Particulate aerosol generating article having dispersed susceptor material

Abstract

The present invention relates to an aerosol generating article 10 for an aerosol generating device, wherein the aerosol generating article 10 is in the form of particles. The aerosol generating article 10 comprises a first aerosol generating substrate 16 and a plurality of pieces 18 of susceptor material. The plurality of pieces 18 of susceptor material are dispersed throughout the first aerosol generating substrate 16. The present invention further relates to a method for manufacturing the aerosol generating article 10.

Description

Technical Field

[0001] The present disclosure relates to an aerosol-generating article for an aerosol-generating device, the aerosol-generating article being in the form of particles, and the aerosol-generating article being in the form of particles.

Background Art

[0002] Aerosol-generating articles that generate aerosol from an aerosol-generating substrate without the need for combustion of the aerosol-generating substrate are known. Such articles are often referred to as "heat-not-burn" aerosol-generating articles because the aerosol-generating substrate is heated to a relatively low temperature to induce the formation of aerosol, while preventing combustion of the materials contained within the aerosol-generating substrate.

[0003] Known aerosol-forming substrates are typically not heatable to an operating temperature by induction. This means that typically a separate susceptor element is required for induction heating. If the induction heating susceptor element is placed at the central position of the aerosol-generating substrate, the parts of the aerosol-generating substrate that are located furthest from the susceptor element may not reach a temperature high enough to release many volatile compounds.

[0004] In addition, most of the aerosol-generating articles already existing in the market have a rod shape, reproducing the shape of a standard cigarette. Such aerosol-generating articles have multiple parts and different functional elements in order to enable their performance.

[0005] It is desirable to have an aerosol-generating article with an improved thermal contact between the aerosol-generating substrate and the susceptor element. It is also desirable to have such an aerosol-generating article that requires a simpler manufacturing process than a rod-shaped aerosol-generating article that requires multiple parts to be assembled in a specific order.

Summary of the Invention

[0006] According to one aspect of the present invention, an aerosol generating article for an aerosol generating device is provided, wherein the aerosol generating article is in the form of particles, or has a spherical shape, or has a granular shape formed by a granulation process. The aerosol generating article comprises a first aerosol generating substrate and a plurality of pieces of susceptor material. The plurality of pieces of susceptor material are dispersed throughout the first aerosol generating substrate.

[0007] The first aerosol-generating substrate may be a substrate capable of releasing volatile compounds that can form aerosols when heated. The dispersion of multiple pieces of susceptor material throughout the first aerosol-generating substrate in an aerosol-generating article having a particulate shape provides direct physical contact between the first aerosol-generating substrate and each piece of susceptor material. Therefore, each piece of the susceptor may be configured to transfer heat to the first aerosol-generating substrate. This can provide a more uniform temperature distribution throughout the first aerosol-forming substrate during use than in an article where one of the susceptors is centrally located within the aerosol-generating substrate. In this aerosol-generating article, it may be possible to increase the proportion of the first aerosol-forming substrate that reaches a temperature high enough to release volatile compounds, and therefore, the utilization efficiency of the first aerosol-forming substrate may be increased.

[0008] Aerosol-generating articles may be directly usable in an electrically heated aerosol generator, in particular, without requiring assembly with other elements or a forming process to fit them into a capsule, such as a rod-shaped article. This can improve the sustainability of aerosol-generating articles, in that small amounts of components, namely a first aerosol-forming substrate and multiple pieces of susceptor material, are sufficient to easily provide consumable aerosol-generating articles, especially in an electrically heated aerosol generator.

[0009] Aerosol-generating articles may be solid. A solid state can be defined as a state in which a material is not fluid but maintains its boundaries without support. In a solid state, a material retains its shape or substantially returns to its shape after elastic deformation. In particular, the shape of the aerosol-generating article in its final state may remain rigid and stable even when handled by the user for consumption in an aerosol generator.

[0010] The aerosol-generating article may have a longest dimension less than twice its shortest dimension. The aerosol-generating article may have a convex shape, particularly a spherical or elliptical shape. An elliptical shape is a quasi-spherical shape such as an egg shape. Alternatively, the aerosol-generating article may have an angular shape. The surface of the aerosol-generating article may be angular or rough.

[0011] The external surface of an aerosol-generating article, or at least the external covering that surrounds the aerosol-generating article, may have an anti-adhesion property. This anti-adhesion property can prevent users from experiencing a sticky sensation when handling the aerosol-generating article. It can also prevent multiple aerosol-generating articles from sticking to each other, particularly inside packaging, especially under the influence of heat or moisture.

[0012] The external surface of an aerosol-generating article, or at least an external covering, may facilitate the visual or tactile identification of the aerosol-generating article. For example, the external surface of an aerosol-generating article, or at least an external covering, may be colored according to the fragrance or substance content of the aerosol-generating substrate, such as nicotine content. Alternatively, or in combination, the external surface of an aerosol-generating article, or at least an external covering, may have a defined average surface roughness. Average surface roughness may be defined by selecting particle size measurements for the materials and compounds used to generate the aerosol-generating article by particle size measurement. The mean square of the profile height deviation from the mean square (RMS) may be obtained to perform roughness measurements in surface roughness testing. When the aerosol-generating article does not have an outer coating, the average surface roughness of the outer surface of the aerosol-generating article may be related to the first or second aerosol-generating substrate and have an RMS roughness of 200 to 1000 microinches (5 to 25 micrometers), particularly 200 to 900 microinches (5 to 23 micrometers), and particularly 300 to 560 microinches (8 to 14 micrometers). When the aerosol-generating article has an outer coating, the average surface roughness of the outer surface of the aerosol-generating article may be related to the outer coating and have an RMS roughness of 120 to 900 microinches (3 to 23 micrometers), particularly 200 to 720 microinches (5 to 18 micrometers), and particularly 200 to 420 microinches (5 to 11 micrometers). The RMS value can be converted, for example, by the arithmetic mean or center line mean (CLA) of the profile height deviations from the mean line (Ra).

[0013] The particle shape of the aerosol-generating article may correspond to a granular shape. The particle shape or granular shape may be achieved by a granulation process. Thus, the aerosol-generating article may be formed by a granulation process. The granulation process can improve the uniformity of the distribution of susceptor material within the first aerosol-generating substrate. The granulation process may be an agglomeration process, particularly wet granulation or dry granulation. Before the compression step, wet granulation uses a binding solution that can be removed in the granulation process, particularly through a drying process. The wet granulation process may consist of one or more of high-shear granulation, reverse wet granulation, water-activated dry granulation, thermal bonding granulation, melt granulation, freeze granulation, foam granulation, or steam granulation. A fluidized bed granulator may be used for wet granulation, particularly for melt granulation. A fluidized bed dryer may be used in combination with or in sequence with a fluidized bed granulator. In particular, the aerosol-generating article may be formed by high-shear wet granulation. High-shear wet granulation may be configured to use a high-shear granulator. Single-pot granulation can combine mixing, high-shear wet granulation, and drying all in one process bowl. Dry granulation processes use the application of pressure without the use of liquids in between. Dry granulation processes may include air dry granulation (PDG). As an alternative configuration, molding or overmolding techniques may be used to achieve dispersion of multiple susceptor material pieces throughout the first aerosol-generating substrate. The granulation process may then follow the molding or overmolding step.

[0014] Multiple pieces of the susceptor material may be conductive pieces having the ability to convert electromagnetic energy into heat. When located in an alternating electromagnetic field, eddy currents are induced within the susceptor material, resulting in hysteresis losses and causing the susceptor to heat up. Similar to an aerosol generating article, the multiple pieces of the susceptor material are located in direct physical and therefore thermal contact with a first aerosol generating substrate, and the first aerosol generating substrate may be heated by the susceptor material so that an aerosol can be formed.

[0015] Multiple pieces of susceptor material may have different shapes from each other. Multiple pieces of susceptor material may be susceptor granules, susceptor beads, susceptor grits, susceptor flakes, susceptor fibers, susceptor rods, or combinations thereof. Pieces of susceptor material, particularly susceptor granules, susceptor beads, susceptor grits, and susceptor flakes, may be manufactured from raw materials, such as melting alloys to create metal droplets. The raw materials may consist of recycled materials, such as industrial residues from stainless steel processing plants. The metal droplets may be shaped and sieved to obtain a specific particle size range. The metal droplets may be crushed into particles, particularly angular particles, and sieved to obtain a specific particle size range. Susceptor flakes may consist of substantially flat shapes. Susceptor flakes may be manufactured, for example, by milling techniques using various raw materials, including recycled materials. The susceptor material pieces may be manufactured by a process that allows for a defined thickness and an overall sizing range. The process for manufacturing the susceptor material pieces may include steps to prevent the susceptor pieces from agglomerating. Alternatively, or in combination, the process for manufacturing the susceptor material pieces may include steps to verify that the susceptor pieces do not agglomerate. The maximum dimensions of a single piece of susceptor material may range from 0.1 mm to 2.5 mm, particularly from 0.25 mm to 1.85 mm, and more specifically from 0.45 mm to 1.55 mm. Multiple pieces of susceptor material may be of different sizes to one another.

[0016] The susceptor material may be a paramagnetic material, a ferromagnetic material, or one of the ferromagnetic materials. The susceptor material includes a metal foam. For example, the first susceptor material may consist of one of the following: aluminum, iron, nickel, copper, bronze, cobalt, ordinary carbon steel, stainless steel, ferritic stainless steel, martensitic stainless steel, or austenitic stainless steel. The susceptor material may consist of Inconel alloy (austenitic nickel-chromium superalloy). The susceptor material may consist of a transition metal such as Fe, Co, or Ni, or a metalloid component such as B, C, Si, P, or Al. The susceptor material may contain mu-metal or permalloy. The susceptor material may consist of a carbon material, or may be made from a carbon material. The susceptor material may consist of a ceramic such as graphite, molybdenum, silicon carbide, niobium, or zirconia, or may be made from them. The susceptor material may be heated to a temperature exceeding 250 degrees Celsius.

[0017] The susceptor material may consist of multiple pieces, including a piece of the first susceptor material and at least a piece of the second susceptor material. The first susceptor material and at least the second susceptor material may have different properties, particularly different electrical or thermal conductivity. The first susceptor material may have a Curie temperature above the ignition point of the first aerosol generating substrate. Preferably, the second susceptor material has a Curie temperature lower than the ignition point of the aerosol generating substrate. The first susceptor material may be used to heat the first aerosol generating substrate when the susceptor is placed in a fluctuating electromagnetic field. The second susceptor material can be used to indicate when the susceptor has reached a specific temperature (which is the Curie temperature of the second susceptor material). In particular, suitable materials for the second susceptor material may include nickel and nickel alloys. Thus, heating of the first aerosol generating substrate and temperature control of the heating may be separated.

[0018] Multiple pieces of susceptor material may be evenly distributed within the first aerosol-generating substrate. In particular, the uniform distribution is substantially uniform. The uniform distribution of susceptor material pieces may be achieved by a granulation process for forming the aerosol-generating article. Uniform distribution can be achieved in such a way that the manufacturing process does not include means to support uneven distribution, such as aggregation of susceptor material pieces. The distribution density of susceptor material pieces may be defined according to different methods. For example, the distribution density may be defined as the volume of susceptor material pieces within the first aerosol-generating substrate as a function of the total volume of the first aerosol-generating substrate.

[0019] The first aerosol generating substrate may contain 10 to 40% by weight, particularly 15 to 30% by weight, of susceptor material. The weight percentage of susceptor material in the first aerosol generating substrate may be determined on a dry mass basis. The dry mass basis may refer to the weight percentage of susceptor material in the first aerosol generating substrate after moisture has been removed from the aerosol generating article.

[0020] In the final state of the aerosol-generating article, that is, when the aerosol-generating article is ready for consumption, the moisture content of the first aerosol-generating substrate may be 5 to 35% by weight, particularly 10 to 25% by weight. The aerosol-generating substrate may also be in solid form. This is especially true for the aerosol-generating substrate in the final state of the aerosol-generating article, i.e., when the aerosol-generating article is ready for consumption.

[0021] The first aerosol-generating substrate may further comprise 15–55% by weight, particularly 25–45% by weight, of the first compound. The first aerosol-generating substrate may further comprise 3–25% by weight, particularly 7–18% by weight, of the second compound. The first compound may comprise at least one of an aerosol-forming body, a tobacco leaf blend, cellulose fibers, tobacco fibers, and a binder. The first compound may comprise 15–45% by weight, particularly 20–35% by weight, of a tobacco leaf blend. The tobacco blend may comprise at least one of bright tobacco, dark tobacco, and aromatic tobacco. "Tobacco type" refers to one of the various varieties of tobacco based on the unique curing process that tobacco undergoes before being further processed into a tobacco product. Examples of bright tobacco include fully cured Brazilian tobacco, fully cured Indian tobacco, fully cured Chinese tobacco, fully cured American tobacco (such as Virginia tobacco), and fully cured Tanzanian tobacco. Examples of aromatic tobaccos include Oriental Turkish, Greek Oriental, and Semi-Oriental tobaccos, as well as fire-cured US Burley such as Perique, and Rustica. Examples of dark tobaccos include dark-cured Brazil Galpao, Burley Malawi, or other African Burley, sun-cured, or air-cured Indonesian Kastri. The tobacco blends may have particle sizes consisting of 100 to 380 mesh particles, particularly 170 to 320 mesh particles. The first composition may contain about 1% to about 15% by weight, specifically about 3% to about 7% by weight, of cellulose fibers. The cellulose fibers in the first compound may have lengths consisting of 10 to 250 micrometers, particularly 10 to 120 micrometers. The first compound may contain 5 to 20% by weight, particularly 7 to 15% by weight, of tobacco fibers of any tobacco type or as a filler for a blend of tobacco types, from stems or petioles, or a combination of stems and petioles. The fibers in the first compound may have a length of 10 to 350 micrometers, particularly 20 to 180 micrometers.The first composition may contain 1 to 10% by weight, particularly 1 to 5% by weight, of a binder. The binder in the first compound may include, for example, natural pectins such as fruit pectin, e.g., citrus pectin, or tobacco pectin; guar gum, land locust bean gum, e.g., hydroxyethyl or hydroxypropyl of these gums; starch, e.g., modified starch or derivatized starch; alginates; methylcellulose, ethylcellulose, ethylhydroxymethylcellulose, and carboxymethylcellulose; dextran; and xanthan gum, or be made from these. In a preferred embodiment, the binder included in the first composition is made from guar.

[0022] The first aerosol generating substrate may contain at least 3% by weight, specifically at least 5% by weight, and more specifically at least 10% by weight of an aerosol forming agent, relative to the weight of the aerosol generating substrate. The first compound may contain less than 45% by weight, particularly less than 35% by weight, and more specifically less than 25% by weight of an aerosol forming agent. The aerosol forming agent contained in the first composition may be 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 such as dimethyl esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids.

[0023] The first aerosol generating substrate may further contain a wetting agent such as glycerol, propylene glycol, or triethylene glycol.

[0024] The first aerosol generating substrate may be configured to include at least a fragrance substance. The fragrance substance may be at least partially absorbed into the first aerosol generating substrate. The fragrance substance may be configured to include at least one fragrance component. The fragrance substance may be natural, for example, natural menthol. Alternatively, the fragrance substance may be artificial, for example, synthetic menthol. The fragrance substance may be configured to include essential oils. The fragrance substance may be configured to include at least one of organic vegetable glycerin, organic plant extracts, and plant essential oils. The fragrance substance may be configured to include allyl hexanoate, benzyl alcohol, citral, ethanol, isea cubeba oil, lemon oil, lime oil, L-menthol, menthol, mint such as peppermint or spearmint, sweet orange oil, terpene-free orange oil, terpene orange oil, terpene-free tangerine oil, tobacco flavor, or a combination thereof. The second compound may be configured to include a fragrance substance.

[0025] The second compound may contain 10-40% by weight, particularly 20-30% by weight, of glycerin. The second compound may contain 10-30% by weight, particularly 15-25% by weight, of organic fibers. The organic fibers in the second compound may include, or be made from, cotton, wood, or tea plants. The organic fibers in the second compound may have a length of 10-400 micrometers, particularly 10-200 micrometers. The second compound may contain 15-55% by weight, particularly 20-35% by weight, of organic vegetable glycerin. The organic vegetable glycerite in the second compound may be derived from plants such as clove, echinacea, fennel, ginger, holberry, elderberry, monada, mulein leaf, inetol, plant, turmeric, yarrow, and compounds thereof. The second compound may contain 1-15% by weight, particularly 2-7% by weight, of organic plant extracts. The menthol may be derived from organic plant extracts, such as those obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related plant varieties (dl-menthol, C10H2O, 2-isopropyl-5-methylcyclohexanol), or from p-menthan-3-ol as any secondary alcohol as a diastereoisomer of 5-methyl-2-(propan-2-yl)cyclohexane-1-ol. The organic plant extract may be derived from plants such as clove, echinacea, fennel, ginger, hawthorn berry, elderberry, monarda, mullein leaves, nettle, plantain, turmeric, yarrow, and compound thereof. Alternatively, the second compound may consist of 0.5–5% by weight, particularly 1–3% by weight, of a vegetable essential oil. The vegetable essential oil may be palm oil, coconut oil, or chocolate essential oil.

[0026] The aerosol-generating article may be configured to include a second aerosol-generating substrate. The second aerosol-generating substrate may be different from the first aerosol-generating substrate. The second aerosol-generating substrate may be in solid form. This applies particularly to the second aerosol-generating substrate in the final state of the aerosol-generating article, i.e., the state in which the aerosol-generating article is ready for consumption.

[0027] The second aerosol-generating substrate may be configured to have a maximum thickness in the range of 0.5 millimeters to 5 millimeters, particularly 1 millimeter to 4 millimeters. The aerosol-generating article may be characterized by the absence of susceptor material within the second aerosol-generating substrate.

[0028] The first aerosol-generating substrate may be formed by wet granulation or dry granulation. The second aerosol-generating substrate may be formed by dry granulation.

[0029] The first aerosol-generating substrate may be configured to produce at least 60%, particularly at least 80%, of the total volume of aerosol generated by the heated aerosol-generating article. The second aerosol-generating substrate may be configured to produce less than 40% of the total volume of aerosol generated by the heated aerosol-generating article.

[0030] The intermediate layer may be applied between the first aerosol generating substrate and the second aerosol generating substrate. The aerosol generating article may be configured to further include at least an additional aerosol generating substrate. At least one of the intermediate layer and any additional aerosol generating substrate may be in a solid state. This is particularly applied in the final state of the aerosol generating article, i.e., the state where the aerosol generating article is ready for consumption, and the second aerosol generating substrate may be coated with at least one additional aerosol generating substrate. At least one aerosol generating substrate may be configured to contain a cannabinoid compound selected from the group consisting 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), cannabicitran (CBT), and combinations thereof.

[0031] The plurality of aerosol generating substrates may differ in at least one of the composition, porosity, water content, coating thickness, or shape of the coating surface. The first aerosol generating substrate may be configured to have a water content of 5 to 35% by weight, particularly 10 to 25% by weight. The second aerosol generating substrate may be configured to have a water content of 5 to 20% by weight, particularly 7 to 12% by weight.

[0032] The porosity of the second aerosol generating substrate may be greater than that of the first aerosol generating substrate. The value of the porosity can be defined by the ratio of the volume of pores to the volume of a defined material to its total volume. The porosity of the second aerosol generating substrate is at least 1.5 times that of the first aerosol generating substrate. The porosity of the second aerosol generating substrate may be between 30 and 80%, particularly between 40 and 70%, and more specifically between 45 and 55%. Each specific porosity of the aerosol generating substrate can be defined by incorporating a fibrous material, particularly a biodegradable fibrous material, into each aerosol generating substrate. The size of the fibers may differ between the first and second aerosol generating substrates. The difference in porosity may allow the aerosol airflow generated by heating the first aerosol generating substrate to pass through the second aerosol generating substrate. Therefore, the larger the porosity of the second aerosol generating substrate, the more the aerosol generated by heating the first aerosol generating substrate can be washed away by the air surrounding the aerosol generating article and subsequently inhaled by the user. Thus, the first aerosol generating substrate may be configured to generate a large portion of the aerosol content or volume, in particular more than 60% of the aerosol content or volume that can be inhaled by the user. The second aerosol generating substrate may be configured to primarily release the airflow of the aerosol generated by the first aerosol generating substrate. The airflow dispersion of aerosols in a particulate aerosol generating article may be defined by the selection of the second aerosol generating substrate.

[0033] The composition of the first aerosol generating substrate may differ from the composition of the second aerosol generating substrate.

[0034] The second aerosol generating substrate may contain a larger amount of tobacco material than the first aerosol generating substrate. The second aerosol generating substrate may further contain 3 to 15% by weight, particularly 5 to 10% by weight, of the second compound, as described above. The second aerosol generating substrate may further contain 45 to 95% by weight, particularly 65 to 85% by weight, of the third compound. The third compound may contain a blend of tobacco leaves in an amount of 15 to 55% by weight, particularly 20 to 40% by weight. The tobacco blend may contain at least one of bright tobacco, dark tobacco, and aromatic tobacco. The tobacco blend may have a particle size consisting of 100 to 380 mesh particles, particularly 170 to 320 mesh particles. The third compound may contain 3 to 20% by weight, particularly 7 to 15% by weight, of cellulose fibers. The cellulose fibers in the third compound may have a length consisting of 10 to 380 micrometers, particularly 90 to 270 micrometers. The third compound may consist of 15-40% by weight, particularly 20-35% by weight, of tobacco fiber as a filler for any tobacco type tobacco fiber or tobacco type blend from stems or petioles, or a combination of stems and petioles. The fiber in the third compound may consist of a length of 25-350 micrometers, particularly 50-220 micrometers. The third compound may consist of 1-10% by weight, particularly 2-5% by weight, of a binder. The binder in the third compound may consist of, or be made from, natural pectins such as fruit pectin, e.g., citrus pectin, or tobacco pectin; guar gum, land locust bean gum, e.g., hydroxyethyl or hydroxypropyl of those gums; starch, e.g., modified starch or derivatized starch; alginate; methylcellulose, ethylcellulose, ethylhydroxymethylcellulose, and carboxymethylcellulose; dextran; and xanthan gum. In a preferred embodiment, the binder in the third compound is made from guar.

[0035] The first aerosol generating substrate may have a higher aerosol-forming content than the second aerosol generating substrate. The third compound may contain 1 to 15% by weight, particularly 3 to 7% by weight, of aerosol-forming materials. The aerosol-forming materials in the third compound may be 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 acids, dicarboxylic acids, or polycarboxylic acids, such as dimethyl esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids.

[0036] The shape of the outer surface of the first aerosol generating substrate may differ from the shape of the outer surface of the second aerosol generating substrate. The second aerosol generating substrate may define the outer shape of the aerosol generating article, while the first aerosol generating substrate may define the core of the aerosol generating article. The overall aerosol generating article may have a substantially spherical particle shape, while the first aerosol generating substrate may have an angular particle shape.

[0037] The longest dimension of the aerosol generating article may be greater than 7 millimeters and particularly less than 21 millimeters. The longest dimension of the aerosol generating article may be in the range of 7 to 16 millimeters. The longest dimension of the first aerosol generating substrate may be in the range of 3.5 to 17 millimeters, particularly 4 to 14 millimeters. The second aerosol generating substrate has a thickness in the range of 0.5 to 5 millimeters, particularly 1 to 4 millimeters. The particle size of the aerosol generating article may, advantageously, allow for the operation of a single aerosol generating article for consumption. The size of the aerosol generating article may allow for the delivery of a desired amount of aerosol to the consumer. In particular, the aerosol generating article may be delivered in 5 to 20 fumigations, preferably 10 to 13 fumigations, and more preferably 11 to 12 fumigations, when consumed in an aerosol generating device.

[0038] The aerosol generating article may also be configured to include an external coating. Providing an external coating on a first or second aerosol generating substrate may be advantageous in that it may limit the penetration of oxygen or water vapor into the aerosol generating article, which may help extend the shelf life of the aerosol generating article. As an alternative or additional configuration, the coating may serve to protect the structural integrity of the aerosol generating article or to provide an improved smoothness to the aerosol generating article. The external coating may serve to provide an aerosol generating article in the form of particles that can be directly handled by hand in a hygienic manner. In certain embodiments, a relatively fragile external coating may be added to an aerosol generating element that is adapted to be destroyed by the consumer before use. Thus, this type of external coating can provide the consumer with a tactile and audible indication that the aerosol generating article is ready for use. As an alternative or additional configuration, providing an external coating on the aerosol generating article may be used to adjust the color of the aerosol generating element in order to provide a visual indication of the characteristics of the aerosol generating article, such as the content of fragrance or nicotine.

[0039] The outer coating may be in a solid state. This is particularly applicable to the final state of the aerosol generating article, i.e., when the aerosol generating article is ready for consumption, and the outer coating may be a porous coating. The porosity of the outer coating may allow the aerosol airflow generated in the first aerosol generating substrate, which may optionally pass through the second aerosol generating substrate first, to be released to the outside of the particles by passing through the pores in the outer coating.

[0040] The porosity of the second aerosol generating substrate may be greater than the porosity of the outer coating. The outer coating may be configured to completely cover the first aerosol generating substrate or the second aerosol generating substrate. Alternatively, the outer coating may be configured to partially cover the first aerosol generating substrate or the second aerosol generating substrate. The outer coating may be applied according to a predetermined pattern on the first aerosol generating substrate or the second aerosol generating substrate.

[0041] The outer coating material may have an alginate-based formulation.

[0042] The outer coating material may comprise at least one of the following: alginate, alginate-maltodextrin, alginate-gabanum gum, starch-alginate, crosslinking with CaCl2, CaCl2-CMC, calcium gluconate, calcium lactate, and tapioca starch. The outer coating material may further comprise antimicrobial substances. The outer coating material may have anti-adhesion properties. The outer coating may be biodegradable. The outer coating may comprise only bio-derived materials. Bio-derived materials are materials produced from biomass. The outer coating may comprise only natural materials. Natural materials are materials produced from plants, animals, or the ground. Alternatively, the outer coating may comprise only a combination of natural materials and bio-derived materials.

[0043] The outer coating may contain or be made of vanillin, thyme oil, lemongrass extract, carvacrol, methyl cinnamate, herring, acetic acid, lactic acid, potassium sorbate, dipidophora persica essential oil and extract(s), sodium lactate, sodium diacetate, pomegranate peat extract, lemongrass extract(s), etc.

[0044] According to one aspect of the present invention, an aerosol generating article for an aerosol generator is provided, wherein the aerosol generating article has a maximum dimension less than twice the minimum dimension of the aerosol generating article. The maximum dimension of the article is greater than 7 millimeters and particularly less than 21 millimeters. The particle size of the aerosol generating article can advantageously allow for the operation of a single aerosol generating article for consumption. The size of the aerosol generating article can enable the delivery of a desired amount of aerosol to the consumer. In particular, the aerosol generating article may be delivered in 5 to 20 smokes, preferably 10 to 13 smokes, more preferably 11 to 12 smokes when consumed in an aerosol generator.

[0045] According to one aspect of the present invention, a method for manufacturing an aerosol generating article is provided, comprising the steps of (a) preparing a first aerosol generating substrate, (b) preparing a plurality of pieces of susceptor material, (c) dispersing the plurality of pieces of susceptor material throughout the first aerosol generating substrate, and forming an aerosol generating article in the shape of particles.

[0046] Step (c) may be carried out by a granulation process.

[0047] The manufacturing method may further include a step (d) of coating an aerosol-generating article with a second aerosol-generating substrate. At least one of steps (c) and (d) of the manufacturing method may be carried out by a granulation process. The manufacturing method may be carried out by a wet granulation process such as high-shear granulation, reverse wet granulation, moisture-activated dry granulation, heat-bonding granulation, melt granulation, freeze granulation, foam granulation, or steam granulation. The manufacturing method may be carried out by a fluidized bed granulator, particularly for melt granulation. The manufacturing method may be carried out by a fluidized bed dryer in combination with or in succession to a fluidized bed granulator. In particular, the manufacturing method may be carried out by high-shear wet granulation. Therefore, the manufacturing method may be carried out by a high-shear granulator. Alternatively, the manufacturing method may be carried out by single-pot granulation. Single-pot granulation may be a configuration that combines mixing, high-shear wet granulation, and drying all in one process bowl. Alternatively, the method may be a configuration carried out by a dry granulation process. The dry granulation process may include air-dried granulation (PDG).

[0048] The method may further include a step of applying an external coating. The step of applying an external coating may be carried out by a fluidized bed coating and drying process.

[0049] The present invention is defined in the claims. However, a non-exclusive list of non-limiting embodiments is provided below. Any one or more of the configurations in these embodiments may be combined with any one or more configurations in other embodiments, other embodiments, or other aspects described herein.

[0050] Example 1: An aerosol generating article for an aerosol generating device, wherein the aerosol generating article is in the form of particles, and comprises a first aerosol generating substrate and a plurality of susceptor material pieces, wherein the plurality of susceptor material pieces are dispersed throughout the first aerosol generating substrate.

[0051] Example 2: An aerosol generating article according to Example 1, having a maximum dimension less than twice the minimum dimension of the aerosol generating article.

[0052] Example 3: An aerosol generating article having a longest dimension less than twice the shortest dimension of the aerosol generating article, wherein the longest dimension of the article is greater than 7 millimeters, and in particular less than 21 millimeters.

[0053] Example 4: An aerosol generating article according to any one of Examples 1 to 3, wherein the aerosol generating article is formed by a granulation process.

[0054] Example 5: The aerosol generating article according to any one of Examples 1 to 4, wherein the aerosol generating article has a convex shape, particularly a spherical or elliptical shape.

[0055] Example 6: An aerosol generating article according to any one of Examples 1 to 5, wherein the multiple pieces of the susceptor material are susceptor granules, susceptor beads, susceptor flakes, susceptor fibers, susceptor rods, or a combination thereof.

[0056] Example 7: An aerosol generating article according to any one of Examples 1 to 6, wherein the susceptor material is one of paramagnetic, ferromagnetic, or ferromagnetic materials.

[0057] Example 8: An aerosol generating article according to any of Examples 1 to 7, wherein the size of a piece of the susceptor material is 0.1 mm to 2.5 mm, particularly 0.25 mm to 1.85 mm, and more specifically 0.45 mm to 1.55 mm.

[0058] Example 9: An aerosol generating article according to any one of Examples 1 to 8, wherein the first aerosol generating substrate contains 10 to 40% by weight of a susceptor material.

[0059] Example 10: An aerosol generating article according to any one of Examples 1 to 9, wherein multiple pieces of the susceptor material are evenly dispersed within a first aerosol generating substrate.

[0060] Example 11: An aerosol generating article according to any one of Examples 1 to 10, wherein the first aerosol generating substrate comprises a first compound comprising at least one of an aerosol forming body, a tobacco leaf blend, cellulose fibers, tobacco fibers, and a binder.

[0061] Example 12: The aerosol generating article according to Example 11, wherein the aerosol generating substrate comprises at least 3% by weight, specifically at least 5%, and more specifically at least 10% by weight of an aerosol forming body relative to the weight of the aerosol generating substrate.

[0062] Example 13: The aerosol generating article according to Example 11 or Example 12, wherein the first aerosol generating substrate further comprises a wetting agent.

[0063] Example 14: An aerosol generating article according to any one of Examples 1 to 13, wherein the first aerosol generating substrate contains at least a fragrance substance.

[0064] Example 15: The aerosol generating article according to Example 14, wherein the fragrance substance comprises at least one of organic plant glycerin, organic plant extract, and plant essential oil.

[0065] Example 16: An aerosol generating article according to any one of Examples 1 to 15, further comprising the second aerosol generating substrate, wherein the first aerosol generating substrate is covered with the second aerosol generating substrate.

[0066] Example 17: The aerosol generating article according to Example 16, wherein the second aerosol generating substrate has a thickness in the range of 0.5 mm to 5 mm, particularly 1 mm to 4 mm.

[0067] Example 18: The aerosol generating article according to Example 16 or Example 17, wherein the aerosol generating article is characterized by the absence of a susceptor material in the second aerosol generating substrate.

[0068] Example 19: An aerosol generating article according to any one of Examples 16 to 18, wherein the intermediate layer is coated between the first aerosol generating substrate and the cavity of the second aerosol generating substrate.

[0069] Example 20: The aerosol generating article according to any one of Examples 16 to 19, wherein the aerosol generating article further comprises at least an additional aerosol generating substrate, and the second aerosol generating substrate is covered with at least one additional aerosol generating substrate.

[0070] Example 21: An aerosol generating article according to any one of Examples 16 to 20, wherein the plurality of aerosol generating substrates differ in at least one of the following: the composition of the coating surface, the porosity, the coating thickness, or the shape.

[0071] Example 22: An aerosol generating article according to any one of Examples 16 to 21, wherein the porosity of the second aerosol generating substrate is greater than that of the first aerosol generating substrate.

[0072] Example 23: The aerosol generating article according to Example 22, wherein the porosity values ​​of the first aerosol generating substrate and the second aerosol generating substrate are defined by the ratio of the pore volume of the defined material volume to its total volume.

[0073] Example 24: The aerosol generating article according to Example 22 or Example 23, wherein the porosity of the second aerosol generating substrate is at least 1.5 times that of the first aerosol generating substrate.

[0074] Example 25: An aerosol generating article according to any of Examples 22 to 24, wherein the porosity of the second aerosol generating substrate is 30 to 80%, particularly 40 to 70%, and more specifically 45 to 55%.

[0075] Example 26: An aerosol generating article according to any one of claims 16 to 25, wherein the composition of the first aerosol generating substrate is different from the composition of the second aerosol generating substrate.

[0076] Example 27: The aerosol generating article according to Example 26, wherein the first aerosol generating substrate contains an aerosol forming body in a larger amount than the second aerosol generating substrate.

[0077] Example 28: An aerosol generating article according to Example 26 or Example 27, wherein the second aerosol generating substrate contains a tobacco cut filter in a larger amount than the first aerosol generating substrate.

[0078] Example 29: An aerosol generating article according to any one of Examples 26 to 28, wherein the shape of the outer surface of the first aerosol generating substrate is different from the shape of the outer surface of the second aerosol generating substrate.

[0079] Example 30: An aerosol generating article according to any of Examples 1 to 29, wherein the longest dimension of the aerosol generating article is greater than 7 millimeters, and in particular less than 21 millimeters.

[0080] Example 31: The aerosol generating article according to Example 30, wherein the maximum dimensions of the aerosol generating article are in the range of 7 mm to 16 mm.

[0081] Example 32: An aerosol generating article according to Example 30 or Example 31, wherein the longest dimension of the first aerosol generating substrate is 3.5 mm to 17 mm, particularly 4 mm to 14 mm.

[0082] Example 33: An aerosol-generating article according to any one of Examples 1 to 32, further including an external coating.

[0083] Example 34: The aerosol generating article according to Example 33, wherein the outer coating is a porous coating.

[0084] Example 35: The aerosol generating article according to Examples 16 and 34, wherein the porosity of the second aerosol generating substrate is greater than the porosity of the outer coating.

[0085] Example 36: The aerosol generating article according to Examples 16 and 33, wherein the outer covering partially covers the first aerosol generating substrate or the second aerosol generating substrate.

[0086] Example 37: An aerosol generating article according to one of Examples 33 to 36, wherein the outer coating is applied to the first aerosol generating substrate or the second aerosol generating substrate according to a predetermined pattern.

[0087] Example 38: An aerosol generating article according to one of Examples 33 to 36, wherein the outer covering completely covers the first aerosol generating substrate or the second aerosol generating substrate.

[0088] Example 39: The material of the outer coating is an aerosol generating article according to one of Examples 33 to 38, having an alginate-based formulation.

[0089] Example 40: An aerosol generating article according to Example 39, wherein the material of the outer coating comprises at least one of alginate, alginate-maltodextrin, alginate-galbanum gum, starch-alginate, crosslinking with CaCl2, CaCl2-CMC, calcium gluconate, calcium lactate, and tapioca starch.

[0090] Example 41: The aerosol-generating article according to Example 39 or Example 40, wherein the material of the outer coating further contains an antimicrobial substance.

[0091] Example 42: An aerosol-generating article according to either Example 39 or Example 41, wherein the material of the outer coating has anti-adhesion properties.

[0092] Example 43: The aerosol-generating article according to either Example 39 or Example 42, wherein the outer coating is biodegradable.

[0093] Example 44: The aerosol-generating article according to either Example 39 or Example 43, wherein the outer coating comprises only bio-derived materials.

[0094] Example 45: The aerosol-generating article according to either Example 39 or Example 43, wherein the outer coating comprises only natural materials.

[0095] Example 46: An aerosol-generating article according to either Example 39 or Example 43, wherein the outer coating comprises only a combination of natural materials and bio-derived materials.

[0096] Example 47: An aerosol generating article according to either Example 39 or Example 46, wherein the outer coating comprises vanillin, thyme oil, lemongrass extract, carvacrol, methyl cinnamate, herring, acetic acid, lactic acid, potassium sorbate, dipyrrolepacea essential oil and extract(s), sodium lactate, sodium diacetate, pomegranate peat extract, lemongrass extract(s).

[0097] Example 48: An aerosol generating article according to one of Examples 33 to 38, wherein the outer coating is made of vanillin, thyme oil, lemongrass extract, carvacrol, methyl cinnamate, herring, acetic acid, lactic acid, potassium sorbate, dipyrrolepessica essential oil and extract(s), sodium lactate, sodium diacetate, pomegranate peat extract, and lemongrass extract(s).

[0098] Example 49: A manufacturing method for producing an aerosol generating article, comprising the steps of (a) preparing a first aerosol generating substrate, (b) preparing a plurality of pieces of susceptor material, and (c) dispersing the plurality of pieces of susceptor material throughout the first aerosol generating substrate to form an aerosol generating article in the shape of particles.

[0099] Example 50: The manufacturing method according to Example 49, further comprising the step of coating the aerosol generating article with a second aerosol generating substrate.

[0100] Example 51: The manufacturing method according to Example 49 or Example 50, wherein at least one of steps (c) and (d) is carried out by a granulation process.

[0101] Example 52: The manufacturing method according to any one of Examples 49 to 51, wherein the granulation process includes a fluid granulation process and a drying process.

[0102] Example 53: The manufacturing method according to any one of Examples 49 to 51, wherein the granulation process includes a high-shear granulation process.

[0103] Example 54: The manufacturing method according to any one of Examples 49 to 51, wherein the granulation process includes a single-pot granulation process.

[0104] Example 55: The manufacturing method according to any one of Examples 49 to 51, wherein the manufacturing granulation process is carried out by a compact granulation system.

[0105] Example 56: The manufacturing method according to any one of Examples 49 to 55, further comprising the step of applying an external coating.

[0106] Here, we will further describe the examples with reference to the figures. [Brief explanation of the drawing]

[0107] [Figure 1]Figure 1 shows a schematic diagram of an aerosol generating article according to the first embodiment, with the article cut in half and slightly opened to reveal the interior. [Figure 2] Figure 2 shows a schematic diagram of half of the aerosol-generating article according to the second embodiment. [Figure 3] Figure 3 schematically shows the method for manufacturing the aerosol-generating article 1 according to the first embodiment. [Figure 4] Figure 4 schematically shows the method for manufacturing the aerosol-generating article 1 according to the second embodiment. [Modes for carrying out the invention]

[0108] Figure 1 shows an aerosol generating article 10 according to a first embodiment. The aerosol generating article 10 is in the form of particles, particularly spherical particles. In the schematic diagram of Figure 1, the aerosol generating article 10 is cut into two halves 12 and 14 so that the inside of the aerosol generating article 10 is visible. As can be seen from the halves 12 and 14 of Figure 1, the aerosol generating article 10 comprises a first aerosol generating substrate 16 and a plurality of pieces 18 of susceptor material. The first aerosol generating substrate 16 may be configured to contain 10 to 40% by weight, particularly 15 to 30% by weight, of susceptor material 18. The plurality of pieces 18 of susceptor material are dispersed throughout the first aerosol generating substrate 16. Thus, the plurality of pieces 18 of susceptor material are separated from each other by the first aerosol generating substrate 16. The plurality of pieces 18 of susceptor material are conductive pieces that have the ability to convert electromagnetic energy and convert it into heat. When placed in an alternating electromagnetic field, eddy currents are induced within the susceptor material 18, resulting in hysteresis losses and causing heating of the susceptor material 18. Similar to the aerosol generating article 10, the multiple pieces 18 of the susceptor material are positioned in direct physical and therefore thermal contact with the first aerosol generating substrate 16, and the first aerosol generating substrate 16 can be heated by the susceptor pieces 18 so that aerosols can be formed.

[0109] The maximum dimension of the aerosol-generating article 10 according to the first embodiment corresponds to the diameter 20 of the spherical particles. The diameter 20 is greater than 7 millimeters and, in particular, less than 21 millimeters.

[0110] The aerosol generating article 10 may also be configured to further include an outer coating 22. As shown in Figure 1, the outer coating 22 defines the outermost layer of the aerosol generating article 10. The outer coating 22 may provide a protective layer to the aerosol generating article 10, in particular to limit the penetration of oxygen or water vapor into the aerosol generating article 10, which may help extend the shelf life of the aerosol generating article 10. As an alternative or additional configuration, the outer coating 22 may help protect the structural integrity of the aerosol generating article 10, which is the shape of the particles. The outer coating 22 may be colored to indicate characteristics of the aerosol generating article 10, such as flavoring or nicotine content. As an alternative or additional configuration, the outer coating 22 may have anti-adhesion properties, in particular to prevent adhesion between multiple aerosol generating articles 10 when they are stored together.

[0111] Figure 2 shows half 28 of an aerosol generating article 30 according to the second embodiment. Similar to the aerosol generating article 10 according to the first embodiment, the aerosol generating article 30 is in the form of particles, particularly spherical particles. The aerosol generating article 30 has a core 32. The core 32 consists of a first aerosol generating substrate 16 and a plurality of pieces 18 of susceptor material dispersed throughout the first aerosol generating substrate 16, as described in relation to the first embodiment. In the second embodiment, the core 32 is coated with a second aerosol generating substrate 34. In contrast to the first aerosol generating substrate 16, the second aerosol generating substrate 34 does not contain susceptor material. The first aerosol generating substrate 16 and the second aerosol generating substrate 34 may differ in at least one of the following: composition, porosity, water content, or coating thickness. The porosity of the second aerosol generating substrate 34 is at least 1.5 times that of the first aerosol generating substrate 16.

[0112] The maximum dimensions of the aerosol generating article 30 correspond to the diameter 20 of the spherical particles. The diameter 20 is greater than 7 millimeters and particularly less than 21 millimeters. The maximum dimensions 36 of the core 32 may be in the range of 3.5 millimeters to 17 millimeters, particularly 4 millimeters to 14 millimeters. The maximum thickness 38 of the second aerosol generating substrate 34 may be in the range of 0.5 millimeters to 5 millimeters, particularly 1 millimeter to 4 millimeters.

[0113] Similar to the first embodiment, the aerosol generating article 30 may further comprise an outer coating 22. In the second embodiment, the outer coating 22 covers the outermost surface of the second aerosol generating substrate 34. The outer coating 22 may be porous. The porosity of the outer coating 22 may allow for an aerosol airflow, represented by the arrow 40 in Figure 2, which is generated by heating the first aerosol generating substrate 16 with a piece of susceptor material 18, first passing through the second aerosol generating substrate 34, and then being released to the outside of the particles 30 by passing through pores in the porous outer coating 22 (not shown in Figure 2).

[0114] The overlay of the aerosol generating substrate may help further define the airflow velocity, airflow dispersion, or both of the aerosol 40 generated within the core 32 of the aerosol generating article 30. As an alternative configuration, or in combination, the overlay of the aerosol generating substrates 16, 34 may help further define the fragrance of the aerosol 40 generated by the aerosol generating article 30. To further enhance these properties, in another embodiment (not shown), the aerosol generating article may comprise at least one additional aerosol generating substrate in addition to the first aerosol generating substrate 16 and the second aerosol generating substrate 34.

[0115] Figure 3 shows a schematic diagram of a manufacturing method 100 for an aerosol generating article 10 according to a first aspect of the present invention. The schematic diagram of Figure 3 illustrates a manufacturing method 100 that includes a step 102 for preparing a first aerosol generating substrate 16, a step 104 for preparing a plurality of pieces 18 of susceptor material, and a step 106 for dispersing the plurality of pieces 18 of susceptor material throughout the first aerosol generating substrate 16 to form an aerosol generating article 10 in the shape of particles.

[0116] The manufacturing method 100 includes a step 102 for preparing a first aerosol substrate 16. The first aerosol generating substrate 16 comprises at least one of an aerosol former, a tobacco leaf blend, cellulose fibers, tobacco fibers, and a binder. The manufacturing method 100 includes a step 104 for preparing a plurality of pieces 18 of susceptor material. The plurality of pieces 18 of susceptor material may be susceptor granules, susceptor beads, susceptor grits, susceptor flakes, susceptor fibers, susceptor rods, or a combination thereof. The manufacturing method 100 further includes a step 106 for distributing the plurality of pieces 18 of susceptor material throughout the first aerosol generating substrate 16 to form an aerosol generating article 10 in particle form. Step 106 of the manufacturing method 100 may be carried out by a granulation process, particularly a wet granulation process. The granulation process allows for improved homogeneity of the dispersion of multiple pieces 18 of the susceptor material throughout the first aerosol-generating substrate 16. Optionally, the manufacturing method 100 includes a further step of applying an external coating, particularly by a film coating process or a fluidized coating process.

[0117] Figure 4 shows a schematic diagram of a manufacturing method 300 for an aerosol generating article 30 according to a second embodiment. The schematic diagram of Figure 4 illustrates a manufacturing method 300 that includes a step 302 for preparing a first aerosol generating substrate 16, a step 304 for preparing a plurality of pieces 18 of susceptor material, a step 306 for dispersing the plurality of pieces 18 of susceptor material over the entire first aerosol generating substrate 16 to form a core 32, and a step 308 for covering the core 32 with a second aerosol generating substrate 34 to form an aerosol generating article 30 in the shape of particles.

[0118] Similar to the manufacturing method 100 of the first embodiment, the manufacturing method 300 also includes a step 302 for preparing a first aerosol substrate 16 and a step 304 for preparing a plurality of pieces 18 of susceptor material. The manufacturing method 300 further includes a step 306 for distributing the plurality of susceptor material pieces 18 throughout the first aerosol generating substrate 16 to form a core 32. The manufacturing method 300 then includes a step 308 for coating the core 32 with a second aerosol generating substrate 34 to form an aerosol generating article 30 in the shape of particles. Steps 306 and 308 of the manufacturing method 300 may be carried out by a granulation process. Step 306 may be carried out by a wet granulation process. Step 308 may be carried out by a dry granulation process. Optionally, the manufacturing method 300 includes a further step of applying an outer coating, in particular by a film coating process or a fluid coating process.

[0119] For the purposes of this specification and the appended claims, unless otherwise indicated, all numerical values ​​representing quantities, amounts, percentages, etc., should be understood in all examples as being modified by the term “approximately.” Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges within them, which may or may not be specifically listed herein. Thus, in this context, numerical value A is understood as A ± 5% of A. In this context, numerical value A may be considered to include numerical values ​​within the range of general standard errors for the measurement of the characteristic that numerical value A modifies. In some examples used in the appended claims, numerical value A may deviate by the percentages listed above, as long as the amount of deviation from A does not substantially affect the basic and novel characteristics of the invention described in the claims. Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges contained within them, whether or not they are specifically listed herein.

Claims

1. Aerosol generating article for aerosol generating device, The aerosol generating article is in the form of particles, The aerosol-generating article is: The first aerosol generating substrate, It comprises multiple pieces of susceptor material, An aerosol generating article in which multiple pieces of the susceptor material are dispersed throughout the first aerosol generating substrate.

2. The aerosol generating article according to claim 1, wherein the first aerosol generating substrate comprises 10 to 40% by weight of a susceptor material.

3. The aerosol generating article according to claim 1 or 2, wherein the first aerosol generating substrate comprises at least a fragrance substance.

4. The aerosol generating article according to any one of claims 1 to 3, further comprising a second aerosol generating substrate, wherein the first aerosol generating substrate is covered by the second aerosol generating substrate.

5. The aerosol generating article according to claim 4, wherein the porosity of the second aerosol generating substrate is greater than the porosity of the first aerosol generating substrate.

6. The aerosol generating article according to claim 5, wherein the porosity of the second aerosol generating substrate is at least 1.5 times that of the first aerosol generating substrate.

7. The aerosol generating article according to claim 5 or 6, wherein the composition of the first aerosol generating substrate is different from the composition of the second aerosol generating substrate.

8. The aerosol generating article according to any one of claims 1 to 7, wherein the longest dimension of the aerosol generating article is greater than 7 millimeters and particularly less than 21 millimeters.

9. The aerosol generating article according to any one of claims 1 to 8, further comprising an external covering.

10. The aerosol generating article according to claim 9, wherein the outer coating is a porous coating.

11. The aerosol generating article according to claim 9 or 10, wherein the material of the outer coating comprises an alginate-based formulation.

12. A method for manufacturing an aerosol-generating article, (a) A step of preparing a first aerosol generating substrate, (b) A step of preparing multiple pieces of susceptor material, (c) A manufacturing method comprising the step of dispersing a plurality of pieces of the susceptor material over the first aerosol generating substrate to form an aerosol generating article in the shape of particles.

13. The manufacturing method according to claim 12, further comprising the step (d) of coating the aerosol generating article with a second aerosol generating substrate.

14. The manufacturing method according to claim 12 or 13, wherein at least one of steps (c) and (d) is carried out by a granulation process.

15. The method according to any one of claims 12 to 14, further comprising the step of applying an external coating.

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