Aerosol generating article having a surface conforming to the substrate

Abstract

An aerosol generating article (600) for generating an aerosol by use with an aerosol generating device. The aerosol generating article (600) comprises a cavity (630) defined between an upper surface, a lower surface, and at least one side surface. The aerosol generating article (600) comprises an aerosol forming substrate (640) arranged within the cavity (630). The aerosol generating article (630) is defined by a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction. The upper and lower surfaces are separated from each other in the z-direction. The thickness of the aerosol generating article (600) is smaller than the length and width, respectively, of the aerosol generating article (600). At least one of the upper surface, the lower surface, and at least one side surface is a contact surface. At least a portion of the contact surface is in contact with the aerosol forming substrate (640) and is configured to conform to the shape of the aerosol forming substrate (640) when the surface is in contact with the aerosol forming substrate (640).

Description

Technology Field

[0001] The present disclosure relates to an aerosol generating article comprising 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] 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.

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

[0005] According to the present disclosure, an aerosol generating article is provided. The aerosol generating article may be used in conjunction with an aerosol generating device to generate an aerosol. The aerosol generating article may include a cavity. The cavity may be defined between an upper surface, a lower surface, and at least one side surface. The aerosol generating article may include an aerosol forming substrate. The aerosol forming substrate may be arranged in the cavity. The aerosol generating article may be defined by a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction. The upper and lower surfaces may be separated from each other in the z-direction. The thickness of the aerosol generating article may be smaller than the width and length of the aerosol generating article, respectively. At least one of the upper surface, the lower surface, and at least one side surface may be a contact surface. At least a portion of the contact surface may be configured to contact the aerosol forming substrate. At least a portion of the contact surface may be configured to conform to the shape of the aerosol forming substrate when the surface contacts the aerosol forming substrate.

[0006] According to the present disclosure, an aerosol generating article is provided for use with an aerosol generating device to generate an aerosol. The aerosol generating article comprises a cavity defined between an upper surface, a lower surface, and at least one side. The aerosol generating article comprises an aerosol forming substrate arranged within the cavity. The aerosol generating article is defined by a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction. The upper and lower surfaces are separated from each other in the z-direction. The thickness of the aerosol generating article is smaller than the length and width, respectively, of the aerosol generating article. At least one of the upper surface, the lower surface, and at least one side surface is a contact surface. At least a portion of the contact surface is in contact with the aerosol forming substrate and is configured to conform to the shape of the aerosol forming substrate when the surface is in contact with the aerosol forming substrate.

[0007] If at least a portion of at least one of an upper surface, a lower surface, and at least one side surface is configured as a contact surface such that the surface contacts the aerosol-forming substrate and conforms to the shape of the aerosol-forming substrate, it is advantageous to reduce the presence of an air gap or space between the aerosol-forming substrate and the surface of the cavity. Advantageously, reducing the presence of an air gap or space between the aerosol-forming substrate and the surface of the cavity can facilitate most of the airflow through the aerosol-generating article passing through the aerosol-forming substrate. Advantageously, reducing the presence of an air gap or space between the aerosol-forming substrate and the surface of the cavity can increase the airflow through the aerosol-forming substrate rather than around the periphery of the aerosol-forming substrate. Ensuring that the airflow through the aerosol-generating article passes through the aerosol-forming substrate as much as possible can improve the entrainment of vapor released from the heated aerosol-generating article and increase the delivery of aerosols from the aerosol-generating article.

[0008] At least one of the upper surface, the lower surface, and at least one side surface is a contact surface. In some embodiments, the upper surface is a contact surface. In some embodiments, the lower surface is a contact surface. In some embodiments, at least one side surface is a contact surface. In some embodiments, two or more of the upper surface, the lower surface, and at least one side surface are contact surfaces. The upper surface and the lower surface may be contact surfaces. The upper surface and at least one side surface may be contact surfaces. The lower surface and at least one side surface may be contact surfaces. The upper surface, the lower surface, and at least one side surface may be contact surfaces.

[0009] At least one side surface may include a first side surface and a second side surface. The first side surface and the second side surface may be separated from each other in the y-direction. The first side surface may be a contact surface. The second side surface may be a contact surface. The first side surface and the second side surface may be contact surfaces.

[0010] At least a portion of the contact surface is configured to be in contact with an aerosol-forming substrate. At least a portion of the contact surface may be in contact with an aerosol-forming substrate.

[0011] At least a portion of the contact surface is configured to conform to the shape of the aerosol-forming substrate when the surface comes into contact with the aerosol-forming substrate. The contact surface may be configured to conform to the shape of the aerosol-forming substrate when the contact surface comes into contact with the aerosol-forming substrate.

[0012] In some preferred embodiments, at least a portion of the contact surface is non-planar when the contact surface contacts the aerosol-forming substrate. In some of these preferred embodiments, the contact surface is substantially planar except when the contact surface contacts the aerosol-forming substrate.

[0013] As used herein, "conforms" refers to a contact surface that has an external shape or a shape or shape similar to an external shape of an aerosol-forming substrate, or assumes an external shape or a shape or shape similar to an external shape of an aerosol-forming substrate during use. In one embodiment, the contact surface may be deformable to conform to the external shape of the aerosol-forming substrate when the contact surface contacts the aerosol-forming substrate. In another embodiment, the aerosol-forming substrate may have a predetermined external shape, and the contact surface may have a predetermined external shape that conforms to at least a portion of the predetermined external shape of the aerosol-forming substrate when the contact surface contacts the aerosol-forming substrate.

[0014] In some preferred embodiments, the contact surface is deformable. The contact surface may be deformable to conform to the shape of the aerosol-forming substrate when the contact surface contacts the aerosol-forming substrate. That is, the contact surface may assume the shape of the aerosol-forming substrate when the contact surface contacts the aerosol-forming substrate. In some embodiments, the contact surface is flexible. Advantageously, providing a contact surface that is deformable to take on the external shape of the aerosol-forming substrate when the contact surface contacts the aerosol-forming substrate may enable close contact between the external surface of the aerosol-forming substrate and the contact surface. This may minimize the air gap between the external surface of the aerosol-forming substrate and the contact surface.

[0015] The deformable contact surface can be formed from any suitable deformable material. The contact surface can be formed from a deformable or flexible material such as paper or cardboard.

[0016] According to the present disclosure, an aerosol generating article is provided for use with an aerosol generating device to generate an aerosol. The aerosol generating article comprises a cavity defined between an upper surface, a lower surface, and at least one side. The aerosol generating article comprises an aerosol forming substrate arranged within the cavity. The aerosol generating article is defined by a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction. The upper and lower surfaces are separated from each other in the z-direction. The thickness of the aerosol generating article is smaller than the length and width, respectively, of the aerosol generating article. At least one of the upper surface, the lower surface, and at least one side surface is a deformable contact surface. The contact surface may be deformable so that when the contact surface contacts the aerosol forming substrate, the contact surface conforms to the shape of the aerosol forming substrate.

[0017] In some preferred embodiments, at least a portion of the aerosol-forming substrate has a predefined external shape. In some of these preferred embodiments, at least a portion of the contact surface has a predefined shape. At least a portion of the predefined shape of the contact surface may be identical to at least a portion of the predefined external shape of the aerosol-forming substrate. The predefined shape of the contact surface may be identical to the predefined external shape of the aerosol-forming substrate. The predefined shape of the contact surface may correspond to the predefined external shape of the aerosol-forming substrate when the contact surface contacts the aerosol-forming substrate. Advantageously, providing the contact surface with a predefined shape that is identical to or corresponds to the predefined external shape of the aerosol-forming substrate when the contact surface contacts the aerosol-forming substrate may enable close contact between the external surface of the aerosol-forming substrate and the contact surface. This may minimize the air gap between the external surface of the aerosol-forming substrate and the contact surface.

[0018] According to the present disclosure, an aerosol generating article is provided for use with an aerosol generating device to generate an aerosol. The aerosol generating article comprises a cavity defined between an upper surface, a lower surface, and at least one side. The aerosol generating article comprises an aerosol forming substrate arranged within the cavity. The aerosol generating article is defined by a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction. The upper and lower surfaces are separated from each other in the z-direction. The thickness of the aerosol generating article is smaller than the length and width, respectively, of the aerosol generating article. At least one of the upper surface, the lower surface, and at least one side surface is a contact surface having a predetermined shape. At least a portion of the aerosol forming substrate has a predetermined external shape, and at least a portion of the predetermined shape of the contact surface corresponds to at least a portion of the predetermined external shape of the aerosol forming substrate when the contact surface contacts the aerosol forming substrate.

[0019] In some preferred embodiments, the aerosol generating article comprises a frame. The frame may define at least one side surface. The frame may define at least one outer side surface of the aerosol generating article.

[0020] In some particularly preferred embodiments, the aerosol generating article comprises an upper layer and a lower layer. The upper layer may define an upper surface. The lower layer may define a lower surface. The upper layer may define an upper outer surface of the aerosol generating article. The lower layer may define a lower outer surface of the aerosol generating article. In some particularly preferred embodiments, the aerosol generating article comprises an upper layer and a lower layer, wherein the upper layer defines an upper surface and the lower layer defines a lower surface, and the aerosol generating article comprises a frame arranged between the upper layer and the lower layer, wherein the frame defines at least one side surface.

[0021] In some of these particularly preferred embodiments, at least one of the upper layer and the lower layer may be a contact surface. At least one of the upper layer and the lower layer may be a deformable contact surface. At least one of the upper layer and the lower layer may be a deformable contact surface that takes on the external shape of the aerosol-forming substrate when the contact surface contacts the aerosol-forming substrate. In some of these particularly preferred embodiments, the frame has a height in the z-direction, the aerosol-forming substrate has a height in the z-direction, and the height of at least a portion of the frame is smaller than the height of the aerosol-forming substrate.

[0022] The aerosol-forming substrate may have a length extending in the x-direction. At points along the length of the aerosol-forming substrate, the cross-section of the aerosol-forming substrate may have a periphery. At least one contact surface may contact the aerosol-forming substrate around substantially the entire periphery of the cross-section of the aerosol-forming substrate at points along the length of the aerosol-forming substrate. Advantageously, providing contact with at least one contact surface around the entire periphery of the cross-section of the aerosol-forming substrate at points along the length of the aerosol-forming substrate may reduce the presence of an air gap or space between the aerosol-forming substrate and the surface of the cavity. Advantageously, reducing the presence of an air gap or space between the aerosol-forming substrate and the surface of the cavity may facilitate most of the airflow through the aerosol-generating article passing through the aerosol-forming substrate.

[0023] In some embodiments, the cavity of the aerosol generating article is filled with the aerosol forming substrate. In some embodiments, the cavity of the aerosol generating article is filled with the aerosol forming substrate such that the upper surface, the lower surface, and at least one side surface defining the cavity are all in contact with the aerosol forming substrate.

[0024] In some embodiments, the cavity of the aerosol generating article is not filled with an aerosol forming substrate. In some embodiments, at least one of the at least one contact surface does not come into contact with the aerosol forming substrate when the aerosol generating article is not accommodated in the cavity of the aerosol generating device. In some of these embodiments, at least one of the at least one contact surface is deformable. Preferably, when the aerosol generating article is accommodated in the cavity of the aerosol generating device, the aerosol generating device and the aerosol generating article are configured to deform at least one of the at least one contact surface so that at least one of the at least one contact surface comes into contact with an outer surface of the aerosol forming substrate.

[0025] In some embodiments, the aerosol generating article includes a first end portion and a second end portion. The first end portion and the second end portion may be separated from each other in the x-direction.

[0026] In some embodiments, the aerosol generating article includes a narrow portion arranged between a first end portion and a second end portion.

[0027] The narrow portion may have a minimum width in the y-direction that is smaller than the maximum width of the first end portion and smaller than the maximum width of the second end portion. The narrow portion may have a minimum height in the z-direction that is smaller than the maximum height of the first end portion and smaller than the maximum height of the second end portion. The narrow portion may include a notch, or a concave, or a channel, or a groove on the outer surface of the aerosol generating article. The narrow portion may include a pair of opposing notches, or a pair of opposing concaves, or a pair of opposing channels, or a pair of opposing grooves on the opposing outer surfaces of the aerosol generating article.

[0028] Providing a narrow portion of the aerosol generating article between the first end portion and the second end portion can provide several different advantages. For example, the narrow portion provides an improved grip on the aerosol generating article to a user holding the aerosol generating article, allowing the user to remove the aerosol generating article more easily from the cavity of the aerosol generating device. For example, the narrow portion can prevent the aerosol generating article from falling out of the cavity, for instance, under the influence of gravity, by keeping the aerosol generating article held within the cavity by the aerosol generating device. For example, the narrow portion of the aerosol generating article can increase the amount of contact between the aerosol forming material and the surface of the cavity, reduce the air gap between the aerosol forming material and the surface of the cavity, and increase the airflow through the aerosol forming material rather than around the periphery of the aerosol forming material.

[0029] The aerosol generating article includes a cavity. The cavity may be positioned between an upper outer surface and a lower outer surface. In some preferred embodiments, an aerosol-forming substrate is arranged within the cavity. In some of these embodiments, a narrow portion is spaced apart from the aerosol-forming substrate in the x-direction. In some embodiments, a narrow portion is arranged within the aerosol-forming substrate inside the cavity.

[0030] Arranging narrow sections in the aerosol-forming substrate can reduce the presence of air gaps or spaces between the aerosol-forming substrate and the surface of the cavity. Advantageously, reducing the presence of air gaps or spaces between the aerosol-forming substrate and the surface of the cavity can facilitate most of the airflow through the aerosol-generating article passing through the aerosol-forming substrate. Ensuring that the airflow through the aerosol-generating article passes through the aerosol-forming substrate as much as possible can improve the entrainment of vapors released from the heated aerosol-generating substrate and increase the delivery of aerosols from the aerosol-generating article.

[0031] In some preferred embodiments, the aerosol generating article comprises a frame. The frame may be positioned between an upper outer surface and a lower outer surface. Preferably, the frame comprises at least one side wall.

[0032] In some of these preferred embodiments, in which the aerosol generating article comprises a frame including at least one sidewall, the at least one sidewall may have a minimum height in the z-direction at the narrow portion. The minimum height of the at least one sidewall at the narrow portion may be smaller than the maximum height of the at least one sidewall at the first end portion. The minimum height of the at least one sidewall at the narrow portion may be smaller than the maximum height of the at least one sidewall at the second end portion. When the aerosol forming material is arranged within a cavity and the narrow portion is arranged on the aerosol forming material, the aerosol forming material may have a maximum height greater than the minimum height of the at least one sidewall at the narrow portion.

[0033] In some particularly preferred embodiments, the frame comprises a first sidewall and a second sidewall, and the first sidewall and the second sidewall are separated in the y direction. The first sidewall may have a minimum height in the z direction at a narrow portion. The minimum height of the first sidewall at the narrow portion may be smaller than the maximum height of the first sidewall at the first end portion. The minimum height of the first sidewall at the narrow portion may be smaller than the maximum height of the first sidewall at the second end portion. The second sidewall may have a minimum height in the z direction at a narrow portion. The minimum height of the second sidewall at the narrow portion may be smaller than the maximum height of the second sidewall at the first end portion. The minimum height of the second sidewall at the narrow portion may be smaller than the maximum height of the second sidewall at the second end portion.

[0034] If the aerosol generating article includes a cavity, the frame may at least partially define the cavity. If the aerosol generating article has a frame having at least one sidewall, and the frame at least partially defines the cavity, and an aerosol forming material is arranged within the cavity, at least one sidewall of the frame may have a minimum height in the narrow portion that is smaller than the maximum height of the aerosol forming material in the narrow portion. In some of these embodiments, the height of the aerosol forming material in the narrow portion is greater than the minimum height of at least one sidewall of the frame in the narrow portion.

[0035] The narrow portion may have any suitable shape. The narrow portion may include a notch on the outer surface of the aerosol generating article. The narrow portion may include a recess on the outer surface of the aerosol generating article. The narrow portion may include a channel on the outer surface of the aerosol generating article. The narrow portion may include a groove on the outer surface of the aerosol generating article.

[0036] Notches, depressions, channels, or grooves may extend across a portion of the width of the aerosol-generating article. Notches, depressions, channels, or grooves may extend across the width of the aerosol-generating article. Notches, depressions, channels, or grooves may extend across the entire width of the aerosol-generating article.

[0037] Notches, depressions, channels, or grooves may extend across a portion of the height of the aerosol-generating article. Notches, depressions, channels, or grooves may extend across the height of the aerosol-generating article. Notches, depressions, channels, or grooves may extend over the entire height of the aerosol-generating article.

[0038] Notches, depressions, channels, or grooves can surround aerosol-generating articles.

[0039] The narrow portion may include a pair of opposing notches on the opposing outer surface of the aerosol generating article. The narrow portion may include a pair of opposing concave portions on the opposing outer surface of the aerosol generating article. The narrow portion may include a pair of opposing channels on the opposing outer surface of the aerosol generating article. The narrow portion may include a pair of opposing grooves on the opposing outer surface of the aerosol generating article.

[0040] Aerosol-generating articles can have any appropriate length.

[0041] Aerosol-generating articles may have a length of 15 mm or more, or 20 mm or more, or 25 mm or more, or 30 mm or more, or 35 mm or more, or 40 mm or more.

[0042] Aerosol-generating articles may have a length of 45 mm or less, or 40 mm or less, or 35 mm or less, or 30 mm or less.

[0043] The aerosol generating article may have a length of 10 mm to 100 mm, or 10 mm to 50 mm, or 10 mm to 40 mm, or 12 mm to 30 mm, or 14 mm to 26 mm, or 16 mm to 24 mm, or 18 mm to 22 mm, or 15 mm to 45 mm, or 20 mm to 40 mm, or 20 mm to 35 mm, or 25 mm to 30 mm.

[0044] The aerosol-generating article may have a length of about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.

[0045] The gap between the upper outer surface and the lower outer surface can define the height of the aerosol-generating article.

[0046] Aerosol-generating items can have any suitable height.

[0047] The aerosol-generating article may have a height of 0.3 mm or more, or 0.4 mm or more, or 0.5 mm or more, or 0.7 mm or more, or 0.8 mm or more, or 0.9 mm or more, or 1 mm or more, or 1.5 mm or more, or 2 mm or more, or 2.5 mm or more, or 3 mm or more, or 3.5 mm or more, or 4 mm or more, or 4.5 mm or more, or 5 mm or more, or 6 mm or more, or 7 mm or more, or 8 mm or more, or 9 mm or more, or 10 mm or more, or 12 mm or more, or 14 mm or more, or 16 mm or more, or 18 mm or more, or 20 mm or more, or 22 mm or more.

[0048] The aerosol-generating article may have a height of 25 mm or less, or 23 mm or less, or 21 mm or less, or 19 mm or less, or 17 mm or less, or 15 mm or less, or 13 mm or less, or 11 mm or less, or 10 mm or less, or 9 mm or less, or 8 mm or less, or 7 mm or less, or 6 mm or less, or 5.5 mm or less, or 5 mm or less, or 4.5 mm or less, or 4 mm or less, or 3.5 mm or less, or 3 mm or less, or 2.5 mm or less, or 2 mm or less, or 1 mm or less, or 0.9 mm or less, or 0.8 mm or less, or 0.7 mm or less, or 0.6 mm or less, or 0.5 mm or less.

[0049] The aerosol generating article may have a height of 0.3 mm to 25 mm, 0.4 mm to 23 mm, or 0.5 mm to 21 mm, or 0.6 mm to 19 mm, or 0.7 mm to 17 mm, or 0.8 mm to 15 mm, or 0.9 mm to 13 mm, or 1 mm to 10 mm, or 1 mm to 5 mm, or 1.2 mm to 8 mm, or 1.4 mm to 7 mm, or 1.5 mm to 5 mm, or 1.5 mm to 4 mm, or 1.5 mm to 3 mm, or 1.5 mm to 2 mm, or 1.6 mm to 6 mm, or 1.7 mm to 5 mm, or 2 mm to 4.5 mm, or 2.5 mm to 4 mm, or 3 mm to 3.5 mm.

[0050] The aerosol-generating article may have a height of about 1.7 mm, or about 4.5 mm, or about 2 mm, or about 3 mm, or about 4 mm.

[0051] As previously stated, the "height" of the aerosol generating article is the maximum height of the aerosol generating article. The aerosol generating article has a maximum height and a minimum height. When the maximum height and the minimum height are the same, the aerosol generating article has a completely consistent height along its length and width, and the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article is 1.

[0052] The ratio of the minimum height of an aerosol-generating article to the maximum height of an aerosol-generating article may be 0.5 or more, or 0.55 or more, or 0.6 or more, or 0.65 or more, or 0.7 or more, or 0.75 or more, or 0.8 or more, or 0.85 or more, or 0.9 or more, or 0.95 or more, or about 1.

[0053] The ratio of the minimum height of an aerosol-generating article to the maximum height of an aerosol-generating article may be 1 or less, or 0.95 or less, or 0.9 or less, or 0.85 or less, or 0.8 or less, or 0.75 or less, or 0.7 or less.

[0054] The ratio of the minimum height of an aerosol-generating article to the maximum height of an aerosol-generating article may be 0.5 to 1, or 0.55 to 1, or 0.6 to 1, or 0.65 to 1, or 0.7 to 1, or 0.75 to 1, or 0.8 to 1, or 0.85 to 1, or 0.9 to 1, or 0.95 to 1, or about 1.

[0055] Aerosol-generating articles can have any appropriate width.

[0056] Aerosol-generating articles may have a width of 3 mm or more, or exceeding 5 mm, or exceeding 7.5 mm, or exceeding 9 mm, or exceeding 11 mm, or exceeding 13 mm.

[0057] The aerosol-generating article may have a width of 17 mm or less, or 15 mm or less, or 12.5 mm or less, or 11 mm or less, or 9 mm or less.

[0058] The aerosol generating article may have a width of 3 mm to 20 mm, or 3 mm to 17 mm, or 5 mm to 20 mm, or 5 mm to 15 mm, or 7.5 mm to 12.5 mm, or 8 mm to 18 mm, or 9 mm to 11 mm, or 10 mm to 16 mm, or 11 mm to 15 mm, or 12 mm to 14 mm.

[0059] The aerosol generating article may have a width of about 10 mm, or about 11 mm, or about 12 mm, or about 13 mm, or about 14 mm, or about 15 mm, or about 16 mm.

[0060] As previously stated, the "width" of the aerosol generating article is the maximum width of the aerosol generating article. The aerosol generating article has a maximum width and a minimum width. When the maximum width and the minimum width are the same, the aerosol generating article has a completely consistent width along its length and height, and the ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article is 1.

[0061] The ratio of the minimum width of an aerosol-generating article to the maximum width of an aerosol-generating article may be 0.5 or more, or 0.55 or more, or 0.6 or more, or 0.65 or more, or 0.7 or more, or 0.75 or more, or 0.8 or more, or 0.85 or more, or 0.9 or more, or 0.95 or more, or about 1.

[0062] The ratio of the minimum width of an aerosol-generating article to the maximum width of an aerosol-generating article may be 1 or less, or 0.95 or less, or 0.9 or less, or 0.85 or less, or 0.8 or less, or 0.75 or less, or 0.7 or less.

[0063] The ratio of the minimum width of an aerosol-generating article to the maximum width of an aerosol-generating article may be 0.5 to 1, or 0.55 to 1, or 0.6 to 1, or 0.65 to 1, or 0.7 to 1, or 0.75 to 1, or 0.8 to 1, or 0.85 to 1, or 0.9 to 1, or 0.95 to 1, or about 1.

[0064] The ratio between the length and thickness of the aerosol-generating article and between the width and thickness of the aerosol-generating article may be greater than 2:1, greater than 5:1, greater than 10:1, greater than 12:1, or greater than 15:1.

[0065] The ratio between the length and height of an aerosol-generating article and between the width and thickness of an aerosol-generating article may be less than 15:1, less than 12:1, less than 10:1, less than 5:1, or less than 2.5:1.

[0066] The ratio between the length and height of the aerosol-generating article and between the width and height of the aerosol-generating article may be 2:1 to 15:1, 2:1 to 12:1, 2:1 to 10:1, or 5:1 to 10:1.

[0067] The ratio between the length and width of an aerosol-generating article may be greater than 1:1, greater than 2:1, greater than 3:1, greater than 4:1, or greater than 5:1.

[0068] The ratio between the length and width of an aerosol-generating article may be less than 10:1, less than 8:1, less than 5:1, less than 4:1, less than 3:1, or less than 2:1.

[0069] The ratio between the length and width of the aerosol-generating article may be 1:1 to 10:1, 1:1 to 5:1, 1:1 to 4:1, 1:1 to 3:1, 2:1 to 4:1, or 2:1 to 3:1.

[0070] In some embodiments, at least one of the at least one contact surface is deformable, and when an aerosol generating article is received in the cavity of an aerosol generating device, the aerosol generating device and the aerosol generating article are configured to interlock to deform at least one of the at least one contact surface so that at least one of the at least one contact surface comes into contact with the outer surface of an aerosol forming substrate.

[0071] If one or both of the upper surface and the lower surface are contact surfaces and the contact surface is deformable, deformation of the contact surface by the aerosol generating device can reduce the minimum height of the aerosol generating article, thereby resulting in an aerosol generating article with a lower ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article than before deformation.

[0072] If one or both of the upper surface and the lower surface are contact surfaces and the contact surface is deformable, before the contact surface is deformed by the aerosol generating device, the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article may be 0.5 or more, or 0.55 or more, or 0.6 or more, or 0.65 or more, or 0.7 or more, or 0.75 or more, or 0.8 or more, or 0.85 or more, or 0.9 or more, or 0.95 or more, or about 1.

[0073] If one or both of the upper surface and the lower surface are contact surfaces and the contact surface is deformable, the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article may be 1 or less, or 0.95 or less, or 0.9 or less, or 0.85 or less, or 0.8 or less, or 0.75 or less, or 0.7 or less, prior to deformation of the contact surface by the aerosol generating device.

[0074] If one or both of the upper surface and the lower surface are contact surfaces and the contact surface is deformable, before deformation of the contact surface by the aerosol generating device, the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article may be 0.5 to 1, or 0.55 to 1, or 0.6 to 1, or 0.65 to 1, or 0.7 to 1, or 0.75 to 1, or 0.8 to 1, or 0.85 to 1, or 0.9 to 1, or 0.95 to 1, or about 1.

[0075] When one or both of the upper surface and the lower surface are contact surfaces and the contact surface is deformable, when the contact surface is deformed by an aerosol generating device, the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article may be 0.3 or more, or 0.35 or more, or 0.4 or more, or 0.45 or more, or 0.5 or more, or 0.55 or more, or 0.6 or more, or 0.65 or more, or 0.7 or more, or 0.75 or more, or 0.8 or more, or 0.85 or more, or 0.9 or more.

[0076] When one or both of the upper surface and the lower surface are contact surfaces and the contact surface is deformable, when the contact surface is deformed by an aerosol generating device, the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article may be 1 or less, or 0.95 or less, or 0.9 or less, or 0.85 or less, or 0.8 or less, or 0.75 or less, or 0.7 or less, or 0.65 or less, or 0.6 or less, or 0.55 or less, or 0.5 or less, or 0.45 or less, or 0.4 or less.

[0077] If one or both of the upper surface and the lower surface are contact surfaces and the contact surface is deformable, when the contact surface is deformed by an aerosol generating device, the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article may be 0.3 to 1, or 0.3 to 0.95, or 0.4 to 0.95, or 0.45 to 0.9, or 0.5 to 0.9, or 0.55 to 0.85, or 0.6 to 0.85.

[0078] If one or both of the upper surface and the lower surface are contact surfaces and the contact surface is deformable, the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article when the contact surface is deformed by the aerosol generating device and the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article before the deformation of the contact surface by the aerosol generating device is less than 1.

[0079] If one or both of the upper surface and the lower surface are contact surfaces and the contact surface is deformable, the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article when the contact surface is deformed by the aerosol generating device and the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article before the deformation of the contact surface by the aerosol generating device may be 0.3 or more, or 0.35 or more, or 0.4 or more, or 0.45 or more, or 0.5 or more, or 0.55 or more, or 0.6 or more, or 0.65 or more, or 0.7 or more, or 0.75 or more, or 0.8 or more, or 0.85 or more, or 0.9 or more.

[0080] If one or both of the upper surface and the lower surface are contact surfaces and the contact surface is deformable, the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article when the contact surface is deformed by the aerosol generating device and the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article before the deformation of the contact surface by the aerosol generating device may be 1 or less, or 0.95 or less, or 0.9 or less, or 0.85 or less, or 0.8 or less, or 0.75 or less, or 0.7 or less, or 0.65 or less, or 0.6 or less, or 0.55 or less, or 0.5 or less, or 0.45 or less, or 0.4 or less.

[0081] If one or both of the upper surface and the lower surface are contact surfaces and the contact surface is deformable, the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article when the contact surface is deformed by the aerosol generating device and the ratio of the minimum height of the aerosol generating article to the maximum height of the aerosol generating article before the deformation of the contact surface by the aerosol generating device may be 0.3 to 0.95, or 0.4 to 0.95, or 0.45 to 0.9, or 0.5 to 0.9, or 0.55 to 0.85, or 0.6 to 0.85.

[0082] If at least one side surface is a contact surface and the contact surface is deformable, deformation of the contact surface by an aerosol generating device can reduce the minimum width of the aerosol generating article, thereby resulting in an aerosol generating article having a lower ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article than before deformation.

[0083] If at least one side surface is a contact surface and the contact surface is deformable, before deformation of the contact surface by the aerosol generating device, the ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article may be 0.5 or more, or 0.55 or more, or 0.6 or more, or 0.65 or more, or 0.7 or more, or 0.75 or more, or 0.8 or more, or 0.85 or more, or 0.9 or more, or 0.95 or more, or about 1.

[0084] If at least one side surface is a contact surface and the contact surface is deformable, before deformation of the contact surface by the aerosol generating device, the ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article may be 1 or less, or 0.95 or less, or 0.9 or less, or 0.85 or less, or 0.8 or less, or 0.75 or less, or 0.7 or less.

[0085] If at least one side surface is a contact surface and the contact surface is deformable, before deformation of the contact surface by the aerosol generating device, the ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article may be 0.5 to 1, or 0.55 to 1, or 0.6 to 1, or 0.65 to 1, or 0.7 to 1, or 0.75 to 1, or 0.8 to 1, or 0.85 to 1, or 0.9 to 1, or 0.95 to 1, or about 1.

[0086] If at least one side surface is a contact surface and the contact surface is deformable, when the contact surface is deformed by an aerosol generating device, the ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article may be 0.3 or more, or 0.35 or more, or 0.4 or more, or 0.45 or more, or 0.5 or more, or 0.55 or more, or 0.6 or more, or 0.65 or more, or 0.7 or more, or 0.75 or more, or 0.8 or more, or 0.85 or more, or 0.9 or more.

[0087] If at least one side surface is a contact surface and the contact surface is deformable, when the contact surface is deformed by an aerosol generating device, the ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article may be 1 or less, or 0.95 or less, or 0.9 or less, or 0.85 or less, or 0.8 or less, or 0.75 or less, or 0.7 or less, or 0.65 or less, or 0.6 or less, or 0.55 or less, or 0.5 or less, or 0.45 or less, or 0.4 or less.

[0088] If at least one side surface is a contact surface and the contact surface is deformable, when the contact surface is deformed by an aerosol generating device, the ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article may be 0.3 to 1, or 0.3 to 0.95, or 0.4 to 0.95, or 0.45 to 0.9, or 0.5 to 0.9, or 0.55 to 0.85, or 0.6 to 0.85.

[0089] If at least one side surface is a contact surface and the contact surface is deformable, the ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article when the contact surface is deformed by the aerosol generating device and the ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article before the deformation of the contact surface by the aerosol generating device is less than 1.

[0090] If at least one side surface is a contact surface and the contact surface is deformable, the ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article when the contact surface is deformed by the aerosol generating device and the ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article before the deformation of the contact surface by the aerosol generating device may be 0.3 or more, or 0.35 or more, or 0.4 or more, or 0.45 or more, or 0.5 or more, or 0.55 or more, or 0.6 or more, or 0.65 or more, or 0.7 or more, or 0.75 or more, or 0.8 or more, or 0.85 or more, or 0.9 or more.

[0091] If at least one side surface is a contact surface and the contact surface is deformable, the ratio between the minimum width of the aerosol generating article and the maximum width of the aerosol generating article when the contact surface is deformed by the aerosol generating device and the ratio between the minimum width of the aerosol generating article and the maximum width of the aerosol generating article before the deformation of the contact surface by the aerosol generating device may be 1 or less, or 0.95 or less, or 0.9 or less, or 0.85 or less, or 0.8 or less, or 0.75 or less, or 0.7 or less, or 0.65 or less, or 0.6 or less, or 0.55 or less, or 0.5 or less, or 0.45 or less, or 0.4 or less.

[0092] If at least one side surface is a contact surface and the contact surface is deformable, the ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article when the contact surface is deformed by the aerosol generating device and the ratio of the minimum width of the aerosol generating article to the maximum width of the aerosol generating article before the deformation of the contact surface by the aerosol generating device may be 0.3 to 0.95, or 0.4 to 0.95, or 0.45 to 0.9, or 0.5 to 0.9, or 0.55 to 0.85, or 0.6 to 0.85.

[0093] An airflow channel can be defined between the upper outer surface and the lower outer surface.

[0094] In some preferred embodiments, the upper outer surface is substantially flat and the lower outer surface is substantially flat. In some particularly preferred embodiments, the flat upper outer surface and the flat lower outer surface extend in a substantially parallel plane. The aerosol generating article may have a constant height along the length of the aerosol generating article. The aerosol generating article may have a constant height along the width of the aerosol generating article.

[0095] If the aerosol generating article has a narrow portion having a minimum height in the z-direction that is less than the maximum height of the first end portion and less than the maximum height of the second end portion, the planar upper outer surface and the planar lower outer surface may be non-planar in the narrow portion. If the aerosol generating article has a narrow portion having a minimum height in the z-direction that is less than the maximum height of the first end portion and less than the maximum height of the second end portion, the aerosol generating article may have a constant height along the length of the aerosol generating article excluding the narrow portion. If the aerosol generating article has a narrow portion having a minimum height in the z-direction that is less than the maximum height of the first end portion and less than the maximum height of the second end portion, the aerosol generating article may have a constant height along the width of the aerosol generating article excluding the narrow portion.

[0096] In some preferred embodiments, the aerosol generating article comprises a first outer side surface and a second outer side surface, wherein the second outer side surface is spaced apart from the first outer side surface in the y-direction. In some particularly preferred embodiments, the first outer side surface is substantially planar, and the second outer side surface is substantially planar. The planar first outer side surface and the planar second outer side surface may extend in parallel planes. The aerosol generating article may have a constant width along the length of the aerosol generating article. The aerosol generating article may have a constant width along the height of the aerosol generating article. If the aerosol generating article has a narrow portion having a minimum width in the y-direction that is less than the maximum width of the first end portion and less than the maximum width of the second end portion, the planar first outer side surface and the planar second outer side surface may be non-planar in the narrow portion. If an aerosol generating article has a narrow portion having a minimum width in the y-direction that is less than the maximum width of the first end portion and less than the maximum width of the second end portion, the aerosol generating article may have a constant width along the length of the aerosol generating article excluding the narrow portion. If an aerosol generating article has a narrow portion having a minimum width in the y-direction that is less than the maximum width of the first end portion and less than the maximum width of the second end portion, the aerosol generating article may have a constant width along the height of the aerosol generating article excluding the narrow portion.

[0097] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol, and the aerosol generating article comprises an aerosol forming substrate for generating an aerosol, and the aerosol generating article is a planar aerosol generating article having a length extending in the x direction, a base defined by a width extending in the y direction, and a height extending in the z direction.

[0098] The height of the aerosol generating article is smaller than both the length and the width of the aerosol generating article. For the purposes of this disclosure, it will be understood that the “height” of the aerosol generating article may also be referred to as the “thickness” of the aerosol generating article.

[0099] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol, the aerosol generating article comprises an aerosol forming substrate for generating an aerosol, and the aerosol generating article comprises a substantially flat upper surface defined by a length extending in the x-direction and a width extending in the y-direction, and a substantially flat lower surface defined by a length extending in the x-direction and a width extending in the y-direction. The substantially flat upper surface and the substantially flat lower surface may be spaced perpendicularly apart from each other by a height defined in the z-direction.

[0100] The aerosol generating article according to the present disclosure may preferably be a substantially flat article or a substantially planar article. Such an article has a large base area relative to the volume of the article. In particular, the height of the aerosol generating article may be less than 50% 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 released. Alternatively or additionally, this can reduce the time required to heat the aerosol-forming substrate sufficiently to release the aerosol.

[0101] An aerosol generating article according to any one of the aspects disclosed herein may have an airflow path extending through the aerosol generating article. The aerosol generating article may have an airflow path defined through the aerosol generating article in the x / y plane from one side of the aerosol generating article to another side of the aerosol generating article. The aerosol generating article preferably has a resistance to suction (RTD) of less than 20 mm H2O, for example, less than 10 mm H2O, in the direction of the airflow path. Preferably, the aerosol generating article has an RTD of less than 20 mm H2O, for example, less than 10 mm H2O, in at least one direction in the x / y plane of the aerosol generating article. An aerosol generating article having a low resistance airflow path can enable excellent airflow management and allow aerosols to be extracted more efficiently from the aerosol generating article and delivered to the user.

[0102] 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%.

[0103] An aerosol generating article according to any one of the aspects disclosed herein may comprise an upper and lower surface that is substantially planar. A vertical separation between the substantially planar upper surface and the lower surface may define the height (e.g., z-dimension) of the aerosol generating article. An airflow channel may be defined between the substantially planar upper surface and the lower surface. The aerosol generating article may have a height of less than 5 mm, e.g., 1.5 mm to 5 mm, e.g., 1.5 mm to 4 mm, e.g., 1.5 mm to 3 mm, e.g., 1.5 mm to 2 mm. One or both of the substantially planar upper and lower surfaces may comprise an aerosol-forming substrate. The aerosol generating article may comprise an upper and lower layer, wherein the upper layer forms a substantially planar upper surface and the lower layer forms a substantially planar lower surface. At least one of the upper layer and the lower layer may comprise or be composed of an aerosol-forming substrate.

[0104] According to the present disclosure, an aerosol generating article for use with an aerosol generating device to generate an aerosol may be provided, and the aerosol generating article comprises 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 comprise or be made of an aerosol forming substrate.

[0105] 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.

[0106] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol. The aerosol generating article may comprise a first planar outer surface, a second planar outer surface, a cavity, and a frame. The frame is positioned between the first planar outer surface and the second planar outer surface. The frame defines the cavity at least partially. The aerosol generating article comprises an aerosol forming substrate. The aerosol generating article may comprise an air inlet and an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity.

[0107] Preferably, the aerosol-forming substrate is located between the first planar outer surface and the second planar outer surface.

[0108] 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.

[0109] The aerosol generating article may include a first planar outer layer and a second planar outer layer, wherein the first planar outer layer forms a first planar outer surface and the second planar outer layer forms a second planar outer surface. Optionally, at least one of the first planar outer layer, the second planar outer layer, and the frame may include or be made of an aerosol forming substrate.

[0110] The common area can be practically empty.

[0111] The aerosol-forming substrate can be located within the cavity.

[0112] The wavy layer can be located within the cavity.

[0113] The frame can be a flat frame.

[0114] 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.

[0115] 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.

[0116] The frame may be manufactured from or contain biodegradable materials. The frame may be manufactured entirely from biodegradable materials.

[0117] 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.

[0118] 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.

[0119] When viewed in a planar view, any one of the aspects of the present disclosure may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an ellipse, or a circle, or a combination thereof. Where the aerosol generating article comprises 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 quadrilateral (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof. When viewed in a planar view, the perimeter of the aerosol generating article may be formed by a plurality of straight sides, a plurality of curved sides, or a combination of straight sides and curved sides. Where the aerosol generating article comprises 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 quadrilateral (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof.

[0120] An aerosol-generating article may be entirely composed of an aerosol-generating substrate. Alternatively, the aerosol-generating substrate may be one of a plurality of component parts of an aerosol-forming article.

[0121] The aerosol-forming material may contain nicotine. Nicotine may exist in the form of a tobacco material or in the form of a nicotine extract.

[0122] The aerosol-forming substrate may include one or more organic materials such as tobacco, mint, tea, and cloves. The 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.

[0123] The aerosol-forming material may include or be made of homogenized tobacco material, for example, reconstituted tobacco material or cast leaf tobacco material.

[0124] The aerosol-forming substrate may be in the form of a shredded aerosol-generating material. The shredded aerosol-generating material may include: one or more of strips and strands of the aerosol-generating material, such as strips and strands of tobacco or homogenized tobacco material. The shredded aerosol-generating material may be in the form of shredded sheets of homogenized tobacco material.

[0125] The aerosol-forming material may be cut filler. The aerosol-forming material may be tobacco cut filler. 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 such as Virginia tobacco, and Tanzanian yellow. 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, which includes one or more of leaf blades, processed stems, and ribs.

[0126] The 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.

[0127] The 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. The aerosol-forming substrate may be in the form of strips, strands, or particles of tobacco material bonded together in a binder matrix.

[0128] The 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 be one or both of glycerin and propylene glycol, or comprise them. The aerosol-forming agent may consist of glycerin or propylene glycol, or a combination of glycerin and propylene glycol.

[0129] The 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, exceeding 20 weight% based on dry weight, or exceeding 25 weight% based on dry weight, or exceeding 30 weight% based on dry weight, or exceeding 40 weight% based on dry weight, or exceeding 50 weight% based on dry weight.

[0130] The aerosol-forming substrate may have an aerosol-forming agent content of 30% by weight or less, 25% by weight or less, or 20% by weight or less based on dry weight. That is, the aerosol-forming substrate 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.

[0131] The 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.

[0132] The aerosol-forming substrate may comprise at least 50 weight% of an aerosol-forming agent, at least 60 weight% of an aerosol-forming agent, or at least 70 weight% of an aerosol-forming agent.

[0133] The aerosol-forming material may include 85% by weight or less of an aerosol-forming agent, 80% by weight or less of an aerosol-forming agent, or 75% by weight or less of an aerosol-forming agent.

[0134] The aerosol-forming substrate may comprise 50% to 85% by weight of an aerosol-forming agent, 50% to 80% by weight of an aerosol-forming agent, or 50% to 75% by weight of an aerosol-forming agent.

[0135] The aerosol-forming material may include nicotine. The aerosol-forming material may include natural nicotine, synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0136] The aerosol-forming substrate may contain at least 0.5% by weight of nicotine, at least 1% by weight of nicotine, at least 1.5% by weight of nicotine, or at least 2% by weight of nicotine.

[0137] The aerosol-forming material may include one or more flavoring agents. One or more flavoring agents may include one or more essential oils such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and one or more herbal 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.

[0138] The aerosol-forming substrate may include one or more plant components. For example, the aerosol-forming substrate may include 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 in an amount of about 1 to 90%, for example, about 15 to 55%, preferably about 20 to 35%.

[0139] The aerosol-forming substrate may have a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state. For example, the aerosol-forming substrate may be a homogenized tobacco material having a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state.

[0140] The aerosol-forming substrate may include a binder. For example, the aerosol-forming substrate may include about 1 to 10%, preferably about 1 to 5%, of a binder such as either a common gum or pectin used in the food and beverage (F&B) industry. Preferred binders may be natural pectins, e.g., fruit, e.g., citrus or tobacco pectins; guar gum, land locust bean gum, e.g., their hydroxyethyl and hydroxypropyl; starch, e.g., modified or derived starch; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; dextran; and xanthan gum. A preferred binder is guar.

[0141] The aerosol-forming substrate may include or be composed of an aerosol-forming material. The aerosol-forming substrate may include a liquid aerosol-forming material, for example, a liquid aerosol-forming material retained within a porous matrix. The aerosol-forming substrate may include a gel aerosol-forming material.

[0142] The aerosol-forming substrate may be in the form of a plurality of beads. The plurality of beads may have an average particle diameter of 0.1 mm to 4 mm, for example, 0.5 mm to 4 mm.

[0143] The term "bead" refers to individual, solid particles formed from an aerosol-forming substrate. Beads may be round, typically spherical in shape. The substrate may also be defined using other terms, such as "granule."

[0144] Providing an aerosol-forming substrate as multiple beads can offer specific advantages. Beads can be handled more easily than other aerosol-forming substrates, such as fine powder or bits. Since beads flow easily, the cavities of aerosol-generating articles can be reliably and consistently filled during manufacturing. This allows a consistent and reproducible amount of aerosol-forming substrate to be loaded into each article during manufacturing. Beads can also be cleaner to handle than powders and bits, which can cause dust in the factory and leak from aerosol-generating articles during transport or use. By selecting beads with appropriate bead size and appropriate particle size distribution, airflow through the cavities of aerosol-generating articles can be controlled more reproducibly than with bits.

[0145] When a particle is not perfectly spherical but its diameter is referred to, the term "diameter" may refer to the largest dimension of the particle. Alternatively, the term "diameter" may refer to the diameter of a perfectly spherical particle having the same volume as a non-perfectly spherical particle.

[0146] As used herein, the term "average particle diameter" may refer to the number average particle diameter. Other methods for determining the average particle diameter are known. Thus, the average particle diameter may be, for example, the volume average particle diameter.

[0147] The aerosol-forming substrate may be in the form of a wrapped body of the aerosol-forming substrate, and the wrapped body includes a wrapper that at least partially surrounds the aerosol-forming substrate.

[0148] The wrapped body of the aerosol-forming substrate may occupy 15% to 100% of the internal volume of the cavity. The wrapped body of the aerosol-forming substrate may occupy 30% to 100% of the internal volume of the cavity. The wrapped body of the aerosol-forming substrate may occupy 50% to 100% of the internal volume of the cavity. The wrapped body of the aerosol-forming substrate may occupy 50% to 80% of the internal volume of the cavity. The wrapped body of the aerosol-forming substrate may occupy 50% to 70% of the internal volume of the cavity.

[0149] According to the present disclosure, an aerosol generating system is provided. The aerosol generating system may include the aerosol generating article described above and an aerosol generating device. The aerosol generating device is configured to be used with the aerosol generating article to generate an aerosol.

[0150] An aerosol generating device may be configured to accommodate an aerosol generating article. An aerosol generating device may be configured to accommodate at least a portion of an aerosol generating article. An aerosol generating device may be configured to accommodate a portion of an aerosol generating article such that when the aerosol generating article is accommodated within the aerosol generating device, a portion of the aerosol generating article is arranged outside the aerosol generating device. An aerosol generating device may be configured to accommodate the entire aerosol generating article such that the aerosol generating article is entirely surrounded within the aerosol generating device. An aerosol generating device may be configured to accommodate the entire aerosol generating article.

[0151] The aerosol generating device may include a cavity configured to receive the aerosol generating article. The cavity may be dimensioned to accommodate the aerosol generating article. The cavity may be configured to accommodate at least a portion of the aerosol generating article. The cavity may be configured to accommodate a portion of the aerosol generating article. The cavity may be configured to accommodate the entire aerosol generating article.

[0152] In some preferred embodiments, the aerosol generating device comprises a cavity configured to receive at least a portion of an aerosol generating article. In some particularly preferred embodiments, where the contact surface of the aerosol generating article is deformable, the aerosol generating device is configured to deform at least a portion of the deformable contact surface of the aerosol generating article when the aerosol generating article is received in the cavity, thereby prompting the contact surface to come into contact with an aerosol forming substrate.

[0153] An aerosol generating device may be configured to deform at least a portion of a deformable contact surface in any suitable manner. Preferably, the cavity of the aerosol generating device is shaped to deform at least a portion of the deformable contact surface of an aerosol generating article when the aerosol generating article is received within the cavity of the aerosol generating device. The aerosol generating device may include at least one protrusion within the cavity, and the protrusion is configured to deform at least a portion of the deformable contact surface of an aerosol generating article when the aerosol generating article is received within the cavity of the aerosol generating device.

[0154] In some particularly preferred embodiments, at least one protrusion of the aerosol generating device is a heating element of the aerosol generating device. When an aerosol generating article is received within the cavity of the aerosol generating device, the heating element may be configured to heat the aerosol forming substrate of the aerosol generating article. Advantageously, configuring at least one protrusion as a heating element allows the heating element to be positioned very close to the aerosol forming substrate when the aerosol generating article is received within the cavity of the aerosol generating device, thereby improving heat transfer between the heating element and the aerosol forming substrate.

[0155] In some embodiments, the aerosol generator may include two opposing protrusions, each of which extends into the cavity of the aerosol generator. The two opposing protrusions may extend toward each other into the cavity of the aerosol generator. In some embodiments, one of the two opposing protrusions is a heating element of the aerosol generator. In some embodiments, both of the two opposing protrusions are heating elements of the aerosol generator.

[0156] An aerosol generation system includes an aerosol generating device.

[0157] An aerosol generating device may include a cavity configured to accommodate at least a portion of the aforementioned aerosol generating article. The aerosol generating device may include a heater or a heating means. The aerosol generating device may include a power source for supplying power to the heater or the heating means. The aerosol generating device may also include a controller to control the power supply to the heater or the heating means. Preferably, the aerosol generating device is configured to heat an aerosol forming substrate, for example, an aerosol forming substrate that is a component part of the aerosol generating article, to form an aerosol, for example, an inhalable aerosol.

[0158] The cavity may include an opening into which the distal end of an aerosol-generating article can be inserted. The cavity may have any suitable cross-sectional shape. For example, the cavity 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.

[0159] Preferably, at least one internal surface of the cavity is a heating surface configured to heat an aerosol generating article. The heating surface may include a heater, for example, a resistance heater or an infrared heater, or a susceptor configured to be heated by coupling 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 space. 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 couple with a susceptor disposed inside the cavity.

[0160] According to the present disclosure, an aerosol generating device for receiving an aerosol generating article as disclosed herein or an aerosol forming substrate as disclosed herein may include a cavity dimensioned to receive at least a portion of the aerosol generating article or the aerosol forming substrate, a heater or heating means, a power source for supplying power to the heater or heating means, and a controller for controlling the power supply to the heater or heating means. The aerosol generating device is configured to heat an aerosol forming substrate, for example, an aerosol forming substrate that is a component part of an aerosol generating article, to form an aerosol, for example, an inhalable aerosol.

[0161] As used herein, the term "aerosol generating article" may refer to an article capable of generating or releasing aerosols.

[0162] 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.

[0163] 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.

[0164] 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.

[0165] 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.

[0166] As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salt.

[0167] As used herein, the term "transverse direction" refers to the direction extending between the upper outer surface and the lower outer surface. The transverse direction may also be referred to as the "z-direction."

[0168] As used herein, the term "longitudinal direction" refers to a direction perpendicular to the transverse direction. For example, it is the direction between the front and rear walls of an aerosol-generating article. The lateral direction may also be referred to as the "x-direction."

[0169] As used herein, the term "lateral direction" refers to a direction perpendicular to the transverse and longitudinal directions. For example, it is the direction from the first side wall to the second side wall of an aerosol-generating article. The lateral direction may also be referred to as the "y-direction."

[0170] As used herein, the term “height” refers to the transverse dimension of an aerosol generating article or a component of an aerosol generating article. Unless otherwise specified, the term “height” refers to the maximum transverse dimension of an aerosol generating article or a component of an aerosol generating article.

[0171] As used herein, the term “length” refers to the longitudinal dimension of an aerosol generating article or a component of an aerosol generating article. Unless otherwise specified, the term “length” refers to the maximum longitudinal dimension of an aerosol generating article or a component of an aerosol generating article.

[0172] As used herein, the term “width” refers to the lateral dimension of an aerosol-generating article or a component of an aerosol-generating article. Unless otherwise specified, the term “width” refers to the maximum lateral dimension of an aerosol-generating article or a component of an aerosol-generating article.

[0173] 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.

[0174] 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.

[0175] 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.

[0176] 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.

[0177] 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 example, 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.

[0178] 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.

[0179] 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.

[0180] EX1. As an aerosol generating article for generating aerosols by using it together with an aerosol generating device, the aerosol generating article is:

[0181] A cavity defined between an upper surface, a lower surface, and at least one lateral surface; and

[0182] It includes an aerosol-forming substrate arranged within the above cavity,

[0183] The above aerosol generating article is defined by a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction, and

[0184] The upper and lower surfaces are separated from each other in the z-direction, and

[0185] The thickness of the above aerosol generating article is smaller than the length and width of the aerosol generating article, respectively, and

[0186] An aerosol generating article, wherein at least one of the upper surface, lower surface, and at least one side surface is a contact surface.

[0187] EX2. An aerosol generating article in Example EX1, wherein at least a portion of the contact surface contacts the aerosol forming substrate and is configured to conform to the shape of the aerosol forming substrate in the portion where the surface contacts the aerosol forming substrate.

[0188] EX3. An aerosol generating article in Example EX1 or EX2, wherein at least a portion of the contact surface is non-planar in the portion where the contact surface contacts the aerosol forming substrate.

[0189] EX4. An aerosol generating article, wherein in any one of Examples EX1 to EX3, the contact surface is substantially flat except when the contact surface is in contact with the aerosol forming substrate.

[0190] EX5. In any one of Examples EX1 to EX4, the contact surface is an aerosol generating article that is deformable to conform to the shape of the aerosol forming substrate when the contact surface comes into contact with the aerosol forming substrate.

[0191] EX6. An aerosol generating article in any one of Examples EX1 to EX4, wherein at least a portion of the aerosol-forming substrate has a predetermined external shape, and at least a portion of the contact surface has a predetermined shape that corresponds to at least a portion of the predetermined external shape of the aerosol-forming substrate when the contact surface comes into contact with the aerosol-forming substrate.

[0192] EX7. An aerosol generating article in any one of Examples EX1 to EX6, wherein at least two of the upper surface, the lower surface, and the at least one side surface are contact surfaces.

[0193] EX8. An aerosol generating article in Example EX7, wherein the upper surface is a contact surface and the lower surface is a contact surface, and optionally the at least one side surface is a contact surface.

[0194] EX9. An aerosol generating article in Example EX7, wherein the at least one side surface comprises a first side surface and a second side surface, the first side surface and the second side surface are separated from each other in the y-direction, and at least one of the first side surfaces is a contact surface and the second side surface is a contact surface.

[0195] EX10. An aerosol generating article in Example Ex9, wherein the first side surface is a contact surface and the second side surface is a contact surface.

[0196] EX11. An aerosol generating article in any one of Examples EX1 to EX9, wherein the aerosol generating article comprises a frame, the frame defines at least one side surface, and optionally the frame defines at least one outer side surface of the aerosol generating article.

[0197] EX12. In any one of Examples EX1 to EX11, the aerosol generating article comprises an upper layer and a lower layer, wherein the upper layer defines the upper surface and the lower layer defines the lower surface, optionally the upper layer defines the upper outer surface of the aerosol generating article and optionally the lower layer defines the lower outer surface of the aerosol generating article.

[0198] EX13. In any one of Examples Ex1 to Ex12,

[0199] The above aerosol generating article comprises an upper layer and a lower layer, wherein the upper layer defines the upper surface and the lower layer defines the lower surface;

[0200] The aerosol generating article comprises a frame arranged between the upper layer and the lower layer, wherein the frame defines at least one side surface.

[0201] EX14. An aerosol generating article, wherein in any one of Examples EX1 to EX13, the aerosol forming substrate has a length extending in the x-direction, the cross-section of the aerosol forming substrate has a periphery at a point along the length of the aerosol forming substrate, and the at least one contact surface contacts the aerosol forming substrate around substantially the entire periphery of the cross-section of the aerosol forming substrate at a point along the length of the aerosol forming substrate.

[0202] EX15. As an aerosol generation system,

[0203] An aerosol generating article according to any one of Examples Ex1 to Ex14; and

[0204] An aerosol generating system comprising an aerosol generating article and an aerosol generating device configured to be used to generate an aerosol.

[0205] EX16. An aerosol generating system comprising an aerosol generating article according to Example EX5 and an aerosol generating device configured to be used together with the aerosol generating article to generate an aerosol, wherein the aerosol generating device comprises a cavity configured to accommodate at least a portion of the aerosol generating article; and wherein the aerosol generating device is configured to deform at least a portion of a deformable contact surface of the aerosol generating article when the aerosol generating article is accommodated in the cavity, thereby bringing the contact surface into contact with the aerosol forming substrate.

[0206] EX17. An aerosol generating system in Example EX16, wherein the aerosol generating device comprises at least one protrusion extending into a cavity of the aerosol generating device, and the at least one protrusion is configured to deform at least a portion of a deformable contact surface of the aerosol generating article when the aerosol generating article is received in the cavity, thereby bringing the contact surface into contact with the aerosol forming substrate.

[0207] EX18. In Example EX17, the aerosol generating system, wherein at least one protrusion of the aerosol generating device is a heating element of the aerosol generating device. Brief explanation of the drawing

[0208] Now, embodiments will be further described with reference to the drawings. Figure 1 shows a side perspective view of an aerosol generating article. Figure 2 shows a side perspective view of an aerosol-generating article. Figure 3 shows a schematic end view of an aerosol generating article. Figure 4 shows a schematic side view of the aerosol generating article of Figure 3. Figure 5 shows a schematic plan view of the aerosol generating article of Figure 3. Figure 6 shows a schematic diagram of a wavy element used in the aerosol generating article of Figure 3. Figure 7 shows a perspective view of an aerosol-generating article. Figure 8 shows an exploded perspective view of the aerosol generating article of Figure 7. Figure 9 shows an additional exploded perspective view of the aerosol generating article of Figure 7. Figure 10 shows a schematic cross-sectional view of the aerosol-generating article of Figure 7. Figure 11 shows a schematic longitudinal cross-sectional view of the aerosol generating article of Figure 7. Figure 12 shows an exploded perspective view of an aerosol generating article. Figure 13 shows a schematic cross-sectional view of the aerosol-generating article of Figure 12. Figure 14 shows a schematic side cross-sectional view of the aerosol generating article of Figure 12. FIG. 15 shows an exploded perspective view of an aerosol generating article according to an embodiment of the present disclosure. FIG. 16 shows a schematic side perspective view of the aerosol generating article of FIG. 15. FIG. 17 shows an exploded perspective view of an aerosol generating article according to an embodiment of the present disclosure. FIG. 18 shows a schematic side perspective view of the aerosol generating article of FIG. 17. FIG. 19 shows a schematic plan view of an aerosol generating article according to an embodiment of the present disclosure. Figure 20 shows a schematic cross-sectional view of the aerosol-generating article of Figure 19. FIG. 21 shows a schematic cross-sectional view of a heating element of an aerosol generating device configured for use with the aerosol generating articles of FIG. 19 and FIG. 20 and the aerosol generating articles of FIG. 19 and FIG. 20. FIG. 22 shows a schematic longitudinal cross-sectional view of the aerosol generating article of FIG. 19 and FIG. 20 in use with the heating element of FIG. 21. FIG. 23 shows a schematic diagram of an aerosol generating device including the heating elements of FIG. 21 and FIG. 22, and the device is configured to be connected to the aerosol generating articles of FIG. 19 and FIG. 20. FIG. 24 shows a schematic end view of the aerosol generating device of FIG. 23. FIG. 25 shows a schematic diagram of the aerosol generating article of FIG. 19 and FIG. 20 connected to the aerosol generating device of FIG. 23 and FIG. 24. FIG. 26 shows a schematic diagram of an alternative embodiment of FIG. 23 to 25, showing an aerosol generating article coupled with an aerosol generating device. Specific details for implementing the invention

[0209] FIG. 1 illustrates a side perspective view of an aerosol generating article (100). The aerosol generating article (100) has upper and lower surfaces (110, 120) that are flat or planar.

[0210] 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.

[0211] A suitable aerosol-forming substrate may be a homogenized tobacco.

[0212] 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).

[0213] FIG. 2 illustrates a side perspective view of an aerosol generating article (200), and the aerosol generating article (200) of FIG. 2 is a modified example of the aerosol generating article (100) of FIG. 1. 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 the 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).

[0214] 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). The aerosol generating article (300) comprises a flat upper layer (310), a flat lower layer (320), and an intermediate or separating layer (340) arranged between the upper layer (310) and the lower layer (320).

[0215] 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. Accordingly, the middle layer (340) may be formed from a wavy sheet of a homogenized tobacco material (345).

[0216] 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.

[0217] 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.

[0218] 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.

[0219] 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) 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.

[0220] The aerosol-forming substrate (345) may be any suitable aerosol-forming substrate sheet.

[0221] 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).

[0222] FIG. 7 illustrates an aerosol generating article (400). 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) located between the first planar outer layer (424) and the second planar outer layer (425). The second planar outer surface (422) is located parallel to the first planar outer surface (421).

[0223] FIGS. 8 and 9 show exploded views of the aerosol generating article (400) of FIG. 7. A frame (450) surrounds and at least partially defines the cavity (430). FIG. 8 shows the cavity (430) in an empty state. FIG. 9 shows the cavity (430) filled with an aerosol forming substrate (440). FIGS. 10 and 11 show a cross-sectional view and a longitudinal cross-sectional view, respectively, of the aerosol generating article (400) when the cavity (430) is filled with an aerosol forming substrate (440).

[0224] The first planar outer layer (424) and the second planar outer layer (425) are made of cigarette paper having a thickness of 35 μm and are physically in contact with and bonded to the frame (450). The first planar outer layer (424) is placed over the first end of the cavity (430) and forms the first cavity end wall (431). The second planar outer layer (425) is placed over the second end of the cavity (430) and forms the second cavity end wall (432), and the second cavity end wall (432) faces the first cavity end wall (431). That is, the frame (450), the first planar outer layer (424), and the second planar outer layer (425) collectively define the cavity (430).

[0225] 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).

[0226] 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-forming substrate in the form of a tobacco stick and has an aerosol-forming agent content of 5% by weight based on dry weight. As shown, the aerosol-forming substrate (440) fills the entire volume of the cavity (430).

[0227] 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.

[0228] FIG. 12 illustrates an aerosol generating article (500). 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 (540) of the aerosol forming substrate, in particular a wavy sheet of homogenized tobacco material. FIG. 13 and FIG. 14 show a cross-sectional view and a side cross-sectional view, respectively, of the aerosol generating article (500) of FIG. 12.

[0229] Similar to the aerosol generating article (400), the aerosol generating article (500) comprises a first planar outer layer (524) forming a first planar outer surface (521), a second planar outer layer (525) forming a second planar outer surface (522), and a frame (550) positioned between the first planar outer layer (524) and the second planar outer layer (525). The second planar outer surface (522) is positioned parallel to the first planar outer surface (521). An air inlet (511) and an air outlet (512) are defined by and extend through the peripheral wall surface (551) of the frame (550). The frame (550) surrounds and at least partially defines a cavity (530). The cavity (530) comprises an aerosol generating substrate (540) in the form of a corrugated sheet of homogenized tobacco material.

[0230] 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 (530), 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.

[0231] A plurality of parallel wavy folds form a plurality of channels (545) between the sheet (540) of the aerosol-forming material and the first cavity end wall (531), and form a plurality of channels (546) between the sheet (540) of the aerosol-forming substrate 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).

[0232] 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).

[0233] FIGS. 15 and FIGS. 16 show an aerosol generating article (600) according to an embodiment of the present disclosure. FIG. 15 shows an exploded view of the aerosol generating article (600), FIG. 16 shows a side perspective view of the aerosol generating article (600), and the aerosol generating article (600) is a variation of the aerosol generating article (400) of FIGS. 7 through 11. Features common to the aerosol generating article (400) are referred to by similar reference numerals, but start with the number 6 instead of the number 4.

[0234] The aerosol generating article (600) comprises a first planar outer layer (624) forming a first planar outer surface (621), a second planar outer layer (625) forming a second planar outer surface (622), and a frame (650) positioned between the first planar outer layer (624) and the second planar outer layer (625). The second planar outer surface (622) is positioned parallel to the first planar outer surface (621).

[0235] The frame (650) surrounds the cavity (630) and defines it at least partially. As described in more detail below, an aerosol-forming substrate (640) is arranged within the cavity (630).

[0236] The first planar outer layer (624) and the second planar outer layer (625) are made of cigarette paper having a thickness of 35 μm and are physically in contact with and bonded to the frame (650). The first planar outer layer (624) is placed over the first end of the cavity (630) and forms the first cavity end wall. The second planar outer layer (625) is placed over the second end of the cavity (630) and forms the second cavity end wall, and the second cavity end wall faces the first cavity end wall. That is, the frame (650), the first planar outer layer (624), and the second planar outer layer (625) collectively define the cavity (630).

[0237] The frame (650) has a hollow rectangular shape and is made of cardboard. The frame (650) defines an aperture that extends through the height (also referred to as thickness) of the frame (650), and the aperture forms at least partially a cavity (630) of the aerosol generating article (600). The frame (650) includes a perimeter wall surface that surrounds the cavity (630).

[0238] The air inlet (611) and air outlet (612) are defined by and extend through the peripheral wall surface of the frame (650). More specifically, the air inlet (611) extends through the front wall surface and the air outlet (612) extends through the rear wall surface. The air inlet (611) and the air outlet (612) have an equivalent diameter of 5 mm. An airflow passage extends through a cavity (630) between the air inlet (611) and the air outlet (612).

[0239] The aerosol generating article (600) generally has a rectangular shape and has a height (or thickness) of 8 mm extending in the z-dimension, a width of 40 mm extending in the y-dimension, and a length of 60 mm extending in the x-dimension, as measured between the first planar outer surface (621) and the second planar outer surface (622). The frame (650) has a height (or thickness) of 7.93 mm extending in the z-dimension, a width of 40 mm extending in the y-dimension, and a length of 60 mm extending in the x-dimension. The cavity (630) has a height (or thickness) of 7.93 mm extending in the z-dimension, a width of 30 mm extending in the y-dimension, and a length of 50 mm extending in the x-dimension.

[0240] The aerosol-forming substrate (640) is located within the cavity (630). The aerosol-forming substrate (640) includes an aerosol-forming substrate in the form of a tobacco stick and has an aerosol-forming agent content of 5% by weight based on dry weight.

[0241] In this embodiment, the aerosol-forming substrate does not fill the entire volume of the cavity (630). Instead, the aerosol-forming substrate (640) occupies the central region of the cavity (630), and the entire periphery of the aerosol-forming substrate (640) is in contact with the surface of the cavity (630). That is, the inner surface of the frame (650) is in contact with the aerosol-forming substrate (640), and the inner surfaces of the first outer layer (624) and the second outer layer (625) are in contact with the aerosol-forming substrate (640).

[0242] In this embodiment, the aerosol forming substrate (640) has a height of 9.93 mm in z-dimension, which means that the aerosol forming substrate (640) has a height 2 mm greater than the height of the cavity (630) defined by the height of the frame (650). Consequently, when the first outer layer (624) is bonded to the frame (650), the upper portion of the aerosol forming substrate (640) extends over the frame (650) and deforms the first outer layer (624). Since the first outer layer (624) is formed of paper, it deforms and conforms to the external shape of the upper portion of the aerosol forming substrate (640). Similarly, when the second outer layer (625) is bonded to the frame (650), the lower portion of the aerosol forming substrate (640) extends under the frame (650) and deforms the second outer layer (625). Since the second outer layer (625) is formed of paper, it is deformed to conform to the external shape of the lower part of the aerosol-forming substrate (640). The first outer layer (624) and the second outer layer (625) are deformed so that the layers (624 and 625) match the external shape of the aerosol-forming substrate (640), thereby ensuring close contact between the aerosol-forming substrate (640) and the layers (624 and 625). This reduces the formation of air channels between the aerosol-forming substrate (640) and the layers (624 and 625), thereby facilitating the flow of air through the aerosol-generating article (600) through the aerosol-forming substrate (640).

[0243] FIGS. 17 and 18 show an aerosol generating article (700) according to an embodiment of the present disclosure. FIG. 17 shows an exploded view of the aerosol generating article (700), FIG. 18 shows a side perspective view of the aerosol generating article (700), and the aerosol generating article (700) is a variation of the aerosol generating article (600) of FIGS. 15 and 16. Features common to the aerosol generating article (600) are referred to by similar reference numerals, but start with the number 7 instead of the number 6.

[0244] The aerosol generating article (700) of FIGS. 17 and 18 differs from the aerosol generating article (600) of FIGS. 15 and 16 in that, as in FIGS. 16, the aerosol generating article (600) has an aerosol forming substrate (740) that is not larger than the frame and has a height of 7.93 mm with a z-dimension equal to the height of the frame (750). However, in this embodiment, the frame (750) has a narrow portion (703) arranged in the aerosol forming substrate. The narrow portion (703) includes a channel having a depth of about 1 mm, which extends around the circumference of the aerosol generating article (700) to reduce the width and height of the frame (750). Thus, the height of the frame (750) in the narrow portion (703) is 5.93 mm, which is lower than the height of the aerosol forming substrate (740). As a result, when the first outer layer (724) is bonded to the frame (750) and deformed into a channel of the narrow portion (703), the first outer layer (724) is deformed around the upper portion of the aerosol forming substrate (740) to conform to the external shape of the aerosol forming substrate (740). Similarly, when the second outer layer (724) is bonded to the frame (750) and deformed into a channel of the narrow portion (703), the second outer layer (724) is deformed around the upper portion of the aerosol forming substrate (740) to conform to the external shape of the aerosol forming substrate (740).

[0245] FIGS. 19 and FIGS. 20 show an aerosol generating article (800) according to an embodiment of the present disclosure. FIG. 19 shows a schematic plan view of the aerosol generating article (800), FIG. 20 shows a schematic side view of the aerosol generating article (800), and the aerosol generating article (800) is a variation of the aerosol generating article (600) of FIGS. 15 and FIGS. 16. Features common to the aerosol generating article (600) are referred to by similar reference numerals, but start with the number 8 instead of the number 6.

[0246] The aerosol generating article (800) of FIGS. 19 and 20 has an aerosol forming substrate (940) that is not larger than the frame as in the aerosol generating article (600) of FIGS. 15 and 16, and the height (H) of the frame (750) A Height (H) at a z dimension of 5.93 mm, which is smaller than ) S It differs from the aerosol generating article (600) of FIGS. 15 and FIGS. 16 in that it has ). Consequently, when the first outer layer (824) is bonded to the frame (850), the first outer layer (824) does not come into contact with the aerosol forming substrate (840). Similarly, when the second outer layer (825) is bonded to the frame (850), the second outer layer (825) does not come into contact with the aerosol forming substrate (840).

[0247] FIG. 21 shows a schematic cross-section of a heating element (6030) of an aerosol generating device (6000), which is configured to be used with the aerosol generating article (800) of FIG. 19 and FIG. 20 and will be described in more detail below, and FIG. 22 shows the heating element (6030) of FIG. 21 and the aerosol generating article (800) of FIG. 19 and FIG. 20 in use.

[0248] The heating elements (6030) are substantially identical and each includes a protrusion sized and shaped to be fitted into the gap between the first outer layer (824) and the aerosol forming substrate (840), and the gap between the second outer layer (825) and the aerosol forming substrate (840). The heating elements (6030) are arranged facing each other, and the protrusions are spaced apart in the z-direction with a gap of 5.93 mm, which is the thickness of the aerosol forming substrate (840). The space between the heating elements (6030) forms a part of the cavity of the aerosol generating device, as described in more detail below. When an aerosol generating article (800) is inserted into the cavity, the protrusions of the heating elements (6030) are pushed into the gap between the first outer layer (824) and the aerosol forming substrate (840), and the gap between the second outer layer (825) and the aerosol forming substrate (840). One heating element (6030) presses the first outer layer (824) to contact the aerosol forming substrate (840) so that the first outer layer (824) conforms to the external shape of the aerosol forming substrate (840). Another heating element (6030) presses the second outer layer (825) to contact the aerosol forming substrate (840) so that the second outer layer (825) conforms to the external shape of the aerosol forming substrate (840). In this arrangement, the heating element (6030) is arranged very close to the aerosol forming substrate (840), and no air gap is provided between the heating element (6030), the layers (824, and 825), and the aerosol forming substrate (840).

[0249] FIGS. 21 and 22 illustrate an aerosol generating device (6000) configured for use with an aerosol generating article (800). The device (6000) is an elongated aerosol generating device extending between a proximal end (6001) and a distal end (6002). As previously described, the device (6000) includes a battery (6010), a controller (6020), and a pair of heaters (6030). The controller (6020) controls the power supply from the battery (6010) to the heaters (6030). A cavity (6050) is defined in the device (6000), and the cavity 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 the aerosol generating article (800). The cavity (6050) includes an upper flat surface (6052) and a lower flat surface (6053). One of the heaters (6030) extends through the lower flat surface (6053) to heat the lower surface of the aerosol generating article (800) inserted into the cavity (6050), and the other of the heaters (6030) extends through the upper flat surface (6052) to heat the upper surface of the aerosol generating article (800) inserted into the cavity (6050). An airflow path is configured so that air can flow from outside the device (6000) into the cavity (6050).

[0250] FIG. 25 illustrates the device (6000) of FIG. 23 connected to an aerosol generating article (800). There is almost no tolerance between the outer surface of the aerosol generating article (800) and the inner surface of the cavity (6050). Therefore, there is a tight fit between the aerosol generating article (800) and the device (6000). Since the RTD of the aerosol generating article (800) is negligible, the RTD of the system formed by the combination of the aerosol generating article (800) and the aerosol generating device (6000) is controlled by an airflow path defined within the device. When a user inserts the aerosol generating article (800) into the cavity (6050), the device (6000) can be operated. A heater (6030) heats the lower and upper surfaces of the aerosol generating article (800), and as a result, the aerosol forming substrate (840) of the aerosol generating article (800) is heated. The volatile components of the aerosol-forming substrate (840) vaporize and condense in the longitudinal airflow channels defined within the aerosol-generating article (800) to form an aerosol. The user inhales the aerosol by inhaling the proximal end of the aerosol-generating article (800). Once the volatile components in the aerosol-generating substrate (840) of the aerosol-generating article (800) are depleted, the aerosol-generating article (800) is removed from the cavity (6050) of the device (6000) and disposed of.

[0251] FIG. 25 shows a portion of an aerosol generating article (800) 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. 26 illustrates an alternative embodiment of FIG. 25, in which similar features are referred to by the same reference numeral but with the addition of the prime symbol '.

[0252] Similar to the aerosol generating article (800), the aerosol generating article (800') comprises an aerosol forming substrate (840'). Similar to the aerosol generating device (6000), the aerosol generating device (6000') is an elongated aerosol generating device extending between a proximal end (6001') and a distal end (6002'). The aerosol generating device (6000') comprises a battery (6010'), a controller (6020'), and a heater (6030') located within a housing (6040'). A cavity (6050') is defined in the device (6000'), and the cavity (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 the aerosol generating article (800'). The cavity (6050') includes an upper planar surface (6052') and a lower planar surface (6053'). The airflow path is configured so that air can flow from outside the device (6000') into the cavity (6050').

[0253] In an alternative embodiment of FIG. 26, the entire aerosol generating article (800') is enclosed within the interior of an aerosol generating device (6000'). Additionally, the aerosol generating device (6000') includes a single heating element extending into a cavity (6050') through a lower flat surface (6053'). In this embodiment, when the aerosol generating article (800) is received within the cavity (6050'), the protrusion of the heating element (6030') is sufficiently large to press the aerosol forming substrate (840') against both layers (824' and 825').

[0254] For the purposes of this description and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, etc., shall be understood in all cases to be modified by the term “about.” Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein. Accordingly, in this context, the number “A” is understood as 10% of “A” ± “A”. In this context, the number “A” may be considered to include numerical values ​​within the general standard error for measuring the characteristic modified by the number “A”. In some cases used in the appended claims, the number “A” may deviate by the percentage listed above, provided that the amount of deviation by “A” does not substantially affect the basic and novel feature(s) of the claimed invention. Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein. The terms “here” and “the” are used as synonyms throughout this specification.

Claims

Claim 1 As an aerosol generating article for generating aerosols by use with an aerosol generating device, the aerosol generating article is: A cavity defined between an upper surface, a lower surface, and at least one lateral surface; and An aerosol generating article comprising an aerosol forming substrate arranged within the above cavity, wherein the aerosol generating article is defined by a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction; wherein the upper and lower surfaces are separated from each other in the z-direction; wherein the thickness of the aerosol generating article is smaller than the length and width of the aerosol generating article, respectively; wherein at least one of the upper surface, the lower surface, and the at least one side surface is a contact surface, and at least a portion of the contact surface is in contact with the aerosol forming substrate and is configured to conform to the shape of the aerosol forming substrate in the portion where the surface contacts the aerosol forming substrate. Claim 2 An aerosol generating article according to claim 1, wherein at least a portion of the contact surface is non-planar in the portion where the contact surface contacts the aerosol forming substrate. Claim 3 An aerosol generating article according to claim 1 or 2, wherein the contact surface is substantially flat except when the contact surface is in contact with the aerosol forming substrate. Claim 4 In any one of claims 1 to 3, the contact surface is an aerosol generating article that is deformable to conform to the shape of the aerosol forming substrate when the contact surface comes into contact with the aerosol forming substrate. Claim 5 An aerosol generating article according to any one of claims 1 to 3, wherein at least a portion of the aerosol-forming substrate has a predetermined external shape, and at least a portion of the contact surface has a predetermined external shape that corresponds to at least a portion of the predetermined external shape of the aerosol-forming substrate when the contact surface comes into contact with the aerosol-forming substrate. Claim 6 An aerosol generating article according to any one of claims 1 to 5, wherein at least two of the upper surface, the lower surface, and at least one side surface are contact surfaces. Claim 7 An aerosol generating article according to claim 6, wherein the upper surface is a contact surface and the lower surface is a contact surface, and optionally, the at least one side surface is a contact surface. Claim 8 An aerosol generating article according to claim 6, wherein the at least one side surface comprises a first side surface and a second side surface, the first side surface and the second side surface are separated from each other in the y-direction, and at least one of the first side surfaces is a contact surface and the second side surface is a contact surface. Claim 9 An aerosol generating article according to claim 8, wherein the first side surface is a contact surface and the second side surface is a contact surface. Claim 10 An aerosol generating article according to any one of claims 1 to 9, wherein the aerosol generating article comprises a frame, the frame defines at least one side surface, and optionally the frame defines at least one outer side surface of the aerosol generating article. Claim 11 An aerosol generating article according to any one of claims 1 to 10, wherein the aerosol generating article comprises an upper layer and a lower layer, wherein the upper layer defines an upper surface and the lower layer defines a lower surface, optionally the upper layer defines an upper outer surface of the aerosol generating article and optionally the lower layer defines a lower outer surface of the aerosol generating article. Claim 12 In any one of claims 1 to 9, the aerosol generating article comprises an upper layer and a lower layer, wherein the upper layer defines the upper surface and the lower layer defines the lower surface; and the aerosol generating article comprises a frame arranged between the upper layer and the lower layer, wherein the frame defines the at least one side surface. Claim 13 An aerosol generating article according to any one of claims 1 to 12, wherein the aerosol forming substrate has a length extending in the x-direction, the cross-section of the aerosol forming substrate has a perimeter at a point along the length of the aerosol forming substrate, and the at least one contact surface contacts the aerosol forming substrate substantially around the entire perimeter of the cross-section of the aerosol forming substrate at a point along the length of the aerosol forming substrate. Claim 14 An aerosol generating system comprising: an aerosol generating article according to any one of claims 1 to 13; and an aerosol generating device configured to be used with the aerosol generating article to generate an aerosol. Claim 15 An aerosol generating system comprising an aerosol generating article according to claim 4, and an aerosol generating device configured to be used together with said aerosol generating article to generate an aerosol, wherein the aerosol generating device comprises a cavity configured to accommodate at least a portion of said aerosol generating article; and wherein the aerosol generating device is configured to deform at least a portion of a deformable contact surface of said aerosol generating article when said aerosol generating article is accommodated in said cavity, thereby inducing said contact surface to come into contact with said aerosol forming substrate.

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