Aerosol generating items

Abstract

An aerosol generating article (100) is provided for use with an aerosol generating device to generate an aerosol. The aerosol generating article (100) has a length extending in the x direction, a width extending in the y direction, and a height extending in the z direction, wherein the height is smaller than the length and the width, respectively. The aerosol generating article (100) includes first and second cavities (104, 105), an aerosol forming substrate (115, 116) disposed in each of the first and second cavities, and a third cavity (106) located between the first and second cavities.

Description

Technology Field

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

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

[0003] However, a significant portion of the aerosol-forming substrate within these cylindrical aerosol-generating articles may not be heated sufficiently to form an aerosol during use. This is undesirable because the insufficiently heated portion of the aerosol-forming substrate contributes only to manufacturing and transport costs of the aerosol-generating article and does not contribute to the aerosol delivered to the end user. This may apply regardless of how the aerosol-forming substrate is heated—for example, whether a resistive or inductive heater is used—and whether the aerosol-forming substrate is heated from the inside or the outside. Furthermore, since the components of these cylindrical aerosol-generating articles generally have the same or very similar outer diameters, they need to be joined, precisely positioned in coaxial alignment, and wrapped in cigarette paper. This can increase manufacturing costs and complexity.

[0004] The purpose of the present disclosure is to provide an aerosol generating article that enables two user experiences.

[0005] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol. The aerosol generating article may have a length extending in the x-direction, a width extending in the y-direction, and a height extending in the z-direction, wherein the height is smaller than the length and the width, respectively. The aerosol generating article may include first and second cavities. An aerosol forming substrate may be disposed within each of the first and second cavities. The aerosol generating article may further include a third cavity located between the first and second cavities.

[0006] For the purposes of this disclosure, it will be understood that the “height” of an aerosol-generating article may also be referred to as the “thickness” of an aerosol-generating article.

[0007] The positioning of the third cavity between the first and second cavities facilitates thermal isolation of the first and second cavities from one another. The presence of the third cavity facilitates delaying the action of heat applied to the aerosol-forming substrate within one of the first and second cavities on the aerosol-forming substrate within the other of the first and second cavities. Thus, the third cavity helps ensure that the substrate within the first cavity can be heated during a single use session without inadvertently heating and depleting the aerosol-forming substrate within the second cavity intended for use in a second use session.

[0008] Each of the first and second cavities may include an air inlet and an air outlet. In this way, each of the first and second cavities may be configured to be suitable for delivering air into and out of each cavity. For example, a first airflow path may be defined between the air inlet and the air outlet of the first cavity, and a second airflow path may be defined between the air inlet and the air outlet of the second cavity.

[0009] Preferably, the third cavity can be hermetically isolated from the outside of the aerosol-generating article.

[0010] Preferably, the third cavity can be hermetically isolated from the first and second cavities, respectively. In this way, the thermal isolation of the first and second cavities from each other can be improved.

[0011] The third cavity preferably does not have an aerosol-forming substrate.

[0012] The third cavity may contain a thermally insulating filler material, but advantageously, the third cavity may instead define a void. The use of a void helps to efficiently thermally isolate the first and second cavities from each other, while also helping to minimize the mass of the aerosol-generating article compared to the case where the third cavity contains a filler material. "Void" means empty except for the presence of air.

[0013] Preferably, the first and second cavities may be arranged relative to each other in opposing halves of an aerosol-generating article. If the first cavity is intended for use in a first use session and the second cavity is intended for use in a second use session, then each of the two halves of the article may be connected to the other half of the first and second use sessions. For example, heat may be applied to the half of the article containing the first cavity in the first use session, and heat may be applied to the other half of the article containing the second cavity in the second use session.

[0014] Preferably, the first and second cavities may be arranged relative to each other in opposite halves of the length of the aerosol generating article. Advantageously, the first and second cavities may be arranged symmetrically relative to each other in opposite halves of the length of the aerosol generating article. The use of a symmetrical arrangement of the first and second cavities over the length of the article may allow any end of the article to be inserted into a receiving section of an aerosol generating device for applying heat to an aerosol forming substrate within a specific one of the first and second cavities. The third cavity may extend over at least 75%, for example, at least 85%, for example, at least 95% of the width of the aerosol generating article. An increase in the proportion of the width of the article occupied by the third cavity may correspondingly increase the level of thermal isolation between the first and second cavities resulting from the third cavity. Each of the first and second cavities may include an air inlet and an air outlet, and each of the air inlets and air outlets for each of the first and second cavities is arranged on opposite sides of the width of the aerosol-generating article. In this way, the first airflow path may be defined through the first cavity extending in the width (or y) direction of the article between the air inlet and the air outlet of the first cavity. Similarly, the second airflow path may be defined through the second cavity extending in the width (or y) direction of the article between the air inlet and the air outlet of the second cavity.

[0015] The first and second cavities may be arranged relative to each other in opposing halves of the width of the aerosol generating article. Advantageously, the first and second cavities may be arranged symmetrically relative to each other in opposing halves of the width of the aerosol generating article. The use of a symmetrical arrangement of the first and second cavities over the width of the article may allow any side of the article to be inserted into a receiving section of an aerosol generating device for applying heat to an aerosol forming substrate within a specific one of the first and second cavities. The third cavity may extend over at least 75%, for example, at least 85%, for example, at least 95% of the length of the aerosol generating article. An increase in the proportion of the length of the article occupied by the third cavity may correspondingly increase the level of thermal isolation between the first and second cavities caused by the third cavity. Each of the first and second cavities may include an air inlet and an air outlet, and each air inlet and air outlet for each of the first and second cavities is arranged at opposite ends of the length of the aerosol-generating article. In this way, the first airflow path may be defined through the first cavity extending in the length (or x) direction of the article between the air inlet and the air outlet of the first cavity. Similarly, the second airflow path may be defined through the second cavity extending in the length (or x) direction of the article between the air inlet and the air outlet of the second cavity.

[0016] Preferably, the aerosol generating article may be symmetric along any one or more of the length, width, and height of the aerosol generating article. The symmetry may be symmetric in a profile defined by the external surface(s) of the article. Alternatively or additionally, the symmetry may be symmetric in the internal structure of the aerosol generating article. Such symmetry may allow the article to be inserted in different orientations within the receiving section of the aerosol generating device, thereby allowing heat to be applied to the aerosol forming substrate within one of the first and second cavities for a specific use session. The aerosol generating article may be symmetric along the length, width, and height of the aerosol generating article, respectively.

[0017] Preferably, substantially the entirety of each of the first and second cavities is filled with an aerosol-forming material. Filling the first and second cavities with an aerosol-forming material can reduce the likelihood of the material settling into one side or end of the first and second cavities during the manufacture and / or transport of the aerosol-generating article. Having the entire volume of the first and second cavities filled with an aerosol-forming material can facilitate providing a consistent user experience for different parts of the aerosol-generating article.

[0018] If it is desirable for the first and second cavities to provide the same user experience to the consumer of the aerosol-generating article in different usage sessions, the first and second cavities may contain an aerosol-forming material of the same composition. Alternatively, however, the composition of the aerosol-forming material in the first cavity may differ from the composition of the aerosol-forming material in the second cavity. Such difference in composition of the aerosol-forming materials in the first and second cavities may provide the consumer of the aerosol-generating article with variety and choice in user experience through different usage sessions.

[0019] The ratio of the volume of the third cavity to the volumes of the first and second cavities, respectively, may be less than 0.5:1, e.g., less than 0.25:1, e.g., less than 0.1:1. Minimizing the volume of the third cavity may help minimize the physical size of the aerosol-generating article and / or maximize the available space within the article for the first and second cavities and their respective aerosol-forming substrates.

[0020] The ratio of the volume of the first cavity to the volume of the second cavity may be 0.9 to 1.11, for example, 0.95 to 1.05. Preferably, the first and second cavities have the same volume, thereby providing the same amount of space for containing an aerosol-forming substrate.

[0021] The ratio of the mass of the aerosol-forming material in the first cavity to the mass of the aerosol-forming material in the second cavity may be 0.9 to 1.11, for example, 0.95 to 1.05.

[0022] The aerosol-forming substrate used in either one or both of the first and second joints may be in any one or more of the following forms: a shredded aerosol-forming substrate, a strip of an aerosol-forming substrate, a strand of an aerosol-forming substrate, a particle of an aerosol-forming substrate, one or more sheets of an aerosol-forming substrate, one or more corrugated sheets of an aerosol-forming substrate, a spore dispersed in a solid binder matrix, a plurality of beads or granules of an aerosol-forming substrate.

[0023] The aerosol-forming substrate may include a free-flowing aerosol-forming substrate. For example, the aerosol-forming substrate may include or be composed of a plurality of beads or granules.

[0024] The aerosol-forming substrate preferably comprises tobacco, for example, tobacco particles, tobacco sticks, or cast-leaf tobacco. The aerosol-forming substrate may comprise homogenized tobacco.

[0025] The aerosol-forming substrate may include an aerosol-forming agent selected from a list consisting of, for example, glycerin and propylene glycol, wherein the aerosol-forming substrate has an aerosol-forming agent content of more than 20% by weight, for example, more than 25% by weight, or more than 30% by weight, for example, more than 35% by weight, based on dry weight. The use of an aerosol-forming agent can facilitate the promotion of aerosol generation from the aerosol-forming substrate through heating rather than combustion of the substrate.

[0026] The aerosol-forming substrate may include one or more flavoring compounds.

[0027] The aerosol generating article may include opposing upper and lower outer flat surfaces, and the opposing upper and lower outer flat surfaces are spaced apart from each other in the z-direction. Preferably, the upper outer flat surface and the lower outer flat surface may be parallel to each other.

[0028] Alternatively, the aerosol generating article may include opposing outwardly convex upper and lower outer surfaces, and the opposing outwardly convex upper and lower outer surfaces are spaced apart from each other in the z-direction.

[0029] The aerosol generating article may include a frame, and the frame partially defines first, second, and third cavities, respectively.

[0030] The frame can improve the flexural rigidity of the aerosol-generating article and can provide most of the flexural rigidity of the aerosol-generating article.

[0031] The frame may include one or both of an air inlet and an air outlet for each of the first and second cavities.

[0032] Preferably, each of the first and second cavities may extend over the entire height of the frame to define opposing upper and lower openings passing through the corresponding upper and lower surfaces of the frame. For convenience, the aerosol generating article may further include upper and lower sheets bonded to the respective upper and lower surfaces of the frame to cover the opposing upper and lower openings of the first and second cavities. Accordingly, the upper and lower sheets may help to retain the aerosol-forming material within the first and second cavities.

[0033] The upper and lower sheets can be formed from paper, metal foil, or a thin layer of paper and metal foil.

[0034] The upper and lower sheets may be substantially impermeable, for example, water impermeable. The upper and lower sheets may have a permeability of 1 to 5 Coresta units.

[0035] Alternatively, one or both of the upper and lower sheets may be porous to allow airflow to pass into and / or out of the first and second cavities.

[0036] The third cavity may extend over the entire height of the frame. Alternatively, the third cavity may extend over only a portion of the height of the frame. For example, the third cavity may extend over 50% to 95% of the height of the frame. By having a third cavity that extends only over a portion of the height of the frame, the frame has a greater level of bending stiffness than when the third cavity extends over the entire height of the frame.

[0037] The frame may include a plurality of layers arranged continuously so as to overlap each other. Each of the plurality of layers may extend along the length of the aerosol-generating article.

[0038] The frame may include cellulose material. The cellulose material is 300 g / m²2 Up to 900 g / m² 2 It can have a basis weight. The cellulose material can be paper, cardboard, or cardboard.

[0039] The aerosol generating article may include one or more surface regions configured to change color upon heating. The color change may be irreversible. The one or more surface regions may include a first surface region connected to a first cavity and a second surface region connected to a second cavity. In this way, a color change in the first surface region may indicate whether the aerosol-forming substrate within the first cavity has already been consumed, whereas a color change in the second surface region may indicate whether the aerosol-forming substrate within the second cavity has already been consumed. The one or more surface regions may include a heat-sensitive ink or a heat-sensitive coating. The one or more surface regions may preferably form a portion of the outer surface of the aerosol generating article.

[0040] According to another aspect of the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol, the aerosol generating article having a length extending in the x direction, a width extending in the y direction, and a height extending in the z direction, wherein the height is smaller than the length and the width, respectively. The aerosol generating article may include an aerosol forming substrate and a cavity. The cavity may not have an aerosol forming substrate, and the cavity may be hermetically isolated from the outside of the aerosol generating article.

[0041] The cavity can function as a finger access means that allows a user to hook their finger onto an article, and, for example, the empty cavity can prevent the user's finger from coming into contact with a hot aerosol-forming material and getting burned during or after the heating of the article.

[0042] The aerosol generating article may include at least one additional cavity, and an aerosol-forming material is disposed within the additional cavity. The additional cavity may be distinguishable from a cavity without an aerosol-forming material and may be hermetically isolated from it.

[0043] As used herein, the term "aerosol generating article" may refer to an article capable of generating or releasing aerosols.

[0044] As used herein, the term "aerosol-forming substrate" may refer to a substrate capable of releasing an aerosol or a volatile compound capable of forming an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may comprise an aerosol-forming material. The aerosol-forming substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. For convenience, the aerosol-forming substrate may be part of an aerosol-generating article or a smoking article.

[0045] As used herein, the term “granule” refers to individual solid particles formed from an aerosol-forming substrate as defined above. Granules may have a regular or irregular shape.

[0046] As used herein, the term "bead" refers to individual solid particles formed from an aerosol-forming substrate as defined above and having a round, typically spherical shape.

[0047] As used herein, the term "aerosol generating device" may refer to a device for use with an aerosol generating article that enables the generation or release of an aerosol.

[0048] 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-forming substrate or the aerosol-generating article.

[0049] As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salt.

[0050] As used herein with respect to the present invention, the terms "proximal," "distal," "upstream," and "downstream" are used to describe the relative positions of a component of an aerosol-generating article, or a part of a component.

[0051] As used herein, the term “homogenized tobacco material” encompasses any tobacco material formed by the aggregation of particles of tobacco material. A sheet or web of homogenized tobacco material is formed by aggregating particulate tobacco obtained by crushing or otherwise pulverizing one or both of tobacco leaf blades and tobacco leaf stalks. Additionally, the homogenized tobacco material may contain trace amounts of one or more of tobacco powder, tobacco fines, and other particulate tobacco by-products formed during the processing, handling, and delivery of tobacco. A sheet of homogenized tobacco material may be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0052] The term “cast leaf” is used herein to refer to a product produced by a casting process based on casting a slurry comprising plant particles (e.g., clove particles, or a mixture of tobacco particles and clove particles) and a binder (e.g., guar gum) onto a supporting surface, such as a belt conveyor, drying the slurry, and removing the dried sheet from the supporting surface. Examples of casting or cast leaf processes are described, for instance, in US-A-5,724,998 for the production of cast leaf tobacco. In a cast leaf process, particulate plant material is produced by pulverizing, grinding, or crushing a portion of a plant. Particles produced from one or more plants are mixed with a liquid component, typically water, to form a slurry. Other components within the slurry may include fibers, a binder, and an aerosol-forming agent. The particulate plant material may aggregate in the presence of a binder. The slurry is cast onto a supporting surface and dried to become a sheet of homogenized plant material. Preferably, the homogenized plant material used in the article according to the present invention can be produced by casting. Such homogenized plant material may comprise aggregated particulate plant material.

[0053] As used herein, suction resistance is expressed as "mm H2O" or "mm WG" or "mm water level gauge" and is measured according to ISO 6565:2002.

[0054] The present invention is defined in the claims. However, a non-limiting, non-comprehensive list of embodiments is provided below. Any one or more of the features of these examples may be combined with any one or more features of other embodiments, embodiments, or aspects described herein.

[0055] Example Ex1: An aerosol generating article for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article has a length extending in the x-direction, a width extending in the y-direction, and a height extending in the z-direction, the height being smaller than the length and the width, respectively, and the aerosol generating article

[0056] First and second joint

[0057] Aerosol-forming substrate disposed within each of the first and second cavities; and

[0058] An aerosol generating article comprising a third cavity located between the first and second cavities.

[0059] Example Ex2: An aerosol generating article in Ex1, wherein each of the first and second cavities includes an air inlet and an air outlet, respectively.

[0060] Example Ex3: In Ex1 or Ex2, the third cavity is hermetically isolated from the outside of the aerosol generating article.

[0061] Example Ex3a: In any one of Ex1 to Ex3, the third cavity is hermetically isolated from each of the first and second cavities, an aerosol generating article.

[0062] Example Ex4: An aerosol generating article in any one of Ex1 to Ex3a, wherein the third cavity does not have an aerosol-forming substrate.

[0063] Example Ex5: An aerosol generating article in any one of Ex1 to Ex4, wherein the third cavity defines an empty void.

[0064] Example Ex6: In any one of Ex1 to Ex5, the first and second cavities are arranged relative to each other in opposite halves of the aerosol generating article.

[0065] Example Ex7: In Ex6, the first and second cavities are arranged relative to each other at opposite half lengths of the aerosol generating article.

[0066] Example Ex8: An aerosol generating article in which the first and second cavities of Ex7 are arranged symmetrically with respect to each other in opposite halves of the length of the aerosol generating article.

[0067] Example Ex9: In Ex7 or Ex8, the third cavity extends over at least 75%, for example, at least 85%, for example, at least 95% of the width of the aerosol-generating article.

[0068] Example Ex10: In any one of Ex7 to Ex9, the first and second cavities each include an air inlet and an air outlet, and the air inlet and air outlet for each of the first and second cavities are arranged on opposite sides of the width of the aerosol generating article.

[0069] Example Ex11: In Ex6, the first and second cavities are arranged relative to each other in opposite halves of the width of the aerosol generating article.

[0070] Example Ex12: An aerosol generating article in which the first and second cavities of Ex11 are arranged symmetrically with respect to each other in opposite halves of the width of the aerosol generating article.

[0071] Example Ex13: In Ex11 or Ex12, the third cavity extends over at least 75%, for example, at least 85%, for example, at least 95% of the length of the aerosol-generating article.

[0072] Example Ex14: In any one of Ex11 to Ex13, each of the first and second cavities comprises an air inlet and an air outlet, and each of the air inlet and air outlet for each of the first and second cavities is arranged at opposite ends of the length of the aerosol generating article.

[0073] Example Ex15: In any one of Ex1 to Ex14, the aerosol generating article is symmetrical along any one or more of the length, width, and height of the aerosol generating article.

[0074] Example Ex16: In Ex15, the aerosol generating article is symmetrical along the length, width, and height of the aerosol generating article.

[0075] Example Ex17: An aerosol generating article in any one of Ex1 to Ex16, wherein the first and second cavities, substantially the entirety of each, are filled with an aerosol-forming substrate.

[0076] Example Ex18: An aerosol generating article in any one of Ex1 to Ex17, wherein the composition of the aerosol-forming substrate in the first cavity is different from the composition of the aerosol-forming substrate in the second cavity.

[0077] Example Ex19: An aerosol generating article in any one of Ex1 to Ex18, wherein the ratio of the volume of the third cavity to the volumes of the first and second cavities, respectively, is less than 0.5:1, e.g., less than 0.25:1, e.g., less than 0.1:1.

[0078] Example Ex20: An aerosol generating article in any one of Ex1 to Ex19, wherein the ratio of the volume of the first cavity to the volume of the second cavity is 0.9 to 1.11, for example, 0.95 to 1.05.

[0079] Example Ex21: An aerosol generating article in any one of Ex1 to Ex20, wherein the ratio of the mass of the aerosol-forming substrate in the first cavity to the mass of the aerosol-forming substrate in the second cavity is 0.9 to 1.11, for example, 0.95 to 1.05.

[0080] Example Ex22: An aerosol generating article in any one of Ex1 to Ex21, wherein the aerosol forming substrate comprises a free-flowing aerosol forming substrate.

[0081] Example Ex23: In Ex22, the free-flowing aerosol-forming substrate comprises or is composed of a plurality of beads, an aerosol-generating article.

[0082] Example Ex24: In any one of Ex1 to Ex23, the aerosol generating article comprises opposing upper and lower outer flat surfaces, and the opposing upper and lower outer flat surfaces are spaced apart from each other in the z-direction.

[0083] Example Ex25: An aerosol generating article in Ex24, wherein the upper outer flat surface and the lower outer flat surface are parallel to each other.

[0084] Example Ex26: In any one of Ex1 to Ex23, the aerosol generating article comprises an upper and lower outer surfaces that are convex outwardly opposite each other, and the upper and lower outer surfaces that are convex outwardly opposite each other in the z-direction.

[0085] Example Ex27: In any one of Ex1 to Ex26, the aerosol generating article comprises a frame, wherein the frame partially defines each of the first, second, and third joints.

[0086] Example Ex28: In Ex27, the first and second cavities each extend over the entire height of the frame to define opposing upper and lower openings passing through the corresponding upper and lower surfaces of the frame, an aerosol generating article.

[0087] Example Ex29: An aerosol generating article of Ex28, further comprising upper and lower sheets coupled to the respective upper and lower surfaces of a frame to cover the opposing upper and lower openings of the first and second joints.

[0088] Example Ex30: An aerosol generating article in Ex29, wherein the upper and lower sheets are substantially impermeable, for example, water impermeable.

[0089] Example Ex31: In Ex30, the upper and lower sheets are aerosol generating articles having a permeability of 1 to 5 Coresta units.

[0090] Example Ex32: An aerosol generating article in Ex29, wherein one or both of the upper and lower sheets are porous to allow the passage of airflow into and / or out of the first and second cavities.

[0091] Example Ex33: An aerosol generating article in any one of Ex27 to Ex32, wherein the third cavity extends over the entire height of the frame.

[0092] Example Ex34: An aerosol generating article in any one of Ex27 to Ex32, wherein the third cavity extends only over a portion of the total height of the frame.

[0093] Example Ex35: An aerosol generating article in Ex34, wherein the third cavity extends over 50% to 95% of the height of the frame.

[0094] Example Ex36: An aerosol generating article in any one of Ex27 to Ex35, wherein the frame comprises a plurality of layers arranged continuously so as to overlap each other.

[0095] Example Ex37: The aerosol generating article of Ex36, wherein each of the plurality of layers extends along the length of the aerosol generating article.

[0096] Example Ex38: An aerosol generating article for use with an aerosol generating device to generate an aerosol (e.g., an aerosol generating article according to any one of Ex1 to Ex37), wherein the aerosol generating article has a length extending in the x direction, a width extending in the y direction, and a height extending in the z direction, wherein the height is smaller than the length and the width, respectively, and the aerosol generating article comprises an aerosol forming substrate and a cavity, wherein the cavity does not have an aerosol forming substrate and the cavity is hermetically isolated from the outside of the aerosol generating article.

[0097] Example Ex39: An aerosol generating article in Ex38, wherein at least one additional cavity is additionally included, and the aerosol forming substrate is disposed within the additional cavity.

[0098] Example Ex40: An aerosol generating article in Ex39, wherein the additional cavity is distinguished from the cavity without an aerosol-forming substrate and hermetically isolated from the cavity. Brief explanation of the drawing

[0099] Now, embodiments will be further described with reference to the drawings. FIG. 1 is an exploded perspective view of a component of an aerosol generating article according to a first embodiment of the present disclosure. Figure 2 is a plan view of the frame of the aerosol generating article of Figure 1. FIG. 3 is a perspective view of the aerosol generating article of FIG. 1 when partially assembled. FIG. 4 is a perspective view of the aerosol generating article of FIG. 1 when fully assembled. FIG. 5 is an exploded perspective view of a component of an aerosol generating article according to a second embodiment of the present disclosure. FIG. 6 is a perspective view of the aerosol generating article of FIG. 5 when fully assembled. FIG. 7 is an exploded perspective view of a component of an aerosol generating article according to a third embodiment of the present disclosure. FIG. 8 is a perspective view of the aerosol generating article of FIG. 7 when fully assembled. FIG. 9 is an exploded perspective view of a multilayer frame to be used as part of the aerosol generating article of FIG. 1 to 4. FIG. 10 shows a schematic diagram of an aerosol generating device according to an embodiment of the present disclosure, wherein the device is configured to engage with an aerosol generating article. Figure 11 shows a schematic end view of the aerosol generator of Figure 10. FIG. 12 is a schematic diagram showing an aerosol generating article that engages with the aerosol generating device of FIG. 11. Specific details for implementing the invention

[0100] FIG. 1 is an exploded perspective view of the components of an aerosol generating article (100) according to a first embodiment of the present disclosure. The components of the article (100) are illustrated along the x, y, and z axes of a Cartesian coordinate system. The article (100) has a frame (101) located between lower and upper sheets (102, 103). The frame (101) has two cavities (104, 105) symmetrically located in opposite halves of the frame length. A third cavity (106) is centrally located along the length direction of the frame between the first and second cavities (104, 105). The third cavity (106) extends in the y-direction over approximately 75% of the width of the frame (101) (see FIG. 2). The third cavity (106) extends in the y-direction by a distance corresponding to and aligned with the widths of the first and second cavities (104, 105). In this first embodiment, the first and second cavities (104, 105) have substantially the same volume, and the third cavity (106) has a volume approximately 1 / 6 of the volume of each of the first and second cavities. The first air inlet (107) and the first air outlet (108) are defined on opposing side walls of the frame (101). The first air inlet (107) and the first air outlet (108) are in fluid communication with the first cavity (104). An airflow path (109) is defined through the first cavity (104) between the first air inlet (107) and the first air outlet (108). The second air inlet (110) and the second air outlet (111) are defined on opposing side walls of the frame (101). The second air inlet (110) and the second air outlet (111) are in fluid communication with the second cavity (105). An airflow path (112) is defined through the second cavity (105) between the second air inlet (110) and the second air outlet (111). The first and second cavities (104, 105) are not in fluid communication with each other or with the third cavity (106).The first and second cavities (104, 105) extend in the z-direction over the entire height of the frame (101) and define holes or openings that pass through the lower and upper surfaces (113, 114) of the frame.

[0101] The first and second portions (115, 116) of the aerosol-forming substrate are provided for the respective first and second cavities (104, 105). In the embodiment illustrated in FIG. 1, the aerosol-forming substrate is in the form of a plurality of beads of an aerosol-generating material. The aerosol-generating material may contain nicotine. The aerosol-generating material may contain tobacco. The aerosol-generating material may contain an aerosol-generating agent such as glycerin or any other suitable aerosol-generating agent. It will be understood that in other embodiments, instead of a plurality of beads, other forms of aerosol-generating substrates, such as whole tobacco, or shreds, strips, or sheets of homogenized tobacco, may be used.

[0102] The frame (101) is formed of cardboard. The frame (101) has a length of about 30 mm (extending in the x-direction), a width of about 12 mm (extending in the y-direction), and a height of about 3 mm (extending in the z-direction). The first and second cavities (104, 105) each have a length of about 12 mm (extending in the x-direction) and a width of about 7 mm (extending in the y-direction). The third cavity has a length of about 7 mm (extending in the y-direction) and a width of about 2 mm (extending in the x-direction).

[0103] The lower and upper sheets (102, 103) are formed as a thin layer of a paper layer and a metal foil layer. The lower and upper sheets (102, 103) are essentially impermeable to water. The lower and upper sheets (102, 103) each have a thickness of about 45 μm. The length and width of the lower and upper sheets (102, 103) correspond to the length and width of the frame (101).

[0104] The aerosol generating article (100) has a length of about 30 mm (extended in the x direction), a width of about 12 mm (extended in the y direction), and a height of about 3.1 mm (extended in the z direction).

[0105] While assembling the components of the aerosol generating article (100), the lower sheet (102) is bonded to the lower surface (113) of the frame (101). Then, the first and second cavities (104, 105) are filled with respective parts (115, 116) of the beads of the aerosol forming material until the beads are approximately the same height as the upper surface (114) of the frame (101). The third cavity (106) is empty except for the presence of air. Then, the upper sheet (103) is bonded to the upper surface (114) of the frame (101) to cover and close the first, second, and third cavities (104, 105, 106) (see FIG. 3).

[0106] An assembled aerosol generating article (100) is illustrated in FIG. 4. The aerosol generating article (100) of FIG. 4 is configured to be suitable for use in two separate use sessions. In the first use session, heat will be applied to deplete the aerosol-forming material within one of the first and second cavities (104, 105). In the second use session, heat will be applied to deplete the aerosol-forming material within the other of the first and second cavities (104, 105). More specifically, when used over the use sessions, heat will be applied to approximately half the length of the aerosol generating article (100) to heat the portion (115, 116) of the aerosol-forming material contained within each cavity (104 or 105) for that half of the article. When sufficient heat is applied, the aerosol-forming material within the heated cavity (104 or 105) will begin to vaporize. Applying suction at the air outlet (108 or 111) of the heated cavity (104 or 105) will eventually induce an inflow of air through the air inlet (107 or 110) of the heated cavity and pass it through the heated cavity. The vaporized aerosol-forming material will be accompanied by the inflow airflow entering the heated cavity (104 or 105), and the accompanying flow will be cooled and condensed, forming an aerosol as it flows toward the air outlet (108 or 111) of the heated cavity and exit the aerosol-generating article (100). The third cavity (106) will help to thermally isolate the first and second cavities (104, 105) from each other. Since air is a good thermal insulator, the thermal insulation ability of the third cavity (106) is aided by the fact that the cavity contains only air.Accordingly, when heat is applied to half of the article (100) containing the first cavity (104), the empty third cavity (106) will function as a thermal insulating barrier that limits unwanted heat flow from the aerosol-forming substrate (115) in the first cavity to the aerosol-forming substrate (116) in the second cavity (105). In this way, the third cavity (106) will reduce the possibility of any unwanted premature depletion of the aerosol-forming substrate (116) in the second cavity (105) caused by applying heat to the aerosol-forming substrate (115) in the first cavity (104). Instead, the same principle applies when heat is applied to half of the article (100) containing the second cavity (105), and the third cavity (106) will reduce the possibility of any unwanted premature depletion of the aerosol-forming material (115) in the first cavity (104) caused by applying heat to the aerosol-forming material (116) in the second cavity (105).

[0107] FIGS. 5 and 6 relate to a second embodiment of an aerosol generating article (200). The aerosol generating article (200) differs from an article (100) within a frame (200) that has no holes or cuts defining an air inlet or an air outlet. Rather, the aerosol generating article (200) of FIGS. 5 and 6 utilizes a porous structure for the lower and upper sheets (202, 203). As schematically indicated in the representation of the lower and upper sheets in FIG. 5, the pores extend across the thickness of the lower and upper sheets (202, 203). Common to the first embodiment, the frame (201) has first and second cavities (204, 205) within opposite halves of the length of the article (200), and a third cavity (206) is located between the first and second cavities. The first and second portions (215, 216) of the aerosol-forming substrate are provided to substantially fill each cavity (204, 205). The lower and upper sheets (202, 203) are bonded to the respective lower and upper surfaces (213, 214) of the frame (201) to cover and close each of the cavities (204, 205, 206).

[0108] An assembled aerosol generating article (200) is illustrated in FIG. 6. Common to the aerosol generating article (100), the aerosol generating article (200) is configured to be suitable for use in two separate use sessions. In the first use session, heat will be applied to deplete the aerosol-forming material within one of the first and second cavities (204, 205). In the second use session, heat will be applied to deplete the aerosol-forming material within the other of the first and second cavities (204, 205). More specifically, when used over the use sessions, heat will be applied to approximately half the length of the aerosol generating article (200) to heat the portion (215, 216) of the aerosol-forming material contained within each cavity (204 or 205) for that half of the article. When sufficient heat is applied, the aerosol-forming material within the heated cavity (204 or 205) will begin to vaporize. Applying suction across the corresponding portion of the porous upper sheet (203) placed over the heated cavity (204 or 205) will eventually induce an inflow of air into the cavity through the corresponding portion of the porous lower sheet (202) placed over the heated cavity, causing it to pass through the cavity. The vaporized aerosol-forming material will be accompanied by the inflow of air entering the heated cavity (204 or 205), and the accompanying flow will be cooled and condensed, exiting the aerosol-generating article (200) while forming an aerosol flowing toward the porous upper sheet (203). In the same manner as described for the aerosol generating article (100), the third cavity (206) will help to thermally isolate the first and second cavities (204, 205) from each other and will also help to avoid the premature depletion of the aerosol-forming material in the unheated cavity among the cavities (204, 205).

[0109] FIGS. 7 and 8 relate to a third embodiment of an aerosol generating article (300). The aerosol generating article (300) differs from the article (100) in that first and second cavities (304, 305) are provided in opposing half-widths of the frame (300). The first and second cavities (304, 305) are intended to be filled with a portion (315, 316) of an aerosol-forming substrate. A third cavity (306) is provided between the first and second cavities (304, 305). As can be seen in FIGS. 7 and 8, the third cavity (306) extends in the x-direction by a distance corresponding to and aligned with the lengths of the first and second cavities (304, 305). A first air inlet (307) and a first air outlet (308) are defined at opposing end walls of the frame (301). The first air inlet (307) and the first air outlet (308) are in fluid communication with the first cavity (304). An airflow path (309) is defined within the first cavity (304) between the first air inlet (307) and the first air outlet (308). Additionally, the second air inlet (310) and the second air outlet (311) are defined at the opposing end walls of the frame (301). The second air inlet (310) and the second air outlet (311) are in fluid communication with the second cavity (305). An airflow path (312) is defined within the second cavity (305) between the second air inlet (310) and the second air outlet (311). In common with the aerosol generating article (100, 200), the first and second cavities (304, 305) are not fluidly connected to each other or to the third cavity (306). The first and second cavities (304, 305) extend in the z-direction over the entire height of the frame (301) to define holes or openings that pass through the lower and upper surfaces (313, 314) of the frame.

[0110] While assembling the components of the aerosol generating article (300), the lower sheet (302) is bonded to the lower surface (313) of the frame (301). Then, the first and second cavities (304, 305) are filled with respective parts (315, 316) of the beads of the aerosol forming material until the beads are approximately the same height as the upper surface (314) of the frame (301). The third cavity (306) remains empty except for the presence of air. Then, the upper sheet (303) is bonded to the upper surface (314) of the frame (301) to cover and close the first, second, and third cavities (304, 305, 306) (see FIG. 8).

[0111] An assembled aerosol generating article (300) is illustrated in FIG. 8. The aerosol generating article (300) of FIG. 8 is configured to be suitable for use in two separate use sessions. In the first use session, heat will be applied to deplete the aerosol-forming material within one of the first and second cavities (304, 305). In the second use session, heat will be applied to deplete the aerosol-forming material within the other of the first and second cavities (304, 305). More specifically, when used over the use sessions, heat will be applied to half the width of the aerosol generating article (300) to heat the portion (315, 316) of the aerosol-forming material contained within each cavity (304 or 305) located in that half of the article. When sufficient heat is applied, the aerosol-forming material within the heated cavity (304 or 305) will begin to vaporize. Applying suction at the air outlet (308 or 311) of the heated cavity (304 or 305) will eventually induce air to flow into the heated cavity through the air inlet (307 or 310) of the heated cavity and pass through it. The vaporized aerosol-forming material will be accompanied by the incoming airflow, and the accompanying flow will be cooled and condensed, flowing toward the air outlet (308 or 311) of the heated cavity to form an aerosol and exit the aerosol-generating article (300). The third cavity (306) will help to thermally isolate the first and second cavities (304, 305) from each other.

[0112] In the case of the aerosol generating article (100, 200, 300), the frame (101, 201, 301) is depicted as a homogeneous element. However, in other embodiments, the frame (101, 201, 301) may instead be formed as a plurality of layers that are continuously overlapped and overlapped with one another, for example in the z-direction. FIG. 9 illustrates an exploded view of a frame (401) formed of three layers (4011, 4012, 4013). The middle layer (4012) among the three layers is provided with various cuts. When the three layers (4011, 4012, 4013) are joined together to form the frame (401), the cuts in the middle layer define openings for air flow into and / or out of the first and second cavities (404, 405) defined by the frame (401). As can be seen, each layer (4011, 4012, 4013) defines a portion of the height of the first, second, and third cavities (404, 405, 406). When the multilayer frame structure of FIG. 9 is applied to the frame (101) of the aerosol generating article (100) shown in FIG. 1, the cutout of the intermediate layer (4012) may define an air inlet (107, 110) and an air outlet (108, 111).

[0113] FIGS. 10 and FIGS. 11 illustrate an aerosol generating device (5000) configured for use with an aerosol generating article (500).

[0114] The aerosol generating article (500) generally corresponds to the composition of the aerosol generating article (100) and has a portion (515, 516) of an aerosol forming material located in first and second cavities (504, 505) located in opposite halves of the length of the aerosol generating article (500). An empty third cavity (506) is located between the first and second cavities (504, 505).

[0115] The device (5000) is an elongated aerosol generating device extending between a proximal end (5001) and a distal end (5002). The device (5000) includes a battery (5010), a controller (5020), and a heater (5030) located within a housing (5040). The controller (5020) controls the power supply from the battery (5010) to the heater (5030). A cavity (5050) is defined in the device (5000), and the cavity has an opening (5051) defined in the proximal end (5001) of the device. The opening (5051) is rectangular in shape and has dimensions to accommodate a cross-section of an aerosol generating article (500). The cavity (5050) includes an upper flat surface (5052) and a lower flat surface (5053). The heater (5030) is positioned within the lower flat surface (5053) to heat the lower surface of half the length of the aerosol generating article (500) when inserted into the cavity (5050). An incoming airflow path (not shown) is configured to allow air to flow from outside the device (5000) into the cavity (5050).

[0116] FIG. 12 illustrates the device (5000) of FIG. 10 engaged with an aerosol generating article (500) ready to start a first use session. Half of the aerosol generating article (500), containing a first cavity (504) and a portion (515) of its respective aerosol-forming substrate, is inserted into the opening (5051) of the cavity (5050). When the aerosol generating article (500) is received within the cavity (5050), a heater (5030) is positioned adjacent to the lower surface of the aerosol generating article and extends over the first cavity (504). Then, the user can activate the aerosol generating device (5000) for the first use session. The heater (5030) heats the lower surface of the aerosol generating article (500), and as a result, the portion (515) of the aerosol-forming substrate within the first cavity (504) of the aerosol generating article (500) is heated. Due to the heating action of the heater (5030), the volatile components of the portion (515) of the aerosol-forming substrate are evaporated. The user inhales the proximal end (5001) of the aerosol-generating device (500) to guide the airflow into the interior of the device (5000), introducing it into and passing through the first cavity (504) through the air inlet and air outlet of the cavity. The volatile compounds vaporized from the portion (515) of the aerosol-forming substrate are accompanied by the airflow through the cavity (504) and, as they flow toward the air outlet of the cavity (504), are cooled and condensed to form an aerosol. Then, the aerosol flows within an exhaust airflow path (not shown) defined within the aerosol-generating device (5000) to be inhaled by the user. Upon completion of the first usage session, the volatile components of the portion (515) of the aerosol-generating substrate within the first cavity (504) of the aerosol-generating article (500) will be depleted. Then, the aerosol generating article (500) is removed and reinserted into the cavity (5050) of the device (5000), so that half of the article containing the second cavity (505) is positioned adjacent to the heater (5030) to start the second use session.Then, the aerosol generating device (5000) is activated to start a second use session in the same manner as described for the first use session, thereby depleting the second portion (516) of the aerosol forming material.

[0117] For the purposes of this description and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, etc., shall be understood in all cases to be modified by the term “about.” Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein. Accordingly, in this context, the number “A” is understood as 10% of “A” ± “A”. In this context, the number “A” may be considered to include numerical values ​​within the general standard error for measuring the characteristic modified by the number “A”. In some cases used in the appended claims, the number “A” may deviate by the percentage listed above, provided that the amount of deviation by “A” does not substantially affect the basic and novel feature(s) of the claimed invention. Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein. The terms “among them” and “here” are used as synonyms throughout this specification.

Claims

Claim 1 An aerosol generating article for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article has a length extending in the x direction, a width extending in the y direction, and a height extending in the z direction, wherein the height is smaller than the length and the width, respectively, and the aerosol generating article comprises: a first and a second cavity; an aerosol forming substrate disposed within each of the first and second cavities; and a third cavity located between the first and second cavities. Claim 2 An aerosol generating article according to claim 1, wherein each of the first and second joints includes an air inlet and an air outlet, respectively. Claim 3 In paragraph 1 or 2, the aerosol generating article, wherein the third cavity is hermetically isolated from the outside of the aerosol generating article. Claim 4 An aerosol generating article according to any one of paragraphs 1 to 3, wherein the third cavity defines an empty void. Claim 5 An aerosol generating article according to any one of claims 1 to 4, wherein the first and second cavities are arranged relative to each other at opposite half lengths of the aerosol generating article. Claim 6 In paragraph 5, the third joint extends over at least 75%, for example at least 85%, for example at least 95% of the width of the aerosol-generating article. Claim 7 An aerosol generating article according to any one of claims 1 to 4, wherein the first and second cavities are arranged relative to each other in opposite halves of the width of the aerosol generating article. Claim 8 In any one of claims 1 to 7, the aerosol generating article is an aerosol generating article that is symmetrical along any one or more of the length, width, and height of the aerosol generating article. Claim 9 An aerosol generating article according to any one of claims 1 to 8, wherein the ratio of the volume of the third cavity to the volume of each of the first and second cavities is less than 0.5:1, for example, less than 0.25:1, for example, less than 0.1:

1. Claim 10 An aerosol generating article according to any one of claims 1 to 9, wherein the aerosol forming substrate comprises a free-flowing aerosol forming substrate. Claim 11 An aerosol generating article according to any one of claims 1 to 10, wherein the aerosol generating article comprises opposing upper and lower outer flat surfaces, and the opposing upper and lower outer flat surfaces are spaced apart from each other in the z-direction. Claim 12 In any one of claims 1 to 10, the aerosol generating article comprises opposing outwardly convex upper and lower outer surfaces, and the opposing outwardly convex upper and lower outer surfaces are spaced apart from each other in the z-direction. Claim 13 In any one of claims 1 to 12, the aerosol generating article comprises a frame, and the frame partially defines each of the first, second, and third joints. Claim 14 In paragraph 13, the aerosol generating article, wherein each of the first and second joints extends over the entire height of the frame and defines opposing upper and lower openings passing through the corresponding upper and lower surfaces of the frame. Claim 15 An aerosol generating article according to claim 14, further comprising upper and lower sheets coupled to the respective upper and lower surfaces of the frame to cover the opposing upper and lower openings of the first and second cavities, wherein optionally, the upper and lower sheets are substantially impermeable, e.g., water impermeable, or one or both of the upper and lower sheets are porous to allow the passage of airflow into and / or out of the first and second cavities.

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