Aerosol-generating articles and systems

Abstract

[0013] Provided is an aerosol-generating article (100, 200, 300, 400, 500) for use in an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising an aerosol-forming substrate containing thermally conductive particles, each of the thermally conductive particles having a thermal conductivity of at least 1 W / mK in at least one direction at 25 degrees Celsius, the aerosol-generating article (100, 200, 300, 400, 500) being a planar aerosol-generating article having an article length, an article width, and an article thickness, the article thickness being no more than 0.5 times the article length and no more than 0.5 times the article width. Also provided is an aerosol generation system.

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 resemble a conventional cigarette in appearance. 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] Research has 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 heat 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 may 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 a first aspect of the present disclosure, there may be provided an aerosol-generating article for use in an aerosol-generating device to generate an aerosol, the aerosol-generating article being a planar aerosol-generating article having an article length, an article width, and an article thickness, the article thickness being no more than 0.5 times the article length and no more than 0.5 times the article width.

[0006] According to a second aspect of 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.

[0007] According to a third aspect of 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 vertically apart from each other by a height defined in the z-direction.

[0008] Advantageously, such articles may 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 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 allows a greater proportion of the aerosol-forming substrate of the aerosol-generating article to be heated to a temperature at which the aerosol will be 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. [Brief explanation of the drawings]

[0009] [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 side 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 cross-sectional view of the aerosol-generating article of FIG. [Figure 11] FIG. 11 shows a schematic longitudinal cross-section 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 cross-sectional view of the aerosol-generating article of FIG. [Figure 14] FIG. 14 shows a schematic cross-sectional side view of the aerosol-generating article of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0010] The aerosol-forming substrate may comprise thermally conductive particles, each of which may have a thermal conductivity in at least one direction of at least 1 W / mK at 25 degrees Celsius.

[0011] Advantageously, the thermally conductive particles can increase the overall thermal conductivity of the aerosol-forming substrate. Advantageously, the thermally conductive particles can allow for smaller temperature gradients or differences across the substrate during heating. For example, if the base of the substrate is heated, e.g., by a planar heater, the presence of the thermally conductive particles can result in a smaller temperature difference between the base and the top surface of the substrate opposite the base. Advantageously, this allows a greater proportion of the substrate to be heated to a temperature at which the aerosol will be emitted, while minimizing the risk of burning the hottest portion of the substrate closest to the heater. Alternatively, or additionally, the presence of the thermally conductive particles can reduce the time required to heat the substrate sufficiently to emit the aerosol.

[0012] Thus, according to a fourth particularly preferred aspect of the present disclosure, there is provided an aerosol-generating article for use in an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising an aerosol-forming substrate containing thermally conductive particles, each of the thermally conductive particles having a thermal conductivity of at least 1 W / mK in at least one direction at 25°C, the aerosol-generating article being a planar aerosol-generating article having an article length, an article width and an article thickness, the article thickness being no more than 0.5 times the article length and no more than 0.5 times the article width. Optional features described herein may be applied to this particularly preferred fourth aspect of the present disclosure.

[0013] Advantageously, in such articles, the features of the article being planar and the substrate comprising thermally conductive particles may cooperate synergistically to reduce temperature gradients across the substrate or article during use and reduce the time required to heat the aerosol-forming substrate sufficiently to emit an aerosol. These advantages are described in more detail earlier in this disclosure.

[0014] The aerosol-forming substrate may be substantially flat or substantially planar. The aerosol-forming substrate may have a substrate length, a substrate width, and a substrate thickness. The substrate thickness may be 0.5 times the substrate length or less. The substrate thickness may be 0.5 times the substrate width or less. The substrate thickness may also be referred to as the substrate height. The substrate thickness, substrate length, and article width may all be perpendicular to one another.

[0015] Such a substrate may have a large base area relative to the volume of the substrate. 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 substrate during heating. For example, if the base of the substrate is heated by the planar heater, a smaller spacing 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 allows a larger proportion of the substrate to be heated to a temperature at which an aerosol will be 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 substrate sufficiently to emit an aerosol.

[0016] 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 having a low-resistance airflow path may advantageously enable superior airflow management, allowing aerosol to be more efficiently extracted from the aerosol-generating article and directed to the user.

[0017] Unless otherwise specified, resistance to draw (RTD) is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to pump 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 may also refer to "resistance to draw." Such terms generally refer to measurements performed in accordance with ISO 6565-2015 and performed normally 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.

[0018] An aerosol-generating article according to any of the embodiments disclosed herein may include substantially planar upper and lower surfaces. The separation, e.g., vertical separation, between the substantially planar upper and lower surfaces of the article may define the height (e.g., z-dimension) of the aerosol-generating article. This height may be referred to herein as a thickness, e.g., article thickness. An airflow channel may be defined between the substantially planar upper and lower surfaces. The height or article thickness of the aerosol-generating article may be less than 5 millimeters, e.g., 1.5 millimeters to 5 millimeters, e.g., 1.5 millimeters to 4 millimeters, e.g., 1.5 millimeters to 3 millimeters, e.g., 1.5 millimeters to 2 millimeters.

[0019] The aerosol-generating article may comprise an upper layer and a lower layer, at least one of which may comprise or consist of an aerosol-forming substrate, and the upper layer may form a substantially planar upper surface and the lower layer may form a substantially planar lower surface.

[0020] The aerosol-generating article may include a first planar layer. The first planar layer may be the lower layer referred to above. The aerosol-generating article may include a second planar layer. The second planar layer may be the upper layer referred to above. The aerosol-generating article may include an intermediate layer. The intermediate layer may be disposed between the first and second planar layers. The aerosol-forming substrate of the aerosol-generating article may include any one, two, or all of the first planar layer, second planar layer, and intermediate layer.

[0021] The aerosol-generating article, for example, the aerosol-forming substrate of the article, may include a corrugated element. The intermediate layer may include a corrugated element. The corrugated element may be disposed between the first planar layer and the second planar layer. The aerosol-forming substrate of the aerosol-generating article may include any one, two, or all of the first planar layer, the second planar layer, and the corrugated element.

[0022] 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 low-density, low-RTD aerosol-generating articles using high-speed manufacturing methods similar to those used to manufacture corrugated cardboard.

[0023] Optionally, the corrugated element is or includes a corrugated sheet of material. The sheet of material may be bent or folded to form the corrugations. The thickness of the sheet of material may vary by 50%, 20%, or 10% or less. The sheet of material may have a substantially constant thickness. Advantageously, this may allow for a simple manufacturing process.

[0024] Optionally, at least some of the thermally conductive particles comprise or consist of one or more susceptor materials. Optionally, each of the thermally conductive particles comprises or consists of one or more susceptor materials and is inductively heatable to a temperature of at least 100, 200, or 300 degrees Celsius during use of the aerosol-generating article in an aerosol-generating device. Advantageously, this may enable inductive heating of the thermally conductive particles, and therefore heating of components comprising or in thermal proximity to the thermally conductive particles.

[0025] Suitable susceptor materials include, but are not limited to, carbon, carbon-based materials, graphene, graphite, expanded graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. Suitable susceptor materials may include ferromagnetic materials, such as ferritic iron, ferromagnetic steel, or ferromagnetic alloys such as stainless steel, ferromagnetic particles, and ferrite. Suitable susceptor materials may be or include aluminum. The susceptor material preferably contains more than 5% ferromagnetic or paramagnetic material, preferably more than 20%, and more preferably more than 50% or more than 90% ferromagnetic or paramagnetic material. Preferred susceptor materials may include metals, metal alloys, or carbon.

[0026] Particularly preferred susceptor materials may be or include carbon, carbon-based materials, graphene, graphite, or expanded graphite. Advantageously, such materials have relatively high thermal conductivity, relatively low density, and may be inductively heated.

[0027] Optionally, the first planar layer is adjacent to and optionally contacts the corrugated elements. Optionally, the first planar layer comprises an aerosol-forming material. Optionally, the first planar layer comprises at least a portion of the thermally conductive particles.

[0028] Optionally, a second planar layer is adjacent to and optionally contacts the corrugated elements. Optionally, the second planar layer comprises an aerosol-forming material. Optionally, the second planar layer comprises at least a portion of the thermally conductive particles.

[0029] Optionally, the intermediate layer comprises at least a portion of the thermally conductive particles.Optionally, the corrugated elements comprise at least a portion of the thermally conductive particles.

[0030] In particular, when one or both of the first and second planar layers includes an aerosol-forming material and is adjacent to or in contact with the intermediate layer or corrugated elements, it may be particularly advantageous for the intermediate layer or corrugated elements to include at least a portion of the thermally conductive particles, since heating of the intermediate layer or corrugated elements can then be used to affect heating of the aerosol-forming material in one or both of the first and second planar layers, as discussed in more detail below.

[0031] Optionally, the first planar layer has a first region and a second region. Optionally, the first region is closer to the corrugation elements than the second region. Optionally, the shortest distance between the first region and the corrugation elements is less than the shortest distance between the second region and the corrugation elements. Optionally, at least a portion of the first region contacts the corrugation elements, for example, contacts a peak or a valley of the corrugation elements. Optionally, the second region does not contact the corrugation elements.

[0032] Advantageously, in this situation, when the corrugated element is heated, for example, by induction heating of the thermally conductive particles of the corrugated element, the corrugated element heats the first region of the first planar layer more than the second region of the first planar layer. This may advantageously allow the first and second regions of the first planar layer to be heated to different temperatures. This may allow preferential vaporization of different components of the first planar layer in the first and second regions. For example, flavorants or botanicals that do not need to be heated to the same temperature as other components, such as nicotine, being vaporized may be included in or coated on the second region rather than the first region. Such options are discussed in more detail below.

[0033] Optionally, the second planar layer has a second planar layer first region and a second planar layer second region. Optionally, the first region of the second planar layer is closer to the corrugation elements than the second region of the second planar layer. Optionally, the shortest distance between the first region of the second planar layer and the corrugation elements is less than the shortest distance between the second region of the second planar layer and the corrugation elements. Optionally, at least a portion of the first region of the second planar layer contacts the corrugation elements, e.g., contacts a peak or a valley of the corrugation elements. Optionally, the second region of the second planar layer does not contact the corrugation elements. The same advantages may apply to these first and second regions of the second planar layer as presented for the first and second regions of the first planar layer.

[0034] Optionally, the first planar layer has one or more first portions and one or more second portions. Optionally, the or each first portion is closer to the corrugated element than the or each second portion. Optionally, the shortest distance between the or each first portion and the corrugated element is shorter than the shortest distance between the or each second portion and the corrugated element. Optionally, at least a portion of the or each first portion contacts the corrugated element, e.g., contacts a peak or a valley of the corrugated element. This may allow preferential vaporization of different components of the first planar layer in different portions. For example, a flavorant, which may not need to be heated to the same temperature as other components, such as nicotine, to be vaporized, may be contained within or coated on the second portion rather than the first portion. Such options are discussed in more detail below.

[0035] Optionally, there are multiple first portions, each first portion adjacent to, e.g., contacting, a peak or valley of a corrugation element with no adjacent or contacting other first portions. Optionally, a single second portion or each second portion does not contact a corrugation element. Optionally, at least one first portion is located between two second portions. Optionally, at least one second portion is located between two first portions.

[0036] Optionally, the second planar layer has one or more second planar layer first portions and one or more second planar layer second portions. Optionally, the first portion of the single second planar layer or each second planar layer first portion is closer to the corrugation elements than the second portion of the single second planar layer or each second planar layer second portion. Optionally, the shortest distance between the first portion of the single second planar layer or each second planar layer first portion and the corrugation elements is less than the shortest distance between the second portion of the single second planar layer or each second planar layer second portion and the corrugation elements. Optionally, at least a portion of the first portion of the single second planar layer or each second planar layer first portion contacts the corrugation elements, for example, contacts a peak or a valley of the corrugation elements. The same advantages may apply to these first and second portions of the second planar layer as presented for the first and second portions of the first planar layer.

[0037] Optionally, there are multiple second planar layer first portions, and each second planar layer first portion is adjacent to, e.g., contacts, a peak or valley of a corrugation element without an adjacent or contacting first portion of another second planar layer. Optionally, the second portion of a single second planar layer or the second portion of each second planar layer does not contact a corrugation element. Optionally, at least one second planar layer first portion is located between two second planar layer second portions. Optionally, at least one second planar layer second portion is located between two second planar layer first portions.

[0038] Optionally, the first region has a different material composition than the second region. Optionally, the first region has a coating and the second region does not have a coating, or the second region has a coating and the first region does not have a coating, or the first region and the second region have different coatings. Optionally, the second region contains a greater proportion, on a dry weight basis, than the first region of at least one component, such as a flavorant or botanical, having a vaporization temperature at atmospheric pressure below 250 degrees Celsius or 200 degrees Celsius. The features of this paragraph are described in relation to the first and second regions of the first planar layer. However, as one skilled in the art will understand after reading this disclosure, these features are equally applicable to the first and second regions of the second planar layer, referred to above as the first region of the second planar layer and the second region of the second planar layer.

[0039] As mentioned above, it may be advantageous for the first and second regions to have different compositions or coatings because these regions may be heated to different temperatures during use, for example, as a result of a corrugated element that includes thermally conductive particles and heats the first region more than the second region. Thus, by way of example, a flavorant that may not need to be heated to the same temperature as other components, such as nicotine being vaporized, may be contained within or coated on the second region.

[0040] Optionally, the or each first portion has a different material composition than the or each second portion. Optionally, the or each first portion has a coating and the or each second portion does not have a coating, or the or each second portion has a coating and the or each first portion does not have a coating, or the or each first portion and the or each second portion have different coatings. Optionally, the or each second portion includes a greater proportion, on a dry weight basis, than the or each first portion, of at least one component, such as a flavorant or botanical, having a vaporization temperature at atmospheric pressure below 250°C or 200°C. The features of this paragraph are described in relation to the first and second portions of the first planar layer. However, as one skilled in the art would understand after reading this disclosure, these features are equally applicable to the first and second portions of the second planar layer, which are referred to as the first and second portions of the second planar layer.

[0041] With respect to the first region and the second region, it may be advantageous for the first portion and the second portion to have different compositions or coatings because, as discussed above, these portions may be heated to different temperatures during use, for example, as a result of the first portion being larger than the second portion, where the corrugated element includes thermally conductive particles. It may be advantageous for the first portion and the second portion to have different compositions or coatings because, as discussed above, these portions may be heated to different temperatures during use, for example, as a result of the first portion being larger than the second portion, where the corrugated element includes thermally conductive particles. Thus, by way of example, a flavorant, which may not need to be heated to the same temperature as other components, such as nicotine, being vaporized, may be contained within or coated on the second portion.

[0042] Those skilled in the art will understand, after reading this disclosure, that when a first planar layer contacts one of the peaks or valleys of a corrugated element, a second planar layer may contact the other of the peaks or valleys of the corrugated element.

[0043] Optionally, the first planar layer is substantially parallel to the second planar layer. Optionally, the first planar layer has a substantially planar upper surface defined by a length extending in the x-direction and a width extending in the y-direction. Optionally, the second planar layer has a substantially planar lower surface defined by a length extending in the x-direction and a width extending in the y-direction.

[0044] Optionally, the substantially planar upper surface and the substantially planar lower surface are vertically spaced apart from one another by a height defined in the z direction.

[0045] Optionally, the corrugated elements are attached to, and optionally contact, one or both of the first planar layer and the second planar layer.

[0046] Optionally, a first plurality of channels is defined between the first planar layer and the corrugated elements. Optionally, a second plurality of channels is defined between the corrugated elements and the second planar layer. One or both of the first and second plurality of channels may form a portion of an airflow path through the article.

[0047] The aerosol-generating article may comprise a first planar outer surface and a second planar outer surface. The article may comprise a cavity. The article may comprise a frame, for example a planar frame. The frame may be positioned between the first planar outer surface and the second planar outer surface. The frame may at least partially define the cavity. The aerosol-forming substrate may be positioned between the first planar outer surface and the second planar outer surface. The article may comprise an air inlet and an air outlet. The article may comprise an airflow passage extending between the air inlet and the air outlet and through the cavity. The aerosol-forming material may be positioned between the first planar outer surface and the second planar outer surface. At least a portion of the aerosol-forming substrate may be positioned between the first planar outer surface and the second planar outer surface.

[0048] Thus, the article may comprise a first planar outer surface, a second planar outer surface, a cavity, a frame, for example a planar frame positioned between the first and second planar outer surfaces, the frame at least partially defining the cavity, an air inlet, an air outlet, and an air flow passage extending between the air inlet and the air outlet and through the cavity, wherein at least a portion of the aerosol-forming substrate is positioned between the first and second planar outer surfaces.

[0049] 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.

[0050] The aerosol-generating article may include a first planar outer layer and a second planar outer layer, where the first planar outer layer forms the first planar outer surface and the second planar outer layer forms the 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 material. The aerosol-forming substrate may include any one, two, or more of the first planar outer layer, the second planar outer layer, and the frame. Advantageously, this may allow the article to include more aerosol-forming material for a given mass, for example, because the structural components not only provide structural integrity but also the aerosol-forming material.

[0051] The cavity can be substantially empty, which can advantageously result in a very low RTD article.

[0052] The aerosol-forming material may be positioned within the cavity. At least a portion of the aerosol-forming substrate may be positioned within the cavity. The cavity may advantageously provide a secure area for the aerosol-forming substrate, and the airflow path through or past the substrate may be easily adjusted by adjustments to the cavity.

[0053] A corrugated element, such as those previously described in this disclosure, may be positioned within the cavity. Advantageously, the corrugated element may provide only a minimal increase to the RTD of the article.

[0054] The corrugated elements may include at least a portion of the thermally conductive particles. The corrugated elements may include an aerosol-forming material.

[0055] Optionally, the first planar layer described above in this disclosure is or includes a first planar outer layer. Optionally, the second planar layer described above in this disclosure is or includes a second planar outer layer.

[0056] Optionally, at least one of the first planar outer layer, the second planar outer layer, and the frame comprises or consists of an aerosol-forming substrate.

[0057] Optionally, each of the thermally conductive particles may have a thermal conductivity of at least 2, 5, 10, 20, 50, 100, 200 or 500 W / mK in at least one direction at 25 degrees Celsius.

[0058] Optionally, some or all of the thermally conductive particles are non-metallic particles. Optionally, some or all of the thermally conductive particles comprise carbon, e.g., at least 10, 30, 50, 70, 90, 95, 98, or 99% carbon by weight. Optionally, the thermally conductive particles comprise one or more of graphite particles, expanded graphite particles, diamond particles, such as synthetic diamond particles, graphene particles, carbon nanotubes, ferrite particles, and charcoal particles. Optionally, some or all of the thermally conductive particles are graphite particles. Optionally, some or all of the thermally conductive particles are expanded graphite particles.

[0059] It may be particularly preferred for at least a portion of the thermally conductive particles to be graphite particles, which advantageously are relatively inexpensive, may have relatively high thermal conductivity, and may be inductively heated.

[0060] Optionally, some or all of the thermally conductive particles comprise one or more of one or more metals, one or more metallic materials, one or more alloys, and one or more intermetallic particles. Optionally, some or all of the thermally conductive particles comprise one or more of copper, aluminum, and nickel. Advantageously, such particles may have relatively high thermal conductivity.

[0061] Thermally conductive particles can be characterized by a particle size distribution. The particle size distribution can have particle sizes designated D10, D50, and D90. The particle size designated D10 is defined as 10% of the particles having a particle size equal to or less than the particle size designated D10. Similarly, the particle size designated D50 is defined as 50% of the particles having a particle size equal to or less than the particle size designated D50. Thus, the particle size designated D50 can also be referred to as the median particle size. The particle size designated D90 is defined as 90% of the particles having a particle size equal to or less than the particle size designated D90. Therefore, if there are 1,000 particles in a distribution and the particles are arranged in order of increasing particle size, the particle size of number D10 is expected to be approximately equal to the particle size of the 100th particle, the particle size of number D50 is expected to be approximately equal to the particle size of the 500th particle, and the particle size of number D90 is expected to be approximately equal to the particle size of the 900th particle.

[0062] The particle size distribution may have particle sizes of volume D10, D50, and D90. The particle size of volume D10 is defined such that 10% of the total volume of all particles is occupied by the total volume of particles having a particle size equal to or smaller than the particle size of volume D10. Similarly, the particle size of volume D50 is defined such that 50% of the total volume of all particles is occupied by the total volume of particles having a particle size equal to or smaller than the particle size of volume D50. Furthermore, the particle size of volume D90 is defined such that 90% of the total volume of all particles is occupied by the total volume of particles having a particle size equal to or smaller than the particle size of volume D90.

[0063] Optionally, the thermally conductive particles have a particle size distribution with a particle size number D10, where the particle size number D10 is at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Optionally, the thermally conductive particles have a particle size distribution with a particle size number D10, where the particle size number D10 is no greater than 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns.

[0064] Optionally, the thermally conductive particles have a particle size distribution with a particle size number D50, where the particle size number D50 is at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Optionally, the thermally conductive particles have a particle size distribution with a particle size number D50, where the particle size number D50 is no greater than 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns.

[0065] Optionally, the thermally conductive particles have a particle size distribution with a particle size number D90, where the particle size number D90 is at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Optionally, the thermally conductive particles have a particle size distribution with a particle size number D90, where the particle size number D90 is no greater than 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns.

[0066] Optionally, the thermally conductive particles have a particle size distribution with a particle size at volume D10 that is at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Optionally, the thermally conductive particles have a particle size distribution with a particle size at volume D10 that is no greater than 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns.

[0067] Optionally, the thermally conductive particles have a particle size distribution with a particle size, volume D50, of at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Optionally, the thermally conductive particles have a particle size distribution with a particle size, volume D50, of no more than 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns.

[0068] Optionally, the thermally conductive particles have a particle size distribution with a particle size, volume D90, of at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Optionally, the thermally conductive particles have a particle size distribution with a particle size, volume D90, of no more than 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns.

[0069] A compromise must be made when determining particle size. Advantageously, larger thermally conductive particles may increase the thermal conductivity of the aerosol-forming substrate compared to smaller thermally conductive particles. However, larger thermally conductive particles may reduce the space available for the aerosol-forming material within the substrate. The above particle sizes may provide an optimal compromise between these factors.

[0070] Optionally, the thermally conductive particles have a particle size number D10, a particle size number D90, a particle size volume D10, and a particle size distribution having a particle size volume D90, wherein the particle size number D90 is no more than 50, 40, 30, 20, 10, or 5 times the particle size number D10, or the particle size volume D10 is no more than 50, 40, 30, 20, 10, or 5 times the particle size number D10, or both the particle size number D90 is no more than 50, 40, 30, 20, 10, or 5 times the particle size number D10 and the particle size volume D10 is no more than 50, 40, 30, 20, 10, or 5 times the particle size number D10.

[0071] A compromise must be made regarding particle size distribution. For example, a tighter particle size distribution, characterized by a smaller ratio between the D90 particle size and the D10 particle size, can advantageously provide a more uniform thermal conductivity throughout the aerosol-forming substrate. This is because there is less variation in particle size at different locations within the substrate. This can advantageously allow for more efficient use of the aerosol-forming material throughout the aerosol-forming substrate. However, a tighter particle size distribution can disadvantageously be more difficult and expensive to achieve. The particle size distributions described above can provide an optimal compromise between these factors.

[0072] It may be particularly preferred for the thermally conductive particles to have a D10 volume particle size of at least 1 micron, e.g., 1 to 20 microns. Alternatively, or additionally, it may be particularly preferred for the thermally conductive particles to have a D90 volume particle size of 300 microns or less, preferably 200 microns or less, e.g., 30 to 300 microns or 40 to 200 microns.

[0073] Optionally, each of the thermally conductive particles has a particle size of at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Optionally, each of the thermally conductive particles has a particle size of no more than 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns.

[0074] Optionally, each of the thermally conductive particles has three mutually perpendicular dimensions, with the largest of the three dimensions being no more than 10, 8, 5, 3, or 2 times larger than one or both of the smallest of the three dimensions and a second largest of the three dimensions. Optionally, each of the thermally conductive particles is substantially spherical.

[0075] Advantageously, the orientation of substantially spherical particles may not affect the thermal conductivity of the substrate as much as the orientation of non-spherical particles. Thus, the use of more spherical particles may result in reduced variability between different substrates where particle orientation is uncontrolled. Furthermore, substantially spherical particles may be easier to characterize.

[0076] Optionally, the thermally conductive particles include at least 10, 20, 50, 100, 200, 500, or 1000 particles.

[0077] Optionally, the substrate comprises at least 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, or 85 weight percent thermally conductive particles on a dry weight basis. Weight percent (wt. %) herein is on a dry weight basis unless related to water or moisture or unless expressly stated otherwise. Optionally, the substrate comprises no more than 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, or 15 weight percent thermally conductive particles on a dry weight basis. Optionally, the substrate comprises 10-90, 20-90, 30-90, 40-90, 50-90, 60-90, 70-90, 80-90, 10-80, 20-80, 30-80, 40-80, 50-80, 60-80, 70-80, 10-70, 20-70, 30-70, 40-70, 50-70, 60-70, 10-60, 20-60, 30-60, 40-60, 50-60, 10-50, 20-50, 30-50, 40-50, 10-40, 20-40, 30-40, 10-30, 20-30, or 10-20 weight percent thermally conductive particles on a dry weight basis.

[0078] A compromise must be made with the weight percentage of thermally conductive particles in the substrate. Increasing the weight percentage of particles in the aerosol-forming substrate can advantageously increase the thermal conductivity of the substrate. However, increasing the weight percentage of particles in the aerosol-forming substrate may also reduce the space available to the aerosol former, potentially resulting in a substrate that forms less aerosol.

[0079] Optionally, the aerosol-forming substrate has a thermal conductivity at 25 degrees Celsius in at least one direction, for example in all directions, of greater than 0.05, 0.2, 0.5, 1 or 1.5 W / (mK).

[0080] Optionally, the aerosol-forming substrate has a density of less than 1500, 1050, 1000, 950, 900, 850, 800, 850, 800, 750, 700, or 650 kg / m. Optionally, the aerosol-forming substrate has a density of between 500 and 900 kg / m, or between 600 and 800 kg / m. 3 It has a density of

[0081] Optionally, the aerosol-forming substrate has a moisture content of 1 to 20, or 3 to 15% by weight. Optionally, the aerosol-forming substrate comprises 1 to 20, or 3 to 15% by weight of water. The moisture content or moisture content of the substrate may be measured using a titration method. The moisture content or moisture content of the substrate may be measured using the Karl Fisher method.

[0082] The aerosol-generating article may have a length (e.g., x-dimension) of 10 mm to 100 mm, or 10 mm to 50 mm, such as 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.

[0083] 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.

[0084] The aerosol-generating article may have a height (e.g., z-dimension) of from 1 millimeter to 10 millimeters, such as from 1.2 millimeters to 8 millimeters, for example, from 1.4 millimeters to 7 millimeters, for example, from 1.6 millimeters to 6 millimeters, for example, from 1.7 millimeters to 5 millimeters, for example, about 1.7 millimeters, or about 4.5 millimeters, or about 2 millimeters, or about 3 millimeters, or about 4 millimeters.

[0085] An aerosol-generating article, when viewed in a plan view, may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or square), an oval, or a circle, or a combination thereof. When an 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 defining a polygon, a quadrilateral (e.g., a rectangle or square), an oval, 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. When an 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 defining a polygon, a quadrilateral (e.g., a rectangle or square), an oval, a circle, or a combination thereof.

[0086] The aerosol-forming substrate may be one of several component parts of the aerosol-generating article.

[0087] 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.

[0088] 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.

[0089] The aerosol-forming substrate may comprise or consist of a solid aerosol-forming material. The aerosol-forming substrate may comprise a liquid aerosol-forming material, for example a liquid aerosol-forming material held within a porous matrix. The aerosol-forming substrate may comprise a gel aerosol-forming material.

[0090] 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 be or include glycerin.

[0091] 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.

[0092] 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.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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.

[0097] 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.

[0098] 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.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] 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.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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.

[0107] The aerosol-forming substrate may comprise tobacco, e.g., about 15-45%, preferably about 20-35%, of a tobacco blend incorporating at least one of the following tobacco varieties: bright tobacco, dark tobacco, and aromatic tobacco. The tobacco material, e.g., tobacco, is preferably ground and graded to a particle size of about 100-380 mesh, preferably about 170-320 mesh.

[0108] "Tobacco type" means one of different types of tobacco, for example, based on the distinct curing processes that the tobacco undergoes before being further processed into a tobacco product.

[0109] Examples of bright tobaccos include Brazilian Fulcure, Indian Fulcure, Chinese Fulcure, American Fulcure such as Virginia tobacco, and Tanzanian Fulcure.

[0110] Examples of aromatic tobaccos are Turkish Oriental, Greek Orient, and Semi-Orient tobaccos, but also fire-cured, American burleys such as Perique, and rustica.

[0111] Examples of dark tobaccos include dark-cured Brazilian Galpao, Burley Malawi or other African Burley, Sun-cured or air-cured Indonesian Kastri.

[0112] 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.

[0113] 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, the organic fibers may be derived from cellulose, cotton, wood, tea plant varieties as by-products, and by-processing waste from the tea industry. The length of the organic fibers is preferably about 10 to 400 μm, and more preferably about 10 to 200 μm.

[0114] 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 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.

[0115] The aerosol-forming substrate may comprise organic vegetable glycerite. For example, the aerosol-forming substrate may comprise about 15 to 55%, preferably about 20 to 35%, of botanical ingredients such as clove, echinacea species, fennel, ginger, houthorn berry, elderberry, monarda, mullein leaf, nettle, plantain, turmeric, yarrow, and combinations thereof.

[0116] The aerosol-forming substrate may contain organic plant extracts. For example, the aerosol-forming substrate may contain about 1% to 15%, preferably 2% to 7%, of any of the aforementioned plant components, as well as menthol (dl-menthol, CHO, 2-isopropyl-5-methylcyclohexanol) obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related plant varieties, and p-menthone-3-ol as an optional secondary alcohol, a diastereoisomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.

[0117] The aerosol-forming substrate may contain 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.

[0118] The aerosol-forming substrate preferably comprises an aerosol former, for example, about 5-35%, preferably about 10-25%, of the 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, for example, their dimethyl esters.

[0119] According to a fifth aspect of the present disclosure, there is provided an aerosol generating system comprising an aerosol-generating article and an aerosol-generating device. The aerosol-generating article may be an article described herein, such as an article according to any of the first, second, third or fourth aspects.

[0120] An aerosol-generating device can be a device for use with an aerosol-generating article to enable the generation or emission of an aerosol.

[0121] The apparatus may include a power source. The apparatus may include a cavity for receiving at least a portion of the article. The apparatus may include a heater. The apparatus may include an induction heater. Alternatively, or additionally, the apparatus may include a resistance heater.

[0122] The apparatus may be configured to heat the article, e.g., a substrate of the article, during use. The apparatus may be configured to inductively heat the article, e.g., a substrate of the article, e.g., thermally conductive particles, the particles comprising one or more susceptor materials during use. Alternatively, or additionally, the apparatus may be configured to resistively heat the article, e.g., a substrate of the article, during use.

[0123] As used herein, the term "aerosol-generating article" may refer to an article that is capable of generating or emitting an aerosol.

[0124] 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 otherwise loaded onto a carrier or support. The aerosol-forming substrate may conveniently be part of an aerosol-generating article or a smoking article.

[0125] 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.

[0126] 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 in 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.

[0127] 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.

[0128] As used herein, the term "nicotine" is used to refer to nicotine, nicotine base, or nicotine salts.

[0129] As used herein, the terms "proximal," "distal," "upstream," and "downstream" may be used to indicate the relative locations of components or portions of components of an aerosol-generating article.

[0130] As used herein, the term "longitudinal" may refer 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.

[0131] As used herein, the term "sheet" can refer to a layered element having a width and length substantially greater than its thickness. The width of the sheet is 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 described herein may have a thickness of from 10 μm to about 1000 μm, e.g., from 10 μm to about 300 μm.

[0132] As used herein, the term "homogenized tobacco material" may encompass 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 small amounts of one or more 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 molding, extrusion, a papermaking process, or any other suitable process known in the art.

[0133] The term "cast leaf" as used herein may refer to a product made by a molding process based on molding a slurry containing plant particles (e.g., clove particles or tobacco particles and clove particles in a mixture) 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. An example of a molding or cast leaf process is 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 plants 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 molded onto a support surface and dried into a sheet of homogenized plant material. Preferably, the homogenized plant material used in the article of the present invention may be produced by molding. Such homogenized plant material may include agglomerated particulate plant material.

[0134] As used herein, withdrawal resistance is expressed using the units of pressure "mmH2O" or "mmWG" or "millimeters of water column" and may be measured in accordance with ISO 6565:2002.

[0135] As used herein, the term "thermally conductive particles" may refer to particles having a thermal conductivity of greater than 1 W / (MK) in all directions at 25 degrees Celsius, for example, and in at least one direction at 25 degrees Celsius. The particles may exhibit anisotropic or isotropic thermal conductivity.

[0136] As used herein, the term "expanded graphite" may refer to a graphite-based material or a material having a graphite-like structure. Expanded graphite may have carbon layers (e.g., similar to graphite) with larger spacing between the carbon layers than found between the carbon layers in regular graphite. Expanded graphite may also have carbon layers with elements or compounds interposed within the spaces between the carbon layers.

[0137] The term "particle size" as used herein may refer to a single dimension and may be used to characterize a given particle size. The dimension may be the diameter of a spherical particle that occupies the same volume as the given particle. All particle sizes and particle size distributions herein may be obtained using standard laser diffraction techniques. The particle sizes and particle size distributions described herein may be obtained using commercially available sensors, such as Sympatec's HELOS laser diffraction sensor.

[0138] As used herein, the term "density" may refer to true density unless otherwise specified. Therefore, unless otherwise specified, the density of a powder or particles may refer to the true density of the powder or particles (rather than the bulk density of the powder or particles, which can vary significantly depending on how the powder or particles are handled). True density measurements can be performed using several standard methods, and these methods are often based on Archimedes' principle. When used to measure the true density of a powder, the most widely used method involves the powder being placed and weighed inside a container of known volume (a pycnometer). The pycnometer is then filled with a fluid of known density in which the powder is not soluble. The volume of the powder is determined by the difference between the volume indicated by the pycnometer and the volume of the added liquid (i.e., the volume of air displaced). [Example]

[0139] 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.

[0140] Example 1 1. An aerosol-generating article for use in an aerosol-generating device to generate an aerosol, comprising: an aerosol-forming substrate comprising thermally conductive particles, each of the thermally conductive particles having a thermal conductivity of at least 1 W / mK in at least one direction at 25 degrees Celsius; The aerosol-generating article is a planar aerosol-generating article having an article length, an article width, and an article thickness, wherein the article thickness is 0.5 times or less the article length and 0.5 times or less the article width. Example 2. 10. The aerosol-generating article of claim 1, wherein the thickness of the article is no more than 0.2 times the length of the article and no more than 0.2 times the width of the article. Example 3 The aerosol-generating article according to any one of Examples 1 and 2, wherein the aerosol-forming substrate is a planar aerosol-forming substrate having a substrate length, a substrate width, and a substrate thickness, and the substrate thickness is 0.5 times or less the substrate length and 0.5 times or less the substrate width. Example 4. 4. The aerosol-generating article of claim 3, wherein the substrate thickness is no more than 0.2 times the substrate length and no more than 0.2 times the substrate width. Example 5. An aerosol-generating article according to any one of Examples 1 to 4, wherein the aerosol-generating article comprises a corrugated element. Example 6 6. The aerosol-generating article of example 5, wherein the aerosol-forming substrate comprises a corrugated element. Example 7 7. The aerosol-generating article of example 5 or 6, wherein the corrugated element is or comprises a corrugated sheet of material that has been bent or folded to form the corrugations. Example 8 An aerosol-generating article according to any one of Examples 5 to 7, wherein the corrugated element comprises at least a portion of thermally conductive particles. Example 9. 9. The aerosol-generating article of example 8, wherein at least a portion of the thermally conductive particles of the corrugated elements comprise or consist of one or more susceptor materials. Example 10. The aerosol-generating article of any one of Examples 5 to 9, wherein the corrugated element comprises an aerosol-forming material. Example 11 11. The aerosol-generating article of any one of Examples 5 to 10, wherein the aerosol-forming substrate comprises a first planar layer adjacent to, and optionally contacting, the corrugated element. Example 12 12. The aerosol-generating article of example 11, wherein the first planar layer comprises an aerosol-forming material. Example 13 13. The aerosol-generating article of any one of Examples 5 to 12, wherein the aerosol-forming substrate comprises a second planar layer adjacent to, and optionally contacting, the corrugated element. Example 14. 14. The aerosol-generating article of example 13, wherein the second planar layer comprises an aerosol-forming material. Example 15. 11. The aerosol-generating article of any one of Examples 5 to 10, wherein the aerosol-forming substrate comprises a first planar layer, a second planar layer, and an intermediate layer disposed between the first and second planar layers, and optionally the intermediate layer comprises a corrugated element. Example 16. 16. The aerosol-generating article of example 15, wherein the intermediate layer comprises corrugated elements. Example 17. 17. The aerosol-generating article of any one of Examples 15 to 16, wherein the intermediate layer comprises an aerosol-forming material. Example 18. 18. The aerosol-generating article of Example 15, 16, or 17, wherein the first planar layer comprises at least a portion of thermally conductive particles. Example 19. The aerosol-generating article of any one of Examples 15 to 18, wherein the second planar layer contains at least a portion of thermally conductive particles. Example 20. The intermediate layer comprises at least a portion of the thermally conductive particles, for example, the article is an article described in any of Examples 16 to 19, and the corrugated elements of the intermediate layer comprise at least a portion of the thermally conductive particles. An aerosol-generating article described in any of Examples 15 to 19. Example 21. An aerosol-generating article described in any one of Examples 11-12 or Examples 13-14, when dependent on Example 11 or 12, or one of Examples 15-20, wherein the first planar layer has a first region and a second region. Example 22. 22. The aerosol-generating article of Example 21, wherein the first region is closer to the corrugated element than the second region. Example 23. 23. The aerosol-generating article of any one of claims 21 to 22, wherein the shortest distance between the first region and the corrugated element is less than the shortest distance between the second region and the corrugated element. Example 24. 24. The aerosol-generating article of any one of Examples 21, 22, or 23, wherein the first region contacts the corrugated element, e.g., contacts a peak or a valley of the corrugated element. Example 25. 25. The aerosol-generating article of any one of Examples 21 to 24, wherein the second region is not in contact with the corrugated element. Example 26. An aerosol-generating article described in any one of Examples 11-12 or Examples 13-14, when dependent on one of Examples 11 or 12, Examples 15-20, or Examples 21-25, wherein the first planar layer has one or more first portions and one or more second portions. Example 27. 27. The aerosol-generating article of Example 26, wherein the or each first portion is closer to the corrugated element than the or each second portion. Example 28. 28. An aerosol-generating article as described in Example 26 or 27, wherein the shortest distance between the or each first portion and the corrugated element is less than the shortest distance between the or each second portion and the corrugated element. Example 29. 29. The aerosol-generating article of any one of Examples 26 to 28, wherein the or each first portion contacts the corrugated element, e.g., contacts a peak or a valley of the corrugated element. Example 30. An aerosol-generating article as described in any of Examples 26 to 29, wherein there are multiple first portions, and each first portion is adjacent to, e.g., contacting, a peak or valley of a corrugated element with no adjacent or contacting other first portions. Example 31. 31. The aerosol-generating article of any one of Examples 26 to 30, wherein the or each second portion does not contact the corrugated element. Example 32. 32. The aerosol-generating article of any one of Examples 26 to 31, wherein at least one first portion is located between two second portions. Example 33. An aerosol-generating article according to any one of Examples 26 to 32, wherein at least one second portion is located between two first portions. Example 34. An aerosol-generating article according to any one of Examples 21 to 25 or any one of Examples 26 to 33, when dependent on any one of Examples 21 to 25, wherein the first region has a different material composition than the second region. Example 35. the first region has a coating and the second region does not have a coating; or the second region has a coating and the first region does not have a coating; or The aerosol-generating article of any of Examples 21-25 or any of Examples 26-34, when dependent on any of Examples 21-25, wherein the first region and the second region have different coatings. Example 36. An aerosol-generating article as described in Example 34 or 35, wherein the second region contains a greater proportion, on a dry weight basis, of at least one component, such as a flavorant or botanical ingredient, having a vaporization temperature at atmospheric pressure of less than 250 degrees Celsius or 200 degrees Celsius than the first region. Example 37. The aerosol-generating article of any of Examples 26-33 or any of Examples 34-36, when dependent on any of Examples 26-33, wherein the or each first portion has a different material composition than the or each second portion. Example 38. the or each first portion has a coating and the or each second portion does not have a coating; or the or each second portion has a coating and the or each first portion does not have a coating; or 38. The aerosol-generating article of Example 37, wherein the or each first portion and the or each second portion have different coatings. Example 39. An aerosol-generating article as described in Example 37 or 38, wherein the or each second portion contains a greater proportion, on a dry weight basis, of at least one component, such as a flavoring or botanical ingredient, having a vaporization temperature at atmospheric pressure of less than 250 degrees Celsius or 200 degrees Celsius than the or each first portion. Example 40. The aerosol-generating article of any of Examples 15-20 or any of Examples 21-39, when dependent on any of Examples 15-20, wherein the first planar layer is substantially parallel to the second planar layer. Example 41. An aerosol-generating article as described in Example 40, wherein the first planar layer includes a substantially planar upper surface defined by a length extending in the x-direction and a width extending in the y-direction, and the second planar layer includes a substantially planar lower surface defined by a length extending in the x-direction and a width extending in the y-direction. Example 42. The aerosol-generating article of any of Examples 15-20 or any of Examples 21-41, when dependent on any of Examples 15-20, wherein the substantially planar upper surface and the substantially planar lower surface are vertically spaced apart from one another by a height, for example, a height equal to the substrate thickness defined in the z-direction. Example 43. The aerosol-generating article of any of Examples 15-20 or any of Examples 21-42, when dependent on any of Examples 15-20, wherein the corrugated element is attached to, and optionally contacts, one or both of the first planar layer and the second planar layer. Example 44. The aerosol-generating article of any of Examples 15-20 or any of Examples 21-43, when dependent on any of Examples 15-20, wherein the first plurality of channels is defined between the upper layer and the corrugated element, and the second plurality of channels is defined between the corrugated element and the lower layer. Example 45. The goods are a first planar exterior surface; a second planar outer surface; and Cavities and a frame positioned between the first planar outer surface and the second planar outer surface, the frame at least partially defining a cavity; An air intake, An air outlet; An aerosol-generating article according to any one of Examples 1 to 44, comprising an airflow passage extending through the cavity between the air inlet and the air outlet, wherein the aerosol-forming substrate is positioned between the first planar outer surface and the second planar outer surface. Example 46. The aerosol-generating article of Example 45 when dependent on any of Examples 15 to 20, wherein the first planar layer comprises a first planar outer surface and the second planar layer comprises a second planar outer surface. Example 47. 47. The aerosol-generating article of example 45 or 46, wherein the frame comprises a peripheral wall that at least partially surrounds or encloses the cavity. Example 48. 48. An aerosol-generating article as described in Example 45, 46, or 47, wherein the article comprises a first planar outer layer and a second planar outer layer, the first planar outer layer forming the first planar outer surface, and the second planar outer layer forming the second planar outer surface. Example 49. The aerosol-generating article of Example 48 when dependent on any of Examples 15 to 20, wherein the first planar layer is or comprises a first planar outer layer and the second planar layer is or comprises a second planar outer layer. Example 50. 50. The aerosol-generating article of any of Examples 48-49, wherein 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. Example 51. The aerosol-generating article of any one of Examples 45 to 50, wherein the cavity is substantially empty. Example 52. 51. The aerosol-generating article of any of Examples 45 to 50, wherein the aerosol-forming material is positioned within the cavity, e.g., some or all of the aerosol-forming substrate is positioned within the cavity. Example 53. 53. The aerosol-generating article of any one of Examples 45-50 or 52, wherein the corrugated element or layer is positioned within the cavity. Example 54. The aerosol-generating article of any of Examples 45-50 or 52 when dependent on Example 5, wherein the corrugated element is positioned within the cavity. Example 55. An aerosol-generating article according to any one of Examples 1 to 54, wherein each of the thermally conductive particles has a thermal conductivity of at least 2, 5, 10, 20, 50, 100, 200, or 500 W / mK in at least one direction at 25 degrees Celsius. Example 56. 56. The aerosol-generating article of any one of Examples 1-55, wherein each of the thermally conductive particles comprises or consists of one or more susceptor materials. Example 57. An aerosol-generating article described in any of Examples 1 to 56, wherein each of the thermally conductive particles comprises or consists of one or more susceptor materials and is inductively heatable to a temperature of at least 100 degrees Celsius, 200 degrees Celsius, or 300 degrees Celsius during use of the aerosol-generating article in an aerosol-generating device. Example 58. The aerosol-generating article of any one of Examples 1 to 57, wherein some or all of the thermally conductive particles are non-metallic particles. Example 59. The aerosol-generating article of any of Examples 1-58, wherein some or all of the thermally conductive particles comprise carbon, e.g., at least 10, 30, 50, 70, 90, 95, 98, or 99 wt. % carbon. Example 60. The aerosol-forming substrate according to any one of Examples 1 to 59, wherein some or all of the thermally conductive particles are graphite particles. Example 61. The aerosol-forming substrate according to any one of Examples 1 to 60, wherein some or all of the thermally conductive particles are expanded graphite particles. Example 62. The aerosol-forming substrate according to any one of Examples 1 to 61, wherein the thermally conductive particles include one or more of graphite particles, expanded graphite particles, diamond particles such as artificial diamond particles, graphene particles, carbon nanotubes, ferrite particles, and charcoal particles. Example 63. 63. An aerosol-generating article according to any one of Examples 1 to 62, wherein some or all of the thermally conductive particles comprise one or more of one or more metals, one or more metallic materials, one or more alloys, and one or more intermetallic particles. Example 64. An aerosol-generating article according to any one of Examples 1 to 63, wherein some or all of the thermally conductive particles comprise one or more of copper, aluminum, and nickel. Example 65. 65. An aerosol-generating article according to any one of Examples 1 to 64, wherein the thermally conductive particles have a particle size distribution with a particle size number D10, and the particle size number D10 is at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Example 66. 66. An aerosol-generating article according to any one of Examples 1 to 65, wherein the thermally conductive particles have a particle size distribution with a particle size number D10, and the particle size number D10 is 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns or less. Example 67. 67. An aerosol-generating article according to any one of Examples 1 to 66, wherein the thermally conductive particles have a particle size distribution with a particle size number D50, and the particle size number D50 is at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Example 68. 68. An aerosol-generating article according to any one of Examples 1 to 67, wherein the thermally conductive particles have a particle size distribution with a particle size number D50, and the particle size number D50 is 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns or less. Example 69. 69. An aerosol-generating article according to any one of Examples 1 to 68, wherein the thermally conductive particles have a particle size distribution with a particle size number D90, and the particle size number D90 is at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Example 70. 69. An aerosol-generating article according to any one of Examples 1 to 69, wherein the thermally conductive particles have a particle size distribution with a particle size number D90, and the particle size number D90 is 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns or less. Example 71. 71. An aerosol-generating article according to any one of Examples 1 to 70, wherein the thermally conductive particles have a particle size distribution with a particle size in volume D10 of at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Example 72. 72. An aerosol-generating article according to any one of Examples 1 to 71, wherein the thermally conductive particles have a particle size distribution with a particle size in volume D10 of 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns or less. Example 73. 73. An aerosol-generating article according to any one of Examples 1 to 72, wherein the thermally conductive particles have a particle size distribution with a particle size, volume D50, of at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Example 74. 74. An aerosol-generating article according to any one of Examples 1 to 73, wherein the thermally conductive particles have a particle size distribution with a particle size, volume D50, of 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns or less. Example 75. 75. An aerosol-generating article according to any one of Examples 1 to 74, wherein the thermally conductive particles have a particle size distribution with a particle size by volume D90 of at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Example 76. 76. An aerosol-generating article according to any one of Examples 1 to 75, wherein the thermally conductive particles have a particle size distribution with a volume D90 particle size of 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns or less. Example 77. The thermally conductive particles have a particle size distribution having a particle size number D10, a particle size number D90, a particle size volume D10, and a particle size volume D90; The particle size of the D90 number is 50, 40, 30, 20, 10, or 5 times less than the particle size of the D10 number, or the particle size in volume D10 is less than or equal to 50, 40, 30, 20, 10, or 5 times the particle size in volume D10; or An aerosol-generating article described in any of Examples 1 to 76, wherein the particle diameter of number D90 is 50, 40, 30, 20, 10, or 5 times or less the particle diameter of number D10, and the particle diameter of volume D10 is 50, 40, 30, 20, 10, or 5 times or less the particle diameter of volume D10. Example 78. An aerosol-generating article according to any one of Examples 1 to 77, wherein the thermally conductive particles have a particle size distribution, and one or both of the particle size by number D10 and the particle size by volume D10 is between 1 and 20 microns. Example 79. An aerosol-generating article according to any one of Examples 1 to 78, wherein the thermally conductive particles have a particle size distribution, and one or both of the number D90 particle size and volume D90 particle size is 50 to 300 microns, or 50 to 200 microns. Example 80. 80. The aerosol-generating article of any one of Examples 1 to 79, wherein each of the thermally conductive particles has a particle size of at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Example 81. 81. The aerosol-generating article of any one of Examples 1 to 80, wherein each of the thermally conductive particles has a particle size of 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns or less. Example 82. An aerosol-generating article described in any of Examples 1 to 81, wherein each of the thermally conductive particles has three mutually perpendicular dimensions, and the largest of the three dimensions is 10, 8, 5, 3, or 2 times larger than one or both of the smallest of the three dimensions and the second largest of the three dimensions. Example 83. The aerosol-generating article of any one of Examples 1 to 82, wherein each of the thermally conductive particles is substantially spherical. Example 84. The aerosol-generating article of any one of Examples 1 to 83, wherein the thermally conductive particles comprise at least 10, 20, 50, 100, 200, 500, or 1000 particles. Example 85. 85. The aerosol-generating article of any one of Examples 1 to 84, wherein the substrate comprises at least 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, or 85 weight percent thermally conductive particles on a dry weight basis. Example 86. 86. The aerosol-generating article of any one of Examples 1 to 85, wherein the substrate comprises, on a dry weight basis, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, or 15 wt. % or less of thermally conductive particles. Example 87. 87. The aerosol-generating article of any one of Examples 1 to 86, wherein the substrate comprises, on a dry weight basis, 10 to 90, 20 to 90, 30 to 90, 40 to 90, 50 to 90, 60 to 90, 70 to 90, 80 to 90, 10 to 80, 20 to 80, 30 to 80, 40 to 80, 50 to 80, 60 to 80, 70 to 80, 10 to 70, 20 to 70, 30 to 70, 40 to 70, 50 to 70, 60 to 70, 10 to 60, 20 to 60, 30 to 60, 40 to 60, 50 to 60, 10 to 50, 20 to 50, 30 to 50, 40 to 50, 10 to 40, 20 to 40, 30 to 40, 10 to 30, 20 to 30, or 10 to 20 wt. % of thermally conductive particles. Example 88. 88. An aerosol-generating article according to any one of Examples 1 to 87, wherein the aerosol-forming substrate has a thermal conductivity of greater than 0.05, 0.1, 0.15, 0.2, 0.3, 0.4, 0.5, 0.75, 1, 1.25, or 1.5 W / (mK) at 25 degrees Celsius. Example 89. The aerosol-forming substrate may have a viscosity of 1500, 1050, 1000, 950, 900, 850, 800, 850, 800, 750, 700, or 650 kg / m 3 89. The aerosol-generating article of any one of Examples 1 to 88, having a density of less than 1000 kJ / g. Example 90. The aerosol-forming substrate is 500 to 900 kg / m 3 , or 600-800 kg / m 3 89. The aerosol-generating article of any one of Examples 1 to 89, having a density of Example 91. 91. The aerosol-generating article of any one of Examples 1 to 90, wherein the aerosol-forming substrate has a moisture content of 1 to 20, or 3 to 15 wt. %. Example 92. 92. The aerosol-generating article of any one of Examples 1 to 91, wherein the aerosol-forming substrate comprises 1 to 20, or 3 to 15 wt. % water.

[0141] The embodiments will now be further described with reference to the figures.

[0142] 1 shows a perspective side view of an aerosol-generating article 100 according to a first embodiment of the present invention. The aerosol-generating article 100 has an upper surface 110 and a lower surface 120 that are flat or planar.

[0143] The aerosol-generating article 100 comprises an aerosol-forming substrate (not shown). In one embodiment, the aerosol-generating article 100 may consist essentially of the aerosol-forming substrate. 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 or surrounded 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.

[0144] In this embodiment, the aerosol-forming substrate includes an aerosol-forming material and a plurality of thermally conductive particles (not shown) dispersed substantially uniformly therein.

[0145] In this embodiment, the thermally conductive particles are graphite particles, in particular FP 99.5 (>99.5% purity) graphite particles commercially available from Graphit Kropfmul GmbH, AMG Graphite GK, although other particles or mixtures of particles may also be used.

[0146] Each of the thermally conductive particles is substantially spherical in shape and has a thermal conductivity in all directions of greater than 1 W / (mK) at 25 degrees Celsius. The particle size distribution of the thermally conductive particles includes a volume D10 particle size of about 6 microns, a volume D50 particle size of about 21 microns, and a volume D90 particle size of about 55 microns. The thermally conductive particles constitute about 10% by weight of the aerosol-forming substrate on a dry mass basis.

[0147] 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.

[0148] 2 shows a perspective side 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. Features in common with the aerosol-generating article 100 are referred to by like reference numerals. Features identical to the aerosol-generating article 100 will not be repeated below.

[0149] 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 enable the user to inhale aerosol generated as a result of heating the aerosol-forming substrate of the aerosol-generating article 200.

[0150] 3, 4, and 5 show end, side, and top views, respectively, of an aerosol-generating article 300 according to a third embodiment of the present disclosure.

[0151] The aerosol-generating article 300 comprises an aerosol-forming substrate comprising a planar upper layer 310 , a planar lower layer 320 , and an intermediate or separating layer 330 disposed between the upper and lower layers 310 , 320 .

[0152] Planar upper layer 310 is formed from a sheet of aerosol-forming material having a thickness of 300 microns. In this embodiment, planar upper layer 310 does not include thermally conductive particles, although other embodiments could. Planar lower layer 320 is formed from a sheet of aerosol-forming material having a thickness of 300 microns. In this embodiment, planar upper layer 310 does not include thermally conductive particles, although other embodiments could. Intermediate layer 340 is a corrugated element formed from a corrugated sheet 345 of aerosol-forming material having a plurality of thermally conductive particles (not shown) substantially uniformly dispersed therein. The combination of planar lower layer 320, planar upper layer 310, and the corrugated sheet of aerosol-forming material 345 with the thermally conductive particles dispersed therein may together be considered the aerosol-forming substrate of aerosol-generating article 300.

[0153] In this embodiment, the thermally conductive particles are graphite particles, in particular FP 99.5 (>99.5% purity) graphite particles commercially available from Graphit Kropfmul GmbH, AMG Graphite GK, although other particles or mixtures of particles may also be used.

[0154] Each of the thermally conductive particles is substantially spherical in shape and has a thermal conductivity in all directions of greater than 1 W / (mK) at 25 degrees Celsius. The particle size distribution of the thermally conductive particles includes a volume D10 particle size of about 6 microns, a volume D50 particle size of about 21 microns, and a volume D90 particle size of about 55 microns. The thermally conductive particles constitute about 10% by weight of the aerosol-forming substrate on a dry mass basis.

[0155] 6 shows a corrugated sheet of aerosol-forming material 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.

[0156] The intersections 351, 352 between the top layer 310 and the middle layer 340, and between the bottom layer 320 and the middle layer 340, include adhesive that joins the respective layers together.

[0157] 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.

[0158] 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 a proximal end 371 of the substrate 345 and a 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 across both sides of the aerosol-forming substrate sheet 345. The porosity of the aerosol-generating article along the airflow path is in the 90% range. This provides a very low resistance to draw (RTD) of less than 5 mmH2O. In fact, the RTD is close to zero.

[0159] Planar upper layer 310 comprises a plurality of first portions and a plurality of second portions. The first portions of planar upper layer 310 are portions within approximately 0.5 mm of an intersection or line of intersection 351 between top layer 310 and middle layer 340, which in this embodiment extends along the entire length of middle layer 340. The second portions of planar upper layer 310 are the remainder of planar upper layer 310. The first portions have a different material composition than the second portions. Specifically, the first portions do not include any botanicals or flavorings. However, the second portions include 5% by weight of botanicals, specifically cloves, on a dry weight basis.

[0160] The planar upper layer 310 may be formed in a number of ways, for example, by first forming a substantially homogenous sheet of aerosol-forming material and then impregnating or otherwise adding cloves to a second portion.

[0161] The planar lower layer 320 is formed from a substantially homogenous sheet of aerosol-forming material. Similar to the planar upper layer 310, the planar lower layer 320 includes a plurality of first portions and a plurality of second portions. The first portion of the planar lower layer 320, in this embodiment, extends along the entire length of the middle layer 340 and is within about 0.5 mm of the intersection or line of intersection 352 between the planar lower layer 320 and the middle layer 340. The second portion of the planar lower layer 320 is the remainder of the planar lower layer 320. The upper surface of the second portion of the planar lower layer 320 is coated with botanicals, particularly cloves, in this embodiment. The upper surface of the first portion of the planar lower layer 320 is free of the coating.

[0162] During use of the aerosol-generating article 300, the aerosol-forming substrate is inserted into the cavity of the aerosol-generating device and inductively heated. Specifically, an alternating current is passed through the device's inductor coil, which surrounds the cavity in which the article 300 is received, thereby generating a varying magnetic field within the cavity. This varying magnetic field induces eddy currents and hysteresis losses in the graphite particles, which are the susceptor particles, causing them to heat. The device can also resistively heat the substrate, for example, using a heating surface that at least partially defines the cavity and is placed in contact with one or both of the upper surface of the planar upper layer 310 and the lower surface of the planar lower layer 320 when the article is received in the cavity.

[0163] Heating of the substrate causes the release of volatile compounds from the aerosol-forming material in the substrate, which are then entrained in air drawn into channels 361, 362 through distal end 372 of article 300 in response to a user drawing on proximal end 372 of article 300 or a mouthpiece (not shown) attached to proximal end 372 of article 300. The volatile compounds then cool and condense to form an aerosol, which can be drawn out of channels 361, 362 of aerosol-generating article 300 through proximal end 371 and inhaled by a user.

[0164] 3-5, induction heating is used, and for example, as described above, the corrugated elements are heated to a higher temperature than the upper and lower planar layers 310, 320 due to the presence of graphite particles within the inductively heated corrugated elements. Thus, the first portions of the upper and lower planar layers 310, 320 are heated to a higher temperature than the second portions of the upper and lower planar layers 310, 320 because the first portions are closer to the corrugated elements than the second portions of the upper and lower planar layers 310, 320. With this in mind, components of the aerosol-forming substrate, particularly the plant cloves, that do not need to be heated to particularly high temperatures to vaporize are advantageously part of or coated on the second portions of the upper and lower planar layers 310, 320. Thus, a greater proportion of heat is transferred from the corrugated elements to the upper and lower planar layers 310, 320, targeting components that need to be heated to higher temperatures, compared to, for example, completely homogeneous upper and lower planar layers 310, 320 without a coating.

[0165] 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 planar outer surface 421, a second planar outer layer 425 forming a second planar outer surface 422, and a frame 450 positioned between the first planar outer layer 424 and the second planar outer layer 425. The second planar outer surface 422 is positioned parallel to the first planar outer surface 421.

[0166] 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 is filled with an aerosol-forming substrate 440.

[0167] 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, the second cavity end wall 432 being 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.

[0168] The frame 450 has a hollow rectangular parallelepiped shape and is made from cardboard. The frame 450 defines an opening that extends through the height (also referred to as the 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.

[0169] The air inlet 411 and the air outlet 412 are defined by and extend through a peripheral wall 451 of the frame 450. More specifically, the air inlet 411 extends through a front wall 413, and the air outlet 412 extends through a rear wall 414. The air inlet 411 and the air outlet 412 have an equivalent diameter of 5 millimeters. An airflow passage extends through the cavity 430 between the air inlet 411 and the air outlet 412.

[0170] As shown in Figures 9-11, the aerosol-forming substrate 440 is positioned within the cavity 430. The aerosol-forming substrate 440 is in the form of a cut filler. The cut filler is formed from pieces of aerosol-forming material, including homogenized tobacco, and an aerosol-forming material content of 5 weight percent on a dry mass basis. Additionally, a plurality of thermally conductive particles are dispersed substantially uniformly throughout the aerosol-forming material before the material is shredded to form the cut filler. Thus, the thermally conductive particles are dispersed throughout the aerosol-forming substrate of this embodiment.

[0171] In this embodiment, the thermally conductive particles are graphite particles, in particular FP 99.5 (>99.5% purity) graphite particles commercially available from Graphit Kropfmul GmbH, AMG Graphite GK, although other particles or mixtures of particles may also be used.

[0172] Each of the thermally conductive particles is substantially spherical in shape and has a thermal conductivity in all directions of greater than 1 W / (mK) at 25 degrees Celsius. The particle size distribution of the thermally conductive particles includes a particle size at volume D10 of about 6 microns, a particle size at volume D50 of about 21 microns, and a particle size at volume D90 of about 55 microns. The thermally conductive particles constitute about 10% by weight of the aerosol-forming substrate.

[0173] As shown, the aerosol-forming substrate 440 fills the entire volume of the cavity 430 .

[0174] The aerosol-generating article 400 has a cubic shape and has a height (or thickness) extending in the z-dimension measured between the first planar outer surface 421 and the second planar outer surface 422 of 8 millimeters, a width extending in the y-dimension of 40 millimeters, and a length extending in the x-dimension of 60 millimeters. The frame 450 has a height (or thickness) extending in the z-dimension of 7.93 millimeters, a width extending in the y-dimension of 40 millimeters, and a length extending in the x-dimension of 60 millimeters. The cavity 430 has a height (or thickness) extending in the z-dimension of 7.93 millimeters, a width extending in the y-dimension of 39.93 millimeters, and a length extending in the x-dimension of 52 millimeters.

[0175] 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. Features identical to aerosol-generating article 400 will not be described again.

[0176] 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-forming material 540, specifically a corrugated sheet of homogenized tobacco material having thermally conductive particles substantially uniformly dispersed therein. Figures 13 and 14 show cross-sectional and side views, respectively, of the aerosol-generating article 500 of Figure 12.

[0177] The corrugated sheet 540 of homogenized tobacco material includes 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 FIG. 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.

[0178] The parallel corrugations form a plurality of channels 545 between the sheet of aerosol-forming material 540 and the first hollow end wall 431, and a plurality of channels 546 between the sheet of aerosol-forming material 540 and the second hollow 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.

[0179] During use of each of the aerosol-generating articles 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 out of the aerosol-generating article 400, 500 through the air outlet 412.

[0180] For illustrative purposes applicable to the above-described embodiments, the composition of a suitable aerosol-forming material 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 its final product state. The aerosol-forming substrate may further comprise: 1. Tobacco leaf; for example, about 15-45%, preferably about 20-35%, of a tobacco leaf blend containing 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, for example, 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 starches or derivatized starches; alginates; methylcellulose, ethylcellulose, ethylhydroxymethylcellulose, and carboxymethylcellulose; dextran; and xanthan gum. A preferred binder is guar. 5. 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 monocarboxylic, dicarboxylic, or polycarboxylic acids, for example, their dimethyl esters.

[0181] "Tobacco type" means one of different types of tobacco, for example, based on the distinct curing processes that the tobacco undergoes before being further processed into a tobacco product.

[0182] For illustrative purposes, further aerosol-forming substrate compositions that may also be suitable for use as the aerosol-forming material in the above-described embodiments are set forth 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: For example, any suitable plant variety commonly available on the market with a purity of 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 length of the organic fiber is preferably 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 combinations thereof. 4. Organic plant extracts; for example, about 1% to 15%, preferably 2% to 7%, of any of the aforementioned plant components, as well as menthol (dl-menthol, CHO, 2-isopropyl-5-methylcyclohexanol) obtained from Chaerophyllum macrosperm, Mesosphaerum sidifolium, or other related plant varieties, and p-menthone-3-ol as an optional secondary alcohol as a diastereoisomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.

[0183] Alternatively, such an aerosol-forming substrate may also contain about 0.5 to 5%, preferably about 1 to 3%, of a plant-based essential oil such as palm-based essential oil, coconut-based essential oil, and wood-based essential oil.

[0184] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like should be understood in all instances to be 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 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 in an aerosol-generating device to generate an aerosol, comprising: an aerosol-forming substrate comprising thermally conductive particles, each of the thermally conductive particles having a thermal conductivity of at least 1 W / mK in at least one direction at 25 degrees Celsius; The aerosol-generating article is a planar aerosol-generating article having an article length, an article width, and an article thickness, wherein the article thickness is 0.5 times or less the article length and 0.5 times or less the article width.

2. 2. The aerosol-generating article according to claim 1, wherein the aerosol-forming substrate is a planar aerosol-forming substrate having a substrate length, a substrate width, and a substrate thickness, the substrate thickness being no more than 0.5 times the substrate length and no more than 0.5 times the substrate width.

3. 3. The aerosol-generating article of claim 1, wherein the aerosol-generating article comprises a corrugated element.

4. The aerosol-generating article of claim 3 , wherein the aerosol-forming substrate comprises the corrugated element.

5. 5. The aerosol-generating article according to claim 3 or 4, wherein the corrugated elements comprise at least a portion of the thermally conductive particles.

6. 6. The aerosol-generating article of claim 5, wherein at least a portion of the thermally conductive particles of the corrugated elements comprise or consist of one or more susceptor materials.

7. 7. The aerosol-generating article according to claim 3, wherein the corrugated element comprises an aerosol-forming material.

8. 8. The aerosol-generating article according to claim 3, wherein the aerosol-forming substrate comprises a first planar layer adjacent to the corrugated elements, the first planar layer comprising an aerosol-forming material.

9. 8. The aerosol-generating article of claim 3, wherein the aerosol-forming substrate comprises a first planar layer, a second planar layer, and an intermediate layer disposed between the first planar layer and the second planar layer, the intermediate layer comprising the corrugated element.

10. 10. The aerosol-generating article of claim 9, wherein one or both of the first planar layer and the second planar layer comprises an aerosol-forming material.

11. 11. The aerosol-generating article according to claim 8, wherein the first planar layer contains at least a portion of the thermally conductive particles.

12. 12. An aerosol-generating article according to any one of claims 8 to 11, wherein the first planar layer has a first region and a second region, the shortest distance between the first region and the corrugated element is smaller than the shortest distance between the second region and the corrugated element, and the first region has a different material composition from the second region.

13. 12. The aerosol-generating article of claim 8, wherein the first planar layer has a first region and a second region, the shortest distance between the first region and the corrugated elements is smaller than the shortest distance between the second region and the corrugated elements, and the first region has a coating and the second region does not have a coating, or the second region has a coating and the first region does not have a coating, or the first region and the second region have different coatings.

14. 14. An aerosol-generating article according to any preceding claim, wherein at least a portion of the thermally conductive particles comprise or consist of one or more susceptor materials.

15. An aerosol generation system comprising an aerosol-generating article according to any one of claims 1 to 14 and an aerosol-generating device, wherein the aerosol-generating device is configured to engage with the aerosol-generating article and generate an aerosol from the aerosol-generating article.

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