Aerosol-generating items

Abstract

Aerosol-generating items An aerosol-generating article (100) for use in an aerosol-generating device is provided. The aerosol-generating article (100) comprises a substantially planar upper surface (110), a substantially planar lower surface (120), and an aerosol-forming substrate. The upper and lower surfaces (110, 120) are vertically spaced apart from each other by a height defined in the z-direction. At least 50% by weight of the aerosol-generating article (100) is paper or cardboard.

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 look similar to a conventional cigarette. For example, such an aerosol-generating article may be a substantially cylindrical article comprising an aerosol-forming substrate and other components, such as a mouthpiece filter element, all wrapped in cigarette paper. The dimensions of a typical aerosol-generating article are often similar to those of a conventional cigarette.

[0003] Studies have shown that in such typical aerosol-generating articles including a plug of aerosol-forming substrate, a large 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 transporting 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. Summary of the Invention

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

[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. At least 50% by weight of the aerosol-generating article may be paper or cardboard.

[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 having a substantially planar upper surface defined by a length extending in the x-direction and a width extending in the y-direction, and a substantially planar lower surface defined by a length extending in the x-direction and a width extending in the y-direction. The substantially planar upper surface and the substantially planar lower surface may be vertically spaced apart from each other by a height defined in the z-direction. At least 50% by weight of the aerosol-generating article may be paper or cardboard.

[0007] According to the present disclosure, there may be provided an aerosol-generating article for use in an aerosol-generating device, the aerosol-generating article comprising a substantially planar upper surface, a substantially planar lower surface, and an aerosol-forming substrate. The upper and lower surfaces may be vertically spaced apart from each other by a height defined in the z-direction. At least 50% by weight of the aerosol-generating article may be paper or cardboard.

[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 use of paper or cardboard to form the majority of the mass of an aerosol-generating article can provide an article that can be disposed of and / or recycled with reduced environmental impact. For example, the use of paper or cardboard rather than cellulose acetate enhances the disposability and recyclability of the aerosol-generating article.

[0011] The aerosol-generating articles of the present disclosure are generally flat and thin. Providing a generally flat and thin aerosol-generating article allows for rapid and efficient heating of the aerosol-forming substrate and improved uniformity in heating throughout its thickness. The use of paper or cardboard to form at least 50% by weight of the aerosol-generating article provides an aerosol-generating article with improved sustainability. Paper and cardboard are also particularly suitable for being formed and provided in a flat form to match the flat shape of the aerosol-generating articles of the present disclosure. The aerosol-generating article preferably does not contain any single-use plastic. 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).

[0012] At least 55% by weight, or at least 60% by weight, or at least 65% by weight, or at least 70% by weight, or at least 75% by weight, or at least 80% by weight, or at least 85% by weight, or at least 90% by weight of the aerosol-generating article, excluding the aerosol-forming substrate, may be paper or cardboard. Increasing the proportion of the aerosol-generating article made from paper or cardboard enhances the disposability and recyclability of the aerosol-generating article, with reduced environmental impact. Advantageously, substantially the entire aerosol-generating article, excluding the aerosol-forming substrate and adhesive (if present), may be paper or cardboard.

[0013] Preferably, the aerosol-generating article has a cellulose acetate content of less than 5%, or less than 3%, or less than 1%. Cellulose acetate recycling facilities are relatively rare. Therefore, reducing the cellulose acetate content increases the recyclability of the aerosol-generating article.

[0014] The aerosol-generating article may comprise a frame disposed between a substantially planar upper surface and a substantially planar lower surface. The frame may define one or more cavities. The frame may comprise or consist of paper or cardboard. The one or more cavities defined by the frame may contain an aerosol-forming substrate and / or may form part of an airflow path extending through the aerosol-generating article.

[0015] The aerosol-generating article may comprise a laminated structure disposed between a substantially planar upper surface and a substantially planar lower surface. The laminated structure may comprise two or more layers disposed on top of one another. The layers may comprise or consist of paper or cardboard.

[0016] The laminate structure may define a frame, which preferably defines one or more cavities which may contain an aerosol-forming substrate and / or form part of an airflow path extending through the aerosol-generating article.

[0017] The layers of the laminate structure may be bonded to one another by an adhesive, optionally the adhesive is guar gum or PVOH.

[0018] Each of the layers may extend the length of the aerosol-generating article.

[0019] Each of the layers of the laminate structure may have a thickness in the range of 0.1 millimeters to 5 millimeters, or 0.4 millimeters to 4 millimeters, or about 0.5 millimeters, or about 1 millimeter.

[0020] The laminated structure may define at least a portion of an airflow path through the aerosol-generating article between the distal end and the proximal end of the aerosol-generating article. The laminated structure may define a frame, the frame defining one or more cavities, the airflow path extending through the one or more cavities. At least a portion of the aerosol-forming substrate may be disposed in the cavity.

[0021] The paper or cardboard may have a basis weight of 300 grams per square meter or more. The paper or cardboard may have a basis weight of 350 grams per square meter or more. The paper or cardboard may have a basis weight of 390 grams per square meter or more. The paper or cardboard may have a basis weight of 420 grams per square meter or more. The paper or cardboard may have a basis weight of 620 grams per square meter or more. The paper or cardboard may have a basis weight of 720 grams per square meter or more. The paper or cardboard may have a basis weight of 800 grams per square meter or more.

[0022] The paper or cardboard may have a basis weight of 900 grams per square meter or less. The cellulosic material may have a basis weight of 800 grams per square meter or less. The paper or cardboard may have a basis weight of 720 grams per square meter or less. The paper or cardboard may have a basis weight of 620 grams per square meter or less. The paper or cardboard may have a basis weight of 420 grams per square meter or less. The paper or cardboard may have a basis weight of 390 grams per square meter or less. The paper or cardboard may have a basis weight of 350 grams per square meter or less.

[0023] The paper or cardboard may have a basis weight of 300 grams per square meter to 900 grams per square meter. The paper or cardboard may have a basis weight of 300 grams per square meter to 800 grams per square meter. The paper or cardboard may have a basis weight of 350 grams per square meter to 800 grams per square meter. The paper or cardboard may have a basis weight of 400 grams per square meter to 700 grams per square meter.

[0024] Preferably, the frame or laminate structure may extend in the z-direction over at least 85%, or at least 90%, or at least 95%, or at least 97.5%, or 100% of its height. The frame or laminate structure may provide the majority of the bending stiffness of the aerosol-generating article.

[0025] The frame or laminate structure may have a height defined in the z-direction, the height of the frame or laminate structure being 5 millimeters or less.

[0026] The upper and lower surfaces may be parallel to each other.

[0027] The aerosol-generating article may have a length extending between the distal end and the proximal end of the aerosol-generating article, and 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 the entire 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 located closer to the distal end than the proximal end. The aerosol-forming substrate may extend to the distal end. The proximal end may be the oral end of the aerosol-generating article.

[0028] An airflow path may be defined through the aerosol-generating article between the distal end and the proximal end of the aerosol-generating article.

[0029] 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 temperature difference across the height of the aerosol-generating article during heating. For example, if the base of the aerosol-generating article is in contact with (and heated by) 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 larger portion 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 in addition, this may reduce the time required to heat the aerosol-forming substrate sufficiently to emit an aerosol.

[0030] An aerosol-generating article according to any of the embodiments disclosed herein may have an airflow path extending 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 extracted from the aerosol-generating article and directed to the user.

[0031] 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.

[0032] An aerosol-generating article according to any of the embodiments disclosed herein may have 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.

[0033] 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.

[0034] The resistance to draw (RTD) of the aerosol-generating article along the airflow path may be less than 20 millimeters H2O.

[0035] One or more of the top, middle and bottom layers may comprise or consist of paper or cardboard.

[0036] One or both of the upper and lower layers may comprise or consist of an aerosol-forming substrate, and the middle layer comprises or consists of paper or cardboard.

[0037] The middle layer may comprise or consist of an aerosol-forming substrate, and the upper and lower layers may comprise or consist of paper or cardboard.

[0038] A plurality of longitudinally extending channels may be defined by corrugations between the upper and middle layers and between the middle and lower layers. The longitudinally extending channels may extend along an x / y plane between the distal end and the proximal end.

[0039] The middle layer may be secured to at least one of the upper and lower layers by an adhesive. By way of example, the adhesive may include guar gum. The adhesive may include an aerosol-forming material, such as a homogenized tobacco slurry.

[0040] The intermediate layer may comprise a corrugated element. The corrugated element may comprise or consist of an aerosol-forming substrate. The corrugated element may comprise or consist of paper or cardboard.

[0041] The intermediate layer may comprise a plurality of corrugated elements, two or more of which may be disposed in a mutually perpendicular relationship between the upper and lower layers, and the intermediate layer may further comprise a planar element positioned between two of the plurality of corrugated elements.

[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. At least 50% by weight of the aerosol-generating article may be paper or cardboard.

[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 while being 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 comprise a planar frame positioned between the upper layer and the lower layer. The upper surface may define an outer surface of the upper layer. 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 extending through the cavity.

[0045] The upper and lower layers may be bonded to opposite surfaces of the frame and overlie opposite ends of the cavity.

[0046] Preferably, one or more of the upper layer, lower layer and frame may comprise or consist of paper or cardboard. Preferably, at least the frame comprises or consists of paper or cardboard. Advantageously, each of the upper layer, lower layer and frame comprises or consists of cardboard.

[0047] When one or both of the upper and lower layers comprise or consist of paper or cardboard: The paper or cardboard used in the upper and / or lower layers may have a basis weight of more than 10 grams per square meter. The paper or cardboard used in the upper and / or lower layers may have a basis weight of more than 20 grams per square meter. The paper or cardboard used in the upper and / or lower layers may have a basis weight of less than 30 grams per square meter. The paper or cardboard used in the upper and / or lower layers may have a basis weight of less than 25 grams per square meter. The paper or cardboard used in the upper and / or lower layers may have a basis weight of between 10 grams per square meter and 30 grams per square meter. The paper or cardboard used in the upper and / or lower layers may have a basis weight of between 15 grams per square meter and 25 grams per square meter.

[0048] If the frame comprises or consists of paper or cardboard: The paper or cardboard used in the frame may have a basis weight of 300 grams per square meter or more. The paper or cardboard used in the frame may have a basis weight of 350 grams per square meter or more. The paper or cardboard used in the frame may have a basis weight of 390 grams per square meter or more. The paper or cardboard used in the frame may have a basis weight of 420 grams per square meter or more. The paper or cardboard used in the frame may have a basis weight of 620 grams per square meter or more. The paper or cardboard used in the frame may have a basis weight of 720 grams per square meter or more. The paper or cardboard used in the frame may have a basis weight of 800 grams per square meter or more.

[0049] If the frame comprises or consists of paper or cardboard: The paper or cardboard used in the frame may have a basis weight of 900 grams per square meter or less. The paper or cardboard used in the frame may have a basis weight of 800 grams per square meter or less. The paper or cardboard used in the frame may have a basis weight of 720 grams per square meter or less. The paper or cardboard used in the frame may have a basis weight of 620 grams per square meter or less. The paper or cardboard used in the frame may have a basis weight of 420 grams per square meter or less. The paper or cardboard used in the frame may have a basis weight of 390 grams per square meter or less. The paper or cardboard used in the frame may have a basis weight of 350 grams per square meter or less.

[0050] If the frame comprises or consists of paper or cardboard: The paper or cardboard used in the frame may have a basis weight of 300 grams per square meter to 900 grams per square meter. The paper or cardboard used in the frame may have a basis weight of 300 grams per square meter to 800 grams per square meter. The paper or cardboard used in the frame may have a basis weight of 350 grams per square meter to 800 grams per square meter. The paper or cardboard used in the frame may have a basis weight of 400 grams per square meter to 700 grams per square meter.

[0051] One or both of the upper and lower layers may comprise or consist of an aerosol-forming substrate, and the frame comprises or consists of paper or cardboard.

[0052] Both the upper and lower layers may comprise or consist of paper or cardboard, and the frame comprises or consists of an aerosol-forming substrate.

[0053] Preferably, each of the upper layer, lower layer and frame may comprise or consist of paper or cardboard. The aerosol-forming substrate may be contained within a cavity between the upper and lower layers.

[0054] The corrugated element may be disposed within a cavity between the upper and lower layers. The corrugated element may comprise or consist of an aerosol-forming substrate. The corrugated element may comprise or consist of paper or cardboard. A plurality of longitudinally extending channels may be defined by the corrugations between the upper layer and the corrugated element and between the corrugated element and the lower layer. The longitudinally extending channels may extend along the x / y plane between opposing ends of the frame.

[0055] The airflow path is preferably defined at least in part by the frame. The frame may include 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. 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.

[0056] According to the present disclosure, there may be provided an aerosol-generating article comprising: a first out-of-plane surface, a second out-of-plane surface, a cavity, a frame positioned between the first out-of-plane surface and the second out-of-plane surface, the frame at least partially defining the cavity, an aerosol-forming substrate positioned between the first out-of-plane surface and the second out-of-plane surface, an air inlet and an air outlet, and an airflow passage extending through the cavity between the air inlet and the air outlet. At least 50% by weight of the aerosol-generating article may be paper or cardboard.

[0057] The frame may be as described in any of the preceding paragraphs.

[0058] The frame may comprise a peripheral wall that at least partially surrounds or encloses the cavity. The frame may comprise a peripheral wall that completely surrounds or encloses the cavity.

[0059] The aerosol-generating article may comprise 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.

[0060] The cavity may be substantially empty.

[0061] The aerosol-forming substrate may be positioned within the cavity.

[0062] The corrugated layer may be positioned within the cavity.

[0063] Any aerosol-generating article according to embodiments 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.

[0064] 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.

[0065] 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.

[0066] Any aerosol-generating article according to the embodiments 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. If the aerosol-generating article has 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. The periphery of the aerosol-generating article, when viewed in a plan view, may be formed with a plurality of straight sides, a plurality of curved sides, or a combination of straight and curved sides. If the aerosol-generating article has substantially planar upper and lower surfaces, the periphery 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.

[0067] The aerosol-generating article may consist entirely of the aerosol-forming substrate, or the aerosol-forming substrate may be one of several component parts of the aerosol-generating article.

[0068] The aerosol-forming substrate may comprise nicotine, which may be present in the form of tobacco material or in the form of a nicotine extract.

[0069] 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.

[0070] 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.

[0071] 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, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.). It may be particularly preferred that the aerosol former is or comprises glycerin.

[0072] 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 by weight, or more than 25 percent by weight, or more than 30 percent by weight, or more than 40 percent by weight, or more than 50 percent by weight of aerosol formers.

[0073] 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.

[0074] The aerosol-forming substrate may comprise from 1 weight percent to 30 weight percent aerosol formers, from 1 weight percent to 25 weight percent aerosol formers, or from 1 weight percent to 20 weight percent aerosol formers.

[0075] The aerosol-forming substrate may comprise 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.

[0076] The aerosol-forming substrate may comprise 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.

[0077] The aerosol-forming substrate may comprise 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.

[0078] 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.

[0079] The aerosol-forming substrate may comprise 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.

[0080] The aerosol-forming substrate may 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.

[0081] The aerosol-forming substrate may 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.

[0082] The aerosol-forming substrate may 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.

[0083] 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.

[0084] 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.

[0085] The aerosol-forming substrate may comprise 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). Preferably, the cannabinoid compound is CBD or THC. Particularly preferably, the cannabinoid compound is CBD.

[0086] 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, or 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 (e.g., peppermint, 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.

[0087] 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.

[0088] The aerosol-forming substrate may comprise tobacco, for example a blend of about 15-45%, preferably about 20-35%, tobacco, incorporating at least one of bright tobacco, dark tobacco, and aromatic tobacco. The tobacco material, such as tobacco, is preferably ground and graded to a particle size of about 100-380 mesh, preferably about 170-320 mesh.

[0089] "Tobacco variety" means one of the different types of tobacco, based, for example, on the unique curing process that occurs before the tobacco is further processed into tobacco products.

[0090] Examples of bright tobaccos include Brazilian Fulcure, Indian Fulcure, Chinese Fulcure, American Fulcure, e.g., Virginia tobacco, and Tanzanian Fulcure.

[0091] 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.

[0092] Examples of dark tobaccos include dark-cured Brazilian Galpao, Burley Malawi or other African Burley, Sun-cured or air-cured Indonesian Kastri.

[0093] 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. The cellulose fibers may have a length of about 10 to 250 μm, preferably about 10 to 120 μm.

[0094] 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 and are 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.

[0095] 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 one of the common gums or pectins used in the food and beverage (F&B) industry. Preferred binders may be natural pectin (e.g., fruit (e.g., citrus) pectin or tobacco pectin), guar gum, land locust bean gum (e.g., their hydroxyethyl and / or hydroxypropyl derivatives), starch (e.g., modified starch or derivatized starch), alginate, methylcellulose, ethylcellulose, ethylhydroxymethylcellulose, carboxymethylcellulose, dextran, or xanthan gum. A preferred binder is guar.

[0096] The aerosol-forming substrate may comprise organic vegetable glycerite. For example, the aerosol-forming substrate may comprise about 15-55%, preferably about 20-35%, of botanical ingredients such as clove, echinacea species, fennel, ginger, hawthorn berry, elderberry, monarda, mullein leaf, nettle, plantain, turmeric, yarrow, and composites thereof.

[0097] 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 any of the aforementioned plants, as well as menthol (dl-menthol, C ) obtained from 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.

[0098] The aerosol-forming substrate may contain, for example, about 0.5 to 5%, preferably about 1 to 3%, of a plant essential oil (such as palm oil, coconut oil, or wood-based essential oil).

[0099] The aerosol-forming substrate preferably comprises an aerosol former, for example, 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 mono-, di-, or polycarboxylic acids (such as the dimethyl esters thereof).

[0100] Paper and cardboard are primarily composed of cellulose (e.g., cellulose fibers). By way of example, paper and cardboard may be made from wood pulp, cotton, flax, straw, hemp, or jute. Paper and cardboard may include lignin, e.g., when paper and cardboard include cellulose fibers and lignin, the lignin facilitates binding the cellulose fibers together. Cardboard may be single-ply or multi-ply. The term cardboard encompasses cardboard.

[0101] As used herein, the term "aerosol-generating article" may refer to an article that is capable of generating (or emitting) an aerosol.

[0102] 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.

[0103] As used herein, the term "aerosol-generating device" may refer to a device used in conjunction with an aerosol-generating article to enable the generation (or emission) of an aerosol.

[0104] 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.

[0105] As used herein, the term "aerosol former" may refer to any suitable known compound or mixture of compounds that facilitates the formation of an aerosol upon use. 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.

[0106] As used herein in connection with the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salts.

[0107] As used herein in connection with 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.

[0108] 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 may be drawn longitudinally through the aerosol-generating article.

[0109] 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, the sheet of material used to form the aerosol-forming substrate described herein may have a thickness of from 10 μm to about 1000 μm, e.g., from 10 μm to about 300 μm.

[0110] 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, 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. A sheet of homogenized tobacco material may be produced by casting, extrusion, a papermaking process, or any other suitable process known in the art.

[0111] The term "cast leaf" is used herein to refer 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 belt conveyor), drying the slurry, and removing the dried sheet from the support surface. Examples of casting 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 allowed to dry into a sheet of homogenized plant material. Preferably, the homogenized plant material used in the article according to the present invention can be produced by casting. Such homogenized plant material may include agglomerated particulate plant material.

[0112] As used herein, withdrawal resistance is expressed in units of pressure "mmH2O" or "mm WG" or "millimeters of water column" and may be measured in accordance with ISO 6565:2002.

[0113] 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 of any other example, embodiment, or aspect described herein. [Brief explanation of the drawings]

[0114] [Figure 1] FIG. 1 is a perspective 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 shows a perspective view of an aerosol-generating article according to a fourth embodiment of the present disclosure. [Figure 8] FIG. 8 shows an exploded perspective view of the aerosol-generating article of FIG. [Figure 9] FIG. 9 shows a further exploded perspective view of the aerosol-generating article of FIG. [Figure 10] FIG. 10 shows a schematic transverse cross-section of the aerosol-generating article of FIG. [Figure 11] FIG. 11 shows a schematic longitudinal cross-sectional view of the aerosol-generating article of FIG. [Figure 12]FIG. 12 shows an exploded perspective view of an aerosol-generating article according to a fifth embodiment of the present disclosure. [Figure 13] FIG. 13 shows a schematic transverse cross-section of the aerosol-generating article of FIG. [Figure 14] FIG. 14 shows a schematic transverse cross-sectional view of the aerosol-generating article of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0115] Example 1: An aerosol-generating article for use in an aerosol-generating device, comprising: a substantially planar upper surface and a substantially planar lower surface; an aerosol-forming substrate; the upper and lower surfaces are spaced apart perpendicularly from one another by a height defined in the z direction; An aerosol-generating article, wherein at least 50% by weight of the aerosol-generating article is paper or cardboard.

[0116] Example 2: An aerosol-generating article as described in Example 1, wherein at least 55% by weight, or at least 60% by weight, or at least 65% by weight, or at least 70% by weight, or at least 75% by weight, or at least 80% by weight, or at least 85% by weight, or at least 90% by weight of the aerosol-generating article, excluding the aerosol-forming substrate, is paper or cardboard.

[0117] Example 3: An aerosol-generating article as described in Example 2, wherein substantially the entire aerosol-generating article, excluding the aerosol-forming substrate and adhesive (if present), is paper or cardboard.

[0118] Example 4: An aerosol-generating article according to any one of Examples 1 to 3, wherein the aerosol-generating article has a cellulose acetate content of less than 5%, or less than 3%, or less than 1%.

[0119] Example 5: An aerosol-generating article described in any one of Examples 1 to 4, wherein the aerosol-generating article comprises a frame disposed between a substantially planar upper surface and a substantially planar lower surface, the frame defining one or more cavities, and the frame comprising or consisting of paper or cardboard.

[0120] Example 6: An aerosol-generating article described in any one of Examples 1 to 5, wherein the aerosol-generating article comprises a laminated structure disposed between a substantially planar upper surface and a substantially planar lower surface, the laminated structure comprising two or more layers overlapping each other, and the layers comprising or consisting of paper or cardboard.

[0121] Example 7: An aerosol-generating article as described in Example 6, wherein the layers of the laminate structure are bonded to one another by an adhesive, optionally the adhesive being guar gum or PVOH.

[0122] Example 8: An aerosol-generating article as described in either Example 6 or Example 7, wherein each of the layers extends the length of the aerosol-generating article.

[0123] Example 9: An aerosol-generating article described in any one of Examples 6 to 8, wherein each layer of the laminated structure has a thickness in the range of 0.1 millimeters to 5 millimeters, or 0.4 millimeters to 4 millimeters, or about 0.5 millimeters, or about 1 millimeter.

[0124] Example 10: An aerosol-generating article as described in Example 9, wherein the laminate structure defines at least a portion of an airflow path through the aerosol-generating article between the distal end and the proximal end of the aerosol-generating article.

[0125] Example 11: An aerosol-generating article according to Example 10, wherein the laminate structure defines a frame, the frame defines one or more cavities, and the airflow pathway extends through the cavities.

[0126] Example 12: An aerosol-generating article as described in Example 11, wherein at least a portion of the aerosol-forming substrate is disposed in a cavity.

[0127] Example 13: An aerosol-generating article described in any one of Examples 5 to 12, wherein the paper or cardboard content of the frame or laminated structure has a basis weight of 300 grams / square meter or more, or 350 grams / square meter or more, or 390 grams / square meter or more, or 420 grams / square meter or more, or 620 grams / square meter or more, or 720 grams / square meter or more, or 800 grams / square meter or more.

[0128] Example 13A: An aerosol-generating article described in any one of Examples 5 to 13, wherein the paper or cardboard content of the frame or laminated structure has a basis weight of 900 grams per square meter or less, or a basis weight of 800 grams per square meter or less, or a basis weight of 720 grams per square meter or less, or a basis weight of 620 grams per square meter or less, or a basis weight of 420 grams per square meter or less, or a basis weight of 390 grams per square meter or less, or a basis weight of 350 grams per square meter or less.

[0129] Example 13B: An aerosol-generating article described in any one of Examples 5 to 13A, wherein the paper or cardboard content of the frame or laminate structure has a basis weight of 300 grams / square meter to 900 grams / square meter, or a basis weight of 300 grams / square meter to 800 grams / square meter, or a basis weight of 350 grams / square meter to 800 grams / square meter, or a basis weight of 400 grams / square meter to 700 grams / square meter.

[0130] Example 14: An aerosol-generating article described in any one of Examples 5 to 13B, wherein the frame or laminate structure extends in the z-direction over at least 85%, or at least 90%, or at least 95%, or at least 97.5%, or 100% of its height. Example 15: An aerosol-generating article described in any one of Examples 5 to 14, wherein the frame or laminate structure has a height defined in the z-direction, and the height of the frame or laminate structure is 5 millimeters or less.

[0131] 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.

[0132] Example 17: An aerosol-generating article according to any one of Examples 1 to 16, wherein the aerosol-generating article has a length extending between the distal end and the proximal end of the aerosol-generating article, and wherein 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.

[0133] 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.

[0134] Example 19: An aerosol-generating article according to either Example 17 or Example 18, wherein the aerosol-forming substrate extends to the distal end.

[0135] Example 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.

[0136] Example 20a: An aerosol-generating article according to any one of Examples 1 to 20, wherein an airflow path is defined through the aerosol-generating article between the distal end and the proximal end of the aerosol-generating article.

[0137] Example 21: An aerosol-generating article described in any one of Examples 1 to 20a, 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.

[0138] 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 H2O.

[0139] Example 23: An aerosol-generating article according to either Example 21 or Example 22, wherein one or more of the upper layer, middle layer, and lower layer comprises or consists of paper or cardboard.

[0140] Example 24: An aerosol-generating article according to any one of Examples 21 to 23, 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 paper or cardboard.

[0141] Example 25: An aerosol-generating article according to any one of Examples 21 to 23, wherein the middle layer comprises or consists of an aerosol-forming substrate, and the upper and lower layers comprise or consist of paper or cardboard.

[0142] Example 26: An aerosol-generating article described in any one of Examples 21 to 25, wherein a plurality of longitudinally extending channels are defined by corrugations between the upper and middle layers and between the middle and lower layers.

[0143] Example 27: An aerosol-generating article as described in Example 26, wherein the longitudinally extending channels extend along the x / y plane between the distal end and the proximal end.

[0144] Example 28: An aerosol-generating article described in any one of Examples 21 to 27, 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.

[0145] Example 29: An aerosol-generating article according to any one of Examples 21 to 28, wherein the intermediate layer comprises corrugated elements.

[0146] Example 30: An aerosol-generating article as described in Example 29, wherein the corrugated element comprises or consists of an aerosol-forming substrate.

[0147] Example 30a: The aerosol-generating article of Example 29, wherein the corrugated elements comprise or consist of paper or cardboard.

[0148] Example 31: An aerosol-generating article described in any one of Examples 29 to 30a, wherein the intermediate layer has a plurality of corrugated elements, and two or more of the corrugated elements are arranged in a mutually perpendicular relationship between the upper and lower layers.

[0149] Example 32: An aerosol-generating article as described in Example 31, wherein the intermediate layer further comprises a planar element positioned between two of the plurality of corrugated elements.

[0150] Example 33: An aerosol-generating article described in any one of Examples 1 to 20a, 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.

[0151] Example 34: An aerosol-generating article as described in Example 33, wherein the upper and lower layers are bonded to opposite surfaces of the frame and overlie opposite ends of the cavity.

[0152] Example 35: An aerosol-generating article according to either Example 33 or Example 34, wherein one or more of the upper layer, lower layer, and frame comprises or consists of paper or cardboard.

[0153] Example 35A: An aerosol-generating article according to Example 35, wherein at least the frame comprises or consists of paper or cardboard.

[0154] Example 35B: An aerosol-generating article according to either Example 35 or Example 35A, wherein each of the upper layer, lower layer, and frame comprises or consists of paper or cardboard.

[0155] Example 35C: An aerosol-generating article described in any one of Examples 35 to 35B, wherein the paper or cardboard content of the frame has a basis weight of 300 grams / square meter or more, or 350 grams / square meter or more, or 390 grams / square meter or more, or 420 grams / square meter or more, or 620 grams / square meter or more, or 720 grams / square meter or more, or 800 grams / square meter or more.

[0156] Example 35D: An aerosol-generating article described in any one of Examples 35 to 35C, wherein the paper or cardboard content of the frame or laminated article has a basis weight of 900 grams per square meter or less, or a basis weight of 800 grams per square meter or less, or a basis weight of 720 grams per square meter or less, or a basis weight of 620 grams per square meter or less, or a basis weight of 420 grams per square meter or less, or a basis weight of 390 grams per square meter or less, or a basis weight of 350 grams per square meter or less.

[0157] Example 35E: An aerosol-generating article described in any one of Examples 35 to 35D, wherein the paper or cardboard content of the frame or laminated article has a basis weight of 300 grams per square meter to 900 grams per square meter, or a basis weight of 300 grams per square meter to 800 grams per square meter, or a basis weight of 350 grams per square meter to 800 grams per square meter, or a basis weight of 400 grams per square meter to 700 grams per square meter.

[0158] Example 36: An aerosol-generating article described in any one of Examples 33 to 35D, wherein one or both of the upper and lower layers comprises or consists of an aerosol-forming substrate, and the frame comprises or consists of paper or cardboard.

[0159] Example 37: An aerosol-generating article described in any one of Examples 33 to 35D, wherein both the upper and lower layers comprise or consist of paper or cardboard, and the frame comprises or consists of an aerosol-forming substrate.

[0160] Example 38: An aerosol-generating article described in any one of Examples 33 to 35D, wherein each of the upper layer, lower layer, and frame comprises or consists of paper or cardboard, and the aerosol-forming substrate is contained within a cavity between the upper and lower layers.

[0161] Example 39: An aerosol-generating article according to any one of Examples 33 to 38, wherein the corrugated element is disposed within a cavity between the upper and lower layers.

[0162] Example 40: An aerosol-generating article as described in Example 39, wherein the corrugated element comprises or consists of an aerosol-forming substrate.

[0163] Example 41: An aerosol-generating article as described in Example 39, wherein the corrugated elements comprise or consist of paper or cardboard.

[0164] Example 42: An aerosol-generating article described in any one of Examples 39 to 41, 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.

[0165] Example 43: An aerosol-generating article as described in Example 42, wherein the longitudinally extending channels extend along the x / y plane between opposing ends of the frame.

[0166] Example 44: An aerosol-generating article according to any one of Examples 33 to 43, wherein the airflow path is at least partially defined by a frame.

[0167] Example 45: An aerosol-generating article as described in Example 44, 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.

[0168] Example 46: An aerosol-generating article as described in Example 45, wherein the inlet airflow channel and the outlet airflow channel are defined on opposite ends of the frame.

[0169] Example 47: An aerosol-generating article described in either Example 45 or Example 46, 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.

[0170] The embodiments will now be further described with reference to the figures.

[0171] 1 illustrates 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.

[0172] The aerosol-generating article 100 is primarily constructed from paper or cardboard, with the aerosol-generating article 100 being formed from more than 50% by weight of paper or cardboard. The paper and cardboard provide the majority of the bending stiffness to the aerosol-generating article 100.

[0173] The aerosol-generating article 100 also includes an aerosol-forming substrate (not shown). In another embodiment, the aerosol-forming substrate may be one of multiple component parts 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. If the aerosol-forming substrate is excluded, the remainder of the aerosol-generating article 100 is substantially composed of paper or cardboard. The aerosol-generating article 100 does not include cellulose acetate.

[0174] A suitable aerosol-forming substrate may be homogenized tobacco.

[0175] 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.

[0176] FIG. 2 illustrates a side perspective view of an aerosol-generating article 200 (which is a variation of the aerosol-generating article 100) according to a second embodiment of the present disclosure. Features in common with the aerosol-generating article 100 are referred to with 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 opposed 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 enable the user to inhale the aerosol generated as a result of heating the aerosol-forming substrate of the aerosol-generating article 200.

[0177] 3, 4, and 5 illustrate 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 comprises 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.

[0178] 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. The middle layer 340 is a corrugated element formed from a corrugated sheet of aerosol-forming substrate 345. A suitable aerosol-forming substrate may be homogenized tobacco. Therefore, the middle layer 340 may be formed from a corrugated sheet of homogenized tobacco material 345.

[0179] 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 of aerosol-forming substrate 345 forming the intermediate layer 340 has a thickness of 150 microns.

[0180] Intersections 351 between top layer 310 and middle layer 340 and intersections 352 between bottom layer 320 and middle layer 340 include adhesive bonding the respective layers together.

[0181] 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. The aerosol-generating article 300 is composed primarily of paper (represented by the planar upper layer 310 and planar lower layer 320 formed of paper), with the aerosol-generating article 300 being formed of more than 50% paper by weight.

[0182] 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. The airflow path thus passes through both sides of the sheet of aerosol-forming substrate 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.

[0183] The aerosol-forming substrate 345 may be a sheet of any suitable aerosol-forming substrate.

[0184] During use of the aerosol-generating article 300, the aerosol-forming substrate 345 is heated, causing the aerosol-forming substrate 345 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.

[0185] In other embodiments, the proportion of the mass of the aerosol-generating article 300 defined by the paper-based planar upper and lower layers 310, 320 may be increased by using heavier weight sheets of paper (or cardboard) for layers 310, 320. In an alternative embodiment, the planar upper and lower layers 310, 320 may instead each be formed from a sheet of aerosol-forming substrate, and the middle layer 340 may be formed from a corrugated sheet of cardboard.

[0186] 7 shows an aerosol-generating article 400 according to a fourth embodiment of the present disclosure. The aerosol-generating article 400 comprises a first planar outer layer 424 forming a first outer planar surface 421, a second planar outer layer 425 forming a second outer planar surface 422, and a frame 450 positioned between the first outer planar layer 424 and the second outer planar layer 425. The second outer planar surface 422 is positioned parallel to the first outer planar surface 421.

[0187] Figures 8 and 9 show exploded views of the aerosol-generating article 400 of Figure 7. A frame 450 surrounds and at least partially defines a cavity 430. Figure 8 shows the cavity 430 in an empty state. Figure 9 shows the cavity 430 filled with an aerosol-forming substrate 440. Figures 10 and 11 show transverse and longitudinal cross-sectional views, respectively, of the aerosol-generating article 400 when the cavity 430 has been filled with an aerosol-forming substrate 440.

[0188] The mass of the aerosol-forming substrate 440 in the cavity 430 is 150 milligrams. However, in other embodiments, the mass of the aerosol-forming substrate may be less or greater. For example, the mass of the aerosol-forming substrate may be as low as 80 milligrams, or as high as 500 milligrams, or any value between these two values.

[0189] First planar outer layer 424 and second planar outer layer 425 are made from cigarette paper having a thickness of 35 micrometers and are in physical contact with and bonded to frame 450. First planar outer layer 424 overlies a first end of cavity 430 and forms a first cavity end wall 431. Second planar outer layer 425 overlies a second end of cavity 430 and forms a second cavity end wall 432, which is opposite first cavity end wall 431. That is, frame 450, first planar outer layer 424, and second planar outer layer 425 collectively define cavity 430.

[0190] The first and second planar outer layers 424, 425 have a basis weight of 25 grams per square meter. However, in other embodiments, the first and second planar outer layers 424, 425 may have a lesser or greater basis weight. For example, the first and second planar outer layers 424, 425 may have a basis weight of 10 grams per square meter to 30 grams per square meter.

[0191] The frame 450 has a hollow cubic shape and is made from cardboard. The frame 450 defines an opening that extends through the height (also referred to as thickness) of the frame 450, the opening at least partially forming the cavity 430 of the aerosol-generating article 400. The frame 450 includes a peripheral wall 451 that surrounds the cavity 430. The peripheral wall 451 includes a front wall 413 and a rear wall 414. More specifically, the peripheral wall 451 is defined by an inner cross-section 452 of the frame 450 and an outer cross-section 453 of the frame 450. The inner cross-section 452 of the peripheral wall 451 at least partially defines the perimeter of the cavity 430. The outer cross-section 453 of the peripheral wall 451 at least partially defines the perimeter of the aerosol-generating article 400. The peripheral wall 451 has a radial thickness measured between an inner cross-section 452 of the frame 450 and an outer cross-section 453 of the frame 450 of about 5 millimeters.

[0192] The cardboard of frame 450 has a basis weight of 450 grams per square meter. However, in other embodiments, the cardboard of frame 450 may have a smaller or larger basis weight. For example, the cardboard of frame 450 may have a basis weight of 300 grams per square meter to 900 grams per square meter.

[0193] Although frame 450 is shown schematically in these figures as a homogenous single layer, it is understood that in other embodiments, frame 450 may be a laminated structure formed from a series of layers of cardboard, each extending in the x-direction and stacked successively on top of one another to define the height of frame 450. Guar gum or PVOH may be used as an adhesive to bond the layers together to form frame 450 as a laminated structure. Each of the layers may have a thickness of 0.5 millimeters, although it is understood that the layer thicknesses may be greater (e.g., up to 5 millimeters) or smaller (e.g., down to 0.1 millimeters). Air inlet 411 and air outlet 412 are defined by and extend through peripheral wall 451 of frame 450. More specifically, air inlet 411 extends through front wall 413, and air outlet 412 extends through rear wall 414. Air inlet 411 and air outlet 412 have an equivalent diameter of 5 millimeters. An airflow passage extends through cavity 430 between air inlet 411 and air outlet 412. As shown in Figures 9-11, an aerosol-forming substrate 440 is positioned within cavity 430. Aerosol-forming substrate 440 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, aerosol-forming substrate 440 fills the entire volume of cavity 430.

[0194] Aerosol-generating article 400 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 first outer planar surface 421 and second outer planar surface 422. Frame 450 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. Cavity 430 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.

[0195] The combination of the frame 450 and the first and second planar outer layers 424, 425 forms approximately 64% of the mass of the aerosol-generating article 400. The proportion of the mass of the aerosol-generating article 400 that is formed from paper or cardboard can be further increased by one or more of: i) reducing the mass and / or packing density of the aerosol-forming substrate 440 that fills the cavity 430; ii) changing the physical dimensions of the first and second planar outer layers 424, 425 and / or the frame 450; and iii) changing the basis weight of the material used in the first and second planar outer layers 424, 425 and / or the frame 450.

[0196] Excluding the aerosol-forming substrate 440 and any adhesive that may be present (e.g., if the frame 450 is a laminated structure formed of successive layers bonded together by adhesive), substantially the entire aerosol-generating article 400 is formed from paper or cardboard.

[0197] Figure 12 shows an aerosol-generating article 500 according to a fifth embodiment of the present disclosure. Features in common with aerosol-generating article 400 are referred to by like reference numerals. Aerosol-generating article 500 differs from aerosol-generating article 400 in that the aerosol-forming substrate is in the form of a sheet of aerosol-generating material 540, specifically a corrugated sheet of homogenized tobacco material. Figures 13 and 14 show transverse and lateral cross-sectional views, respectively, of the aerosol-generating article 500 of Figure 12. The first planar outer layer 424 and the second planar outer layer 425 form more than 50% by weight of the aerosol-generating article 500.

[0198] The corrugated sheet of homogenized tobacco material 540 comprises a plurality of parallel corrugations having a plurality of substantially parallel peaks 543 and valleys 544. The plurality of parallel corrugations is defined by a corrugation profile that is sinusoidal, as seen in Figure 13. The plurality of parallel corrugations has a corrugation wavelength of approximately 4.6 millimeters. The corrugation amplitude is approximately the same as the height (or thickness) of the cavities 430, as indicated by the peaks 543 and valleys 544 coinciding with the first and second cavity end walls 431 and 432, respectively.

[0199] The parallel corrugations form a plurality of channels 545 between the sheet of aerosol-generating material 540 and the first cavity end wall 431, and a plurality of channels 546 between the sheet of aerosol-generating material 540 and the second cavity end wall 432. The channels 545, 546 extend longitudinally through the aerosol-generating article 500 and form at least a portion of an airflow passageway extending between the air inlet 411 and the air outlet 412.

[0200] During use of each aerosol-generating article 400, 500, the aerosol-forming substrate 440, 540 is heated, causing the aerosol-forming substrate 440, 540 to release volatile compounds, which are then entrained in air drawn into the cavity 430 through the air inlet 411. The volatile compounds then cool and condense to form an aerosol, which can be drawn from the aerosol-generating article 400, 500 through the air outlet 412.

[0201] By way of example 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 of the final product. 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 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, containing about 1 to 15%, preferably about 3 to 7%, of cellulose fibers, the length of which is about 10 to 250 μm, preferably about 10 to 120 μm. 3. Tobacco fiber, e.g., about 5-20%, preferably about 7-15%, of tobacco fiber as a filler, the tobacco fiber being of any tobacco species or a mixture of tobacco species. The tobacco fiber is preferably derived from the stem and / or petiole and graded to a length of about 10-350 μm, preferably about 10-180 μm. 4. Binder. For example, about 1-10%, preferably about 1-5%, of a binder may be included. Examples of binders include any gum or pectin commonly used in the food and beverage (F&B) industry. Preferred binders may be natural pectin (e.g., fruit (e.g., citrus) pectin or tobacco pectin), guar gum, land locust bean gum (e.g., their hydroxyethyl and / or hydroxypropyl), starch (e.g., modified starch or derivatized starch), alginate, methylcellulose, ethylcellulose, ethylhydroxymethylcellulose, carboxymethylcellulose, dextran, or 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 (e.g., menthol), polyhydric alcohols (e.g., triethylene glycol), esters of polyhydric alcohols (e.g., glycerol monoacetate, glycerol diacetate, or glycerol triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (e.g., their dimethyl esters).

[0202] "Tobacco variety" means one of the different types of tobacco, based, for example, on the unique curing process that occurs before the tobacco is further processed into tobacco products.

[0203] 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 set out below. Percentages are given as weight percent of the finished product. The aerosol-forming substrate may comprise: 1. An aerosol former (such as glycerin), for example about 10-40%, preferably about 20-30%. 2. Organic fiber. For example, the composition contains about 10% to 30%, preferably about 15% to 25%, of organic fiber, which may be any suitable plant variety commonly available on the market and having a purity that meets applicable FDA food and beverage (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, preferably about 10 to 200 μm. 3. Organic vegetable glycerides, for example, about 15-55%, preferably about 20-35%, of organic vegetable glycerides, such as those from cloves, echinacea, fennel, ginger, hawthorn berries, elderberries, monarda, mullein leaves, nettles, plantains, turmeric, yarrow, and composites thereof. 4. Organic plant extracts, such as about 1-15%, preferably 2-7%, of organic plant extracts, including menthol (dl-menthol, C ) obtained from any of the aforementioned plants, as well as from Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related plant varieties. 10 H 20 0, 2-isopropyl-5-methylcyclohexanol), and that of P-menthone-3-ol as an optional secondary alcohol as a diastereoisomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.

[0204] Alternatively, such an aerosol-forming substrate may also contain about 0.5 to 5%, preferably about 1 to 3%, of a plant essential oil (such as palm oil, coconut oil, wood-based essential oil, etc.).

[0205] 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. Accordingly, in this context, the number "A" is to be understood as "A" ± 10%. Within this context, the number "A" may be considered to include numerical values ​​that are within the common standard error for measurement of the property that the number "A" modifies. The number "A," as used in the appended claims, may, in some cases, deviate by the percentages recited above, provided that the amount by which "A" deviates does not materially affect the basic and novel property(ies) 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. An aerosol-generating article for use in an aerosol generating device, a substantially planar upper surface and a substantially planar lower surface; an aerosol-forming substrate; the upper surface and the lower surface are spaced apart vertically from one another by a height defined in the z-direction; An aerosol-generating article, wherein at least 50% by weight of the aerosol-generating article is paper or cardboard.

2. 2. The aerosol-generating article of claim 1, wherein at least 55% by weight, or at least 60% by weight, or at least 65% by weight, or at least 70% by weight, or at least 75% by weight, or at least 80% by weight, or at least 85% by weight, or at least 90% by weight of the aerosol-generating article excluding the aerosol-forming substrate is paper or cardboard.

3. 3. The aerosol-generating article of claim 2, wherein substantially the entire aerosol-generating article, except for the aerosol-forming substrate and adhesive (if present), is paper or cardboard.

4. 4. An aerosol-generating article according to any one of claims 1 to 3, wherein the aerosol-generating article has a cellulose acetate content of less than 5%, or less than 3%, or less than 1%.

5. 5. An aerosol-generating article according to any one of claims 1 to 4, wherein the aerosol-generating article comprises a frame disposed between the substantially planar upper surface and the substantially planar lower surface, the frame defining one or more cavities, and the frame comprising or consisting of paper or cardboard.

6. 6. An aerosol-generating article according to any one of claims 1 to 5, wherein the aerosol-generating article comprises a laminated structure disposed between the substantially planar upper surface and the substantially planar lower surface, the laminated structure comprising two or more layers superimposed on one another, the layers comprising or consisting of paper or cardboard.

7. 7. The aerosol-generating article of claim 6, wherein each of the layers of the laminate structure has a thickness in the range of 0.1 millimeters to 5 millimeters, or 0.4 millimeters to 4 millimeters, or about 0.5 millimeters, or about 1 millimeter.

8. 8. An aerosol-generating article according to claim 6 or claim 7, wherein the laminate structure defines at least a portion of an airflow path through the aerosol-generating article between a distal end and a proximal end of the aerosol-generating article.

9. 9. The aerosol-generating article of claim 8, wherein the laminate structure defines a frame, the frame defines one or more cavities, and the airflow path extends through the one or more cavities.

10. 10. An aerosol-generating article according to any one of claims 5 to 9, wherein the paper or cardboard content of the frame or laminate structure has a basis weight of 300 grams per square meter or more, or 350 grams per square meter or more, or 390 grams per square meter or more, or 420 grams per square meter or more, or 620 grams per square meter or more, or 720 grams per square meter or more, or 800 grams per square meter or more.

11. 11. The aerosol-generating article according to claim 1, wherein the upper surface and the lower surface are parallel to each other.

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 one or more of the upper layer, the middle layer, and the lower layer comprises or consists of paper or cardboard.

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 the outer surface of the upper layer, the lower surface defining 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.

15. 15. The aerosol-generating article of claim 14, wherein one or more of the upper layer, the lower layer, and the frame comprise or consist of paper or cardboard.

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