Aerosol generating items

Abstract

An aerosol generating article (100) is provided for generating an aerosol by using it in conjunction with an aerosol generating device. The aerosol generating article (100) comprises an upper outer surface (110), a lower outer surface (120), and an aerosol forming substrate that is hermetically isolated from the environment outside the aerosol generating article. The aerosol generating article (100) is defined by a length extending in the x direction, a width extending in the y direction, and a height extending in the z direction. The upper and lower outer surfaces (110, 120) are opposite and separated from each other in the z direction. The height is smaller than the width and length, respectively.

Description

Technology Field

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

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

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

[0004] The objective of the present disclosure is to provide an aerosol generating article, wherein a larger portion of the aerosol-forming substrate of the aerosol generating article is heated sufficiently to form an aerosol during use. Additionally, the objective of the present disclosure is to provide an aerosol generating article that can be manufactured relatively efficiently and at a low cost. means of solving the problem

[0005] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article comprises an aerosol forming substrate for producing an aerosol, and the aerosol generating article is a planar aerosol generating article having a base defined by a length extending in the x-direction, a width extending in the y-direction, and a height extending in the z-direction. The aerosol forming substrate may be hermetically isolated from the environment outside the aerosol generating article.

[0006] The hermetic isolation of the aerosol-forming material can facilitate maintaining the freshness of the aerosol-forming material and avoid the loss of the aerosol-forming material from the article before use of the aerosol-generating article during the transportation and storage of the article, that is, during the use session to deplete the aerosol-forming material.

[0007] The height of the aerosol generating article is less than both the length and width of the aerosol generating article. For the purposes of this disclosure, the “height” of the aerosol generating article may also be referred to as the “thickness” of the aerosol generating article.

[0008] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article comprises an aerosol forming substrate for producing an aerosol, and the aerosol generating article comprises a substantially flat upper surface defined by a length extending in the x-direction and a width extending in the y-direction, and a substantially flat lower surface defined by a length extending in the x-direction and a width extending in the y-direction. The substantially flat upper surface and the substantially flat lower surface may be spaced perpendicularly apart from each other by a height defined in the z-direction. The aerosol forming substrate may be hermetically isolated from the environment outside the aerosol generating article.

[0009] The hermetic isolation of the aerosol-forming material can facilitate maintaining the freshness of the aerosol-forming material and avoid the loss of the aerosol-forming material from the article before use of the aerosol-generating article during the transportation and storage of the article, that is, during the use session to deplete the aerosol-forming material.

[0010] The aerosol generating article according to the present disclosure may preferably be a substantially flat article or a substantially planar article. Such an article has a large base area relative to the volume of the article. In particular, the height of the aerosol generating article may be less than 50 percent of both the length and width of the aerosol generating article. Advantageously, a larger base area may provide a larger surface area for heating by a planar heater of the aerosol generating device. Advantageously, a smaller height may allow for a smaller temperature gradient or difference across the height of the aerosol generating article during heating. For example, if the base of the aerosol generating article is in contact with a planar heater and heated by it, a smaller gap or height between the base and the upper surface may result in a smaller temperature difference between the base and the upper surface facing the base. Advantageously, this may minimize the risk of the hottest part of the substrate closest to the heater burning while enabling a greater proportion of the aerosol-forming substrate of the aerosol generating article to be heated to the temperature at which the aerosol is released. Alternatively or additionally, this can reduce the time required to heat the aerosol-forming substrate sufficiently to release the aerosol.

[0011] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol. For example, the aerosol generating article may be as described in any of the preceding paragraphs of the present disclosure. The aerosol generating article may comprise an upper outer surface, a lower outer surface, and an aerosol forming substrate hermetically isolated from the environment outside the aerosol generating article. The aerosol generating article may be defined by a length extending in the x direction, a width extending in the y direction, and a height extending in the z direction. The upper and lower outer surfaces may be opposite and separated from each other in the z direction, and the height is smaller than the width and length, respectively.

[0012] The hermetic isolation of the aerosol-forming material can facilitate maintaining the freshness of the aerosol-forming material and avoid the loss of the aerosol-forming material from the article before use of the aerosol-generating article during the transportation and storage of the article, that is, during the use session to deplete the aerosol-forming material.

[0013] An aerosol-generating article according to any one of the embodiments disclosed herein may comprise upper and lower surfaces that are substantially planar. The substantially planar upper and lower surfaces may be the upper and lower outer surfaces described in the preceding paragraph. A vertical separation between the substantially planar upper surface and the lower surface may define the height (e.g., z-dimension) of the aerosol-generating article. The height of the aerosol-generating article may be less than 5 millimeters, e.g., 1.5 millimeters to 5 millimeters, e.g., 1.5 millimeters to 4 millimeters, e.g., 1.5 millimeters to 3 millimeters, e.g., 1.5 millimeters to 2 millimeters. One or both of the substantially planar upper and lower surfaces may comprise an aerosol-forming substrate. The aerosol-generating article may comprise upper and lower layers, wherein the upper layer forms the substantially planar upper surface and the lower layer forms the substantially planar lower surface. The upper and lower layers may form the respective upper and lower outer surfaces described in the preceding paragraph of the present disclosure. At least one of the upper layer and the lower layer may include or be composed of an aerosol-forming substrate.

[0014] The cavity can be positioned between the upper outer surface and the lower outer surface.

[0015] The aerosol-generating article may additionally include a frame disposed between an upper outer surface and a lower outer surface. The frame may define a cavity at least partially.

[0016] The upper and lower outer surfaces, respectively, can preferably be thinner than the frame.

[0017] The frame may have a height within the range of 1.5 mm to 5 mm, for example, 1.5 millimeters to 4 millimeters, for example, 1.5 millimeters to 3 millimeters.

[0018] At least a portion of the aerosol-forming substrate may be located within the cavity.

[0019] The aerosol generating article may be configured such that the cavity is hermetically sealed from the environment outside the aerosol generating article. When the aerosol forming material is placed within the cavity, the hermetically sealed isolation of the cavity can facilitate maintaining the freshness of the aerosol forming material and avoid loss of the aerosol forming material from the article during transport and storage of the article, that is, before use of the aerosol generating article in a session of use to deplete the aerosol forming material.

[0020] The aerosol generating article may have an unperforated state without air openings defining an airflow path through the aerosol generating article. Preferably, at least one of the upper and lower outer surfaces may include one or more predetermined regions, and one or more predetermined regions are configured to be perforated to define one or more air openings penetrating the perforated state of the aerosol generating article. When an aerosol forming substrate is located within the aerosol generating article, the unperforated state facilitates ensuring that the aerosol forming substrate remains contained within the article and is hermetically isolated from the environment outside the article before use. Conversely, forming a perforated state by perforating one or more predetermined regions of the upper and / or lower outer surfaces may provide airflow into and / or out of the aerosol generating article.

[0021] An unperforated aerosol-generating article is particularly suitable for packaging, storage, and transportation of the aerosol-generating article, and the unperforated state helps maintain freshness and prevent loss of the aerosol-forming material from the article. The aerosol-generating article may remain unperforated until immediately prior to the commencement of a use session by a consumer, at which point it is expected that at least one of the upper and lower outer surfaces may be perforated at a location in one or more predetermined areas to transform the article into a perforated state ready to deplete the material during the use session.

[0022] In a perforated state, an aerosol generating article according to any one of the embodiments disclosed herein may have an airflow path extending through the aerosol generating article. For example, in a perforated state, one or more openings may form part of an airflow path through the aerosol generating article; preferably, the airflow path may extend through a cavity disposed between the upper outer surface and the lower outer surface of the aerosol generating article or through said cavity. In a perforated state, the aerosol generating article may have an airflow path defined through the aerosol generating article in the x / y plane from one side of the aerosol generating article to the other side of the aerosol generating article. In a perforated state, the aerosol generating article may preferably have a suction resistance (RTD) of less than 20 millimeters H2O, for example, less than 10 millimeters H2O, in the direction of the airflow path. Preferably, in a perforated state, the aerosol generating article may have an RTD of less than 20 millimeters H2O, for example, less than 10 millimeters H2O, in at least one direction in the x / y plane of the aerosol generating article. An aerosol generating article having a low-resistance airflow path enables excellent airflow management and allows the aerosol to be extracted more efficiently from the aerosol generating article and guided to the user.

[0023] Unless otherwise specified, resistance to suction (RTD) is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through the entire length of a component, such as in an aerosol-generating article. The terms "pressure drop" or "resistance to suction" with respect to a component or article may also refer to "resistance to suction." These terms generally refer to measurements performed under testing in accordance with ISO 6565-2015 at a volumetric flow rate of about 17.5 milliliters per second at the output or downstream end of the component, measured at a temperature of about 22°C, a pressure of about 101 kPa (about 760 Torr), and a relative humidity of about 60%.

[0024] Preferably, one or more predetermined regions of the upper and / or lower outer surface may include weakening features. The presence of such weakening features may facilitate perforation of the upper and / or lower outer surface at the locations of the one or more predetermined regions. The weakening features may include areas of local thinning and / or score lines on the upper and / or lower outer surface.

[0025] The upper and lower outer surfaces may each have a thickness of 20 microns to 500 microns, for example, 20 microns to 150 microns, for example, 20 microns to 80 microns.

[0026] The upper and lower outer surfaces can preferably be aligned perpendicular to the longitudinal axis of the article.

[0027] Preferably, the aerosol generating article is symmetrical along any two of the length, width, and height directions of the article. Such symmetrical orientation in the aerosol generating article allows the aerosol generating article to be inserted into the cavity of the aerosol generating device in different orientations, while still ensuring that the aerosol-forming substrate of the article can be depleted during a session of use by the action of the aerosol generating device on the article (e.g., heating action). As discussed in a later paragraph, the aerosol generating device may include a heater element, which is operable to impart heat to the aerosol generating article to deplete the aerosol-forming substrate. The aerosol generating device may include a power source configured to electrically supply power to the heater element. The power source is preferably a battery, for example, a rechargeable battery.

[0028] At least one first predetermined area among the upper and lower outer surfaces may be configured to be perforated to define an air inlet opening of the aerosol generating article. Similarly, at least one second predetermined area among the upper and lower outer surfaces may be configured to be perforated to define an air outlet opening of the aerosol generating article.

[0029] When perforating an article to define an air inlet opening and an air outlet opening, the air inlet opening and the air outlet opening may define a part of the airflow path through an aerosol-generating article.

[0030] The first and second predetermined regions form part of the same of the upper and lower outer surfaces. In this way, the air inlet opening and the air outlet opening can be formed through the same of the upper and lower outer surfaces of the aerosol generating article.

[0031] Alternatively, the first predetermined region may form part of the upper outer surface and the second predetermined region may form part of the lower outer surface. In this way, the air inlet opening and the air outlet opening may be formed within different of the upper and lower outer surfaces of the aerosol generating article.

[0032] Preferably, the first and second predetermined regions may be positioned symmetrically with respect to each other along the longitudinal direction of the aerosol-generating article.

[0033] Preferably, the first and second predetermined regions may be positioned symmetrically with respect to each other along the width direction of the aerosol-generating article.

[0034] This symmetry in the positioning of the first and second predetermined regions allows the aerosol generating article to be inserted into the aerosol generating device in a number of different orientations, while still ensuring that the aerosol-forming substrate of the article can be depleted during a usage session by the action of the aerosol generating device on the article (e.g., through heating of the aerosol-forming substrate).

[0035] The aerosol generating article may additionally include a frame disposed between an upper outer surface and a lower outer surface. The frame may at least partially define a cavity, and the frame includes one or more incisions located adjacent to first and second predetermined regions of the upper and / or lower outer surfaces. The cavity may be the same as the cavity described in the previous paragraph.

[0036] Preferably, one or more incisions can be fluidly connected to the cavity.

[0037] At least a portion of the aerosol-forming material may be located within one or more incisions.

[0038] Preferably, one or more brittle capsule regions are accommodated within one or more incisions. One or more brittle capsules may comprise one or more of an aerosol-forming substrate and a flavor-releasing element.

[0039] Advantageously, at least one predetermined area of ​​at least one of the upper and lower outer surfaces may be configured to be perforated to define one or more groups of ventilation holes. The one or more predetermined areas may be identical to or distinct from the predetermined areas discussed in the preceding paragraph of the present disclosure.

[0040] At least one pair of predetermined areas among the upper and lower outer surfaces may be configured to be perforated to define a group of corresponding pairs of ventilation holes.

[0041] Each of the pair of predetermined regions can be positioned symmetrically with respect to each other along the longitudinal direction of the aerosol-generating article.

[0042] Each of the pair of predetermined regions can be positioned symmetrically with respect to each other along the width direction of the aerosol-generating article.

[0043] The upper and lower outer surfaces may be formed from one or more materials selected from the following list: paper, board paper, cardboard, metal foil, and aerosol-forming substrates.

[0044] Preferably, the upper and lower outer surfaces are configured to be impermeable, for example, impermeable to water, for example, impermeable to air. Where the upper and lower outer surfaces comprise a porous or permeable material, preferably each surface comprises an impermeable coating or film, for example, a polymer-based coating or film, placed over the porous or permeable material.

[0045] The upper and lower outer surfaces may have a permeability of 1 to 10 coresta units, for example, 1 to 5 coresta units, for example, 1 to 3 coresta units.

[0046] Preferably, the upper and lower outer surfaces are substantially flat. Alternatively, the upper and lower outer surfaces may be outwardly convex.

[0047] At least one of the upper and lower outer surfaces may include an aperture closed and sealed by a peelable membrane, and removal of the peelable membrane exposes the aperture, thereby defining an air opening. Closing the aperture by the peelable membrane can help ensure that the aerosol-forming substrate of the aerosol-generating article is hermetically sealed from the environment outside the aerosol-generating article. Conversely, removal of the peelable membrane to expose the aperture may break the hermetically sealed seal, and the resulting air opening may, for example, define one of the air inlets and outlets of the aerosol-generating article.

[0048] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol. For example, the aerosol generating article may be as described in any of the preceding paragraphs of the present disclosure. The aerosol generating article may comprise a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer. The aerosol generating article may comprise an aerosol forming substrate hermetically isolated from the environment outside the aerosol generating article.

[0049] The hermetic isolation of the aerosol-forming material can facilitate maintaining the freshness of the aerosol-forming material and avoid the loss of the aerosol-forming material from the article before use of the aerosol-generating article during the transportation and storage of the article, that is, during the use session to deplete the aerosol-forming material.

[0050] The first planar layer may define one of the upper outer surface and the lower outer surface described in the preceding paragraph of the present disclosure, whereas the second planar layer may define the other of the upper outer surface and the lower outer surface.

[0051] At least one of the first planar layer, the second planar layer, and the wavy layer may include or be made of an aerosol-forming substrate.

[0052] A cavity may be disposed between a first planar layer and a second planar layer. A corrugated layer may be arranged within the cavity. The aerosol generating article may be configured so that the cavity can be hermetically sealed from the environment outside the aerosol generating article.

[0053] The use of a corrugated structure within an aerosol generating article can advantageously allow for the production of an aerosol generating article that has a very low RTD (when the hermetic seal of the aerosol generating article is perforated) while remaining sufficiently rigid for user handling. Additionally, the use of a corrugated structure can allow for the manufacture of aerosol generating articles with low density and low RTD (when the hermetic seal is perforated) using high-speed production methods similar to those used in the production of corrugated cardboard.

[0054] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol. For example, the aerosol generating article may be as described in any of the preceding paragraphs of the present disclosure. The aerosol generating article may comprise a first planar outer surface, a second planar outer surface, a cavity, and a frame. The frame is located between the first planar outer surface and the second planar outer surface. The frame defines the cavity at least partially. The aerosol generating article comprises an aerosol forming substrate that is hermetically isolated from the environment outside the aerosol generating article.

[0055] The hermetic isolation of the aerosol-forming material can facilitate maintaining the freshness of the aerosol-forming material and avoid the loss of the aerosol-forming material from the article before use of the aerosol-generating article during the transportation and storage of the article, that is, during the use session to deplete the aerosol-forming material.

[0056] The aerosol generating article can be configured so that the cavity is hermetically sealed from the environment outside the aerosol generating article.

[0057] The first and second planar outer surfaces may define the upper and lower outer surfaces described in the preceding paragraph of the present disclosure.

[0058] Preferably, the aerosol-forming substrate is located between the first planar outer surface and the second planar outer surface.

[0059] The frame may include a perimeter wall that at least partially surrounds or encloses the cavity. The frame may include a perimeter wall that completely surrounds or encloses the cavity. Advantageously, the frame can make the aerosol-generating article relatively thin while maintaining structural rigidity.

[0060] The aerosol generating article may include a first planar outer layer and a second planar outer layer, wherein the first planar outer layer forms a first planar outer surface and the second planar outer layer forms a second planar outer surface. Optionally, at least one of the first planar outer layer, the second planar outer layer, and the frame may include or be made of an aerosol forming substrate.

[0061] The common area can be practically empty.

[0062] The aerosol-forming substrate can be located within the cavity.

[0063] The wavy layer can be located within the cavity.

[0064] The frame can be a flat frame.

[0065] The frame may have a height of 50 percent to 95 percent of the height of the aerosol-generating article. The frame may have a height of 60 percent to 95 percent of the height of the aerosol-generating article. The frame may have a height of 70 percent to 95 percent of the height of the aerosol-generating article. The frame may have a height of 80 percent to 95 percent of the height of the aerosol-generating article.

[0066] The frame may have a height of 1 millimeter to 5.5 millimeters. The frame may have a height of 1 millimeter to 5 millimeters. Preferably, the frame may have a height of 1.5 millimeters to 5 millimeters.

[0067] The frame may be manufactured from or contain biodegradable materials. The frame may be manufactured entirely from biodegradable materials.

[0068] The frame may be manufactured from or contain a cellulose material. The cellulose material may contain a sheet of cellulose material. The cellulose material may contain cellulose fibers. The cellulose material may be paper, board paper, 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.

[0069] The frame may be a single component. Alternatively, the frame may include two or more layers. That is, the frame may have a stacked structure.

[0070] An aerosol-generating article of any one embodiment of the present disclosure may have a length (e.g., x-dimension) of 10 millimeters to 100 millimeters, or 10 millimeters to 50 millimeters, for example, 10 millimeters to 40 millimeters, for example, 12 millimeters to 30 millimeters, for example, 14 millimeters to 26 millimeters, for example, 16 millimeters to 24 millimeters, for example, 18 millimeters to 22 millimeters, for example, about 18 millimeters, or about 19 millimeters, or about 20 millimeters, or about 21 millimeters, or about 22 millimeters.

[0071] The aerosol generating article may have a width (e.g., y-dimension) of 5 to 20 millimeters, e.g. 8 to 18 millimeters, e.g. 10 to 16 millimeters, e.g. 11 to 15 millimeters, e.g. 12 to 14 millimeters, e.g. about 13 millimeters.

[0072] The aerosol generating article may have a height (e.g., z-dimension) of 1 millimeter to 10 millimeters, for example 1.2 millimeters to 8 millimeters, for example 1.4 millimeters to 7 millimeters, for example 1.6 millimeters to 6 millimeters, for example 1.7 millimeters to 5 millimeters, for example about 1.7 millimeters, or about 4.5 millimeters, or about 2 millimeters, or about 3 millimeters, or about 4 millimeters.

[0073] When viewed in a planar view, an aerosol generating article of any one of the embodiments of the present disclosure may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an oval, a circle, or a combination thereof. Where the aerosol generating article comprises upper and lower surfaces that are substantially planar, when viewed in a planar view, one or both of the upper and lower surfaces may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an oval, a circle, or a combination thereof. When viewed in a planar view, the periphery of the aerosol generating article may be formed by a plurality of straight sides, a plurality of curved sides, or a combination of straight sides and curved sides. Where the aerosol generating article comprises upper and lower surfaces that are substantially planar, when viewed in a planar view, the periphery of one or both of the upper and lower surfaces may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an oval, a circle, or a combination thereof.

[0074] An aerosol-generating article may be composed entirely of an aerosol-forming substrate. Alternatively, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-generating article.

[0075] The aerosol-forming material may contain nicotine. Nicotine may exist in the form of a tobacco material or in the form of a nicotine extract.

[0076] The aerosol-forming substrate may include one or more organic materials such as tobacco, peppermint, tea, and cloves. The aerosol-forming substrate may include one or more of homogenized tobacco such as herb leaves, tobacco leaves, tobacco rib pieces, regenerated tobacco, cast leaves, extruded tobacco, puffed tobacco, aerosol-generating films, and gel compositions.

[0077] The aerosol-forming substrate may include or be composed of homogenized tobacco materials, for example, recycled tobacco materials or cast leaf tobacco materials.

[0078] The aerosol-forming substrate may be in the form of shredded aerosol-generating material. The shredded aerosol-generating material may include one or more strips and strands of aerosol-generating material, such as strips and strands of tobacco or homogenized tobacco material. The shredded aerosol-generating material may be in the form of shredded sheets of homogenized tobacco material.

[0079] The aerosol-forming material may be a cut herb. The aerosol-forming material may be a tobacco cut herb. The cut herb may include one or more of bright tobacco, dark tobacco, flavored tobacco, and cut herb tobacco. Examples of bright tobacco are Brazilian yellow, Indian yellow, Chinese yellow, American yellow such as Virginia tobacco, and Tanzanian yellow. Examples of flavored tobacco include Oriental Turkish tobacco, Greek Oriental tobacco, semi-Oriental tobacco, as well as perique and fire-dried American Burley such as Rustica. Examples of dark tobacco are fumigated Brazilian Galpao, Burley Malawi or other African Burley, and sun-dried or air-dried Indonesian Kasturi. As used herein, the term “cut herb” is used to describe a blend of chopped plant material, such as tobacco plant material and homogenized plant material, which includes one or more of leaf blades, processed stems, and ribs.

[0080] The aerosol-forming substrate may be in the form of a sheet of aerosol-generating material. As used herein, the term “sheet” describes a laminated element in which the width and length are substantially greater than the thickness. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenized tobacco material, such as a cast leaf sheet.

[0081] The aerosol-forming material may comprise a combined aggregate of strips, strands, or particles of tobacco material. The aerosol-forming material may be in the form of a compressed plug of tobacco material, for example, a plug having a substantially circular cross-section in the initial state of the plug is compressed into a flatter cross-sectional profile in a subsequent state of the plug. The tobacco material may be enclosed by a wrapper. The aerosol-forming material may be in the form of strips, strands, or particles of tobacco material bonded together in a binder matrix.

[0082] The aerosol-forming substrate may comprise one or more aerosol-forming agents. Suitable aerosol-forming agents are widely known in the art and comprise, but are not limited to, one or more aerosol-forming agents selected from polyhydric alcohols such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable that the aerosol-forming agent is one or both of glycerin and propylene glycol, or comprises them. The aerosol-forming agent may consist of glycerin or propylene glycol, or a combination of glycerin and propylene glycol.

[0083] The aerosol-forming substrate may have an aerosol-forming agent content of 1, 2, 5, 10, or 15 weight percent or more based on dry weight. The aerosol-forming substrate may have an aerosol-forming agent content of 15 weight percent or more based on dry weight, for example, exceeding 20 weight percent based on dry weight, or exceeding 25 weight percent based on dry weight, or exceeding 30 weight percent based on dry weight, or exceeding 40 weight percent based on dry weight, or exceeding 50 weight percent based on dry weight.

[0084] The aerosol-forming substrate may have an aerosol-forming agent content of 30 weight percent or less based on dry weight, 25 weight percent or less based on dry weight, or 20 weight percent or less based on dry weight. That is, the aerosol-generating material may have an aerosol-forming agent content of 30 weight percent or less based on dry weight, 25 weight percent or less based on dry weight, or 20 weight percent or less based on dry weight.

[0085] The aerosol-forming substrate may have an aerosol-forming agent content of 1 weight percent to 30 weight percent based on dry weight, 1 weight percent to 25 weight percent based on dry weight, or 1 weight percent to 20 weight percent based on dry weight.

[0086] The aerosol-forming substrate may comprise at least 50 weight percent of an aerosol-forming agent, at least 60 weight percent of an aerosol-forming agent, or at least 70 weight percent of an aerosol-forming agent.

[0087] The aerosol-forming material may include 85 weight percent or less of an aerosol-forming agent, 80 weight percent or less of an aerosol-forming agent, or 75 weight percent or less of an aerosol-forming agent.

[0088] The aerosol-forming substrate may comprise 50 weight percent to 85 weight percent of an aerosol-forming agent, 50 weight percent to 80 weight percent of an aerosol-forming agent, or 50 weight percent to 75 weight percent of an aerosol-forming agent.

[0089] The aerosol-forming material may include nicotine. The aerosol-forming material may include natural nicotine, synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0090] The aerosol-forming material may contain at least 0.5 weight percent nicotine, at least 1 weight percent nicotine, at least 1.5 weight percent nicotine, or at least 2 weight percent nicotine.

[0091] The aerosol-forming material may include one or more flavoring agents. One or more flavoring agents may include one or more essential oils such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and one or more herbal materials. Suitable herbal materials include, but are not limited to, other herbal materials from herb leaves or herbal plants, including peppermint such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway. One or more flavoring agents may include tobacco materials.

[0092] The aerosol-forming material may include one or more plants. For example, the aerosol-forming material may include about 1 to 90%, for example about 15 to 55%, preferably about 20 to 35% of plants such as clove, echinacea species, fennel, ginger, hawthorn berry, elderberry, monarda, murein leaf, nettle, plantain, turmeric, yarrow, rooibos, star anise, thyme, anetum, chamomile, and compounds thereof.

[0093] The aerosol-forming substrate may have a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state. For example, the aerosol-forming substrate may be a homogenized tobacco material having a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state.

[0094] The aerosol-forming substrate may include a binder. For example, the aerosol-forming substrate may include about 1 to 10%, preferably about 1 to 5%, of a binder, such as either a common gum or pectin used in the food and beverage (F&B) industry. Preferred binders may be natural pectins, e.g., fruit, e.g., citrus or tobacco pectin; guar gum, land locust bean gum, e.g., their hydroxyethyl and hydroxypropyl forms; starch, e.g., modified or derivatized starch; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl, cellulose; dextran; and xanthan gum. A preferred binder is guar.

[0095] The aerosol-forming substrate may include or be composed of a solid aerosol-forming material. The aerosol-forming substrate may include a liquid aerosol-forming material, for example, a liquid aerosol-forming material retained within a porous matrix. The aerosol-forming substrate may include a gel aerosol-forming material.

[0096] According to the present disclosure, an aerosol generating device for receiving an aerosol generating article as disclosed herein, or an aerosol forming substrate as disclosed herein, may include a cavity dimensioned to receive at least a portion of the aerosol generating article or the aerosol forming substrate, a heater or heating means, a power source for supplying power to the heater or heating means, and a controller for controlling the supply of power to the heater or heating means. The aerosol generating device is configured to heat the aerosol forming substrate, for example, the aerosol forming substrate which is a component part of the aerosol generating article, to form an aerosol, for example, an inhalable aerosol.

[0097] The aerosol generating device may preferably be configured to accommodate the entire aerosol generating article, and accordingly, the aerosol generating article is completely enclosed within the aerosol generating device.

[0098] The cavity may include an opening into which the distal end of an aerosol-generating article can be inserted. The cavity may have any suitable cross-sectional shape. For example, the cavity may have a rectangular cross section, for example, a rectangular cross section having opposing top and bottom sides that are longer than the left and right sides.

[0099] Preferably, at least one internal surface of the cavity is a heating surface configured to heat an aerosol generating article. The heating surface may include a heater, for example, a resistance heater or an infrared heater, or a susceptor configured to be heated by engagement with an inductor. The heating surface may include an inductor, and for example, the surface may include a coil arranged to generate a fluctuating electromagnetic field within the cavity space. The heating surface may be a surface permeable to the fluctuating electromagnetic field so that an inductor arranged outside the cavity can project the fluctuating electromagnetic field through the heating surface and engage with a susceptor arranged inside the cavity.

[0100] As used herein, the term "aerosol generating article" may refer to an article capable of generating or releasing aerosols.

[0101] 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.

[0102] As used herein, the term "aerosol generating device" may refer to a device for use with an aerosol generating article to enable the generation or release of an aerosol.

[0103] As used herein, the term “aerosol generating system” refers to a combination of an aerosol generating device and one or more aerosol forming articles for use with a device. The aerosol generating system may include additional components, such as a charging unit for recharging an embedded electric power supply within an electrically operated or electric aerosol generating device.

[0104] 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.

[0105] As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salt.

[0106] 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.

[0107] As used herein, the term "longitudinal" refers to a direction corresponding to the main longitudinal axis of the aerosol generating article extending between the upstream and downstream ends of the aerosol generating article. During use, air may be drawn longitudinally through the aerosol generating article.

[0108] As used herein, the term “sheet” refers to a laminated element having a width and length substantially greater than its thickness. The width of the sheet may be greater than 10 mm, preferably greater than 20 mm or 30 mm. In certain embodiments, the sheet of material to be used to form an aerosol-forming substrate as described herein may have a thickness of 10 μm to about 1000 μm, for example, 10 μm to about 300 μm.

[0109] 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 fine 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 fine 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.

[0110] 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 finely grinding a portion of a plant. Particles produced from one or more plants are mixed with a liquid component, typically water, to form a slurry. Other components within the slurry may include fibers, a binder, and an aerosol-forming agent. The particulate plant material may aggregate in the presence of a binder. The slurry is cast onto a supporting surface and dried into a sheet of homogenized plant material. Preferably, the homogenized plant material used in the article according to the present invention can be produced by casting. Such homogenized plant material may comprise aggregated fine particulate plant material.

[0111] As used herein, suction resistance is expressed in units of pressure such as "mm H2O" or "mm WG" or "mm water level gauge" and can be measured according to ISO 6565:2002.

[0112] 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.

[0113] Example Ex1: An aerosol generating article for generating an aerosol by using it together with an aerosol generating device, wherein the aerosol generating article is,

[0114] Upper outer surface;

[0115] Lower outer surface; and

[0116] It includes an aerosol-forming substrate that is hermetically isolated from the environment outside the aerosol-generating article;

[0117] An aerosol generating article is defined by a length extending in the x-direction, a width extending in the y-direction, and a height extending in the z-direction, wherein the upper and lower outer surfaces are opposite and separated from each other in the z-direction, and the height is smaller than the width and length, respectively.

[0118] Example Ex2: An aerosol generating article of Ex1, further comprising a cavity disposed between an upper outer surface and a lower outer surface.

[0119] Example Ex3: An aerosol generating article of Ex2, further comprising a frame disposed between an upper outer surface and a lower outer surface, wherein the frame defines at least partially a cavity.

[0120] Example Ex4: An aerosol generating article in Ex3, wherein the upper and lower outer surfaces are each thinner than the frame.

[0121] Example Ex5: An aerosol generating article in Ex3 or Ex4, wherein the frame has a height within the range of 1.5 mm to 5 mm, for example, 1.5 millimeters to 4 millimeters, for example, 1.5 millimeters to 3 millimeters.

[0122] Example Ex6: In any one of Ex2 to Ex5, the article is configured such that the cavity is hermetically sealed from the environment outside the aerosol-generating article.

[0123] Example Ex7: An aerosol generating article in any one of Ex2 to Ex6, wherein at least a portion of the aerosol-forming substrate is located within a cavity.

[0124] Example Ex8: In any one of Ex1 to Ex7, the aerosol generating article has an unperforated state in which there is no air opening defining an airflow path through the aerosol generating article.

[0125] Example Ex9: The aerosol generating article of Ex8, wherein at least one of the upper and lower outer surfaces comprises one or more predetermined regions, and the one or more predetermined regions are configured to be perforated to define one or more air openings penetrating the perforated state of the aerosol generating article.

[0126] Example Ex10: In Ex9, in a perforated state, one or more openings form part of an airflow path through the aerosol generating article, preferably the airflow path is a cavity disposed between an upper outer surface and a lower outer surface or extends through said cavity, the aerosol generating article.

[0127] Example Ex11: An aerosol generating article in which, in Ex9 or Ex10, one or more predetermined regions of the upper and / or lower outer surface comprise a weakening feature.

[0128] Example Ex12: An aerosol generating article in Ex11, wherein the weakening feature comprises an area of ​​localized thinning and / or score lines on the upper and / or lower outer surface.

[0129] Example Ex13: An aerosol generating article, wherein, in any one of the preceding claims, the upper and lower outer surfaces each have a thickness of 20 microns to 500 microns, for example 20 microns to 150 microns, for example 20 microns to 80 microns.

[0130] Example Ex14: An aerosol generating article in any one of Ex1 to Ex13, wherein the upper and lower outer surfaces are aligned perpendicular to the longitudinal axis of the article.

[0131] Example Ex15: In any one of Ex1 to Ex14, the article is symmetrical along any two of the length direction, width direction, and height direction of the article, an aerosol-generating article.

[0132] Example Ex16: In Ex9 or any embodiment dependent thereon,

[0133] At least one of the upper and lower outer surfaces is configured to be perforated to define an air inlet opening for an aerosol generating article;

[0134] An aerosol generating article, wherein at least one of the upper and lower outer surfaces is configured to have a second predetermined area perforated to define an air outlet opening of the aerosol generating article.

[0135] Example Ex17: In Ex16, when perforating the article to define an air inlet opening and an air outlet opening, the air inlet opening and the air outlet opening define a part of the airflow path through the aerosol generating article.

[0136] Example Ex18: An aerosol generating article in Ex16 or Ex17, wherein the first and second predetermined regions form part of the same of the upper and lower outer surfaces.

[0137] Example Ex19: An aerosol generating article in Ex16 or Ex17, wherein the first predetermined region forms part of one of the upper outer surface and the lower outer surface, and the second predetermined region forms part of the other of the upper outer surface and the lower outer surface.

[0138] Example Ex20: An aerosol generating article in any one of Ex16 to Ex19, wherein the first and second predetermined regions are positioned symmetrically with respect to each other along the longitudinal direction of the aerosol generating article.

[0139] Example Ex21: An aerosol generating article in any one of Ex16 to Ex20, wherein the first and second predetermined regions are positioned symmetrically with respect to each other along the width direction of the aerosol generating article.

[0140] Example Ex22: An aerosol generating article in any one of Ex16 to Ex21, further comprising a frame disposed between an upper outer surface and a lower outer surface, wherein the frame at least partially defines a cavity, and the frame comprises one or more incisions located adjacent to first and second predetermined regions of the upper and / or lower outer surfaces.

[0141] Example Ex23: An aerosol generating device according to Ex22, wherein one or more incisions are fluidly connected to a cavity.

[0142] Example Ex24: An aerosol generating device in which, in Ex22 or Ex23, at least a portion of the aerosol-forming substrate is located within one or more incisions.

[0143] Example Ex25: An aerosol generating article comprising one or more brittle capsules contained within one or more incisions in any one of Ex22 to Ex24.

[0144] Example Ex26: In Ex25, one or more brittle capsules comprise one or more of an aerosol-forming substrate and a flavor-releasing element, an aerosol-generating article.

[0145] Example Ex27: An aerosol generating article in any one of Ex1 to Ex26, wherein at least one predetermined area of ​​at least one of the upper and lower outer surfaces is configured to be perforated to define one or more groups of ventilation holes.

[0146] Example Ex28: An aerosol generating article in which, in Ex27, at least one of a pair of predetermined regions of the upper and lower outer surfaces is configured to be perforated to define a group of corresponding pairs of ventilation holes.

[0147] Example Ex29: An aerosol generating article, wherein each of a pair of predetermined regions is positioned symmetrically with respect to each other along the longitudinal direction of the aerosol generating article.

[0148] Example Ex30: An aerosol generating article, wherein each of a pair of predetermined regions is positioned symmetrically with respect to each other along the width direction of the aerosol generating article.

[0149] Example Ex31: An aerosol generating article in any one of Ex1 to Ex30, wherein the upper and lower outer surfaces are formed from one or more materials selected from the following list: paper, board paper, cardboard, metal foil, and aerosol forming substrate.

[0150] Example Ex32: An aerosol generating article in any one of Ex1 to Ex31, wherein the upper and lower outer surfaces are configured to be impermeable, for example, impermeable to water, for example, impermeable to air.

[0151] Example Ex33: An aerosol generating article in any one of Ex1 to Ex32, wherein the upper and lower outer surfaces are substantially flat.

[0152] Example Ex34: An aerosol generating article in any one of Ex1 to Ex32, wherein the upper and lower outer surfaces are outwardly convex.

[0153] Example Ex35. An aerosol generating article in any one of Ex1 to Ex34, wherein at least one of the upper and lower outer surfaces comprises an aperture closed and sealed by a peelable membrane, and removal of the peelable membrane exposes the aperture to define an air opening therethrough. Brief explanation of the drawing

[0154] Now, embodiments will be further described with reference to the drawings. FIG. 1 is a side perspective view of an aerosol generating article according to a first embodiment of the present disclosure. FIG. 2 is a side perspective view of an aerosol generating article according to a second embodiment of the present disclosure, and the aerosol generating article is in an unperforated state. FIG. 3 is a side perspective view of the aerosol-generating article of FIG. 2 after deformation into a perforated state. FIG. 4 is a side perspective view of an aerosol generating article according to a third embodiment of the present disclosure, and the aerosol generating article is in an unperforated state. FIG. 5 is a side perspective view of the aerosol-generating article of FIG. 4 after deformation into a perforated state. FIG. 6 is a schematic end view of an aerosol generating article according to a fourth embodiment of the present disclosure. Figure 7 is a schematic side view of the aerosol generating article of Figure 6. Figure 8 is a schematic plan view of the aerosol-generating article of Figure 6 in an unperforated state. FIG. 9 is a schematic plan view of the aerosol generating article of FIG. 6 in a perforated state. FIG. 10 illustrates a schematic diagram of a wavy element as used in the aerosol generating article of FIG. 6. FIG. 11 illustrates a perspective view of an aerosol generating article according to a fifth embodiment of the present disclosure, wherein the aerosol generating article is in an unperforated state. FIG. 12 shows a perspective view of the aerosol-generating article of FIG. 11 after deformation into a perforated state. FIG. 13 shows an exploded perspective view of the aerosol generating article of FIG. 11. FIG. 14 shows an additional exploded perspective view of the aerosol generating article of FIG. 11. FIG. 15 illustrates a schematic cross-sectional view of the aerosol-generating article of FIG. 11. FIG. 16 illustrates a schematic cross-sectional view of the aerosol-generating article of FIG. 11. FIG. 17 illustrates an exploded perspective view of an aerosol generating article according to a sixth embodiment of the present disclosure, in which the aerosol generating article is in an unperforated state. FIG. 18 shows a perspective view of the aerosol-generating article of FIG. 17 after deformation into a perforated state. FIG. 19 illustrates a schematic cross-sectional view of the aerosol-generating article of FIG. 17. FIG. 20 illustrates a schematic lateral cross-sectional view of the aerosol-generating article of FIG. 17. FIG. 21 illustrates a perspective view of an aerosol generating article according to a seventh embodiment of the present disclosure. FIG. 22 illustrates a schematic diagram of an aerosol generating device according to one embodiment of the present disclosure, wherein the device is configured to engage with an aerosol generating article, for example, any one of FIG. 1 to FIG. 21. FIG. 23 shows a schematic end view of the aerosol generating device of FIG. 22. FIG. 24 is a schematic diagram illustrating an aerosol generating article (e.g., an aerosol generating article of any one of FIG. 1 to FIG. 21) that engages with the aerosol generating device of FIG. 22. FIG. 25 is a schematic diagram of an alternative embodiment of FIG. 22 to FIG. 24, which illustrates an aerosol generating article coupled with an aerosol generating device. Specific details for implementing the invention

[0155] FIG. 1 illustrates a side perspective view of an aerosol generating article (100) according to a first embodiment of the present disclosure. The aerosol generating article (100) has upper and lower surfaces (110, 120) that are flat or planar.

[0156] The aerosol generating article (100) includes an aerosol forming substrate (not shown). The aerosol forming substrate is enclosed inside the aerosol generating article (100). A suitable aerosol forming substrate may be a homogenized tobacco.

[0157] The exterior of the aerosol generating article (100) is configured such that the aerosol forming substrate of the aerosol generating article is hermetically sealed from the environment outside the aerosol generating article (i.e., outside the aerosol generating article).

[0158] The aerosol generating article (100) has a length of 80 millimeters extending in the x dimension, a width of 15 millimeters extending in the y dimension, and a height of 3.6 millimeters extending in the z dimension (which may also be referred to as thickness).

[0159] FIG. 2 illustrates a side perspective view of an aerosol generating article (200) according to a second embodiment of the present disclosure, which is a variation of the aerosol generating article (100). Features common to the aerosol generating article (100) are referred to by similar reference numerals, but begin with the number 2 instead of the number 1. FIG. 2 illustrates an unperforated aerosol generating article (200) in which a hermetic seal is maintained between the inside and outside of the aerosol generating article. However, first, second, and third regions (211, 212, 213) (shown as dashed outlines in FIG. 2) are predetermined regions of the upper surface (210) intended to be subsequently perforated to break the hermetic seal before starting a session of use with the aerosol generating article (200). The first and second regions (211, 212) are circular and are symmetrically spaced apart from each other on the upper surface (210) along the longitudinal direction (i.e., x-direction) of the aerosol generating article (200). The third region (213) extends linearly between the lateral side edges of the upper surface (210) at the midpoint of the length of the upper surface. The upper and lower surfaces (210, 220) each have a uniform thickness of about 50 microns. The thinner the thickness of the upper surface (210), the lower the force required to puncture the upper surface at the predetermined locations of the first, second, and third regions (211, 212, 213). In an alternative embodiment, a score line may be formed along the periphery of the predetermined circular first and second regions (211, 212) and along the predetermined linear third region (213). In this alternative embodiment, the dashed outlines shown for the predetermined first, second, and third regions (211, 212, 213) of FIG. 2 will also represent score lines. The score lines extend only partially through the thickness of the upper surface (210), thereby maintaining a hermetic seal between the inside and outside of the aerosol generating article (200). The score lines will reduce the force required to puncture the upper surface (210).The unperforated state of the aerosol-generating article (200) exemplified in FIG. 2 is particularly suitable for packaging, transporting, and storing the article.

[0160] When a consumer intends to prepare an aerosol generating article (200) for use in a use session, the consumer will first perforate the upper surface (210) around the periphery of predetermined circular first and second regions (211, 212) to form respective first and second circular openings (214, 215) through the upper surface (210) (as shown in FIG. 3). The consumer will also discontinuously perforate the upper surface (210) along a path defined by a predetermined linear third region (213) to define a row of ventilation holes (216) through the upper surface (210) (also shown in FIG. 3). The consumer may manually perforate the predetermined circular first and second regions (211, 212) to form the first and second circular openings (214, 215) by using a punch or a suitable cutting tool (e.g., a circular cutting tool). Similarly, the consumer may manually perforate a predetermined linear third region (213) to form a row of ventilation holes (216) by using a linear cutting tool having a plurality of spaced teeth. Markings are printed on the upper surface (210) to indicate the locations of the predetermined circular first and second regions (211, 212) and / or the predetermined linear third region, thereby providing a visual cue as to which part of the upper surface (210) should be perforated. In some embodiments, the upper surface (210) may be ruptured at the locations of the predetermined first, second, and third regions (211, 212, 213) as a result of the aerosol generating article (200) being inserted into the cavity of the aerosol generating device; For example, the device has one or more cutting tools or protrusions adapted to engage with the upper surface (210) of the article to rupture the upper surface and thereby create first and second circular openings (214, 215) and ventilation holes (216).If a score line is defined within the upper surface (210) along the path of the predetermined circular first and second regions (211, 212) and the predetermined linear third region (213) (as described in the previous paragraph), local thinning of the upper surface (210) along the score line reduces the force required to rupture the upper surface (210) and can also ensure that the upper surface (210) ruptures only along the path defined by the score line or preferentially along it. The first circular opening (214) defines the air inlet of the aerosol generating article (200). The second circular opening (215) defines the air outlet of the aerosol generating article (200). An airflow path (217) is defined through the interior of the aerosol generating article (200) between the air inlet (214) and the air outlet (215). The arrow in FIG. 3 indicates the path through which air is taken in through the air inlet (214) and out through the air outlet (215) along the airflow path (217). The first end (201) may define the distal end of the aerosol generating article (200), and the second end (202) may define the proximal or mouse end of the aerosol generating article. The airflow path (217) may be directed toward the user's mouth to allow the user to inhale the aerosol generated as a result of heating the aerosol forming substrate of the aerosol generating article (200).

[0161] In an alternative embodiment of FIGS. 2 and FIGS. 3, one of the predetermined first and second regions (211, 212) is located within the upper surface (210), and the other of the predetermined first and second regions (211, 212) is located within the lower surface (220). The predetermined third region (213) may be located only within the upper surface (210) (as shown in FIG. 2), only within the lower surface (220), or within both the upper and lower surfaces (210, 220). It will also be understood that the predetermined first and second regions (211, 212) may have shapes other than circular, such as egg-shaped, ovate, square, rectangular, or any other shape.

[0162] FIG. 4 illustrates a side perspective view of an aerosol generating article (300) according to a third embodiment of the present disclosure, which is a variation of the aerosol generating article (200). Features common to the aerosol generating article (200) are referred to by similar reference numerals, but start with the number 3 instead of the number 2. The aerosol generating article (300) of FIG. 4 is in an unperforated state in which a hermetic seal is maintained between the inside and outside of the aerosol generating article (300). The aerosol generating article (300) of FIG. 4 differs from the aerosol generating article (200) of FIG. 2 in that a peelable foil membrane (318) covers the first and second openings (314, 315) and the ventilation hole (316) performed through the upper surface (310) of the aerosol generating article (300). The peelable foil membrane (318) has a layer of aluminum, and an adhesive is applied to one or both of the sides of the membrane (318) and the upper surface (310) to peelably attach the membrane to the upper surface. The peelable foil membrane (318) covers the first and second openings (314, 315) and the ventilation hole (316) out of sight, thereby retaining the aerosol generating article (300) in the unperforated state of FIG. 4. The first and second openings (314, 315) and the ventilation hole (316) are not shown in FIG. 4 because they are covered by the foil membrane (318), but can be seen in FIG. 5 after the removal of the membrane (318).

[0163] When a consumer intends to prepare the aerosol generating article (300) for use in a usage session, the consumer will place their finger on the tab (319) of the peelable membrane (318) and pull the tab in the direction of the arrow shown in FIG. 4 to gradually remove the membrane from the upper surface (310). Removal of the peelable membrane (318) exposes the first and second openings (314, 315) and the ventilation hole (316), thereby transforming the article (300) into a perforated state as shown in FIG. 5. The first and second openings (314, 315) define the air inlet and air outlet of the aerosol generating article (300). The arrow in FIG. 5 indicates the path through which air is taken out of the air outlet (315) along the defined airflow path (317) through the interior of the aerosol generating article (300) into the air inlet (314).

[0164] FIGS. 6, FIGS. 7, and FIGS. 8 / 9 illustrate, respectively, an end view, a side view, and a top view of an aerosol generating article (400) according to a fourth embodiment of the present disclosure. The aerosol generating article (400) comprises a planar upper layer (410), a planar lower layer (420), and an intermediate or separating layer (440) arranged between the upper layer (410) and the lower layer (420).

[0165] The flat upper layer (410) is formed from a sheet of paper having a thickness of 300 microns. The flat lower layer (420) is formed from a sheet of paper having a thickness of 300 microns. The sheets of paper defining the upper and lower layers (410, 420) each contain a polymer film, so that each layer (410, 420) is essentially impermeable to the passage of water or air. The intermediate layer (440) is a wavy element formed from a wavy sheet of an aerosol-forming substrate (445). A suitable aerosol-forming substrate may be a homogenized tobacco. Thus, the intermediate layer (440) may be formed from a wavy sheet of a homogenized tobacco material (445).

[0166] FIG. 10 illustrates a wavy sheet of an aerosol-forming substrate (445). The wavy folds have an amplitude (446) of 3 millimeters and a wavelength (447) of 3 millimeters. The sheet of the aerosol-forming substrate (445) forming the intermediate layer (440) has a thickness of 150 microns.

[0167] The intersections (451, 452) between the upper layer (410) and the middle layer (440) and between the lower layer (420) and the middle layer (440) contain an adhesive that bonds each layer.

[0168] The aerosol generating article (400) has a length of 80 millimeters extending in the x dimension, a width of 15 millimeters extending in the y dimension, and a height (or thickness) of 3.6 millimeters extending in the z dimension.

[0169] The wavy folds of the middle layer (440) form a first set of longitudinally extending channels (461) bounded by the upper layer (410) and the middle layer (440), and a second set of longitudinally extending channels (462) bounded by the lower layer (420) and the middle layer (440). The first and second sets of longitudinally extending channels (461, 462) extend through the length of the aerosol-forming substrate between the proximal end (471) of the substrate (445) and the distal end (472) of the substrate (445).

[0170] FIG. 8 illustrates an unperforated aerosol generating article (400) in which a hermetic seal is maintained between the inside and outside of the aerosol generating article. First and second regions (411, 412) (shown as dashed outlines in FIG. 8) are predetermined regions of the upper layer (410) intended to be subsequently perforated to break the hermetic seal before starting a session of use with the aerosol generating article (400). The first and second regions (411, 412) are circular and are symmetrically spaced from each other on the upper layer (410) along the longitudinal direction (i.e., x-direction) of the aerosol generating article (400). The upper layer (410) may have a uniform thickness, but in an alternative embodiment, the score line may be defined along the periphery of the predetermined first and second regions (411, 412) to reduce the force required to rupture the upper layer (410) and / or ensure that the upper layer (410) ruptures along a desired path (defined by the score line). In this alternative embodiment, the dashed outline shown in FIG. 8 for the predetermined circular first and second regions (411, 412) of the upper layer (410) will represent the score line.

[0171] As illustrated in FIG. 9, perforation of the upper layer (410) centered on the periphery of the predetermined circular first and second regions (411, 412) results in circular first and second openings (414, 415) being defined through the upper layer. The perforated state of the aerosol generating article (400) illustrated in FIG. 9 is suitable for initiating a use session using the article. The first and second openings (414, 415) define the air inlet and air outlet of the aerosol generating article (400), and the openings are located over one or more of the first set of longitudinally extending channels (461). The arrows in FIG. 9 indicate the path through which air is taken out of the air outlet (415) along the airflow path (417) defined through the interior of the aerosol generating article (400) into the air inlet (414). A longitudinally extending channel (461) defines an airflow path through the substrate (445). The porosity of the aerosol-generating article (400) along the airflow path is in the 90% region. This provides a very low resistance to suction (RTD) of less than 5 mm H2O. In fact, the RTD is close to 0.

[0172] In an alternative embodiment of FIGS. 8 and 9, two predetermined circular regions (not shown) may be defined within the lower layer (420) to complement the predetermined first and second circular regions (411, 412) defined within the upper layer (410). Perforations in the two predetermined regions in the lower layer (420) will provide third and fourth air openings (not shown) through the lower layer. Thus, in this alternative embodiment, perforations in the upper and lower layers (410, 420) at the locations of the predetermined circular regions will provide an airflow path passing through both sides of the sheet of the aerosol-forming substrate (445). Additionally, the porosity of the aerosol-generating article along the airflow path is in the 90% area. This provides a very low resistance to suction (RTD) of less than 5 mm H2O. In practice, the RTD is close to zero.

[0173] The aerosol-forming substrate (445) may be a sheet of any suitable aerosol-forming substrate.

[0174] During use of an aerosol generating article (400) (including an alternative embodiment discussed in the previous paragraph), the aerosol forming substrate (445) is heated to cause the aerosol forming substrate (445) to release a volatile compound, which is then entrained in air drawn into the channel (461) through the distal end (472) (and into the channel (462) for the alternative embodiment discussed above). Then, the volatile compound is cooled and condensed to form an aerosol that can be drawn from the channels (461, 462) of the aerosol generating article (400) through the proximal end (471).

[0175] FIG. 11 illustrates an aerosol generating article (500) according to a fifth embodiment of the present disclosure. The aerosol generating article (500) comprises a first planar outer layer (524) forming a first planar outer surface (521), a second planar outer layer (525) forming a second planar outer surface (522), and a frame (550) positioned between the first planar outer layer (524) and the second planar outer layer (525). The second planar outer surface (522) is positioned parallel to the first planar outer surface (521). First and second score lines (511, 512) are defined within the first planar outer surface (521) of the first planar outer layer (524). Neither of the first and second score lines (511, 512) penetrates the entire thickness of the first planar outer layer (524), thereby maintaining a hermetic seal between the inside and outside of the aerosol generating article (500). Rather, the first and second score lines (511, 512) define predetermined first and second regions of the first planar outer layer (524) adapted to be perforated to define respective air openings (514, 515) through the layer (524). The score lines (511, 512) reduce the force required to perforate the layer (524) and / or ensure that the layer (524) is perforated along a desired path (defined by the score lines (511, 512)). However, it will be understood that in optional and alternative embodiments, the score lines may not be present. The aerosol generating article (500) of Fig. 11 is in an unperforated state.

[0176] As illustrated in FIG. 12, perforations in the first planar outer layer (524) along each of the circular score lines (511, 512) result in first and second openings (514, 515) being defined through the first planar outer layer. The perforated state of the aerosol generating article (500) illustrated in FIG. 12 is suitable for initiating a use session using the article. The first and second openings (513, 514) define the air inlet and air outlet of the aerosol generating article (500). The arrows in FIG. 12 indicate the path through which air is taken out of the air outlet (515) along the airflow path (517) defined through the interior of the aerosol generating article (500) into the air inlet (514). The airflow path (517) extends through the cavity (530) of the aerosol generating article (500).

[0177] FIGS. 13 and 14 illustrate exploded views of the aerosol generating article (500) of FIG. 11, which is a drawing of the aerosol generating article (500) in an unperforated state of FIG. 11. A frame (550) surrounds and defines at least partially the cavity (530). FIG. 13 illustrates the cavity (531) in an empty state. FIG. 14 illustrates the cavity (530) filled with an aerosol forming substrate (540). FIGS. 15 and 16 illustrate the respective cross-sectional and longitudinal views of the aerosol generating article (500) when the cavity (530) is filled with the aerosol forming substrate (540).

[0178] The first planar outer layer (524) and the second planar outer layer (525) are manufactured from cigarette paper having a thickness of 35 micrometers and are physically in contact with and bonded to the frame (550). The cigarette paper defining the first and second planar outer layers (524, 525) each includes a polymer coating to make each layer (510, 520) essentially impermeable to water or air. The first planar outer layer (524) is placed over the first end of the cavity (530) and forms the first cavity end wall (531). The second planar outer layer (525) is placed over the second end of the cavity (530) and forms the second cavity end wall (532), the second cavity end wall (532) facing the first cavity end wall (531). That is, the frame (550), the first planar outer layer (524), and the second planar outer layer (525) collectively define the cavity (530).

[0179] The frame (550) has a hollow rectangular shape and is manufactured from cardboard. The frame (550) defines an aperture that extends through the height (also referred to as thickness) of the frame (550), and the aperture forms at least partially the cavity (530) of the aerosol generating article (500). The frame (550) includes a periphery wall surface (551) surrounding the cavity (530). The periphery wall (551) includes a front wall (552) and a rear wall (553). More specifically, the periphery wall (551) is defined by an inner transverse surface (554) of the frame (550) and an outer transverse surface (555) of the frame (550). The inner transverse surface (554) of the periphery wall (551) defines at least partially the periphery of the cavity (530). The outer transverse surface (555) of the periphery wall (551) defines at least partially the periphery of the aerosol generating article (500). The periphery wall (551) has a radial thickness of about 5 millimeters measured between the inner transverse surface (554) of the frame (550) and the outer transverse surface (555) of the frame (550).

[0180] As illustrated in FIGS. 14 to 16, an aerosol-forming substrate (540) is positioned within the cavity (530). The aerosol-forming substrate (540) comprises an aerosol-generating material in the form of a tobacco stick and has an aerosol-forming agent content of 5 weight percent based on dry weight. As illustrated, the aerosol-forming substrate (540) fills the entire volume of the cavity (530).

[0181] The aerosol generating article (500) has a rectangular shape and, as measured between the first planar outer surface (521) and the second planar outer surface (522), has a height (or thickness) of 8 millimeters extending in the z-dimension, a width of 40 millimeters extending in the y-dimension, and a length of 60 millimeters extending in the x-dimension. The frame (550) has a height (or thickness) of 7.93 millimeters extending in the z-dimension, a width of 40 millimeters extending in the y-dimension, and a length of 60 millimeters extending in the x-dimension. The cavity (530) has a height (or thickness) of 7.93 millimeters extending in the z-dimension, a width of 30 millimeters extending in the y-dimension, and a length of 50 millimeters extending in the x-dimension.

[0182] FIG. 17 illustrates an aerosol generating article (600) according to the sixth embodiment of the present disclosure in an unperforated state. Features common to the aerosol generating article (500) are referred to by similar reference numerals, but start with the number 6 instead of the number 5. The aerosol generating article (600) differs from the aerosol generating article (500) in that the aerosol forming substrate is in the form of a sheet of aerosol generating material (640), in particular a wavy sheet of homogenized tobacco material. FIG. 19 and FIG. 20 illustrate a cross-sectional view and a lateral cross-sectional view, respectively, of the aerosol generating article (600) of FIG. 17 / 18.

[0183] As illustrated in FIG. 17, the first and second score lines (611, 612) are defined on the first planar outer surface (621) of the first planar outer layer (624). The score lines (611, 612) extend only partially through the thickness of the first planar outer layer (624), thereby maintaining a hermetic seal between the inside and outside of the aerosol generating article (600). Additionally, it will be understood that in an optional and alternative embodiment, the score lines may not be present. The aerosol generating article (600) of FIG. 17 is in an unperforated state.

[0184] As illustrated in FIG. 18, perforations in the first planar outer layer (624) around each of the circular score lines (611, 612) result in first and second openings (614, 615) being defined through the first planar outer layer. The perforated state of the aerosol generating article (600) illustrated in FIG. 18 is suitable for initiating a use session using the article. The first and second openings (614, 615) define the air inlet and air outlet of the aerosol generating article (600), respectively. The arrows in FIG. 18 indicate the path through which air is taken out of the air outlet (615) along the airflow path (617) defined through the interior of the aerosol generating article (600) into the air inlet (614).

[0185] The wavy sheet of the homogenized tobacco material (640) comprises a plurality of parallel wavy lines having a plurality of substantially parallel peaks (643) and troughs (644). The plurality of parallel wavy lines are defined by a sinusoidal wavy line profile as shown in FIG. 19. The plurality of parallel wavy lines have a wavy line wavelength of about 4.6 millimeters. The wavy line amplitude is approximately equal to the height (or thickness) of the cavity (630), as shown by the peaks (643) and troughs (644) coinciding with the first cavity end wall (631) and the second cavity end wall (632), respectively.

[0186] A plurality of parallel wavy folds form a plurality of channels (645) between the sheet of aerosol generating material (640) and the first cavity end wall (631), and form a plurality of channels (646) between the sheet of aerosol generating material (640) and the second cavity end wall (632). The plurality of channels (645, 646) extend in the longitudinal direction of the aerosol generating article (600). An airflow path (617) defined by a perforation in the first planar outer layer (624) extends along one or more of the channels (645).

[0187] In an alternative embodiment of FIG. 17, third and fourth score lines (not shown) may be defined within a second planar outer layer (625) to complement the first and second score lines (611, 612) defined within the first planar outer layer (624). Perforations of the third and fourth score lines in the second planar outer layer (625) will provide third and fourth air openings (not shown) through the second layer. In this alternative embodiment, perforations in the first and second planar outer layers (624, 625) at the locations of the score lines defined within both layers will provide an airflow path passing through both sides of the sheet of aerosol generating material (640).

[0188] During the use of each aerosol generating article (500, 600), the aerosol forming material (540, 640) is heated to cause the aerosol forming material (540, 640) to release volatile compounds, which are then entrained in air drawn into the cavity (530, 630) through the air inlet (514, 614). Then, the volatile compounds are cooled and condensed to form an aerosol, which can be drawn from the aerosol generating article (500, 600) through the air outlet (515, 615).

[0189] FIG. 21 illustrates an aerosol generating article (700) according to the seventh embodiment of the present disclosure in an unperforated state. The aerosol generating article (700) shares common features with the aerosol generating article (500) illustrated in FIG. 13. In particular, the aerosol generating article (700) comprises a first planar outer layer (724) forming a first planar outer surface (721), a second planar outer layer (725) forming a second planar outer surface (722), and a frame (750) positioned between the first planar outer layer (724) and the second planar outer layer (725). The second planar outer surface (722) is positioned parallel to the first planar outer surface (721). First and second score lines (711, 712) are defined within the first planar outer surface (721) of the first planar outer layer (724). The frame (750) includes first and second cuts (756, 757), the first and second cuts being positioned adjacent to and in fluid communication with the opposite end of the cavity (730) defined by the frame (750). The cuts (756, 757) are each sized to accommodate a capsule containing one or more of a fragrance formulation and an aerosol-forming substrate so that the capsule (760) fits snugly within each cut. First and second score lines (711, 712) are positioned over the cuts. The capsule (760) is formed from a brittle material so that when the first and second score lines (711, 712) are perforated by a cutting tool, the cutting tool also comes into contact with the capsule and breaks the capsule, thereby releasing the fragrance compound and / or the aerosol-forming substrate. For example, the capsule (760) may be formed from a plastic material.

[0190] FIGS. 22 and 23 illustrate an aerosol generating device (8000) configured for use with an aerosol generating article (800) comprising or composed of an aerosol forming substrate (840). The device (8000) is an elongated aerosol generating device extending between a proximal end (8001) and a distal end (8002). The device (8000) includes a battery (8010), a controller (8020), and a heater (8030) located within a housing (8040). The controller (8020) controls the supply of power from the battery (8010) to the heater (8030). A cavity (8050) is defined within the device (8000), and the cavity has an opening (8051) defined within the proximal end (8001) of the device. The opening (8051) is rectangular in shape and is dimensioned to accommodate a cross section of the aerosol generating article (800). The cavity (8050) includes an upper planar surface (8052) and a lower planar surface (8053). A heater (8030) is located within the lower planar surface (8053) to heat the lower surface of the aerosol generating article (800) inserted into the cavity (8050). An airflow path is configured to allow air to flow from outside the device (8000) into the cavity (8050).

[0191] FIG. 24 illustrates the device (8000) of FIG. 22 engaging with the aerosol generating article (800). There is almost no tolerance between the outer surface of the aerosol generating article (800) and the inner surface of the cavity (8050). Therefore, there is a tight fit between the aerosol generating article (800) and the device (8000). Since the RTD of the aerosol generating article (800) can be ignored, the RTD of the system formed by the combination of the aerosol generating article (800) and the aerosol generating device (8000) is controlled by an airflow path defined within the device. When a user inserts the aerosol generating article (800) into the cavity (8050), the device (8000) can be activated. A heater (8030) heats the lower surface of the aerosol generating article (800), and as a result, the aerosol forming substrate (840) of the aerosol generating article (800) is heated. The volatile component of the aerosol-forming substrate (840) evaporates and condenses in a longitudinal airflow channel defined within the aerosol-generating article (800) to form an aerosol. The user inhales the aerosol by inhaling the proximal end (801) of the aerosol-generating article (800). When the volatile component in the aerosol-generating substrate (840) of the aerosol-generating article (800) is depleted, the aerosol-generating article is removed from the cavity (8050) of the device (8000) and disposed of. The aerosol-generating article (800) may be any one of the aerosol-generating articles (100, 200, 300, 400, 500, 600, 700) previously described in this disclosure or any other aerosol-generating article.

[0192] FIG. 24 illustrates a portion of an aerosol generating article (800) extending outward from an aerosol generating device (8000), but in other embodiments, the entire aerosol generating article may be completely enclosed within the aerosol generating device. As an example, FIG. 25 illustrates an alternative embodiment of FIG. 24, in which similar features are referred to by the same reference numeral but with the addition of the prime symbol '. For the alternative embodiment of FIG. 25, the entire aerosol generating article (800') is enclosed within the aerosol generating device (8000').

[0193] 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 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 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 generating an aerosol by use with an aerosol generating device, wherein the aerosol generating article comprises: an upper outer surface; a lower outer surface; and an aerosol forming substrate hermetically isolated from an environment outside the aerosol generating article; wherein the aerosol generating article is defined by a length extending in the x direction, a width extending in the y direction, and a height extending in the z direction, wherein the upper and lower outer surfaces are opposite and separated from each other in the z direction, and the height is smaller than the width and the length, respectively. Claim 2 An aerosol generating article according to claim 1, further comprising a cavity disposed between the upper outer surface and the lower outer surface. Claim 3 In paragraph 2, the aerosol generating article further comprises a frame disposed between the upper outer surface and the lower outer surface, wherein the frame defines at least partially the cavity. Claim 4 In any one of claims 1 to 3, the aerosol generating article is an aerosol generating article having an unperforated state in which there is no air opening defining an airflow path through the aerosol generating article. Claim 5 In paragraph 4, at least one of the upper and lower outer surfaces comprises one or more predetermined regions, and the one or more predetermined regions are configured to be perforated to define one or more air openings penetrating the perforated state of the aerosol generating article. Claim 6 In paragraph 5, in the perforated state, the one or more openings form part of an airflow path through the aerosol generating article, preferably the airflow path is a cavity disposed between the upper outer surface and the lower outer surface or extends through the cavity, the aerosol generating article. Claim 7 An aerosol generating article according to claim 5 or 6, wherein one or more predetermined regions of the upper and / or lower outer surface include a weakening feature, preferably the weakening feature includes a region of local thinning and / or score lines of the upper and / or lower outer surface. Claim 8 An aerosol generating article according to any one of claims 5 to 7, wherein at least one first predetermined area among the upper and lower outer surfaces is configured to be perforated to define an air inlet opening of the aerosol generating article; and at least one second predetermined area among the upper and lower outer surfaces is configured to be perforated to define an air outlet opening of the aerosol generating article. Claim 9 In paragraph 8, the first and second predetermined regions are positioned symmetrically with respect to each other along the longitudinal direction of the aerosol generating article. Claim 10 An aerosol generating article, wherein, in claim 8 or 9, the first and second predetermined regions are positioned symmetrically with respect to each other along the width direction of the aerosol generating article. Claim 11 An aerosol generating article according to any one of claims 8 to 10, further comprising a frame disposed between the upper outer surface and the lower outer surface, wherein the frame at least partially defines a cavity, and the frame comprises one or more incisions located adjacent to first and second predetermined regions of the upper and / or lower outer surface, preferably wherein the one or more incisions are fluidly communicating with the cavity. Claim 12 An aerosol generating device according to claim 11, wherein at least a portion of the aerosol-forming substrate is located within one or more of the incisions. Claim 13 An aerosol generating article according to claim 11 or 12, comprising one or more brittle capsules accommodated within one or more incisions. Claim 14 An aerosol generating article according to any one of claims 1 to 13, wherein the upper and lower outer surfaces are substantially flat. Claim 15 An aerosol generating article according to any one of claims 1 to 13, wherein the upper and lower outer surfaces are outwardly convex.

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