Aerosol generating article including a subframe
Patent Information
- Authority / Receiving Office
- KR · KR
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-12-17
- Publication Date
- 2026-08-12
Smart Images
Figure PCT00008_ABST
Abstract
Description
Technology Field
[0001] The present disclosure relates to an aerosol generating article. The present disclosure also relates to an aerosol generating system comprising an aerosol generating article and an aerosol generating device. The present disclosure also relates to a method for manufacturing an aerosol generating article. Background Technology
[0002] A conventional aerosol generating system comprises an aerosol generating device and an aerosol generating article comprising an aerosol generating substrate. In use, the aerosol generating device is arranged to heat a heating element positioned near or in contact with the aerosol generating substrate, causing the aerosol generating substrate to heat and release volatile compounds. These volatile compounds are then entrained into air drawn through the aerosol generating article. As the released compounds cool, they condense to form an aerosol that can be inhaled by a consumer.
[0003] Conventional aerosol generating articles may look similar to conventional cigarettes and may have similar dimensions. For example, such aerosol generating articles may be substantially cylindrical and may include an aerosol generating material in addition to other components such as a mouthpiece filter element and a cooling element arranged in the form of rods and wrapped in cigarette paper.
[0004] However, a significant portion of the aerosol generating material within these cylindrical aerosol generating articles may not be heated sufficiently to form an aerosol during use. This is undesirable because the insufficiently heated portion of the aerosol generating material contributes to the manufacturing and transportation costs of the aerosol generating article but does not contribute to the aerosol delivered to the consumer. Additionally, the components of these cylindrical aerosol generating articles generally need to have the same or very similar outer diameters so that they can be joined, positioned accurately in axial alignment, and wrapped in cigarette paper. This can increase manufacturing costs and complexity.
[0005] The object of the present disclosure is to provide an aerosol generating article in which a larger portion of the aerosol generating material is heated sufficiently to form an aerosol during use. Additionally, the object of the present disclosure is to provide an aerosol generating article that can be manufactured relatively efficiently and at a low cost.
[0006] According to the present disclosure, an aerosol generating article is provided. The aerosol generating article is intended to be used in conjunction with an aerosol generating device to generate an aerosol. The aerosol generating article comprises a first planar outer surface and a second planar outer surface. The aerosol generating article comprises a cavity and one or more aerosol generating substrates located within the cavity. The aerosol generating article comprises an air inlet, an air outlet, and a frame that at least partially defines the cavity, the air inlet, and the air outlet. The frame comprises a first subframe and a second subframe connected to the first subframe.
[0007] Advantageously, the frame can make the aerosol-generating article relatively thin while maintaining structural rigidity.
[0008] Advantageously, the first planar outer surface and the second planar outer surface allow good contact with an external heater, in particular with an external heater of an aerosol generating device, thereby providing optimal heating of the aerosol generating substrate.
[0009] Advantageously, the aerosol generating article of the present disclosure can be heated substantially along its entire length and width, thereby allowing the entire aerosol generating material to be heated sufficiently to generate an aerosol.
[0010] Advantageously, the aerosol generating article of the present disclosure can be manufactured by laminating sheet materials that can be achieved through a continuous manufacturing process, thereby making the aerosol generating article relatively easy and inexpensive to manufacture.
[0011] Advantageously, forming a frame with first and second subframes facilitates the construction of a frame having a complex geometric structure while maintaining a frame that is relatively easy and inexpensive to manufacture.
[0012] Advantageously, forming a frame from the first and second subframes can facilitate the production of multiple frames or multiple aerosol-generating articles from a series of repeating subunits that reduce waste and produce aerosol-generating articles that are relatively easy and inexpensive to manufacture.
[0013] Preferably, the first subframe is identical to the second subframe. Advantageously, providing identical first and second subframes can reduce waste and produce aerosol-generating articles that are relatively easy and inexpensive to manufacture.
[0014] An air inlet may be defined by a first subframe, and an air outlet may be defined by a second subframe. The air inlet may include one or more inlet apertures extending through a portion of the first subframe. The air outlet may include one or more outlet apertures extending through a portion of the second subframe.
[0015] The first subframe is spaced apart from the second subframe, so that a cavity can be defined at least partially between the first subframe and the second subframe.
[0016] The frame may include a first side portion extending from a first subframe to a second subframe, and a second side portion extending from the first subframe to the second subframe. Advantageously, providing the first and second side portions to the frame can facilitate connecting the first subframe to the second subframe in a spaced manner to define a cavity at least partially. Advantageously, forming the frame from the first and second subframes and the first and second side portions can facilitate the manufacture of a frame having a relatively complex shape from individual parts, each having a relatively simple shape.
[0017] The first side portion may be formed separately from the first subframe and the second subframe. The first side portion may be directly connected to the first subframe and the second subframe. The second side portion may be formed separately from the first subframe and the second subframe. The second side portion may be directly connected to the first subframe and the second subframe. The second side portion may be spaced apart from the first side portion to define a cavity at least partially between the first side portion and the second side portion.
[0018] The first subframe may at least partially define the first end of the aerosol-generating article. An air inlet may be located at the first end of the aerosol-generating article.
[0019] The second subframe may at least partially define the second end of the aerosol-generating article. An air outlet may be located at the second end of the aerosol-generating article.
[0020] The first subframe may include a body portion defining a chamber and a first opening at a first end of the chamber. The first subframe may include a first flap formed integrally with the body portion and a second flap formed integrally with the body portion. Each of the first flap and the second flap may be positioned over a second end of the chamber, and the first flap and the second flap together define a second opening at the second end of the chamber. The first opening may form an air inlet, and the second opening may provide fluid communication between the chamber and the cavity. Alternatively, the second opening may form an air inlet, and the first opening may provide fluid communication between the chamber and the cavity. Advantageously, the first and second flaps may facilitate the formation of the second opening in a desired cross-sectional shape. Advantageously, this may provide a desired suction resistance for the aerosol generating article.
[0021] The second subframe may include a body portion defining the chamber and a first opening at a first end of the chamber. The second subframe may include a first flap formed integrally with the body portion and a second flap formed integrally with the body portion. Each of the first flap and the second flap may be positioned over a second end of the chamber, and the first flap and the second flap together define a second opening at the second end of the chamber. The first opening may form an air outlet, and the second opening may provide fluid communication between the chamber and the cavity. Alternatively, the second opening may form an air outlet, and the first opening may provide fluid communication between the chamber and the cavity. Advantageously, the first and second flaps may facilitate the formation of the second opening in a desired cross-sectional shape. Advantageously, this may provide a desired suction resistance for the aerosol generating article.
[0022] The aerosol generating article may define a longitudinal direction extending from an air inlet to an air outlet. Each of the first subframe, the second subframe, and the cavity may have a length extending in the longitudinal direction. Preferably, the length of the first subframe is equal to the length of the second subframe, and the length of the cavity is an integer multiple of the length of the first subframe.
[0023] Advantageously, by providing a length that is an integer multiple of the lengths of the first and second subframes, it is possible to reduce waste and facilitate the production of multiple aerosol generating articles from a series of repeating subunits that produce aerosol generating articles that are relatively easy and inexpensive to manufacture.
[0024] Each of the first subframe and the second subframe may be in the form of a tube. Each of the first subframe and the second subframe may define a first opening at a first end of the subframe, a second opening at a second end of the subframe, and an airflow passage extending between the first opening and the second opening. The first opening of the first subframe may form an air inlet. The first opening of the second subframe may form an air outlet. Preferably, each of the first opening, the second opening, and the airflow passage has the same cross-sectional size and shape, and optionally, the tube has a rectangular cross-sectional shape.
[0025] Each of the first subframe and the second subframe may include a first part and a second part, wherein the first part is formed separately from the second part and the first part is placed on top of the second part. Each of the first part and the second part may have an L-shaped cross-sectional shape.
[0026] Each of the first subframe and the second subframe may be formed from a folded sheet material. The folded sheet material may be folded along three fold lines so that each of the first subframe and the second subframe has a rectangular cross-sectional shape.
[0027] A first subframe may partially define an air inlet and an air outlet. A second subframe may partially define an air inlet and an air outlet. The first subframe and the second subframe may together define an air inlet. The first subframe and the second subframe may together define an air outlet. Advantageously, if the first and second subframes provide a frame in which the air inlet and air outlet are each defined together, it may be easy to form a frame having a relatively complex configuration from the first and second subframes, each having a relatively simple configuration.
[0028] The aerosol generating article may include a first end and a second end, wherein each of the first subframe and the second subframe may extend between the first end and the second end.
[0029] The first subframe may include at least one first protrusion and at least one first recess, and the second subframe may include at least one second protrusion and at least one second recess, each first protrusion being received within the second recess and each second protrusion being received within the first recess. Advantageously, the first and second protrusions and recesses may provide an interlocking connection to the first and second subframes. Advantageously, the interlocking connection may facilitate the correct positioning of the second subframe relative to the first subframe during the manufacture of an aerosol-generating article. Advantageously, the interlocking connection may facilitate the rigid connection of the second subframe to the first subframe.
[0030] The cavity may have a hexagonal shape. The hexagonal shape may be a rounded hexagonal shape. Each of the first subframe and the second subframe may define half of a hexagonal shape or a rounded hexagonal shape.
[0031] The first subframe and the second subframe may be connected to each other at the first and second ends of the aerosol generating article. Each of the first subframe and the second subframe may define a half extending in the longitudinal direction of a hexagonal shape or a rounded hexagonal shape.
[0032] The first subframe and the second subframe may be connected to each other on the first and second sides of the aerosol generating article. Each of the first subframe and the second subframe may define a laterally extending half of a hexagonal shape or a rounded hexagonal shape.
[0033] At least a portion of each of the first subframe and the second subframe may have an L-shaped cross-sectional shape. The first subframe may include a first aperture extending through the first subframe, and the second subframe may include a second aperture extending through the second subframe. The first subframe may be placed over the second subframe so that the first aperture and the second aperture work together to define a cavity at least partially.
[0034] Each of the first subframe and the second subframe may be formed from a compressed particulate material. Advantageously, forming each of the first subframe and the second subframe from a compressed particulate material may provide the desired mechanical strength to each of the first and second subframes. Advantageously, forming each of the first subframe and the second subframe from a compressed particulate material may facilitate the production of the first and second subframes using a pressure molding process. Advantageously, the pressure molding process may facilitate the formation of the first and second subframes having relatively complex shapes. Suitable particulate materials may include those used in the pharmaceutical industry to form compressed tablets. Suitable particulate materials may include at least one of sorbitol, erythritol, and other sugar-like materials. Suitable particulate materials may include at least one cellulose material, such as wood-based particles.
[0035] At least one of the first subframe and the second subframe may contain a flavoring agent. Advantageously, incorporating the flavoring agent into the compressed particulate material may facilitate the delivery of the flavoring agent to the consumer during use of the aerosol generating article. Advantageously, incorporating the flavoring agent into the compressed material may facilitate the separation of the flavoring agent from one or more aerosol generating substrates within the cavity. Advantageously, separating the flavoring agent from one or more aerosol generating substrates may reduce or eliminate the reaction between the flavoring agent and one or more components of the aerosol generating substrates before use of the aerosol generating article.
[0036] According to the present disclosure, an aerosol generating system is provided comprising an aerosol generating article according to any one of the embodiments or embodiments described herein. The aerosol generating system also comprises an aerosol generating device, wherein the aerosol generating device suitable for use with an aerosol generating article as described herein comprises a chamber for receiving at least a portion of the aerosol generating article and an electric heater arranged to heat at least a portion of the aerosol generating article when the aerosol generating article is received within the chamber.
[0037] Preferably, the aerosol generating device includes a controller for controlling the power supply to a heater. Preferably, the aerosol generating device is configured to heat at least one of one or more aerosol generating substrates to form an aerosol, e.g., an inhalable aerosol. The aerosol generating device may be configured to heat each of one or more aerosol generating substrates to form an aerosol, e.g., an inhalable aerosol.
[0038] According to the present disclosure, a method for forming an aerosol generating article for use with an aerosol generating device to generate an aerosol is also provided. The method comprises the step of providing a plurality of subframes, wherein each subframe has a tubular shape and each subframe has the same length. The method comprises the step of positioning the first and second of the subframes such that the second subframe is spaced apart from the first subframe by a spacing distance, wherein the spacing distance is an integer multiple of the length of each subframe. The method comprises the step of providing a first side portion and a second side portion, wherein each of the first side portion and the second side portion has a length equal to the sum of the length of the first subframe, the length of the second subframe, and the spacing distance. The method comprises the step of positioning one or more aerosol generating materials between the first subframe and the second subframe. The above method includes the step of forming a frame by fixing each of the first side portion and the second side portion to both the first subframe and the second subframe, wherein the frame defines at least partially a cavity between the first subframe, the second subframe, the first side portion, and the second side portion, and one or more aerosol generating materials are located within the cavity, and the frame and the one or more aerosol generating materials together form an aerosol generating article.
[0039] Advantageously, forming a frame with first and second subframes facilitates the construction of a frame having a complex geometric structure while maintaining a frame that is relatively easy and inexpensive to manufacture.
[0040] Advantageously, forming a frame with first and second subframes having the same length and spaced apart from each other by an integer multiple of the lengths of the first and second subframes facilitates the production of multiple aerosol generating articles from a series of repeating subunits, which reduces waste and produces aerosol generating articles that are relatively easy and inexpensive to manufacture.
[0041] Preferably, the tubular shape of the first subframe defines an air inlet for an aerosol generating article, and the tubular shape of the second subframe defines an air outlet for an aerosol generating article.
[0042] Preferably, the step of providing a plurality of subframes includes the step of providing a series of subframes, wherein consecutive subframes of the series of subframes are in contact with each other, and the first subframe and the second subframe are discontinuous subframes. Advantageously, providing a series of subframes in contact with each other facilitates an accurate spacing between the first and second subframes by an integer multiple of the lengths of the first and second subframes.
[0043] Preferably, the step of positioning the first and second subframes includes removing one or more subframes between the first subframe and the second subframe to form a space between the first subframe and the second subframe. Preferably, the aerosol generating article is the first aerosol generating article, and the method further includes the step of forming the second aerosol generating article using one or more subframes removed between the first subframe and the second subframe. Advantageously, using the removed subframes to form the second aerosol generating article can reduce or minimize waste material when forming the aerosol generating article.
[0044] Preferably, the step of providing a series of subframes includes the step of providing a continuous tubular substrate and the step of cutting the continuous tubular substrate to form a series of subframes.
[0045] Preferably, the step of providing a first side portion and a second side portion comprises: providing a first continuous side material and a second continuous side material; fixing the first continuous side material to a first subframe and a second subframe; fixing the second continuous side material to a first subframe and a second subframe; and cutting the first continuous side material and the second continuous side material to form the first side portion and the second side portion.
[0046] An aerosol generating article formed according to the above method may include any one of the features of an aerosol generating article according to the present disclosure, in accordance with any one of the embodiments and embodiments described herein.
[0047] According to the present disclosure, a method for forming an aerosol generating article for use with an aerosol generating device to generate an aerosol is also provided, the method comprising the step of providing a first subframe and a second subframe, wherein each of the first subframe and the second subframe is formed of compressed particulate material. The method comprises the step of fixing the first subframe to the second subframe to form a frame, wherein the frame defines at least partially a cavity, an air inlet, and an air outlet. The method comprises the step of positioning one or more aerosol generating materials within the cavity, wherein the frame and the one or more aerosol generating materials together form an aerosol generating article.
[0048] Advantageously, by forming the first subframe and the second subframe, respectively, with a compressed particulate material, the desired mechanical strength can be provided to each of the first and second subframes.
[0049] Suitable particulate materials may include those used in the pharmaceutical industry to form compressed tablets. Suitable particulate materials may include at least one of sorbitol, erythritol, and other sugar-like substances. Suitable particulate materials may include at least one cellulose material, such as wood-based particles.
[0050] Preferably, the step of providing a first subframe and a second subframe includes the step of press-molding the first subframe from a particulate material and the step of press-molding the second subframe from a particulate material.
[0051] Advantageously, pressure molding can facilitate the formation of first and second subframes having relatively complex shapes.
[0052] The compressed particulate material may contain a flavoring agent. Advantageously, incorporating the flavoring agent into the compressed particulate material can facilitate the delivery of the flavoring agent to the consumer during use of the aerosol generating article. Advantageously, incorporating the flavoring agent into the compressed material can facilitate the separation of the flavoring agent from one or more aerosol generating materials within the cavity. Advantageously, separating the flavoring agent from one or more aerosol generating materials can reduce or eliminate the reaction between the flavoring agent and one or more components of the aerosol generating material before use of the aerosol generating article.
[0053] A method according to the present disclosure for forming an aerosol-generating article may also include the step of machining a frame to smooth one or more joints between a first subframe and a second subframe. The machining may include at least one of sanding and milling.
[0054] The aerosol generating article may have a length extending in the x-direction. The aerosol generating article may have a width extending in the y-direction. The aerosol generating article may have a thickness extending in the z-direction.
[0055] The aerosol generating article may be a substantially flat aerosol generating article or a substantially planar aerosol generating article. In particular, the thickness of the aerosol generating article may be less than 50% of both the length and width of the aerosol generating article. Advantageously, a thinner thickness may provide a small temperature gradient or temperature difference across the thickness of the aerosol forming substrate during heating.
[0056] The aerosol generating article may have a quadrilateral cuboid shape. The aerosol generating article may have a right-angled prism shape. The aerosol generating article may have a rectangular prism shape. The aerosol generating article may have a cylindrical shape. The aerosol generating article may have a right-angled cylindrical shape.
[0057] The aerosol generating article may have a laminated structure, for example, the aerosol generating article may include or be formed of at least two layers. In particular, as discussed in more detail below, the aerosol generating article may include at least two of a first outer layer, a second outer layer, a frame, a first frame layer, a second frame layer, a third frame layer, a first aerosol generating substrate layer, and a second aerosol generating substrate layer.
[0058] A substantial portion of the aerosol-generating article, excluding one or more aerosol-generating materials and (if present) adhesive, may be paper or cardboard.
[0059] Aerosol-generating articles may have a cellulose acetate content of less than 5%. Aerosol-generating articles may have a cellulose acetate content of less than 3%. Aerosol-generating articles may have a cellulose acetate content of less than 1%.
[0060] The frame can be a flat frame.
[0061] The frame may define frame perforations that extend through the thickness of the frame. The frame perforations may define or form airflow passages for the aerosol-generating article. The frame perforations may define or form cavities for the aerosol-generating article. For example, the frame may have a hollow rectangular shape or a square hollow tube shape. As an additional embodiment, the frame may have a cross-section that is annular in shape, and preferably, the cross-section in the x / y plane is annular in shape.
[0062] The frame may include an outer surface of the frame. The outer surface of the frame may extend transversely, for example, between a first planar outer surface and a second planar outer surface. The outer surface of the frame may at least partially define or form one or more outer surfaces of an aerosol-generating article. For example, the outer surface of the frame may at least partially define or form one or more outer wall surfaces of an aerosol-generating article. The outer surface of the frame may surround or encircle a frame perforation. The outer surface of the frame may surround or encircle a cavity.
[0063] The frame may include an inner surface of the frame. The inner surface of the frame may extend transversely, for example, between a first planar outer surface and a second planar outer surface. The inner surface of the frame may define or form an outer wall of the frame aperture. The inner surface of the frame may define or form an outer wall of the cavity. The inner surface of the frame may surround or encircle a frame perforation extending through the thickness of the frame. The inner surface of the frame may surround or encircle a cavity.
[0064] The outer surface of the frame may surround or encircle the inner surface of the frame. The inner surface of the frame and the outer surface of the frame may be concentric with each other.
[0065] The aerosol generating article may include one or more outer wall surfaces extending between a first planar outer surface and a second planar outer surface. The one or more outer wall surfaces may collectively define the entire transverse outer area of the aerosol generating article. A frame may define at least partially each of the one or more outer wall surfaces. The one or more outer wall surfaces may surround or enclose a cavity. A frame may define at least 60%, at least 70%, at least 80%, or at least 90% of the entire transverse outer area of the aerosol generating article.
[0066] The frame may include surrounding walls. The surrounding walls may surround or encircle at least a portion of the frame opening extending through the thickness of the frame. The surrounding walls may surround or encircle at least a portion of the cavity. The surrounding walls may surround or encircle the frame opening extending through the thickness of the frame. The surrounding walls may surround or encircle the cavity.
[0067] The periphery wall surface may be defined or formed by the outer surface of the frame and the inner surface of the frame. The periphery wall surface may at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The periphery wall surface may define or form the outer wall surface of the frame perforation. The periphery wall surface may define or form the outer wall surface of the cavity.
[0068] The surrounding walls may have a radial thickness. The radial thickness can be defined, for example, as the minimum distance between the outer surface of the frame and the inner surface of the frame in the x / y plane.
[0069] The surrounding wall surface may have a radial thickness of 0.5 mm or more. The surrounding wall surface may have a radial thickness of 1.5 mm or more. The surrounding wall surface may have a radial thickness of 2.5 mm or more.
[0070] The surrounding wall surface may have a radial thickness of 3.5 mm or less. The surrounding wall surface may have a radial thickness of 2.5 mm or less.
[0071] The surrounding wall surface may have a radial thickness of 0.5 mm to 3.5 mm. The surrounding wall surface may have a radial thickness of 0.5 mm to 2.5 mm.
[0072] Advantageously, it has been found that a peripheral wall having a radial thickness of 0.5 mm to 3.5 mm provides good structural strength to an aerosol generating article without using an excess amount of material that can increase manufacturing costs and limit the amount of heat undesirably transferred to the frame rather than the aerosol generating substrate.
[0073] The frame may be manufactured from or contain biodegradable materials. The frame may be manufactured entirely from biodegradable materials.
[0074] The frame may be manufactured from or contain a cellulose material. The cellulose material may contain a sheet of cellulose material. The cellulose material may contain cellulose fibers. The cellulose material may be paper, cardboard, or cardboard. The frame may be manufactured from or contain a plant material such as tobacco. The frame may be manufactured entirely from a cellulose material.
[0075] The aerosol generating article may include one or more susceptor materials. The frame may include one or more susceptor materials. One or more susceptor materials may be in thermal contact with the aerosol generating substrate. One or more susceptor materials may be in thermal contact with the cavity. One or more susceptor materials may be incorporated within the material of the frame. For example, one or more susceptor materials may be incorporated within the peripheral wall surface of the frame.
[0076] One or more susceptor materials may be one or more particles, strips, threads, or wires of the susceptor material. One or more susceptor materials may be one or more sheets or layers of the susceptor material. One or more sheets or layers of the susceptor material may be in the form of a mesh of the susceptor material.
[0077] The susceptor material may comprise, in any form, one or more materials selected from the list consisting of aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.
[0078] The frame may have a thickness of 50% or more of the thickness of the aerosol-generating article. The frame may have a thickness of 70% or more of the thickness of the aerosol-generating article. The frame may have a thickness of 90% or more of the thickness of the aerosol-generating article. The frame may have a thickness of 95% or more of the thickness of the aerosol-generating article.
[0079] The frame may have a thickness of 95% or less of the thickness of the aerosol-generating article. The frame may have a thickness of 90% or less of the thickness of the aerosol-generating article. The frame may have a thickness of 70% or less of the thickness of the aerosol-generating article.
[0080] The frame may have a thickness of 50% to 95% of the thickness of the aerosol-generating article. The frame may have a thickness of 70% to 95% of the thickness of the aerosol-generating article.
[0081] The frame may have a thickness of 1 mm or more, 2 mm or more, 3 mm or more, or 4 mm or more. The frame may have a thickness of 5.5 mm or less, 4.5 mm or less, 3.5 mm or less, 2.5 mm or less, or 1.5 mm or less. The frame may have a thickness of 1 mm to 5.5 mm. Preferably, the frame may have a thickness of 1.5 mm to 5.5 mm.
[0082] The frame may have a length equal to the length of the aerosol-generating article. The frame may have a length of at least 90% of the length of the aerosol-generating article. The frame may have a length of at least 95% of the length of the aerosol-generating article.
[0083] The frame may have a width equal to the width of the aerosol-generating article. The frame may have a width that is at least 90% of the width of the aerosol-generating article.
[0084] The frame may be a single component. Alternatively, the frame may include two or more layers. That is, the frame may have a laminated structure. Advantageously, the characteristics of each layer may be individually optimized according to the relative distance between the layer and the aerosol generating substrate or heater of the aerosol generating device.
[0085] The frame may include a first frame layer and a second frame layer. The first frame layer and the second frame layer may be the only layers of the frame. That is, the frame may include two or fewer layers, or exactly two layers. Frame perforations may be defined through both the first frame layer and the second frame layer.
[0086] The frame may include a first frame layer, a second frame layer, and a third frame layer. The second frame layer may be located between the first frame layer and the third frame layer. The first frame layer, the second frame layer, and the third frame layer may be the only layers of the frame. That is, the frame may include three or fewer layers, or exactly three layers.
[0087] One or more aerosol generating substrates may include an aerosol generating substrate layer. Advantageously, the aerosol generating substrate layer may be made thin so as to rapidly heat and release a volatile compound to form an aerosol. Advantageously, the aerosol generating substrate layer may be located close to a heater of an aerosol generating device.
[0088] The aerosol generating substrate layer may comprise an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. The aerosol generating material may be in the form of a sheet of aerosol generating material. The sheet of aerosol generating material may be any sheet of aerosol generating material described herein. The aerosol generating substrate layer may be a sheet of aerosol generating material and may be manufactured entirely therefrom.
[0089] The aerosol generating substrate layer may be located between the frame and the first planar outer surface. The aerosol generating substrate layer may be located between the frame and the second planar outer surface. The aerosol generating substrate layer may be in physical contact with the frame and may be bonded to the frame.
[0090] The aerosol generating substrate layer may be positioned between the frame and the outer wrapper. The outer wrapper is discussed in more detail below. The aerosol generating substrate layer may physically contact both the frame and the outer wrapper and may be bonded thereto.
[0091] The aerosol generating substrate layer may be located between the frame and the first planar outer layer. The aerosol generating substrate layer may be located between the frame and the second planar outer layer. The first planar outer layer and the second planar outer layer are discussed in more detail below. The aerosol generating substrate layer may be in physical contact with both the frame and the first planar outer layer and may be bonded thereto. The aerosol generating substrate layer may be in physical contact with both the frame and the second planar outer layer and may be bonded thereto.
[0092] The aerosol generating substrate layer may be placed over the end of the cavity. The aerosol generating substrate layer may define or form a wall surface of the cavity, such as a first cavity end wall surface or a second cavity end wall surface. Accordingly, advantageously, the aerosol generating substrate layer may be within an airflow passage or may at least partially define or form an airflow passage, thereby enabling the released volatile compound to rapidly form an aerosol.
[0093] One or more aerosol generating substrates may include a first aerosol generating substrate layer and a second aerosol generating substrate layer. Advantageously, the first and second aerosol generating substrate layers can rapidly generate a satisfactory volume of aerosol compared to using a single aerosol generating substrate layer.
[0094] The first aerosol generating substrate may include an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. The aerosol generating material may be in the form of a sheet of aerosol generating material. The sheet of aerosol generating material may be any sheet of aerosol generating material described herein. The first aerosol generating substrate layer may be a sheet of aerosol generating material and may be manufactured entirely therefrom.
[0095] The second aerosol generating substrate layer may include an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. The aerosol generating material may be in the form of a sheet of aerosol generating material. The sheet of aerosol generating material may be any sheet of aerosol generating material described herein. The second aerosol generating substrate layer may be a sheet of aerosol generating material and may be manufactured entirely therefrom.
[0096] The first aerosol generating substrate layer may be located between the frame and the first planar outer surface. The first aerosol generating substrate layer may be in physical contact with the frame and may be bonded to the frame.
[0097] The first aerosol generating substrate layer may be located between the frame and the outer wrapper. The first aerosol generating substrate layer may physically contact both the frame and the outer wrapper and may be bonded thereto.
[0098] The first aerosol generating substrate layer may be located between the frame and the first planar outer layer. The first aerosol generating substrate layer may be in physical contact with both the frame and the first planar outer layer and may be bonded thereto.
[0099] The second aerosol generating substrate layer may be located between the frame and the second planar outer surface. The second aerosol generating substrate layer may be in physical contact with the frame and may be bonded to the frame.
[0100] The second aerosol generating substrate layer may be located between the frame and the outer wrapper. The second aerosol generating substrate layer may physically contact both the frame and the outer wrapper and may be bonded thereto.
[0101] The second aerosol generating substrate layer may be located between the frame and the second planar outer layer. The second aerosol generating substrate layer may be in physical contact with both the frame and the second planar outer layer and may be bonded thereto.
[0102] The first aerosol generating substrate layer and the second aerosol generating substrate layer may be placed on opposite ends of the cavity. The first aerosol generating substrate layer and the second aerosol generating substrate layer may define or form the wall surface of the opposite ends of the cavity. That is, the frame, the first aerosol generating substrate layer, and the second aerosol generating substrate layer may collectively define the cavity.
[0103] One or more of the aerosol generating substrate layer, the first aerosol generating substrate layer, and the second aerosol generating substrate layer may have a thickness of 100 μm or more, 200 μm or more, 300 μm or more, 400 μm or more, or 500 μm or more.
[0104] One or more of the aerosol generating substrate layer, the first aerosol generating substrate layer, and the second aerosol generating substrate layer may have a thickness of 600㎛ or less, 500㎛ or less, 400㎛ or less, 300㎛ or less, or 300㎛ or less.
[0105] One or more of the aerosol generating substrate layer, the first aerosol generating substrate layer, and the second aerosol generating substrate layer may have a thickness of 100 μm to 600 μm, 200 μm to 500 μm, 200 μm to 400 μm, or 200 μm to 300 μm.
[0106] The aerosol generating substrate layer may have a length substantially equal to the length of the frame. The aerosol generating substrate layer may have a length substantially equal to the length of the aerosol generating article.
[0107] The first aerosol generating substrate layer may have a length substantially equal to the length of the frame. The first aerosol generating substrate layer may have a length substantially equal to the length of the aerosol generating article.
[0108] The second aerosol generating substrate layer may have a length substantially equal to the length of the frame. The second aerosol generating substrate layer may have a length substantially equal to the length of the aerosol generating article.
[0109] The aerosol generating substrate layer may have a width substantially equal to the width of the frame. The aerosol generating substrate layer may have a width substantially equal to the width of the aerosol generating article.
[0110] The first aerosol generating substrate layer may have a width substantially equal to the width of the frame. The first aerosol generating substrate layer may have a width substantially equal to the width of the aerosol generating article.
[0111] The second aerosol generating substrate layer may have a width substantially equal to the width of the frame. The second aerosol generating substrate layer may have a width substantially equal to the width of the aerosol generating article.
[0112] The first planar outer surface may be a planar upper surface, and the second planar outer surface may be a planar lower surface. The first planar outer surface may be positioned parallel to the second planar outer surface. The first planar outer surface may extend in the x / y plane. The second planar outer surface may extend in the x / y plane. The second planar outer surface may be spaced apart from the first planar outer surface in the z direction or the transverse direction. The distance between the first planar outer surface and the second planar outer surface in the z direction or the transverse direction may define the thickness of the aerosol-generating article.
[0113] The aerosol-generating article may include an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may contain a hydrophobic material.
[0114] The outer wrapper may define or form a first planar outer surface. The outer wrapper may define or form a second planar outer surface. The outer wrapper may define or form both the first planar outer surface and the second planar outer surface.
[0115] The outer wrapper may surround or encircle the frame. The outer wrapper may physically contact the frame and may be bonded to the frame. The outer wrapper may be placed over the opposing end of the cavity. The outer wrapper may define or form opposing end walls of the cavity, such as a first cavity end wall and a second cavity end wall. That is, the frame and the outer wrapper may collectively define the cavity.
[0116] The outer wrapper may surround or encircle the frame and the aerosol generating substrate layer. The outer wrapper may physically contact both the frame and the aerosol generating substrate layer and may be bonded thereto.
[0117] The outer wrapper may surround or enclose the frame, the first aerosol generating substrate layer, and the second aerosol generating substrate layer. The outer wrapper may physically contact both the first aerosol generating substrate layer and the second aerosol generating substrate layer and may be bonded thereto.
[0118] The aerosol generating article may include a first planar outer layer and a second planar outer layer. The first planar outer layer may be an upper layer, and the second planar outer layer may be a lower layer.
[0119] The first planar outer layer may define or form a first planar outer surface. The first planar outer layer may extend in the x / y plane. The second planar outer layer may define or form a second planar outer surface. The second planar outer layer may extend in the x / y plane.
[0120] The first planar outer layer can physically contact the frame and can be bonded to the frame. The first planar outer layer can be placed over the end of the cavity. The first planar outer layer can define or form a wall surface of the cavity such as the wall surface of the first cavity end.
[0121] The second planar outer layer can physically contact the frame and can be bonded to the frame. The second planar outer layer can be placed over the end of the cavity. The second planar outer layer can define or form a wall surface of the cavity, such as the wall surface of the second cavity end.
[0122] The first planar outer layer and the second planar outer layer may be placed on the opposing ends of the cavity. The first planar outer layer and the second planar outer layer may define or form the opposing end walls of the cavity, such as the first cavity end wall and the second cavity end wall. That is, the frame, the first planar outer layer, and the second planar outer layer may collectively define the cavity.
[0123] The first planar outer layer may be spaced apart from the frame, for example, in the horizontal direction. For example, the aerosol generating substrate layer or the first aerosol generating substrate layer may be located between the first planar outer layer and the frame. The first planar outer layer may be in physical contact with the aerosol generating substrate layer or the first aerosol generating substrate layer and may be bonded thereto.
[0124] The second planar outer layer may be spaced apart from the frame, for example, in the horizontal direction. For example, the aerosol generating substrate layer or the second aerosol generating substrate layer may be located between the second planar outer layer and the frame. The second planar outer layer may physically contact the aerosol generating substrate layer or the second aerosol generating substrate layer and may be bonded thereto.
[0125] The first planar outer layer may be hydrophobic. The first planar outer layer may include a hydrophobic material. The second planar outer layer may be hydrophobic. The second planar outer layer may include a hydrophobic material.
[0126] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may comprise a cellulose-based material or be manufactured from this material. The cellulose material may be paper, cigarette paper, tobacco paper, cardboard, wood, fabric, natural fiber, or artificial fiber.
[0127] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may be an aerosol generating substrate comprising an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. In particular, the aerosol generating material may be in the form of a sheet of the aerosol generating material. The sheet of the aerosol generating material may be any sheet of the aerosol generating material described herein. Alternatively, one or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may not include any aerosol generating material, particularly in an embodiment comprising an aerosol generating substrate layer, a first aerosol generating substrate layer, a second aerosol generating substrate layer, or an aerosol generating substrate located within a cavity. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may be substantially nicotine-free.
[0128] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness of 25㎛ or more, 30㎛ or more, 35㎛ or more, 40㎛ or more, or 45㎛ or more.
[0129] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness of 55㎛ or less, 50㎛ or less, 45㎛ or less, 40㎛ or less, or 35㎛ or less.
[0130] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness of 25㎛ to 55㎛, 25㎛ to 45㎛, or 30㎛ to 45㎛.
[0131] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length substantially equal to the length of the frame. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length substantially equal to the length of the aerosol-generating article.
[0132] One or more of the first planar outer layer and the second planar outer layer may have a width substantially equal to the width of the frame. One or more of the first planar outer layer and the second planar outer layer may have a width substantially equal to the width of the aerosol-generating article.
[0133] The cavity may have a thickness of 0.5 mm or more. The cavity may have a thickness of 1.5 mm or more. The cavity may have a thickness of 2.5 mm or more. The cavity may have a thickness of 3.5 mm or more.
[0134] The cavity may have a thickness of 4.5 mm or less. The cavity may have a thickness of 3.5 mm or less. The cavity may have a thickness of 2.5 mm or less. The cavity may have a thickness of 1.5 mm or less.
[0135] The cavity may have a thickness of 0.5 mm to 4.5 mm. The cavity may have a thickness of 1 mm to 4.5 mm. Preferably, the cavity may have a thickness of 2.8 mm to 3.3 mm.
[0136] The cavity may have a length of 14 mm or more. The cavity may have a length of 18 mm or more. The cavity may have a length of 22 mm or more. The cavity may have a thickness of 30 mm or more. The cavity may have a thickness of 38 mm or more.
[0137] The cavity may have a length of 40 mm or less. The cavity may have a thickness of 34 mm or less. The cavity may have a thickness of 28 mm or less. The cavity may have a thickness of 22 mm or less. The cavity may have a thickness of 18 mm or less.
[0138] The cavity may have a length of 14 mm to 40 mm. The cavity may have a length of 14 mm to 34 mm. The cavity may have a length of 24 mm to 28 mm.
[0139] The cavity may have a width of 4.5 mm or more. The cavity may have a width of 7 mm or more. The cavity may have a width of 11 mm or more.
[0140] The cavity may have a width of 13 mm or less. The cavity may have a width of 11 mm or less. The cavity may have a width of 7 mm or less. The cavity may have a width of 5 mm or less.
[0141] The cavity may have a width of 4.5 mm to 13 mm. The cavity may have a width of 7 mm to 10 mm. The cavity may have a width of 7.5 mm to 8.5 mm.
[0142] The cavity may have a length of 14 mm to 40 mm, a width of 4.5 mm to 13 mm, and a thickness of 0.5 mm to 4.5 mm.
[0143] Preferably, the cavity may have a length of 20 mm to 30 mm, a width of 7 mm to 10 mm, and a thickness of 2.5 mm to 4 mm.
[0144] Most preferably, the cavity may have a length of 26 mm, a width of 8 mm, and a thickness of 3.1 mm.
[0145] The cavity may have a volume of 30 mm³ or more, 100 mm³ or more, 300 mm³ or more, 500 mm³ or more, 700 mm³ or more, 900 mm³ or more, 1000 mm³ or more, 2000 mm³ or more, or 30 mm³ or more.
[0146] The cavity may have a volume of 3500 mm³ or less, 2500 mm³ or less, 1500 mm³ or less, 1000 mm³ or less, 800 mm³ or less, 600 mm³ or less, 500 mm³ or less, 400 mm³ or less, or 300 mm³ or less.
[0147] The cavity may have a volume of 30 mm³ to 3500 mm³. The cavity may have a volume of 30 mm³ to 2500 mm³. The cavity may have a volume of 100 mm³ to 1500 mm³. The cavity may have a volume of 100 mm³ to 1000 mm³.
[0148] The common area can be practically empty.
[0149] One or more aerosol generating materials may include an aerosol generating material located within a cavity. The aerosol generating material located within the cavity may fill the cavity.
[0150] The aerosol generating material located within the cavity may include an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. For example, the aerosol generating material may be in the form of a crushed aerosol generating material.
[0151] The aerosol generating material may be in the form of a sheet of the aerosol generating material. The sheet of the aerosol generating material may be any sheet of the aerosol generating material described herein. For example, the sheet of the aerosol generating material may be a sheet of homogenized tobacco material.
[0152] A sheet of aerosol-generating material can extend along the entire length of the cavity. A sheet of aerosol-generating material can extend along the entire width of the cavity.
[0153] The sheet of aerosol generating material may be a corrugated sheet of aerosol generating material. That is, the sheet of aerosol generating material may be wavy, folded, otherwise compressed or shrunk substantially perpendicular to the transverse direction of the aerosol generating article.
[0154] The sheet of aerosol generating material may be a crimped sheet of aerosol generating material. The sheet of aerosol generating material may be a wavy sheet of aerosol generating material. The crimped sheet of aerosol generating material or the wavy sheet of aerosol generating material may include a plurality of parallel wavy folds. For example, the crimped sheet of aerosol generating material may include a plurality of substantially parallel peaks and valleys.
[0155] Multiple parallel ripples can be defined by a ripple profile, where the ripple profile is sinusoidal, triangular, rectangular, trapezoidal, toroidal, or parabolic.
[0156] Multiple parallel wavy folds may define or form multiple channels between a sheet of aerosol-generating material and one or more walls of a cavity. The multiple channels may be multiple longitudinally extending channels. The multiple channels may be multiple laterally extending channels. The multiple channels may define or form at least a portion of an airflow passage extending between an air inlet and an air outlet of an aerosol-generating article.
[0157] The aerosol generating material may include one or more organic materials such as tobacco, mint, tea, and cloves. The aerosol generating material may include one or more of herb leaves, tobacco leaves, tobacco rib pieces, reconstituted tobacco, homogenized tobacco such as cast leaves, extruded tobacco, puffed tobacco, aerosol generating films, and gel compositions.
[0158] The aerosol generating material may be in the form of a shredded aerosol generating material. The shredded aerosol generating material may include: one or more strips and strands of the aerosol generating material, such as strips and strands of tobacco or homogenized tobacco material. The shredded aerosol generating material may be in the form of shredded sheets of homogenized tobacco material.
[0159] The aerosol-generating material may be a cut grass. The aerosol-generating material may be tobacco cut grass. As used herein, the term “cut grass” is used to describe a blend of shredded plant material, such as tobacco plant material, homogenized plant material, which includes one or more of leaf blades, processed stems, and ribs in particular.
[0160] The aerosol generating material may be in the form of a sheet of the aerosol generating material. As used herein, the term “sheet” describes a laminated element in which the width and length are substantially greater than the thickness. The sheet of the aerosol generating material may be a sheet of plant material. The sheet of the aerosol generating material may be a sheet of tobacco material. The sheet of the aerosol generating material may be a sheet of homogenized tobacco material, such as a cast leaf sheet.
[0161] The aerosol generating material may comprise one or more aerosol-forming agents. Suitable aerosol-forming agents are known in the art and include, but are not limited to, polyhydric alcohols such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable that the aerosol-forming agent be one or both of glycerin and propylene glycol, or comprise them. The aerosol-forming agent may consist of glycerin or propylene glycol, or a combination of glycerin and propylene glycol.
[0162] The aerosol generating material may have an aerosol forming agent content of 1, 2, 5, 10, or 15 weight percent or more based on dry weight. The aerosol generating material 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.
[0163] The aerosol generating material may have an aerosol forming agent content of 30% by weight or less based on dry weight, 25% by weight or less based on dry weight, or 20% by weight or less based on dry weight.
[0164] The aerosol generating material may have an aerosol forming agent content of 5% to 30% by weight based on dry weight, 5% to 25% by weight based on dry weight, or 5% to 20% by weight based on dry weight.
[0165] The aerosol generating material may have an aerosol forming agent content of 10% to 30% by weight based on dry weight, 10% to 25% by weight based on dry weight, or 10% to 20% by weight based on dry weight.
[0166] The aerosol generating material may contain nicotine. The aerosol generating material may contain natural nicotine, synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.
[0167] The aerosol generating material may contain at least 0.5% by weight of nicotine, at least 1% by weight of nicotine, at least 1.5% by weight of nicotine, or at least 2% by weight of nicotine. That is, the aerosol generating material may have a nicotine content of at least 0.5% by weight, at least 1% by weight, at least 1.5% by weight, or at least 2% by weight.
[0168] The aerosol generating material may be in the form of multiple beads. The multiple beads may have an average particle diameter of 0.1 mm to 4 mm, for example, 0.5 mm to 4 mm.
[0169] The term "bead" refers to individual solid particles formed from an aerosol-generating substrate. Beads may be round, typically spherical in shape. Other terms, such as "granule," may be used to define the substrate, for example.
[0170] Providing an aerosol-generating material as multiple beads can offer specific advantages. Beads can be handled more easily than other aerosol-forming substrates, such as fine powders or bits. Since beads flow easily, they can reliably and consistently fill the cavity of an aerosol-generating article during manufacturing. This can enable a consistent and reproducible amount of aerosol-generating material to be loaded into each article during manufacturing. Beads can also be cleaner to handle than powders and bits, which can cause dust in the factory and leak from the aerosol-generating article during transport or use. By selecting beads with appropriate bead size and a suitable particle size distribution, the airflow through the cavity of the aerosol-generating article can be controlled more reproducibly, so to speak, than in the case of bits.
[0171] When a particle is not perfectly spherical but its diameter is referred to, the term "diameter" may refer to the largest dimension of the particle. Alternatively, the term "diameter" may refer to the diameter of a perfectly spherical particle having the same volume as a non-perfectly spherical particle.
[0172] As used herein, the term "average particle diameter" may refer to the number average particle diameter. Other methods for determining the average particle diameter are known. Thus, the average particle diameter may be, for example, the volume average particle diameter.
[0173] The aerosol generating material may be in the form of a wrapped body of the aerosol generating material, and the wrapped body includes a wrapper that at least partially surrounds the aerosol generating material.
[0174] The wrapped body of the aerosol generating material may occupy 15% to 100% of the internal volume of the cavity. The wrapped body of the aerosol generating material may occupy 30% to 100% of the internal volume of the cavity. The wrapped body of the aerosol generating material may occupy 50% to 100% of the internal volume of the cavity. The wrapped body of the aerosol generating material may occupy 50% to 80% of the internal volume of the cavity. The wrapped body of the aerosol generating material may occupy 50% to 70% of the internal volume of the cavity.
[0175] An air inlet may be defined by the front wall surface of the aerosol-generating article. An air inlet may be defined by a frame and may extend through the frame. An air inlet may be defined by the periphery wall surface of the frame. An air inlet may extend through the periphery wall surface of the frame. An air outlet may be defined by the rear wall surface of the aerosol-generating article. An air outlet may be defined by a frame and may extend through the frame. An air outlet may be defined by the periphery wall surface of the frame. An outlet may extend through the periphery wall surface of the frame.
[0176] The air inlet may have a round cross-section, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section. The air outlet may have a round cross-section, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section.
[0177] An air inlet may be defined by a first planar outer surface and may extend through it. An air inlet may be defined by an outer wrapper and may extend through it. An air inlet may be defined by an outer wrapper and an aerosol generating substrate layer and may extend through it. An air inlet may be defined by an outer wrapper and a first aerosol generating substrate layer and may extend through it. An air inlet may be defined by a first planar outer layer and an aerosol generating substrate layer and may extend through it. An air inlet may be defined by a first planar outer layer and a first aerosol generating substrate layer and may extend through it.
[0178] An air inlet may be defined by a second planar outer surface and may extend through it. An air inlet may be defined by an outer wrapper and a second aerosol generating substrate layer and may extend through it. An air inlet may be defined by a second planar outer layer and an aerosol generating substrate layer and may extend through it. An air inlet may be defined by a second planar outer layer and a second aerosol generating substrate layer and may extend through it.
[0179] An air outlet can be defined by a first planar outer surface and can be extended through it. An air outlet can be defined by an outer wrapper and can be extended through it. An air outlet can be defined by an outer wrapper and an aerosol generating substrate layer and can be extended through it. An air outlet can be defined by an outer wrapper and a first aerosol generating substrate layer and can be extended through it. An air outlet can be defined by a first planar outer layer and an aerosol generating substrate layer and can be extended through it. An air outlet can be defined by a first planar outer layer and a first aerosol generating substrate layer and can be extended through it.
[0180] An air outlet may be defined by a second planar outer surface and may extend through it. An air outlet may be defined by an outer wrapper and a second aerosol generating substrate layer and may extend through it. An air outlet may be defined by a second planar outer layer and an aerosol generating substrate layer and may extend through it. An air outlet may be defined by a second planar outer layer and a second aerosol generating substrate layer and may extend through it.
[0181] One or both of the air inlet and air outlet may have an equivalent diameter of 0.1 mm or more, 0.4 mm or more, 0.7 mm or more, or 1.0 mm or more.
[0182] One or both of the air inlet and the air outlet may have an equivalent diameter of 3 mm or less, 2.7 mm or less, 2.4 mm or less, or 2.1 mm or less. The air inlet may have an equivalent diameter of 2.7 mm or less, 1.8 mm or less, or 1.5 mm or less.
[0183] One or both of the air inlet and the air outlet may have an equivalent diameter of 0.1 mm to 3 mm, 0.1 mm to 2.4 mm, 0.4 mm to 2.1 mm, 0.4 mm to 1.8 mm, 0.7 mm to 1.5 mm, or 1.0 mm to 1.5 mm.
[0184] The air inlet may have a width narrower than the width of the cavity. The air outlet may have a width narrower than the width of the cavity. The air inlet may have a thickness thinner than the thickness of the cavity. The air outlet may have a thickness thinner than the thickness of the cavity.
[0185] One or both of the air inlet and the air outlet may have a width of 0.3 mm to 3 mm, or 0.5 mm to 2 mm.
[0186] One or both of the air inlet and the air outlet may have a thickness of 0.3 mm to 3 mm or 0.5 mm to 2 mm.
[0187] Preferably, the air inlet may have a width of 0.3 mm to 3 mm and a thickness of 0.3 mm to 3 mm.
[0188] Preferably, the air outlet may have a width of 0.3 mm to 3 mm and a thickness of 0.3 mm to 3 mm.
[0189] Advantageously, an aerosol generating article having an air outlet or air inlet having a width of 0.3 mm to 3 mm and a thickness of 0.3 mm to 3 mm can provide a relatively large inlet or outlet opening while allowing improved retention of the aerosol generating material within the aerosol generating article. Improved retention of the aerosol generating material within the aerosol generating article can reduce the risk of the aerosol generating material falling out of the aerosol generating article.
[0190] The ratio of the width of the air inlet to the thickness of the air inlet may be 0.33 to 3. The ratio of the width of the air inlet to the thickness of the air inlet may be 0.5 to 1.5. The ratio of the width of the air inlet to the thickness of the air inlet may be 0.75 to 1.25.
[0191] The ratio of the width of the air outlet to the thickness of the air outlet may be 0.33 to 3. The ratio of the width of the air outlet to the thickness of the air outlet may be 0.5 to 1.5. The ratio of the width of the air outlet to the thickness of the air outlet may be 0.75 to 1.25.
[0192] An aerosol generating article may include a plurality of air inlets. One or each of the air inlets may have one or more of the features of the air inlets described herein.
[0193] An aerosol generating article may include a plurality of air outlets. One or each of the air outlets may have one or more of the features of the air outlets described herein.
[0194] The aerosol generating article may include a filter element located downstream of an aerosol forming substrate. The aerosol generating article may include a filter element located downstream of a cavity. The aerosol generating article may include a filter element located at least partially within an air outlet. The aerosol generating article may include a filter element located within a cavity and may be located at the downstream end of the cavity.
[0195] The aerosol generating article may include a filter element located upstream of an aerosol forming substrate. The aerosol generating article may include a filter element located upstream of a cavity. The aerosol generating article may include a filter element located at least partially within an air inlet. The aerosol generating article may include a filter element located within a cavity and may be located at the upstream end of the cavity.
[0196] The filter element may comprise one or more filter segments of a fibrous filtration material. Suitable fibrous filtration materials will be known to those skilled in the art. The filter element may comprise cellulose acetate.
[0197] The ratio between the length and thickness of the aerosol-generating article and between the width and thickness of the aerosol-generating article may be greater than 2:1, greater than 5:1, greater than 10:1, greater than 12:1, or greater than 15:1.
[0198] The ratio between the length and thickness of the aerosol-generating article, and the ratio between the width and thickness of the aerosol-generating article may be less than 15:1, less than 12:1, less than 10:1, less than 5:1, and less than 2.5:1.
[0199] The ratio between the length and thickness of the aerosol-generating article and between the width and thickness of the aerosol-generating article may be 2:1 to 15:1, 2:1 to 12:1, 2:1 to 10:1, or 5:1 to 10:1.
[0200] The ratio between the length and width of an aerosol-generating article may be greater than 1:1, greater than 2:1, greater than 3:1, greater than 4:1, or greater than 5:1.
[0201] The ratio between the length and width of an aerosol-generating article may be less than 10:1, less than 8:1, less than 5:1, less than 4:1, less than 3:1, or less than 2:1.
[0202] The length-to-width ratio of the aerosol-generating article may be 1:1 to 10:1, 1:1 to 5:1, 1:1 to 4:1, 1:1 to 3:1, 2:1 to 4:1, or 2:1 to 3:1.
[0203] Aerosol-generating articles may have a length of 15 mm or more, 20 mm or more, 25 mm or more, 30 mm or more, 35 mm or more, or 40 mm or more.
[0204] Aerosol-generating articles may have a length of 45 mm or less, 40 mm or less, 35 mm or less, or 30 mm or less.
[0205] The aerosol generating article may have a length of 15 mm to 45 mm, 20 mm to 40 mm, 20 mm to 35 mm, or 25 mm to 30 mm.
[0206] Aerosol-generating articles may have a width of 3 mm or more, 5 mm or more, 7.5 mm or more, 9 mm or more, 11 mm or more, or 13 mm or more.
[0207] Aerosol-generating articles may have a width of 17 mm or less, 15 mm or less, 12.5 mm or less, 11 mm or less, or 9 mm or less.
[0208] The aerosol generating article may have a thickness of 3 mm to 17 mm, 5 mm to 15 mm, 7.5 mm to 12.5 mm, or 9 mm to 11 mm.
[0209] Aerosol-generating articles may have a thickness of 1 mm or more, 1.5 mm or more, 2 mm or more, 2.5 mm or more, 3 mm or more, 3.5 mm or more, 4 mm or more, or 4.5 mm or more.
[0210] Aerosol-generating articles may have a thickness of 5.5 mm or less, 5 mm or less, 4.5 mm or less, 4 mm or less, 3.5 mm or less, 3 mm or less, 2.5 mm or less, or 2 mm or less.
[0211] The aerosol generating article may have a thickness of 0.1 mm to 5 mm, 1.5 mm to 5 mm, 2 mm to 4.5 mm, 2.5 mm to 4 mm, or 3 mm to 3.5 mm.
[0212] As used herein, the term "aerosol generating article" refers to an article comprising an aerosol generating material. The article can be heated upon use to generate an inhalable aerosol and deliver it to a consumer.
[0213] As used herein, the term "aerosol generating material" refers to a material capable of releasing a volatile compound upon heating, for example, a compound that generates an aerosol upon cooling and condensation when in use.
[0214] As used herein, the term "aerosol generating device" refers to a device that, when in use, interacts with an aerosol generating substrate of an aerosol generating article to generate an aerosol, for example, by heating it.
[0215] As used herein, the term “planar” may generally refer to a feature formed on a single Euclidean plane that is not wrapped around a curved non-planar shape or other non-planar shape, or otherwise is not conformed to be fitted with it. A planar surface extends two dimensions in a single Euclidean plane. A planar object extends two dimensions in a single Euclidean plane substantially further than at a third dimension perpendicular to the plane. More specifically, a planar object may extend at least two, five, or ten times further to a first dimension and a second dimension perpendicular to the first dimension than to a third dimension perpendicular to the first dimension.
[0216] As used herein, the term "transverse direction" refers to the direction extending between the first planar outer surface and the second planar outer surface. The transverse direction may also be referred to as the "z direction."
[0217] As used herein, the term "longitudinal direction" refers to a direction perpendicular to the transverse direction. For example, it is the direction between the front and rear walls of an aerosol-generating article. The longitudinal direction may also be referred to as the "x-direction."
[0218] As used herein, the term "lateral direction" refers to a direction perpendicular to the transverse and longitudinal directions. For example, it is the direction from the first side wall to the second side wall of an aerosol-generating article. The lateral direction may also be referred to as the "y-direction."
[0219] As used herein, the term "thickness" refers to the maximum dimension in the transverse direction of an aerosol-generating article or a component of an aerosol-generating article.
[0220] As used herein, the term "length" refers to the maximum longitudinal dimension of an aerosol-generating article or a component of an aerosol-generating article.
[0221] As used herein, the term "width" refers to the maximum lateral dimension of an aerosol-generating article or a component of an aerosol-generating article.
[0222] As used herein, the terms “upstream” and “downstream” refer to the relative positions of a component or part of a component of an aerosol generating article with respect to the direction in which air or aerosol is transported through the aerosol generating article during use.
[0223] As used herein, the term "bulk density" may refer to the total weight of an aerosol generating material divided by the bulk volume of the aerosol generating material.
[0224] As used herein, the term "aerosol-forming agent" may refer to any suitable known compound or mixture of compounds that facilitates the formation of an aerosol upon use. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal decomposition at the operating temperature of the aerosol-generating substrate or aerosol-generating article.
[0225] As used herein, the term "aerosol-forming agent content" may refer to the aerosol-forming agent content as a percentage based on dry weight, unless otherwise specified.
[0226] As used herein, "susceptor" refers to a conductive element that heats up when affected by a variable magnetic field. This may be the result of eddy currents and / or hysteresis losses induced within the susceptor element.
[0227] As used herein, the term "hydrophobic" refers to a surface that exhibits water repellency. One useful method for determining hydrophobicity is to measure the water contact angle. The "water contact angle" is the angle at which the liquid / vapor interface meets the solid surface, typically measured through a liquid. The water contact angle quantifies the wettability of a solid surface by a liquid using Young's equation.
[0228] As used herein, the term "equivalent diameter" of an opening or perforation is used herein to denote the diameter of a circular opening or perforation having the same cross-sectional area as the opening or perforation.
[0229] The present invention is defined in the claims. However, a non-limiting, non-comprehensive list of embodiments is provided below. Any one or more of the features of these embodiments may be combined with any one or more features of other embodiments, embodiments, or aspects described herein.
[0230] Example 1: As an aerosol generating article for generating aerosols by use with an aerosol generating device, the aerosol generating article is:
[0231] First planar outer surface;
[0232] Second planar outer surface;
[0233] cavity;
[0234] One or more aerosol generating materials located within the cavity;
[0235] Air inlet;
[0236] Air outlet; and
[0237] A frame that at least partially defines the above cavity, the air inlet, and the air outlet;
[0238] The above frame is an aerosol generating article comprising a first subframe and a second subframe connected to the first subframe.
[0239] Example 2: In Example 1, the first subframe is an aerosol generating article identical to the second subframe.
[0240] Example 3: An aerosol generating article in Example 1 or Example 2, wherein the air inlet is defined by the first subframe and the air outlet is defined by the second subframe.
[0241] Example 4: An aerosol generating article in Example 1, 2 or 3, wherein the first subframe is spaced apart from the second subframe and defines at least partially a cavity between the first subframe and the second subframe.
[0242] Example 5: In any one of the prior embodiments, the first subframe defines at least partially a first end of the aerosol generating article, and the second subframe defines at least partially a second end of the aerosol generating article.
[0243] Example 6: In any one of the previous embodiments, the frame is
[0244] A first side portion extending from the first subframe to the second subframe; and
[0245] An aerosol generating article further comprising a second side portion extending from the first subframe to the second subframe.
[0246] Example 7: An aerosol generating article in Example 6, wherein the second side portion is spaced apart from the first side portion and defines at least partially a cavity between the first side portion and the second side portion.
[0247] Example 8: An aerosol generating article in Example 6 or Example 7, wherein each of the first side portion and the second side portion is directly connected to both the first subframe and the second subframe.
[0248] Example 9: In any one of Examples 6 to 9 combined with Example 5, the aerosol generating article, wherein each of the first side portion and the second side portion extends between the first end of the aerosol generating article and the second end of the aerosol generating article.
[0249] Example 10: In any one of the previous embodiments, the first subframe is
[0250] A chamber and a body portion defining a first opening at a first end of the chamber;
[0251] A first flap formed integrally with the above body part; and
[0252] A second flap formed integrally with the above body part;
[0253] An aerosol generating article, wherein each of the first flap and the second flap is placed over a second end of the chamber, and the first flap and the second flap together define a second opening at the second end of the chamber.
[0254] Example 11: An aerosol generating article in Example 10, wherein the first opening forms the air inlet and the second opening provides fluid communication between the chamber and the cavity.
[0255] Example 12: In any one of the previous embodiments, the second subframe is
[0256] A chamber and a body portion defining a first opening at a first end of the chamber;
[0257] A first flap formed integrally with the above body part; and
[0258] A second flap formed integrally with the above body part;
[0259] An aerosol generating article, wherein each of the first flap and the second flap is placed over a second end of the chamber, and the first flap and the second flap together define a second opening at the second end of the chamber.
[0260] Example 13: An aerosol generating article in Example 12, wherein the first opening forms the air outlet and the second opening provides fluid communication between the chamber and the cavity.
[0261] Example 14: In any one of the prior embodiments, the aerosol generating article defines a longitudinal direction extending from the air inlet to the air outlet, and each of the first subframe, the second subframe, and the cavity has a length extending in the longitudinal direction, the length of the first subframe is equal to the length of the second subframe, and the length of the cavity is an integer multiple of the length of the first subframe.
[0262] Example 15: An aerosol generating article in Example 14 in combination with Example 6, wherein each of the first side portion and the second side portion has a length extending in the longitudinal direction, the length of the first side portion is equal to the length of the second side portion, and the length of the second side portion is an integer multiple of the length of the first subframe.
[0263] Example 16: In any one of the prior embodiments, the first subframe and the second subframe are each in the form of a tube, an aerosol generating article.
[0264] Example 17: In Example 16, the aerosol generating article, wherein each of the first subframe and the second subframe defines a first opening at the first end of the subframe, a second opening at the second end of the subframe, and an airflow passage extending between the first opening and the second opening.
[0265] Example 18: An aerosol generating article in Example 17, wherein the first opening of the first subframe forms the air inlet and the first opening of the second subframe forms the air outlet.
[0266] Example 19: An aerosol generating article in Example 17 or 18, wherein each of the first opening, the second opening, and the airflow passage has the same cross-sectional size and shape.
[0267] Example 20: An aerosol generating article, wherein in any one of Examples 16 to 19, the tube has a rectangular cross-sectional shape.
[0268] Example 21: An aerosol generating article in any one of Examples 16 to 20, wherein each of the first subframe and the second subframe comprises a first part and a second part, the first part is formed separately from the second part, and the first part is placed on the second part.
[0269] Example 22: In Example 21, the aerosol generating article, wherein each of the first part and the second part has an L-shaped cross-sectional shape.
[0270] Example 23: An aerosol generating article in any one of Examples 16 to 20, wherein the first subframe and the second subframe are each formed of a folded sheet material.
[0271] Example 24: An aerosol generating article in Example 1 or Example 2, wherein the first subframe partially defines the air inlet and the air outlet, and the second subframe partially defines the air inlet and the air outlet.
[0272] Example 25: In Example 24, the aerosol generating article comprises a first end and a second end, wherein each of the first subframe and the second subframe extends between the first end and the second end.
[0273] Example 26: An aerosol generating article in Example 24 or 25, wherein the first subframe comprises at least one first protrusion and at least one first concave portion, and the second subframe comprises at least one second protrusion and at least one second concave portion, each first protrusion being received within the second concave portion and each second protrusion being received within the first concave portion.
[0274] Example 27: An aerosol generating article in Examples 24, 25, or 26, wherein the cavity has a hexagonal shape or a rounded hexagonal shape.
[0275] Example 28: In Example 27, the first subframe and the second subframe each define the hexagonal shape or half of the rounded hexagonal shape, an aerosol generating article.
[0276] Example 29: An aerosol generating article in Examples 24, 25, or 26, wherein at least a portion of each of the first subframe and the second subframe has an L-shaped cross-sectional shape.
[0277] Example 30: An aerosol generating article in Example 29, wherein the first subframe includes a first opening extending through the first subframe, the second subframe includes a second opening extending through the second subframe, and the first subframe is placed over the second subframe so that the first aperture and the second aperture cooperate to define the cavity at least partially.
[0278] Example 31: In any one of the prior embodiments, the first subframe and the second subframe are each formed of compressed particulate material, an aerosol generating article.
[0279] Example 32: In Example 31, the aerosol generating article wherein at least one of the first subframe and the second subframe is a compressed particulate material comprising a flavoring agent.
[0280] Example 33: As an aerosol generation system,
[0281] Aerosol generating article according to any one of the prior claims; and
[0282] Includes an aerosol generating device, wherein the aerosol generating device is:
[0283] A chamber for accommodating at least a portion of the above-mentioned aerosol generating article; and
[0284] An aerosol generating system comprising an electric heater arranged to heat at least a portion of the aerosol generating article when the aerosol generating article is received within the chamber.
[0285] Example 34: A method for forming an aerosol generating article for use with an aerosol generating device to generate an aerosol, wherein the method comprises:
[0286] A step of providing a plurality of subframes, wherein each subframe has a tubular shape and each subframe has the same length;
[0287] A step of positioning the first of the subframes and the second of the subframes such that the second subframe is spaced apart from the first subframe by a spacing distance, wherein the spacing distance is an integer multiple of the length of each subframe;
[0288] A step of providing a first side portion and a second side portion, wherein each of the first side portion and the second side portion has a length equal to the sum of the length of the first subframe, the length of the second subframe, and the gap distance;
[0289] A step of positioning one or more aerosol generating materials between the first subframe and the second subframe; and
[0290] A method comprising the step of forming a frame by fixing each of the first side portion and the second side portion to both the first subframe and the second subframe, wherein the frame partially defines a cavity between the first subframe, the second subframe, the first side portion and the second side portion, and the one or more aerosol generating materials are located within the cavity, and the frame and the one or more aerosol generating materials together form an aerosol generating article.
[0291] Example 35: A method according to Example 34, wherein the tubular shape of the first subframe defines an air inlet of the aerosol generating article, and the tubular shape of the second subframe defines an air outlet of the aerosol generating article.
[0292] Example 36: A method according to Example 34 or 35, wherein the step of providing a plurality of subframes includes the step of providing a series of subframes, wherein consecutive subframes within the series of subframes are in contact with each other, and the first subframe and the second subframe are discontinuous subframes.
[0293] Example 37: In Example 36, the step of positioning the first and second subframes comprises removing one or more subframes between the first subframe and the second subframe to form a space between the first subframe and the second subframe.
[0294] Example 38: In Example 37, the aerosol generating article is a first aerosol generating article, and the method further comprises the step of forming a second aerosol generating article using one or more subframes removed between the first subframe and the second subframe.
[0295] Example 39: A method according to Examples 36, 37, or 38, wherein the step of providing a series of subframes comprises the step of providing a continuous tubular substrate and the step of cutting the continuous tubular substrate to form a series of subframes.
[0296] Example 40: In any one of Examples 34 to 39, the step of providing the first side portion and the second side portion is,
[0297] A step of providing a first continuous side substrate and a second continuous side substrate;
[0298] A step of fixing the first continuous side material to the first subframe and the second subframe;
[0299] A step of fixing the second continuous side material to the first subframe and the second subframe; and
[0300] A method comprising the step of cutting the first continuous side substrate and the second continuous side substrate to form the first side portion and the second side portion.
[0301] Example 41: A method for forming an aerosol generating article for use with an aerosol generating device to generate an aerosol, wherein the method comprises:
[0302] A step of providing a first subframe and a second subframe, wherein each of the first subframe and the second subframe is formed of a compressed particulate material;
[0303] A step of fixing the first subframe to the second subframe to form a frame, wherein the frame partially defines a cavity, an air inlet, and an air outlet; and
[0304] A method comprising the step of positioning one or more aerosol generating materials within the above cavity, wherein the frame and the one or more aerosol generating materials together form an aerosol generating article.
[0305] Example 42: In Example 41, the step of providing the first subframe and the second subframe comprises the step of press-molding the first subframe from the particulate material and the step of press-molding the second subframe from the particulate material.
[0306] Example 43: A method according to Example 41 or 42, wherein the particulate material comprises a flavoring agent. Brief explanation of the drawing
[0307] Now, embodiments will be further described with reference to the drawings. FIG. 1 shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 2 shows an exploded perspective view of the aerosol generating article of FIG. 1; FIG. 3 shows an exploded perspective view of an aerosol generating article according to the present disclosure; FIG. 4 shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 5 shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 6 shows an exploded perspective view of an aerosol-generating article according to the present disclosure; FIG. 7 shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 8 shows a perspective view of an alternative configuration of a frame for an aerosol-generating article according to the present disclosure; FIG. 9 shows a perspective view of an alternative configuration of the subframe of FIG. 8; FIG. 10 shows a perspective view of an additional alternative configuration of the subframe of FIG. 8; FIG. 11 shows a perspective view of an additional alternative configuration of the subframe of FIG. 8; FIG. 12 shows a perspective view of an additional alternative configuration of the subframe of FIG. 8; FIG. 13 shows a method for manufacturing the frame of FIG. 8; FIG. 14 shows a top view of an additional alternative configuration of a frame for an aerosol-generating article according to the present disclosure; FIG. 15 shows a cross-sectional view of the frame of FIG. 14 along line 14-14; FIG. 16 illustrates a cross-sectional view of the frame of FIG. 14 along line 14-14, showing an alternative configuration of the frame; FIG. 17 shows an exploded perspective view of an additional alternative configuration of a frame for an aerosol-generating article according to the present disclosure; FIG. 18 shows a perspective view of the frame of FIG. 17; FIG. 19 shows a perspective view of a subframe precursor; FIG. 20 shows an additional perspective view of the subframe precursor of FIG. 19; FIG. 21 shows a perspective view of a subframe formed from the subframe precursor of FIG. 19 and FIG. 20; FIG. 22 shows a perspective view of an additional alternative configuration of a frame for an aerosol-emitting article according to the present disclosure, which comprises two of the subframes of FIG. 21; FIG. 23 shows a schematic cross-sectional view of an aerosol generating device according to the present disclosure; FIG. 24 shows a schematic cross-sectional view of the aerosol generating device of FIG. 23 that engages with the aerosol generating article of the present disclosure. Specific details for implementing the invention
[0308] FIG. 1 illustrates an aerosol generating article (10) comprising a first planar outer layer (24) forming a first planar outer surface (21), a second planar outer layer (25) forming a second planar outer surface (22), and a frame (50) positioned between the first planar outer layer (24) and the second planar outer layer (25). Both the first planar outer layer (24) and the second planar outer layer (25) comprise an aerosol generating substrate comprising an aerosol generating material, namely tobacco. However, it will be understood that in some embodiments, only one of the first planar outer layer (24) and the second planar outer layer (25) may comprise an aerosol generating substrate. Alternatively or additionally, the aerosol generating substrate may be located elsewhere within the aerosol generating article (10).
[0309] The aerosol generating article (10) has a length extending in the x direction, a width extending in the y direction, and a thickness extending in the z direction. The aerosol generating article (10) has a length of 30 mm, a width of 10 mm, and a thickness of 3.1 mm.
[0310] The aerosol generating article (10) is substantially flat or substantially planar aerosol generating article. In particular, the thickness of the aerosol generating article (10) is less than 50% of both the length and width of the aerosol generating article. The aerosol generating article (10) generally has a rectangular cuboid shape and has a laminated structure formed by a first planar outer layer (24), a frame (50), and a second planar outer layer (25). The first planar outer layer (24), the frame (50), and the second planar outer layer (25) are bonded together with an adhesive, in particular guar gum, as will be discussed in more detail below in relation to FIG. 2.
[0311] Figure 2 shows an exploded view of the aerosol generating article (10) of Figure 1.
[0312] The frame (50) has a length of 30 mm, a width of 10 mm, and a thickness of 2.7 mm. The frame (50) is made of cardboard and defines a frame aperture that extends through the thickness of the frame (50). The frame aperture forms at least partially a cavity (30). The cavity (30) has a length of 26 mm, a width of 6 mm, and a thickness of 2.7 mm. Thus, the cavity (30) has a volume of approximately 421.2 mm³. In this embodiment, the cavity (30) is substantially empty.
[0313] The frame (50) has an inner frame surface (52) extending in the z-direction or transverse direction between the first planar outer surface (21) and the second planar outer surface (22). The inner frame surface (52) defines a joint outer wall surface. The frame (50) has an outer frame surface (53) extending in the z-direction or transverse direction between the first planar outer surface (21) and the second planar outer surface (22). The outer frame surface (53) defines at least one or more outer surfaces of an aerosol generating article, such as a front wall surface (13) and a rear wall surface (14).
[0314] The frame (50) includes a perimeter wall surface (51) surrounding the cavity (30). More specifically, the perimeter wall surface (51) is defined by an inner surface (52) of the frame and an outer surface (53) of the frame. The perimeter wall surface (51) has a radial thickness of about 2 mm when measured between the inner surface (52) of the frame and the outer surface (53) of the frame in the x / y plane.
[0315] The first planar outer layer (24) and the second planar outer layer (25) have a thickness of 200 μm and are in physical contact with the frame (50). The first planar outer layer (24) and the second planar outer layer (25) are bonded to the frame with an adhesive (15). The first planar outer layer (24) defines at least a portion of the cavity (30). The second planar outer layer (25) defines at least a portion of the cavity (30).
[0316] The aerosol generating article (10) includes an air inlet (11) and an air outlet (12). The air inlet (11) and the air outlet (12) are defined by and extend through the peripheral wall surface (51) of the frame (50). The air inlet (11) and the air outlet (12) each have a rectangular cross-section, a width of 2 mm, and a thickness of 0.9 mm. An airflow passage extends through a cavity (30) between the air inlet (11) and the air outlet (12).
[0317] FIG. 3 shows an exploded view of an aerosol generating article similar to the aerosol generating article (10) of FIG. 1, except that the first planar outer layer (24) and the second planar outer layer (25) do not contain an aerosol generating substrate. Instead, the aerosol generating substrate (40) is located within the cavity (30). The aerosol generating substrate (40) contains an aerosol generating material in the form of a tobacco stick and has an aerosol forming agent content of 5% by weight based on dry weight. As illustrated, the aerosol generating substrate (40) fills the entire volume of the cavity (30). In the example of FIG. 3, the aerosol generating substrate (40) has a packing density of about 0.87, a density of about 0.3 g / cm³, and a mass of about 110 mg. In other embodiments, the aerosol generating substrate (40) may have a different packing density, a different density, and a different mass. For example, the aerosol generating material has a packing density of 0.64, a density of 0.35 g / cm3, and a mass of about 95 mg.
[0318] FIG. 4 shows an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 1 and FIG. 3, except that the aerosol generating article (10) of FIG. 4 includes an outer wrapper (23) defining a first planar outer surface (21) and a second planar outer surface (22) instead of a first planar outer layer (24) and a second planar outer layer (25).
[0319] FIG. 5 shows an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 1, except that the aerosol generating article (10) of FIG. 5 further includes a first aerosol generating substrate layer (41) and a second aerosol generating substrate layer (42). The first aerosol generating substrate layer (41) and the second aerosol generating substrate layer (42) are formed from sheets of aerosol generating material. In particular, the sheets of homogenized tobacco material have an aerosol forming agent content of 5% by weight based on dry weight. The first aerosol generating substrate layer (41) and the second aerosol generating substrate layer (42) each have a length equal to the length of the aerosol generating article (10), a width equal to the width of the aerosol generating article (10), and a thickness of 200 μm. That is, the aerosol generating article (10) has a length of 30 mm, a width of 10 mm, and a thickness of 3.5 mm.
[0320] The first aerosol generating substrate layer (41) and the second aerosol generating substrate layer (42) are in physical contact with the frame (50) and are bonded to the frame with an adhesive (15). The first aerosol generating substrate layer (41) defines at least a portion of the cavity (30). The second aerosol generating layer (42) defines at least a portion of the cavity (30).
[0321] The first planar outer layer (24) is physically in contact with the first aerosol generating substrate layer (41) and bonded together with an adhesive (15). The second planar outer layer (25) is physically in contact with the second aerosol generating substrate layer (42) and bonded together with an adhesive (15).
[0322] FIG. 6 shows an exploded view of an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 5, except that the aerosol generating substrate (40) is located within the cavity (30) as described in relation to FIG. 3. The aerosol generating substrate (40) contains an aerosol generating material in the form of a tobacco stick and has an aerosol forming agent content of 5% by weight based on dry weight. As illustrated, the aerosol generating substrate (40) fills the entire volume of the cavity (30). FIG. 7 shows an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 5, except that the aerosol generating article (10) of FIG. 7 includes an outer wrapper (23) defining a first planar outer surface (21) and a second planar outer surface (22) instead of a first planar outer layer (24) and a second planar outer layer (25).
[0323] FIG. 8 illustrates a perspective view of an alternative frame (150) suitable for use in the aerosol generating article (10) of FIGS. 1 to 7. The frame (150) comprises a first subframe (152) and a second subframe (154). The first and second subframes (152, 154) are identical and each have a tubular shape for defining an air inlet and an air outlet (12). The first and second subframes (152, 154) may be formed from compressed particulate material or manufactured using a pressure molding process.
[0324] The first and second subframes (152, 154) are spaced apart from each other to define a cavity (30) between them. The frame (150) also includes a first side portion (156) and a second side portion (158), and the first and second side portions (156, 158) are attached to the first and second subframes (152, 154) so that the first and second subframes (152, 154) are connected to each other.
[0325] FIG. 9 illustrates an alternative configuration for the first and second subframes (152, 154). In FIG. 9, each of the first and second subframes (152, 154) has a laminated structure in which a plurality of layers (158) are attached to each other to form the tubular shape of the first and second subframes (152, 154).
[0326] FIG. 10 illustrates an additional alternative configuration for the first and second subframes (152, 154). In FIG. 10, each of the first and second subframes (152, 154) is formed by two L-shaped sections (160, 162) connected to each other at first and second joints (164, 166) extending along the side and end surfaces of the first and second subframes (152, 154).
[0327] FIG. 11 illustrates an additional alternative configuration for the first and second subframes (152, 154). In FIG. 10, each of the first and second subframes (152, 154) is formed by two L-shaped sections (168, 170) connected to each other at first and second joints (172, 174) extending along the top and bottom surfaces and end surfaces of the first and second subframes (152, 154).
[0328] FIG. 12 illustrates an additional alternative configuration for the first and second subframes (152, 154). In FIG. 12, each of the first and second subframes (152, 154) is formed from a sheet (176) of material that is folded along a predetermined fold line (178) to form the tubular shape of the first and second subframes (152, 154).
[0329] FIG. 13 illustrates a method for forming the frame (150) of FIG. 8. In the first step, a continuous tubular subframe (200) precursor is cut into a series of subframes (202). In the second step, first and second continuous side portion precursors (204, 206) are attached to opposite sides of the series of subframes (202). The first and second side portion precursors (204, 206) are attached only to all first and second subframes (202) (indicated as "1" and "2" in FIG. 13). As such, all third subframes (202) (indicated as "3" in FIG. 13) are not attached to the first and second side portion precursors (204, 206). In the third step, the first and second side portion precursors (204, 206) are cut between each consecutive pair of the first and second subframes (202) to form a plurality of frames (150), and the third subframe (202) is removed to form a cavity (30).
[0330] FIG. 14 shows a top view of an alternative suitable frame (250) suitable for use in the aerosol generating article (10) of FIGS. 1 to 7. The frame (250) includes a first subframe (252) and a second subframe (254). The first and second subframes (252, 254) are identical and cooperate to define a cavity (30) having a rounded hexagonal shape.
[0331] FIG. 15 shows a cross-sectional view of a frame (250) taken along line 14-14 of FIG. 14. Each of the first and second subframes (252, 254) has a laminated structure comprising a plurality of layers (258). The first and second subframes (252, 254) are connected to each other along a joint (260) at the first and second ends of the cavity (30). The plurality of layers (258) are also sized and shaped to define an air inlet (11) and an air outlet at opposite ends of the frame (250).
[0332] FIG. 16 illustrates an alternative configuration of the laminated structure of the first and second subframes (252, 254). In the alternative configuration, the layers (258) of the laminated structure form interlocking joints (262) at the first and second ends of the cavity (30).
[0333] FIG. 17 shows an exploded perspective view of an alternative frame (350) suitable for use with the aerosol generating article (10) of FIGS. 1 through 7; the frame (350) comprises a first subframe (352) and a second subframe (354). The first and second subframes (352, 354) are identical to each other and each has an L-shaped cross-sectional shape. Each of the first and second subframes (352, 354) comprises a pair of protrusions (356) and a pair of protrusions (358). When the first subframe (352) is connected to the second subframe (354) to form the frame (350) as shown in FIG. 18, the pair of protrusions (356) on each of the first and second subframes (352, 354) are received within a corresponding pair of recesses (358) on the other subframe. The protrusions (356) and concave portions (358) provide an interlocking arrangement to the first and second subframes (352, 354) that facilitates a secure connection of the first subframe (352) to the second subframe (354).
[0334] The first subframe (352) includes a first opening (360) extending through the first subframe (352), and the second subframe (354) includes a second opening (362) extending through the second subframe (364). The first and second openings (360, 362) are placed on top of each other to form a cavity (30). The L-shape of the first and second subframes (352, 354) cooperates to define an air inlet and an air outlet (12).
[0335] FIG. 19 shows a perspective view of a subframe precursor (400). The subframe precursor (400) can be used to form both a first subframe and a second subframe. The subframe precursor (400) includes a body portion (402) defining a chamber (404) and a first opening (406) at a first end of the chamber (404). The subframe precursor (400) also includes a first flap (408) and a second flap (410), each formed integrally with the body portion (402). Each of the first and second flaps (408, 410) has a U-shape. FIG. 20 and FIG. 21 illustrate the folding of the first and second flaps (408, 410) so that the flaps are placed over the second end of the chamber (404) to form a subframe (414). The U-shaped of the first and second flaps (408, 410) together defines a second opening (413) at the second end of the chamber (404).
[0336] FIG. 22 illustrates a perspective view of an alternative frame (450) suitable for use with the aerosol generating article (10) of FIG. 1 through 7. The frame (450) includes a first subframe (452) and a second subframe (454). Each of the first and second subframes (452, 454) is identical to the subframe (414) of FIG. 21. The first and second subframes (452, 454) are connected to each other by a first side portion (456) and a second side portion (458) to form a frame (450) that defines a cavity (30). The frame (450) is illustrated in FIG. 22 together with an aerosol generating material (40) located within the cavity (30).
[0337] The first opening (406) of the first subframe (452) forms an air inlet at the first end of the frame (450), and the second opening (413) of the first subframe (452) provides fluid communication between the chamber (404) of the first subframe (452) and the cavity (30). Similarly, the first opening (406) of the second subframe (454) forms an air outlet (412) at the first end of the frame (450), and the second opening (413) of the second subframe (454) provides fluid communication between the chamber (404) of the second subframe (454) and the cavity (30).
[0338] FIG. 23 shows a schematic cross-sectional view of an aerosol generating device (90) configured for use with the aerosol generating article (10) described herein. The aerosol generating device (90) is an elongated aerosol generating device extending between a proximal end (91) and a distal end (92). The aerosol generating device (90) includes a battery (93), a controller (94), a first heater (95), and a second heater (96) located within a housing (97). The controller (94) controls the power supply from the battery (93) to the first heater (95) and the second heater (96). A cavity (1000) is defined in the device (90), and the cavity (1000) has an opening (1010) defined at the proximal end (91) of the device (90). The opening (1010) is rectangular in shape and is dimensioned to accommodate a cross-section of the aerosol generating article (10). The cavity (1000) includes an upper planar surface (1020) and a lower planar surface (1030). A first heater (95) is located on the upper planar surface (1020) to heat the first planar outer surface (21) of an aerosol generating article (10) inserted into the cavity (1000), and a second heater (96) is located on the lower planar surface (1030) to heat the second planar outer surface (22) of an aerosol generating article (10) inserted into the cavity (1000). The device (90) includes an air inlet (98) that defines an airflow path configured to allow air to flow from outside the device into the cavity (1000).
[0339] FIG. 24 shows a schematic cross-sectional view of the aerosol generating device (90) of FIG. 23 that engages with the aerosol generating article (10) of FIG. 1. There is almost no tolerance between the first planar outer surface (21) and the second planar outer surface (22) of the aerosol generating article (10) and the inner surface (1020, 1030) of the cavity (1000). Therefore, there is a tight fit between the aerosol generating article (10) and the aerosol generating device (90). When a consumer inserts the aerosol generating article (10) into the cavity (1000), the device can be operated. The first heater (95) heats the first planar outer surface (21) of the aerosol generating article (10), and the second heater (96) heats the second planar outer surface (22) of the aerosol generating article, and as a result, the aerosol generating material is heated. The volatile components of the aerosol generating material evaporate and condense within the cavity (30) of the aerosol generating article (10) to form an aerosol. A consumer inhales the aerosol by sucking on the end of the aerosol generating article (10) which includes an air outlet (12). Once the volatile components in the aerosol generating material are depleted, the aerosol generating article (10) is removed from the cavity (1000) and disposed of.
[0340] For the purposes of this description and the attached 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 contain any intermediate ranges that may or may not be specifically enumerated herein. Accordingly, in this context, the number A is understood as 10% of A ± A. Within 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 examples used in the attached claims, the number A may deviate by the percentages listed above, provided that the amount of deviation 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 contain any intermediate ranges that may or may not be specifically enumerated herein.
Claims
Claim 1 An aerosol generating article for generating an aerosol by use with an aerosol generating device, wherein the aerosol generating article comprises: a first planar outer surface; a second planar outer surface; a cavity; one or more aerosol generating materials located within the cavity; an air inlet; an air outlet; and a frame that at least partially defines the cavity, the air inlet, and the air outlet; wherein the frame comprises a first subframe and a second subframe connected to the first subframe. Claim 2 In paragraph 1, the first subframe is an aerosol generating article identical to the second subframe. Claim 3 An aerosol generating article according to claim 1 or 2, wherein the air inlet is defined by the first subframe and the air outlet is defined by the second subframe. Claim 4 An aerosol generating article according to claim 1, 2, or 3, wherein the first subframe is spaced apart from the second subframe and defines at least partially a cavity between the first subframe and the second subframe. Claim 5 An aerosol generating article according to any one of claims 1 to 4, wherein the first subframe at least partially defines the first end of the aerosol generating article and the second subframe at least partially defines the second end of the aerosol generating article. Claim 6 An aerosol generating article according to any one of claims 1 to 5, wherein the frame further comprises a first side portion extending from the first subframe to the second subframe and a second side portion extending from the first subframe to the second subframe, optionally the second side portion is spaced apart from the first side portion to define at least partially a cavity between the first side portion and the second side portion, and optionally each of the first side portion and the second side portion is directly connected to both the first subframe and the second subframe. Claim 7 An aerosol generating article according to any one of claims 1 to 6, wherein the first subframe comprises a body portion defining a chamber and a first opening at a first end of the chamber; a first flap formed integrally with the body portion; and a second flap formed integrally with the body portion; wherein each of the first flap and the second flap is positioned over a second end of the chamber, and the first flap and the second flap together define a second opening at the second end of the chamber, optionally the first opening forms an air inlet, and the second opening provides fluid communication between the chamber and the cavity. Claim 8 An aerosol generating article according to any one of claims 1 to 7, wherein the second subframe comprises: a body portion defining a chamber and a first opening at a first end of the chamber; a first flap formed integrally with the body portion; and a second flap formed integrally with the body portion; wherein each of the first flap and the second flap is positioned over a second end of the chamber, and the first flap and the second flap together define a second opening at the second end of the chamber, optionally the first opening forms an air outlet, and the second opening provides fluid communication between the chamber and the cavity. Claim 9 An aerosol generating article according to any one of claims 1 to 8, wherein the aerosol generating article defines a longitudinal direction extending from the air inlet to the air outlet, and each of the first subframe, the second subframe, and the cavity has a length extending in the longitudinal direction, the length of the first subframe is equal to the length of the second subframe, and the length of the cavity is an integer multiple of the length of the first subframe. Claim 10 An aerosol generating article according to any one of claims 1 to 9, wherein each of the first subframe and the second subframe is in the form of a tube, optionally the first subframe and the second subframe each define a first opening at a first end of the subframe, a second opening at a second end of the subframe, and an airflow passage extending between the first opening and the second opening, optionally the first opening of the first subframe forms the air inlet, and the first opening of the second subframe forms the air outlet, optionally the first opening, the second opening and the airflow passage each have the same cross-sectional size and shape, and optionally the tube has a rectangular cross-sectional shape. Claim 11 An aerosol generating article according to claim 10, wherein each of the first subframe and the second subframe comprises a first part and a second part, wherein the first part is formed separately from the second part, the first part is placed on the second part, and optionally, each of the first part and the second part has an L-shaped cross-sectional shape. Claim 12 In claim 10, the aerosol generating article wherein each of the first subframe and the second subframe is formed of a folded sheet material. Claim 13 In claim 1 or 2, the first subframe partially defines the air inlet and the air outlet, and the second subframe partially defines the air inlet and the air outlet; optionally, the aerosol generating article comprises a first end and a second end, and each of the first subframe and the second subframe extends between the first end and the second end; optionally, the first subframe comprises at least one first protrusion and at least one first recess, and the second subframe comprises at least one second protrusion and at least one second recess, each first protrusion is received within the second recess, and each second protrusion is received within the first recess; optionally, the cavity has a hexagonal shape or a rounded hexagonal shape; optionally, each of the first subframe and the second subframe defines half of the hexagonal shape or the rounded hexagonal shape; optionally, at least a portion of each of the first subframe and the second subframe has an L-shaped cross-section. An aerosol generating article, wherein optionally the first subframe comprises a first aperture extending through the first subframe, and the second subframe comprises a second aperture extending through the second subframe, and the first subframe is placed over the second subframe so that the first aperture and the second aperture cooperate to define the cavity at least partially. Claim 14 An aerosol generating system comprising: an aerosol generating article according to any one of claims 1 to 13; and an aerosol generating device, wherein the aerosol generating device comprises: A chamber for accommodating at least a portion of the above-mentioned aerosol generating article; and An aerosol generating system comprising an electric heater arranged to heat at least a portion of the aerosol generating article when the aerosol generating article is received within the chamber. Claim 15 A method for forming an aerosol generating article for use with an aerosol generating device to generate an aerosol, the method comprising: providing a plurality of subframes, wherein each subframe has a tubular shape and each subframe has the same length; positioning the first of the subframes and the second of the subframes such that the second subframe is spaced apart from the first subframe by a spacing distance, wherein the spacing distance is an integer multiple of the length of each subframe; providing a first side portion and a second side portion, wherein each of the first side portion and the second side portion has a length equal to the sum of the length of the first subframe, the length of the second subframe, and the spacing distance; and positioning one or more aerosol generating materials between the first subframe and the second subframe. A method comprising the step of fixing each of the first side portion and the second side portion to both the first subframe and the second subframe to form a frame, wherein the frame partially defines a cavity between the first subframe, the second subframe, the first side portion and the second side portion, and the one or more aerosol generating materials are located within the cavity, and the frame and the one or more aerosol generating materials together form an aerosol generating article.