Aerosol generating article comprising a material having nicotine

Abstract

An aerosol generating article (10)(110)(210)(410) for use with an aerosol generating device to generate an inhalable aerosol comprises: a first planar outer surface (21); a second planar outer surface (22); a cavity (30); a frame (50) positioned between the first planar outer surface (21) and the second planar outer surface (22), the frame (50) defining at least partially the cavity (30); one or more sheets of an aerosol generating substrate (140); and an air inlet (11) and an air outlet (12), and an airflow passage extending through the cavity (30) between the air inlet (11) and the air outlet (12). The aerosol generating substrate (140) comprises exogenous nicotine and one or more aerosol forming agents. The total aerosol forming agent content of the aerosol generating substrate is at least 40 weight percent.

Description

Technology Field

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

[0002] A conventional aerosol generating system comprises an aerosol generating device and an aerosol generating article comprising an aerosol generating substrate. In use, the aerosol generating device is positioned near or arranged to heat a heating element in contact with the aerosol generating substrate, causing the aerosol generating substrate to heat and release volatile compounds. These volatile compounds are then entrained in droplets into air drawn through the aerosol generating article. As the volatile compounds cool, they condense to form an aerosol that can be inhaled by a consumer.

[0003] Conventional aerosol generating articles may look similar to conventional cigarettes and may have similar dimensions. For example, such aerosol generating articles may be substantially cylindrical and may include an aerosol generating material in addition to other components such as a mouthpiece filter element and a cooling element arranged in the form of rods and wrapped in cigarette paper.

[0004] However, a significant portion of the aerosol generating 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 generating material contributes to the manufacturing and transportation costs of the aerosol generating article but does not contribute to the aerosol delivered to the consumer. Additionally, the components of these cylindrical aerosol generating articles generally need to have the same or very similar outer diameters so that they can be joined, accurately positioned in axial alignment, and wrapped in cigarette paper. This can increase manufacturing costs and complexity.

[0005] The object of the present disclosure is to provide an aerosol generating article in which a larger portion of the aerosol generating material is heated sufficiently to form an aerosol during use. Additionally, the object of the present disclosure is to provide an aerosol generating article capable of providing optimized delivery of aerosol to a consumer upon heating. 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.

[0006] According to the present disclosure, an aerosol generating article is provided. The aerosol generating article is used in conjunction with an aerosol generating device to generate an inhalable aerosol. The aerosol generating article may comprise a first planar outer surface. The aerosol generating article may comprise a second planar outer surface. The aerosol generating article may comprise a cavity. The aerosol generating article may comprise a frame positioned between the first planar outer surface and the second planar outer surface. The frame may at least partially define the cavity. The aerosol generating article may comprise an aerosol generating substrate. The aerosol generating substrate may comprise exogenous nicotine. The aerosol generating substrate may comprise one or more aerosol forming agents. The total aerosol forming agent content of the aerosol generating substrate may be at least 40 weight percent based on dry weight. The aerosol generating article may comprise an air inlet and an air outlet. The aerosol generating article may comprise an airflow passage extending through a cavity between the air inlet and the air outlet.

[0007] According to the present invention, an aerosol generating article for use with an aerosol generating device to generate an inhalable aerosol is provided, wherein the aerosol generating article comprises: a first planar outer surface; a second planar outer surface; a cavity; a frame positioned between the first planar outer surface and the second planar outer surface, the frame defining at least partially the cavity; an aerosol generating substrate comprising exogenous nicotine and one or more aerosol forming agents, wherein the total aerosol forming agent content of the aerosol generating substrate is at least 40 weight percent based on dry weight; and an air inlet and an air outlet, and an airflow passage extending through the cavity between the air inlet and the air outlet.

[0008] Preferably, the article has an article length, an article width, and an article thickness, and the article length and article width are at least twice the article thickness.

[0009] According to the present disclosure, an aerosol generating system is further provided. The aerosol generating system may include an aerosol generating article according to the present disclosure as defined above. The aerosol generating system may include an aerosol generating device for use with the aerosol generating article to generate an inhalable article. The aerosol generating device may include a heater for heating an aerosol generating substrate of the aerosol generating article. The heater may be configured to heat the aerosol generating substrate to a maximum temperature of 210 degrees Celsius.

[0010] According to the present invention, an aerosol generating system is provided, wherein the aerosol generating system comprises an aerosol generating article according to the present invention as defined and an aerosol generating device for use with the aerosol generating article to generate an inhalable aerosol, and the aerosol generating device comprises a heater for heating an aerosol generating substrate of the aerosol generating article, and the heater is configured to heat the aerosol generating substrate to a maximum temperature of 210 degrees Celsius.

[0011] According to the present disclosure, an aerosol generating article is a planar aerosol generating article having a length extending in the x direction (corresponding to the length of the article), a width extending in the y direction (corresponding to the width of the article), and a thickness extending in the z direction (corresponding to the thickness of the article).

[0012] For the purposes of the present disclosure, the “thickness” of an aerosol-generating article may also be referred to as the “height” of an aerosol-generating article.

[0013] Any reference to the length, width, height, or thickness of an aerosol-generating article shall be deemed to relate to the average length, width, height, or thickness, respectively, unless otherwise specified.

[0014] Preferably, the thickness of the aerosol-generating article is 50 percent or less of both the length and width of the aerosol-generating article.

[0015] The aerosol generating article according to the present disclosure may preferably be a substantially flat article or a substantially planar 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 over 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 the temperature at which the aerosol is released. Alternatively or additionally, this may reduce the time required to heat the aerosol-forming substrate sufficiently to release the aerosol.

[0016] The aerosol generating article of the present invention provides a planar structure including a frame.

[0017] Advantageously, the frame can make the aerosol-generating article relatively thin while maintaining structural rigidity.

[0018] Advantageously, the first planar outer surface and the second planar outer surface allow good contact with an external heater, in particular with an external heater of an aerosol generator, thereby providing optimal heating of the aerosol generating substrate.

[0019] Advantageously, the aerosol generating article of the present disclosure can be heated substantially along its entire length and width, thereby allowing the entire aerosol generating material to be heated sufficiently to generate an aerosol.

[0020] Advantageously, the aerosol generating article of the present disclosure can be manufactured by laminating sheet materials that can be achieved through a continuous manufacturing process, thereby making the aerosol generating article relatively easy and inexpensive to manufacture.

[0021] The aerosol generating article of the present invention comprises an aerosol generating substrate comprising exogenous nicotine and a relatively high level of an aerosol-forming agent.

[0022] The use of such an aerosol generating substrate is particularly advantageous for planar or flat aerosol generating articles such as that of the present invention. As described herein, due to the reduced time required to heat the aerosol generating substrate of a planar aerosol generating article to generate an aerosol, activators such as nicotine, as well as other relatively volatile components such as flavoring agents, can be released relatively quickly from the aerosol generating substrate upon heating. Consequently, this activator may be present at a relatively high level during the initial puff. Providing an aerosol generating substrate having a relatively high aerosol forming agent content has been found to advantageously provide faster and more consistent delivery of the aerosol forming agent into the aerosol, which ensures an optimal balance of the aerosol between the aerosol forming agent and the activator. As described herein, while this balance may be particularly important during the initial puff, a relatively high level of the aerosol forming agent within the aerosol generating substrate also allows the balance to be maintained throughout the heating process.

[0023] Due to more efficient heating of the aerosol generating substrate in flat or flat aerosol generating articles, it is advantageously possible to heat such articles at a lower temperature than conventional aerosol generating articles having a cylindrical rod of the aerosol forming substrate. When a lower temperature is used for heating the aerosol forming substrate, the inclusion of a relatively high level of aerosol forming agent, as in the present invention, helps ensure that optimal delivery of the aerosol to the consumer is still maintained throughout the entire heating cycle.

[0024] The use of an aerosol generating material as described herein has also been found to provide a highly stable method for incorporating nicotine into an aerosol generating article. The inclusion of exogenous nicotine within the aerosol generating material provides a high degree of control over the amount of nicotine delivered into the aerosol and also facilitates the delivery of nicotine at lower temperatures that can be used in flat or planar consumables.

[0025] The use of an aerosol generating material having a relatively high level of aerosol-forming agent has been found to be particularly effective in aerosol generating articles such as those described below that do not contain a filter material. In the absence of a filter material, there is minimal removal of the aerosol-forming agent from the aerosol as it passes through the aerosol generating article, so that an optimized volume of aerosol can be delivered to the consumer with a desirable balance between the aerosol-forming agent and the activator.

[0026] In some embodiments of the present invention, the aerosol generating substrate may advantageously be formed of a low (or zero) level of tobacco particles, which means that the level of undesirable tobacco compounds in the aerosol is reduced while still maintaining an acceptable delivery of nicotine or other active agents.

[0027] The aerosol-generating substrate of the aerosol-generating article according to the present invention may comprise one or more aerosol-forming agents. Suitable aerosol-forming agents for inclusion in homogenized plant material are known in the art, but are not limited thereto, include polyhydric alcohols such as triethylene glycol, propylene glycol, 1,3-butanediol, and glycerol; 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. Preferably, the aerosol-forming agent comprises one or more of glycerol and propylene glycol. The aerosol-forming agent may be composed of glycerol or propylene glycol or a combination of glycerol and propylene glycol.

[0028] According to the present invention, the aerosol generating substrate has an aerosol forming agent content of at least 40 weight percent based on dry weight. Preferably, the aerosol generating substrate has an aerosol forming agent content of at least 45 weight percent based on dry weight. More preferably, the aerosol generating substrate has an aerosol forming agent content of at least 50 weight percent.

[0029] The aerosol generating substrate preferably has an aerosol forming agent content of 70 weight percent or less based on dry weight. More preferably, the aerosol generating substrate has an aerosol forming agent content of 65 weight percent or less based on dry weight, and more preferably 60 weight percent or less.

[0030] For example, the aerosol-forming agent content of the aerosol-generating substrate is preferably 40 weight percent to 70 weight percent, or 45 weight percent to 70 weight percent, or 50 weight percent to 70 weight percent based on dry weight.

[0031] For example, the aerosol-forming agent content of the aerosol-generating substrate is preferably 40 weight percent to 65 weight percent, or 45 weight percent to 65 weight percent, or 50 weight percent to 65 weight percent based on dry weight.

[0032] For example, the aerosol-forming agent content of the aerosol-generating substrate is preferably 40 weight percent to 60 weight percent, or 45 weight percent to 60 weight percent, or 50 weight percent to 60 weight percent based on dry weight.

[0033] Preferably, the aerosol generating substrate comprises glycerol as an aerosol forming agent. For example, the aerosol generating substrate may comprise, on a dry weight basis, 40 weight percent to 65 weight percent glycerol, or 45 weight percent to 60 weight percent glycerol, or 50 weight percent to 60 weight percent glycerol, or 50 weight percent to 55 weight percent glycerol.

[0034] According to the present invention, the aerosol generating substrate further comprises exogenous nicotine.

[0035] As used herein with respect to the present invention, the term “nicotine” is used to describe nicotine, nicotine base, or nicotine salt. In embodiments in which the aerosol generating material comprises a nicotine base or a nicotine salt, the amount of nicotine cited herein is, respectively, an amount of free base nicotine or an amount of protonated nicotine.

[0036] As used herein in connection with the present invention, the term “exogenous” refers to any nicotine incorporated into an aerosol generating substrate that is provided exogenously from a tobacco substance present in the aerosol generating substrate. Accordingly, exogenous nicotine is a separate and distinct source of nicotine from the nicotine essentially provided within any tobacco substance present.

[0037] Exogenous nicotine can be in the form of natural nicotine, synthetic nicotine, or a combination of natural and synthetic nicotine.

[0038] The aerosol generating material may have a total exogenous nicotine content of at least 0.5 weight percent, at least 1 weight percent, at least 1.5 weight percent, or at least 2 weight percent based on dry weight.

[0039] The aerosol generating material may have a total exogenous nicotine content of 10 weight percent or less, 8 weight percent or less, 6 weight percent or less, or 4 weight percent or less based on dry weight.

[0040] The aerosol generating material may have a total exogenous nicotine content of 0.5 weight percent to 10 weight percent, 0.5 weight percent to 8 weight percent, 0.5 weight percent to 6 weight percent, or 0.5 weight percent to 4 weight percent based on dry weight.

[0041] The aerosol generating material may have a total exogenous nicotine content of 1 weight percent to 10 weight percent, 1 weight percent to 8 weight percent, 1 weight percent to 6 weight percent, or 1 weight percent to 4 weight percent based on dry weight.

[0042] The aerosol generating material may have a total exogenous nicotine content of 1.5 weight percent to 10 weight percent, 1.5 weight percent to 8 weight percent, 1.5 weight percent to 6 weight percent, or 1.5 weight percent to 4 weight percent.

[0043] The aerosol generating material may have a total exogenous nicotine content of 2 weight percent to 10 weight percent, 2 weight percent to 8 weight percent, 2 weight percent to 6 weight percent, or 2 weight percent to 4 weight percent.

[0044] Alternatively or additionally to the activator, the aerosol generating substrate may further include one or more flavoring agents. The inclusion of one or more flavoring agents may be advantageous for providing a desired level of flavoring, considering the potentially relatively low sensory impact of the non-tobacco plant particles used in the aerosol generating substrate.

[0045] Suitable flavoring agents will be known to those skilled in the art. 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; and one or both of anethole and linalool.

[0046] The aerosol generating material may have a flavoring agent content of at least 0.5 weight percent, preferably at least 1 weight percent, and more preferably at least 2 weight percent based on dry weight.

[0047] The aerosol generating material may have a flavoring agent content of 10 weight percent or less, preferably 8 weight percent or less, and more preferably 5 weight percent or less, based on dry weight.

[0048] For example, the aerosol generating material may have a flavoring agent content of 0.5 weight percent to 10 weight percent, or 1 weight percent to 8 weight percent, or 2 weight percent to 5 weight percent based on dry weight.

[0049] The aerosol generating substrate of the aerosol generating article according to the present invention preferably further comprises one or more cellulose-based preparations.

[0050] As used herein in connection with the present invention, the term "cellulose-based formulation" is used to describe cellulose materials. Examples of cellulose-based formulations include cellulose-based film-forming agents, cellulose-based reinforcing agents, and cellulose-based binders.

[0051] The aerosol generating substrate may include multiple cellulose-based preparations. That is, the aerosol generating substrate may include two or more cellulose-based preparations. For example, the aerosol generating substrate may include two cellulose-based preparations, three cellulose-based preparations, four cellulose-based preparations, or five cellulose-based preparations.

[0052] Preferably, the aerosol generating substrate has a total cellulose-based composition content of at least 35 weight percent.

[0053] As used herein in connection with the present invention, the term “total cellulose-based formulation” is used to describe the combined content of all cellulose-based formulations within an aerosol generating substrate. For example, where the aerosol generating substrate comprises a plurality of cellulose-based formulations consisting of a cellulose-based film-forming agent, a cellulose-based reinforcing agent, and a cellulose-based binder, the term “total cellulose-based formulation content” describes the combined content of the cellulose-based film-forming agent, the cellulose-based reinforcing agent, and the cellulose-based binder of the aerosol generating substrate.

[0054] The aerosol generating material may have a total cellulose-based composition content of at least 36 weight percent, at least 38 weight percent, or at least 40 weight percent based on dry weight.

[0055] The aerosol generating material may have a total cellulose-based composition content of 52 weight percent or less, 50 weight percent or less, 48 ​​weight percent or less, 46 weight percent or less, or 44 weight percent or less based on dry weight.

[0056] The aerosol generating substrate may include one or more cellulose-based film-forming agents.

[0057] As used herein in connection with the present invention, the term “cellulose-based film-forming agent” is used to describe a cellulose polymer capable of forming a continuous film, either by itself or in the presence of an auxiliary thickener.

[0058] Advantageously, the aerosol generating substrate may comprise one or more cellulose-based film-forming agents selected from carboxymethyl cellulose (CMC), ethylcellulose (EC), hydroxyethyl cellulose (HEC), hydroxyethyl methylcellulose (HEMC), hydroxypropyl cellulose (HPC), hydroxypropyl methylcellulose (HPMC), and methylcellulose (MC).

[0059] More advantageously, the aerosol generating substrate may comprise one or more cellulose-based film-forming agents selected from carboxymethyl cellulose (CMC), ethylcellulose (EC), methylcellulose (MC), and hydroxypropyl methylcellulose (HPMC).

[0060] Most advantageously, the aerosol generating substrate comprises one or more cellulose-based film-forming agents selected from carboxymethyl cellulose (CMC) and hydroxypropyl methylcellulose (HPMC).

[0061] Preferably, the aerosol generating substrate comprises carboxymethyl cellulose (CMC) and hydroxypropyl methylcellulose (HPMC).

[0062] One or more cellulose-based film-forming agents can act as binders for the aerosol-generating substrate.

[0063] The aerosol generating substrate may have a total cellulose-based film-forming agent content of at least 15 weight percent, at least 20 weight percent, or at least 25 weight percent based on dry weight.

[0064] As used herein in connection with the present invention, the term "total cellulosic film-forming agent content" is used to describe the combined content of all cellulosic film-forming agents within the aerosol-generating substrate.

[0065] The aerosol generating material may have a total cellulose-based film-forming agent content of 40 weight percent or less, 35 weight percent or less, or 30 weight percent or less based on dry weight.

[0066] The aerosol generating material may include sodium carboxymethyl cellulose.

[0067] The aerosol generating substrate may have a carboxymethyl cellulose content of at least 2 weight percent, at least 3 weight percent, at least 4 weight percent, or at least 5 weight percent based on dry weight.

[0068] The aerosol generating material may have a carboxymethyl cellulose content of 12 weight percent or less, 10 weight percent or less, 8 weight percent or less, or 6 weight percent or less based on dry weight.

[0069] The aerosol generating material may include one or more cellulose-based reinforcing agents.

[0070] Inclusion of one or more cellulose-based reinforcing agents in the aerosol generating substrate can advantageously increase the tensile strength of the aerosol generating substrate.

[0071] Advantageously, the aerosol generating substrate may comprise one or more cellulose-based reinforcing agents selected from cellulose fibers, cellulose powder, and microcrystalline cellulose (MCC).

[0072] The aerosol generating substrate may have a total cellulose-based reinforcing agent content of at least 5 weight percent, at least 10 weight percent, or at least 15 weight percent based on dry weight.

[0073] As used herein in connection with the present invention, the term "total cellulose-based reinforcing agent content" is used to describe the combined content of all cellulose-based reinforcing agents within the aerosol generating substrate.

[0074] The aerosol generating material may have a total cellulose-based reinforcing agent content of 30 weight percent or less, 25 weight percent or less, or 20 weight percent or less based on dry weight.

[0075] Preferably, the aerosol generating substrate comprises cellulose fibers. Cellulose fibers can be particularly effective in increasing the tensile strength of the aerosol generating substrate.

[0076] The aerosol generating material may include cellulose fibers having a length of at least 0.2 millimeters, at least 0.5 millimeters, at least 0.7 millimeters, or at least 0.9 millimeters.

[0077] The aerosol generating material may include cellulose fibers having a length of 2 millimeters or less, 1.8 millimeters or less, 1.6 millimeters or less, or 1.4 millimeters or less.

[0078] The aerosol generating substrate may have a cellulose fiber content of at least 2 weight percent, at least 5 weight percent, at least 10 weight percent, or at least 15 weight percent based on dry weight.

[0079] The aerosol generating material may have a cellulose fiber content of 30 weight percent or less, 25 weight percent or less, or 20 weight percent or less based on dry weight.

[0080] The aerosol generating material may include microcrystalline cellulose having a D50 size of at least 5 micrometers, at least 10 micrometers, or at least 15 micrometers.

[0081] As used herein in connection with the present invention, the term "D50 size" describes the median particle size of a particulate material. The D50 size is the particle size that divides the distribution in half, where half of the particles are larger than the D50 size and half of the particles are smaller than the D50 size. As described above, the particle size distribution can be determined by laser diffraction.

[0082] The aerosol generating material may include microcrystalline cellulose having a D50 size of 100 micrometers or less, 90 micrometers or less, or 80 micrometers or less.

[0083] The aerosol generating substrate may have a microcrystalline cellulose content of at least 2 weight percent, at least 5 weight percent, at least 10 weight percent, or at least 15 weight percent based on dry weight.

[0084] The aerosol generating material may have a microcrystalline cellulose content of 30 weight percent or less, 25 weight percent or less, or 20 weight percent or less based on dry weight.

[0085] The aerosol generating material may include cellulose powder having a D50 size of at least 25 micrometers, at least 30 micrometers, or at least 35 micrometers.

[0086] The aerosol generating material may include cellulose powder having a D50 size of 250 micrometers or less, 225 micrometers or less, or 200 micrometers or less.

[0087] The aerosol generating material may have a cellulose powder content of at least 2 weight percent, at least 5 weight percent, at least 10 weight percent, or at least 15 weight percent based on dry weight.

[0088] The aerosol generating material may have a cellulose powder content of 30 weight percent or less, 25 weight percent or less, or 20 weight percent or less based on dry weight.

[0089] The aerosol generating material may include one or more carboxylic acids.

[0090] The aerosol generating material may include multiple carboxylic acids. That is, the aerosol generating material may include two or more carboxylic acids. For example, the aerosol generating material may include two carboxylic acids, three carboxylic acids, four carboxylic acids, or five carboxylic acids.

[0091] The aerosol generating material may include one or more diprotic carboxylic acids. For example, the aerosol generating material may include one or more diprotic carboxylic acids selected from fumaric acid, maleic acid, malic acid, adipic acid, and succinic acid.

[0092] The aerosol generating substrate may include one or more triproton carboxylic acids. For example, the solid aerosol generating substrate may include citric acid.

[0093] The aerosol generating material may include one or more carboxylic acids selected from lactic acid, levulinic acid, acetic acid, benzoic acid, citric acid, fumaric acid, maleic acid, and malic acid.

[0094] The aerosol generating material may include one or more carboxylic acids selected from acetic acid, benzoic acid, citric acid, fumaric acid, maleic acid, and malic acid.

[0095] Preferably, the aerosol generating material comprises one or more carboxylic acids selected from fumaric acid, maleic acid, and malic acid.

[0096] More preferably, the aerosol generating material contains fumaric acid.

[0097] The aerosol generating material may further include one or more carboxylic acids selected from lactic acid and levulinic acid. For example, the aerosol generating material may include fumaric acid and lactic acid, or a combination of fumaric acid and levulinic acid.

[0098] The aerosol generating material has a total carboxylic acid content of at least 0.5 weight percent.

[0099] As used herein in connection with the present invention, the term "total carboxylic acid content" is used to describe the combined content of all carboxylic acids within an aerosol generating substrate. For example, if the aerosol generating substrate comprises a plurality of carboxylic acids consisting of benzoic acid and fumaric acid, the term "total carboxylic acid content" describes the combined benzoic acid content and fumaric acid content of the aerosol generating substrate.

[0100] The aerosol generating material may have a total carboxylic acid content of at least 1 weight percent, at least 1.5 weight percent, or at least 2 weight percent.

[0101] The aerosol generating material may have a total carboxylic acid content of 8 weight percent or less, 6 weight percent or less, or 4 weight percent or less.

[0102] The aerosol generating material may include one or more non-cellulose-based thickeners.

[0103] As used herein in connection with the present invention, the term “non-cellulose thickener” is used to describe a non-cellulose material that, when added to an aqueous or non-aqueous liquid composition, increases the viscosity of the liquid composition without substantially altering its other properties. One or more non-cellulose thickeners may increase stability and improve the suspension of components within the liquid composition. The thickener may also be referred to as a “thickener,” a “rheology modifier,” or a “viscosifying agent.”

[0104] The aerosol generating material may include one or more non-cellulose thickeners selected from alginate, gellan gum, guar gum, gum arabic, locust bean gum, pectin, starch, and xanthan gum.

[0105] The aerosol generating material may have a total non-cellulose-based thickener content of at least 1 weight percent, at least 2 weight percent, or at least 3 weight percent based on dry weight.

[0106] As used herein in connection with the present invention, the term “total non-cellulose thickener content” is used to describe the combined content of all non-cellulose thickeners within the aerosol generating substrate.

[0107] The aerosol generating material may have a total non-cellulose-based thickener content of 10 weight percent or less, 8 weight percent or less, or 6 weight percent or less.

[0108] The aerosol generating device may be an aerosol generating device that is substantially tobacco-free.

[0109] As used herein in connection with the present invention, the term “substantially tobacco-free aerosol generating material” is used to describe an aerosol generating material having a tobacco content of less than 1 weight percent. For example, the aerosol generating material may have a tobacco content of less than 0.75 weight percent, less than 0.5 weight percent, or less than 0.25 weight percent.

[0110] The aerosol generating substrate may be provided in any suitable form. For example, the aerosol generating substrate may be in the form of one or more sheets. As used herein in connection with the present invention, the term "sheet" describes a laminated element having a width and length substantially greater than its thickness.

[0111] Alternatively or additionally, the aerosol generating material may be in the form of multiple strands, strips, or shreds. As used herein, the term “strand” describes an elongated element of material having a length substantially greater than its width and thickness. The term “strand” should be considered to include strips, shreds, and any other aerosol generating material having similar forms. Strands of the aerosol generating material may be formed from sheets of the aerosol generating material, for example by cutting or crushing, or by other methods.

[0112] Preferably, the aerosol generating material is in the form of one or more sheets.

[0113] Each of one or more sheets of aerosol generating material may have a basis weight of at least 130 grams per square meter, or at least 135 grams per square meter, or at least 140 grams per square meter.

[0114] Each of one or more sheets of aerosol generating material may have a basis weight of gram or less per 160 square meters, gram or less per 155 square meters, or gram or less per 150 square meters.

[0115] As used herein, the term "basis weight" is defined as equivalent to the "base weight" of the sheet of the aerosol generating substrate and equal to the mass per unit area of ​​the sheet. The basis weight may be determined according to ISO standard 536:2012.

[0116] Unless otherwise noted, measurements performed on the aerosol-generating substrate sheets described herein are performed at 23 degrees Celsius and 50 percent relative humidity.

[0117] Each of one or more sheets of the aerosol generating substrate may have an average thickness of at least 175 microns, or at least 180 microns, or at least 185 microns, or at least 190 microns.

[0118] Each of one or more sheets of the aerosol generating substrate may have an average thickness of 225 microns or less, or 220 microns or less, or 215 microns or less, or 210 microns or less.

[0119] As used herein, the term "thickness" is used to describe the minimum dimension of a sheet of aerosol generating material. Thickness is measured perpendicular to the length and width of the sheet. Thickness can be determined according to ISO standard 534:2012.

[0120] Each of one or more sheets of the aerosol generating material may have a density of at least 0.5 grams per cubic centimeter, or at least 0.55 grams per cubic centimeter, or at least 0.6 grams per cubic centimeter.

[0121] Each of one or more sheets of the aerosol generating material may have a density of gram or less per 1 cubic centimeter, or gram or less per 0.9 cubic centimeters, or gram or less per 0.8 cubic centimeters.

[0122] For a sheet of an aerosol generating substrate as described herein, the density can be calculated by dividing the basis weight of the sheet by the thickness of the sheet. The basis weight and thickness of the sheet can be measured as described above.

[0123] One or more sheets of the aerosol generating material may be wrinkled.

[0124] One or more sheets of the aerosol generating substrate may have a texture formed thereon. This facilitates the formation of wrinkles in the aerosol generating substrate, thereby forming an aerosol generating rod to be included in the aerosol generating article according to the first embodiment of the present invention.

[0125] As used herein in connection with the present invention, the term “textured” is used to describe a sheet of an aerosol generating substrate that is crimped, embossed, intaglio, perforated, or otherwise modified. A textured processed sheet of an aerosol generating substrate may include a plurality of spaced indentations, protrusions, perforations, or a combination thereof.

[0126] One or more sheets of the aerosol generating material can be crimped.

[0127] As used herein in connection with the present invention, the term “crimped” is intended to be synonymous with the term “creped” and is used to describe a sheet of aerosol generating substrate having a plurality of substantially parallel ridges or corrugations.

[0128] Each sheet may have a tensile strength at a peak in the cross direction of at least 150 Newtons / meter (N / m), or at least 160 N / m, or at least 170 N / m, or at least 180 N / m. The tensile strength at a peak in the cross direction may be up to 400 N / m, or up to 300 N / m.

[0129] Each sheet may have a tensile strength at a peak in the machine direction of at least 450 Newtons / meter (N / m), or at least 475 N / m, or at least 500 N / m, or at least 525 N / m. The tensile strength at a peak in the machine direction may be up to 700 N / m or up to 600 N / m.

[0130] Throughout this specification, the term “tensile strength” is used to denote a measure of the force required to stretch a sheet of an aerosol-generating substrate until it breaks. More specifically, tensile strength is the maximum tensile force per unit width that the sheet material will withstand before breaking, measured in the mechanical or cross direction of the sheet material. This is expressed in units of Newtons per meter of material (N / m). Tests for measuring the tensile strength of sheet materials are known. Suitable tests are described in the 2008 publication of the international standard ISO 1924-2 titled “Paper and Board – Determination of Tensile Properties – Part 2: Method of Stretching at Constant Speed”.

[0131] The aerosol generating material can be an aerosol generating membrane.

[0132] As used herein in connection with the present invention, the term 'film' is used to describe an aerosol generating substrate having a thickness substantially smaller than its width and length.

[0133] The aerosol generating substrate can be formed by any suitable method. For example, the aerosol generating substrate can be formed by batch casting, continuous casting, or extrusion.

[0134] Preferably, the aerosol generating substrate is formed by a casting method. In this method, a slurry is formed from the solid component of the aerosol generating substrate in water. Then, the slurry is cast onto a support surface and dried to solidify the slurry into a sheet of the aerosol generating substrate. The casting slurry may be heated to facilitate drying.

[0135] The aerosol generating device may be self-supporting.

[0136] The aerosol generating material may be placed on a support or the aerosol generating material may be sandwiched between other materials.

[0137] The aerosol generating material as described herein may be provided within the cavity. Alternatively, the cavity may be empty and the aerosol generating material may be provided outside the cavity.

[0138] Alternatively or additionally, one or more sheets or layers of an aerosol generating material as described herein may be positioned between the frame and the first outer surface. One or more sheets of an aerosol generating material as described herein may be positioned between the frame and the second outer surface. The aerosol generating material may be in physical contact with the frame and bonded thereto.

[0139] One or more sheets or layers of an aerosol generating material as described herein may be positioned between the frame and the outer wrapper. The outer wrapper is discussed in more detail below. The aerosol generating material may be in physical contact with both the frame and the outer wrapper and may be bonded thereto.

[0140] One or more sheets or layers of an aerosol generating substrate as described herein may be positioned between the frame and the first planar outer layer. One or more sheets of homogenized plant material as described herein may be positioned between the frame and the second planar outer layer. The first planar outer layer and the second planar outer layer are discussed in more detail below. The aerosol generating substrate may be in physical contact with both the frame and the first planar outer layer and may be bonded thereto. The aerosol generating substrate may be in physical contact with both the frame and the second planar outer layer and may be bonded thereto.

[0141] An aerosol generating article may have a length extending in the x-direction. An aerosol generating article may have a width extending in the y-direction. An aerosol generating article may have a thickness extending in the z-direction.

[0142] The aerosol generating article may be substantially flat or substantially planar. In particular, the thickness of the aerosol generating article may be less than 50 percent of both the length and width of the aerosol generating article. Advantageously, a thinner thickness may provide a small temperature gradient or temperature difference across the thickness of the aerosol generating substrate during heating.

[0143] The aerosol generating article may have a quadrilateral cuboid shape. The aerosol generating article may have a right-angled prism shape. The aerosol generating article may have a rectangular prism shape. The aerosol generating article may have a cylindrical shape. The aerosol generating article may have a right-angled cylindrical shape.

[0144] The aerosol generating article may have a laminated structure, for example, the aerosol generating article may include or be formed of at least two layers. In particular, as discussed in more detail below, the aerosol generating article may include at least two of a first outer layer, a second outer layer, a frame, a first frame layer, a second frame layer, a third frame layer, a first aerosol generating substrate layer, and a second aerosol generating substrate layer.

[0145] The aerosol generating article, substantially the entirety thereof, may be paper or cardboard, except for one or more aerosol generating materials (if present) and adhesives (if present).

[0146] Aerosol-generating articles may have a cellulose acetate content of less than 5 percent. Aerosol-generating articles may have a cellulose acetate content of less than 3 percent. Aerosol-generating articles may have a cellulose acetate content of less than 1 percent.

[0147] The frame can be a flat frame.

[0148] The frame may define a frame aperture that extends through the thickness of the frame. The frame aperture may define or form an airflow passage for the aerosol-generating article. The frame aperture may define or form a cavity for the aerosol-generating article. For example, the frame may have a hollow rectangular shape or a square hollow tube shape. As a further embodiment, the frame may have a cross-section that is annular in shape, and preferably, the cross-section in the x / y plane is annular in shape.

[0149] The frame may include an outer surface of the frame. The outer surface of the frame may extend transversely, for example, between a first planar outer surface and a second planar outer surface. The outer surface of the frame may at least partially define or form one or more outer surfaces of an aerosol-generating article. For example, the outer surface of the frame may at least partially define or form one or more outer walls of an aerosol-generating article. The outer surface of the frame may surround or encircle the frame aperture. The outer surface of the frame may surround or encircle the cavity.

[0150] The frame may include an inner surface of the frame. The inner surface of the frame may extend laterally, for example, between a first planar outer surface and a second planar outer surface. The inner surface of the frame may define or form an outer wall of the frame aperture. The inner surface of the frame may define or form an outer wall of the cavity. The inner surface of the frame may surround or enclose the frame aperture extending through the thickness of the frame. The inner surface of the frame may surround or enclose the cavity.

[0151] The outer surface of the frame may surround or encircle the inner surface of the frame. The inner surface of the frame and the outer surface of the frame may be concentric with each other.

[0152] The aerosol generating article may include one or more outer walls extending between a first planar outer surface and a second planar outer surface. One or more outer walls may collectively define the entire transverse outer area of ​​the aerosol generating article. A frame may define at least partially each of the one or more outer walls. One or more outer walls may surround or enclose a cavity. A frame may define at least 60 percent, at least 70 percent, at least 80 percent, or at least 90 percent of the entire transverse outer area of ​​the aerosol generating article.

[0153] The frame may include surrounding walls. The surrounding walls may surround or encircle at least a portion of the frame aperture extending through the thickness of the frame. The surrounding walls may surround or encircle at least a portion of the cavity. The surrounding walls may surround or encircle the frame aperture extending through the thickness of the frame. The surrounding walls may surround or encircle the cavity.

[0154] The periphery wall surface may be defined or formed by the frame's outer surface and the frame's inner surface. The periphery wall surface may at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The periphery wall surface may define or form the frame aperture's outer wall surface. The periphery wall surface may define or form the cavity's outer wall surface.

[0155] The surrounding walls may have a radial thickness. The radial thickness can be defined, for example, as the minimum distance between the outer surface of the frame and the inner surface of the frame in the x / y plane.

[0156] The surrounding wall surface may have a radial thickness of 0.5 millimeters or more. The surrounding wall surface may have a radial thickness of 1.5 millimeters or more. The surrounding wall surface may have a radial thickness of 2.5 millimeters or more.

[0157] The surrounding wall surface may have a radial thickness of 3.5 millimeters or less. The surrounding wall surface may have a radial thickness of 2.5 millimeters or less.

[0158] The surrounding wall surface may have a radial thickness of 0.5 millimeters to 3.5 millimeters. The surrounding wall surface may have a radial thickness of 0.5 millimeters to 2.5 millimeters.

[0159] Advantageously, a peripheral wall having a radial thickness of 0.5 to 3.5 millimeters has been found to provide good structural strength to the aerosol generating article without using an excess amount of material that could increase manufacturing costs, and can limit heat that is undesirably transferred to the frame rather than to the aerosol generating substrate.

[0160] The frame may be manufactured from or contain biodegradable materials. The frame may be manufactured entirely from biodegradable materials.

[0161] The frame may be manufactured from or contain a cellulose material. The cellulose material may contain sheets of cellulose material. The cellulose material may contain cellulose fibers. The cellulose material may be paper, cardboard, or cardboard. The frame may be manufactured from or contain a plant material such as tobacco. The frame may be manufactured entirely from a cellulose material.

[0162] The aerosol generating article may include one or more susceptor materials. The frame may include one or more susceptor materials. One or more susceptor materials may be in thermal contact with the aerosol generating substrate. One or more susceptor materials may be in thermal contact with the cavity. One or more susceptor materials may be incorporated within the material of the frame. For example, one or more susceptor materials may be incorporated within the peripheral wall surface of the frame.

[0163] One or more susceptor materials may be one or more particles, strips, threads, or wires of the susceptor material. One or more susceptor materials may be one or more sheets or layers of the susceptor material. One or more sheets or layers of the susceptor material may be in the form of a mesh of the susceptor material.

[0164] The susceptor material may comprise, in any form, one or more materials selected from the list consisting of aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0165] The frame may have a thickness of at least 50 percent of the thickness of the aerosol-generating article. The frame may have a thickness of at least 70 percent of the thickness of the aerosol-generating article. The frame may have a thickness of at least 90 percent of the thickness of the aerosol-generating article. The frame may have a thickness of at least 95 percent of the thickness of the aerosol-generating article.

[0166] The frame may have a thickness of 95 percent or less of the thickness of the aerosol-generating article. The frame may have a thickness of 90 percent or less of the thickness of the aerosol-generating article. The frame may have a thickness of 70 percent or less of the thickness of the aerosol-generating article.

[0167] The frame may have a thickness of 50 percent to 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness of 70 percent to 95 percent of the thickness of the aerosol-generating article.

[0168] The frame may have a thickness of 1 millimeter or more, 2 millimeters or more, 3 millimeters or more, or 4 millimeters or more. The frame may have a thickness of 5.5 millimeters or less, 4.5 millimeters or less, 3.5 millimeters or less, 2.5 millimeters or less, or 1.5 millimeters or less. The frame may have a thickness of 1 millimeter to 5.5 millimeters. Preferably, the frame may have a thickness of 1.5 millimeters to 5.5 millimeters.

[0169] The frame may have a length equal to the length of the aerosol-generating article. The frame may have a length of at least 90 percent of the length of the aerosol-generating article. The frame may have a length of at least 95 percent of the length of the aerosol-generating article.

[0170] The frame may have a width equal to the width of the aerosol-generating article. The frame may have a width that is at least 90 percent of the width of the aerosol-generating article.

[0171] The frame may be a single component. Alternatively, the frame may include two or more layers. That is, the frame may have a laminated structure. Advantageously, the characteristics of each layer may be individually optimized according to the relative distance between the layer and the aerosol generating substrate or heater of the aerosol generating device.

[0172] A frame may include a first frame layer and a second frame layer. The first frame layer and the second frame layer may be the only layers of the frame. That is, the frame may include two or fewer layers, or exactly two layers. A frame aperture may be defined through both the first frame layer and the second frame layer.

[0173] The frame may include a first frame layer, a second frame layer, and a third frame layer. The second frame layer may be positioned between the first frame layer and the third frame layer. The first frame layer, the second frame layer, and the third frame layer may be the only layers of the frame. That is, the frame may include three or fewer layers, or exactly three layers.

[0174] The first planar outer surface may be a planar upper surface, and the second planar outer surface may be a planar lower surface. The first planar outer surface may be positioned parallel to the second planar outer surface. The first planar outer surface may extend in the x / y plane. The second planar outer surface may extend in the x / y plane. The second planar outer surface may be spaced apart from the first planar outer surface in the z-direction or transverse direction. The distance between the first planar outer surface and the second planar outer surface in the z-direction or transverse direction may define the thickness of the aerosol-generating article.

[0175] The aerosol-generating article may include an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may contain a hydrophobic material.

[0176] The outer wrapper may define or form a first planar outer surface. The outer wrapper may define or form a second planar outer surface. The outer wrapper may define or form both the first planar outer surface and the second planar outer surface.

[0177] The outer wrapper may surround or encircle the frame. The outer wrapper may physically contact the frame and may be bonded to the frame. The outer wrapper may be placed over the opposing end of the cavity. The outer wrapper may define or form the opposing end walls of the cavity, such as the first cavity end wall and the second cavity end wall. That is, the frame and the outer wrapper may collectively define the cavity.

[0178] The outer wrapper may surround or enclose the frame and the aerosol generating substrate layer. The outer wrapper may physically contact both the frame and the aerosol generating substrate layer and may be bonded thereto.

[0179] The outer wrapper may surround or enclose the frame, the first aerosol generating substrate layer, and the second aerosol generating substrate layer. The outer wrapper may physically contact both the first aerosol generating substrate layer and the second aerosol generating substrate layer and may be bonded thereto.

[0180] The aerosol generating article may include a first planar outer layer and a second planar outer layer. The first planar outer layer may be an upper layer, and the second planar outer layer may be a lower layer.

[0181] The first planar outer layer may define or form a first planar outer surface. The first planar outer layer may extend in the x / y plane. The second planar outer layer may define or form a second planar outer surface. The second planar outer layer may extend in the x / y plane.

[0182] The first planar outer layer may be in physical contact with the frame and may be bonded to the frame. The first planar outer layer may be placed over the end of the cavity. The first planar outer layer may define or form a wall surface of the cavity such as the wall surface of the first cavity end.

[0183] The second planar outer layer may be in physical contact with the frame and may be bonded to the frame. The second planar outer layer may be placed over the end of the cavity. The second planar outer layer may define or form a wall surface of the cavity such as the wall surface of the second cavity end.

[0184] The first planar outer layer and the second planar outer layer may be placed over the opposing ends of the cavity. The first planar outer layer and the second planar outer layer may define or form the opposing end walls of the cavity, such as the first cavity end wall and the second cavity end wall. That is, the frame, the first planar outer layer and the second planar outer layer may collectively define the cavity.

[0185] The first planar outer layer may be spaced apart from the frame in the lateral direction, for example. For example, the aerosol generating substrate layer or the first aerosol generating substrate layer may be positioned between the first planar outer layer and the frame. The first planar outer layer may be in physical contact with the aerosol generating substrate layer or the first aerosol generating substrate layer and may be bonded thereto.

[0186] The second planar outer layer may be spaced apart from the frame in the lateral direction, for example. For example, the aerosol generating substrate layer or the second aerosol generating substrate layer may be positioned between the second planar outer layer and the frame. The second planar outer layer may be in physical contact with the aerosol generating substrate layer or the second aerosol generating substrate layer and may be bonded thereto.

[0187] The first planar outer layer may be hydrophobic. The first planar outer layer may include a hydrophobic material. The second planar outer layer may be hydrophobic. The second planar outer layer may include a hydrophobic material.

[0188] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may comprise a cellulose material or be manufactured therefrom. The cellulose material may be paper, cigarette paper, tobacco paper, cardboard, wood, fabric, natural fiber, or artificial fiber.

[0189] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may include an aerosol generating substrate as described herein.

[0190] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness of 25 micrometers or more, 30 micrometers or more, 35 micrometers or more, 40 micrometers or more, or 45 micrometers or more.

[0191] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness of 55 micrometers or less, 50 micrometers or less, 45 micrometers or less, 40 micrometers or less, or 35 micrometers or less.

[0192] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness of 25 micrometers to 55 micrometers, 25 micrometers to 45 micrometers, or 30 micrometers to 45 micrometers.

[0193] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length substantially equal to the length of the frame. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length substantially equal to the length of the aerosol-generating article.

[0194] One or more of the first planar outer layer and the second planar outer layer may have a width substantially equal to the width of the frame. One or more of the first planar outer layer and the second planar outer layer may have a width substantially equal to the width of the aerosol-generating article.

[0195] The cavity may have a thickness of 0.5 millimeters or more. The cavity may have a thickness of 1.5 millimeters or more. The cavity may have a thickness of 2.5 millimeters or more. The cavity may have a thickness of 3.5 millimeters or more.

[0196] The cavity may have a thickness of 4.5 millimeters or less. The cavity may have a thickness of 3.5 millimeters or less. The cavity may have a thickness of 2.5 millimeters or less. The cavity may have a thickness of 1.5 millimeters or less.

[0197] The cavity may have a thickness of 0.5 millimeters to 4.5 millimeters. The cavity may have a thickness of 1 millimeter to 4.5 millimeters. Preferably, the cavity may have a thickness of 2.8 millimeters to 3.3 millimeters.

[0198] The cavity may have a length of 14 millimeters or more. The cavity may have a length of 18 millimeters or more. The cavity may have a length of 22 millimeters or more. The cavity may have a thickness of 30 millimeters or more. The cavity may have a thickness of 38 millimeters or more.

[0199] The cavity may have a length of 40 millimeters or less. The cavity may have a thickness of 34 millimeters or less. The cavity may have a thickness of 28 millimeters or less. The cavity may have a thickness of 22 millimeters or less. The cavity may have a thickness of 18 millimeters or less.

[0200] The cavity may have a length of 14 millimeters to 40 millimeters. The cavity may have a length of 14 millimeters to 34 millimeters. The cavity may have a length of 24 millimeters to 28 millimeters.

[0201] The cavity may have a width of 4.5 millimeters or more. The cavity may have a width of 7 millimeters or more. The cavity may have a width of 11 millimeters or more.

[0202] The cavity may have a width of 13 millimeters or less. The cavity may have a width of 11 millimeters or less. The cavity may have a width of 7 millimeters or less. The cavity may have a width of 5 millimeters or less.

[0203] The cavity may have a width of 4.5 millimeters to 13 millimeters. The cavity may have a width of 7 millimeters to 10 millimeters. The cavity may have a width of 7.5 millimeters to 8.5 millimeters.

[0204] The cavity may have a length of 14 to 40 millimeters, a width of 4.5 to 13 millimeters, and a thickness of 0.5 to 4.5 millimeters.

[0205] Preferably, the cavity may have a length of 20 to 30 millimeters, a width of 7 to 10 millimeters, and a thickness of 2.5 to 4 millimeters.

[0206] Most preferably, the cavity may have a length of 26 millimeters, a width of 8 millimeters, and a thickness of 3.1 millimeters.

[0207] The cavity may have a volume of 30 cubic millimeters or more, 100 cubic millimeters or more, 300 cubic millimeters or more, 500 cubic millimeters or more, 700 cubic millimeters or more, 900 cubic millimeters or more, 1000 cubic millimeters or more, 2000 cubic millimeters or more, or 30 cubic millimeters or more.

[0208] The cavity may have a volume of 3500 cubic millimeters or less, 2500 cubic millimeters or less, 1500 cubic millimeters or less, 1000 cubic millimeters or less, 800 cubic millimeters or less, 600 cubic millimeters or less, 500 cubic millimeters or less, 400 cubic millimeters or less, or 300 cubic millimeters or less.

[0209] The cavity may have a volume of 30 cubic millimeters to 3,500 cubic millimeters. The cavity may have a volume of 30 cubic millimeters to 2,500 cubic millimeters. The cavity may have a volume of 100 cubic millimeters to 1,500 cubic millimeters. The cavity may have a volume of 100 cubic millimeters to 1,000 cubic millimeters.

[0210] As defined above, the aerosol generating article according to the present invention comprises an air inlet and an air outlet. The air inlet may be defined by the front wall of the aerosol generating article. The air inlet may be defined by a frame and may extend through the frame. The air inlet may be defined by the peripheral wall surface of the frame. The air inlet may extend through the peripheral wall surface of the frame. The air outlet may be defined by the rear wall of the aerosol generating article. The air outlet may be defined by a frame and may extend through the frame. The air outlet may be defined by the peripheral wall surface of the frame. The outlet may extend through the peripheral wall surface of the frame.

[0211] The air inlet may have a round cross-section, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section. The air outlet may have a round cross-section, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section.

[0212] An air inlet may be defined by a first planar outer surface and may extend through it. An air inlet may be defined by an outer wrapper and may extend through it. An air inlet may be defined by an outer wrapper and an aerosol generating substrate layer and may extend through it. An air inlet may be defined by an outer wrapper and a first aerosol generating substrate layer and may extend through it. An air inlet may be defined by a first planar outer layer and an aerosol generating substrate layer and may extend through it. An air inlet may be defined by a first planar outer layer and a first aerosol generating substrate layer and may extend through it.

[0213] An air inlet may be defined by a second planar outer surface and may extend through it. An air inlet may be defined by an outer wrapper and a second aerosol generating substrate layer and may extend through it. An air inlet may be defined by a second planar outer layer and an aerosol generating substrate layer and may extend through it. An air inlet may be defined by a second planar outer layer and a second aerosol generating substrate layer and may extend through it.

[0214] An air outlet may be defined by a first planar outer surface and may extend through it. An air outlet may be defined by an outer wrapper and may extend through it. An air outlet may be defined by an outer wrapper and an aerosol generating substrate layer and may extend through it. An air outlet may be defined by an outer wrapper and a first aerosol generating substrate layer and may extend through it. An air outlet may be defined by a first planar outer layer and an aerosol generating substrate layer and may extend through it. An air outlet may be defined by a first planar outer layer and a first aerosol generating substrate layer and may extend through it.

[0215] An air outlet may be defined by a second planar outer surface and may be extended therethrough. An air outlet may be defined by an outer wrapper and a second aerosol generating substrate layer and may be extended therethrough. An air outlet may be defined by a second planar outer layer and an aerosol generating substrate layer and may be extended therethrough. An air outlet may be defined by a second planar outer layer and a second aerosol generating substrate layer and may be extended therethrough.

[0216] One or both of the air inlet and air outlet may have an equivalent diameter of 0.1 millimeter or more, 0.4 millimeters or more, 0.7 millimeters or more, or 1.0 millimeter or more.

[0217] One or both of the air inlet and the air outlet may have an equivalent diameter of 3 millimeters or less, 2.7 millimeters or less, 2.4 millimeters or less, or 2.1 millimeters or less. The air inlet may have an equivalent diameter of 2.7 millimeters or less, 1.8 millimeters or less, or 1.5 millimeters or less.

[0218] One or both of the air inlet and the air outlet may have an equivalent diameter of 0.1 to 3 millimeters, 0.1 to 2.4 millimeters, 0.4 to 2.1 millimeters, 0.4 to 1.8 millimeters, 0.7 to 1.5 millimeters, or 1.0 to 1.5 millimeters.

[0219] The air inlet may have a width narrower than the width of the cavity. The air outlet may have a width narrower than the width of the cavity. The air inlet may have a thickness thinner than the thickness of the cavity. The air outlet may have a thickness thinner than the thickness of the cavity.

[0220] One or both of the air inlet and the air outlet may have a width of 0.3 to 3 millimeters or 0.5 to 2 millimeters.

[0221] One or both of the air inlet and the air outlet may have a thickness of 0.3 to 3 millimeters or 0.5 to 2 millimeters.

[0222] Preferably, the air inlet may have a width of 0.3 millimeters to 3 millimeters and a thickness of 0.3 millimeters to 3 millimeters.

[0223] Preferably, the air outlet may have a width of 0.3 millimeters to 3 millimeters and a thickness of 0.3 millimeters to 3 millimeters.

[0224] Advantageously, an aerosol generating article having an air outlet or air inlet having a width of 0.3 to 3 millimeters and a thickness of 0.3 to 3 millimeters may provide a relatively large inlet or outlet opening while allowing improved retention of the aerosol generating material within the aerosol generating article. Improved retention of the aerosol generating material within the aerosol generating article may reduce the risk of the aerosol generating material falling out of the aerosol generating article.

[0225] The ratio of the width of the air inlet to the thickness of the air inlet may be 0.33 to 3. The ratio of the width of the air inlet to the thickness of the air inlet may be 0.5 to 1.5. The ratio of the width of the air inlet to the thickness of the air inlet may be 0.75 to 1.25.

[0226] The ratio of the width of the air outlet to the thickness of the air outlet may be 0.33 to 3. The ratio of the width of the air outlet to the thickness of the air outlet may be 0.5 to 1.5. The ratio of the width of the air outlet to the thickness of the air outlet may be 0.75 to 1.25.

[0227] In an alternative embodiment, the ratio of the width of the air outlet to the thickness of the air outlet can be at least 3.5, more preferably at least 4.

[0228] Providing a relatively wide air outlet may be particularly advantageous for an aerosol generating article according to the present invention comprising an aerosol generating substrate having a relatively high aerosol forming agent content. A relatively high width of the air outlet ensures sufficient airflow through the aerosol generating article, reduces turbulence downstream of the aerosol generating substrate, and reduces the time required for the aerosol to pass through the air outlet downstream of the aerosol generating substrate. Cooling of the aerosol can be controlled so that the aerosol remains hot when in contact with any ventilation air. Thus, advantageously, the risk of aerosol condensation inside the aerosol generating system during use can be reduced.

[0229] However, the thickness can be maintained at a level small enough to protect any aerosol generating material within the cavity and prevent the aerosol generating material from escaping through the air outlet.

[0230] As defined above, the aerosol generating article according to the present invention defines an airflow path from an air inlet through a cavity to an air outlet.

[0231] Preferably, the length of the airflow path is less than the length of the aerosol-generating article. The length of the airflow path may be 90 percent or less of the length of the aerosol-generating article, optionally 80 percent or less of the length of the aerosol-generating article, optionally 70 percent or less of the length of the aerosol-generating article, optionally 60 percent or less of the length of the aerosol-generating article, or optionally 50 percent or less of the length of the aerosol-generating article.

[0232] Advantageously, providing a relatively short airflow path enables the provision of air inlets and air outlets as close as possible to the aerosol generating substrate. Advantageously, this can increase or maximize the temperature of the airflow through the air inlets and air outlets, which can reduce or minimize aerosol condensation that might otherwise occur as a result of turbulent airflow at the air inlets and air outlets. It is desirable to minimize turbulent airflow, as otherwise it promotes undesirable condensation of aerosols within the aerosol generating article. Reducing condensation is particularly advantageous in light of the relatively high aerosol-forming agent content of the aerosol generating substrate within the aerosol generating article of the present invention.

[0233] An aerosol generating article may include a plurality of air inlets. One or each of the air inlets may have one or more of the features of the air inlets described herein.

[0234] An aerosol generating article may include a plurality of air outlets. One or each of the air outlets may have one or more of the features of the air outlets described herein.

[0235] The aerosol generating article may include a filter element positioned downstream of an aerosol forming substrate. The aerosol generating article may include a filter element positioned downstream of a cavity. The aerosol generating article may include a filter element positioned at least partially within an air outlet. The aerosol generating article may include a filter element positioned within a cavity and may be positioned at the downstream end of the cavity.

[0236] The aerosol generating article may include a filter element positioned upstream of an aerosol forming substrate. The aerosol generating article may include a filter element positioned upstream of a cavity. The aerosol generating article may include a filter element positioned at least partially within an air inlet. The aerosol generating article may include a filter element positioned within a cavity and may be positioned at the upstream end of the cavity.

[0237] The filter element may comprise one or more filter segments of a fibrous filtration material. Suitable fibrous filtration materials will be known to those skilled in the art. The filter element may comprise cellulose acetate.

[0238] Preferably, a portion of the aerosol-generating article located downstream of the common comprises a hollow portion defining a longitudinal channel that provides an unrestricted flow channel. This may include or be configured with an air outlet.

[0239] Preferably, the portion of the aerosol-generating article downstream of the cavity has a resistance to suction (RTD) of 25 mm H2O or less, more preferably 15 mm H2O or less, more preferably 10 mm H2O or less, and more preferably 5 mm H2O or less. Such a relatively low level of RTD will typically be achieved by providing an unrestricted flow channel downstream of the cavity that has minimal or no fibrous filter material.

[0240] The resistance to suction (RTD) of a component of an aerosol-generating article is measured according to ISO 6565-2015. RTD refers to the pressure required to force air through the entire length of the component.

[0241] Providing a relatively low RTD downstream of the cavity minimizes aerosol filtration and thereby maximizes aerosol delivery to the consumer. The hollow flow channel downstream of the cavity provides a hollow volume of space where the nucleation and growth of aerosol particles are preferred. This can further enhance aerosol generation and delivery. This effect has been found to be particularly beneficial for aerosol generating substrates having a relatively high aerosol-forming agent content, as in the present invention. The relatively low RTD downstream of the cavity provides minimal removal of the aerosol-forming agent from the aerosol generated from the aerosol generating substrate. This allows a desirable volume of aerosol to be delivered to the consumer and maintains a good balance between nicotine and the aerosol-forming agent.

[0242] The ratio between the length and thickness of the aerosol-generating article, and the ratio between the width and thickness of the aerosol-generating article may be greater than 2:1, greater than 5:1, greater than 10:1, greater than 12:1, or greater than 15:1.

[0243] The ratio between the length and thickness of an aerosol-generating article, and the ratio between the width and thickness of an aerosol-generating article may be less than 15:1, less than 12:1, less than 10:1, less than 5:1, or less than 2.5:1.

[0244] The ratio between the length and thickness of the aerosol-generating article, and the ratio between the width and thickness of the aerosol-generating article may be 2:1 to 15:1, 2:1 to 12:1, 2:1 to 10:1, or 5:1 to 10:1.

[0245] The ratio between the length and width of an aerosol-generating article may be greater than 1:1, greater than 2:1, greater than 3:1, greater than 4:1, or greater than 5:1.

[0246] The ratio between the length and width of an aerosol-generating article may be less than 10:1, less than 8:1, less than 5:1, less than 4:1, less than 3:1, or less than 2:1.

[0247] The ratio between the length and width of the aerosol-generating article may be 1:1 to 10:1, 1:1 to 5:1, 1:1 to 4:1, 1:1 to 3:1, 2:1 to 4:1, or 2:1 to 3:1.

[0248] Aerosol-generating articles may have a length of 15 millimeters or more, 20 millimeters or more, 25 millimeters or more, 30 millimeters or more, 35 millimeters or more, or 40 millimeters or more.

[0249] Aerosol-generating articles may have a length of 45 millimeters or less, 40 millimeters or less, 35 millimeters or less, or 30 millimeters or less.

[0250] The aerosol-generating article may have a length of 15 to 45 millimeters, 20 to 40 millimeters, 20 to 35 millimeters, or 25 to 30 millimeters.

[0251] Aerosol-generating articles may have a width of 3 millimeters or more, more than 5 millimeters, more than 7.5 millimeters, more than 9 millimeters, more than 11 millimeters, or more than 13 millimeters.

[0252] Aerosol-generating articles may have a width of 17 millimeters or less, 15 millimeters or less, 12.5 millimeters or less, 11 millimeters or less, or 9 millimeters or less.

[0253] The aerosol-generating article may have a width of 3 to 17 millimeters, 5 to 15 millimeters, 7.5 to 12.5 millimeters, or 9 to 11 millimeters.

[0254] Aerosol-generating articles may have a thickness of 1 millimeter or more, 1.5 millimeters or more, 2 millimeters or more, 2.5 millimeters or more, 3 millimeters or more, 3.5 millimeters or more, 4 millimeters or more, or 4.5 millimeters or more.

[0255] Aerosol-generating articles may have a thickness of 5.5 millimeters or less, 5 millimeters or less, 4.5 millimeters or less, 4 millimeters or less, 3.5 millimeters or less, 3 millimeters or less, 2.5 millimeters or less, or 2 millimeters or less.

[0256] The aerosol generating article may have a thickness of 1 millimeter to 5 millimeters, 1.5 millimeters to 5 millimeters, 2 millimeters to 4.5 millimeters, 2.5 millimeters to 4 millimeters, or 3 millimeters to 3.5 millimeters.

[0257] According to the present disclosure, an aerosol generating device for receiving an aerosol generating article as disclosed herein is provided. The aerosol generating device comprises a cavity dimensioned to receive at least a portion of the aerosol generating article. The aerosol generating device comprises 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 heater is preferably configured to heat an aerosol generating substrate to form an aerosol, e.g., an inhalable aerosol.

[0258] Preferably, the heater is configured to heat the aerosol generating substrate to a maximum temperature of 250 degrees Celsius, more preferably to a maximum temperature of 210 degrees Celsius. As described above, the use of a relatively low temperature in the aerosol generating device has been found to be particularly effective for heating an aerosol generating substrate containing exogenous nicotine and a relatively high level of aerosol-forming agent.

[0259] According to the present disclosure, an aerosol generating system comprises an aerosol generating device as disclosed herein and an aerosol generating article as disclosed herein. The system may include a plurality of such articles for use with the aerosol generating device.

[0260] As used herein, the term "aerosol generating article" refers to an article comprising an aerosol generating material. The article can be heated upon use to generate an inhalable aerosol and deliver it to a consumer.

[0261] As used herein, the term "aerosol generating material" refers to a material capable of releasing a volatile compound upon heating, for example, a compound that generates an aerosol upon cooling and condensation when in use.

[0262] As used herein, the term "aerosol generating device" refers to a device that, when in use, interacts with an aerosol generating substrate of an aerosol generating article to generate an aerosol, for example, by heating it.

[0263] As used herein, the term “planar” may generally refer to a feature formed on a single Euclidean plane that is not wrapped around a curved non-planar shape or other non-planar shape, or otherwise is not conformed to be fitted with it. A planar surface may extend two dimensions in a single Euclidean plane. A planar object may extend two dimensions in a single Euclidean plane substantially further than in a third dimension perpendicular to the plane. More specifically, a planar object may extend at least two, five, or ten times further in a first dimension and a second dimension perpendicular to the first dimension than in a third dimension perpendicular to the first dimension.

[0264] As used herein, the term “transverse direction” refers to the direction extending between the first planar outer surface and the second planar outer surface. The transverse direction may also be referred to as the “z-direction.”

[0265] As used herein, the term "longitudinal direction" refers to a direction perpendicular to the transverse direction. For example, the direction between the front wall and the rear wall of an aerosol-generating article. The longitudinal direction may also be referred to as the "x-direction."

[0266] As used herein, the term “lateral” refers to a direction perpendicular to the transverse and longitudinal directions. For example, the direction from the first side wall to the second side wall of an aerosol-generating article. The lateral direction may also be referred to as the “y-direction.”

[0267] As used herein, the term “thickness” refers to the maximum transverse dimension of an aerosol-generating article or a component of an aerosol-generating article.

[0268] As used herein, the term "length" refers to the maximum longitudinal dimension of an aerosol-generating article or a component of an aerosol-generating article.

[0269] As used herein, the term "width" refers to the maximum lateral dimension of an aerosol-generating article or a component of an aerosol-generating article.

[0270] As used herein, the terms “upstream” and “downstream” refer to the relative positions of a component or part of a component of an aerosol generating article with respect to the direction in which air or aerosol is transported through the aerosol generating article during use.

[0271] As used herein, the term "bulk density" may refer to the total weight of an aerosol generating material divided by the bulk volume of the aerosol generating material.

[0272] 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 degradation at the operating temperature of the aerosol-generating substrate or aerosol-generating article.

[0273] As used herein, the term "aerosol-forming agent content" may refer to the aerosol-forming agent content as a percentage based on dry weight, unless otherwise specified.

[0274] As used herein, "susceptor" refers to a conductive element that heats up when affected by a variable magnetic field. This may be the result of eddy currents and / or hysteresis losses induced within the susceptor element.

[0275] As used herein, the term "hydrophobic" refers to a surface that exhibits water repellency. One useful method for determining hydrophobicity is to measure the water contact angle. The "water contact angle" is the angle at which the liquid / vapor interface meets the solid surface, typically measured through a liquid. The water contact angle quantifies the wettability of a solid surface by a liquid using Young's equation.

[0276] As used herein, the term "equivalent diameter" of an opening or aperture is used herein to denote the diameter of a circular opening or aperture having the same cross-sectional area as the opening or aperture.

[0277] 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.

[0278] Example Ex1. An aerosol generating article for use with an aerosol generating device to generate an inhalable aerosol, wherein the aerosol generating article is,

[0279] First planar outer surface;

[0280] Second planar outer surface;

[0281] cavity;

[0282] A frame positioned between a first planar outer surface and a second planar outer surface, defining at least partially a cavity;

[0283] An aerosol generating substrate comprising exogenous nicotine and one or more aerosol forming agents; and

[0284] An aerosol generating article comprising an air inlet, an air outlet, and an airflow passage extending through a cavity between the air inlet and the air outlet.

[0285] Example Ex2. The aerosol generating article of Example Ex1, wherein the article has an article length, an article width, and an article thickness, and the article length and article width are at least twice the article thickness.

[0286] Example Ex3. An aerosol generating article in Example Ex1, wherein the article length extends in the article length direction, the article width extends in the article width direction, the article thickness extends in the article thickness direction, and the article length direction, article width direction, and article thickness direction are mutually perpendicular.

[0287] Example Ex4. An aerosol-generating article, wherein, in any one of the previous examples, the length and width of the article are at least 3, 4, or 5 times the thickness of the article.

[0288] Example Ex5. In any one of the previous examples, the article is an aerosol generating article that is substantially rectangular in shape.

[0289] Example Ex6. An aerosol generating article, wherein, in any one of the previous examples, the total aerosol forming agent content of the aerosol generating substrate is at least 40 weight percent based on dry weight.

[0290] Example Ex7. An aerosol generating article in Example Ex6, wherein the total aerosol forming agent content of the aerosol generating substrate is at least 45 weight percent or at least 50 weight percent based on dry weight.

[0291] Example Ex8. An aerosol generating article, wherein, in any one of the previous examples, the total aerosol forming agent content of the aerosol generating substrate is 70 weight percent or less, or 65 weight percent or less, or 60 weight percent or less based on dry weight.

[0292] Example Ex9. In any one of the previous examples, the aerosol generating article comprises an aerosol forming agent comprising glycerol.

[0293] Example Ex10. In any one of the previous examples, the aerosol generating material has a total exogenous nicotine content of at least 0.5 weight percent, for example, at least 1 weight percent, or at least 1.5 weight percent, or at least 2 weight percent based on dry weight, an aerosol generating article.

[0294] Example Ex11. In any one of the previous examples, the aerosol generating material has a total exogenous nicotine content of 10 weight percent or less, for example 8 weight percent or less, or 6 weight percent or less, or 4 weight percent or less, based on dry weight.

[0295] Example Ex12. In any one of Examples EX1 to EX10, the aerosol generating substrate is an aerosol generating article that is substantially tobacco-free.

[0296] Example Ex13. An aerosol generating article in any one of the previous examples, wherein the aerosol generating substrate further comprises one or more flavoring agents.

[0297] Example Ex14. In any one of the previous examples, the aerosol generating substrate comprises one or more cellulose-based preparations, an aerosol generating article.

[0298] Example Ex15. The aerosol generating article of Example Ex14, wherein the aerosol generating substrate has a total cellulose-based composition content of at least 25 weight percent, for example, at least 36 weight percent, or at least 38 weight percent, or at least 40 weight percent based on dry weight.

[0299] Example Ex16. The aerosol generating article in Example Ex14 or Ex15, wherein the aerosol generating substrate has a total cellulose-based composition content of 52 weight percent or less, for example 50 weight percent or less, or 48 weight percent or less, or 46 weight percent or less, or 44 weight percent or less, based on dry weight.

[0300] Example Ex17. An aerosol generating article in any one of Examples EX14 to EX16, wherein the aerosol generating substrate comprises one or more cellulose-based film-forming agents.

[0301] Example Ex18. The aerosol generating article of Example EX17, wherein one or more cellulose-based film-forming agents are selected from carboxymethyl cellulose (CMC), ethyl cellulose (EC), hydroxyethyl cellulose (HEC), hydroxyethyl methylcellulose (HEMC), hydroxypropyl cellulose (HPC), hydroxypropyl methylcellulose (HPMC), and methylcellulose (MC).

[0302] Example Ex19. The aerosol generating article in Example EX17 or Ex18, wherein the aerosol generating substrate has a total cellulosic film-forming agent content of at least 15 weight percent, for example, at least 20 weight percent, or at least 25 weight percent based on dry weight.

[0303] Example Ex20. An aerosol generating article in any one of Examples Ex17 to Ex19, wherein the aerosol generating substrate has a total cellulosic film-forming agent content of 40 weight percent or less, 35 weight percent or less, or 30 weight percent or less based on dry weight.

[0304] Example Ex21. In any one of Examples EX14 to EX20, the aerosol generating substrate comprises hydroxypropyl methylcellulose, an aerosol generating article.

[0305] Example Ex22. The aerosol generating article of Example Ex21, wherein the aerosol generating substrate has a hydroxypropyl methylcellulose content of at least 2 weight percent, for example, at least 3 weight percent, or at least 4 weight percent, or at least 5 weight percent based on dry weight.

[0306] Example Ex23. An aerosol generating article in any one of Examples EX14 to EX22, wherein the aerosol generating substrate comprises atrium carboxymethyl cellulose.

[0307] Example Ex24. The aerosol generating article of Example Ex23, wherein the aerosol generating substrate has a carboxymethyl cellulose content of at least 2 weight percent, for example, at least 3 weight percent, or at least 4 weight percent, or at least 5 weight percent based on dry weight.

[0308] Example Ex25. The aerosol generating article in Example Ex23 or Ex24, wherein the aerosol generating substrate has a carboxymethyl cellulose content of 12 weight percent or less, for example 10 weight percent or less, 8 weight percent or less, or 6 weight percent or less based on dry weight.

[0309] Example Ex26. An aerosol generating article in any one of Examples EX14 to EX25, wherein the aerosol generating substrate further comprises one or more cellulose-based reinforcing agents.

[0310] Example Ex27. The aerosol generating article of Example EX26, wherein one or more cellulose-based reinforcing agents are selected from cellulose fibers, cellulose powder, and microcrystalline cellulose (MCC).

[0311] Example Ex28. The aerosol generating article of Example EX26 or Ex27, wherein the aerosol generating substrate has a total cellulose-based reinforcing agent content of at least 5 weight percent, for example, at least 10 weight percent, or at least 15 weight percent based on dry weight.

[0312] Example Ex29. An aerosol generating article in any one of Examples Ex26 to Ex28, wherein the aerosol generating substrate has a total cellulose-based reinforcing agent content of 30 weight percent or less, for example 25 weight percent or less, or 20 weight percent or less, based on dry weight.

[0313] Example Ex30. In any one of Examples EX26 to EX29, the aerosol generating substrate comprises a cellulose fiber, an aerosol generating article.

[0314] Example Ex31. An aerosol generating article in Example Ex30, wherein the cellulose fiber has a length of at least 0.2 millimeters, for example, at least 0.5 millimeters, at least 0.7 millimeters, or at least 0.9 millimeters.

[0315] Example Ex32. The aerosol generating article of Example Ex30 or Ex31, wherein the aerosol generating substrate has a cellulose fiber content of at least 2 weight percent, for example, at least 5 weight percent, at least 10 weight percent, or at least 15 weight percent based on dry weight.

[0316] Example Ex33. In any one of Examples EX27 to EX32, the aerosol generating substrate comprises microcrystalline cellulose, an aerosol generating article.

[0317] Example Ex34. The aerosol generating article of Example Ex33, wherein the microcrystalline cellulose has a D50 size of at least 5 micrometers, for example, at least 10 micrometers, for example, at least 15 micrometers.

[0318] Example Ex35. The aerosol generating article in Example Ex33 or Ex34, wherein the aerosol generating substrate has a microcrystalline cellulose content of at least 2 weight percent, for example, at least 5 weight percent, or at least 10 weight percent, or at least 15 weight percent based on dry weight.

[0319] Example Ex36. In any one of Examples EX27 to EX35, the aerosol generating substrate comprises cellulose powder, an aerosol generating article.

[0320] Example Ex37. The aerosol generating article of Example Ex36, wherein the cellulose powder has a D50 size of at least 25 micrometers, for example, at least 30 micrometers, or at least 35 micrometers.

[0321] Example Ex38. The aerosol generating article in Example Ex36 or Ex37, wherein the aerosol generating substrate has a cellulose powder content of at least 2 weight percent, for example, at least 5 weight percent, at least 10 weight percent, or at least 15 weight percent based on dry weight.

[0322] Example Ex39. An aerosol generating article, wherein, in any one of the previous examples, the aerosol generating substrate further comprises one or more carboxylic acids.

[0323] Example Ex40. The aerosol generating article of Example EX38, wherein the aerosol generating substrate has a total carboxylic acid content of at least 1 weight percent, at least 1.5 weight percent, or at least 2 weight percent.

[0324] Example Ex41. An aerosol generating article in any one of the previous examples, wherein the aerosol generating substrate further comprises one or more non-cellulose-based thickeners.

[0325] Example Ex42. The aerosol generating article of Example EX40, wherein one or more non-cellulose thickeners are selected from alginate, gellan gum, guar gum, gum arabic, locust bean gum, pectin, starch, and xanthan gum.

[0326] Example Ex43. The aerosol generating article of Example Ex40 or Ex41, wherein the aerosol generating substrate has a total non-cellulose-based thickener content of at least 1 weight percent, for example, at least 2 weight percent, or at least 3 weight percent based on dry weight.

[0327] Example Ex44. An aerosol generating article in which, in any one of the previous examples, the aerosol generating substrate is in the form of one or more sheets.

[0328] Example Ex45. The aerosol generating article of Example EX44, wherein each of one or more sheets of the aerosol generating substrate has a basis weight of at least 130 grams per square meter.

[0329] Example Ex46. The aerosol generating article of Example EX44, wherein each of one or more sheets of the aerosol generating substrate has an average thickness of 225 microns or less.

[0330] Example Ex47. The aerosol generating article of Example EX44, wherein each of one or more sheets of the aerosol generating substrate has a density of at least 0.5 grams per cubic centimeter.

[0331] Example Ex48. In any one of Examples EX44 to EX47, one or more sheets are corrugated, aerosol-generating articles.

[0332] Example Ex49. An aerosol generating article in any one of Examples EX44 to EX48, wherein one or more sheets are crimped.

[0333] Example Ex50. An aerosol generating article in any one of Examples EX44 to EX49, wherein one or more sheets are in the form of cast leaves.

[0334] Example Ex51. In any one of the previous examples, the aerosol generating substrate is an aerosol generating article provided within a cavity.

[0335] Example Ex52. An aerosol generating article in any one of Examples Ex1 to Ex50, wherein the cavity is substantially empty.

[0336] Example Ex53. An aerosol generating article, wherein in any one of the previous examples, one or more sheets of an aerosol generating substrate are positioned between a frame and at least one of a first outer surface and a second outer surface.

[0337] Example Ex54. An aerosol generating article in which, in any one of the previous examples, one or more sheets of an aerosol generating substrate are positioned between a frame and an outer wrapper.

[0338] Example Ex55. An aerosol generating article, wherein, in any one of the prior examples, it further comprises a first planar outer layer defining a first planar outer surface and a second planar outer layer defining a second planar outer surface.

[0339] Example Ex56. An aerosol generating article according to Example Ex55, wherein at least one of the first planar outer layer and the second planar outer layer comprises an aerosol generating substrate.

[0340] Example Ex57. In any one of the previous examples, the aerosol generating article further comprises an outer wrapper, for example, an outer wrapper comprising an aerosol generating substrate.

[0341] Example Ex58. An aerosol generating article in any one of the previous examples, wherein the ratio of the width of the air outlet to the thickness of the air outlet is at least 3.5, for example, at least 4.

[0342] Example Ex59. In any one of the previous examples, the aerosol generating article is substantially free of filter material.

[0343] Example Ex60. In any one of the prior examples, the portion of the aerosol generating article downstream of the common has an aspiration resistance (RTD) of 25 mm H2O or less, e.g. 15 mm H2O or less, or 10 mm H2O or less, or 5 mm H2O or less.

[0344] Example Ex61. An aerosol generating system comprising an aerosol generating article according to any one of the previous examples and an aerosol generating device for use with the aerosol generating article to generate an inhalable aerosol, wherein the aerosol generating device comprises a heater for heating an aerosol generating substrate of the aerosol generating article.

[0345] Example Ex62. An aerosol generating system in Example Ex61, wherein the heater is configured to heat the aerosol generating substrate to a maximum temperature of 250 degrees Celsius, for example, a maximum temperature of 210 degrees Celsius. Brief explanation of the drawing

[0346] Now, embodiments will be further described with reference to the drawings. FIG. 1 illustrates a perspective view of an aerosol-generating article according to the present disclosure. Figure 2 shows an exploded perspective view of the aerosol generating article of Figure 1. FIG. 3 illustrates an exploded perspective view of an aerosol generating article according to the present disclosure. FIG. 4 illustrates a perspective view of an aerosol generating article according to the present disclosure. FIG. 5 illustrates a schematic cross-sectional view of an aerosol generating device according to the present disclosure. FIG. 6 illustrates a schematic cross-sectional view of the aerosol generating device of FIG. 5 that engages with the aerosol generating article of the present disclosure. Specific details for implementing the invention

[0347] FIG. 1 illustrates an aerosol generating article (10) comprising a first planar outer layer (24) forming a first planar outer surface (21), a second planar outer layer (25) forming a second planar outer surface (22), and a frame (50) positioned between the first planar outer layer (24) and the second planar outer layer (25). Both the first planar outer layer (24) and the second planar outer layer (25) comprise a sheet of an aerosol generating substrate as described herein. However, it will be understood that in some embodiments, only one of the first planar outer layer (24) and the second planar outer layer (25) may comprise an aerosol generating substrate. Alternatively or additionally, the aerosol generating substrate may be positioned elsewhere within the aerosol generating article (10).

[0348] A composition suitable for an aerosol generating substrate forming the first planar outer layer (24) and the second planar outer layer (25) is provided in Table A below.

[0349] [Table A]

[0350]

[0351] The aerosol generating article (10) has a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction. The aerosol generating article (10) has a length of 30 millimeters, a width of 10 millimeters, and a thickness of 3.1 millimeters.

[0352] The aerosol generating article (10) is substantially flat or substantially planar. In particular, the thickness of the aerosol generating article (10) is less than 50 percent of both the length and width of the aerosol generating article. The aerosol generating article (10) has a shape that is generally rectangular and has a laminated structure formed by a first planar outer layer (24), a frame (50), and a second planar outer layer (25). The first planar outer layer (24), the frame (50), and the second planar outer layer (25) are bonded together using an adhesive, in particular guar gum, as will be discussed in more detail below in relation to FIG. 2.

[0353] FIG. 2 shows an exploded view of the aerosol generating article (10) of FIG. 1.

[0354] The frame (50) has a length of 30 millimeters, a width of 10 millimeters, and a thickness of 2.7 millimeters. The frame (50) is made of cardboard and defines a frame aperture that extends through the thickness of the frame (50). The frame aperture forms at least partially a cavity (30). The cavity (30) has a length of 26 millimeters, a width of 6 millimeters, and a thickness of 2.7 millimeters. Thus, the cavity (30) has a volume of approximately 421.2 cubic millimeters. In this embodiment, the cavity (30) is substantially empty.

[0355] The frame (50) has an inner frame surface (52) extending in the z-direction or transverse direction between the first planar outer surface (21) and the second planar outer surface (22). The inner frame surface (52) defines a cavity outer wall surface. The frame (50) has an outer frame surface (53) extending in the z-direction or transverse direction between the first planar outer surface (21) and the second planar outer surface (22). The outer frame surface (53) defines at least one or more outer surfaces of an aerosol generating article, such as a front wall (13) and a rear wall (14).

[0356] The frame (50) includes a perimeter wall (51) surrounding the cavity (30). More specifically, the perimeter wall (51) is defined by the frame inner surface (52) and the frame outer surface (53). The perimeter wall (51) has a radial thickness of about 2 millimeters when measured between the frame inner surface (52) and the frame outer surface (53) in the x / y plane.

[0357] The first planar outer layer (24) and the second planar outer layer (25) have a thickness of 200 micrometers and are in physical contact with the frame (50). The first planar outer layer (24) and the second planar outer layer (25) are bonded to the frame using an adhesive (15). The first planar outer layer (24) defines at least a portion of the cavity (30). The second planar outer layer (25) defines at least a portion of the cavity (30).

[0358] The aerosol generating article (10) includes an air inlet (11) and an air outlet (12). The air inlet (11) and the air outlet (12) are defined by and extend through the peripheral wall (51) of the frame (50). The air inlet (11) and the air outlet (12) each have a rectangular cross-section, a width of 2 millimeters, and a thickness of 0.9 millimeters. An airflow passage extends through a cavity (30) between the air inlet (11) and the air outlet (12).

[0359] FIG. 3 illustrates an exploded view of an aerosol generating article (110) similar to the aerosol generating article (10) of FIG. 1, except that the first planar outer layer (124) and the second planar outer layer (125) do not include an aerosol generating substrate. Instead, a sheet of the aerosol generating substrate (140) is positioned within the cavity (30). A composition suitable for the aerosol generating substrate (140) is provided in Table A above.

[0360] As illustrated, the aerosol generating substrate (140) fills the entire volume of the cavity (30). In the embodiment of FIG. 3, the aerosol generating substrate (140) has a packing density of about 0.87, a density of about 0.3 grams per cubic centimeter, and a mass of about 110 milligrams. In other embodiments, the aerosol generating substrate (140) may have a different packing density, a different density, and a different mass. For example, the aerosol generating substrate may have a packing density of 0.64, a density of 0.35 grams per cubic centimeter, and a mass of about 95 milligrams.

[0361] FIG. 4 illustrates an aerosol generating article (210) similar to the aerosol generating article (10) of FIG. 1 and FIG. 3, except that the aerosol generating article (210) of FIG. 4 includes an outer wrapper (223) defining a first planar outer surface (221) and a second planar outer surface (222) instead of a first planar outer layer (24) and a second planar outer layer (25).

[0362] FIG. 5 illustrates a schematic cross-sectional view of an aerosol generating device (90) configured for use with an aerosol generating article described herein. The aerosol generating article may be any of the aerosol generating articles (10, 110, 210) as described herein in relation to the drawings.

[0363] The aerosol generating device (90) is an elongated aerosol generating device extending between a proximal end (91) and a distal end (92). The aerosol generating device (90) includes a battery (93), a controller (94), a first heater (95), and a second heater (96) located within a housing (97). The controller (94) controls the power supply from the battery (93) to the first heater (95) and the second heater (96). A cavity (1000) is defined in the device (90), and the cavity (1000) has an opening (1010) defined in the proximal end (91) of the device (90). The opening (1010) is rectangular in shape and is dimensioned to accommodate a transverse cross-section of an aerosol generating article (410). The cavity (1000) includes an upper planar surface (1020) and a lower planar surface (1030). A first heater (95) is positioned within an upper planar surface (1020) to heat a first planar outer surface (21) of an aerosol generating article inserted into a cavity (1000), and a second heater (96) is positioned within a lower planar surface (1030) to heat a second planar outer surface (22) of an aerosol generating article inserted into a cavity (1000). The device (90) includes an air inlet (98) that defines an airflow path configured to allow air to flow from outside the device into the cavity (1000).

[0364] FIG. 7 illustrates a schematic cross-sectional view of the aerosol generating device (90) of FIG. 8 engaging with an aerosol generating article (410). The aerosol generating article (410) may be any of the aerosol generating articles (10, 110, 210) as described herein in relation to the drawings.

[0365] There is almost no tolerance between the first planar outer surface (21) and the second planar outer surface (22) of the aerosol generating article (410) and the inner surface (1020, 1030) of the cavity (1000). Therefore, there is a tight fit between the aerosol generating article (10) and the aerosol generating device (90). When a consumer inserts the aerosol generating article (410) into the cavity (1000), the device can be operated. The first heater (95) heats the first planar outer surface (21) of the aerosol generating article (410), and the second heater (96) heats the second planar outer surface (22) of the aerosol generating article, and as a result, the aerosol generating material is heated. The volatile components of the aerosol generating material evaporate and condense within the cavity (30) of the aerosol generating article (410) to form an aerosol. The consumer inhales the aerosol by inhaling from the end of the aerosol generating article (410) which includes an air outlet (12). When the volatile component in the aerosol generating material is depleted, the aerosol generating article (410) is removed from the cavity (1000) and disposed of.

[0366] 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 as being 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 that the number A modifies. In some cases used in the appended claims, the number A may deviate by the percentage listed above, provided that the amount of deviation of A does not significantly affect the fundamental and novel characteristic(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.

Claims

Claim 1 An aerosol generating article for use with an aerosol generating device to generate an inhalable aerosol, wherein the aerosol generating article comprises: a first planar outer surface; a second planar outer surface; a cavity; a frame positioned between the first planar outer surface and the second planar outer surface and at least partially defining the cavity; one or more sheets of an aerosol forming substrate comprising nicotine and one or more aerosol forming agents, wherein the total aerosol forming agent content of the aerosol forming substrate is at least 40 weight percent based on dry weight; and an air inlet, an air outlet, and an airflow passage extending through the cavity between the air inlet and the air outlet. Claim 2 The aerosol generating article of claim 1, wherein the aerosol generating article has an article length, an article width, and an article thickness, and the article length and the article width are at least twice the article thickness. Claim 3 An aerosol generating article according to claim 1 or 2, wherein the total aerosol forming agent content of the aerosol generating material is at least 50 weight percent based on dry weight. Claim 4 An aerosol generating article according to any one of claims 1 to 3, wherein the aerosol generating substrate has an exogenous nicotine content of at least 1.5 weight percent based on dry weight. Claim 5 In any one of paragraphs 1 to 4, the aerosol generating material is an aerosol generating article that is substantially tobacco-free. Claim 6 In any one of claims 1 to 5, the aerosol generating material comprises one or more cellulose-based preparations, an aerosol generating article. Claim 7 An aerosol-generating article according to claim 6, wherein the total cellulose-based composition content is at least 35 weight percent based on dry weight. Claim 8 An aerosol generating article according to claim 6 or 7, wherein the aerosol generating substrate comprises one or more cellulose-based film-forming agents selected from carboxymethyl cellulose (CMC), ethyl cellulose (EC), hydroxyethyl cellulose (HEC), hydroxyethyl methylcellulose (HEMC), hydroxypropyl cellulose (HPC), hydroxypropyl methylcellulose (HPMC), and methylcellulose (MC). Claim 9 In any one of claims 1 to 8, the aerosol generating material is an aerosol generating article provided within the cavity. Claim 10 An aerosol generating article according to any one of claims 1 to 9, wherein the ratio of the width of the air outlet to the thickness of the air outlet is at least 4. Claim 11 In any one of claims 1 to 10, the portion of the aerosol generating article located downstream of the common has an RTD of less than 25 mm H2O, an aerosol generating article. Claim 12 An aerosol generating system comprising an aerosol generating article according to any one of claims 1 to 11 and an aerosol generating device for use with said aerosol generating article to generate an inhalable aerosol, wherein the aerosol generating device comprises a heater for heating an aerosol generating substrate of said aerosol generating article. Claim 13 In claim 12, the aerosol generating system is configured such that the heater heats the aerosol generating substrate to a maximum temperature of 210 degrees Celsius.

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