about 20-35%, of at least one of the following tobacco leaf types: bright tobacco leaf, dark tobacco leaf, and aromatic tobacco leaf. The tobacco material is ground and graded to a particle size of about 100-380 mesh, preferably about 170-320 mesh. 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. 3. Tobacco fiber, e.g., about 5-20%, preferably about 7-15%, of any tobacco type or blend of tobacco types as a filler. The tobacco fiber is preferably derived from stems and / or petioles graded to fibers of about 10-350 μm, preferably about 10-180 μm in length. 4. Binder: for example, about 1-10%, preferably about 1-5%, of a binder such as any of the common gums or pectins used in the food and beverage (F&B) industry. Preferred binders include natural pectins, such as fruit pectins, e.g., citrus pectins, or tobacco pectins; guar gum, land locust bean gum, e.g., hydroxyethyl and / or hydroxypropyl versions of these gums; starches, e.g., modified or derivatized starches; alginates; methylcellulose, ethylcellulose, ethylhydroxymethylcellulose, and carboxymethylcellulose; dextran; and xanthan gum. A preferred binder is guar. 5. Aerosol formers, e.g., about 5-35%, preferably about 10-25%, of an aerosol former. Suitable aerosol formers known in the art include glycerin; monohydric alcohols such as menthol, polyhydric alcohols such as triethylene glycol; esters of polyhydric alcohols such as glycerol monoacetate, glycerol diacetate, or glycerol triacetate; and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids, e.g., their dimethyl esters.
[0212] "Tobacco type" means one of various types of tobacco, for example, based on different curing processes that are performed on the tobacco before it is further processed into tobacco products.
[0213] For illustrative purposes, further aerosol-forming substrate compositions that may also be suitable for use as the aerosol-forming substrate in any of the above-described embodiments are described below. Percentages are given in weight percent relative to the final product. The aerosol-forming substrate may include: 1. An aerosol former, such as glycerin; for example, about 10-40%, preferably about 20-30%. 2. Organic fiber: any suitable plant variety commonly available on the market, with a purity of, for example, about 10% to 30%, preferably about 15% to 25%, that meets the applicable FDA F&B grade requirements. For example, organic fiber may be obtained from cellulose, cotton, wood, or tea plant varieties as by-products or by-processing waste from the F&B tea industry. The organic fiber preferably has a length of about 10 to 400 μm, and more preferably about 10 to 200 μm. 3. Organic vegetable glycerides; for example, about 15 to 55%, preferably about 20 to 35%, of plants such as clove, echinacea, fennel, ginger, hawthorn berry, elderberry, monarda, mullein leaf, nettle, plantain, turmeric, yarrow, and complexes thereof. 4. Organic plant extracts; for example, about 1% to 15%, preferably 2% to 7%, of any of the aforementioned plants, as well as menthol (dl-menthol, C 10 H 20 O, 2-isopropyl-5-methylcyclohexanol), and P-menthone-3-ol as an optional secondary alcohol as a diastereoisomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.
[0214] Alternatively, such an aerosol-forming substrate may also contain about 0.5 to 5%, preferably about 1 to 3%, of plant-based essential oils such as palm-based essential oils, coconut-based essential oils, and wood-based essential oils.
[0215] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are to be understood in all instances as modified by the term "about." Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number "A" is to be understood as "A" ± 10% of "A." Within this context, the number "A" may be considered to include numerical values that are within the common standard error of measurement for the property that the number "A" modifies. The number "A," in some cases as used in the appended claims, may deviate by the percentages recited above, provided that the amount by which "A" deviates does not materially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. The terms "in which" and "wherein" are used interchangeably throughout this specification.
Claims
1. 1. An aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article comprising a substantially planar upper surface and a substantially planar lower surface, the upper surface and the lower surface being vertically spaced apart from each other by a height defined in the z-direction, the aerosol-generating article further comprising an aerosol-forming substrate and one or more susceptor materials, the one or more susceptor materials being arranged in thermal communication with the aerosol-forming substrate.
2. 10. The aerosol-generating article of claim 1, wherein one or more susceptor materials are in direct contact with the aerosol-forming substrate.
3. 3. The aerosol-generating article of claim 1, wherein one or more susceptor materials are incorporated within the aerosol-forming substrate.
4. 4. The aerosol-generating article of claim 3, wherein particles of susceptor material are dispersed within the aerosol-forming substrate.
5. An aerosol-generating article according to any one of claims 1 to 4, wherein the one or more susceptor materials are incorporated within the aerosol-generating article as one or more strips, threads or wires of susceptor material.
6. 6. The aerosol-generating article of claim 5, wherein one or more strips, threads, or wires of susceptor material are located within the airflow path of the aerosol-generating article.
7. An aerosol-generating article according to any one of claims 1 to 6, wherein one or more susceptor materials are incorporated within the aerosol-generating article as sheets or layers of one or more susceptor materials.
8. 8. The aerosol-generating article of claim 7, wherein one or more sheets or layers of susceptor material are located within or at least partially define the airflow path of the aerosol-generating article.
9. 9. An aerosol-generating article according to claim 7 or 8, wherein one or more sheets or layers of susceptor material cover an outer portion of the aerosol-generating article.
10. 10. The aerosol-generating article of any one of claims 1 to 9, comprising a plurality of susceptor regions spaced apart from one another and arranged in thermal communication with the aerosol-forming substrate, the plurality of susceptor regions comprising or consisting of one or more susceptor materials.
11. 11. The aerosol-generating article of claim 10, wherein the plurality of susceptor regions comprise one or more susceptor materials layered on or incorporated within a paper-based or aerosol-forming substrate.
12. 12. An aerosol-generating article according to any one of claims 1 to 11, further comprising an intermediate layer disposed between an upper layer and a lower layer, the upper surface defining an outer surface of the upper layer and the lower surface defining an outer surface of the lower layer, and an airflow path defined through the aerosol-generating article in the x / y plane between the distal end and the proximal end of the aerosol-generating article.
13. 13. The aerosol-generating article of claim 12, wherein at least one of the upper layer, the middle layer, and the lower layer comprises or consists of one or more susceptor materials.
14. 12. An aerosol-generating article according to any one of claims 1 to 11, further comprising a planar frame positioned between an upper layer and a lower layer, the upper surface defining an outer surface of the upper layer, the lower surface defining an outer surface of the lower layer, the planar frame defining a cavity, an airflow path defined through the aerosol-generating article in the x / y plane, the airflow path passing through the cavity.
15. 15. The aerosol-generating article of claim 14, wherein one or both of the upper layer and the lower layer comprises or consists of one or more susceptor materials.