Aerosol generating article having aerosol-forming beads

Abstract

An aerosol generating article is provided for use with an aerosol generating device to generate an aerosol. The aerosol generating article is defined by the article length, article width, and article thickness, wherein the article width is greater than the article thickness. The aerosol generating article comprises a first outer surface and a second outer surface facing substantially opposite the first outer surface, a cavity located within the aerosol generating article between the first outer surface and the second outer surface, and an airflow passage defined through the aerosol generating article between an air inlet and an air outlet, the airflow passage extending through the cavity. An aerosol forming substrate is located within the cavity, and the aerosol forming substrate is in the form of a plurality of individual beads having an average particle diameter of 0.1 mm to 4 mm.

Description

Technology Field

[0001] The present disclosure relates to an aerosol generating article comprising an aerosol-forming substrate. Background Technology

[0002] Conventional aerosol generating articles may resemble conventional cigarettes. For example, such aerosol generating articles may be substantially cylindrical articles containing other components, such as an aerosol-forming substrate and a mouthpiece filter element, all wrapped in cigarette paper. The dimensions of conventional aerosol generating articles are often similar to the dimensions of conventional cigarettes.

[0003] According to research, in these conventional aerosol-generating articles containing a plug of an aerosol-generating material, it has been found that a significant portion of the plug of the aerosol-generating material may not heat up sufficiently to form an aerosol during use. This is undesirable because this portion of the plug of the aerosol-generating material contributes to the manufacturing and transport costs of the aerosol-generating article but does not contribute to the aerosol delivered to the end user. This may apply regardless of how the aerosol-generating material is heated, for example, whether a resistive or inductive heater is used, and whether the plug of the aerosol-generating material is heated from the inside or the outside.

[0004] The object of the present disclosure is to provide an aerosol generating article, wherein a larger portion of the aerosol-forming substrate of the aerosol generating article is heated sufficiently to form an aerosol during use.

[0005] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol. The aerosol generating article is defined by an article length, an article width, and an article thickness, wherein the article width is greater than the article thickness. The aerosol generating article may include a first outer surface and an opposing second outer surface. A cavity may be located within the aerosol generating article between the first outer surface and the second outer surface. An airflow passage may be defined through the aerosol generating article between an air inlet and an air outlet, and said airflow passage preferably extends through the cavity. An aerosol forming substrate is located within the cavity. The aerosol forming substrate may be in the form of a plurality of beads. The aerosol forming substrate may be in the form of a plurality of individual beads. The aerosol forming substrate may be in the form of a plurality of free-flowing beads. The plurality of beads may have an average particle diameter of 0.1 mm to 4 mm, for example, 0.5 mm to 4 mm. The preferred average particle diameter may be about 1 mm to 1.7 mm.

[0006] In a preferred example, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol, said aerosol generating article is defined by an article length, an article width, and an article thickness, said article width is greater than said article thickness, said aerosol generating article comprises: a first outer surface and a second outer surface facing substantially opposite the first outer surface; a cavity located within the aerosol generating article between the first outer surface and the second outer surface; and an airflow passage defined through the aerosol generating article between an air inlet and an air outlet, said airflow passage extending through said cavity, wherein an aerosol forming substrate is located within said cavity, said aerosol forming substrate is in the form of a plurality of individual beads having an average particle diameter of 0.1 mm to 4 mm, for example, 0.5 mm to 4 mm. Preferably, the plurality of individual beads form a free-flowing bead mass.

[0007] The first outer surface and the second outer surface can be described as opposing outer surfaces.

[0008] The term "bead" refers to individual solid particles formed from an aerosol-generating substrate. Beads may have a round, typically spherical shape. Round or spherical beads have a low contact area with other beads, and multiple such beads may have good fluidity. This means that the mass or volume of these beads can flow freely. The ability of multiple beads to flow or pour can be highly advantageous for providing a consistent input amount of substrate during manufacturing. For example, other terms such as "granules" may be used to define the substrate.

[0009] The aerosol-forming material is in the form of multiple beads, preferably having a specific average particle diameter of 0.1 mm to 4 mm, for example, 0.5 mm to 4 mm. This provides the following advantages. Beads can be handled more easily compared to other aerosol-forming materials such as fine powder or shavings. Since beads flow easily, the cavity of the aerosol-generating article can be reliably and consistently filled during manufacturing. In particular, shavings cannot be reliably and repeatedly poured into the cavity of the article. This allows a consistent and reproducible amount of aerosol-forming material to be loaded into each article during manufacturing. Beads can also be cleaner to handle than powders and shavings, which can cause dust in the factory and leak from the aerosol-generating article during transport or use. By selecting beads with an appropriate bead size and an appropriate particle size distribution, the airflow through the cavity of the aerosol-generating article can be controlled more reproducibly than in the case of shaving materials. Note that the plurality of beads referred to herein are plurality of individual beads, that is, the beads are not bonded to each other in a binder or matrix.

[0010] When a particle is not perfectly spherical but its diameter is referred to, the term "diameter" may refer to the largest dimension of the particle. Alternatively, the term "diameter" may refer to the diameter of a perfectly spherical particle having the same volume as a non-perfectly spherical particle.

[0011] As used herein, the term "average particle diameter" may refer to the number average particle diameter. Other methods for determining the average particle diameter are known. Thus, the average particle diameter may be, for example, the volume average particle diameter.

[0012] Unless otherwise noted, values ​​given for average particle diameter in this specification refer to "number average particle diameter." Specifically, "number average particle diameter" is calculated as the sum of the diameters of the particles in a group divided by the number of particles in the group. Mathematically, this can be expressed as follows:

[0013]

[0014] In the above equation, N is the total number of particles, and is the diameter of the nth particle.

[0015] Each of the multiple beads has a maximum dimension (d 최대 ) and minimum dimension (d 최소 It can be defined in terms of ). Preferably, the plurality of beads have an average d of less than 4 mm, for example, less than 3 mm. 최대 It has. Preferably, the plurality of beads have an average d greater than 0.5 mm, for example, greater than 0.75 mm. 최소 It has. The bead dimensions are selected so that the volume of the beads is not so large that the beads flow easily and volatile components are not substantially completely released from each bead when heated for a short time. The beads may be substantially spherical. The beads may be non-spherical, but in this case, the beads preferably have a low aspect ratio, for example, oval, so that the beads still flow easily.

[0016] Multiple beads may have an average diameter of 0.75 mm to 2.5 mm, for example 1 mm to 2 mm, for example about 1.5 mm or about 1.7 mm, or about 2 mm.

[0017] Multiple beads may have a particle size distribution defined by D10 diameter and D90 diameter. The D10 diameter may be greater than 0.5 mm, for example, greater than 0.75 mm. The D90 diameter may be less than 4 mm, for example, less than 3 mm. The size distribution may be a relatively narrow size distribution. This can facilitate the provision of a consistent amount of aerosol-forming substrate within each article by helping to prevent sedimentation and aggregation within the multiple beads. Thus, multiple beads may have a particle size distribution defined by D10 diameter and D90 diameter, wherein the D10 diameter is within 25% of the value of the D90 diameter.

[0018] Optionally, multiple beads are d 최대 It has a value, and d 최대 is the distance of the longest axis of the bead, and is 0.5 mm to 3 mm, for example 0.75 mm to 2.5 mm, for example 1 mm to 2 mm, for example about 1.5 mm or about 1.7 mm, or about 2 mm.

[0019] Optionally, multiple beads are d 최소 It has a value, and d 최소 The shortest axis distance of the silver particle is 0.5 mm to 3 mm, for example 0.75 mm to 2.5 mm, for example 1 mm to 2 mm, for example about 1.5 mm or about 1.7 mm, or about 2 mm.

[0020] Multiple beads may be substantially spherical beads. Alternatively, non-spherical shapes of the beads, such as oval or ellipsoidal beads, may be used.

[0021] Multiple beads may have a dual-mode size distribution. For example, multiple beads may comprise a first phase of beads having a first average diameter and a second phase having a second average diameter different from the first phase. The first and second phases are distinct phases within the multiple beads. The first phase may have a size distribution different from the second phase. This dual-mode distribution may cause beads of the phase having a smaller average particle size to settle within the gaps formed by the phase having a larger average particle size. The use of a dual-mode distribution may allow for a greater packing density of the aerosol-forming substrate within the cavity than is possible with a narrow single-mode distribution of bead sizes, while maintaining the advantages associated with bead-type aerosol-forming substrates, such as easy handling and free flow.

[0022] Optionally, the first phase of the bead has an average d of less than 3 mm. 최대 and average d greater than 1.75 mm 최소 It may have, and the second phase of the bead has an average d of less than 1.25 mm. 최대 and average d greater than 0.5 mm 최소 has

[0023] The plurality of beads preferably comprise a plant material, for example, tobacco. The plant material may be in the form of plant particles, i.e., small fragments of plant material such as powdered plant material. The plurality of beads preferably comprise a binder, for example, one or more hydrocolloidal binders. The individual beads forming the plurality of beads preferably comprise a binder, for example, one or more hydrocolloidal binders. For example, the total amount of hydrocolloidal binders in the beads forming the aerosol generating substrate may be 0.5% to 5% by weight, or 0.5% to 4% by weight, or 0.5% to 3% by weight, or 0.5% to 2% by weight, based on dry weight.

[0024] The plurality of beads preferably comprise an aerosol-forming agent selected from a list consisting of, for example, glycerin and propylene glycol. The beads may have an aerosol-forming agent content of at least 10% by weight based on dry weight, for example, greater than 20% by weight, for example, greater than 25% by weight, or greater than 30% by weight, for example, greater than 35% by weight. The plurality of beads may comprise one or more flavor compounds.

[0025] Preferably, among the plurality of beads, the beads are at least partially coated with powder. For example, the plurality of beads may be at least partially coated with tobacco powder. Alternatively or additionally, the plurality of beads may be at least partially coated with a cellulose material, for example, microcrystalline cellulose (MCC).

[0026] The provision of a powder coating can advantageously prevent beads or granules from sticking together, which can facilitate the handling of the aerosol generating substrate, for example, during the manufacture of an aerosol generating article containing the aerosol generating substrate. In addition, the powder coating can provide a moisture barrier to protect the aerosol generating substrate from environmental moisture.

[0027] Multiple beads can be formed by a process comprising the step of powder spheroidizing particles of an aerosol-forming material, for example, preferably spheroidizing particles of tobacco by combining them with a binder. The spheroidization process is highly controllable and can produce beads that are substantially spherical and have controlled and consistent particle dimensions.

[0028] Multiple beads may be formed by a process in which a dough of an aerosol-forming material is formed, extruded, and cut into individual particles. These particles may then be spherical and dried to form substantially spherical beads suitable for use in articles according to the present invention.

[0029] A plurality of beads may comprise, based on dry weight, at least 60 weight% of plant particles, for example, at least 65 weight% of plant particles, for example, at least 70 weight% of plant particles, for example, at least 75 weight% of plant particles. A plurality of beads may comprise, based on dry weight, 95 weight% or less of plant particles, for example, 90 weight% or less of plant particles, for example, 85 weight% or less of plant particles.

[0030] The cavity may have a length of at least 10 mm, or at least 12 mm. The cavity may have a length of 20 mm or less, or 15 mm or less. For example, the cavity may have a length of 10 mm to 20 mm or 12 mm to 15 mm.

[0031] The cavity may have a width of at least 5 mm, or at least 6 mm. The cavity may have a width of 10 mm or less, or 8 mm or less. For example, the cavity may have a width of 5 mm to 10 mm or 6 mm to 8 mm.

[0032] The cavity may have a depth of at least 2 mm, or at least 3 mm. The cavity may have a depth of 5 mm or less, or 4 mm or less. For example, the cavity may have a depth of 2 mm to 5 mm, or 3 mm to 4 mm.

[0033] The cavity may have a volume of at least 200 mm² or at least 250 mm². The cavity may have a volume of 400 mm² or less, or 350 mm² or less. For example, the cavity may have a volume of 200 mm² to 400 mm², or 250 mm² to 350 mm².

[0034] Preferably, the cavity comprises a plurality of beads of 50 mg to 300 mg, for example, 100 mg to 200 mg, for example, 125 mg to 175 mg, for example, 140 mg to 160 mg, for example, about 140 mg, or about 150 mg or about 160 mg. By selecting beads of appropriate particle size and distribution, the use of the aerosol-forming compound within the beads can be optimized, thereby allowing for relatively low bead aggregation within each aerosol-forming article.

[0035] Preferably, the cavity contains 50% to 85% of a plurality of beads by volume. The cavity may contain a plurality of beads and 15% to 50% of free space. In addition to the plurality of beads, the cavity may contain additional components such as corrugated elements.

[0036] The aerosol generating article may be 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.

[0037] According to the present disclosure, an aerosol generating article for use with an aerosol generating device may be provided. For example, the aerosol generating article may be as described in any of the preceding paragraphs. The aerosol generating article may comprise a substantially flat upper surface and a substantially flat lower surface. The upper surface and the lower surface may be spaced perpendicularly apart from each other by a height defined in the z-direction. The aerosol generating article may further comprise one or more susceptor materials. One or more susceptor materials may be arranged in thermal contact with an aerosol forming substrate.

[0038] In practice, the planar upper surface can be defined by a length extending in the x-direction and a width extending in the y-direction.

[0039] In practice, the planar lower surface can be defined by a length extending in the x-direction and a width extending in the y-direction.

[0040] If present, one or more susceptor materials may act as heaters to heat an aerosol generating article. Heating of one or more susceptor materials may occur when the aerosol generating article is placed within a changing magnetic field, and the changing magnetic field induces heating of the susceptor materials by either eddy current heating or magnetic hysteresis, or both. Such a changing magnetic field may be generated by supplying alternating current to an inductor coil. Preferably, the inductor coil forms a component part of an aerosol generating device capable of coupling the aerosol generating article.

[0041] The aerosol-generating articles of the present disclosure are generally flat and thin. Providing a generally flat and thin aerosol-generating article provides rapid and efficient heating of the aerosol-forming substrate and improved uniformity of through-thickness heating. The primary source of the aerosol-generating substrate is in the form of beads, and is preferably porous and / or low-density. Preferably, the aerosol-generating article is free of any single-use plastics, thereby providing improved sustainability to the aerosol-generating article.

[0042] The upper surface and the lower surface can be parallel to each other.

[0043] The aerosol-generating article may extend over the length between the proximal and distal ends. The proximal end may be located at the mouse end of the aerosol-generating article.

[0044] The aerosol generating article according to the present disclosure may preferably be a substantially flat article or a substantially planar article. Such an article has 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 a planar heater of the aerosol generating device. Advantageously, a smaller height may allow for 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 a planar heater and heated by it, a smaller gap or height between the base and the upper surface may result in a smaller temperature difference between the base and the upper surface facing the base. Advantageously, this may minimize the risk of the hottest part of the material closest to the heater burning while enabling a greater proportion of the aerosol-forming material of the aerosol generating article to be heated to the temperature at which the aerosol is released. Alternatively or additionally, this may reduce the time required to heat the aerosol-forming material bead located sufficiently within the cavity to release the aerosol.

[0045] An aerosol generating article according to any one 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 another side of the aerosol generating article. The aerosol generating article preferably has a resistance to suction (RTD) of less than 20 mm H2O, for example, less than 10 mm H2O, in the direction of the airflow path. Preferably, the aerosol generating article has an RTD of less than 20 mm H2O, for example, less than 10 mm H2O, 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 can enable excellent airflow management and allow aerosols to be extracted more efficiently from the aerosol generating article and delivered to the user.

[0046] Unless otherwise specified, resistance to suction (RTD) is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through the entire length of a component, such as in an aerosol-generating article. The terms "pressure drop" or "resistance to suction" with respect to a component or article may also refer to "resistance to suction." These terms generally refer to measurements performed under testing in accordance with ISO 6565-2015 at a temperature of approximately 22°C, a pressure of approximately 101 kPa (approx. 760 Torr), and a relative humidity of approximately 60%, at a volumetric flow rate of approximately 17.5 mm / s at the output or downstream end of the component.

[0047] An aerosol-generating article according to any one of the embodiments disclosed herein may comprise an upper and lower surface that is substantially planar. A vertical separation between the substantially planar upper surface and the lower surface may define the height (e.g., z-dimension) of the aerosol-generating article. An airflow channel may be defined between the substantially planar upper surface and the lower surface. The aerosol-generating article may have a height of less than 5 mm, e.g., 1.5 mm to 5 mm, e.g., 1.5 mm to 4 mm, e.g., 1.5 mm to 3 mm, e.g., 1.5 mm to 2 mm. Although beads are the primary source of the aerosol-generating substrate, one or both of the substantially planar upper and lower surfaces may comprise an additional aerosol-generating substrate. The aerosol-generating article may comprise an upper and lower layer, at least one of the upper and lower layer comprises or is composed of an additional aerosol-generating substrate, the upper layer forms a substantially planar upper surface, and the lower layer forms a substantially planar lower surface.

[0048] The aerosol generating article may further include an intermediate layer arranged between the upper layer and the lower layer. The upper surface may define the outer surface of the upper layer, and the lower surface may define the outer surface of the lower layer. An airflow path may be defined through the aerosol generating article in the x / y plane between the distal end and the proximal end of the aerosol generating article. The intermediate layer may be located within a cavity. The intermediate layer may help define the cavity.

[0049] Along the airflow path, the resistance to inhalation (RTD) of the aerosol-generating article may be less than 20 mm H2O.

[0050] One or both of the upper layer and the lower layer may comprise a sublayer of an aerosol-forming substrate laminated with one or more sublayers of susceptor material. The sublayer of the aerosol-forming substrate may define an inward surface of each upper or lower layer.

[0051] The intermediate layer may include or be composed of a paper-based substrate.

[0052] The intermediate layer may not have an aerosol-forming substrate.

[0053] The intermediate layer may include or be composed of an aerosol-forming substrate. The intermediate layer may additionally include one or more susceptor materials.

[0054] Multiple longitudinal extension channels can be defined by wavy folds between the upper and middle layers and between the middle and lower layers. The longitudinal extension channels can extend along the x / y plane between the distal and proximal ends. The wavy folds can be located within a cavity, and beads can be placed in one or more wavy folds.

[0055] The intermediate layer may be fixed to at least one of the upper layer and the lower layer by an adhesive. For example, the adhesive may include guar gum. The adhesive may include an aerosol-forming material such as homogenized tobacco slurry.

[0056] The middle layer may include wavy elements.

[0057] The intermediate layer may include a plurality of wavy elements. Two or more of the plurality of wavy elements may be arranged in a perpendicular relationship between the upper layer and the lower layer. One or more of the plurality of wavy elements may include one or more susceptor materials, and one or more of the plurality of wavy elements may include an aerosol-forming substrate. The intermediate layer may further include a planar element located between two of the plurality of wavy elements. The planar element may include or be composed of one or more susceptor materials.

[0058] According to the present disclosure, an aerosol generating article may be provided comprising a first planar layer, a second planar layer, and a wavy layer arranged between the first planar layer and the second planar layer. Beads may be located within one or more channels of the wavy layer.

[0059] The use of a corrugated structure within aerosol-generating articles makes it advantageous to produce articles that have a very low RTD while remaining sufficiently rigid for user handling. Additionally, the use of the corrugated structure enables the production of low-density, low-RTD aerosol-generating articles using high-speed manufacturing methods similar to those used in the production of corrugated cardboard.

[0060] The aerosol generating article may further include a planar frame located between the upper layer and the lower layer. The upper surface may define the outer surface of the upper layer, and the lower surface may define the outer surface of the lower layer. The planar frame may define a cavity. An airflow path may be defined in the x / y plane through the aerosol generating article, and the airflow path extends through the cavity.

[0061] The upper and lower layers can be joined to the opposing surfaces of the frame so as to be placed over the opposing ends of the cavity.

[0062] One or both of the upper and lower layers may include or be composed of one or more susceptor materials.

[0063] The wavy element can be placed within the cavity between the upper layer and the lower layer. Multiple longitudinally extending channels are defined by the wavy lines between the upper layer and the wavy element, and the wavy lines between the wavy element and the lower layer. The longitudinally extending channels can extend along the x / y plane between opposing ends of the frame.

[0064] The airflow path may be defined at least partially by a frame. The frame may include an inlet airflow channel and an outlet airflow channel, wherein the inlet airflow channel is configured to allow airflow into the cavity and the outlet airflow channel is configured to allow airflow to exit the cavity. The inlet airflow channel and the outlet airflow channel may be defined on opposite ends of the frame. The inlet airflow channel may be defined on a first width edge of the frame, and the outlet airflow channel may be defined on a second width edge of the frame.

[0065] According to the present disclosure, an aerosol generating article may be provided, said aerosol generating article comprises a first planar outer surface, a second planar outer surface, a cavity, a frame positioned between the first planar outer surface and the second planar outer surface and defining at least partially the cavity, and a bead of an aerosol forming substrate positioned in the cavity between the first planar outer surface and the second planar outer surface, and comprises an air inlet and an air outlet, and an airflow passage extending between the air inlet and the air outlet through said cavity. The aerosol generating article may also further comprise one or more susceptor materials arranged to be in thermal communication with the aerosol forming substrate.

[0066] The frame may include a surrounding wall surface that at least partially surrounds or encloses the cavity. The frame may include a surrounding wall that completely surrounds or encloses the cavity.

[0067] The aerosol generating article may include a first planar outer layer and a second planar outer layer, wherein the first planar outer layer forms a first planar outer surface and the second planar outer layer forms a second planar outer surface. Optionally, at least one of the first planar outer layer, the second planar outer layer, and the frame may include or be made of an additional aerosol-forming substrate.

[0068] The wavy fold layer can be located within the cavity.

[0069] Any of the aerosol-generating articles of any aspect of the present disclosure may have a length (e.g., in x-dimension) of 10 mm to 100 mm, or 10 mm to 50 mm, for example, 12 mm to 30 mm, for example, 14 mm to 26 mm, for example, 16 mm to 24 mm, for example, 18 mm to 22 mm, for example, about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.

[0070] The aerosol generating article may have a width (e.g., in y-dimension) of 5 mm to 20 mm, e.g. 8 mm to 18 mm, e.g. 10 mm to 16 mm, e.g. 11 mm to 15 mm, e.g. 12 mm to 14 mm, e.g. about 13 mm.

[0071] The aerosol generating article may have a height (e.g., in z-dimension) of 1 mm to 10 mm, e.g. 1.2 mm to 8 mm, e.g. 1.4 mm to 7 mm, e.g. 1.6 mm to 6 mm, e.g. 1.7 mm to 5 mm, e.g. about 1.7 mm, or about 4.5 mm, or about 2 mm, or about 3 mm, or about 4 mm.

[0072] When viewed in a planar view, an aerosol generating article of any one of the embodiments of the present disclosure may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an ellipse, or a circle, or a combination thereof. Where the aerosol generating article comprises substantially planar upper and lower surfaces, when viewed in a planar view, one or both of the upper and lower surfaces may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof. When viewed in a planar view, the perimeter of the aerosol generating article may be formed by a plurality of straight sides, a plurality of curved sides, or a combination of straight sides and curved sides. Where the aerosol generating article comprises substantially planar upper and lower surfaces, when viewed in a planar view, the perimeter of one or both of the upper and lower surfaces may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof.

[0073] The aerosol-forming material may contain nicotine. Nicotine may exist in the form of a tobacco material or in the form of a nicotine extract.

[0074] The following references to aerosol-forming materials may refer to the aerosol-forming material of the bead or any additional aerosol-forming material present in the article. The aerosol-forming material may comprise one or more aerosol-forming agents. Suitable aerosol-forming agents are known in the art and include, but are not limited to, polyhydric alcohols such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferred that the aerosol-forming agent be glycerin or include it.

[0075] The aerosol-forming substrate may comprise at least 1, 2, 5, 10, or 15 weight percent of an aerosol-forming agent. The aerosol-forming substrate may comprise more than 15 weight percent of an aerosol-forming agent, for example, more than 20 weight percent of an aerosol-forming agent, or more than 25 weight percent of an aerosol-forming agent, or more than 30 weight percent of an aerosol-forming agent, or more than 40 weight percent of an aerosol-forming agent, or more than 50 weight percent of an aerosol-forming agent.

[0076] The aerosol-forming substrate may contain 30% by weight or less of an aerosol-forming agent, 25% by weight or less of an aerosol-forming agent, or 20% by weight or less of an aerosol-forming agent. That is, the aerosol-forming substrate may have an aerosol-forming agent content of 30% by weight or less, 25% by weight or less, or 20% by weight or less.

[0077] The aerosol-forming substrate may comprise 1% to 30% by weight of an aerosol-forming agent, 1% to 25% by weight of an aerosol-forming agent, or 1% to 20% by weight of an aerosol-forming agent.

[0078] The aerosol-forming substrate may comprise 5% to 30% by weight of an aerosol-forming agent, 5% to 25% by weight of an aerosol-forming agent, or 5% to 20% by weight of an aerosol-forming agent.

[0079] The aerosol-forming substrate may comprise 10% to 30% by weight of an aerosol-forming agent, 10% to 25% by weight of an aerosol-forming agent, or 10% to 20% by weight of an aerosol-forming agent.

[0080] The aerosol-forming substrate may comprise 15% to 30% by weight of an aerosol-forming agent, 15% to 25% by weight of an aerosol-forming agent, or 15% to 20% by weight of an aerosol-forming agent.

[0081] The aerosol-forming substrate may comprise at least 50 weight% of an aerosol-forming agent, at least 60 weight% of an aerosol-forming agent, or at least 70 weight% of an aerosol-forming agent.

[0082] The aerosol-forming material may include 85% by weight or less of an aerosol-forming agent, 80% by weight or less of an aerosol-forming agent, or 75% by weight or less of an aerosol-forming agent.

[0083] The aerosol-forming substrate may comprise 50% to 85% by weight of an aerosol-forming agent, 50% to 80% by weight of an aerosol-forming agent, or 50% to 75% by weight of an aerosol-forming agent.

[0084] The aerosol-forming substrate may comprise 60% to 85% by weight of an aerosol-forming agent, 60% to 80% by weight of an aerosol-forming agent, or 60% to 75% by weight of an aerosol-forming agent.

[0085] The aerosol-forming substrate may comprise 70% to 85% by weight of an aerosol-forming agent, 70% to 80% by weight of an aerosol-forming agent, or 70% to 75% by weight of an aerosol-forming agent.

[0086] The aerosol-forming material may include nicotine. The aerosol-forming material may include natural nicotine, synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0087] The aerosol-forming substrate may contain at least 0.5% by weight of nicotine, at least 1% by weight of nicotine, at least 1.5% by weight of nicotine, or at least 2% by weight of nicotine. That is, the aerosol-forming substrate may have a nicotine content of at least 0.5% by weight, at least 1% by weight, at least 1.5% by weight, or at least 2% by weight.

[0088] The aerosol-forming substrate may comprise one or more cannabinoid compounds such as tetrahydrocannabinol (THC), tetrahydrocannabinol acid (THCA), cannabidiol (CBD), cannabidiol acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannavivarin (CBV), cannavivarin (CBDV), tetrahydrocannavivarin (THCV), cannabicromin (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.

[0089] The aerosol-forming material may include one or more flavoring agents. 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 herbal materials. Suitable herbal materials include, but are not limited to, mints such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, coffee, thyme, and caraway, and other herbal materials derived from herb leaves or herbal plants. One or more flavoring agents may include tobacco materials.

[0090] The aerosol generating substrate may additionally include one or more carboxylic acids. Advantageously, when the activator includes nicotine, including one or more carboxylic acids in the aerosol generating substrate may produce a nicotine salt. The carboxylic acid may include one or more of lactic acid, levulinic acid, benzoic acid, fumaric acid, or acetic acid. Preferably, the carboxylic acid is at least one of lactic acid or levulinic acid.

[0091] The aerosol generating material may have a carboxylic acid content of at least 0.5% by weight, preferably at least 1% by weight, and more preferably at least 2% by weight based on dry weight.

[0092] The aerosol generating material may have a carboxylic acid content of 10% by weight or less, preferably 8% by weight or less, more preferably 8% by weight or less, based on dry weight.

[0093] For example, the aerosol generating material may contain about 0.5% to about 10% by weight of acid, or about 1% to about 8% by weight of acid, or about 2% to about 6% by weight of acid based on the weight of the acid.

[0094] 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.

[0095] The aerosol-forming material may comprise about 15 to 45%, preferably about 20 to 35%, of tobacco leaves, for example, a blend of tobacco leaves, which comprises at least one of the following tobacco types: bright tobacco; dark tobacco; flavored tobacco. Tobacco materials such as tobacco leaves are preferably ground and graded to a particle size of about 100 to 380 mesh, preferably about 170 to 320 mesh. Such tobacco materials may be used, for example, to form beads of the aerosol-forming material.

[0096] "Tobacco type" refers to one of different varieties of tobacco, for example, based on the distinct drying process the tobacco undergoes before being further processed in tobacco products.

[0097] Examples of bright tobacco include the Brazilian yellow variety, the Indian yellow variety, the Chinese yellow variety, the American yellow variety such as Virginia tobacco, and the Tanzanian yellow variety.

[0098] Examples of flavored tobaccos include Oriental Turkish tobacco, Greek Oriental tobacco, and semi-Oriental tobacco, as well as American Burley dry tobaccos such as Perique and Rustica.

[0099] Examples of dark tobacco include dark-cured Brazil Galpao, Burley Malawi or other African Burley, and sun-cured or air-cured Indonesian Kasturi.

[0100] The aerosol-forming substrate may include cellulose fibers. For example, the aerosol-forming substrate may include about 1 to 15% cellulose fibers, preferably about 3 to 7% cellulose fibers. Preferably, the cellulose fibers may have a length of about 10 to 250 μm, preferably about 10 to 120 μm.

[0101] The aerosol-forming substrate may comprise organic fibers, such as non-tobacco fibers, or tobacco fibers. For example, the aerosol-forming substrate may comprise about 5 to 20%, preferably about 7 to 15%, of tobacco fibers. The tobacco fibers are preferably derived from stems and / or stalks graded into fibers with a length of about 10 to 350 µm, preferably about 10 to 180 µm. The aerosol-forming substrate may comprise about 10 to 30%, preferably about 15 to 25%, of non-tobacco organic fibers. For example, the organic fibers may be derived from cellulose, cotton, wood, or tea plant varieties as by-products and reprocessed waste of the tea industry. The organic fibers are preferably about 10 to 400 µm, preferably about 10 to 200 µm in length.

[0102] The aerosol-forming substrate may include a binder. For example, the aerosol-forming substrate may include about 1 to 10%, preferably about 1 to 5%, of a binder such as either a common gum or pectin used in the food and beverage (F&B) industry. Preferred binders may be natural pectins, e.g., fruit, e.g., citrus or tobacco pectins; guar gum, land locust bean gum, e.g., their hydroxyethyl and hydroxypropyl; starch, e.g., modified or derived starch; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; dextran; and xanthan gum. A preferred binder is guar.

[0103] The aerosol-forming substrate may include organic vegetable glycerin. For example, the aerosol-forming substrate may include about 15 to 55%, preferably about 20 to 35%, of plant components, such as clove, echinacea species, fennel, ginger, hawthorn berry, elderberry, monarda, mullein leaf, nettle, plantain, turmeric, yarrow, and compounds thereof.

[0104] The aerosol-forming substrate may include organic plant extracts. For example, the aerosol-forming substrate comprises about 1 to 15%, preferably about 2 to 7%, of the previously mentioned plant material, as well as menthol (dl-menthol, C) obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related plant varieties. 10 H 20 It may include p-mentan-3-ol, a secondary alcohol that is a diastereomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol (2-isopropyl-5-methylcyclohexanol).

[0105] The aerosol-forming substrate may include vegetable essential oils, for example, about 0.5 to 5%, preferably about 1 to 3%, of vegetable essential oils, such as palm, coconut, and wood essential oils.

[0106] The aerosol-forming substrate preferably comprises an aerosol-forming agent, for example, about 5 to 35%, preferably about 10 to 25%. Suitable aerosol-forming agents known in the art include glycerin; monohydric alcohols such as menthol, polyhydric alcohols such as triethylene glycol; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids, for example, their dimethyl.

[0107] As used herein, the term "aerosol generating article" may refer to an article capable of generating or releasing aerosols.

[0108] As used herein, the term "aerosol-forming substrate" may refer to a substrate capable of releasing an aerosol or a volatile compound capable of forming an aerosol. Such volatile compounds may be released 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. For convenience, the aerosol-forming substrate may be part of an aerosol-generating article or a smoking article.

[0109] 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 release of an aerosol.

[0110] As used herein, the term 'aerosol generating system' refers to a combination of an aerosol generating device and one or more aerosol forming articles for use with the device. The aerosol generating system may include additional components, such as a charging unit for recharging an on-board electric power supply to an electrically operated or electric aerosol generating device.

[0111] As used herein, the term "aerosol-forming agent" may refer to any suitable known compound or mixture of compounds that facilitates the formation of an aerosol upon use. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal decomposition at the operating temperature of the aerosol-forming substrate or the aerosol-generating article.

[0112] As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salt.

[0113] As used herein with respect to the present invention, the terms "proximal," "distal," "upstream," and "downstream" are used to describe the relative positions of a component or a part of a component of an aerosol-generating article.

[0114] As used herein, the term "longitudinal" refers to a direction corresponding to the main 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.

[0115] As used herein, the term “sheet” refers to a laminated element in which the width and length are substantially greater than the thickness. The width of the sheet is greater than 10 mm, and preferably greater than 20 mm or 30 mm. In certain embodiments, the sheet of material to be used to form an aerosol-forming substrate as described herein may have a thickness of 10 μm to about 1000 μm, for example, 10 μm to about 300 μm.

[0116] As used herein, the term “homogenized tobacco material” includes any tobacco material formed by the aggregation of fine particles of tobacco material. A sheet or web of homogenized tobacco material is formed by aggregating fine tobacco obtained by crushing or pulverizing one or both of tobacco leaf lamina and tobacco leaf stem. Additionally, the homogenized tobacco material may contain trace amounts of one or more of tobacco powder, tobacco fines, and other fine tobacco by-products formed during the processing, handling, and delivery of tobacco. A sheet of homogenized tobacco material may be manufactured by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0117] The term “cast leaf” is used herein to refer to a product produced by a casting process based on casting a slurry containing plant particles (e.g., clove particles, or a mixture of tobacco particles and clove particles) and a binder (e.g., guar gum) onto a supporting surface, such as a belt conveyor, drying the slurry, and removing the dried sheet from the supporting surface. Examples of casting or cast leaf processes are described, for instance, in US-A-5,724,998 for the manufacture of cast leaf tobacco. In a cast leaf process, particulate plant material is produced by pulverizing, grinding, or crushing a portion of a plant. Particles produced from one or more plants are mixed with a liquid component, typically water, to form a slurry. Other components within the slurry may include fibers, a binder, and an aerosol-forming agent. The particulate plant material may aggregate in the presence of a binder. The slurry is cast onto a supporting surface and dried into a sheet of homogenized plant material. Preferably, the homogenized plant material used in the article according to the present invention can be produced by casting. Such homogenized plant material may comprise aggregated particulate plant material.

[0118] As used herein, suction resistance is expressed as "mm H2O" or "mm WG" or "mm water level gauge" and is measured according to ISO 6565:2002.

[0119] The present invention is defined in the claims. However, a non-limiting, non-comprehensive list of embodiments is provided below. Any one or more features of these embodiments may be combined with any one or more features of other embodiments, embodiments, or aspects described herein.

[0120] Exi. An aerosol generating article for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article is defined by an article length, an article width, and an article thickness, wherein the article length is greater than or equal to the article width, and the article width is greater than the article thickness, and the aerosol generating article,

[0121] A cavity located within the above-mentioned aerosol generating article; and

[0122] An aerosol generating article comprising an aerosol forming substrate located within the above cavity, wherein the aerosol forming substrate is in the form of a plurality of individual and / or free-flowing beads.

[0123] ExiA. An aerosol generating article for use with an aerosol generating device to generate an aerosol, e.g., an aerosol generating article according to Exi, wherein the aerosol generating article is defined by an article length, an article width, and an article thickness, wherein the article length is greater than or equal to the article width, and the article width is greater than the article thickness, and the aerosol generating article,

[0124] A cavity located within the above-mentioned aerosol generating article; and

[0125] An aerosol generating article comprising an aerosol-forming substrate located within the above cavity, wherein the aerosol-forming substrate is in the form of a plurality of individual beads having an average particle diameter of 0.1 mm to 4 mm, for example, 0.5 mm to 4 mm.

[0126] ExiB. An aerosol generating article for use with an aerosol generating device to generate an aerosol, for example, an aerosol generating article according to any one of the prior embodiments, wherein the aerosol generating article comprises: a first planar outer surface; and a second planar outer surface, and

[0127] A cavity located within the aerosol generating article between the first planar outer surface and the second planar outer surface; and

[0128] An aerosol generating article comprising an aerosol forming substrate located within the above cavity, wherein the aerosol forming substrate is in the form of a plurality of individual and / or free-flowing beads.

[0129] ExiC. An aerosol generating article for use with an aerosol generating device to generate an aerosol, for example, an aerosol generating article according to any one of the prior embodiments, wherein the aerosol generating article comprises: a first planar outer surface; and a second planar outer surface, and

[0130] A cavity located within the aerosol generating article between the first planar outer surface and the second planar outer surface; and

[0131] An aerosol generating article comprising an aerosol forming substrate located within the above cavity, wherein the aerosol forming substrate is in the form of a plurality of individual beads having an average particle diameter of 0.1 mm to 4 mm, for example, 0.5 mm to 4 mm.

[0132] ExiD. An aerosol generating article for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article, e.g., an aerosol generating article according to any one of the prior embodiments, wherein the aerosol generating article is defined by an article length, an article width, and an article thickness, wherein the article width is greater than the article thickness, and the aerosol generating article,

[0133] A first outer surface and a second outer surface facing in a direction substantially opposite to the first outer surface, for example, a first outer surface and a second outer surface facing;

[0134] It includes a cavity located within the aerosol generating article between the first outer surface and the second outer surface,

[0135] An aerosol generating article, wherein an aerosol forming substrate is located within the cavity, and the aerosol forming substrate is in the form of a plurality of individual beads having an average particle diameter of 0.1 mm to 4 mm, for example, 0.5 mm to 4 mm.

[0136] ExiE. An aerosol generating article for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article, e.g., an aerosol generating article according to any one of the prior embodiments, wherein the aerosol generating article is defined by an article length, an article width, and an article thickness, wherein the article width is greater than the article thickness, and the aerosol generating article,

[0137] A first outer surface and a second outer surface facing in a direction substantially opposite to the first outer surface, for example, a first outer surface and a second outer surface facing;

[0138] It includes a cavity located within the aerosol generating article between the first outer surface and the second outer surface,

[0139] An aerosol generating article comprising an aerosol forming substrate located within the cavity, wherein the aerosol forming substrate is in the form of a plurality of individual and / or free-flowing beads.

[0140] Ex1. An aerosol generating article for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article, e.g., an aerosol generating article according to any one of the prior embodiments, wherein the aerosol generating article is defined by an article length, an article width, and an article thickness, wherein the article width is greater than the article thickness, and the aerosol generating article,

[0141] A first outer surface and a second outer surface facing in a direction substantially opposite to the first outer surface, for example, a first outer surface and a second outer surface facing;

[0142] A cavity located within the aerosol generating article between the first outer surface and the second outer surface; and

[0143] It includes an airflow passage defined between an air inlet and an air outlet through an aerosol generating article and extending through said cavity,

[0144] An aerosol generating article, wherein an aerosol forming substrate is located within the cavity, and the aerosol forming substrate is in the form of a plurality of beads having an average particle diameter of 0.1 mm to 4 mm, for example, 0.5 mm to 4 mm.

[0145] Ex2. In any prior embodiment, each of the plurality of beads has a maximum dimension (d 최대 ) and minimum dimension (d 최소 ) having, wherein the plurality of beads have an average d of less than 4 mm, for example, less than 3 mm. 최대 , and average d exceeding 0.5 mm, e.g., 0.75 mm 최소 Aerosol generating article having

[0146] Ex3. An aerosol generating article, wherein, in any prior embodiment, the plurality of beads have a particle size distribution defined by a D10 diameter and a D90 diameter, wherein the D10 diameter is greater than 0.1 mm, e.g., greater than 0.5 mm, e.g., greater than 0.75 mm, and the D90 diameter is less than 4 mm, e.g., less than 3 mm.

[0147] Ex4. An aerosol generating article in which, in any prior embodiment, the plurality of beads have a particle size distribution defined by a D10 diameter and a D90 diameter, and the D10 diameter is within 25% of the value of the D90 diameter.

[0148] Ex5. An aerosol generating article in which, in any prior embodiment, the plurality of beads have a dual-mode size distribution, for example, the plurality of beads include a first phase and a second phase, and the first phase has a size distribution different from the second phase.

[0149] Ex6. In Ex5, the first phase of the bead has an average d of less than 3 mm. 최대 and average d greater than 1.75 mm 최소 having, and the second phase of the bead has an average d of less than 1.25 mm. 최대 and average d greater than 0.1 mm 최소 Aerosol generating article having

[0150] Ex7. An aerosol generating article, wherein, in any prior embodiment, the plurality of beads comprises a plant material, e.g., tobacco, and a binder, e.g., one or more hydrocolloid binders, and, e.g., the plant material is in the form of plant particles.

[0151] Ex8. An aerosol generating article, wherein, in any prior embodiment, the plurality of beads comprises an aerosol forming agent selected from a list consisting of, for example, glycerin and propylene glycol, and, for example, the aerosol forming particles have an aerosol forming agent content of more than 20% by weight, for example, more than 25% by weight, or more than 30% by weight, for example, more than 35% by weight, based on dry weight.

[0152] Ex9. An aerosol generating article in which, in any prior embodiment, the plurality of beads comprises one or more flavor compounds.

[0153] Ex10. An aerosol generating article in which, in any prior embodiment, the plurality of beads are formed by a process comprising the step of powder-spherizing particles of an aerosol-forming material, for example, preferably in combination with a binder, the step of powder-spherizing tobacco particles, or the plurality of beads are formed by a spherizing process, for example, the spherizing of a dough formed of an aerosol-forming material.

[0154] Ex11. An aerosol generating article in which, in any prior embodiment, the plurality of beads comprises, on a dry weight basis, at least 60 weight% of plant particles, for example, at least 65 weight% of plant particles, for example, at least 70 weight% of plant particles, for example, at least 75 weight% of plant particles.

[0155] Ex12. An aerosol generating article in which, in any prior embodiment, the plurality of beads comprises, on a dry weight basis, 95% by weight or less of plant particles, for example, 90% by weight or less of plant particles, for example, 85% by weight or less of plant particles.

[0156] Ex13. An aerosol generating article, wherein, in any prior embodiment, the cavity comprises a plurality of beads of 50 mg to 300 mg, for example, 100 mg to 200 mg, for example, 125 mg to 175 mg, for example, 140 mg to 160 mg, for example, about 140 mg, or about 150 mg or about 160 mg.

[0157] Ex14. An aerosol generating article, wherein, in any prior embodiment, the plurality of beads have an average diameter of 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm, for example, about 1.5 mm or about 1.7 mm, or about 2 mm.

[0158] Ex15. In any preceding embodiment, the plurality of beads is d 최대 Having a value, and the above d 최대 An aerosol generating article, the distance of the longest axis of a bead is 0.5 mm to 3 mm, for example 0.75 mm to 2.5 mm, for example 1 mm to 2 mm, for example about 1.5 mm or about 1.7 mm, or about 2 mm.

[0159] Ex16. In any preceding embodiment, the plurality of beads is d 최소 Having a value, and the above d 최소 An aerosol generating article, wherein the shortest axis distance of the particle is 0.5 mm to 3 mm, for example 0.75 mm to 2.5 mm, for example 1 mm to 2 mm, for example about 1.5 mm to about 1.7 mm, or about 2 mm.

[0160] Ex17. An aerosol generating article in which, in any prior embodiment, the plurality of beads are low aspect ratio beads, e.g., spherical beads, e.g., substantially spherical beads.

[0161] Ex17A. An aerosol generating article in which, in any prior embodiment, the plurality of beads are a plurality of free-flowing beads.

[0162] Ex17B. An aerosol generating article, wherein, in any preceding embodiment, the plurality of beads are formed to be poured into the aerosol generating article during manufacturing.

[0163] Ex18. An aerosol generating article, wherein, in any prior embodiment, the cavity contains 50% to 85% of the plurality of beads by volume.

[0164] Ex19. In any prior embodiment, the cavity is an aerosol generating article containing a plurality of beads and 15% to 50% of free space.

[0165] Ex20. An aerosol generating article, wherein, in any preceding embodiment, a frame is positioned between the first outer surface and the second outer surface, the frame at least partially defines a cavity, for example, the sidewall of the cavity is at least partially defined by the frame.

[0166] Ex21. An aerosol generating article, wherein in any prior embodiment, at least one of the first outer surface and the second outer surface is substantially a planar surface, for example, the first outer surface is substantially a planar surface, for example, both the first outer surface and the second outer surface are substantially planar surfaces.

[0167] Ex22. In any preceding embodiment, the cavity has a width of 30% to 95% of the width of the aerosol generating article.

[0168] Ex23. In any preceding embodiment, the cavity has a length of 30% to 95% of the length of the aerosol generating article.

[0169] Ex24. In any preceding embodiment, the cavity has a thickness of 30% to 95% of the thickness of the aerosol generating article.

[0170] Ex25. An aerosol generating article, wherein, in any prior embodiment, the cavity has a length of 14 mm to 40 mm, a width of 4.5 mm to 13 mm, and a thickness of 0.5 mm to 4.5 mm.

[0171] Ex26. In any prior embodiment, the cavity is an aerosol generating article having a length of 20 mm to 30 mm, a width of 7 mm to 10 mm, and a thickness of 2.5 mm to 4 mm.

[0172] Ex27. An aerosol generating article in any prior embodiment, wherein the thickness of the aerosol generating article is less than 50% of both the length and width of the aerosol generating article.

[0173] Ex28. An aerosol generating article in which, in any preceding embodiment, the frame comprises a surrounding wall surface that surrounds or encloses the cavity.

[0174] Ex29. An aerosol generating article according to Ex28, wherein the peripheral wall surface is formed by an inner surface of a frame and an outer surface of a frame, the inner surface of the frame defines a common outer wall surface, and the outer surface of the frame defines at least one or more outer wall surfaces of the aerosol generating article.

[0175] Ex30. An aerosol generating article in Ex28 or Ex29, wherein the peripheral wall surface has a radial thickness of 1 mm to 3 mm.

[0176] Ex31. An aerosol generating article, wherein in any one of Ex20 to Ex30, the frame has a thickness of 80% or more of the thickness of the aerosol generating article.

[0177] Ex32. An aerosol generating article, wherein in any one of Ex20 to Ex31, the frame has a thickness of 80% to 95% of the thickness of the aerosol generating article.

[0178] Ex33. An aerosol generating article, wherein in any one of Ex20 to Ex32, the frame has a thickness of 1 mm to 5.5 mm.

[0179] Ex34. An aerosol generating article in any one of Ex20 to Ex33, wherein the frame comprises a cellulose material.

[0180] Ex35. An aerosol generating article according to Ex34, wherein the cellulose material has a basis weight of 300 g / m2 to 900 g / m2.

[0181] Ex36. An aerosol generating article in Ex34 or Ex35, wherein the cellulose material is paper, cardboard, or cardboard.

[0182] Ex37. An aerosol generating article in any one of Ex20 to Ex36, wherein the frame is a single component.

[0183] Ex38. An aerosol generating article in any one of Ex20 to Ex37, wherein the frame comprises a first frame layer and a second frame layer.

[0184] Ex39. An aerosol generating article in Ex21, wherein the first frame layer is bonded to the second frame layer with an adhesive.

[0185] Ex40. An aerosol generating article in Ex21 or Ex22, wherein the frame comprises a third frame layer.

[0186] Ex42. An aerosol generating article in Ex40, wherein the second frame layer is located between the first frame layer and the third frame layer.

[0187] Ex43. An aerosol generating article in Ex40 or Ex41, wherein the second frame layer is bonded to the third frame layer with an adhesive.

[0188] Ex44. An aerosol generating article in any one of Ex20 to Ex43, wherein the one or more aerosol generating substrates comprise a first aerosol generating substrate layer located between the first planar outer surface and the frame, and a second aerosol generating substrate layer located between the second planar outer surface and the frame.

[0189] Ex45. An aerosol generating article according to Ex44, wherein one or both of the first aerosol generating substrate layer and the second aerosol generating substrate layer comprise an aerosol generating material in the form of a sheet of aerosol generating material.

[0190] Ex46. An aerosol generating article in Ex45, wherein the sheet of the aerosol generating material is a sheet of homogenized tobacco material.

[0191] Ex47. In Ex44 or Ex45, the aerosol generating material sheet comprises one or more aerosol forming agents, such as glycerin and propylene glycol, or both, an aerosol generating article.

[0192] Ex48. An aerosol generating article in any one of Ex45 to Ex47, wherein the first aerosol generating substrate layer and the second aerosol generating substrate layer define opposite end walls of the cavity.

[0193] Ex49. An aerosol generating article in any one of Ex45 to Ex48, wherein one or both of the first aerosol generating substrate layer and the second aerosol generating substrate layer have a thickness of 100 μm to 600 μm.

[0194] Ex50. An aerosol generating article in any one of Ex45 to Ex49, wherein one or both of the first aerosol generating substrate layer and the second aerosol generating substrate layer have a length substantially equal to the length of the aerosol generating article.

[0195] Ex51. An aerosol generating article in any one of Ex45 to Ex50, wherein one or both of the first aerosol generating substrate layer and the second aerosol generating substrate layer have a width substantially equal to the width of the aerosol generating article.

[0196] Ex52. An aerosol generating article comprising, in any preceding embodiment, an outer wrapper defining the first planar outer surface and the second planar outer surface.

[0197] Ex53. An aerosol generating article comprising, in any preceding embodiment, a first planar outer layer and a second planar outer layer, wherein the first planar outer layer defines a first planar outer surface and the second planar outer layer defines a second planar outer surface.

[0198] Ex54. An aerosol generating article in Ex53, wherein the first planar outer layer and the second planar outer layer are placed on opposite ends of the cavity.

[0199] Ex55. An aerosol generating article according to Ex53 or Ex54, wherein one or both of the first planar outer layer and the second planar outer layer comprise a cellulose-based material.

[0200] Ex56. An aerosol generating article in Ex55, wherein the cellulose-based material is paper or cardboard.

[0201] Ex57. An aerosol generating article in any one of Ex27 to Ex30, wherein one or both of the first planar outer layer and the second planar outer layer have a length substantially equal to the length of the aerosol generating article.

[0202] Ex58. An aerosol generating article in any one of Ex27 to Ex31, wherein one or both of the first planar outer layer and the second planar outer layer have a width substantially equal to the width of the aerosol generating article.

[0203] Ex59. An aerosol generating article in any one of Ex20 to Ex58, wherein the air inlet is defined by the frame.

[0204] Ex60. An aerosol generating article, wherein, in any prior embodiment, the air inlet has an equivalent diameter of 0.1 mm to 3 mm.

[0205] Ex61. An aerosol generating article, wherein, in any prior embodiment, the air inlet has a width of 0.3 mm to 3 mm.

[0206] Ex62. An aerosol generating article, wherein, in any prior embodiment, the air inlet has a thickness of 0.3 mm to 3 mm.

[0207] Ex63. In any one of Ex20 to Ex62, the air outlet is an aerosol generating article defined by the frame.

[0208] Ex64. An aerosol generating article, wherein, in any preceding embodiment, the air outlet has an equivalent diameter of 0.1 mm to 3 mm.

[0209] Ex65. An aerosol generating article, wherein, in any prior embodiment, the air outlet has a width of 0.3 mm to 3 mm.

[0210] Ex66. An aerosol generating article, wherein, in any prior embodiment, the air outlet has a thickness of 0.3 mm to 3 mm.

[0211] Ex67. An aerosol generating article in any prior embodiment, wherein the ratio between the length and thickness of the aerosol generating article and the ratio between the width and thickness of the aerosol generating article is 2:1 to 15:1.

[0212] Ex68. An aerosol generating article, wherein in any prior embodiment, the ratio between the length and width of the aerosol generating article is 1:1 to 10:1.

[0213] Ex69. In any prior embodiment, the aerosol generating article has a length of 15 mm to 45 mm, for example, 25 mm to 30 mm.

[0214] Ex70. In any prior embodiment, the aerosol generating article has a width of 3 mm to 17 mm, for example, 9 mm to 11 mm.

[0215] Ex71. In any prior embodiment, the aerosol generating article has a thickness of 1 mm to 5.5 mm, for example, 3 mm to 3.5 mm.

[0216] Ex72. In any prior embodiment, the aerosol generating article is an aerosol generating article having an inhalation resistance of 0 mm H2O to 9.9 mm H2O.

[0217] Ex73. In any prior embodiment, each of the plurality of beads has a density of 2 g / cm³ or less, for example 1.9 g / cm³ or less, for example 1.8 g / cm³ or less, an aerosol generating article.

[0218] Ex74. An aerosol generating article in which, in any prior embodiment, the total weight of the plurality of beads is at least 50 mg, for example, at least 100 mg, for example, at least 125 mg, for example, at least 150 mg.

[0219] Ex75. An aerosol generating article in which, in any prior embodiment, the total weight of a plurality of beads of granules is 350 mg or less, for example 300 mg or less, for example 250 mg or less.

[0220] Ex76. An aerosol generating article in which, in any prior embodiment, the bulk density of the plurality of beads is at least 200 mg / cm3, for example at least 225 mg / cm3, for example at least 250 mg / cm3.

[0221] Ex77. An aerosol generating article in which, in any prior embodiment, the bulk density of the plurality of beads is 500 mg / cm3 or less, for example 475 mg / cm3 or less, for example 450 mg / cm3 or less.

[0222] Ex78. An aerosol generating article in any prior embodiment, wherein the average surface area of ​​the plurality of beads is at least 3 mm2, for example at least 10 mm2, for example at least 20 mm2.

[0223] Ex79. An aerosol generating article in any prior embodiment, wherein the average surface area of ​​the plurality of beads is 80 mm2 or less, for example 60 mm2 or less, for example 40 mm2 or less.

[0224] Ex80. An aerosol generating article in any prior embodiment, wherein the total surface area of ​​the plurality of beads is at least 120 mm2, for example, at least 240 mm2.

[0225] Ex81. An aerosol generating article in any prior embodiment, wherein the total surface area of ​​the plurality of beads is 650 mm2 or less, for example 500 mm2 or less. Brief explanation of the drawing

[0226] Examples will be further described with reference to the drawings. FIG. 1 is a side perspective view of an aerosol generating article according to a first embodiment of the present disclosure; FIG. 2 is a side perspective view of an aerosol generating article according to a second embodiment of the present disclosure; FIG. 3 is a schematic end view of an aerosol article according to a third embodiment of the present disclosure; FIG. 4 is a schematic side view of the aerosol generating article of FIG. 3; FIG. 5 is a schematic plan view of the aerosol generating article of FIG. 3; FIG. 6 shows a schematic diagram of a wavy element used in the aerosol generating article of FIG. 3; FIG. 7 shows a perspective view of an aerosol generating article according to a sixth embodiment of the present disclosure; FIG. 8 shows an exploded perspective view of the aerosol generating article of FIG. 7; FIG. 9 shows an additional exploded perspective view of the aerosol generating article of FIG. 7; FIG. 10 shows a schematic cross-sectional view of the aerosol-generating article of FIG. 7; Figure 11 shows a schematic longitudinal cross-sectional view of the aerosol generating article of Figure 7. Specific details for implementing the invention

[0227] FIG. 1 shows a side perspective view of an aerosol generating article (100) according to a first embodiment of the present disclosure. The aerosol generating article (100) has upper and lower surfaces (110, 120) that are flat or planar.

[0228] The aerosol generating article (100) comprises an internal cavity containing a bead of an aerosol forming substrate (not shown). In one embodiment, the aerosol generating article (100) may substantially consist of a bead-shaped aerosol forming substrate and other components. In another embodiment, the aerosol forming substrate may be part of a plurality of component parts of the aerosol generating article (100) (e.g., including only the bead). The aerosol forming substrate is enclosed within 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 and lower surfaces (110, 120) may include or be composed of the aerosol forming substrate. One or more susceptor materials may be included within the aerosol generating article (100).

[0229] The aerosol generating article (100) has a length of 80 mm extending in the x dimension, a width of 15 mm extending in the y dimension, and a height of 3.6 mm extending in the z dimension (which may also be referred to as thickness).

[0230] FIG. 2 shows a side perspective view of an aerosol generating article (200) according to a second embodiment of the present disclosure, which is a variation of the aerosol generating article (100). Features common to the aerosol generating article (100) are referred to by similar reference numerals. An airflow path (230) is defined through the aerosol generating article (200) between the upper layer and the lower layer (110, 120). The airflow path (230) extends between opposing first and second ends (201, 202) of the aerosol generating article (200) and passes through a cavity (231) containing a plurality of beads of an aerosol forming substrate (290). 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) can be guided toward the user's mouth so that the user can inhale the aerosol generated as a result of heating the aerosol-forming substrate of the aerosol-generating article (200). Parameters such as the total weight of the aerosol-forming substrate (290) in the cavity (230), the density of the aerosol-forming material in the cavity, and the total porosity in the cavity can be controlled by controlling the bead size and bead size distribution for a plurality of beads (290).

[0231] In this particular embodiment, the beads of the aerosol generating substrate (290) are substantially spherical beads. The beads (290) have an average diameter of 1.5 mm and a density of 1.3 g / cm³. The total weight of the beads (290) within the substrate cavity (231) is approximately 150 mg. The beads (290) are formed from an aerosol generating substrate comprising plant particles, an aerosol forming agent, and a hydrocolloid binder. Examples of suitable compositions of the aerosol generating substrate forming the beads are provided below.

[0232] Examples

[0233] Suitable compositions for forming beads of an aerosol generating substrate according to the present invention are presented in Table 1 below:

[0234]

[0235] All amounts are expressed as weight percent based on dry weight, based on the total weight of the aerosol generating element.

[0236] To manufacture beads, tobacco particles are first mixed with glycerin. An HPMC or CMC binder is dispersed in the glycerin, and then water is added to form an aqueous binder solution. The binder solution is added to the mixture of tobacco particles and glycerin, and all components are mixed to form a dough. The dough is extruded to form multiple discontinuous elements, and then the discontinuous elements are spherical at low speed to form spherical beads with an average diameter of 1.5 mm. The beads are dried in an oven to a desired moisture content. Then, the dried beads can be incorporated into various different aerosol generating articles as described above.

[0237] When these beads are incorporated into an aerosol generating article as described herein and heated, an aerosol containing nicotine and glycerin is generated from the aerosol generating substrate. It was found that the ratio of nicotine to glycerin in each puff of the aerosol remains consistent over the duration of heating. This contrasts with aerosols generated from articles having a similar composition in which the aerosol generating substrate is in the form of a tobacco cast leaf. Under the same conditions, aerosols generated by the tobacco cast leaf substrate were found to have a much more variable ratio of nicotine to glycerin per puff. Providing an aerosol with a more consistent ratio of nicotine to glycerin over the puff provides the consumer with an optimal sensory experience over the duration of heating.

[0238] For exemplary purposes applicable to any of the embodiments described herein, the composition of an aerosol-forming material that can be used to form a plurality of aerosol-forming beads may be as follows. Percentages are given as weight percent relative to the product in the final state. The aerosol-forming substrate may have about 5 to 25%, preferably about 7 to 15%, of moisture in the final product state. The aerosol-forming substrate may further comprise the following:

[0239] 1. Tobacco leaves; for example, about 15 to 45%, preferably about 20 to 35%, of a blend of tobacco leaves, and comprising at least one of the following tobacco types: bright tobacco; dark tobacco; flavored tobacco. The tobacco material is ground and graded to a particle size of about 100 to 380 mesh, preferably about 170 to 320 mesh.

[0240] 2. Cellulose fibers; for example, about 1 to 15%, preferably about 3 to 7%, of cellulose fibers with a length of about 10 to 250 µm, preferably about 10 to 120 µm.

[0241] 3. Tobacco fibers; for example, about 5 to 20%, preferably about 7 to 15%, of tobacco fibers as a filler of any tobacco type or blend of tobacco types. The tobacco fibers are preferably derived from stems and / or stem stalks graded into fibers of about 10 to 350 μm in length, preferably about 10 to 180 μm.

[0242] 4. Binder; for example, about 1 to 10%, preferably about 1 to 5% of a binder, such as a common gum or pectin used in the food and beverage (F&B) industry. Preferred binders may be natural pectin, such as fruit, for example, citrus or tobacco pectin; guar gum, land locust bean gum, for example, their hydroxyethyl and hydroxypropyl forms; starch, for example, modified or derived starch; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; dextran; and xanthan gum. A preferred binder is guar.

[0243] 5. Aerosol forming agent; for example, about 5 to 35%, preferably about 10 to 25% of the aerosol forming agent. Suitable aerosol forming agents known in the art include glycerin; monohydric alcohols such as menthol, polyhydric alcohols such as triethylene glycol; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids, e.g., their dimethyls.

[0244] "Tobacco type" refers to one of different varieties of tobacco, for example, based on the distinct drying process the tobacco undergoes before being further processed in tobacco products.

[0245] For exemplary purposes, the composition of additional aerosol-forming substrates that may be suitable for use as aerosol-forming substrates in any one of the embodiments described above is described below. Percentages are given as weight percent relative to the product in the final state. The aerosol-forming substrates may comprise the following.

[0246] 1. Aerosol-forming agents such as glycerin; for example, about 10 to 40%, preferably about 20 to 30%.

[0247] 2. Organic fibers; for example, about 10 to 30%, preferably about 15 to 25%, of any plant variety suitable for complying with applicable FDA F&B grade requirements and having a purity as generally available in the market. For example, the organic fibers may be derived as downproducts and downprocessed waste from cellulose, cotton, wood, and tea plant varieties of the F&B tea industry. The organic fibers are preferably about 10 to 400 µm in length, preferably about 10 to 200 µm.

[0248] 3. Organic vegetable glycerite; for example, about 15 to 55%, preferably about 20 to 35% of plants, such as cloves, echinacea species, fennel, ginger, hawthorn berries, elderberries, monada, mullet leaves, nettle, plantain, turmeric, yarrow, and compounds thereof.

[0249] 4. Organic plant extracts; for example, about 1 to 15%, preferably about 2 to 7% of any of the previously mentioned plants, as well as any secondary alcohol as a diastereomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol, such as p-mentan-3-ol, as well as menthol (dl-menthol, C) obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related plant varieties. 10 H 20 O, 2-isopropyl-5-methylcyclohexanol).

[0250] Alternatively, such aerosol-forming substrates may also contain about 0.5 to 5%, preferably about 1 to 3%, of vegetable essential oils, such as palm, coconut, and wood essential oils.

[0251] A dough formed from any of these aerosol-forming materials can be extruded to form a plurality of individual elements, and then the individual elements can be spherical at a low speed to form substantially spherical beads having an average diameter of 0.5 mm to 4 mm. The beads are dried in an oven to a desired moisture content. Then, the dried beads can be incorporated into various different aerosol-generating articles as described above.

[0252] FIGS. 3, FIGS. 4, and FIGS. 5 illustrate, respectively, an end view, a side view, and a top view of an aerosol generating article (300) according to a third embodiment of the present disclosure. The aerosol generating article (300) comprises a planar upper layer (310), a planar lower layer (320), and an intermediate or separating layer (340) arranged between the upper layer (310) and the lower layer (320).

[0253] The flat upper layer (310) is formed from a paper sheet having a thickness of 100 μm. The flat lower layer (320) is formed from a paper sheet having a thickness of 100 μm. The middle layer (340) is a wavy element formed from a wavy sheet of paper (345). A suitable aerosol-forming substrate may be a bead of tobacco material (390) located within a longitudinal cavity (361, 362) formed by the wavy sheet. The bead of tobacco material (390) may be as described above in relation to FIG. 1.

[0254] FIG. 6 illustrates a corrugated sheet of paper (345). The wavy corrugations have an amplitude (346) of 3 mm and a wavelength (347) of 3 mm. The corrugated sheet of paper (345) forming the intermediate layer (340) has a thickness of 150 μm.

[0255] The intersection points (351, 352) between the upper layer (310) and the middle layer (340) and between the lower layer (320) and the middle layer (340) contain an adhesive that bonds each layer.

[0256] The aerosol generating article (300) has a length extending by an x ​​dimension of 80 mm, a width extending by a y dimension of 15 mm, and a height (or thickness) extending by a z dimension of 3.6 mm.

[0257] The wavy folds of the intermediate layer (340) form a first set of longitudinally extending cavities or channels (361) bounded by the upper layer (310) and the intermediate layer (340), and a second set of longitudinally extending cavities or channels (362) bounded by the lower layer (320) and the intermediate layer (340). The first and second sets of longitudinally extending channels (361, 362) extend along the length of the wavy sheet between the proximal end (371) of the sheet (345) and the distal end (372) of the sheet (345). The longitudinally extending channels (361, 362) contain beads of the aerosol-forming substrate (390) and also define an airflow path passing through the sheet (345). Thus, the airflow path passes over the beads of the aerosol-forming substrate.

[0258] The corrugated sheet (345) may be a material other than paper, and for example, the corrugated sheet may be a sheet of any suitable aerosol-forming substrate.

[0259] FIG. 7 shows an aerosol generating article (600) according to a sixth embodiment of the present disclosure. The aerosol generating article (600) comprises a first planar outer layer (624) forming a first planar outer surface (621), a second planar outer layer (625) forming a second planar outer surface (622), and a frame (650) positioned between the first planar outer layer (624) and the second planar outer layer (625). The second planar outer surface (622) is positioned parallel to the first planar outer surface (621).

[0260] FIGS. 8 and 9 show exploded views of the aerosol generating article (600) of FIG. 7. A frame (650) surrounds the cavity (630) and defines it at least partially. FIG. 8 shows the cavity (630) in an empty state. FIG. 9 shows the cavity (630) filled with beads of an aerosol forming substrate (640). FIGS. 10 and 11 show cross-sectional and longitudinal views of the aerosol generating article (600) when the cavity (630) is filled with a plurality of beads of an aerosol forming substrate (640). The plurality of beads (640) may be the same substantially spherical beads having an average diameter of 1.5 mm, as described above in relation to FIG. 1.

[0261] The first planar outer layer (624) and the second planar outer layer (625) are made of paper sheets and are physically in contact with and bonded to the frame (650). The first planar outer layer (624) is placed over the first end of the cavity (630) and forms the first cavity end wall (631). The second planar outer layer (625) is placed over the second end of the cavity (630) and forms the second cavity end wall (632), wherein the second cavity end wall (632) faces the first cavity end wall (631). That is, the frame (650), the first planar outer layer (624), and the second planar outer layer (625) collectively define the cavity (630).

[0262] The frame (650) has a hollow rectangular shape and is made of cardboard. The frame (650) defines an aperture that extends through the height (also referred to as thickness) of the frame (650), and the aperture forms at least partially the cavity (630) of the aerosol generating article (600). The frame (650) includes a periphery wall (651) surrounding the cavity (630). The periphery wall (651) includes a front wall (613) and a rear wall (614). More specifically, the periphery wall (651) is defined by an inner transverse surface (652) of the frame (450) and an outer transverse surface (653) of the frame (650). The inner transverse surface (652) of the periphery wall (651) defines at least partially the periphery of the cavity (630). The outer transverse surface (653) of the periphery wall (651) defines at least partially the periphery of the aerosol generating article (600). The periphery wall (651) has a radial thickness of about 5 mm measured between the inner transverse surface (652) of the frame (650) and the outer transverse surface (653) of the frame (650).

[0263] The air inlet (611) and the air outlet (612) are defined by and extend through the peripheral wall surface (651) of the frame (650). More specifically, the air inlet (611) extends through the front wall surface (613) and the air outlet (612) extends through the rear wall surface (614). The air inlet (611) and the air outlet (612) have an equivalent diameter of 5 mm. An airflow passage extends through a cavity (630) between the air inlet (611) and the air outlet (612). As illustrated in FIGS. 11 through 13, an aerosol-forming substrate (640) is located within the cavity (630). The beads of the aerosol-forming substrate (640) may include tobacco. As described, the beads of the aerosol-forming substrate (640) fill the entire volume of the cavity (630), and the airflow through the cavity is provided by the gap between adjacent beads.

[0264] The aerosol generating article (600) has a rectangular shape and has a height (or thickness) of 8 mm extending in the z-dimension, a width of 40 mm extending in the y-dimension, and a length of 60 mm extending in the x-dimension, as measured between the first planar outer surface (621) and the second planar outer surface (622). The frame (650) has a height (or thickness) of 7.93 mm extending in the z-dimension, a width of 40 mm extending in the y-dimension, and a length of 60 mm extending in the x-dimension. The cavity (630) has a height (or thickness) of 7.93 mm extending in the z-dimension, a width of 39.93 mm extending in the y-dimension, and a length of 52 mm extending in the x-dimension.

[0265] An alternative exemplary aerosol generating article having the same structure as illustrated in FIGS. 7 through 11 may have smaller dimensions. For example, in preferred embodiments, when measured between the first planar outer surface (621) and the second planar outer surface (622), the height extending in the z-direction may be 2.8 to 3.6 mm, for example, about 3.3 mm. The width extending in the y-direction may be 10 mm to 12 mm, for example, about 11 mm. The length extending in the x-direction may be 25 mm to 35 mm, for example, about 30 mm. The cavity may have a height (or thickness) extending in the z-direction of 2.8 to 3.6 mm, for example, about 3.3 mm, a width extending in the y-direction of 5 mm to 8 mm, for example, 6 mm or 7 mm, and a length extending in the x-direction of 10 mm to 15 mm, for example, 12 mm.

[0266] For the purposes of this description and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, etc., shall be understood in all cases to be modified by the term “about.” Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein. Accordingly, in this context, the number “A” is understood as 10% of “A” ± “A”. In this context, the number “A” may be considered to include numerical values ​​within the general standard error for measuring the characteristic modified by the number “A”. In some cases used in the appended claims, the number “A” may deviate by the percentage listed above, provided that the amount of deviation by “A” does not substantially affect the basic and novel feature(s) of the claimed invention. Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein. The terms “here” and “the” are used as synonyms throughout this specification.

Claims

Claim 1 An aerosol generating article for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article is defined by an article length, an article width, and an article thickness, wherein the article width is greater than the article thickness, and the aerosol generating article comprises: a first outer surface and a second outer surface facing substantially opposite to the first outer surface; a cavity located within the aerosol generating article between the first outer surface and the second outer surface; and an airflow passage defined between an air inlet and an air outlet through the aerosol generating article and extending through the cavity, wherein an aerosol forming substrate is located within the cavity, and the aerosol forming substrate is in the form of a plurality of individual beads having an average particle diameter of 0.1 mm to 4 mm. Claim 2 In claim 1, each of the plurality of beads has a maximum dimension (d 최대 ) and minimum dimension (d 최소 ) having, wherein the plurality of beads have an average d of less than 4mm, for example, less than 3mm. 최대 , and the average d of greater than 0.1mm, e.g., greater than 0.5mm, e.g., greater than 0.75mm 최소 Aerosol generating article having Claim 3 An aerosol generating article according to claim 1 or 2, wherein the plurality of beads have a particle size distribution defined by a D10 diameter and a D90 diameter, wherein the D10 diameter is greater than 0.5 mm, e.g., greater than 0.75 mm, and the D90 diameter is less than 4 mm, e.g., less than 3 mm. Claim 4 An aerosol generating article according to any one of claims 1 to 3, wherein the plurality of beads have a particle size distribution defined by a D10 diameter and a D90 diameter, and the D10 diameter is within 25% of the D90 diameter value. Claim 5 An aerosol generating article according to any one of claims 1 to 4, wherein the plurality of beads have a dual-mode size distribution, for example, the plurality of beads include a first phase and a second phase, and the first phase has a size distribution different from the second phase. Claim 6 In paragraph 5, the first phase of the bead has an average d of less than 3 mm. 최대 and average d greater than 1.75 mm 최소 having, and the second phase of the bead has an average d of less than 1.25 mm. 최대 and average d greater than 0.1 mm 최소 Aerosol generating article having Claim 7 An aerosol generating article according to any one of claims 1 to 6, wherein the individual beads forming the plurality of beads comprise tobacco and a binder. Claim 8 An aerosol generating article according to any one of claims 1 to 7, wherein the cavity comprises a plurality of beads of 50 mg to 300 mg, for example, 100 mg to 200 mg, for example, 125 mg to 175 mg, for example, 140 mg to 160 mg, for example, about 140 mg, or about 150 mg or about 160 mg. Claim 9 An aerosol generating article according to any one of claims 1 to 8, wherein the plurality of beads are substantially spherical beads. Claim 10 An aerosol generating article according to any one of claims 1 to 9, wherein the cavity contains 50% to 85% of the plurality of beads by volume. Claim 11 An aerosol generating article according to any one of claims 1 to 10, wherein the cavity contains the plurality of beads and 15% to 50% of free space. Claim 12 An aerosol generating article according to any one of claims 1 to 11, wherein at least one of the first outer surface and the second outer surface is substantially a planar surface, for example, the first outer surface is substantially a planar surface, and for example, both the first outer surface and the second outer surface are substantially planar surfaces. Claim 13 In any prior embodiment, the cavity is an aerosol generating article having a length of 14 mm to 40 mm, a width of 4.5 mm to 13 mm, and a thickness of 0.5 mm to 4.5 mm. Claim 14 An aerosol generating article according to any one of claims 1 to 13, wherein both the air inlet and the air outlet have a width of 0.3 mm to 3 mm and a thickness of 0.3 mm to 3 mm. Claim 15 In any prior embodiment, the aerosol generating article is an aerosol generating article having a length of 15 mm to 45 mm, a width of 4.5 mm to 17 mm, and a thickness of 1 mm to 5.5 mm.

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