Aerosol generation system

Abstract

An aerosol generating system is provided, comprising an aerosol generating article (100, 200, 300, 400, 500, 600, 600') and an aerosol generating device (6000). The aerosol generating article comprises at least one aerosol forming substrate (340, 440, 540, 640, 640'). The aerosol generating article is defined by an article length, an article width, and an article thickness, wherein the article length and article width are at least twice the article thickness. The aerosol generating device comprises a heating chamber (6050, 6050') for receiving the aerosol generating article. The aerosol generating device comprises at least one heater (6030, 6030'), wherein the at least one heater defines a heating zone (6100, 6100') within the heating chamber. When an aerosol generating article is completely contained within the heating chamber of an aerosol generating device, 20 to 80% of the total mass of at least one aerosol forming material is located within the heating zone.

Description

Technology Field

[0001] The present disclosure relates to an aerosol generating system. The system comprises an aerosol generating article comprising an aerosol generating device and an aerosol forming substrate. Background Technology

[0002] A typical aerosol generating article may resemble a conventional cigarette. For example, such an aerosol generating article may include an aerosol forming substrate and other components such as a mouthpiece filter element and a cooling element, which may be substantially cylindrical, arranged together in the form of a rod, and wrapped in cigarette paper. The dimensions of a typical aerosol generating article are often similar to the dimensions of a conventional cigarette.

[0003] When in use, the aerosol generating article is typically coupled with an aerosol generating device, and then the aerosol forming substrate is heated by the aerosol generating device.

[0004] However, a significant portion of the aerosol-forming material within these cylindrical aerosol-generating articles may not be heated sufficiently to form an aerosol during use. This is undesirable because the insufficiently heated portion of the aerosol-forming 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-forming 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. Additionally, the components of these cylindrical aerosol-generating articles generally need to have the same or very similar outer diameters so that they can be joined, positioned accurately in axial alignment, and wrapped in cigarette paper. This can increase manufacturing costs and complexity.

[0005] Furthermore, in some aerosol generating systems, the time from when the heater is first activated until the aerosol-forming substrate reaches a temperature high enough to form an aerosol (sometimes referred to as the time to the first puff) is too long. Alternatively, or additionally, in some aerosol generating systems, after the aerosol-forming substrate reaches a temperature high enough to form an aerosol, too much of the substrate is depleted too quickly. This may mean that the flavor of the aerosol delivered to the user diminishes rapidly after the first puff or the first few puffs.

[0006] The object of the present disclosure is to provide an aerosol generating system, wherein a larger portion of the aerosol-forming substrate of the aerosol generating article is heated sufficiently to form an aerosol during use. Additionally, the object of the present disclosure is to provide an aerosol generating article that can be manufactured relatively efficiently and at a low cost. Additionally, the object of the present disclosure is to provide an aerosol generating system in which the time to the first puff is reduced. Additionally, the object of the present disclosure is to provide an aerosol generating system in which the aerosol-forming substrate is not depleted too quickly.

[0007] According to the present disclosure, an aerosol generating system comprising an aerosol generating article and an aerosol generating device is provided. The aerosol generating article may comprise at least one aerosol forming substrate. The aerosol generating article may have an article length, an article width, and an article thickness, or may be defined by these. The article length may be at least twice the article thickness. The article width may be at least twice the article thickness. The aerosol generating device may comprise a heating chamber for receiving at least a portion of the aerosol generating article. The aerosol generating device may comprise at least one heater. The at least one heater may define a heating zone within the heating chamber. When the aerosol generating article is fully received within the heating chamber of the aerosol generating device, 10 to 90%, preferably 20 to 80%, of the total mass of at least one aerosol forming substrate may be located within the heating zone.

[0008] According to a first aspect of the present disclosure, an aerosol generating system comprising an aerosol generating article and an aerosol generating device is provided. The aerosol generating article comprises at least one aerosol forming substrate. The aerosol generating article is defined by an article length, an article width, and an article thickness, wherein the article length and article width are at least twice the article thickness. The aerosol generating device comprises a heating chamber for receiving at least a portion of the aerosol generating article. The aerosol generating device comprises at least one heater, and the at least one heater defines a heating zone within the heating chamber. When the aerosol generating article is fully received within the heating chamber of the aerosol generating device, 10 to 90%, preferably 20 to 80%, of the total mass of the at least one aerosol forming substrate is located within the heating zone.

[0009] Advantageously, by having only up to 80% of the total mass of at least one aerosol-forming material located within the heating zone when the aerosol-generating article is fully contained within the heating chamber, a larger proportion of the thermal energy provided by the heater is transferred to a smaller mass of aerosol-forming material compared to a system where 100% of the total mass of at least one aerosol-forming material is located within the heating zone when the heater is first turned on. This means that the portion of the aerosol-forming material within the heating zone can reach a temperature high enough to form an aerosol earlier. Additionally, the portion of at least one aerosol-forming material outside the heating zone may take longer to reach a temperature high enough to form an aerosol. Therefore, this portion of at least one aerosol-forming material outside the heating zone can release high-quality aerosols later during the usage session of the aerosol-generating system. Thus, the system can reduce the time to the first puff and delay the depletion of the aerosol-forming material.

[0010] As described above, the device includes a heating chamber for receiving at least a portion of an article. The heating chamber may or may not receive the entire article. Accordingly, as understood by those skilled in the art after reading this disclosure, a reference to an article that is fully received within the heating chamber does not refer to the entire article received within the heating chamber. Rather, as understood by those skilled in the art after reading this disclosure, a reference to an article that is fully received within the heating chamber may refer to the article received within the heating chamber to the maximum extent that it can be received within the heating chamber. This may be when the upstream end of the article is in contact with a stop surface of the heating chamber, as described below. Such a stop surface may be the upstream end of the heating chamber or the surface of another component within the heating chamber to prevent the aerosol-generating article from moving further into the heating chamber. When the aerosol-generating article is "fully received" within the heating chamber, a portion of the aerosol-generating article may protrude out of the heating chamber opening of the heating chamber. This may be, for example, when the length of the aerosol-generating article is greater than the length of the heating chamber, or when the length of the aerosol-generating article is greater than the distance between the downstream end of the heating chamber and a surface inside the heating chamber that prevents the article from moving further into the heating chamber.

[0011] At least one heater may include all heaters of the device, or all heaters of the device configured to heat at least one aerosol-forming substrate to form an aerosol. A heating zone may be defined by all heaters of the device, or all heaters of the device configured to heat at least one aerosol-forming substrate to form an aerosol. At least one aerosol-forming substrate may include all aerosol-forming materials within the article, or all aerosol-forming materials within the article configured to be heated during a session of use. The only aerosol-forming material within the article may be at least one aerosol-forming substrate. There may be no aerosol-forming materials other than at least one aerosol-forming substrate within the article. The total mass of at least one aerosol-forming substrate may be the total mass of all weights of the aerosol-forming materials within the article, or all weights of the aerosol-forming materials within the article configured to be heated during a session of use.

[0012] According to a second aspect of the present disclosure, an aerosol generating article is also provided. The article may be intended for use in an aerosol generating system such as the system described above or the system of the first aspect. The article may be intended for use in conjunction with an aerosol generating device to generate an aerosol.

[0013] According to a third aspect of the present disclosure, an aerosol generating device is also provided. The device may be intended for use in an aerosol generating system such as the system described above or the system of the first aspect. The device may be intended for use with an aerosol generating article such as an article according to the second aspect, for example, to generate an aerosol.

[0014] Features described in relation to one aspect may be applied to another aspect. For example, features described in relation to an article of a system of the first aspect may be applicable to an article of the second aspect. Similarly, features described in relation to an article of a system of the first aspect may be applicable to a device of the third aspect.

[0015] The system may be configured such that, during use, for example over the course of an entire session of use, at least a portion of at least one aerosol-forming substrate, for example, at least 20 or 30% of the total mass of the aerosol-forming substrate, is not located within the heating zone.

[0016] A heating chamber may define a heating chamber opening. An article may be received within the heating chamber through the heating chamber opening. The heating chamber opening may be substantially rectangular in shape. The area of ​​the heating chamber opening may be 20% or 10% less than the area defined by the width and thickness of the article. When the article is fully received within the heating chamber, the article may be held in place by friction. Advantageously, such friction or tight fit may allow for efficient heat transfer from at least one heater to at least one substrate.

[0017] The heating chamber may have or define at least a partially closed end. The closed end may face the heating chamber opening. The heating chamber may include a stop surface. At least the partially closed end may include a stop surface. The stop surface may prevent the article from being received within the heating chamber beyond a fully received position. When the article is fully received within the heating chamber, the stop surface may be in contact with the article, for example, the upstream end of the article. Advantageously, the use of the stop surface may ensure that a desired percentage of the total mass of the aerosol-forming material is located within the heating zone when the article is fully received within the heating chamber.

[0018] Optionally, at least one heater is or includes at least one substantially flat or planar heater. Optionally, at least one heater includes a heating surface, for example, a substantially flat or planar heating surface. Advantageously, the flat or planar heating surface can efficiently transfer heat to a substantially flat or planar aerosol-forming substrate.

[0019] The heating surface may be defined by the heating surface length and the heating surface width. Optionally, the inner surface of the heating chamber is at least a part of or includes the heating surface. Advantageously, the inner surface of the heating chamber, which is at least a part of or includes the heating surface, may allow contact between the article or substrate and the heating surface or minimize the distance between them. Advantageously, this may allow for efficient heat transfer.

[0020] Optionally, when the aerosol generating article is fully contained within the heating chamber of the aerosol generating device, the length of the heating surface is substantially aligned with the length of the article. Optionally, when the aerosol generating article is fully contained within the heating chamber of the aerosol generating device, the width of the heating surface is substantially aligned with the width of the article. Advantageously, this alignment may allow for efficient heat transfer from at least one heater to the article. Alternatively, or additionally, this alignment may minimize overheating or underheating of the outer periphery of the article or substrate due to at least one heater that extends past or does not reach the outer periphery.

[0021] Optionally, at least one aerosol-forming substrate comprises or is composed of a first aerosol-forming substrate. The first aerosol-forming substrate may have a first substrate length, a first substrate width, and a first substrate thickness, or be defined by these. Optionally, the first substrate length is at least twice the thickness of the first substrate. Optionally, the first substrate width is at least twice the thickness of the first substrate. The first aerosol-forming substrate may be a plug comprising an aerosol-forming material. The first aerosol-forming substrate may be substantially prismatic in shape, for example, a rectangular prism or a cylinder.

[0022] Optionally, when the aerosol generating article is fully accommodated within the heating chamber of the aerosol generating device, the length of the heating surface is substantially aligned with the length of the first substrate. Optionally, when the aerosol generating article is fully accommodated within the heating chamber of the aerosol generating device, the width of the heating surface is substantially aligned with the width of the first substrate. Optionally, when the aerosol generating article is fully accommodated within the heating chamber of the aerosol generating device, the thickness of the first substrate extends in a direction substantially perpendicular to one or both of the length of the heating surface and the width of the heating surface. Advantageously, this alignment may allow for efficient transfer of heat from at least one heater to the first substrate. Alternatively, or additionally, this alignment may minimize overheating or underheating of the outer periphery of the first substrate due to at least one heater that extends past or does not reach the outer periphery.

[0023] Optionally, when the aerosol generating article is fully contained within the heating chamber of the aerosol generating device, at least 30, 40, 50, or 60% of the total mass of at least one aerosol forming material is located within the heating zone. Optionally, when the aerosol generating article is fully contained within the heating chamber of the aerosol generating device, more than 70, 60, 50, or 40% of the total mass of at least one aerosol forming material is not located within the heating zone. Optionally, when the aerosol generating article is completely contained within the heating chamber of the aerosol generating device, the percentage of the total mass of at least one aerosol forming substrate located within the heating zone is: 30 to 80, or 40 to 80, or 50 to 80, or 60 to 80, or 30 to 70, or 40 to 70, or 50 to 70, or 60 to 70, or 30 to 60, or 40 to 60, or 50 to 60, or 30 to 50, or 40 to 50, or 30 to 40%.

[0024] When an aerosol-generating article is fully contained within the heating chamber of an aerosol-generating device, it may be particularly desirable that at least 55%, for example 55 to 70%, of the total mass of at least one aerosol-forming substrate be located within the heating zone. It has been found that this range can provide a short time to the first puff and a suitable delay in the formation of aerosols from the substrate outside the heating zone.

[0025] Optionally, when the aerosol generating article is fully contained within the heating chamber of the aerosol generating device, at least 80 or 90%, e.g. 100%, of the uppermost half of the total mass of at least one aerosol forming material is located within the heating zone. Optionally, when the aerosol generating article is fully contained within the heating chamber of the aerosol generating device, at least 80 or 90%, e.g. 100%, of the uppermost quarter of the total mass of at least one aerosol forming material is located within the heating zone. Optionally, when the aerosol generating article is fully contained within the heating chamber of the aerosol generating device, at least 80 or 90%, e.g. 100%, of the lowermost quarter of the total mass of at least one aerosol forming material is located outside the heating zone. Since a portion of the substrate within the heating zone is most likely to reach its peak temperature during use, it may be desirable to position the upstream portion of the substrate within the heating zone; by selecting this portion as the upstream part, aerosols generated from this portion will have more time and distance to cool before reaching the downstream user. Alternatively, or additionally, warm air or aerosols from the upstream may flow through or past the downstream portion of the substrate. This can advantageously help to heat the downstream portion of the substrate, particularly if that portion is located outside the heating zone.

[0026] Optionally, when the aerosol generating article is fully accommodated within the heating chamber of the aerosol generating device, the uppermost end of any one, two, or all three of at least one heater, heating zone, and heating surface is aligned with a position of 20, 10, or 5 mm or less from the upstream end of at least one aerosol forming substrate. Optionally, the uppermost end of any one, two, or all three of at least one heater, heating zone, and heating surface is substantially aligned with the upstream end of at least one aerosol forming substrate. Optionally, when the aerosol generating article is fully accommodated within the heating chamber of the aerosol generating device, the lowermost end of any one, two, or all three of at least one heater, heating zone, and heating surface is aligned with a position of at least 2, 5, 10, or 20 mm from the downstream end of the aerosol forming substrate. Advantageously, this alignment can allow efficient heat transfer to the substrate by positioning the upstream portion of the substrate within the heating zone and the downstream portion of the substrate outside the heating zone.

[0027] Optionally, when the aerosol generating article is fully contained within the heating chamber of the aerosol generating device, at least 80 or 90%, e.g. 100%, of the lowest half of the total mass of at least one aerosol forming substrate is located within the heating zone. Optionally, when the aerosol generating article is fully contained within the heating chamber of the aerosol generating device, at least 80 or 90%, e.g. 100%, of the lowest quarter of the total mass of at least one aerosol forming substrate is located within the heating zone. Optionally, when the aerosol generating article is fully contained within the heating chamber of the aerosol generating device, at least 80 or 90%, e.g. 100%, of the highest quarter of the total mass of at least one aerosol forming substrate is located outside the heating zone. It may be desirable to place the downstream portion of the substrate in the heating zone because this can reduce the time to the first puff. This may be because there is little to no downstream substrate capable of absorbing heat or aerosol droplets as the generated aerosol flows toward the user. Alternatively, or additionally, cooling air flowing through the article may flow through or past the upstream portion of the substrate. This can advantageously further delay heat diffusion from the downstream portion to the upstream portion. This advantageously allows more aerosol or flavor to form later in the usage session.

[0028] At least one heater may be configured to individually heat a portion of the heating zone, or to individually heat a portion of the heating zone to an operating temperature. At least one heater may be configured to heat a first portion of the heating zone, for example, to heat the first portion of the heating zone to an operating temperature, but not to heat a second portion of the heating zone, for example, not to heat the second portion of the heating zone to an operating temperature during a first stage. At least one heater may be configured to heat a second portion of the heating zone, for example, to heat the second portion of the heating zone to an operating temperature during a second stage. At least one heater may include at least two, three, or five heaters or heating surfaces. Each heater or heating surface may be individually activated or heated to an operating temperature. A first heater or heating surface of at least one heater may be configured to heat a first portion of the heating zone. A second heater or heating surface of at least one heater may be configured to heat a second portion of the heating zone.

[0029] In the context of the above paragraph, the term "operating temperature" may refer to a temperature sufficiently high for an aerosol-forming substrate, for example, an aerosol-forming substrate of an article, to form an aerosol. The term "operating temperature" may refer to a temperature of at least 100, 150, 200, or 250°C. The term "operating temperature" may refer to a temperature of 800, 500, or 300°C or lower. The term "operating temperature" may refer to a temperature of 100 to 800, or 100 to 500, or 100 to 300, or 150 to 800, or 150 to 500, or 150 to 300°C.

[0030] A second stage may follow a first stage. The first stage and the second stage may occur during the same usage session. The first portion may comprise 30 to 70% of the heating zone. The second portion may comprise 30 to 70% of the heating zone.

[0031] Advantageously, the heating portion of the heating zone as described above can further reduce the time to the first puff as a much smaller mass of the substrate is heated initially. Alternatively or additionally, this can cause the aerosol or flavor to develop for a longer period during the usage session as the heating of a portion of the substrate to a temperature high enough to form an aerosol is delayed.

[0032] Optionally, at least one aerosol-forming substrate comprises or is composed of a positionable aerosol-forming substrate. Optionally, the article comprises a cavity, for example, a cavity for the positionable aerosol-forming substrate. Optionally, the positionable aerosol-forming substrate can be positioned within the article, for example, within a cavity of the article. Optionally, the positionable aerosol-forming substrate may be positioned within the aerosol-generating article with respect to at least one other component of the aerosol-generating article, for example, with respect to a cavity of the aerosol-generating article. Advantageously, this allows for adjusting the percentage of the total mass of at least one substrate within the heating zone when the article is fully accommodated within the heating chamber. This may affect aerosol generation during use, for example, the time to the first puff, or the period during which the substrate can continue to produce high-quality aerosols and flavors.

[0033] Optionally, a positionable aerosol-forming material can be positioned by a user within an aerosol-forming article, for example, before the aerosol-generating article is received within a heating chamber. Optionally, the positionable aerosol-forming material can be positioned within the aerosol-generating article to change the percentage of the positionable aerosol-forming material located within the heating zone when the aerosol-generating article is fully received within the heating chamber. Advantageously, this may allow the user to adjust the percentage of the total mass of at least one material within the heating zone when the article is fully received within the heating chamber.

[0034] Optionally, a positionable aerosol-forming substrate can be positioned within an aerosol-generating article at least at a first position and at a second position different from the first position. Optionally, when the aerosol-generating article is fully contained within a heating chamber and the positionable aerosol-forming substrate is at the first position, a first position percentage of the positionable aerosol-forming substrate is located within the heating zone. Optionally, when the aerosol-generating article is fully contained within a heating chamber and the positionable aerosol-forming substrate is at the second position, a second position percentage of the positionable aerosol-forming substrate is located within the heating zone. The first position percentage may differ from the second position percentage. Optionally, the first position percentage differs from the second position percentage by at least 10, 20, or 30%. Advantageously, this allows for adjusting the percentage of the total mass of at least one substrate within the heating zone when the article is fully contained within the heating chamber.

[0035] The article may include a holding means for holding a positionable aerosol-forming substrate at a specific location. For example, the article may include an adhesive region for adhering to the surface of the positionable aerosol-forming substrate. The adhesive region may be located within a cavity of the article or adjacent to a cavity of the article. The adhesive region may be located on a surface defining the boundary of the cavity. The adhesive region may be located on the upper surface of the base of the article. The adhesive region may be larger than the surface area of ​​the positionable aerosol-forming substrate. Advantageously, this may provide an easy method for a user to position the positionable aerosol-forming substrate.

[0036] Optionally, the aerosol generating article comprises at least one indicator configured to indicate a positionable location of the positionable aerosol forming substrate within the aerosol generating article. Advantageously, this can reduce the risk of the positionable substrate being mispositioned.

[0037] Optionally, the aerosol generating article includes at least one indicator configured to indicate that the location of a positionable aerosol forming material within the aerosol generating article, or a change in location, affects the use of the aerosol generating article in the aerosol generating system. Optionally, the aerosol generating article includes at least one indicator configured to indicate how the location of a positionable aerosol forming material within the aerosol generating article, or a change in location, affects the use of the aerosol generating article in the aerosol generating system. Advantageously, this may inform the user of how the location of the positionable material or a change in location may affect the use. Thus, the user may advantageously allow the positionable material to be placed in a location that provides a more desirable experience to the user during use.

[0038] Optionally, the aerosol generator is configured to estimate or determine the location of a positionable aerosol-forming substrate within the aerosol-generating article. Optionally, the aerosol generator is configured to control the heating profile of at least one heater based at least partially on the location of the positionable aerosol-forming substrate within the aerosol-generating article, or the estimated or determined location. Advantageously, this may allow for customization of the experience depending on the location where the substrate is positioned. This may be a simple method for a user to customize their experience.

[0039] A user may input the location of a positionable aerosol-forming substrate into an aerosol generating device. Alternatively, the device may be configured to determine the location of the positionable aerosol-forming substrate within an aerosol generating article in any suitable manner. Those skilled in the art will recognize a suitable method for detecting the location of the positionable aerosol-forming substrate within an article.

[0040] As an example, the substrate may include a tagant, and the device may include a plurality of detectors configured to detect the tagant. The plurality of detectors may be positioned along a heating chamber. The detector or detectors receiving the strongest signal from the tagant may be the one closest to the substrate. Thus, this information may be used to estimate or determine the location of a locable aerosol-forming substrate within an aerosol-generating article. Any suitable tagant may be used.

[0041] As another example, the device may include one or more emitters and one or more photodetectors. One or more emitters and one or more photodetectors may be located around a heating chamber. One or more photodetectors may be located on the side of the heating chamber opposite to one or more emitters. One or more emitters may emit light into the heating chamber after an article is contained within the heating chamber. Analysis of the light detected by one or more photodetectors may indicate the location of a positionable aerosol-forming substrate. For example, each emitter may attempt to shine light through the article to a corresponding opposing photodetector. If a positionable aerosol-forming substrate is located between a given emitter and a corresponding detector, less light from the given emitter may reach the corresponding detector. Thus, analysis of the light detected by the photodetectors may indicate the location of the positionable aerosol-forming substrate.

[0042] According to the above paragraphs, in one aspect of the present disclosure, an aerosol generating article is provided for use with an aerosol generating device, for example, to generate an aerosol. The article comprises: a cavity and a positionable aerosol forming material positionable within the cavity at least two different locations. The article preferably comprises at least one indicator configured to indicate the position of the positionable aerosol forming material within the aerosol generating article, or how a change in position affects the use of the aerosol generating article with the aerosol generating device, particularly preferably.

[0043] Optionally, the aerosol generating article can be accommodated in the heating chamber of the aerosol generating device in at least a first orientation and a second orientation different from the first orientation.

[0044] Optionally, when the aerosol-generating article is fully accommodated in the heating chamber in a first orientation, a first orientation percentage of at least one aerosol-forming substrate is located within the heating zone. Optionally, when the aerosol-generating article is fully accommodated in the heating chamber in a second orientation, a second orientation percentage of at least one aerosol-forming substrate is located within the heating zone. Optionally, the first orientation percentage is different from the second orientation percentage. Optionally, the first orientation percentage is different from the second orientation percentage by at least 10, 20, or 30%. Advantageously, this allows the user to select the percentage of the total mass of at least one substrate within the heating zone when the article is fully accommodated in the heating chamber by selecting the orientation in which the article is accommodated in the heating chamber. This can provide a simple way for the user to customize their experience.

[0045] Optionally, the aerosol generating article includes at least one indicator configured to indicate that it can be accommodated in the heating chamber of the aerosol generating device in at least two different orientations, for example, a first orientation and a second orientation.

[0046] Optionally, the aerosol generating article includes at least one indicator configured to indicate that the orientation in which the aerosol generating article is received within the heating chamber affects the use of the aerosol generating article in the aerosol generating system. Optionally, the aerosol generating article includes at least one indicator configured to indicate how the orientation in which the aerosol generating article is received within the heating chamber affects the use of the aerosol generating article in the aerosol generating system. Advantageously, this may inform the user how the orientation of the article may affect use. Thus, the user advantageously enables the user to orient the article in a manner that provides a more desirable experience to the user during use.

[0047] Optionally, the aerosol generator is configured to determine the orientation in which the aerosol generating article is received within the heating chamber. Optionally, the aerosol generator is configured to determine whether the aerosol generating article is received within the heating chamber in one of the first and second orientations. Optionally, the aerosol generator is configured to control the heating profile of at least one heater based at least partially on the orientation in which the aerosol generating article is received within the heating chamber, or on the determination of the orientation. Advantageously, this may allow for customization of the experience according to the orientation of the article. This may be a simple method for a user to customize their experience.

[0048] The user may input the orientation of the article into the device. Alternatively, the aerosol generating device may be configured to determine the orientation of the aerosol generating article in any suitable manner. Those skilled in the art will recognize a suitable method for detecting the orientation of the article.

[0049] As an example, the article may have a first end at one end of the article length and a second end at the opposite end of the article length. The first and second ends may be interchangeable such that either one is a mouse end and either one is a distal end. The first end may include a first tagant, and the second end may include a second tagant. The first and second tagants may be any suitable tagant, such as a physical or chemical tagant. For example, the first tagant may be a first barcode, and the second tagant may be a second barcode. The device may include a detector. The detector may be configured to detect a tagant at the distal end of the article, for example, after the article has been fully inserted into a heating chamber. Thus, depending on whether the first tagant or the second tagant is detected, the device may determine which of the first end and the second end has been inserted into the heating chamber, and thus determine the orientation of the article.

[0050] According to the above paragraphs, in one aspect of the present disclosure, an aerosol generating article is provided for use with an aerosol generating device, for example, to generate an aerosol. The aerosol generating article is configured to be received in a heating chamber of the aerosol generating device. The article includes at least one indicator configured to indicate that the orientation of the aerosol generating article affects the use of the aerosol generating article with the aerosol generating device, and preferably how it affects it.

[0051] As will be understood by those skilled in the art after reading this disclosure, the article may comprise a positionable aerosol-forming substrate as described above and may be accommodated within the heating chamber of an aerosol generating device in at least a first orientation and a second orientation different from the first orientation as described above. Other features described in relation to the positionable substrate or the orientation of the article may also be applicable. Advantageously, combining these features may provide the user with many more ways to customize or adjust their experience with a single article.

[0052] The following paragraph describes some optional features of an aerosol-generating article. Below, at least one aerosol-forming substrate may be referred to as an aerosol-forming substrate.

[0053] The length of the article may exceed, for example, at least 2, 3, or 5 times the thickness of the article. The width of the article may exceed, for example, at least 2, 3, or 5 times the thickness of the article. The length of the article may be greater than the width of the article. Advantageously, a relatively small article thickness may reduce the temperature gradient across the article or across the substrate of the article during use. This may mean that, compared to a thicker article or substrate, a larger proportion of the substrate can reach a temperature high enough to form an aerosol without a significant risk of burning the substrate.

[0054] The terms height and thickness may be used interchangeably herein. Accordingly, the terms article height and article thickness may be used interchangeably, and the terms substrate height and substrate thickness may be used interchangeably.

[0055] Optionally, the article length extends in the article length direction. Optionally, the article width extends in the article width direction. Optionally, the article thickness extends in the article thickness direction. Optionally, the article length direction is perpendicular to the article width direction. Optionally, the article length direction is perpendicular to the article thickness direction. Optionally, the article width direction is perpendicular to the article thickness direction. Optionally, the article length direction, article width direction, and article thickness direction are mutually perpendicular. The article length direction may be referred to as the x-direction. The article width direction may be referred to as the y-direction. The article thickness direction may be referred to as the z-direction. The article length may extend from the upstream end of the article to the downstream end.

[0056] Optionally, the article is substantially planar in shape. Optionally, the article is substantially rectangular in shape.

[0057] The aerosol-generating article may comprise an upper surface, for example, a substantially flat upper surface. The upper surface may be defined by a length extending in the x-direction, for example, the length of the article, and a width extending in the y-direction, for example, the width of the article. The article may comprise a lower surface, for example, a substantially flat lower surface. The lower surface may be defined by a length extending in the x-direction, for example, the length of the article, and a width extending in the y-direction, for example, the width of the article. The upper surface and the lower surface may be external surfaces of the article. The upper surface and the lower surface may be spaced perpendicularly apart from each other by a height defined in the z-direction, for example, the thickness of the article or the height of the article.

[0058] At least one aerosol-forming substrate may have a substrate length, a substrate width, and a substrate thickness, or these may be defined by them. The substrate length may extend in the substrate length direction. The substrate width may extend in the substrate width direction. The substrate thickness may extend in the substrate thickness direction. The substrate length direction, the substrate width direction, and the substrate thickness direction may be mutually perpendicular. The substrate length may be, for example, at least 2, 3, or 5 times greater than the substrate thickness. The substrate width may be, for example, at least 2, 3, or 5 times greater than the substrate thickness. The substrate length may be greater than the substrate width. Advantageously, a relatively small substrate thickness may reduce the temperature gradient across the substrate during use. This may mean that, compared to a thicker substrate, a larger proportion of the substrate can reach a temperature high enough to form an aerosol without a significant risk of burning the substrate.

[0059] The length of the sheet may extend from an upstream end of the sheet to a downstream end of at least one sheet. The length direction of the sheet may be aligned with or substantially parallel to the length direction of the article. The width direction of the sheet may be aligned with or substantially parallel to the width direction of the article. The thickness direction of the sheet may be aligned with or substantially parallel to the thickness direction of the article.

[0060] The features described in the two paragraphs above with respect to the material may be applied to the previously introduced first material. For example, features regarding the relative size and orientation of the material length, width, and thickness may be applied to the first material length, width, and thickness of the previously introduced first material.

[0061] The aerosol generating article according to the present disclosure may preferably be a substantially flat article or a substantially planar article. Such an article may have a large base area relative to the volume of the article. In particular, the height of the aerosol generating article may be less than 50% or 25% of both the length and width of the aerosol generating 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 substrate closest to the heater burning while enabling a greater proportion of the aerosol-forming substrate of the aerosol generating article to be heated to the temperature at which the aerosol is emitted. Alternatively or additionally, this can reduce the time required to heat the aerosol-forming substrate sufficiently to release the aerosol.

[0062] An aerosol generating article 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, e.g., 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, e.g., 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 enables excellent airflow management and allows aerosols to be extracted more efficiently from the aerosol generating article and delivered to the user.

[0063] 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 volumetric flow rate of about 17.5 mm / s at the output or downstream end of the component, measured at a temperature of about 22°C, a pressure of about 101 kPa (about 760 Torr), and a relative humidity of about 60%.

[0064] The aerosol generating article may comprise substantially planar upper and lower surfaces. 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. One or both of the substantially planar upper and lower surfaces may comprise an aerosol-forming substrate. The aerosol generating article may comprise upper and lower layers, wherein the upper layer forms a substantially planar upper surface and the lower layer forms a substantially planar lower surface. One or both of the upper and lower layers may comprise or be made of an aerosol-forming substrate. In this case, at least one aerosol-forming substrate may comprise one or both of the substantially planar upper and lower layers.

[0065] The aerosol generating article may include a first planar layer, a second planar layer, and a wavy layer arranged between the first planar layer and the second planar layer. At least one of the first planar layer, the second planar layer, and the wavy layer may include or be made of an aerosol-forming material. In this case, at least one aerosol-forming substrate may include at least one of the first planar layer, the second planar layer, and the wavy layer.

[0066] The use of a corrugated structure within an aerosol-generating article makes it advantageous to produce an aerosol-generating article that has 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.

[0067] An aerosol generating article may comprise a first outer surface, a second outer surface, a cavity, and a frame. One or both of the first and second outer surfaces may be planar. A frame may be located between the first outer surface and the second outer surface. The frame may define the cavity at least partially. The aerosol generating article may comprise an air inlet, an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity.

[0068] Preferably, at least one aerosol-forming substrate is located between the first outer surface and the second outer surface.

[0069] The frame may include a periphery wall surface that at least partially surrounds or encloses the cavity. The frame may include a periphery wall surface that completely surrounds or encloses the cavity. Advantageously, the frame can make the aerosol-generating article relatively thin while maintaining structural rigidity.

[0070] The aerosol generating article may include a first outer layer and a second outer layer, wherein the first outer layer forms a first outer surface and the second outer layer forms a second outer surface. Optionally, at least one of the first outer layer, the second outer layer, and the frame may include or be made of an aerosol-forming material. In such a case, at least one aerosol-forming substrate may include at least one of the first outer layer, the second outer layer, and the frame.

[0071] The cavity may be substantially empty. Therefore, at least one aerosol-forming material may be located outside the cavity.

[0072] Alternatively, at least one aerosol-forming substrate may be located within the cavity.

[0073] A wavy layer or element can be located within the cavity.

[0074] The frame may be a flat frame. The frame may have a height of 50% to 95% of the height of the aerosol-generating article. The frame may have a height of 60% to 95% of the height of the aerosol-generating article. The frame may have a height of 70% to 95% of the height of the aerosol-generating article. The frame may have a height of 80% to 95% of the height of the aerosol-generating article.

[0075] The frame may have a height of 1 mm to 5.5 mm. The frame may have a height of 1 mm to 5 mm. Preferably, the frame may have a height of 1.5 mm to 5 mm.

[0076] The frame may be manufactured from or contain biodegradable materials. The frame may be manufactured entirely from biodegradable materials.

[0077] The frame may be manufactured from or contain a cellulose material. The cellulose material may contain a sheet of cellulose material. The cellulose material may contain cellulose fibers. The cellulose material may be paper, cardboard, or cardboard. The frame may be manufactured from or contain a plant material such as tobacco. The frame may be manufactured entirely from a cellulose material.

[0078] The frame may be a single component. Alternatively, the frame may include two or more layers. That is, the frame may have a stacked structure.

[0079] The length of the article (e.g., x dimension) may be 10 mm to 100 mm, or 10 mm to 50 mm, for example 10 mm to 40 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.

[0080] The width of the article (e.g., y dimension) may be 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.

[0081] The height of the article (e.g., z-dimension) may be 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.

[0082] When viewed in a planar view, the aerosol generating article may have a shape defining a polygon, a square (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof. If the aerosol generating article comprises upper and lower surfaces that are substantially planar, when viewed in a planar view, one or both of the upper and lower surfaces may have a shape defining a polygon, a square (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. If the aerosol generating article comprises upper and lower surfaces that are substantially planar, 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 square (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof.

[0083] An aerosol-generating article may be entirely composed of an aerosol-forming substrate. Alternatively, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-forming article.

[0084] The aerosol-forming material may contain nicotine. Nicotine may exist in the form of a tobacco substance or in the form of a nicotine extract.

[0085] At least one aerosol-forming substrate may include one or more organic materials such as tobacco, mint, tea, and cloves. At least one aerosol-forming substrate may include one or more of herb leaves, tobacco leaves, tobacco rib pieces, reconstituted tobacco, homogenized tobacco such as cast leaves, extruded tobacco, puffed tobacco, aerosol-generating films, and gel compositions.

[0086] At least one aerosol-forming substrate may include or be made of a homogenized tobacco material, for example, a reconstituted tobacco material or a cast leaf tobacco material.

[0087] At least one aerosol-forming substrate may be in the form of a crushed aerosol-generating material. The crushed aerosol-generating material may include: one or more strips and strands of the aerosol-generating material, such as strips and strands of tobacco or homogenized tobacco material. The crushed aerosol-generating material may be in the form of a crushed sheet of homogenized tobacco material.

[0088] At least one aerosol-forming material may be a cut-filler. At least one aerosol-forming material may be a tobacco cut-filler. The cut-filler may include one or more of bright tobacco, dark tobacco, flavored tobacco, and filler tobacco. Examples of bright tobacco are Brazilian yellow, Indian yellow, Chinese yellow, American yellow tobacco such as Virginia tobacco, and Tanzanian yellow tobacco. Examples of flavored tobacco include Oriental Turkish tobacco, Greek Oriental tobacco, and semi-Oriental tobacco, as well as American Burley smoked tobacco such as Perique and Rustica. Examples of dark tobacco are fumigated Brazilian Gaufão, Burley Malawi or other African Burley, and sun-dried or air-dried Indonesian Kasturi. As used herein, the term “cut-filler” is used to describe a blend of shredded plant material, such as tobacco plant material and homogenized plant material, comprising one or more of leaf blades, processed stems, and ribs.

[0089] At least one aerosol-forming substrate may be in the form of a sheet of aerosol-generating material. As used herein, the term “sheet” describes a laminated element in which the width and length are substantially greater than the thickness. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenized tobacco material, such as a cast leaf sheet.

[0090] At least one aerosol-forming substrate may comprise a combined aggregate of strips, strands, or particles of tobacco material. The aerosol-forming substrate may be in the form of a compressed plug of tobacco material, for example, a plug having a substantially circular cross-section in the initial state of the plug is compressed into a flatter cross-sectional profile in a subsequent state of the plug. The tobacco material may be surrounded by a wrapper. At least one aerosol-forming substrate may be in the form of strips, strands, or particles of tobacco material bonded together in a binder matrix.

[0091] At least one aerosol-forming substrate 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 preferable that the aerosol-forming agent is one or both of glycerin and propylene glycol, or comprises them. The aerosol-forming agent may consist of glycerin or propylene glycol, or a combination of glycerin and propylene glycol.

[0092] At least one aerosol-forming substrate may have an aerosol-forming agent content of 1, 2, 5, 10, or 15 weight% or more based on dry weight. The aerosol-forming substrate may have an aerosol-forming agent content of 15 weight% or more based on dry weight, for example, more than 20 weight% based on dry weight, or more than 25 weight% based on dry weight, or more than 30 weight% based on dry weight, or more than 40 weight% based on dry weight, or more than 50 weight% based on dry weight.

[0093] At least one 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 based on dry weight. That is, the aerosol-generating material may have an aerosol-forming agent content of 30% by weight or less, 25% by weight or less based on dry weight, or 20% by weight or less based on dry weight.

[0094] At least one aerosol-forming substrate may have an aerosol-forming agent content of 1% to 30% by weight based on dry weight, 1% to 25% by weight based on dry weight, or 1% to 20% by weight based on dry weight.

[0095] At least one 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.

[0096] At least one aerosol-forming substrate may comprise 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.

[0097] At least one 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.

[0098] At least one aerosol-forming substrate may include nicotine. At least one aerosol-forming substrate may include natural nicotine, synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0099] At least one 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.

[0100] At least one 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 substances. 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, thyme, and caraway, and other herbal materials derived from herb leaves or herbal plants. One or more flavoring agents may include tobacco substances.

[0101] At least one aerosol-forming substrate may include one or more plant components. For example, the aerosol-forming substrate may include about 1 to 90%, for example 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, rooibos, star anise, thyme, anethum, chamomile, and compounds thereof.

[0102] At least one 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.

[0103] At least one 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.

[0104] At least one aerosol-forming substrate may comprise or be made of a solid aerosol-forming material. The aerosol-forming substrate may comprise a liquid aerosol-forming material, for example, a liquid aerosol-forming material retained within a porous matrix. The aerosol-forming substrate may comprise a gel aerosol-forming material.

[0105] According to the present disclosure, an aerosol generating device is provided. The device may be intended to accommodate, for example, an aerosol generating article as disclosed herein, or, for example, an aerosol forming substrate as disclosed herein. The device may be intended for use in the aforementioned system or in the system of the first aspect.

[0106] The heating chamber may be dimensioned to accommodate at least a portion of an aerosol generating article or an aerosol forming substrate. The device may include at least one heater, a power source for supplying power to at least one heater, and a controller for controlling the power supply to at least one heater. The aerosol generating device may be configured to heat at least one aerosol forming substrate of the article when in use.

[0107] The aerosol generating device may preferably be configured to accommodate the entire aerosol generating article so that the aerosol generating article is entirely surrounded within the aerosol generating device.

[0108] The heating chamber may include the aforementioned heating chamber opening. The heating chamber may have a length extending in the lengthwise direction of the heating chamber. The distal end of the aerosol-generating article may be inserted into the heating chamber opening, for example, in the lengthwise direction of the heating chamber. The heating chamber may have any suitable cross-sectional shape. For example, the heating chamber may have a rectangular cross section, for example, a rectangular cross section having opposing top and bottom sides that are longer than the left and right sides.

[0109] Preferably, at least one inner surface of the heating chamber is a heating surface configured to heat an aerosol generating article. The heating surface may include at least one heater, for example, a resistance heater or an infrared heater, or a susceptor configured to be heated by engagement with an inductor. The heating surface may include an inductor, and for example, the surface may include a coil disposed to generate a fluctuating electromagnetic field within the cavity. The heating surface may be a surface permeable to the fluctuating electromagnetic field so that an inductor disposed outside the cavity can project the fluctuating electromagnetic field through the heating surface and engage with a susceptor disposed inside the cavity.

[0110] According to the present disclosure, a method of using an aerosol forming system, for example, a system as described above or according to a first aspect, is provided. The method may include a step corresponding to any of the aforementioned features, for example, any feature described in relation to any of the aforementioned systems, articles, or devices.

[0111] The above method may include the step of inserting an aerosol-generating article into a heating chamber such that the aerosol-generating article is completely contained within the heating chamber and 20 to 80% of the total mass of at least one aerosol-forming substrate is located within the heating zone.

[0112] The above method may include the step of forming an aerosol from at least one aerosol-forming substrate by heating at least a portion of a heating zone to an operating temperature with at least one heater.

[0113] The above method may include, during the first step, a step of heating a first portion of a heating zone to an operating temperature with at least one heater to form an aerosol, for example, from at least one aerosol-forming substrate. The above method may include, during the second step after the first step, a step of heating a second portion of a heating zone to an operating temperature with at least one heater to form an aerosol, for example, from at least one aerosol-forming substrate. The above method may include, during the third step after the second step, a step of heating a third portion of a heating zone to an operating temperature with at least one heater to form an aerosol, for example, from at least one aerosol-forming substrate. Features presented in relation to the first, second, and third steps when discussing the system may be applicable to the first, second, and third steps of this method. Similarly, features presented regarding the operating temperature when discussing the system may be applicable to the operating temperature of this method.

[0114] As used herein, the term "aerosol generating article" may refer to an article capable of generating or releasing aerosols.

[0115] 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.

[0116] 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.

[0117] 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.

[0118] 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.

[0119] As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salt.

[0120] 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.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] 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.

[0125] 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.

[0126] As used herein, the term “heating zone” may refer to a portion of a heating chamber aligned with the heater or heating surface of at least one heater. This alignment may be parallel to the thickness direction of the article when the article is fully accommodated within the heating chamber. The heating zone may be a single continuous zone. Alternatively, the heating zone may comprise a plurality of separate zones.

[0127] As used herein, the term “use session” may refer to a period or session in which a plurality of puffs are applied by a user to an aerosol generating system to extract an aerosol from an aerosol forming substrate. The use session may be a finite use session, and it is a use session having a start and an end. The duration of the use session, measured by time, may be affected by use during the use session. The duration of the use session may have a maximum duration determined by the maximum time from the start of the use session. The duration of the use session may be shorter than the maximum time if one or more monitored parameters reach a predetermined threshold before the maximum time from the start of the use session. As an example, one or more monitored parameters may include one or more of i) the cumulative puff count of a series of puffs inhaled by the user since the start of the use session, and ii) the cumulative volume of aerosol produced from the aerosol forming substrate since the start of the use session. The use session may include at least two or five puffs to the system. A usage session may include 20 or 15 or fewer puffs in the system. A usage session may last for at least 2 minutes or 5 minutes. A usage session may last for 20 or 15 minutes or fewer.

[0128] 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.

[0129] Example Ex1. As an aerosol generating system, the aerosol generating article and the aerosol generating device are included,

[0130] The above-mentioned aerosol generating article comprises at least one aerosol-forming substrate;

[0131] The above aerosol-generating article is defined by the article length, article width, and article thickness, wherein the article length and the article width are at least twice the article thickness;

[0132] The above aerosol generating device includes a heating chamber for accommodating at least a portion of the aerosol generating article;

[0133] The aerosol generating device includes at least one heater, wherein the at least one heater defines a heating zone within the heating chamber;

[0134] An aerosol generating system in which, when the aerosol generating article is completely contained within the heating chamber of the aerosol generating device, 20 to 80% of the total mass of the at least one aerosol forming substrate is located within the heating zone.

[0135] Example Ex2. In any one of the prior embodiments, the at least one heater comprises a substantially flat heating surface, wherein the heating surface is defined by a heating surface length and a heating surface width, an aerosol generating system.

[0136] Example Ex3. An aerosol generating system in Example Ex2, wherein the inner surface of the heating chamber is at least a part of the heating surface or includes the same.

[0137] Example Ex4. An aerosol generating system in Example Ex2 or Ex3, wherein when the aerosol generating article is fully accommodated within the heating chamber of the aerosol generating device, the heating surface length is substantially aligned with the length of the article and the heating surface width is substantially aligned with the width of the article.

[0138] Example Ex5. An aerosol generating system, wherein in any one of the prior embodiments, the at least one aerosol forming substrate comprises or is composed of a first aerosol forming substrate defined by a first substrate length, a first substrate width, and a first substrate thickness, and the first substrate length and the first substrate width are at least twice the thickness of the first substrate.

[0139] Example Ex6. An aerosol generating system in Example Ex5, wherein, when dependent on Example Ex2, the aerosol generating article is fully accommodated within the heating chamber of the aerosol generating device, the heating surface length is substantially aligned with the first substrate length and the heating surface width is substantially aligned with the first substrate width.

[0140] Example Ex7. An aerosol generating system, wherein in any one of the prior embodiments, when the aerosol generating article is fully accommodated within the heating chamber of the aerosol generating device, the uppermost end of the at least one heater or heating zone is aligned with a position of 20, 10, or 5 mm or less from the upstream end of the at least one aerosol forming substrate.

[0141] Example Ex8. An aerosol generating system in any one of the prior embodiments, wherein when the aerosol generating article is fully accommodated within the heating chamber of the aerosol generating device, the downstream end of the at least one heater or heating zone is aligned with a position of at least 2, 5, 10, or 20 mm from the downstream end of the aerosol forming substrate.

[0142] Example Ex9. An aerosol generating system in Example Ex5 or Ex6, wherein, when dependent on Example Ex2, the aerosol generating article is fully contained within the heating chamber of the aerosol generating device, the uppermost end of the heating surface is aligned with a position of 20, 10, or 5 mm or less from the upstream end of the at least one aerosol forming substrate.

[0143] Example Ex10. An aerosol generating system in Example Ex9, wherein the uppermost end of the heating surface is substantially aligned with the upstream end of the at least one aerosol forming substrate.

[0144] Example Ex11. An aerosol generating system in any one of Examples Ex5 to Ex10 when dependent on Example Ex2, wherein when the aerosol generating article is completely contained within the heating chamber of the aerosol generating device, the downstream end of the heating surface is aligned with a position of at least 2, 5, 10, or 20 mm from the downstream end of the at least one aerosol forming substrate.

[0145] Example Ex12. An aerosol generating system in any one of the prior embodiments, wherein when the aerosol generating article is completely contained within the heating chamber of the aerosol generating device, 50 to 70% of the total mass of the at least one aerosol forming substrate is located within the heating zone.

[0146] Example Ex13. An aerosol generating system in any one of the prior embodiments, wherein the at least one aerosol forming substrate comprises or is composed of a positionable aerosol forming substrate positionable within the aerosol generating article.

[0147] Example Ex14. An aerosol generation system in Example Ex13, wherein the positionable aerosol forming substrate is positionable by a user within the aerosol forming article, for example, before the aerosol generating article is received within the heating chamber, thereby changing the percentage of the positionable aerosol forming substrate positioned within the heating zone when the aerosol generating article is fully received within the heating chamber.

[0148] Example Ex15. In Example Ex13 or Ex14, the positionable aerosol-forming substrate is positionable within the aerosol-generating article at least at a first position and at a second position different from the first position, and optionally,

[0149] When the aerosol generating article is completely contained within the heating chamber and the positionable aerosol forming substrate is at the first position, the first position percentage of the positionable aerosol forming substrate is located within the heating zone; and

[0150] When the aerosol generating article is completely contained within the heating chamber and the positionable aerosol forming material is at the second position, the percentage of the second position of the positionable aerosol forming material is located within the heating zone, and

[0151] Here, the first position percentage is different from the second position percentage, in an aerosol generating system.

[0152] Example Ex16. An aerosol generating system in Example Ex15, wherein the first position percentage differs from the second position percentage by at least 10, 20, or 30%.

[0153] Example Ex17. In any one of the prior embodiments, the aerosol generating article comprises at least one indicator configured such that the positionable aerosol forming substrate indicates a positionable location within the aerosol generating article.

[0154] Example Ex18. In any one of the prior embodiments, the aerosol generating article comprises at least one indicator configured to indicate that the position or positional change of a positionable aerosol forming material within the aerosol generating article affects the use of the aerosol generating article in the aerosol generating system.

[0155] Example Ex19. In Example Ex18, the aerosol generating system comprises at least one indicator configured to indicate the location of a positionable aerosol forming substrate within the aerosol generating article, or how a change in location affects the use of the aerosol generating article in the aerosol generating system.

[0156] Example Ex20. An aerosol generation system in any one of Examples Ex13 to Ex19, wherein the aerosol generating device is configured to determine the position of the positionable aerosol forming substrate of the aerosol generating article.

[0157] Example Ex21. In any one of the prior embodiments, the aerosol generating device is configured to control the heating profile of the at least one heater based at least partially on the determination of the position of a positionable aerosol forming substrate within the aerosol generating article.

[0158] Example Ex22. In any one of the prior embodiments, the aerosol generating article is accommodated in the heating chamber of the aerosol generating device in at least a first orientation and a second orientation different from the first orientation, in an aerosol generating system.

[0159] Example Ex23. In Example Ex22,

[0160] When the above aerosol generating article is completely accommodated in the heating chamber in the above first orientation, the percentage of the first orientation of the at least one aerosol forming substrate is located within the heating zone; and

[0161] When the above aerosol generating article is completely accommodated in the heating chamber in the above second orientation, the percentage of the second orientation of the at least one aerosol forming substrate is located within the heating zone, and

[0162] Here, the first orientation percentage is different from the second orientation percentage, in an aerosol generating system.

[0163] Example Ex24. An aerosol generating system in Example Ex23, wherein the first orientation percentage differs from the second orientation percentage by at least 10%, 20%, or 30%.

[0164] Example Ex25. An aerosol generating system, wherein in any one of Examples Ex22 to Ex24, the aerosol generating article comprises at least one indicator configured to indicate that the aerosol generating article can be accommodated in the heating chamber of the aerosol generating device in at least two different orientations, for example, the first orientation and the second orientation.

[0165] Example Ex26. In any one of the prior embodiments, the aerosol generating system comprises at least one indicator configured to indicate that the orientation in which the aerosol generating article is received within the heating chamber affects the use of the aerosol generating article within the aerosol generating system.

[0166] Example Ex27. In Example Ex26, the aerosol generating system comprises at least one indicator configured to indicate how the orientation in which the aerosol generating article is received within the heating chamber affects the use of the aerosol generating article in the aerosol generating system.

[0167] Example Ex28. In any one of the prior embodiments, the aerosol generating article is configured to determine the orientation in which the aerosol generating article is received within the heating chamber, an aerosol generating system.

[0168] Example Ex29. In any one of the prior embodiments, the aerosol generating device is configured to control the heating profile of the at least one heater based at least partially on the orientation in which the aerosol generating article is received within the heating chamber, or on the determination of the orientation.

[0169] Example Ex30. An aerosol generating article for use with an aerosol generating device, wherein the aerosol generating article comprises: a cavity; a positionable aerosol forming substrate positionable within the cavity at least two different positions; and at least one indicator configured to indicate that the position or positional change of the positionable aerosol forming substrate within the aerosol generating article affects the use of the aerosol generating article with the aerosol generating device.

[0170] Example Ex31. An aerosol generating article for use with an aerosol generating device, wherein the aerosol generating article is configured to be received within a heating chamber of the aerosol generating device, and the aerosol generating article comprises at least one indicator configured to indicate that the orientation of the aerosol generating article affects the use of the aerosol generating article with the aerosol generating device, and preferably how it affects. Brief explanation of the drawing

[0171] Now, embodiments 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 an exploded perspective view of an aerosol generating article according to a fourth embodiment of the present disclosure; FIG. 8 shows a perspective view of the aerosol-generating article of FIG. 7; FIG. 9 shows a partially 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; FIG. 11 shows a schematic longitudinal cross-sectional view of the aerosol-generating article of FIG. 7; FIG. 12 shows an exploded perspective view of an aerosol generating article according to a fifth embodiment of the present invention; FIG. 13 shows a schematic cross-sectional view of the aerosol-generating article of FIG. 12; FIG. 14 shows a schematic side cross-sectional view of the aerosol-generating article of FIG. 12; FIG. 15 shows a schematic diagram of an aerosol generating device according to one embodiment of the present disclosure, wherein the device is configured to engage with an aerosol generating article, for example, an aerosol generating article of any one of FIG. 1 to FIG. 14; FIG. 16 shows a schematic end view of the aerosol generator of FIG. 15; FIG. 17 is a schematic diagram showing an aerosol generating article (e.g., an aerosol generating article of any one of FIG. 1 to FIG. 14) that engages with the aerosol generating device of FIG. 15. FIG. 18 is a schematic diagram of an alternative embodiment of FIG. 15 to 17, showing an aerosol generating article coupled with an aerosol generating device. Specific details for implementing the invention

[0172] 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.

[0173] The aerosol generating article (100) comprises an aerosol forming substrate (not shown). In one embodiment, the aerosol generating article (100) may be substantially composed of an aerosol forming substrate. In another embodiment, the aerosol forming substrate may be one of a plurality of component parts of the aerosol generating article (100). The aerosol forming substrate may be surrounded inside 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 comprise or be made of the aerosol forming substrate.

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

[0175] 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).

[0176] 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, but start with the number 2 instead of the number 1. An airflow path (230) is defined through the aerosol generating article (200) between the upper surface and the lower surface (210, 220). The airflow path (230) extends between opposing first and second ends (201, 202) of the aerosol generating article (200). The first end (201) may define the distal end of the aerosol generating article (200), and the second end (202) may define the proximal or mouse 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).

[0177] 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).

[0178] The flat upper layer (310) is formed from a paper sheet having a thickness of 300 μm. The flat lower layer (320) is formed from a paper sheet having a thickness of 300 μm. The middle layer (340) is a wavy element formed from a wavy sheet of an aerosol-forming substrate (345). A suitable aerosol-forming substrate may be a homogenized tobacco. Thus, the middle layer (340) may be formed from a wavy sheet of a homogenized tobacco material (345).

[0179] FIG. 6 illustrates a wavy sheet of an aerosol-forming substrate (345). The wavy lines have an amplitude (346) of 3 mm and a wavelength (347) of 3 mm. The sheet of the aerosol-forming substrate (345) forming the intermediate layer (340) has a thickness of 150 μm.

[0180] The intersections (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.

[0181] 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.

[0182] The wavy folds of the intermediate layer (340) form a first set of longitudinally extending channels (361) bounded by the upper layer (310) and the intermediate layer (340), and a second set of longitudinally extending 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 aerosol-forming substrate between the proximal end (371) of the substrate (345) and the distal end (372) of the substrate (345). The longitudinally extending channels (361, 362) define an airflow path passing through the substrate (345). Thus, the airflow path passes through both sides of the sheet of the aerosol-forming substrate (345). The porosity of the aerosol-generating article along the airflow path is in the 90% region. This provides a very low resistance to inhalation (RTD) of less than 5 mm H2O. In fact, the RTD is close to 0.

[0183] The aerosol-forming substrate (345) may be any suitable aerosol-forming substrate sheet.

[0184] During use of the aerosol generating article (300), the aerosol forming substrate (345) is heated to cause the aerosol forming substrate (345) to release a volatile compound, which is then entrained in air drawn into the channels (361, 362) through the distal end (372). Then, the volatile compound is cooled and condensed to form an aerosol that can be drawn from the channels (361, 362) of the aerosol generating article (300) through the proximal end (371).

[0185] FIG. 7 shows an exploded perspective view of an aerosol generating article (400) according to a fourth embodiment of the present disclosure. The aerosol generating article (400) comprises a first planar outer layer (424) forming a first planar outer surface (421), a second planar outer layer (425) forming a second planar outer surface (422), and a frame (450) positioned between the first planar outer layer (424) and the second planar outer layer (425). The second planar outer surface (422) is positioned parallel to the first planar outer surface (421). The first planar outer layer (424) is optional but is present in the present embodiment. The frame (450) surrounds and at least partially defines the cavity (430). The article also comprises a substantially rectangular plug of an aerosol generating substrate (440). On the upper surface of the second planar outer layer (425), there is a first indicator (470), a second indicator (472), and an adhesive area (474) between them.

[0186] The adhesive region (474) is a substantially rectangular area of ​​adhesive for bonding to the plug of the aerosol-forming substrate (440). The adhesive region (474) has a width or y dimension approximately equal to the plug of the aerosol-forming substrate (440), but has a length or x dimension greater than the length of the plug of the aerosol-forming substrate (440). The article (400) is supplied to the user with the second planar outer layer (425) in physical contact with and bonded to the frame (450), but the first planar outer layer (424) and the plug of the aerosol-forming substrate (440) separated. Thus, the user can position the plug of the aerosol-forming substrate (440) on the adhesive region (474) at a desired location within the cavity (430), and then optionally attach the first planar outer layer (424) to the frame (450), for example with a suitable adhesive, to make the article (400) available for immediate use.

[0187] In this embodiment, the first indicator (470) is printed on the second planar outer layer (425) and read as "insertion end." For a more intense experience, the material is positioned closer to this end. In this embodiment, the second indicator (470) is printed on the second planar outer layer (425) and read as "mouse end." For a milder experience, the material is positioned closer to this end. Thus, the first and second indicators indicate how the position of the aerosol-forming material (440) within the aerosol-generating article (400) affects the use of the aerosol-generating article (400).

[0188] During use, the experience can be fundamentally altered by the position of the substrate within the article. This is because, when the article is housed within the device's heating chamber, the position of the substrate can affect how much of the substrate is located within the device's heating zone for use with the article. As an example of how the experience can differ, if a smaller portion of the substrate is in the device's heating zone, less of the substrate may be heated directly, while a larger portion may rely on conduction through the substrate to reach a temperature high enough to form an aerosol. This can cause the substrate to deplete less rapidly, resulting in a milder experience.

[0189] In the case of an article similar to that illustrated in FIG. 7, for example, where the article must be accommodated in only one orientation within the heating chamber of the device, or where the article can be accommodated in multiple orientations within the heating chamber of the device, but these orientations do not affect the amount of material within the heating zone, the experience may essentially be altered by the position of the material within the article. If the article must be inserted into the device in one specific orientation, the former option may be the case of the article illustrated in FIG. 7. The latter option may be the case of the article illustrated in FIG. 7 where the article has fixed upstream and downstream ends but can still be accommodated in the heating chamber in at least two orientations—the illustrated orientation and an orientation in which the article is rotated 180 degrees around the x-axis from the illustrated orientation.

[0190] Alternatively, or additionally, regarding an experience that is essentially altered by the location of the material within the article, the device may determine or estimate the location of the material (440), or the user may input the location of the material (440) into the device, and then the device may select a heating profile for one or more heaters of the device to alter the experience based at least partially on the location of the material (440).

[0191] The first planar outer layer (424) and the second planar outer layer (425) are made of cigarette paper having a thickness of 35 μm. The second planar outer layer (425) can be physically in contact with and bonded to the frame (450). The first planar outer layer (424) is optional and can be placed in contact with and bonded to the frame (450) by, for example, the user after positioning the plug of the aerosol-forming substrate (440) in the cavity (430) as will be discussed in more detail later. Then, the first planar outer layer (424) is placed over the first upper end of the cavity (430) and forms the first cavity end wall. The second planar outer layer (425) is placed over the second lower end of the cavity (430) and forms the second cavity end wall, and the second cavity end wall faces the first cavity end wall. That is, the frame (450), the first planar outer layer (424), and the second planar outer layer (425) collectively define the boundaries of the cavity (430). If the first planar outer layer (424) is not present, the cavity would be an open cavity that is not bordered by the first planar outer layer (424) in the embodiment shown in FIG. 7.

[0192] The frame (450) has a hollow rectangular shape and is made of cardboard. The frame (450) defines a perforation extending through the height (also referred to as thickness) of the frame (450), and the perforation forms at least partially a cavity (430) of the aerosol generating article (400). The frame (450) includes a periphery wall (451) surrounding the cavity (430). The periphery wall (451) includes a front wall (413) and a rear wall (414). More specifically, the periphery wall (451) is defined by an inner transverse surface (452) of the frame (450) and an outer transverse surface (453) of the frame (450). The inner transverse surface (452) of the periphery wall (451) defines at least partially the periphery of the cavity (430). The outer transverse surface (453) of the periphery wall (451) defines at least partially the periphery of the aerosol generating article (400). The periphery wall (451) has a radial thickness of about 5 mm measured between the inner transverse surface (452) of the frame (450) and the outer transverse surface (453) of the frame (450).

[0193] The air inlet (411) and the air outlet (412) are defined by and extend through the peripheral wall surface (451) of the frame (450). More specifically, the air inlet (411) extends through the front wall surface (413) and the air outlet (412) extends through the rear wall surface (414). The air inlet (411) and the air outlet (412) have an equivalent diameter of 5 mm. An airflow passage extends through a cavity (430) between the air inlet (411) and the air outlet (412). As illustrated in FIGS. 9 through 11, an aerosol-forming substrate (440) is located within the cavity (430). The aerosol-forming substrate (440) comprises an aerosol-generating material in the form of a homogenized tobacco-containing material and has an aerosol-forming agent content of 5% by weight based on dry weight. As described, the aerosol-forming substrate (440) fills part of the volume of the cavity (430).

[0194] On the outer surface of the peripheral wall surface (451) of the frame (450), the surface is in the xz plane near the end having the first air aperture.

[0195] The aerosol generating article (400) 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 (421) and the second planar outer surface (422). The frame (450) 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 (430) has a height (or thickness) of 7.93 mm extending in the z-dimension, a width of 30 mm extending in the y-dimension, and a length of 50 mm extending in the x-dimension.

[0196] FIG. 8 illustrates an article (400) after the first and second planar outer layers (424, 425) are joined to the frame (450) and the article (400) is ready for use.

[0197] FIG. 9 illustrates an article (400) after the second planar outer layer (425) is bonded to the lower surface of the frame (450) and the substrate (440) is placed on the adhesive layer (474) and attached thereto. However, the first planar outer layer (424) is not bonded to the upper surface of the frame (450). This is optional. The first planar outer layer (424) may be discarded or bonded to the upper surface of the frame (450) at this point. In this embodiment, the plug of the aerosol-forming substrate (440) is positioned closer to the first indicator (470) than to the second indicator (472).

[0198] FIGS. 10 and FIGS. 11 illustrate respective transverse and longitudinal cross-sectional views of an aerosol generating article (400) when the cavity (430) contains an aerosol forming substrate (440).

[0199] FIG. 12 shows an aerosol generating article (500) according to a fifth embodiment of the present disclosure. Features common to the aerosol generating article (400) are referred to by similar reference numerals, but start with the number 5 instead of the number 4. The aerosol generating article (500) differs from the aerosol generating article (400) in that the aerosol forming substrate is in the form of a sheet of aerosol generating material (540), particularly a wavy sheet of homogenized tobacco material, and there are no first and second indicators (470, 472) or an adhesive region (474). The aerosol generating article (500) also differs from the aerosol generating article (400) in that there are a third indicator (580) and a fourth indicator (582) on the peripheral wall surface of the frame (550). FIGS. 13 and FIGS. 14 show the respective cross-sectional and lateral cross-sectional views of the aerosol generating article (500) of FIG. 12.

[0200] The wavy sheet of the homogenized tobacco material (540) comprises a plurality of parallel wavy lines having a plurality of substantially parallel peaks (543) and troughs (544). The plurality of parallel wavy lines are defined by a wavy line profile that is in the form of a sinusoidal wave, as shown in FIG. 13. The plurality of parallel wavy lines have a wavy line wavelength of about 4.6 mm. The wavy line amplitude is approximately equal to the height (or thickness) of the cavity (430), as can be seen from the fact that the peaks (543) and troughs (544) correspond to the first cavity end wall (531) and the second cavity end wall (532), respectively.

[0201] A plurality of parallel wavy folds form a plurality of channels (545) between the sheet of aerosol generating material (540) and the first cavity end wall (531), and a plurality of channels (546) between the sheet of aerosol generating material (540) and the second cavity end wall (532). The plurality of channels (545, 546) extend in the longitudinal direction of the aerosol generating article (500) and form at least a portion of an airflow passage extending between the air inlet (511) and the air outlet (512).

[0202] The article (500) is substantially symmetrical from a structural perspective. This means that one end of the article (500) can function as an upstream end and the other end can function as a downstream end. Accordingly, the air inlet and air outlet can be reversed depending on the orientation in which the article (500) is accommodated within the heating chamber of the device.

[0203] The frame (550) includes a third indicator (580) and a fourth indicator (582). The third indicator (580) is located near the first longitudinal end of the article (500) and thus is located near one of the air inlet and the air outlet. The fourth indicator (582) is located near the second opposing longitudinal end of the article (500) and thus is located at the other of the air inlet and the air outlet.

[0204] The third indicator (580) includes a statement that reads, "Insert this end into the device for a shorter and more intense experience," and a third indicator barcode. The fourth indicator (582) includes a statement that reads, "Insert this end into the device for a longer and less intense experience," and a fourth indicator barcode different from the third indicator barcode.

[0205] The user may select which end of the article (500) to insert into the heating chamber of the device. The device may include one or more barcode scanners capable of determining the orientation in which the article (500) is inserted into the device by scanning a barcode at the distal end of the article (500) when the article is received into the heating chamber. Then, the device may control the heating profile of at least one heater of the device to affect the experience during use. For example, in this case, if the user first inserts the end having a third indicator (580) into the heating chamber, the device will scan the third indicator barcode and determine that the user desires a shorter, more intense experience. As such, the operating temperature of at least one heater of the device may be set higher than when the device scans the fourth barcode and determines that the user desires a longer, less intense experience. If the operating temperature is higher, more aerosols may be formed more quickly during use. This allows the user to have a more intense experience. Additionally, the aerosol-forming material may be depleted more quickly. This may result in a shorter experience for the user.

[0206] During the use of each aerosol generating article (400, 500), the aerosol forming material (440, 540) is heated to cause the aerosol forming material (440, 540) to release volatile compounds, which are then entrained by air drawn into the cavity (430, 530) through the air inlet (411, 511). Then, the volatile compounds are cooled and condensed to form an aerosol, which can be drawn from the aerosol generating article (400, 500) through the air outlet (412, 512).

[0207] FIGS. 15 and 16 illustrate an aerosol generating device (6000) configured to be used with an aerosol generating article (600), and FIG. 17 illustrates an aerosol generating device (6000) engaged with an aerosol generating article (600).

[0208] In this embodiment, the article (600) is similar to the article (400) of FIG. 7. However, the article (600) may be any of the aforementioned articles (100, 200, 300, 400, 500). The article (600) includes a plug of an aerosol-forming substrate (640) similar to the plug of the aerosol-forming substrate (440) of the article (400) of FIG. 7.

[0209] The device (6000) is an elongated aerosol generating device extending between a proximal end (6001) and a distal end (6002). The device (6000) includes a battery (6010), a controller (6020), and at least one heater (6030) located within a housing (6040). The controller (6020) controls the power supply from the battery (6010) to at least one heater (6030). A cavity (6050), which may also be referred to as a heating chamber (6050), is defined in the device (6000), and the heating chamber (6050) has an opening (6051) defined at the proximal end (6001) of the device. The opening (6051) is rectangular in shape and is dimensioned to accommodate a cross-section of an aerosol generating article (600). The heating chamber (6050) includes an upper flat surface (6052) and a lower flat surface (6053). At least one heater (6030) may form the lower flat surface (6053) or be located adjacent thereto to heat the lower surface of an aerosol generating article (600) inserted into the heating chamber (6050). At least one heater (6030) defines a heating zone (6100) in the heating chamber (6050). The heating zone (6100) is entirely within the heating chamber (6050). The upstream and downstream boundaries of the heating zone (6100), indicated by dashed lines, coincide with the upstream and downstream boundaries of at least one heater (6030). The device (6000) also includes a component (6102) at the base of the heating chamber (6050). The component (6102) has a stop surface at its far right end. The airflow path is configured so that air can flow from outside the device (6000) into the heating chamber (6050).

[0210] FIG. 17 illustrates the device (6000) of FIG. 15 engaged with an aerosol generating article (600). There is almost no tolerance between the outer surface of the aerosol generating article (600) and the inner surface of the heating chamber (6050). Therefore, there is a tight fit between the aerosol generating article (600) and the device (6000).

[0211] When the article (600) is inserted into the heating chamber (6050) and the upstream end of the article (600) is in contact with the stop surface of the component (6102), the article (600) is fully accommodated within the device (6000) and the stop surface prevents the article (600) from being inserted further into the heating chamber (6050). At this position, the upstream end of the substrate (640) is within 10 mm of the upstream end of the heater (6030) which coincides with the upstream end of the heating zone, and about 70% of the total mass of the aerosol-forming substrate (640) is within the heating zone (6100).

[0212] Since the RTD of the aerosol generating item (600) is negligible, the RTD of the system formed by the combination of the aerosol generating item (600) and the aerosol generating device (6000) is controlled by an airflow path defined within the device.

[0213] When a user inserts an aerosol generating article (600) into a heating chamber (6050), the device (6000) can be operated. At least one heater (6030) heats the lower surface of the aerosol generating article (600), and as a result, the aerosol forming substrate (640) of the aerosol generating article (600) is heated. The volatile components of the aerosol forming substrate (640) vaporize and condense to form an aerosol. The user inhales the aerosol by sucking in the proximal end (601) of the aerosol generating article (600). Once the volatile components are depleted from the aerosol forming substrate (640) of the aerosol generating article (600), the aerosol generating article is removed from the heating chamber (6050) of the device (6000) and disposed of. The aerosol generating article (600) may be any one of the previously described aerosol generating articles (100, 200, 300, 400, 500) or any other aerosol generating article of the present disclosure.

[0214] FIG. 17 shows a portion of an aerosol generating article (600) extending outside of an aerosol generating device (6000), but in other embodiments, the entire aerosol generating article may be completely enclosed within the aerosol generating device. As an example, FIG. 18 illustrates an alternative embodiment of FIG. 17, where similar features are referred to by the same reference numeral but with the addition of the prime symbol '. In the alternative embodiment of FIG. 18, the entire aerosol generating article (600') is enclosed within the interior of the aerosol generating device (6000'), and the heater (6030') is shorter so that 20 to 80% of the total mass of the substrate (640') is still in the heating zone.

[0215] In some embodiments that may appear identical to those illustrated in FIGS. 15 through 17, at least one heater (6030, 6030') may heat a portion of the aerosol-forming substrate (640, 640') at different times. For example, at least one heater (6030, 6030') may include three structurally identical heaters, namely a first heater located along the upstream 1 / 3 of at least one heater (6030, 6030'), a second heater located along the middle 1 / 3 of at least one heater (6030, 6030'), and a third heater located along the downstream 1 / 3 of at least one heater (6030, 6030'). When in use, when the device (6000, 6000') is activated, only one of the three heaters may be activated first, for example, at the first heater. Then, later during the usage session, the second heater may be activated. At this point, the first heater may be deactivated or remain activated. Then, later during the usage session, the third heater may be activated. At this point, the first heater and the second heater may be deactivated or remain activated. The advantage of this staggered activation of the heaters is that a relatively large portion of the substrate (640, 640') can reduce the risk of reaching a temperature high enough to form an aerosol at the same time, which may mean that a large portion of the flavor of the substrate (640, 640') is depleted over a very small puff process.

[0216] 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 “among them” and “here” are used as synonyms throughout this specification.

Claims

Claim 1 An aerosol generating system comprising an aerosol generating article and an aerosol generating device, wherein the aerosol generating article comprises at least one aerosol forming substrate; the aerosol generating article is defined by an article length, an article width, and an article thickness, wherein the article length and the article width are at least twice the article thickness; the aerosol generating device comprises a heating chamber for receiving the aerosol generating article; the aerosol generating device comprises at least one heater, wherein the at least one heater defines a heating zone within the heating chamber; and wherein, when the aerosol generating article is fully received within the heating chamber of the aerosol generating device, 20 to 80% of the total mass of the at least one aerosol forming substrate is located within the heating zone. Claim 2 An aerosol generating system according to claim 1, wherein the at least one heater comprises a substantially flat heating surface, said heating surface is defined by a heating surface length and a heating surface width. Claim 3 In paragraph 2, the internal surface of the heating chamber is at least a part of the heating surface or includes the same, an aerosol generating system. Claim 4 An aerosol generating system according to claim 2 or 3, wherein when the aerosol generating article is fully accommodated within the heating chamber of the aerosol generating device, the heating surface length is substantially aligned with the length of the article and the heating surface width is substantially aligned with the width of the article. Claim 5 An aerosol generating system according to claim 2, 3, or 4, wherein the at least one aerosol forming substrate comprises or is made of a first aerosol forming substrate defined by a first substrate length, a first substrate width, and a first substrate thickness, wherein the first substrate length and the first substrate width are at least twice the thickness of the first substrate, and when the aerosol generating article is fully accommodated within the heating chamber of the aerosol generating device, the heating surface length is substantially aligned with the first substrate length and the heating surface width is substantially aligned with the first substrate width. Claim 6 An aerosol generating system according to any one of claims 1 to 5, wherein when the aerosol generating article is completely contained within the heating chamber of the aerosol generating device, at least 80% of the uppermost 1 / 4 of the total mass of the at least one aerosol forming material is located within the heating zone. Claim 7 An aerosol generating system according to any one of claims 1 to 5, wherein when the aerosol generating article is completely contained within the heating chamber of the aerosol generating device, at least 80% of the downstream 1 / 4 of the total mass of the at least one aerosol forming material is located within the heating zone. Claim 8 An aerosol generating system according to any one of claims 1 to 7, wherein when the aerosol generating article is completely contained within the heating chamber of the aerosol generating device, 55 to 80% of the total mass of the at least one aerosol forming substrate is located within the heating zone. Claim 9 In any one of claims 1 to 8, the at least one aerosol-forming material comprises or is composed of a positionable aerosol-forming material positionable within the aerosol-generating article, at least a first position and a second position different from the first position, and further: when the aerosol-generating article is fully contained within the heating chamber and the positionable aerosol-forming material is at the first position, a first position percentage of the positionable aerosol-forming material is located within the heating zone; and when the aerosol-generating article is fully contained within the heating chamber and the positionable aerosol-forming material is at the second position, a second position percentage of the positionable aerosol-forming material is located within the heating zone, wherein the first position percentage is different from the second position percentage, an aerosol-generating system. Claim 10 In claim 9, the aerosol generating device is configured to estimate or determine the location of a positionable aerosol forming substrate within the aerosol generating article, and is configured to control the heating profile of the at least one heater based at least partially on the estimated or determined location of the positionable aerosol forming substrate within the aerosol generating article. Claim 11 In any one of claims 1 to 10, the aerosol generating article is accommodated in the heating chamber of the aerosol generating device in at least a first orientation and a second orientation different from the first orientation, and when the aerosol generating article is fully accommodated in the heating chamber in the first orientation, the first orientation percentage of the at least one aerosol forming substrate is located within the heating zone; and when the aerosol generating article is fully accommodated in the heating chamber in the second orientation, the second orientation percentage of the at least one aerosol forming substrate is located within the heating zone, wherein the first orientation percentage is different from the second orientation percentage, an aerosol generating system. Claim 12 In claim 11, the aerosol generating device is configured to estimate or determine the orientation in which the aerosol generating article is received within the heating chamber, and is configured to control the heating profile of the at least one heater at least partially based on the estimated or determined orientation in which the aerosol generating article is received within the heating chamber. Claim 13 An aerosol generating system according to any one of claims 1 to 12, wherein the at least one heater is configured to heat a first portion of the heating zone during a first stage but not a second portion of the heating zone, and the at least one heater is configured to heat a second portion of the heating zone during a second stage after the first stage. Claim 14 An aerosol generating system according to claim 13, wherein the first portion comprises 30 to 70% of the heating zone and the second portion comprises 30 to 70% of the heating zone. Claim 15 A method of using an aerosol generating system according to any one of claims 1 to 14, the method comprising: a step of inserting the aerosol generating article into the heating chamber such that the aerosol generating article is completely contained within the heating chamber and 20 to 80% of the total mass of the at least one aerosol forming substrate is located within the heating zone; and a step of heating at least a portion of the heating zone to an operating temperature with the at least one heater to form an aerosol from the at least one aerosol forming substrate.

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