Aerosol generating items

Abstract

An aerosol generating article (100, 200, 300, 400, 500, 600, 700, 800, 1200, 1300, 1401, 1402) comprising an aerosol forming substrate and at least one thread (125, 225, 325, 326, 327, 625, 1208) is provided. At least a portion of the aerosol forming substrate is sewn with the at least one thread. A method of manufacturing is also provided.

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 is substantially cylindrical and may include an aerosol-forming substrate and other components, such as a mouthpiece filter element and a cooling element, all of which are arranged together in a rod form and wrapped in cigarette paper. The dimensions of a typical aerosol generating article are often similar to those 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 only to manufacturing and transport costs of the aerosol-generating article and 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 material is heated from the inside or the outside. Furthermore, since the components of these cylindrical aerosol-generating articles generally have the same or very similar outer diameters, they need to be joined, positioned precisely in coaxial alignment, and wrapped in cigarette paper to hold them together. 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. Additionally, the object of the present disclosure is to provide an aerosol generating article that provides a novel method of holding the aerosol-forming substrate together or holding a plurality of components of the aerosol generating article together.

[0005] According to the present disclosure, an aerosol generating article comprising an aerosol-forming substrate and at least one thread may be provided. At least a portion of the aerosol-forming substrate may be sewn with at least one thread.

[0006] Accordingly, according to the first aspect of the present disclosure, an aerosol generating article comprising an aerosol forming substrate and at least one thread may be provided, wherein at least a portion of the aerosol forming substrate may be sewn with at least one thread.

[0007] Advantageously, sewing the aerosol-forming substrate with at least one thread can hold the substrate together or retain the aerosol-forming substrate in a compressed state. This can advantageously prevent the aerosol-forming substrate from falling off or limit the substrate from occupying more space due to expansion. Alternatively, or additionally, sewing at least a portion of the aerosol-forming substrate with at least one thread can create space for airflow or aerosol generation.

[0008] An aerosol generating article may be intended to be used in conjunction with an aerosol generating device to generate aerosols. The aerosol generating article may be a flat aerosol generating article. The aerosol generating article may have an article length, an article width, and an article thickness, or these may be defined by them. The article length may be, for example, at least 2, 3, or 5 times the article thickness. The article width may be, for example, at least 2, 3, or 5 times the article thickness. The article length may be greater than the article width. Advantageously, a relatively small article thickness may reduce the temperature gradient across the article or across the substrate of the article during use. This may mean that, compared to a thicker article or substrate, a larger proportion of the substrate can reach a temperature high enough to form an aerosol without a significant risk of burning the substrate.

[0009] The terms height and thickness may be used interchangeably herein. Accordingly, the terms article height and article thickness may be used interchangeably, and the terms substrate height and substrate thickness may be used interchangeably.

[0010] Optionally, the article length extends in the article length direction. Optionally, the article width extends in the article width direction. Optionally, the article thickness extends in the article thickness direction. Optionally, the article length direction is perpendicular to the article width direction. Optionally, the article length direction is perpendicular to the article thickness direction. Optionally, the article width direction is perpendicular to the article thickness direction. Optionally, the article length direction, article width direction, and article thickness direction are mutually perpendicular. The article length direction may be referred to as the x-direction. The article width direction may be referred to as the y-direction. The article thickness direction may be referred to as the z-direction. The article length may extend from the upstream end of the article to the downstream end.

[0011] Optionally, the article is substantially planar in shape. Optionally, the article is substantially rectangular in shape.

[0012] The aerosol-generating article may comprise an upper surface, for example, a substantially flat upper surface. The upper surface may be defined by a length extending in the x-direction, for example, the length of the article, and a width extending in the y-direction, for example, the width of the article. The aerosol-generating article may comprise a lower surface, for example, a substantially flat lower surface. The lower surface may be defined by a length extending in the x-direction, for example, the length of the article, and a width extending in the y-direction, for example, the width of the article. The upper surface and the lower surface may be external surfaces of the article. The upper surface and the lower surface may be spaced perpendicularly apart from each other by a height defined in the z-direction, for example, the thickness of the article. The lower surface may be referred to as the base.

[0013] An aerosol-forming substrate may have a substrate length, a substrate width, and a substrate thickness, or these may be defined by them. The substrate length may extend in the substrate length direction. The substrate width may extend in the substrate width direction. The substrate thickness may extend in the substrate thickness direction. The substrate length direction, the substrate width direction, and the substrate thickness direction may be mutually perpendicular. The substrate length may be, for example, at least 2, 3, or 5 times the substrate thickness. The substrate width may be, for example, at least 2, 3, or 5 times the substrate thickness. The substrate length may be greater than the substrate width. Preferably, a relatively small substrate thickness may reduce the temperature gradient across the substrate during use. This may mean that, compared to a thicker substrate, a larger proportion of the substrate can reach a temperature high enough to form an aerosol without a significant risk of burning the substrate.

[0014] The length of the sheet may extend from the upstream end of the sheet to the downstream end of the sheet. The length direction of the sheet may be aligned with the length direction of the article or substantially parallel. The width direction of the sheet may be aligned with the width direction of the article or substantially parallel. The thickness direction of the sheet may be aligned with the thickness direction of the article or substantially parallel.

[0015] The aerosol generating article according to the present disclosure may preferably be a substantially flat article or a substantially planar article. Such an article may have a large base area relative to the volume of the article. In particular, the height of the aerosol generating article is less than 50% or 25% of both the length and width of the aerosol generating article. Advantageously, a larger base area may provide a larger surface area for heating by a planar heater of the aerosol generating device. Advantageously, a smaller height may allow for a smaller temperature gradient or difference across the height of the aerosol generating article during heating. For example, if the base of the aerosol generating article is in contact with a planar heater and heated by it, a smaller gap or height between the base and the upper surface may result in a smaller temperature difference between the base and the upper surface facing the base. Advantageously, this may minimize the risk of the hottest part of the substrate closest to the heater burning while enabling a greater proportion of the aerosol-forming substrate of the aerosol generating article to be heated to the temperature at which the aerosol is emitted. Alternatively or additionally, this can reduce the time required to heat the aerosol-forming substrate sufficiently to release the aerosol.

[0016] Optionally, at least a portion of the aerosol-forming substrate may be sewn with at least one thread to maintain the aerosol-forming substrate in a compressed state. Optionally, the compressed state is a compressed state relative to the natural state or the lowest elastic energy state of the aerosol-forming substrate. Optionally, the compressed state is a compressed state in the thickness direction of the substrate. Optionally, the aerosol-forming substrate stores elastic energy in the compressed state.

[0017] Optionally, at least a portion of the aerosol-forming substrate is sewn with at least one thread to prevent or limit the release of stored elastic energy, such as the stored elastic energy mentioned in the previous sentence. Optionally, at least a portion of the aerosol-forming substrate is sewn with at least one thread to prevent or limit the release of stored elastic energy through the expansion of the aerosol-forming substrate, for example, through the expansion of the aerosol-forming substrate in the substrate thickness direction. Optionally, at least a portion of the aerosol-forming substrate is sewn with at least one thread to limit the expansion of the aerosol-forming substrate, for example, in the substrate thickness direction. Optionally, at least a portion of the at least one thread is under tension, for example, because it acts to cause the aerosol-forming substrate to expand. Optionally, the aerosol-forming substrate sewn with at least one thread occupies a first volume. Optionally, when the at least one thread is removed, the aerosol-forming substrate will expand to occupy a second volume larger than the first volume. This expansion may be expansion in the substrate thickness direction or may be mostly expansion in the substrate thickness direction.

[0018] Advantageously, sewing the aerosol-forming substrate with at least one thread can keep the aerosol-forming substrate in a compressed state. This can advantageously prevent the aerosol-forming substrate from expanding and occupying more space within the aerosol-generating article. Alternatively or additionally, this can advantageously help to keep the aerosol-forming substrate in a desired shape or impart a desired bulk density to the aerosol-forming substrate.

[0019] The aerosol-forming substrate may be a plug of an aerosol-forming material or may include the same. The aerosol-forming substrate may be one or more sheets of an aerosol-forming material or may include the same.

[0020] Optionally, at least a portion of at least one thread extends through the substrate in a first penetration direction. Optionally, at least a portion of at least one thread extends along the substrate in a first extension direction. Optionally, at least a portion of at least one thread extends through the substrate in a second penetration direction that is optionally opposite to the first penetration direction. Optionally, at least a portion of at least one thread extends along the substrate in a second extension direction that is optionally parallel to the first extension direction. The extensions of this paragraph may occur in the order presented in this paragraph and may occur immediately after each other. Thus: optionally, at least a portion of at least one thread extends: through the substrate in a first penetration direction; then optionally immediately, along the substrate in a first extension direction; then optionally immediately, through the substrate, in a second penetration direction that is optionally opposite to the first penetration direction; then optionally immediately, along the substrate, in a second extension direction that is optionally identical to the first extension direction.

[0021] As mentioned in the paragraph above, the extension of at least one thread through the substrate may refer to the extension of at least one thread through the substrate thickness, for example, from the upper surface to the lower surface of the substrate in the first penetration direction and from the lower surface to the upper surface of the substrate in the second penetration direction, or vice versa.

[0022] As mentioned in the two paragraphs above, the extension of at least one thread along the substrate in the first extension direction may refer to the extension of at least one thread along the upper or lower surface of the substrate. And, as mentioned in the two paragraphs above, the extension of at least one thread along the substrate in the second extension direction may refer to the extension of at least one thread along the other of the upper or lower surface of the substrate.

[0023] When at least one thread extends through the substrate, at least one thread may come into contact with the substrate. When at least one thread extends along the substrate, at least one thread may come into contact with the substrate. Alternatively, when at least one thread extends along the substrate, at least one thread may not come into contact with the substrate. For example, when at least one thread extends along the substrate, a component such as a cover may be positioned between at least one thread and the substrate, as will be mentioned later.

[0024] Optionally, the first penetration direction is non-perpendicular to the substrate thickness direction and, for example, substantially parallel to the substrate thickness direction. Optionally, the second penetration direction is substantially opposite to the first penetration direction. Optionally, the second penetration direction is non-perpendicular to the substrate thickness direction and, for example, substantially parallel to the substrate thickness direction. Advantageously, this may allow the substrate to be held in a state where at least one thread is compressed in the substrate thickness direction. In this context and similar contexts, opposite directions may be considered to be parallel to each other.

[0025] Optionally, the first extension direction is non-perpendicular to the substrate length direction and, for example, substantially parallel to the substrate length direction. Optionally, the second extension direction is non-perpendicular to the substrate length direction and, for example, substantially parallel to the substrate length direction. For example, at least one thread can form a linear stitch pattern along the aerosol-forming substrate in the substrate length direction. Advantageously, the linear stitch pattern may be less costly or less difficult to achieve than other stitch patterns. Advantageously, if the substrate length is longer than the substrate width and substrate thickness, the stitch along the substrate length can hold the substrate in a compressed state better than the stitch along the substrate width direction.

[0026] Optionally, the first extension direction is non-perpendicular to the substrate width direction and, for example, substantially parallel to the substrate width direction. Optionally, the second extension direction is non-perpendicular to the substrate width direction and, for example, substantially parallel to the substrate width direction. For example, at least one thread can form a linear stitch pattern along the aerosol-forming substrate in the substrate width direction. Advantageously, the linear stitch pattern may be less costly or less difficult to achieve than other stitch patterns.

[0027] Optionally, the first extension direction is non-perpendicular to the substrate length direction and also non-perpendicular to the substrate width direction. Optionally, the second extension direction is non-perpendicular to the substrate length direction and also non-perpendicular to the substrate width direction. For example, at least one thread can form a zigzag stitch pattern along the aerosol-forming substrate, such as along the substrate length and substrate width directions. Advantageously, the extension direction of this paragraph can keep the substrate in a compressed state in the substrate thickness direction along substantially the entire length and width of the substrate, and may not require more than one thread.

[0028] Optionally, one or both of the first extension direction and the second extension direction are directions within the plane formed by the substrate length direction and the substrate width direction, or within the xy plane.

[0029] Optionally, at least one thread extends into the substrate in a first penetration direction at a first position. Optionally, at least one thread extends out of the substrate in a second penetration direction at a second position. Both the first and second positions may be on the same surface of the aerosol-forming substrate, for example, the upper or lower surface of the substrate. Optionally, the distance between the first position and the second position is 10, 5, 3, or 1 mm or less. Optionally, the distance between the first position and the second position is at least 0.2, 0.5, or 1 mm. Optionally, the distance between the first position and the second position is 0.2 to 10, or 0.2 to 5, or 0.5 to 10, or 0.5 to 5, or 1 to 10, or 1 to 5 mm. There is a compromise in this distance—a smaller distance can advantageously maintain a more tightly compressed substrate with less expansion occurring between the first and second positions, but it may require more threads and result in less space for aerosol-forming material, or thinner and less strong threads may be required.

[0030] Optionally, at least one thread is extended at least 5, 10, or 20 times through the aerosol-forming substrate. Advantageously, more extensions of at least one thread through the substrate can keep the substrate in a more tightly compressed state.

[0031] Optionally, the ratio of the length of the aerosol-forming substrate to the length of the thread of at least one thread is 1:2 to 1:50, or 1:2 to 1:20, or 1:2 to 1:10. In this context, the term “thread length of at least one thread” may refer to the end-to-end measurement of at least one thread when at least one thread is removed from the substrate and laid straight.

[0032] At least one thread may be a single continuous thread. At least one thread may include multiple threads. At least two of the multiple threads may be twisted to form a rope or rope-like structure. Advantageously, this may make at least one thread stronger. Alternatively or additionally, the rope or rope-like structure may be thicker than the thread alone, thus creating a larger space for airflow or aerosol generation, as will be described in more detail later.

[0033] At least one first thread among multiple threads may be attached to at least two threads among multiple threads. This can advantageously increase the length of at least one thread.

[0034] At least one thread may include or be composed of one or more natural fibers. At least one thread may include or be composed of one or more synthetic fibers. At least one thread may include or be composed of any one or more of: cotton, silk, wool, jute, ramie, hemp, linen, rayon, polyester, and nylon.

[0035] At least one thread may contain one or more flavoring agents, or be immersed in or impregnated therein. One or more flavoring agents may include one or more essential oils such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and one or more herbal materials. Suitable herbal materials include, but are not limited to, mints such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway, and other herbal materials from herb leaves or herbal plants. This may advantageously be an easy method of incorporating flavoring agents into the article.

[0036] At least one thread may contain one or more aerosol-forming agents, such as glycerin or propylene glycol, or be immersed in or impregnated therein. This may advantageously help to form an aerosol during use.

[0037] At least one thread may comprise one or more susceptor materials. At least one thread may support one or more susceptor materials. One or more susceptor materials may be attached to or coated over at least one thread. Suitable susceptor materials may be materials configured to heat, for example, up to at least 50, 100, or 200°C when subjected to an alternating electromagnetic field. Suitable susceptor materials include, but are not limited to, carbon, carbon-based materials, graphene, graphite, expanded graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. Suitable susceptor materials may comprise ferromagnetic materials, for example, ferrite iron, ferromagnetic alloys, such as ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrite. Suitable susceptor materials may be aluminum or may comprise it. The susceptor material preferably comprises more than 5%, preferably more than 20%, more preferably more than 50% or 90% of a ferromagnetic or paramagnetic material. The preferred susceptor material may comprise a metal, a metal alloy, or carbon. This allows at least one thread to assist in heating the substrate at multiple locations within or around the substrate, for example, when the substrate is configured to be inductively heated.

[0038] Optionally, the aerosol-forming material is not sewn to any other component of the aerosol-generating article. Optionally, the aerosol-forming material is sewn to itself. Optionally, the aerosol-forming material is sewn to itself and is not sewn to any other component of the aerosol-generating article. This may be advantageous when the material is intended to move independently of other components of the article, for example, when the user places the material directly within the article when the user intends to use the article.

[0039] Optionally, the aerosol-forming substrate is sewn to at least one other component of the aerosol-generating article with at least one thread. Advantageously, this may mean that at least one thread secures the substrate in place to at least one other component of the aerosol-generating article.

[0040] Optionally, the aerosol generating article comprises a first cover. The first cover may comprise or be formed of paper, such as cigarette paper. Optionally, the first cover covers a first surface of the aerosol forming substrate, or at least 50, 80, or 90% of the first surface. Optionally, the first cover contacts the aerosol forming substrate. Optionally, the first cover contacts the first surface of the aerosol forming substrate, or at least 50, 80, or 90% of the first surface. The first surface may be an upper surface of the aerosol forming substrate or may comprise therefrom. Optionally, the first cover covers a second surface of the aerosol forming substrate, or at least 50, 80, or 90% of the second surface. Optionally, the first cover contacts the second surface of the aerosol forming substrate, or at least 50, 80, or 90% of the second surface. The second surface may be a lower surface of the aerosol forming substrate or may comprise therefrom. The first cover may cover both the upper surface and the lower surface by extending, for example, across the upper surface, then across the side of the substrate, and then across the lower surface. The first cover may wrap around the side of the substrate between the upper surface and the lower surface. Advantageously, the first cover may protect the aerosol-forming substrate. Advantageously, the first cover may reduce the risk of the aerosol-forming substrate being contaminated by dust, etc.

[0041] Optionally, the aerosol-forming substrate is sewn to the cover with at least one thread. Advantageously, this can secure the substrate in place against the cover.

[0042] Optionally, at least a portion of the first cover is positioned between a portion of at least one thread and an aerosol-forming substrate, such as an upper or lower surface of the substrate. Optionally, at least a portion of the first cover is positioned between a portion of at least one thread extending along the substrate in a first extension direction and an aerosol-forming substrate. Optionally, at least a portion of the first cover is positioned between a portion of at least one thread extending along the substrate in a second extension direction and an aerosol-forming substrate. At least one thread may come into contact with the first cover as at least one thread extends along the substrate. At least one thread may come into contact with the first cover as at least one thread extends along the substrate in one or both of the first extension direction and the second extension direction.

[0043] Optionally, at least a portion of at least one thread extends through the first cover in a first penetration direction. Then, at least one thread may extend through the substrate in the first penetration direction. Then, at least one thread may extend through the first cover in the first penetration direction. Then, at least one thread may extend along the first cover in a first extension direction. Then, at least one thread may extend through the first cover in a second penetration direction. Then, at least one thread may extend through the substrate in a second penetration direction that is optionally opposite to the first penetration direction. Then, at least one thread may extend through the first cover in a second penetration direction. Then, at least one thread may extend along the first cover in a second extension direction that is optionally identical to the first extension direction.

[0044] Optionally, the aerosol generating article comprises a first cover and a second cover. The second cover may comprise paper or be formed of paper. Optionally, the second cover is in contact with an aerosol generating substrate. Optionally, the first cover covers a first surface of the aerosol generating substrate, or at least 50, 80, or 90% of the first surface, and the second cover covers a second surface of the aerosol generating substrate, or at least 50, 80, or 90% of the second surface. Optionally, the first cover is in contact with a first surface of the aerosol generating substrate, or at least 50, 80, or 90% of the first surface, and the second cover is in contact with a second surface of the aerosol generating substrate, or at least 50, 80, or 90% of the second surface. Optionally, the cover is positioned on a substantially opposite side of the aerosol generating substrate to the second cover. The first surface may be the upper surface of the aerosol-forming substrate or may include it, and the second surface may be the lower surface of the aerosol-forming substrate or may include it, or vice versa. The first cover and the second cover can effectively sandwich the aerosol-forming substrate. Advantageously, the first and second covers can protect the aerosol-forming substrate. Advantageously, the first and second covers can reduce the risk of the aerosol-forming substrate being contaminated by dust, etc.

[0045] Optionally, the aerosol-forming substrate is sewn to the first cover and the second cover with at least one thread. Advantageously, this can secure the substrate in place with respect to the first and second covers.

[0046] Optionally, at least a portion of the second cover is positioned between a portion of at least one thread and an aerosol-forming substrate, such as an upper or lower surface of the substrate. If at least a portion of the first cover is positioned between a portion of at least one thread and an upper or lower surface of the aerosol-forming substrate, at least a portion of the second cover may be positioned between another portion of at least one thread and the other of the upper or lower surface of the substrate. Optionally, at least a portion of the second cover is positioned between a portion of at least one thread extending along the substrate in a second extension direction and an aerosol-forming substrate.

[0047] Optionally, at least a portion of at least one thread extends through the first cover in a first penetration direction. Then, at least one thread may extend through the substrate in the first penetration direction. Then, at least one thread may extend through the second cover in the first penetration direction. Then, at least one thread may extend along the second cover in the first extension direction. Then, at least one thread may extend through the second cover in the second penetration direction. Then, at least one thread may extend through the substrate, optionally in a second penetration direction substantially opposite to the first penetration direction. Then, at least one thread may extend through the first cover in the second penetration direction. Then, at least one thread may extend along the first cover, optionally in a second extension direction substantially identical to the first extension direction.

[0048] Optionally, at least a portion of the first cover is positioned between a portion of at least one thread and the aerosol-forming substrate, and at least a portion of the second cover is positioned between another portion of at least one thread and the aerosol-forming substrate. Optionally, at least a portion of the first cover is positioned between a portion of at least one thread extending along the substrate in a second extension direction and the aerosol-forming substrate. Optionally, at least a portion of the second cover is positioned between a portion of at least one thread extending along the substrate in a first extension direction and the aerosol-forming substrate. At least one thread may come into contact with the first cover as at least one thread extends along the substrate in the second extension direction. At least one thread may come into contact with the second cover as at least one thread extends along the substrate in the first extension direction.

[0049] Optionally, the first cover and the second cover are at least part of the wrapper, and the wrapper optionally surrounds the aerosol-forming substrate or wraps over at least 180, 270, or 315 degrees of the aerosol-forming substrate. The wrapper may be a single component, such as the first cover alone. The wrapper may comprise a plurality of components, such as the first and second covers described above.

[0050] A portion of the aerosol-forming substrate may be exposed. A portion of the aerosol-forming substrate may not be covered, for example, by a first cover or a second cover if present. One or more sides of the substrate defined by the substrate length and substrate thickness, for example, one or both sides, may be exposed. One or more sides of the substrate defined by the substrate length and substrate thickness, for example, one or both sides, may not be covered, for example, by a first cover or a second cover if present. One or more sides of the substrate defined by the substrate width and substrate thickness, for example, one or both sides, may be exposed. One or more sides of the substrate defined by the substrate width and substrate thickness, for example, one or both sides, may not be covered, for example, by a first cover or a second cover if present.

[0051] Optionally, the aerosol forming substrate is a multilayer aerosol forming substrate. Optionally, the aerosol forming substrate comprises a first aerosol forming material layer. Optionally, the aerosol forming substrate comprises a second aerosol forming material layer. Optionally, the first aerosol forming material layer may be a sheet of aerosol forming material, for example, a sheet of tobacco-containing material such as a sheet of homogenized tobacco-containing material. Optionally, the second aerosol forming material layer may be a sheet of aerosol forming material, for example, a sheet of tobacco-containing material such as a sheet of homogenized tobacco-containing material. One or each of the first and second layers of aerosol forming material may be formed by a cast leaf process. The first and second aerosol forming material layers may have the same or different compositions. The first layer or sheet may be crimped. The second layer or sheet may be crimped. In this context, the term "crimped" may mean that the layer or sheet has a plurality of ridges or ripples, optionally a plurality of substantially parallel ridges or ripples.

[0052] Optionally, the first aerosol-forming material layer has a first layer length, a first layer width, and a first layer thickness. The first layer length, first layer width, and first layer thickness may extend in mutually perpendicular directions. The first layer length may extend in the first layer length direction, for example, in the substrate length direction. The first layer width may extend in the first layer width direction, for example, in the substrate width direction. The first layer thickness may extend in the first layer thickness direction, for example, in the substrate thickness direction. The first layer length and the first layer width may be at least 2, 3, or 5 times the first layer thickness.

[0053] Optionally, the second aerosol-forming material layer has a second layer length, a second layer width, and a second layer thickness. The second layer length, second layer width, and second layer thickness may extend in mutually perpendicular directions. The second layer length may extend in the second layer length direction, for example, in the substrate length direction. The second layer width may extend in the second layer width direction, for example, in the substrate width direction. The second layer thickness may extend in the second layer length thickness direction, for example, in the substrate thickness direction. The second layer length and second layer width may be at least 2, 3, or 5 times the second layer thickness.

[0054] Optionally, the first aerosol-forming material layer is sewn with at least one thread, for example, at least one first thread. Optionally, the first aerosol-forming material layer is sewn to itself with at least one thread, for example, at least one first thread, and is not sewn to other components of the article. This may create dimples or ridges, or both, in the first layer. Optionally, the second aerosol-forming material layer is sewn with at least one thread, for example, at least one second thread. Optionally, the second aerosol-forming material layer is sewn to itself with at least one thread or at least one second thread, and is not sewn to other components of the article. This may create dimples or ridges, or both, in the second layer. Advantageously, the dimples and ridges may create a three-dimensional structure for airflow and aerosol generation adjacent to or between the layers.

[0055] Optionally, at least one thread or at least a first portion of at least one first thread is located between the first aerosol-forming material layer and the second aerosol-forming material layer. Optionally, at least one thread or at least a second portion of at least one second thread is located between the first aerosol-forming material layer and the second aerosol-forming material layer. Advantageously, this can provide space for airflow and aerosol generation between the layers.

[0056] Optionally, the first aerosol-forming material layer optionally has a first surface defined by the first layer length and the first layer width. Optionally, the second aerosol-forming material layer optionally has a second surface defined by the second layer length and the second layer width.

[0057] Optionally, at least one thread or at least a first portion of at least one first thread is located between the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer. Optionally, at least one thread or at least a first portion of at least one first thread extends along one or both of the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer. Optionally, at least one thread or at least a first portion of at least one first thread is in contact with one or both of the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer, for example, as at least one thread or at least a first portion of at least one first thread extends along one or both of the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer.

[0058] Optionally, at least one thread or at least a second portion of at least one second thread is located between the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer. Optionally, at least one thread or at least a second portion of at least one second thread extends along one or both of the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer. Optionally, at least one thread or at least a second portion of at least one second thread is in contact with one or both of the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer, for example, as at least one thread or at least a second portion of at least one second thread extends along one or both of the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer.

[0059] Optionally, at least one thread or at least a first portion of at least one first thread acts as a spacer between the first aerosol-forming material layer and the second aerosol-forming material layer, for example, between the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer. Optionally, at least one thread or at least a second portion of at least one second thread acts as a spacer between the first aerosol-forming material layer and the second aerosol-forming material layer, for example, between the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer.

[0060] Optionally, the aerosol generating article defines at least a portion of the airflow path between the first aerosol-forming material layer and the second aerosol-forming material layer, for example, between the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer.

[0061] Advantageously, as described in the above paragraphs, at least one thread can act as a spacer between the first layer and the second layer of the substrate. This can advantageously provide space for airflow or aerosol generation between the layers.

[0062] At least one thread may include at least one first thread. At least one thread may include at least one thread or at least one second thread.

[0063] At least one thread or the first thread may extend through the first aerosol-forming material layer, for example, in a first penetration direction. Then, at least one thread or the first thread may extend along the first aerosol-forming material layer, optionally along the first surface of the first aerosol-forming material layer, and optionally in a first extension direction. Then, at least one thread or the first thread may extend through the first aerosol-forming material layer, for example, in a second penetration direction. Then, at least one thread or the first thread may extend along the first aerosol-forming material layer, optionally along the second surface of the first aerosol-forming material layer, and optionally in a first extension direction.

[0064] When extended through the first layer, at least one thread or at least one first thread may extend through the thickness of the first layer. When extended along the first layer, at least one thread or at least one first thread may extend in a direction perpendicular to the thickness direction of the first layer, for example, in one or both of the length and width directions of the first layer. In this context and similar contexts, a direction extending in both the length direction and the width direction means that the direction has both length and width components.

[0065] At least one second thread may extend through the second aerosol-forming material layer, for example, in a second penetration direction. Then, at least one second thread may extend along the second aerosol-forming material layer, optionally along a second surface of the second aerosol-forming material layer, and optionally in a first extension direction. Then, at least one second thread may extend through the second aerosol-forming material layer, for example, in a first penetration direction. Then, at least one second thread may extend along the second aerosol-forming material layer, optionally along a first surface of the second aerosol-forming material layer, and optionally in a first extension direction.

[0066] When extended through the second layer, at least one thread or at least one second thread may extend through the thickness of the second layer. When extended along the second layer, at least one thread or at least one second thread may extend in a direction perpendicular to the thickness direction of the second layer, for example, in one or both of the length and width directions of the second layer.

[0067] At least one thread or a first thread may be extended through a first layer, along a first surface of the first layer and optionally in contact therewith, again through the first layer, and then along a second surface of the first layer and optionally in contact therewith. Then, at least one thread or a first thread may repeat this. Similarly, at least one thread or a second thread may be extended through a second layer, along a second surface of the second layer and optionally in contact therewith, again through the second layer, and then along a first surface of the second layer and optionally in contact therewith. Then, at least one second thread may repeat this.

[0068] At least one thread or an extension of at least one thread along a first surface of a first layer may be any one, two, or all of: located between the first surface of the first layer and the second surface of the second layer; in contact with one or both of the first surface of the first layer and the second surface of the second layer; and acting as a spacer between the first surface of the first layer and the second surface of the second layer, for example, at least at that specific location.

[0069] At least one thread or an extension of at least one second thread along the second surface of the second layer may be any one, two, or all of: located between the first surface of the first layer and the second surface of the second layer; in contact with one or both of the first surface of the first layer and the second surface of the second layer; and acting as a spacer between the first surface of the first layer and the second surface of the second layer, for example, at least at that specific location.

[0070] Advantageously, having a first layer sewn with at least one thread or at least one first thread and a second layer sewn with at least one thread or at least one second thread can create more space between the layers for airflow and aerosol generation.

[0071] At least one thread may include at least one combination thread. The first aerosol-forming material layer may be sewn to the second aerosol-forming material layer by at least one combination thread. The at least one combination thread may extend through the first aerosol-forming material layer and the second aerosol-forming material layer, for example, in one or both of the first penetration direction and the second penetration direction.

[0072] The aerosol-forming substrate may comprise at least two, three, or five layers of an aerosol-forming material. Each layer may have the same or different composition. Each layer may be sewn with at least one thread, for example, said at least one thread. There may be n layers. The nth layer may be sewn with at least one nth thread. That is, as described above with respect to the first and second layers of the substrate, which are optionally sewn with at least one first thread and at least one second thread, respectively, the first layer may be sewn with at least one first thread, the second layer may be sewn with at least one second thread, and this may continue in this manner. Accordingly, the features described above with respect to the sewing of the first layer with at least one first thread or the sewing of the second layer with at least one second thread may be equally applied to sewing the nth layer with at least one nth thread. Similarly, the features described in relation to a thread located at least partially between the first layer and the second layer may be applied between other adjacent layers, for example, between the second layer and the third layer, or between the third layer and the fourth layer. Each layer may be sewn with at least one combination thread. At least one combination thread may sew the layers together, for example, as described above in relation to sewing the first and second layers of the substrate together.

[0073] Advantageously, sewing each layer with at least one thread can introduce dimples or ridges for airflow or aerosol generation between the layers. Advantageously, the thread can also be positioned at least partially between the layers and thus function to provide one or more spaces between the layers for airflow or aerosol generation. Advantageously, sewing the layers together, for example, with at least one combination thread can easily and reliably secure the layers of the substrate together. Advantageously, the sewing is compatible with linear high-speed processes.

[0074] The length, width, and thickness of each layer of the substrate may be aligned with the length, width, and thickness of the substrate, respectively. In this case, the direction of any thread through the layer thickness of the substrate may be aligned with or parallel to the direction through the thickness of the substrate.

[0075] Alternatively, the length, width, and thickness of each layer of the substrate may not be aligned with the length, width, and thickness of the substrate, respectively. For example, after the layers are sewn together, the resulting sewn substrate may be considered to have a substrate thickness that is aligned with one or each layer's length direction, or one or each layer's width direction, or extends in a substrate thickness direction parallel thereto. This arrangement may advantageously allow for the creation of airflow passages through the substrate in a different orientation compared to the case where each layer of the substrate is aligned with the length, width, and thickness of the substrate, respectively.

[0076] An aerosol generating article may have an airflow path extending through the aerosol generating article. The aerosol generating article may have an airflow path defined through the aerosol generating article in the x / y plane from one side of the aerosol generating article to another side of the aerosol generating article. The aerosol generating article preferably has a resistance to suction (RTD) of less than 20 mm H2O, e.g., less than 10 mm H2O, in the direction of the airflow path. Preferably, the aerosol generating article has an RTD of less than 20 mm H2O, e.g., less than 10 mm H2O, in at least one direction in the x / y plane of the aerosol generating article. An aerosol generating article having a low resistance airflow path enables excellent airflow management and allows aerosols to be extracted more efficiently from the aerosol generating article and delivered to the user.

[0077] Unless otherwise specified, resistance to suction (RTD) is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through the entire length of a component, such as in an aerosol-generating article. The terms "pressure drop" or "resistance to suction" with respect to a component or article may also refer to "resistance to suction." These terms generally refer to measurements performed under testing in accordance with ISO 6565-2015 at a temperature of approximately 22°C, a pressure of approximately 101 kPa (approx. 760 Torr), and a relative humidity of approximately 60%, at a volumetric flow rate of approximately 17.5 mm / s at the output or downstream end of the component.

[0078] The aerosol generating article may comprise substantially planar upper and lower surfaces. A vertical separation between the substantially planar upper surface and the lower surface may define the height (e.g., z-dimension) of the aerosol generating article. An airflow channel may be defined between the substantially planar upper surface and the lower surface. The aerosol generating article may have a height of less than 5 mm, e.g., 1.5 mm to 5 mm, e.g., 1.5 mm to 4 mm, e.g., 1.5 mm to 3 mm, e.g., 1.5 mm to 2 mm. One or both of the substantially planar upper and lower surfaces may comprise an aerosol-forming material. The aerosol generating article may comprise upper and lower layers, wherein the upper layer forms a substantially planar upper surface and the lower layer forms a substantially planar lower surface. At least one of the upper layer and the lower layer may comprise or be composed of an aerosol-forming material.

[0079] The aerosol generating article may include, for example, a wavy element arranged between a first or upper layer and a second or lower layer. At least one of the first layer, the planar layer, and the wavy element may include or be made of an aerosol-forming material.

[0080] The use of a corrugated structure within aerosol-generating articles makes it advantageous to produce articles that have a very low RTD while remaining sufficiently rigid for user handling. Additionally, the use of the corrugated structure enables the production of low-density, low-RTD aerosol-generating articles using high-speed manufacturing methods similar to those used in the production of corrugated cardboard.

[0081] An aerosol generating article may comprise a first outer surface, a second outer surface, a cavity, and a frame. One or both of the first and second outer surfaces may be planar. A frame may be located between the first outer surface and the second outer surface. The frame may define the cavity at least partially. The aerosol generating article may comprise an air inlet, an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity.

[0082] Preferably, the aerosol-forming substrate is positioned between the first outer surface and the second outer surface. At least one thread may be positioned entirely between the first outer surface and the second outer surface. A first cover and, if present, a second cover may be positioned between the first outer surface and the second outer surface.

[0083] Alternatively, the first outer surface may be the surface of the first cover. The second outer surface may be the surface of the second cover.

[0084] 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.

[0085] The aerosol generating article may include a first outer layer and a second outer layer, wherein the first outer layer forms a first outer surface and the second outer layer forms a second outer surface. The first cover may include the first and second outer layers. Alternatively, the first cover may include the first outer layer or be the first outer layer, and the second cover may include the second outer layer or be the second outer layer. 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 material.

[0086] The cavity may be substantially empty. The aerosol-forming substrate may be located outside the cavity. Alternatively, the aerosol-forming substrate may be located inside the cavity. The wavy element may be located inside the cavity.

[0087] The frame may be a flat frame. The frame may have a height of 50% to 95% of the height of the aerosol-generating article. The frame may have a height of 60% to 95% of the height of the aerosol-generating article. The frame may have a height of 70% to 95% of the height of the aerosol-generating article. The frame may have a height of 80% to 95% of the height of the aerosol-generating article.

[0088] 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.

[0089] The frame may be manufactured from or contain biodegradable materials. The frame may be manufactured entirely from biodegradable materials.

[0090] 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, paperboard, 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.

[0091] 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.

[0092] The length of the article may be 10 mm to 100 mm, or 10 mm to 50 mm, for example 10 mm to 40 mm, for example 12 mm to 30 mm, for example 14 mm to 26 mm, for example 16 mm to 24 mm, for example 18 mm to 22 mm, for example about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.

[0093] The width of the article may be 5 mm to 20 mm, for example, 8 mm to 18 mm, for example, 10 mm to 16 mm, for example, 11 mm to 15 mm, for example, 12 mm to 14 mm, for example, about 13 mm.

[0094] The height of the article may be 1 mm to 10 mm, for example 1.2 mm to 8 mm, for example 1.4 mm to 7 mm, for example 1.6 mm to 6 mm, for example 1.7 mm to 5 mm, for example about 1.7 mm, or about 4.5 mm, or about 2 mm, or about 3 mm, or about 4 mm.

[0095] When viewed in a planar view, the aerosol generating article may have a shape defining a polygon, a square (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof. If the aerosol generating article substantially comprises planar upper and lower surfaces, when viewed in a planar view, one or both of the upper and lower surfaces may have a shape defining a polygon, a square (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof. When viewed in a planar view, the perimeter of the aerosol generating article may be formed by a plurality of straight sides, a plurality of curved sides, or a combination of straight sides and curved sides. If the aerosol generating article substantially comprises planar upper and lower surfaces, when viewed in a planar view, the perimeter of one or both of the upper and lower surfaces may have a shape defining a polygon, a square (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof.

[0096] The aerosol-forming substrate may be a plug of the aerosol-forming substrate or may include a plug of the aerosol-forming substrate.

[0097] If an aerosol-forming substrate is present, for example, one or both of the first and second layers of the aerosol-forming material may contain nicotine. Nicotine may be present in the form of a tobacco substance or in the form of a nicotine extract. If an aerosol-forming substrate is present, for example, one or both of the first and second layers of the aerosol-forming material may contain natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0098] One or both of the first and second layers of the aerosol-forming material, for example, if present, may comprise one or more organic materials such as tobacco, mint, tea, and cloves. One or both of the first and second layers of the aerosol-forming material, for example, if present, may comprise 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.

[0099] In the presence of an aerosol-forming substrate, for example, one or both of the first and second layers of the aerosol-forming material comprise or are composed of a homogenized tobacco material, for example, a reconstituted tobacco material or a cast leaf tobacco material.

[0100] The aerosol-forming material may be in the form of a crushed aerosol-generating material. The crushed 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 crushed aerosol-generating material may be in the form of a crushed sheet of homogenized tobacco material.

[0101] The aerosol-forming material may be a cut-filler or may contain a cut-filler. The aerosol-forming material may be a cut-filler tobacco or may contain a cut-filler tobacco. The cut-filler may include one or more of bright tobacco, dark tobacco, flavored tobacco, and filler tobacco. Examples of bright tobacco are Brazilian yellow tobacco, Indian yellow tobacco, Chinese yellow tobacco, American yellow tobacco such as Virginia tobacco, and Tanzanian yellow tobacco. Examples of flavored tobacco include Oriental Turkish tobacco, Greek Oriental tobacco, and semi-Oriental tobacco, as well as American Burley smoked tobacco such as Perique and Rustica. Examples of dark tobacco are fumigated Brazilian Gaufão, Burley Malawi or other African Burley, and sun-dried or air-dried Indonesian Kasturi. As used herein, the term “cut grass” is used to describe a blend of shredded plant material, such as tobacco plant material or homogenized plant material, comprising one or more of leaf blades, processed stems, and ribs.

[0102] If an aerosol-forming substrate is present, for example, one or both of the first and second layers of the aerosol-forming material may be in the form of a sheet of the 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 the aerosol-generating material may be a sheet of plant material. The sheet of the aerosol-generating material may be a sheet of tobacco material. The sheet of the aerosol-generating material may be a sheet of homogenized tobacco material, such as a cast leaf sheet.

[0103] The aerosol-forming material may comprise a combined aggregate of strips, strands, or particles of tobacco material. The aerosol-forming material 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 material may be in the form of strips, strands, or particles of tobacco material bonded together in a binder matrix.

[0104] If an aerosol-forming substrate is present, for example, one or both of the first and second layers of the aerosol-forming material may comprise one or more aerosol-forming agents. Suitable aerosol-forming agents are known in the art and include, but are not limited to, polyhydric alcohols such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable that the aerosol-forming agent is one or both of glycerin and propylene glycol, or comprises them. The aerosol-forming agent may consist of glycerin or propylene glycol, or a combination of glycerin and propylene glycol.

[0105] If an aerosol-forming substrate is present, for example, one or both of the first and second layers of the aerosol-forming material may have an aerosol-forming agent content of 1, 2, 5, 10, or 15 weight% or more based on dry weight. If an aerosol-forming substrate is present, for example, one or both of the first and second layers of the aerosol-forming material may have an aerosol-forming agent content of 15 weight% or more based on dry weight, more than 20 weight% based on dry weight, more than 25 weight% based on dry weight, more than 30 weight% based on dry weight, more than 40 weight% based on dry weight, or more than 50 weight% based on dry weight.

[0106] If an aerosol-forming substrate is present, for example, one or both of the first and second layers of the aerosol-forming material may have an aerosol-forming agent content of 30% by weight or less, 25% by weight or less, or 20% by weight or less based on dry weight. That is, the aerosol-generating material may have an aerosol-forming agent content of 30% by weight or less, 25% by weight or less based on dry weight, or 20% by weight or less based on dry weight.

[0107] If an aerosol-forming substrate is present, for example, one or both of the first and second layers of the aerosol-forming material 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.

[0108] If an aerosol-forming substrate is present, for example, one or both of the first and second layers of the aerosol-forming material 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.

[0109] If an aerosol-forming substrate is present, for example, one or both of the first and second layers of the aerosol-forming material may comprise 85% by weight or less of an aerosol-forming agent, 80% by weight or less of an aerosol-forming agent, or 75% by weight or less of an aerosol-forming agent.

[0110] If an aerosol-forming substrate is present, for example, one or both of the first and second layers of the aerosol-forming material 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.

[0111] If an aerosol-forming substrate is present, for example, one or both of the first and second layers of the aerosol-forming material may contain at least 0.5 weight% nicotine, at least 1 weight% nicotine, at least 1.5 weight% nicotine, or at least 2 weight% nicotine.

[0112] One or both of the first and second layers of the aerosol-forming material, for example, if present, may include one or more flavoring agents. One or more flavoring agents may include one or more essential oils such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and one or more herbal materials. Suitable herbal materials include, but are not limited to, mints such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway, and other herbal materials from herb leaves or herbal plants. One or more flavoring agents may include tobacco materials.

[0113] One or both of the first and second layers of the aerosol-forming material, for example, when present, may contain one or more plant components. For example, the aerosol-forming material may contain about 1 to 90%, for example about 15 to 55%, preferably about 20 to 35%, 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.

[0114] In the aerosol-forming substrate, for example, if present, one or both of the first and second layers of the aerosol-forming material may have a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state. For example, in the aerosol-forming substrate, for example, if present, one or both of the first and second layers of the aerosol-forming material 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.

[0115] One or both of the first and second layers of the aerosol-forming substrate, for example, if present, may comprise a binder. For example, the aerosol-forming substrate may comprise 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.

[0116] One or both of the first and second layers of the aerosol-forming material, if present, in the aerosol-forming substrate may comprise or be made of a solid aerosol-forming material. One or both of the first and second layers of the aerosol-forming material, if present, in the aerosol-forming substrate may comprise a liquid aerosol-forming material, for example, a liquid aerosol-forming material retained within a porous matrix. One or both of the first and second layers of the aerosol-forming material, if present, in the aerosol-forming substrate may comprise a gel aerosol-forming material.

[0117] According to the present disclosure, an aerosol generating device is provided. According to the present disclosure, the device may be for receiving an aerosol-forming article as disclosed herein or an aerosol-forming substrate as disclosed herein, and may include a cavity dimensionally sized to receive at least a portion of the aerosol-forming 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 may be configured to heat an aerosol-forming substrate, for example, an aerosol-forming substrate that is a component part of an aerosol-forming article, to form an aerosol, for example, an inhalable aerosol.

[0118] The aerosol generating device may preferably be configured to accommodate the entire aerosol generating article so that the aerosol generating article is entirely surrounded within the aerosol generating device.

[0119] 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.

[0120] 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.

[0121] According to the present disclosure, an aerosol generating system comprising an aerosol generating device such as the aerosol generating device described above, and an aerosol generating article described above is provided.

[0122] According to the present disclosure, a method for manufacturing an aerosol-generating article as described above is provided. The method comprises the step of sewing at least a portion of an aerosol-forming substrate with at least one thread.

[0123] Optionally, the method comprises the step of sewing the aerosol-forming substrate with at least one thread to maintain the aerosol-forming substrate in a compressed state. Optionally, the method comprises the step of sewing the aerosol-forming substrate with at least one thread to limit the expansion of the aerosol-forming substrate.

[0124] Optionally, the method comprises the step of providing a rod, wherein the rod comprises or is made of an aerosol-forming substrate material. Optionally, the method comprises the step of compressing the rod to form a compressed rod comprising an aerosol-forming substrate in a first compressed state. Optionally, the method comprises the step of sewing the aerosol-forming substrate with at least one thread to maintain the aerosol-forming substrate in a second compressed state, for example, wherein the second compressed state is optionally a compressed state in the direction of the substrate thickness.

[0125] Optionally, the method comprises the step of providing a rod comprising an aerosol-forming substrate material and a wrapper surrounding the aerosol-forming substrate material. The rod may initially be substantially cylindrical, for example, in the shape of a rectangular cylindrical. Optionally, the method comprises the step of compressing the rod to form a compressed rod comprising the aerosol-forming substrate in a first compressed state. Optionally, the method comprises the step of sewing the aerosol-forming substrate to the wrapper with at least one thread to maintain the aerosol-forming substrate in a second compressed state, wherein the second compressed state is optionally a state compressed in the direction of the substrate thickness. Optionally, the method comprises the step of cutting the wrapper. The wrapper may form or include one or both of the aforementioned first cover and second cover. Optionally, the method comprises the step of cutting the wrapper to provide an aerosol-forming substrate having the first cover as described above, or the first and second covers as described above.

[0126] Referring to the two paragraphs above, the rod may be substantially cylindrical, for example, in a rectangular cylindrical shape before compression. The step of compressing the rod may include compressing the rod between two surfaces, for example, between two rollers or between a roller and a fixed surface. The compressed rod may be cylindrical or prismatic in shape. The compressed rod may optionally have a substantially elliptical or rectangular cross section with somewhat rounded corners. The shortest dimension of the compressed rod through the center of the cross section may be considered as the substrate thickness. Thus, in the case of a rectangular cross section, the substrate thickness may be equal to the smaller dimension of the rectangular cross section, and in the case of an elliptical cross section, the substrate thickness may be equal to the minor axis of the elliptical cross section.

[0127] Referring to the three paragraphs above, the second compressed state may be more compressed than, equal to, or less compressed than the first compressed state. For example, when the substrate is sewn, the substrate may be more compressed, which means that the second compressed state is more compressed than the first compressed state. Or the substrate may expand slightly between being compressed and being sewn, which means that the second compressed state is less compressed than the first compressed state. Or it may be both, or neither, which means that the second compressed state is substantially equal to the first compressed state. As will be understood by those skilled in the art after reading this disclosure, the features described above may apply to these first and second compressed states with respect to the compressed state of the substrate or with respect to the state in which expansion is limited or constrained.

[0128] Optionally, the aerosol-forming substrate is a multilayer substrate. Optionally, the aerosol-forming substrate comprises a first aerosol-forming material layer and a second aerosol-forming material layer, for example as described above. In this case, the method may include the step of sewing the first aerosol-forming material layer of the aerosol-forming substrate with at least one first thread. The first aerosol-forming material layer may not be sewn to other components of the article with at least one first thread. The first aerosol-forming material layer may be sewn to itself only with at least one first thread. Optionally, the method may include the step of sewing the second aerosol-forming material layer of the aerosol-forming substrate with at least one second thread. The second aerosol-forming material layer may not be sewn to other components of the article with at least one second thread. The second aerosol-forming material layer may be sewn to itself only with at least one second thread. Optionally, the method may include the step of sewing the first aerosol-forming material layer to the second aerosol-forming material layer with at least one combination thread.

[0129] The aerosol-forming substrate may comprise at least two, three, or five layers of an aerosol-forming material. Each layer may have the same or different composition. Each layer may be sewn with at least one thread. There may be n layers. The nth layer may be sewn with at least one nth thread. That is, the first layer may be sewn with at least one first thread, the second layer may be sewn with at least one second thread, and so on. Each layer may be sewn with at least one combination thread. At least one combination thread may sew the layers together.

[0130] Advantageously, sewing each layer with at least one thread can introduce dimples or ridges for airflow or aerosol generation between the layers. Advantageously, sewing the layers together can easily and reliably secure the layers of the substrate together. Advantageously, sewing is compatible with linear high-speed processes.

[0131] For example, the aerosol-forming substrate of the first aspect may include a plurality of aerosol-generating elements, for example, an array of aerosol-generating elements. At least one thread may connect or sew the aerosol-generating elements together. Providing an aerosol-forming substrate in the form of a plurality of elements can advantageously provide a substrate having a desirable surface-to-volume ratio, which optimizes the release of aerosols from the substrate upon heating.

[0132] A plurality of aerosol generating elements optionally include a first set of aerosol generating elements facing a second set of aerosol generating elements. At least one airflow passage may be defined between at least one air inlet and at least one air outlet of the article. Optionally, at least a portion of the at least one airflow passage is defined between the first and second sets of aerosol generating elements. Advantageously, this may result in predictable and controlled suction resistance.

[0133] At least one of the plurality of aerosol generating elements of the preceding paragraph, preferably each, may be substantially planar. Optionally, at least one of the aerosol generating elements, preferably each, has a length of 1 mm to 30 mm, preferably 2 mm to 10 mm. Optionally, at least one of the aerosol generating elements, preferably each, has a width of 1 mm to 30 mm, preferably 2 mm to 10 mm. Optionally, at least one of the aerosol generating elements, preferably each, has a thickness of 50 to 500 μm.

[0134] Optionally, the first set of aerosol generating elements is arranged in a regular pattern, e.g., a grid pattern. Optionally, the second set of aerosol generating elements may be arranged in a regular pattern, e.g., a grid pattern. Optionally, the array of aerosol generating elements is arranged in a regular pattern. Optionally, at least one of the aerosol generating elements partially overlaps with another of the aerosol generating elements. This can advantageously facilitate the integration of a given number of elements within a given volume. Providing an array-type aerosol-forming substrate can make the location of the substrate within the article predictable, which can lead to a more consistent experience between different articles.

[0135] Optionally, the first type aerosol generating element and the second type aerosol generating element are provided in an alternating pattern. Advantageously, this may mean that the types of elements are not excessively separated and the aerosols generated from the types of elements are well mixed before delivery.

[0136] Optionally, the aerosol generating element comprises a first type of aerosol generating element and a second type of aerosol generating element different from the first type. Optionally, the second type of aerosol generating element differs from the first type of aerosol generating element by at least one of: the type of aerosol forming material, the amount of aerosol forming material, the type of aerosol forming agent, the amount of aerosol forming agent, the type of flavoring agent, the amount of flavoring agent, the shape or size. Advantageously, this can provide an easy method for providing different compositions to the article.

[0137] Optionally, at least one thread passes through at least one aerosol generating element. Optionally, at least one thread passes through each aerosol generating element. Optionally, the article comprises a carrier sheet for carrying the aerosol generating element. Optionally, the article comprises an adhesive for attaching at least two aerosol generating elements to the carrier sheet. Optionally, the aerosol generating elements are connected to the carrier sheet by at least one thread passing through each aerosol generating element. Advantageously, these features can help secure the aerosol generating elements in place within the article.

[0138] Optionally, the carrier sheet is fluid-permeable to allow air and aerosols to pass through the carrier sheet. Optionally, the carrier sheet is formed of or comprises cotton. Optionally, the carrier sheet is or comprises a woven fabric. Advantageously, this can improve airflow within the article.

[0139] As used herein, the term "aerosol generating article" may refer to an article capable of generating or releasing aerosols.

[0140] 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.

[0141] 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.

[0142] 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 a device. The aerosol generating system may include additional components, such as a charging unit for recharging an embedded power supply within an electrically operated or electric aerosol generating device.

[0143] 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.

[0144] As used herein, the term "nicotine" is used to describe nicotine, nicotine bases, or nicotine salts.

[0145] As used herein, the terms "proximal," "distal," "upstream," and "downstream" may be used, for example, to describe the relative positions of a component or a part of a component of an aerosol-generating article.

[0146] 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.

[0147] As used herein, the term “sheet” refers to a laminated element having a width and length substantially greater than its thickness. The width of the sheet may be greater than 10 mm, 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.

[0148] As used herein, the term “homogenized tobacco material” encompasses any tobacco material formed by the aggregation of particles of tobacco material. Sheets or webs of homogenized tobacco material are formed by aggregating fine tobacco obtained by crushing or otherwise pulverizing one or both of tobacco leaf blades and tobacco leaf stalks. Additionally, 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. Sheets of homogenized tobacco material may be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0149] The term “cast leaf” is used herein to refer to a product produced by a casting process based on casting a slurry comprising plant particles (e.g., clove particles, or a mixture of tobacco particles and clove particles) and a binder (e.g., guar gum) onto a supporting surface, such as a belt conveyor, drying the slurry, and removing the dried sheet from the supporting surface. Examples of casting or cast leaf processes are described, for instance, in US-A-5,724,998 for the production 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 to become 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.

[0150] 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.

[0151] 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.

[0152] Example Ex1. As an aerosol-generating article,

[0153] Aerosol-forming substrate; and

[0154] Includes at least one thread,

[0155] An aerosol generating article, wherein at least a portion of the above-mentioned aerosol forming substrate is sewn with at least one thread.

[0156] Example Ex2. In any one of the prior embodiments, the aerosol generating article has an article length, an article width, and an article thickness, wherein the article length is at least 2, 3, or 5 times the article thickness, and the article width is at least 2, 3, or 5 times the article thickness.

[0157] Example Ex3. An aerosol generating article, wherein in any one of the prior embodiments, the aerosol forming substrate has a substrate length, a substrate width, and a substrate thickness, wherein the substrate length is at least 2, 3, or 5 times the substrate thickness and the substrate width is at least 2, 3, or 5 times the substrate thickness.

[0158] Example Ex4. In any one of the prior embodiments, the aerosol-forming substrate is sewn with at least one thread to maintain the aerosol-forming substrate in a compressed state, for example, in a compressed state relative to the natural state of the aerosol-forming substrate, an aerosol-generating article.

[0159] Example Ex5. In any one of the prior embodiments, the aerosol-forming substrate is an aerosol-generating article that is sewn with at least one thread to limit the expansion of the aerosol-forming substrate.

[0160] Example Ex6. In any one of the previous embodiments, the at least one thread is under tension, for example, because it acts to cause the aerosol-forming substrate to expand.

[0161] Example Ex7. An aerosol generating article, wherein in any one of the prior embodiments, the aerosol forming substrate sewn with at least one thread occupies a first volume, and when the at least one thread is removed, the aerosol forming substrate expands to occupy a second volume larger than the first volume.

[0162] Example Ex8. In any one of the prior embodiments, at least a portion of the at least one thread is:

[0163] Through the above description in the first penetration direction; then optionally immediately,

[0164] In the first extension direction along the above description; then optionally immediately,

[0165] Through the above description, optionally a second penetration direction substantially opposite to the first penetration direction; then optionally immediately,

[0166] According to the description above, an aerosol generating article that is optionally extended in a second extension direction substantially identical to the first extension direction.

[0167] Example Ex9. In Example Ex8, the aerosol-forming substrate has a substrate length extending in the substrate length direction, a substrate width extending in the substrate width direction, and a substrate thickness extending in the substrate thickness direction, and optionally, any one or more of the following are true, an aerosol-generating article:

[0168] The above-mentioned length is greater than the above-mentioned thickness, for example, at least 2, 3, or 5 times greater;

[0169] The width of the above-mentioned substrate is greater than the thickness of the above-mentioned substrate, for example, at least 2, 3, or 5 times greater; and

[0170] The above-mentioned length is greater than the above-mentioned width, for example, at least 2, 3, or 5 times greater.

[0171] Example Ex10. In Example Ex9,

[0172] The first penetration direction is non-perpendicular to the substrate thickness direction, for example, the first penetration direction is substantially parallel to the substrate thickness direction; and

[0173] An aerosol generating article in which the second penetration direction is non-perpendicular to the thickness direction of the substrate, for example, the second penetration direction is substantially parallel to the thickness direction of the substrate, or both.

[0174] Example Ex11. In Example Ex9 or Ex10,

[0175] The first extension direction is non-perpendicular to one or both of the length direction of the substrate and the width direction of the substrate; and and

[0176] An aerosol generating article, wherein the second extension direction is one or both of the length direction and the width direction of the above-mentioned material and is non-perpendicular to either or both.

[0177] Example Ex12. In Example Ex11,

[0178] The first extension direction is not perpendicular to the length direction of the substrate, for example, the first extension direction is substantially parallel to the length direction of the substrate; and

[0179] The second extension direction is non-perpendicular to the length direction of the substrate, for example, the second extension direction is one or both of which are substantially parallel to the length direction of the substrate, and

[0180] For example, an aerosol generating article in which at least one thread forms a linear stitch pattern along the aerosol forming substrate in the longitudinal direction of the substrate.

[0181] Example Ex13. In Example Ex11,

[0182] The first extension direction is not perpendicular to the width direction of the substrate, for example, the first extension direction is substantially parallel to the width direction of the substrate; and

[0183] The second extension direction is non-perpendicular to the width direction of the substrate, for example, the second extension direction is one or both of which are substantially parallel to the width direction of the substrate, and

[0184] For example, an aerosol generating article in which at least one thread forms a linear stitch pattern along the aerosol forming substrate in the width direction of the substrate.

[0185] Example Ex14. In Example Ex11,

[0186] The first extension direction is non-perpendicular to the length direction of the substrate and non-perpendicular to the width direction of the substrate; and

[0187] The second extension direction is one or both of the length direction of the substrate and the width direction of the substrate.

[0188] For example, an aerosol generating article in which at least one thread forms a zigzag stitch pattern along the aerosol forming substrate.

[0189] Example Ex15. An aerosol generating article in any one of Examples Ex8 to Ex14, wherein the at least one thread extends into the substrate in the first penetration direction at a first position and extends out of the substrate in the second penetration direction at a second position, and the distance between the first position and the second position is 10, 5, or 3 mm or less.

[0190] Example Ex16. In any one of the prior embodiments, the aerosol generating article, wherein the at least one thread extends at least 5, 10, or 20 times through the aerosol forming substrate.

[0191] Example Ex17. An aerosol generating article, wherein in any one of the previous embodiments, the ratio of the length of the aerosol-forming substrate to the length of the thread of the at least one thread is 1:1.5 to 1:50, or 1:2 to 1:20, or 1:2 to 1:10.

[0192] Example Ex18. In any one of the previous embodiments, the aerosol generating article, wherein the aerosol forming substrate is not sewn to any other component of the aerosol generating article.

[0193] Example Ex19. In any one of the prior embodiments, the aerosol generating article, wherein the aerosol forming substrate is sewn to at least one other component of the aerosol generating article with at least one thread.

[0194] Example Ex20. In any one of the prior embodiments, the aerosol generating article comprises a cover, for example, a paper cover.

[0195] Example Ex21. In Example Ex20, the aerosol-forming substrate is an aerosol-generating article that is sewn to the cover with at least one thread.

[0196] Example Ex22. In Example Ex20 or Ex21, the cover is an aerosol generating article that covers a first surface of the aerosol-forming substrate, or at least 50, 80, or 90% of the first surface.

[0197] Example Ex23. In Example Ex22, an aerosol generating article, wherein at least a portion of the cover is positioned between a portion of the at least one thread extending along the substrate in the first extension direction and the aerosol forming substrate.

[0198] Example Ex24. In any one of the prior embodiments, the aerosol generating article comprises a second hollow tube, for example, a second hollow acetate tube.

[0199] Example Ex25. In Example Ex24, the aerosol-forming substrate is an aerosol-generating article that is sewn to the second cover with at least one thread.

[0200] Example Ex26. In Example Ex24 or Ex25, the cover is an aerosol generating article that covers a second surface of the aerosol-forming substrate, or at least 50, 80, or 90% of the second surface.

[0201] Example Ex27. In Example Ex26, an aerosol generating article, wherein at least a portion of the second cover is positioned between a portion of the at least one thread extending along the substrate in the second extension direction and the aerosol forming substrate.

[0202] Example Ex28. In any one of Examples Ex24 to Ex27, the aerosol generating article is positioned on a substantially opposite side of the aerosol forming substrate with respect to the second cover.

[0203] Example Ex29. An aerosol generating article, wherein in any one of Examples Ex24 to Ex28, the cover and the second cover are part of a wrapper, and the wrapper optionally surrounds the aerosol-forming substrate or surrounds at least 180, 270, or 315 degrees around the aerosol-forming substrate.

[0204] Example Ex30. An aerosol generating article, wherein in any one of Examples Ex1 to Ex3, the aerosol forming substrate comprises a first aerosol forming material layer and a second aerosol forming material layer.

[0205] Example Ex31. In Example Ex30, the aerosol generating article, wherein one or both of the first aerosol-forming material layer and the second aerosol-forming material layer are sewn with the at least one thread.

[0206] Example Ex32. In Example Ex31, an aerosol generating article, wherein at least a first portion of the at least one thread is located between the first aerosol forming material layer and the second aerosol forming material layer.

[0207] Example Ex33. In Example Ex32,

[0208] The first aerosol-forming material layer has a first layer length, a first layer width, and a first layer thickness, wherein the first layer length and the first layer width are at least twice the first layer thickness; and

[0209] The aerosol generating article, wherein the second aerosol-forming material layer has a second layer length, a second layer width, and a second layer thickness, and the second layer length and the second layer width are at least twice the second layer thickness.

[0210] Example Ex34. In Example Ex33,

[0211] The first aerosol-forming material layer has a first surface defined by the first layer length and the first layer width;

[0212] The second aerosol-forming material layer has a second surface defined by the second layer length and the second layer width; and

[0213] An aerosol generating article, wherein at least the first portion of the above-mentioned at least one thread is located between the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer.

[0214] Example Ex35. In Example Ex34, the aerosol generating article, wherein at least the first portion of the at least one thread is in contact with one or both of the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer.

[0215] Example Ex36. An aerosol generating article in Example Ex34 or Ex35, wherein at least the first portion of the at least one thread acts as a spacer between the first surface of the first aerosol-forming material layer and the second surface of the second aerosol-forming material layer.

[0216] Example Ex37. In Example Ex34 or Ex35 or Ex36, the aerosol generating article is an aerosol generating article that defines an airflow path between a first surface of the first aerosol forming material layer and a second surface of the second aerosol forming material layer.

[0217] Example Ex38. A method for manufacturing an aerosol-generating article according to any one of the prior embodiments, wherein the method comprises:

[0218] A method comprising the step of sewing at least a portion of an aerosol-forming substrate with at least one thread.

[0219] Example Ex39. In Example Ex38, the method is:

[0220] A method comprising the step of sewing the aerosol-forming substrate with at least one thread to maintain the aerosol-forming substrate in a compressed state.

[0221] Example Ex40. In Example Ex38, the method follows the following steps:

[0222] A step of providing a rod, wherein the rod comprises or is composed of an aerosol-forming substrate material;

[0223] A step of compressing the above rod to form a compressed rod comprising the aerosol-forming substrate in a first compressed state; and

[0224] A method comprising any one or more of the step of sewing the aerosol-forming substrate with at least one thread to maintain the aerosol-forming substrate in a second compressed state.

[0225] Example Ex41. In Example Ex38, the method follows the following steps:

[0226] A step of providing a rod comprising an aerosol-forming substrate material and a wrapper surrounding the aerosol-forming substrate material;

[0227] A step of compressing the above rod to form a compressed rod including the aerosol-forming substrate in a first compressed state;

[0228] A step of sewing the aerosol-forming substrate to the wrapper with at least one thread to maintain the aerosol-forming substrate in a second compressed state;

[0229] A method comprising any one or more of the steps of cutting the wrapper.

[0230] Example Ex42. In Example Ex38, the aerosol-forming substrate comprises a first aerosol-forming material layer and a second aerosol-forming material layer, and the method comprises the step of sewing the first aerosol-forming material layer of the aerosol-forming substrate with at least one thread, for example, at least one first thread.

[0231] Example Ex43. In Example Ex42, the method comprises the step of sewing a second aerosol-forming material layer of the aerosol-forming substrate with at least one thread, for example, at least one second thread.

[0232] Example Ex44. A method according to Example Ex42 or Ex43, comprising the step of sewing the first aerosol-forming material layer to the second aerosol-forming material layer with the at least one thread, for example, at least one combination thread. Brief explanation of the drawing

[0233] Hereinafter, embodiments will be further described with reference to the drawings. FIG. 1 is a perspective view of an aerosol generating article according to a first embodiment of the present disclosure; FIG. 2 is a perspective view of an aerosol generating article according to a second embodiment of the present disclosure; FIG. 3 is a perspective view of an aerosol generating article according to a third embodiment of the present disclosure. FIG. 4 shows a perspective view of an aerosol generating article according to a fourth embodiment of the present disclosure; FIG. 5 is a perspective view of an aerosol generating article according to a fifth embodiment of the present disclosure; FIG. 6 shows a perspective view of an aerosol generating article according to a sixth embodiment of the present disclosure; FIG. 7 shows a perspective view of an aerosol generating article according to a seventh embodiment of the present disclosure; FIG. 8 shows an exploded perspective view of the aerosol generating article of FIG. 7; FIG. 9 shows an additional exploded perspective view of the aerosol generating article of FIG. 7; FIG. 10 shows a schematic cross-sectional view of the aerosol-generating article of FIG. 7; FIG. 11 shows a schematic longitudinal cross-sectional view of the aerosol-generating article of FIG. 7; FIG. 12 schematically illustrates a method for manufacturing an aerosol-generating article according to the present disclosure; FIG. 13 schematically illustrates a method for manufacturing an aerosol-generating article according to the present disclosure; FIG. 14 shows an exploded view of two additional aerosol-generating articles according to the present disclosure; FIG. 15 shows a schematic diagram of an aerosol generating device according to one embodiment of the present disclosure, said device configured to engage with an aerosol generating device according to the present disclosure; FIG. 16 shows a schematic end view of the aerosol generator of FIG. 15; FIG. 17 is a schematic diagram showing an aerosol generating article (e.g., any aerosol generating article according to the present disclosure) that engages with the aerosol generating device of FIG. 15. FIG. 18 is a schematic diagram of an alternative embodiment of FIG. 15 to 17, showing an aerosol generating article coupled with an aerosol generating device. Specific details for implementing the invention

[0234] FIG. 1 illustrates a perspective view of an aerosol generating article (100) according to a first embodiment of the present disclosure. The aerosol generating article (100) has upper and lower surfaces (110, 120) that are flat or planar.

[0235] The aerosol generating article (100) comprises an aerosol forming substrate (not shown). In one embodiment, the aerosol generating article (100) may substantially consist of an aerosol forming substrate and a thread (125). In another embodiment, the aerosol forming substrate and the thread (125) may be two of three or more component parts of the aerosol generating article (100). The aerosol forming substrate may surround the interior of the aerosol generating article (100). The aerosol forming substrate may at least partially define the exterior of the aerosol generating article (100); for example, one or both of the upper and lower surfaces (110, 120) may comprise or be made of the aerosol forming substrate.

[0236] A suitable aerosol-forming substrate may be a homogenized tobacco.

[0237] 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).

[0238] The thread (125) is a cotton thread impregnated with a menthol flavoring agent. The substrate is sewn with the thread (125) to limit the expansion of the substrate from the shape and size shown in FIG. 1. In particular, the substrate is sewn along the length of the substrate and through the thickness of the substrate to form the linear stitch pattern shown in FIG. 1. The thread (125) extends into the substrate at a first position (131), then through the substrate in a first through direction parallel to the thickness direction of the substrate, then along the lower surface of the substrate in a first extension direction parallel to the length direction of the substrate, then back into the substrate at a second position, then through the substrate in a second through direction substantially opposite to the first through direction, then out of the substrate at a third position (133), and then along the substrate in a second extension direction substantially parallel to the first extension direction. This pattern is repeated along the length of the substrate as shown in FIG. 1.

[0239] FIG. 2 shows a perspective view of an aerosol generating article (200) according to a second embodiment of the present disclosure. Features common to the aerosol generating article (100) are referred to by similar reference numerals, but start with the number 2 instead of the number 1. An airflow path (230) is defined through the aerosol generating article (200) between the upper surface and the lower surface (210, 220). The airflow path (230) extends between opposing first and second ends (201, 202) of the aerosol generating article (200). The first end (201) may define the distal end of the aerosol generating article (200), and the second end (202) may define the proximal or mouse end of the aerosol generating article. The airflow path (230) can be guided toward the user's mouth so that the user can inhale the aerosol generated as a result of heating the aerosol forming substrate of the aerosol generating article (200).

[0240] Similar to the embodiment of FIG. 1, the article (200) of FIG. 2 includes a thread (225). However, unlike the linear stitch pattern of FIG. 1, this thread (225) forms a zigzag stitch pattern. Thus, the thread (225) extends through the article (200) in the z direction similar to the embodiment of FIG. 1, but the first and second extension directions are not parallel to the length of the article or the x direction. Instead, while forming the first part of the zigzag stitch pattern, i.e., the “jig,” the thread (225) extends along the upper surface (210) or the lower surface (220) in one direction in the xy plane at an angle of about 40 degrees from the x direction and about 50 degrees from the y direction. Then, while forming the second part of the zigzag stitch pattern, namely the "zag," the thread (225) is extended along the upper surface (210) or lower surface (220) in one direction in the xy plane at an angle of about 50 degrees from the x direction and about 60 degrees from the y direction.

[0241] FIG. 3 illustrates a perspective view of an aerosol generating article (300) according to a third embodiment of the present disclosure.

[0242] The article (300) is formed by a cast leaf process and then folded or gathered by itself to form an aerosol-forming substrate in the shape of a substantially rectangular parallepiped, and then comprises an aerosol-forming substrate in the form of a sheet (305) of homogenized tobacco sewn with a first thread (325), a second thread (326), and a third thread (327). In another embodiment, there may be a plurality of sheets forming the substrate.

[0243] The sheet (305) defines the upper surface (310) and lower surface (320) of the aerosol-forming substrate. The first thread (325) extends from the upper surface (310) of the substrate at a first position (331), then through the substrate in a first through-direction parallel to the substrate thickness or z-direction, then out of the lower surface (320) of the substrate, then along the lower surface (320) of the substrate in a first extension direction parallel to the substrate length or x-direction, then again into the lower surface (310) at a second position, then through the substrate in a second through-direction substantially opposite to the first through-direction, then out of the upper surface (310) of the substrate at a third position (333), then along the substrate in a second extension direction substantially parallel to the first extension direction. This pattern is repeated along the length of the substrate, as illustrated in FIG. 3. The substrate is similarly sewn with a second thread (326) and a third thread (327), and the first, second, and third threads (325, 326, 327) are spaced apart from each other in the width or y direction of the substrate.

[0244] In this embodiment, the threads (325, 326, 327) are commercially available cotton threads reinforced with stainless steel. The stainless steel acts as a susceptor material. Thus, in at least partially induction heating aerosol generation systems, the threads (325, 326, 327) are heated under an alternating electromagnetic field and help to heat an aerosol-forming substrate to form an aerosol.

[0245] The sheet (305) has a thickness of about 300 μm. 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.

[0246] As will be understood by those skilled in the art after reading the present disclosure, the drawings are schematic. The sheet (305) may be folded more than shown in FIG. 3 to form a substrate.

[0247] FIG. 4 shows an aerosol generating article (600) according to a fourth embodiment of the present disclosure.

[0248] The aerosol generating article (600) includes an aerosol forming substrate in the form of a plurality of coil sheets (605) of homogenized tobacco formed by a cast leaf process.

[0249] To form the article, the sheet (605) is cast, dried, cut, and then corrugated to form a substantially rectangular cylindrical rod of the aerosol-forming material. Then, the rod is wrapped with a paper wrapper (640) to form a wrapped rod. Then, the wrapped rod is compressed between a pair of rollers to form a compressed rod having a substantially rectangular or elliptical cross section. Then, the compressed rod is sewn with a first thread (625) and a second thread (626). This keeps the material in a compressed state and prevents or limits the material from expanding back toward its original shape before being compressed by the pair of rollers.

[0250] The wrapper (640) defines a substantially flat upper surface (610) and a substantially flat lower surface (620) of the article (600). A first thread (625) extends from a first position (631) on the upper surface (610) into the wrapper (640) in a first through direction parallel to the substrate thickness or z-direction, then through the wrapper (640), through the substrate, and again through the wrapper (640) on the lower surface (620). Then, the first thread (625) extends along the lower surface (620) of the wrapper in a first extension direction parallel to the substrate length or x-direction. Then, the first thread (625) extends in a second through-direction substantially opposite to the first through-direction into the wrapper (640) at a second position on the lower surface (620), then through the wrapper (640), through the substrate, and again through the wrapper (640) at a third position (633) on the upper surface (610). Then, the first thread (625) extends along the upper surface (610) in a second extend-direction substantially parallel to the first extension direction. This pattern is repeated along the length of the substrate as illustrated. Thus, the substrate is sewn to the wrapper (640) by the first thread (625).

[0251] The substrate is sewn similarly to the wrapper (640) by a second thread (626), but the second thread (626) is spaced apart from the first thread (625) in the width of the substrate or in the y direction. As will be understood by a person skilled in the art after reading the present disclosure, in other embodiments, the threads (625, 626) may extend along the substrate in the y direction and instead be spaced apart from each other in the x direction.

[0252] In this embodiment, the first thread (625) is a cotton thread impregnated with a liquid menthol flavoring agent, and the second thread (626) is a cotton thread reinforced with stainless steel. The stainless steel acts as a susceptor material. Thus, in at least partially induction heating aerosol generation systems, the thread (626) is heated in the presence of an alternating electromagnetic field and helps to heat an aerosol-forming substrate to form an aerosol.

[0253] Each sheet (605) has a thickness of approximately 300 μm. The aerosol generating article (600) 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.

[0254] The airflow path (630) is defined through the aerosol generating article (600) between the upper surface and the lower surface (610, 620). The airflow path (630) extends between the opposing first and second ends (601, 602) of the aerosol generating article (600). The first end (601) may define the distal end of the aerosol generating article (600), and the second end (602) may define the proximal or mouse end of the aerosol generating article (600). Alternatively, the article (600) may be configured to be inserted into another article having a different mouse end. The airflow path (630) may be directed 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 (600).

[0255] In this embodiment, the paper wrapper (640) forms a cover for an aerosol-forming substrate that surrounds the aerosol-forming substrate in the yz plane. In another embodiment, the paper wrapper (640) and optionally a portion of the substrate may be cut from one or both sides to remove one or all of the sides in the xz plane. If cut from only one side, the paper wrapper may still be a single component but may not completely surround the substrate, in which case the wrapper may have a tacho-like shape around the substrate. If cut from both sides, the wrapper may be effectively cut to form two separate components, namely a first cover forming the upper layer of the article and a second cover forming the lower layer of the article.

[0256] FIG. 5 shows an aerosol generating article (700) according to the fifth embodiment of the present disclosure.

[0257] To form the article (700), the paper wrapper (640) of the article (600) illustrated in FIG. 6 is cut from both sides to remove two sides of the wrapper (640) in the xz plane. Thus, the article (700) comprises a first paper cover (741) forming a first upper layer of the article (700) and a second paper cover (742) forming a second lower layer of the article (700). Alternatively, the article (700) is identical to the article (600) of FIG. 6.

[0258] FIG. 6 illustrates an exploded view of an aerosol generating article (800) according to a sixth embodiment of the present disclosure.

[0259] The article (800) comprises a first layer (810), a second layer (820), a third layer (830), and a fourth layer (840). Each layer is a sheet of an aerosol-forming material, and in particular, in this embodiment, a homogenized tobacco formed by a cast leaf process. These layers together form an aerosol-forming substrate. Each sheet has a thickness of about 300 μm. As will be understood by a person skilled in the art after reading the present disclosure, there may be more or fewer layers in other embodiments.

[0260] The first layer (810) is sewn with the first thread (812) as well as another thread spaced apart from the first thread (812) in the y direction, forming a linear stitch pattern on the layer along the x direction. The second layer (820) is sewn with the second thread (822) as well as another thread spaced apart from the second thread (822) in the y direction, forming a linear stitch pattern on the layer along the x direction. The third layer (830) is sewn with the third thread (832) as well as another thread spaced apart from the third thread (832) in the y direction, forming a linear stitch pattern on the layer along the x direction. The fourth layer (840) is sewn with the fourth thread (842) as well as another thread spaced apart from the fourth thread (842) in the y direction, forming a linear stitch pattern on the layer along the x direction. Each layer (810, 820, 830, 840) includes one or both of dimples and ridges as a result of being sewn with thread.

[0261] Each thread (812, 822, 832, 842) is a cotton thread impregnated with a menthol flavoring agent in this embodiment.

[0262] A portion of each thread (812, 822, 832, 842) is positioned between the layer sewn with that thread and any adjacent layer. For example, a portion of the first thread (812) is positioned between the upper surface of the first layer (810) and the lower surface of the second layer (822). Similarly, a portion of the second thread (822) is positioned between the lower surface of the second layer (822) and the upper surface of the first layer (810), and another portion of the second thread (822) is positioned between the upper surface of the second layer (820) and the lower surface of the third layer (830). The threads (812, 822, 832, 842) act as spacers between the layers (810, 820, 830, 840).

[0263] The article (800) also includes a combination thread (850). Layers (810, 820, 830, 840) are sewn together with the combination thread (850). In FIG. 6, a needle still attached to the combination thread (850) is shown. However, the needle is not part of the article (800).

[0264] The combination thread (850) extends to the upper surface of the fourth layer (840), then through the fourth layer (840), the third layer (830), the second layer (820), and the first layer (810), and then out of the lower surface of the first layer (810). Then, in this embodiment, the combination thread (850) extends along the lower surface of the first layer (810) in the x direction. Then, the combination thread (850) extends again to the lower surface of the first layer (810), then through the first layer (810), the second layer (820), the third layer (830), and the fourth layer (840), and out of the upper surface of the fourth layer (840). Then, in this embodiment, the combination thread (850) extends along the upper surface of the fourth layer (840) in the x direction. Then, this pattern is repeated. This forms a linear stitch pattern in the x direction. As will be understood by those skilled in the art after reading this disclosure, other options are available. For example, in other embodiments, any one or more of the following may be true: there may be more than one combination thread, the stitch pattern may be non-linear, and the stitch pattern may extend in the y-direction.

[0265] In this embodiment, the combination thread (850) is a face thread reinforced with stainless steel. The stainless steel acts as a susceptor material. Thus, in at least partially induction heating aerosol generation systems, the combination thread (850) is heated in the presence of an alternating electromagnetic field and helps to heat an aerosol forming substrate to form an aerosol.

[0266] The aerosol generating article (800) has a length extended by an x ​​dimension of 80 mm, a width extended by a y dimension of 15 mm, and a height (or thickness) extended by a z dimension of 1.6 mm.

[0267] In another embodiment, a cover, e.g. a paper cover, may be present on one or both of the top and bottom of the article. In this case, a combination thread may sew layers of the substrate to the cover or covers, similar to how the cover or covers are another layer of an aerosol-forming material.

[0268] FIG. 7 shows an aerosol generating article (400) according to the seventh embodiment of the present disclosure. The aerosol generating article (400) comprises a first planar outer layer (424) forming a first planar outer surface (421), a second planar outer layer (425) forming a second planar outer surface (422), and a frame (450) 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).

[0269] FIGS. 8 and FIGS. 9 show exploded views of the aerosol generating article (400) of FIGS. 7. A frame (450) surrounds and at least partially defines the cavity (430). FIGS. 8 shows the cavity (430) in an empty state. FIGS. 9 shows the cavity (430) occupied by an aerosol forming substrate (440) or another aerosol generating article, optionally filled therewith. The aerosol forming substrate (440) of this embodiment may be, for example, any one of the aerosol forming substrates of FIGS. 1 through 6 or any one of the aerosol generating articles (100, 200, 300, 500, 600). As will be understood by those skilled in the art, the articles (100, 200, 300, 500, 600) of FIGS. 1 through 6 can be adjusted to have any reasonable dimensions so that the cavity (430) can be filled if desired. FIGS. 10 and FIGS. 11 illustrate a cross-sectional view and a longitudinal cross-sectional view, respectively, of an aerosol generating article (400) when the cavity (430) contains an aerosol forming substrate (440).

[0270] 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).

[0271] The frame (450) has a hollow rectangular shape and is made of cardboard. The frame (450) defines an aperture that extends through the height (also referred to as thickness) of the frame (450), and the aperture forms at least partially the cavity (430) of the aerosol generating article (400). The frame (450) includes a periphery wall surface (451) surrounding the cavity (430). The periphery wall surface (451) includes a front wall surface (413) and a rear wall surface (414). More specifically, the periphery wall surface (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 surface (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).

[0272] The air inlet (411) and the air outlet (412) are defined by and extend through the peripheral wall surface (451) of the frame (450). More specifically, the air inlet (411) extends through the front wall surface (413) and the air outlet (412) extends through the rear wall surface (414). The air inlet (411) and the air outlet (412) have an equivalent diameter of 5 mm. An airflow passage extends through a cavity (430) between the air inlet (411) and the air outlet (412). As illustrated in FIGS. 9 through 11, an aerosol-forming substrate (440) is located within the cavity (430). The aerosol-forming substrate (440) comprises an aerosol-generating material in the form of a tobacco stick and has an aerosol-forming agent content of 5 weight percent based on dry weight. As described, the aerosol-forming substrate (440) can fill the entire volume of the cavity (430), but in other embodiments, it cannot fill.

[0273] 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) extending in the z-dimension of 7.93 mm, a width extending in the y-dimension of 30 mm, and a length extending in the x-dimension of 50 mm.

[0274] FIG. 12 schematically illustrates a method for manufacturing an aerosol generating article (1200).

[0275] Initially, a sheet (1201) of an aerosol-forming material, in this case a homogenized cigarette, is formed. In an embodiment, the sheet (1201) is formed using a cast leaf process. The sheet (1201) may or may not be wound. The sheet (1201) together forms an aerosol-forming substrate of the article.

[0276] Then, the sheet (1201) is wrinkled. In this embodiment, the sheet is passed into a funnel (1202) to wrinkle the sheet and form a substantially right-angled circular cylindrical rod from the sheet (1201).

[0277] Then, the rod is wrapped. In this embodiment, the rod is wrapped with a paper wrapper (1203) to form a wrapped rod (1204). This step is optional because the paper wrapper (1203) is optional.

[0278] Then, the wrapped rod (1204) is compressed. In this embodiment, the wrapped rod (1204) is passed between two rollers (1205), and the rollers (1205) compress the wrapped rod (1204) to form a compressed rod (1206) comprising a compressed aerosol-forming substrate (1207) and a paper wrapper (1203) having a substantially elliptical cross section.

[0279] Then, the compressed rod (1206) is sewn. In this embodiment, the compressed rod (1206) passes through a sewing station where the compressed aerosol-forming substrate (1207) is sewn with at least one thread (1208) to form the sewn rod. In particular, in this embodiment, the substrate (1207) is sewn to a paper wrapper (1203). In this embodiment, a linear stitch pattern is formed along the length of the substrate (1207). At least one thread keeps the substrate (1207) in a compressed state. At least one thread limits the expansion of the substrate (1207).

[0280] Then, the sewn material is cut. This step is optional. In this embodiment, the sewn material is cut by a pair of circular blades (1209) having one blade on each side, but in other embodiments, only a single side may be cut or no side may be cut. This results in an aerosol generating article (1200) having an upper paper cover (1210) and a lower paper cover (1211). This article (1200) may be placed in the cavity of the aforementioned article (400), for example, together with or in place of the material (440). The two sides (1212, 1213) may be discarded or recycled.

[0281] FIG. 13 schematically illustrates a method for manufacturing an aerosol generating article (1300).

[0282] Initially, a sheet (1301) of an aerosol-forming material, in this case a homogenized cigarette, is formed. In an embodiment, the sheet (1301) is formed using a cast leaf process. The sheet (1301) may or may not be wound.

[0283] Sheets (1301) are individually sewn with at least one thread each to form a sewn sheet. In FIG. 13, although more sheets exist, only the first sheet (1302) and the second sheet (1303) are illustrated in this first sewing step. In this embodiment, the first sheet (1302) is sewn with two threads, and the second sheet (1303) is sewn with three threads as illustrated. The two sheets are sewn to form a linear stitch pattern. This sewing creates dimples and ridges in the sheets. These dimples and ridges, as well as the portion of the threads located between adjacent sheets within the final aerosol-generating article, provide space for airflow and aerosol generation during use. As will be understood by those skilled in the art, any given sheet may be sewn with one or more threads, and any given sheet may be sewn in a given direction. It may not be necessary to sew all sheets.

[0284] Then, the sewn sheets are sewn together with at least one combination thread (1304). The combination thread (1304) may be a cotton thread. The combination thread (1304) may be immersed in an aerosol forming agent or a flavoring agent. The combination thread (1304) may contain a susceptor material. In this embodiment, only a single combination thread (1304) is used.

[0285] The generated aerosol generating article (1300) is illustrated in a cross-sectional view on the right side of FIG. 13. The article (1300) can be used with an aerosol generating device to generate an aerosol. For example, the article (1300) can be placed in the cavity of the aforementioned article (400) together with or in place of the substrate (440).

[0286] FIG. 14 illustrates an exploded view of a first article (1401) and a second article (1402). The articles (1401, 1402) are articles manufactured by the process of FIG. 13 and are identical to the article (400) of FIG. 4, except that the substrate (440) is replaced with an article similar or identical to, for example, the article (1300) of FIG. 13 or the article (800) of FIG. 8. In FIG. 14, the substitute for the substrate (440) is enlarged for clarity.

[0287] On the left, the following arrangement is illustrated: the length of the layer or sheet of the substrate, the length of the entire substrate, and the length of the article are all aligned in the x-direction; the width of the layer or sheet of the substrate, the width of the entire substrate, and the width of the article are all aligned in the y-direction; and the thickness of the layer or sheet of the substrate, the thickness of the entire substrate, and the thickness of the article are all aligned in the z-direction.

[0288] The following arrangement is illustrated on the right: the length of the layer or sheet of the substrate, the total length of the substrate, and the length of the article are all aligned in the x-direction; the thickness of the layer or sheet of the substrate, the total width of the substrate, and the width of the article are all aligned in the y-direction; and the width of the layer or sheet of the substrate, the total thickness of the substrate, and the thickness of the article are all aligned in the z-direction.

[0289] In both arrangements, air flows from left to right during use through the space formed between the layers or sheets of aerosol-forming material, said space being created from threads sewn into the layers or sheets as described above.

[0290] FIGS. 15 and 16 illustrate an aerosol generating device (6000) configured for use with an aerosol generating article (900) comprising an aerosol forming substrate (940). The device (6000) is an elongated aerosol generating device extending between a proximal end (6001) and a distal end (6002). The device (6000) includes a battery (6010), a controller (6020), and a heater (6030) located within a housing (6040). The controller (6020) controls the power supply from the battery (6010) to the heater (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 (900). The cavity (6050) includes an upper flat surface (6052) and a lower flat surface (6053). A heater (6030) is located within the lower flat surface (6053) to heat the lower surface of the aerosol generating article (900) inserted into the cavity (6050). An airflow path is configured so that air can flow from outside the device (6000) into the cavity (6050).

[0291] FIG. 17 illustrates the device (6000) of FIG. 15 engaging with an aerosol generating article (900). There is almost no tolerance between the outer surface of the aerosol generating article (900) and the inner surface of the cavity (6050). Therefore, there is a tight fit between the aerosol generating article (900) and the device (6000). Since the RTD of the aerosol generating article (900) is negligible, the RTD of the system formed by the combination of the aerosol generating article (900) and the aerosol generating device (6000) is controlled by an airflow path defined within the device. When a user inserts the aerosol generating article (900) into the cavity (6050), the device (6000) can be operated. A heater (6030) heats the lower surface of the aerosol generating article (900), and as a result, the aerosol forming substrate (940) of the aerosol generating article (900) is heated. The volatile component of the aerosol-forming substrate (940) evaporates and condenses into a longitudinal airflow channel defined within the aerosol-generating article (900) to form an aerosol. The user inhales the aerosol by inhaling the proximal end (901) of the aerosol-generating article (900). Once the volatile component in the aerosol-forming substrate (940) of the aerosol-generating article (900) is depleted, the aerosol-generating article is removed from the cavity (6050) of the device (6000) and disposed of. The aerosol-generating article (900) may be any one of the previously described aerosol-generating articles (100, 200, 300, 400, 500) or any other aerosol-generating article of the present disclosure.

[0292] FIG. 17 illustrates a portion of an aerosol generating article (900) extending outside of an aerosol generating device (6000), but in other embodiments, the entire aerosol generating article may be completely enclosed within the aerosol generating device. As an example, FIG. 18 illustrates an alternative embodiment of FIG. 17, in which similar features are referred to by the same reference numeral but with the addition of a prime symbol '. In the alternative embodiment of FIG. 18, the entire aerosol generating article (900') is enclosed within the aerosol generating device (6000').

[0293] The articles (900 and 900') shown in FIGS. 17 and 18 may be, for example, any one of articles (100, 200, 300, 600, 700, 800, 400, 1200, 1300, 1401, 1402) or article (400), wherein the description (440) is replaced with any one of articles (100, 200, 300, 600, 700, 800, 400, 1200, 1300).

[0294] FIGS. 19 and FIGS. 20 illustrate, respectively, side (or XZ) and top-down (or XY) cross-sections of additional embodiments of an aerosol generating article (19110). The article (19110) is very similar to the article (400) of FIG. 9, except that the aerosol forming substrate (440) of FIG. 9 has been replaced with an alternative aerosol forming substrate (19150). Thus, in FIG. 19, the frame is visible around the aerosol forming substrate (19150), whereas in FIG. 20, the first and second planar outer layers are visible above and below the aerosol forming substrate (19150). In both FIG. 19 and FIG. 20, the air inlet is visible on the left side of the article (19110), and the air outlet is visible on the right side of the article (19110). Below, only the difference between the item (19110) compared with the item (400) of FIG. 9 is explained.

[0295] The article (19110) includes an aerosol-forming substrate (19150) comprising an array of aerosol-generating elements (19152) and a combining element (19160).

[0296] Each aerosol generating element in an array of aerosol generating elements (19152) has a first planar surface and a second planar surface. In this embodiment, both the first planar surface (19158) and the second planar surface (19159) are circular in shape, but other shapes may be used.

[0297] At least one connecting element (19160) includes at least one thread (19162) that attaches an aerosol generating element to an adjacent aerosol generating element by sewing. In this example, the at least one thread (19162) includes a plurality of threads, each thread connecting or sewing rows of aerosol generating elements to each other. At least one connecting element (19160) further includes a carrier sheet (19164). In this embodiment, the carrier sheet (19164) is a fluid-permeable woven fabric sheet. At least one thread (19162) connects an array of aerosol generating elements to the carrier sheet (19164). The array of aerosol generating elements (19152) is arranged in a regular and partially overlapping pattern.

[0298] At least one thread (19162) includes a thread that passes through each of the aerosol generating elements (19152) to join or sew each aerosol generating element to a carrier sheet (19164). In the example illustrated in FIG. 19, at least one thread (19162) passes from the first planar surface (19158) of the aerosol generating element to the second planar surface (19159) of the aerosol generating element, and then passes from the second planar surface (19159) through the carrier sheet (19164). In FIG. 19, a dashed section of at least one thread (19162) indicates where at least one thread (19162) passes behind the aerosol generating element. In FIG. 20, a dashed section of at least one thread (19162) indicates where at least one thread (19162) passes through the aerosol generating element or the carrier sheet (19164).

[0299] The aerosol-forming substrate (19150) comprises a plurality of layers. In this embodiment, the aerosol-forming substrate (19150) comprises a first layer comprising a first set of aerosol-generating elements, a second layer comprising a second set of aerosol-generating elements, a third layer comprising a third set of aerosol-generating elements, and a fourth layer comprising a fourth set of aerosol-generating elements. As illustrated by dashed arrows in FIG. 20, a portion of the airflow passage is defined between each set of aerosol-generating elements.

[0300] At least one connecting element (19160) comprises: a first connecting element that connects or sews together the aerosol generating elements of a first set of aerosol generating elements; a second connecting element that connects or sews together the aerosol generating elements of a second set of aerosol generating elements; a third connecting element that connects or sews together the aerosol generating elements of a third set of aerosol generating elements; and a fourth connecting element that connects or sews together the aerosol generating elements of a fourth set of aerosol generating elements.

[0301] FIGS. 21 and FIGS. 22 respectively illustrate a schematic top view and a schematic side cross-sectional view of a portion of an aerosol-forming substrate for an aerosol-generating article. Similar to the aerosol-forming substrate (19150) of FIGS. 19 and 20, the aerosol-forming substrate of FIGS. 21 and FIGS. 22 may replace the aerosol-forming substrate (440) in the article of FIG. 9.

[0302] In the embodiments illustrated in FIGS. 21 and 22, the aerosol forming substrate includes a first type (21354a) of an aerosol generating element and a second type (21354b) of an aerosol generating element.

[0303] In this embodiment, a first type (21354a) of an aerosol generating element comprises about 35% by weight of an aerosol forming agent based on dry weight of cast leaf tobacco, said aerosol forming agent comprises glycerin. A second type (21354b) of an aerosol generating element comprises about 35% by weight of an aerosol forming agent based on dry weight of cast leaf tobacco, said aerosol forming agent comprises glycerin and additionally a flavoring agent.

[0304] Each aerosol generating element is substantially planar. Each has a first planar surface and a second opposing planar surface. The first and second planar surfaces are circular and have a diameter of about 5 mm. The first and second planar surfaces are separated by the thickness of the aerosol generating element. The thickness of the aerosol generating element is about 100 μm. Therefore, the ratio of diameter to thickness is about 50.

[0305] The first type (21354a) and the second type (21354b) of the aerosol generating elements are located adjacent to each other and arranged in an alternating pattern. The first type (21354a) and the second type (21354b) of the aerosol generating elements partially overlap. As shown in FIG. 22, there is a gap between the aerosol generating elements so that air can flow between the first type (21354a) and the second type (21354b) of the aerosol generating elements when in use.

[0306] Each aerosol generating element is attached to or sewn to the carrier sheet (21364) by its own thread (21362). Thus, each aerosol generating element is attached to or sewn to the carrier sheet (21364). In this embodiment, the carrier sheet (21364) is a fluid-permeable woven fabric sheet.

[0307] For the purposes of this description and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, etc., shall be understood in all cases to be modified by the term “about.” Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein. Accordingly, in this context, the number “A” is understood as 10% of “A” ± “A”. In this context, the number “A” may be considered to include numerical values ​​within the general standard error for measuring the characteristic modified by the number “A”. In some cases used in the appended claims, the number “A” may deviate by the percentage listed above, provided that the amount of deviation by “A” does not substantially affect the basic and novel feature(s) of the claimed invention. Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein. The terms “among them” and “here” are used as synonyms throughout this specification.

Claims

Claim 1 An aerosol generating article comprising: an aerosol forming substrate; and at least one thread, wherein at least a portion of the aerosol forming substrate is sewn with the at least one thread. Claim 2 The aerosol generating article according to claim 1, wherein the aerosol generating article is defined by the length of the article, the width of the article, and the thickness of the article, wherein the length of the article is at least 2, 3, or 5 times the thickness of the article, and the width of the article is at least 2, 3, or 5 times the thickness of the article. Claim 3 An aerosol generating article according to claim 1 or 2, wherein the aerosol-forming substrate is defined by a substrate length, a substrate width, and a substrate thickness, wherein the substrate length is at least 2, 3, or 5 times the substrate thickness and the substrate width is at least 2, 3, or 5 times the substrate thickness. Claim 4 An aerosol generating article according to paragraph 3, wherein the ratio of the length of the aerosol-forming substrate to the length of the thread of at least one thread is 1:2 to 1:

20. Claim 5 An aerosol generating article according to any one of claims 1 to 4, wherein the aerosol forming substrate is sewn with at least one thread to maintain the aerosol forming substrate in a compressed state. Claim 6 In paragraph 3 or 4, the aerosol generating article, wherein the aerosol forming substrate is sewn with at least one thread to maintain the aerosol forming substrate in a compressed state in the direction of the substrate thickness. Claim 7 An aerosol generating article according to any one of claims 1 to 6, wherein at least a portion of the at least one thread extends: through the substrate in a first penetration direction; then along the substrate in a first extension direction; then through the substrate in a second penetration direction; then along the substrate in a second extension direction. Claim 8 An aerosol generating article according to claim 7, wherein at least one thread extends into the substrate in the first penetration direction at a first position and extends out of the substrate in the second penetration direction at a second position, and the distance between the first position and the second position is 10 mm or less. Claim 9 An aerosol generating article according to any one of claims 1 to 8, wherein the aerosol forming substrate is not sewn to any other component of the aerosol generating article. Claim 10 In any one of claims 1 to 8, the aerosol generating article, wherein the aerosol forming substrate is sewn to at least one other component of the aerosol generating article with at least one thread. Claim 11 An aerosol generating article according to any one of claims 1 to 8, wherein the aerosol forming substrate comprises a cover, and the aerosol forming substrate is sewn to the cover with at least one thread. Claim 12 An aerosol generating article according to any one of claims 1 to 11, wherein the aerosol forming substrate comprises a first cover and a second cover separate from the first cover, and the first cover is positioned on a substantially opposite side of the aerosol forming substrate relative to the second cover. Claim 13 An aerosol generating article according to any one of claims 1 to 12, wherein the aerosol forming substrate comprises a first aerosol forming material layer and a second aerosol forming material layer; one or both of the first aerosol forming material layer and the second aerosol forming material layer are sewn with at least one thread; and at least a first portion of the at least one thread is located between the first aerosol forming material layer and the second aerosol forming material layer. Claim 14 In paragraph 13, the at least first portion of the at least one thread acts as a spacer between the first aerosol-forming material layer and the second aerosol-forming material layer, an aerosol generating article. Claim 15 A method for manufacturing an aerosol-generating article according to any one of claims 1 to 14, wherein the method comprises: a step of sewing at least a portion of an aerosol-forming substrate with at least one thread.

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