Aerosol generating article having a protruding mouthpiece

Abstract

The aerosol generating article comprises an aerosol-forming substrate and a mouthpiece. The mouthpiece comprises a proximal portion for insertion into a user's mouth. The aerosol-forming substrate has a length dimension greater than the width dimension and a width dimension greater than the thickness dimension. The proximal portion of the mouthpiece has a maximum width dimension at least 4% greater than the width dimension of the aerosol-forming substrate.

Description

Technology Field

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

[0002] A typical aerosol generating article may look similar to a conventional cigarette. For example, such an aerosol generating article may be a substantially cylindrical article containing other components such as an aerosol-forming substrate and a mouthpiece filter element, all wrapped in cigarette paper. The dimensions of a typical aerosol generating article are often similar to the dimensions of a conventional cigarette.

[0003] According to research, in these conventional aerosol-generating articles containing a plug of an aerosol-generating material, it has been found that a significant portion of the plug of the aerosol-generating material may not heat up sufficiently to form an aerosol during use. This is undesirable because this portion of the plug of the aerosol-generating material contributes to the manufacturing and transport costs of the aerosol-generating article but does not contribute to the aerosol delivered to the end user. This may apply regardless of how the aerosol-generating material is heated, for example, whether a resistive or inductive heater is used, and regardless of whether the plug of the aerosol-generating material is heated from the inside or the outside.

[0004] The object of the present disclosure is to provide an aerosol generating article, wherein a larger portion of the aerosol-forming substrate of the aerosol generating article is heated sufficiently to form an aerosol during use.

[0005] According to the present disclosure, an aerosol generating article may be provided comprising an aerosol forming substrate for generating an aerosol. Preferably, the aerosol generating article is substantially planar. For example, the aerosol generating article may have a base defined by a length extending in the x-direction, a width extending in the y-direction, and a height extending in the z-direction. Preferably, the aerosol generating article comprises a mouthpiece. The mouthpiece may be detachably coupled to the aerosol forming substrate. The mouthpiece may be integrated with the aerosol forming substrate. Preferably, an airflow path is defined through the aerosol forming substrate and the mouthpiece. The mouthpiece may be defined by a length extending in the x-direction, a width extending in the y-direction, and a height extending in the z-direction.

[0006] According to the present disclosure, an aerosol generating article may be provided comprising an aerosol forming substrate for generating an aerosol coupled to a mouthpiece. The aerosol generating article may comprise a substantially flat upper surface defined by a length extending in the x-direction and a width extending in the y-direction, and a substantially flat lower surface defined by a length extending in the x-direction and a width extending in the y-direction. The substantially flat upper surface and the substantially flat lower surface may be spaced perpendicularly apart from each other by a height defined in the z-direction.

[0007] According to the present disclosure, an aerosol generating article comprising an aerosol-forming substrate and a mouthpiece may be provided. The mouthpiece comprises a proximal portion and a distal portion for insertion into a user's mouth. The mouthpiece may be coupled to the aerosol-forming substrate. The mouthpiece may be configured to be coupled to the aerosol-forming substrate. An airflow path is defined by an airflow channel penetrating the mouthpiece between the distal portion and the proximal portion.

[0008] Upon use, the user may inhale air through the aerosol-generating article by inhaling through the mouthpiece. The air is drawn into and through the aerosol-forming substrate, drawn into the mouthpiece through an airflow channel defined by the mouthpiece, and drawn into the user's mouth. Upon use, the airflow entrains volatile components of the aerosol-forming substrate that are released from the substrate, for example by heating. As the airflow cools, the volatile components condense to form an aerosol.

[0009] According to the present disclosure, an aerosol generating article comprising an aerosol-forming substrate and a mouthpiece may be provided, wherein the mouthpiece comprises a proximal portion for insertion into a user's mouth. The aerosol-forming substrate has a length dimension greater than or equal to a width dimension and a width dimension greater than a thickness dimension.

[0010] The proximal portion of the mouthpiece may have a width dimension greater than the width dimension of the aerosol-forming substrate. The proximal portion of the mouthpiece may have a width extending in the y-direction greater than the width extending in the y-direction of the aerosol-forming substrate. The proximal portion of the mouthpiece may have a major axis dimension greater than the width dimension of the aerosol-forming substrate.

[0011] The width dimension of the proximal portion of the mouthpiece, for example, the width extending in the y-direction or the major axis dimension, is preferably at least 4% larger than the width dimension of the substrate, for example, at least 5% larger, at least 10% larger, at least 20% larger, at least 30% larger, for example, at least 50% larger. The width dimension of the proximal portion of the mouthpiece may be 4% to 420%, for example, 10% to 100%, for example, 20% to 33% larger than the width dimension of the substrate.

[0012] The width of the proximal portion of the mouthpiece may preferably be 6 mm to 26 mm. The width of the substrate may preferably be 5 mm to 25 mm and may preferably be larger than the width of the proximal portion of the mouthpiece. Accordingly, the width of the proximal portion of the mouthpiece may preferably be greater than 4% to greater than 420% of the width of the substrate.

[0013] The proximal portion of the mouthpiece may have a cross-section having a larger area than the cross-section of the aerosol-forming substrate, and the cross-section of the substrate and the cross-section of the mouthpiece are cross-sections taken perpendicular to the length dimension of the aerosol-forming substrate.

[0014] The mouthpiece may have a distal portion including a recess dimensioned to engage with an aerosol-forming substrate. An airflow path may be defined between the distal and proximal portions through the mouthpiece.

[0015] Non-rod-shaped aerosol generating articles, particularly thin, flat consumables, have an overall shape that may be uncomfortable for a user to inhale directly. While flat aerosol generating materials offer advantages in rapid heating response and optimized material utilization, the shape is not ergonomic due to the very thin profile containing sharp edges. Advantageously, a mouthpiece can be combined with a flat aerosol generating material to provide an aerosol generating article with a comfortable shape that allows for user inhalation while still maintaining the advantages of the flat material. The mouthpiece may allow the use of very small materials, for example, very narrow materials and / or very thin materials that would otherwise be difficult to handle.

[0016] The mouthpiece may include a recess having substantially the same shape as a cross section of the aerosol-forming substrate, where the cross section is a cross section taken perpendicular to the length dimension of the aerosol-forming substrate. The recess may be dimensioned to form a mechanical interaction with the aerosol-forming substrate to bond the aerosol-forming substrate to the mouthpiece. The recess may define a ridge or a lip for bonding with the aerosol-forming substrate. The recess may be dimensioned to provide an interference fit with the aerosol-forming substrate.

[0017] The mouthpiece may form an integral part of the aerosol-generating article. That is, the mouthpiece may be an inremovable part of the article. However, advantageously, the mouthpiece may be removablely coupled to the aerosol-generating substrate. Thus, a single mouthpiece may be used to consume many individual aerosol-generating substrates. Thus, the mouthpiece may be a detachable mouthpiece and can be separated from the aerosol-generating substrate.

[0018] The proximal portion of the mouthpiece can be shaped to fit the user's mouth ergonomically. For example, the proximal portion of the mouthpiece may have a curved cross-sectional shape, such as a curved non-circular cross-sectional shape. The cross-sectional shape may be described as oval, elliptical, or lens-shaped.

[0019] The proximal portion of the mouthpiece may have a cross-sectional shape defined by a maximum width and a maximum height. The width of the cross-sectional shape may be equivalent to the major axis of the cross-sectional shape. Thus, the maximum width may be the maximum dimension of the major axis. The height of the cross-sectional shape may be equivalent to the minor axis of the cross-sectional shape. Thus, the maximum height may be the maximum dimension of the minor axis. For example, the maximum width may be 6 mm to 26 mm, for example, 11 mm to 25 mm, for example, 13 mm to 23 mm, for example, about 10 mm, or about 13 mm, or about 16 mm, or about 23 mm. The maximum height may be 4 mm to 15 mm, for example, 5 mm to 13 mm, for example, about 6 mm to 9 mm, for example, about 5 mm, or about 5 mm, or about 9 mm, or about 13 mm.

[0020] The cross-section of the proximal portion of the mouthpiece may have a shape defined by the maximum width and maximum height, wherein the ratio of the maximum width to the maximum height is 2:1 to 5:1, e.g. 2.5:1 to 4:1, e.g. 3:1 to 3.5:1. The cross-section of the mouthpiece, e.g. the proximal portion of the mouthpiece, may have an oval, elliptical, or lens shape, and the cross-section of the aerosol-forming substrate may have a rectangular cross-section. The cross-section may be described as a shape with a high aspect ratio. The width may be referred to as the major axis of the shape, and the height may be referred to as the minor axis of the shape.

[0021] The cross-section of the mouthpiece, for example, the proximal portion of the mouthpiece, may have a curved, non-circular shape defined by the major axis and the minor axis. The ratio of the maximum dimension of the major axis to the maximum dimension of the minor axis may be 1.5:1 to 5.5:1, for example, 2:1 to 5:1, for example, 2.5:1 to 4:1, for example, 3:1 to 3.5:1.

[0022] Preferably, the mouthpiece has a length of 10 mm to 25 mm, for example, 12 mm to 21 mm. The airflow path can preferably be defined by the length dimension of the mouthpiece.

[0023] An aerosol generating article according to the present disclosure may include a mouthpiece portion and a substrate portion, for example, a substantially flat substrate portion. Accordingly, the aerosol generating article may be described as a flat article or a flat article.

[0024] The aerosol generating article according to the present disclosure may preferably be a substantially flat article or a substantially planar article. Such an article has a large base area relative to the volume of the article, at least with respect to the portion of the aerosol-forming substrate of the article. Advantageously, a larger base area may provide a larger surface area for heating by a planar heater of the aerosol generating device. Advantageously, a smaller height may allow for a smaller temperature gradient or difference across the height of the aerosol generating article during heating. For example, if the base of the aerosol generating article is in contact with a planar heater and heated by it, a smaller gap or height between the base and the upper surface may result in a smaller temperature difference between the base and the upper surface facing the base. Advantageously, this may minimize the risk of the hottest part of the substrate closest to the heater burning while enabling a greater proportion of the aerosol-forming substrate of the aerosol generating article to the temperature at which the aerosol is released. Alternatively or additionally, this may reduce the time required to heat the aerosol-forming substrate sufficiently to release the aerosol.

[0025] An aerosol generating article according to any one of the embodiments disclosed herein may have an airflow path extending through the aerosol generating article. The aerosol generating article may have an airflow path defined through the aerosol generating article in the x / y plane from one side of the aerosol generating article to another side of the aerosol generating article. The aerosol generating article preferably has a resistance to suction (RTD) of less than 20 mm H2O, for example, less than 10 mm H2O, in the direction of the airflow path. Preferably, the aerosol generating article has an RTD of less than 20 mm H2O, for example, less than 10 mm H2O, in at least one direction in the x / y plane of the aerosol generating article. An aerosol generating article having a low resistance airflow path can enable excellent airflow management and allow aerosols to be extracted more efficiently from the aerosol generating article and delivered to the user.

[0026] Unless otherwise specified, resistance to suction (RTD) is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through the entire length of a component, such as in an aerosol-generating article. The terms "pressure drop" or "resistance to suction" with respect to a component or article may also refer to "resistance to suction." These terms generally refer to measurements performed under testing in accordance with ISO 6565-2015 at a temperature of approximately 22°C, a pressure of approximately 101 kPa (approx. 760 Torr), and a relative humidity of approximately 60%, at a volumetric flow rate of approximately 17.5 mm / s at the output or downstream end of the component.

[0027] An aerosol generating article according to any one of the embodiments disclosed herein may comprise an upper and lower surface that is substantially planar. A vertical separation between the substantially planar upper surface and the lower surface may define the height (e.g., z-dimension) of the aerosol generating article. An airflow channel may be defined between the substantially planar upper surface and the lower surface. The aerosol generating article may have a height of less than 5 mm, e.g., 1.5 mm to 5 mm, e.g., 1.5 mm to 4 mm, e.g., 1.5 mm to 3 mm, e.g., 1.5 mm to 2 mm. One or both of the substantially planar upper and lower surfaces may comprise an aerosol-forming substrate. The aerosol generating article may comprise an upper and lower layer, at least one of the upper and lower layer comprises or is made of an aerosol-forming substrate, the upper layer forms a substantially planar upper surface, and the lower layer forms a substantially planar lower surface.

[0028] According to the present disclosure, an aerosol generating article may be provided comprising a first planar layer, a second planar layer, a wavy layer arranged between the first planar layer and the second planar layer, and a mouthpiece coupled to a substrate portion. At least one of the first planar layer, the second planar layer, and the wavy layer may comprise or be made of an aerosol forming substrate.

[0029] The use of a corrugated structure within aerosol-generating articles makes it advantageous to produce articles that have a very low RTD while remaining sufficiently rigid for user handling. Additionally, the use of the corrugated structure enables the production of low-density, low-RTD aerosol-generating articles using high-speed manufacturing methods similar to those used in the production of corrugated cardboard.

[0030] According to the present disclosure, an aerosol generating article may be provided, and the aerosol generating article comprises a first planar outer surface, a second planar outer surface, a cavity, a frame located between the first planar outer surface and the second planar outer surface and defining at least partially the cavity, an aerosol forming substrate located between the first planar outer surface and the second planar outer surface, an air inlet and an air outlet, an airflow passage extending between the air inlet and the air outlet through the cavity, and a mouthpiece coupled to the substrate portion.

[0031] The frame may include a surrounding wall surface that at least partially surrounds or encloses the cavity. The frame may include a surrounding wall surface that completely surrounds or encloses the cavity.

[0032] The aerosol generating article may include a first planar outer layer and a second planar outer layer, wherein the first planar outer layer forms a first planar outer surface and the second planar outer layer forms a second planar outer surface. Optionally, at least one of the first planar outer layer, the second planar outer layer, and the frame may include or be made of an aerosol forming substrate.

[0033] The common area can be practically empty.

[0034] The aerosol-forming substrate can be located within the cavity.

[0035] The wavy fold layer can be located within the cavity.

[0036] Any of the aerosol-generating articles of any aspect of the present disclosure may have a length (e.g., in x-dimension) of 10 mm to 100 mm, or 10 mm to 50 mm, for example, 12 mm to 30 mm, for example, 14 mm to 26 mm, for example, 16 mm to 24 mm, for example, 18 mm to 22 mm, for example, about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.

[0037] The aerosol generating article may have a width (e.g., in y-dimension) of 5 mm to 20 mm, e.g. 8 mm to 18 mm, e.g. 10 mm to 16 mm, e.g. 11 mm to 15 mm, e.g. 12 mm to 14 mm, e.g. about 13 mm.

[0038] The aerosol generating article may have a height (e.g., in z-dimension) of 1 mm to 10 mm, e.g. 1.2 mm to 8 mm, e.g. 1.4 mm to 7 mm, e.g. 1.6 mm to 6 mm, e.g. 1.7 mm to 5 mm, e.g. about 1.7 mm, or about 4.5 mm, or about 2 mm, or about 3 mm, or about 4 mm.

[0039] When viewed in a planar view, at least a portion of the aerosol generating article of any one of the embodiments of the present disclosure may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an ellipse, or a circle, or a combination thereof. Where the aerosol generating article comprises substantially planar upper and lower surfaces, when viewed in a planar view, one or both of the upper and lower surfaces may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof. When viewed in a planar view, the perimeter of the aerosol generating article may be formed by a plurality of straight sides, a plurality of curved sides, or a combination of straight sides and curved sides. Where the aerosol generating article comprises substantially planar upper and lower surfaces, when viewed in a planar view, the perimeter of one or both of the upper and lower surfaces may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof.

[0040] The aerosol generating article may be composed entirely of an aerosol-forming substrate, in which case any mouthpiece may be integrally formed as part of the aerosol-forming substrate. Alternatively, the aerosol-forming substrate may be one of a plurality of constituent parts of the aerosol generating article and may be removablely coupled to the mouthpiece. The substrate may be described as being separable from the mouthpiece.

[0041] The aerosol-forming material may contain nicotine. Nicotine may exist in the form of a tobacco material or in the form of a nicotine extract.

[0042] Preferably, the aerosol-forming substrate comprises or is made of a homogenized tobacco material, for example, a reconstituted tobacco material or a cast leaf tobacco material.

[0043] The aerosol-forming substrate may include or be composed of an aerosol-forming material. The aerosol-forming substrate may include a liquid aerosol-forming material, for example, a liquid aerosol-forming material retained within a porous matrix. The aerosol-forming substrate may include a gel aerosol-forming material.

[0044] The aerosol-forming substrate may comprise one or more aerosol-forming agents. Suitable aerosol-forming agents are known in the art and include, but are not limited to, polyhydric alcohols such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable that the aerosol-forming agent is glycerin or includes it.

[0045] The aerosol-forming substrate may comprise an aerosol-forming material having at least 1, 2, 5, 10, or 15 weight percent of an aerosol-forming agent. The aerosol-forming material may comprise more than 15 weight percent, for example, more than 20 weight percent, or more than 25 weight percent, or more than 30 weight percent, or more than 40 weight percent, or more than 50 weight percent of an aerosol-forming agent.

[0046] The aerosol-forming material may contain 30% by weight or less of an aerosol-forming agent, 25% by weight or less of an aerosol-forming agent, or 20% by weight or less of an aerosol-forming agent. That is, the aerosol-forming material may have an aerosol-forming agent content of 30% by weight or less, 25% by weight or less, or 20% by weight or less.

[0047] The aerosol-forming material may comprise 1% to 30% by weight of an aerosol-forming agent, 1% to 25% by weight of an aerosol-forming agent, or 1% to 20% by weight of an aerosol-forming agent.

[0048] The aerosol-forming material may comprise 5% to 30% by weight of an aerosol-forming agent, 5% to 25% by weight of an aerosol-forming agent, or 5% to 20% by weight of an aerosol-forming agent.

[0049] The aerosol-forming material may comprise 10% to 30% by weight of an aerosol-forming agent, 10% to 25% by weight of an aerosol-forming agent, or 10% to 20% by weight of an aerosol-forming agent.

[0050] The aerosol-forming material may comprise 15% to 30% by weight of an aerosol-forming agent, 15% to 25% by weight of an aerosol-forming agent, or 15% to 20% by weight of an aerosol-forming agent.

[0051] The aerosol-forming material may comprise at least 50 weight% of an aerosol-forming agent, at least 60 weight% of an aerosol-forming agent, or at least 70 weight% of an aerosol-forming agent.

[0052] The aerosol-forming material may include 85 weight% or less of an aerosol-forming agent, 80 weight% or less of an aerosol-forming agent, or 75 weight% or less of an aerosol-forming agent.

[0053] The aerosol-forming material may comprise 50% to 85% by weight of an aerosol-forming agent, 50% to 80% by weight of an aerosol-forming agent, or 50% to 75% by weight of an aerosol-forming agent.

[0054] The aerosol-forming material may comprise 60% to 85% by weight of an aerosol-forming agent, 60% to 80% by weight of an aerosol-forming agent, or 60% to 75% by weight of an aerosol-forming agent.

[0055] The aerosol-forming material may comprise 70% to 85% by weight of an aerosol-forming agent, 70% to 80% by weight of an aerosol-forming agent, or 70% to 75% by weight of an aerosol-forming agent.

[0056] The aerosol-forming substance may contain nicotine. The aerosol-forming substance may contain natural nicotine, synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0057] The aerosol-forming material may contain at least 0.5 weight% nicotine, at least 1 weight% nicotine, at least 1.5 weight% nicotine, or at least 2 weight% nicotine. That is, the aerosol-forming material may have a nicotine content of at least 0.5 weight%, at least 1 weight%, at least 1.5 weight%, or at least 2 weight%.

[0058] The aerosol-forming material may comprise one or more cannabinoid compounds, such as one or more of tetrahydrocannabinol (THC), tetrahydrocannabinol (THCA), cannabidiol (CBD), cannavidioric acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannavivarin (CBV), cannavivarin (CBDV), tetrahydrocannavivarin (THCV), cannabicromin (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarine (CBGV), cannabielsoin (CBE), and cannabicitran (CBT). The cannabinoid compound may preferably be CBD or THC. The cannabinoid compound may particularly preferably be CBD.

[0059] The aerosol-forming material may include one or more flavoring agents. One or more flavoring agents may include one or more essential oils such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and one or more herbal materials. Suitable herbal materials include, but are not limited to, mints such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway, and other herbal materials derived from herb leaves or herbal plants. One or more flavoring agents may include tobacco materials.

[0060] The aerosol-forming material may have a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state. For example, the aerosol-forming material may be a homogenized tobacco material having about 5 to 25%, preferably about 7 to 15%, moisture in the final product state.

[0061] The aerosol-forming material may comprise about 15 to 45%, preferably about 20 to 35%, of tobacco leaves, for example, a blend of tobacco leaves, and comprises at least one of the following tobacco types: bright tobacco; dark tobacco; aromatic tobacco. Tobacco material such as tobacco leaves is preferably crushed and graded to a particle size of about 100 to 380 mesh, preferably about 170 to 320 mesh.

[0062] "Tobacco type" refers to one of the different varieties of tobacco based on, for example, the unique hardening process that tobacco undergoes before being further processed into tobacco products.

[0063] Examples of bright tobacco include the Brazilian yellow variety, the Indian yellow variety, the Chinese yellow variety, the American yellow variety such as Virginia tobacco, and the Tanzanian yellow variety.

[0064] Examples of flavored tobaccos include Oriental Turkish tobacco, Greek Oriental tobacco, and semi-Oriental tobacco, as well as American Burley dry tobaccos such as Perique and Rustica.

[0065] Examples of dark tobacco are fumigated Brazilian gaupão, Burleigh Malawi or other African burleigh, and sun-dried or air-dried Indonesian kasturi.

[0066] The aerosol-forming material may include cellulose fibers. For example, the aerosol-forming material may include about 1 to 15% cellulose fibers, preferably about 3 to 7% cellulose fibers. Preferably, the cellulose fibers may have a length of about 10 to 250 μm, preferably about 10 to 120 μm.

[0067] The aerosol-forming material may comprise organic fibers, such as non-tobacco fibers, or tobacco fibers. For example, the aerosol-forming material may comprise about 5 to 20%, preferably about 7 to 15%, of tobacco fibers. The tobacco fibers are preferably derived from stems and / or leaf stalks graded into fibers with a length of about 10 to 350 μm, preferably about 10 to 180 μm. The aerosol-forming material may comprise about 10 to 30%, preferably about 15 to 25%, of non-tobacco organic fibers. For example, the organic fibers may be derived as sub-products from cellulose, cotton, wood, or tea plant varieties, and from sub-processed waste in the tea industry. The organic fibers are preferably about 10 to 400 μm, preferably about 10 to 200 μm in length.

[0068] The aerosol-forming material may include a binder. For example, the aerosol-forming material may include about 1 to 10%, preferably about 1 to 5%, of a binder such as either a common gum or pectin used in the food and beverage (F&B) industry. Preferred binders may be natural pectins, e.g., fruit, e.g., citrus or tobacco pectins; guar gum, land locust bean gum, e.g., their hydroxyethyl and hydroxypropyl; starch, e.g., modified or derived starch; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; dextran; and xanthan gum. A preferred binder is guar.

[0069] The aerosol-forming material may include organic plant glycerites. For example, the aerosol-forming material may include about 15 to 55%, preferably about 20 to 35%, of plants, such as clove, echinacea species, fennel, ginger, hawthorn berry, elderberry, monada, mullet leaf, nettle, plantain, turmeric, yarrow, and compounds thereof.

[0070] The aerosol-forming material may include organic plant extracts. For example, the aerosol-forming material may include, in an amount of about 1 to 15%, preferably about 2 to 7%, any one of the aforementioned plant components, as well as menthol (dl-menthol, C10H20O, 2-isopropyl-5-methylcyclohexanol) obtained from Charophyllum macrosperm, Mesosphaerum cidifolium, or other related plant varieties, and p-mentan-3-ol as any secondary alcohol as a diastereomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.

[0071] The aerosol-forming material may include vegetable essential oils, for example, about 0.5 to 5%, preferably about 1 to 3%, of vegetable essential oils, such as palm, coconut, and wood essential oils.

[0072] The aerosol-forming material preferably comprises an aerosol-forming agent, for example, about 5 to 35%, preferably about 10 to 25%. Suitable aerosol-forming agents known in the art include glycerin; monohydric alcohols such as menthol, polyhydric alcohols such as triethylene glycol; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids, for example, their dimethyl forms.

[0073] As used herein, the term "aerosol generating article" may refer to an article capable of generating or releasing an aerosol. The article may include an aerosol-forming substrate and a mouthpiece.

[0074] As used herein, the term “aerosol-forming substrate” may refer to a component part of an aerosol-generating article comprising a material capable of releasing an aerosol or a volatile compound capable of forming an aerosol. Such volatile compounds may be released from the aerosol-forming material by heating the aerosol-forming substrate. The aerosol-forming substrate may substantially comprise or consist entirely of an aerosol-forming material. The aerosol-forming substrate may comprise an aerosol-forming material and a non-aerosol-forming material. The non-aerosol-forming material may provide structure to the aerosol-forming substrate. The aerosol-forming material may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support to form the aerosol-forming substrate.

[0075] As used herein, the term "aerosol generating device" may refer to a device for use with an aerosol generating article to enable the generation or release of an aerosol.

[0076] As used herein, the term “aerosol generating system” refers to a combination of an aerosol generating device and one or more aerosol-forming articles for use with the device. The aerosol generating system may include additional components, such as a charging unit for recharging an embedded power supply within an electrically operated or electric aerosol generating device.

[0077] As used herein, the term "aerosol-forming agent" may refer to any suitable known compound or mixture of compounds that facilitates the formation of an aerosol upon use. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-forming substrate or the aerosol-generating article.

[0078] As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salt.

[0079] As used herein with respect to the present invention, the terms “proximal,” “distal,” “upstream,” and “downstream” are used to describe the relative positions of a component of an aerosol-generating article, or a part of a component. “Upstream” and “downstream” refer to the direction of the airflow when a user inhales the aerosol-generating article or device.

[0080] As used herein, the term "longitudinal" refers to a direction corresponding to the main longitudinal axis of the aerosol generating article extending between the upstream and downstream ends of the aerosol generating article. During use, air may be drawn longitudinally through the aerosol generating article.

[0081] As used herein, the term “sheet” refers to a laminated element having a width and length substantially greater than its thickness. The width of the sheet may be greater than 10 mm, preferably greater than 20 mm or 30 mm. In certain embodiments, the sheet of material to be used to form an aerosol-forming substrate as described herein may have a thickness of 10 μm to about 1000 μm, for example, 10 μm to about 300 μm.

[0082] As used herein, the term “homogenized tobacco material” encompasses any tobacco material formed by the aggregation of particles of tobacco material. A sheet or web of homogenized tobacco material is formed by aggregating fine tobacco obtained by crushing or otherwise pulverizing one or both of tobacco leaf blades and tobacco leaf stalks. Additionally, the homogenized tobacco material may contain trace amounts of one or more of tobacco powder, tobacco fines, and other fine tobacco by-products formed during the processing, handling, and delivery of tobacco. A sheet of homogenized tobacco material may be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0083] The term “cast leaf” is used herein to refer to a product produced by a casting process based on casting a slurry comprising plant particles (e.g., clove particles, or a mixture of tobacco particles and clove particles) and a binder (e.g., guar gum) onto a supporting surface, such as a belt conveyor, drying the slurry, and removing the dried sheet from the supporting surface. Examples of casting or cast leaf processes are described, for instance, in US-A-5,724,998 for the production of cast leaf tobacco. In a cast leaf process, particulate plant material is produced by pulverizing, grinding, or crushing a portion of a plant. Particles produced from one or more plants are mixed with a liquid component, typically water, to form a slurry. Other components within the slurry may include fibers, a binder, and an aerosol-forming agent. The particulate plant material may aggregate in the presence of a binder. The slurry is cast onto a supporting surface and dried to become a sheet of homogenized plant material. Preferably, the homogenized plant material used in the article according to the present invention can be produced by casting. Such homogenized plant material may comprise aggregated particulate plant material.

[0084] As used herein, suction resistance is expressed as "mm H2O" or "mm WG" or "mm water level gauge" and is measured according to ISO 6565:2002.

[0085] 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.

[0086] Exi. An aerosol generating article comprising a substantially flat aerosol forming substrate coupled to a mouthpiece.

[0087] Exii. An aerosol generating article comprising a substantially flat aerosol forming substrate that can be removablely coupled to a mouthpiece or separated from a mouthpiece.

[0088] Exiii. An aerosol generating article comprising a substantially flat aerosol forming substrate coupled to a mouthpiece, wherein the airflow path is defined through the aerosol forming substrate and the mouthpiece.

[0089] Exiv. An aerosol generating article comprising a substantially flat aerosol forming substrate coupled to a mouthpiece, wherein the airflow path is defined through the aerosol forming substrate and the mouthpiece, and the airflow path passes through the mouthpiece.

[0090] Exv. An aerosol generating article, for example, an aerosol generating article according to any one of the prior embodiments, comprising an aerosol forming substrate and a mouthpiece, wherein the mouthpiece comprises a proximal portion for insertion into a user's mouth, wherein the aerosol forming substrate has a length dimension greater than or equal to a width dimension and a width dimension greater than a thickness dimension, and the proximal portion of the mouthpiece has a major axis dimension greater than the width dimension of the aerosol forming substrate.

[0091] Exvi. An aerosol generating article, for example, an aerosol generating article according to any one of the prior embodiments, comprising an aerosol forming substrate and a mouthpiece, wherein the mouthpiece comprises a proximal portion for insertion into a user’s mouth, wherein the aerosol forming substrate has a length dimension greater than or equal to a width dimension and a width dimension greater than a thickness dimension, the proximal portion of the mouthpiece has a cross-section having an area greater than a cross-section of the aerosol forming substrate, and the cross-sections of the substrate and the mouthpiece are cross-sections taken perpendicular to the length dimension of the aerosol forming substrate.

[0092] Exvii. An aerosol generating article, for example, an aerosol generating article according to any one of the prior embodiments, comprising an aerosol forming substrate and a mouthpiece, wherein the mouthpiece comprises a proximal portion for insertion into a user’s mouth and a distal portion including a recess dimensioned to engage with the aerosol forming substrate, the airflow path is defined through the mouthpiece between the distal portion and the proximal portion, and the aerosol forming substrate has a length dimension greater than or equal to the width dimension and a width dimension greater than the thickness dimension.

[0093] Ex1. An aerosol generating article, for example, an aerosol generating article according to any one of the prior embodiments, comprising an aerosol forming substrate and a mouthpiece, wherein the mouthpiece comprises a proximal portion for insertion into a user's mouth and a distal portion configured to engage with the aerosol forming substrate, and the airflow path is defined by an airflow channel passing through the mouthpiece between the distal portion and the proximal portion.

[0094] Ex2. An aerosol generating article, comprising, in any one of Examples Exi to Ex1, a mouthpiece and a planar aerosol forming substrate coupled to the mouthpiece, wherein the planar aerosol forming substrate comprises an intermediate layer disposed between an upper layer and a lower layer, wherein the upper surface defines the outer surface of the upper layer and the lower surface defines the outer surface of the lower layer, and the airflow path is defined through the aerosol generating article in the x / y plane between the distal end and the proximal end of the aerosol generating article.

[0095] Ex3. In Ex2, along the airflow path, the resistance to suction (RTD) of the aerosol generating article is less than 20 mm H2O, for example less than 15 mm H2O, or less than 10 mm H2O.

[0096] Ex4. An aerosol generating article in which, in either Ex2 or Ex3, one or more of the upper layer, the middle layer and the lower layer comprise or are composed of an aerosol-forming substrate.

[0097] Ex5. In Ex4, one or both of the upper layer and the lower layer comprise or are composed of an aerosol-forming substrate, and the intermediate layer is an aerosol-generating article that does not have an aerosol-forming substrate.

[0098] Ex6. In Ex4, the intermediate layer comprises or is composed of an aerosol-forming substrate, and the upper layer and the lower layer are aerosol-generating article in which the aerosol-forming substrate is not present.

[0099] Ex7. An aerosol generating article, wherein in any one of Ex2 to Ex6, a plurality of longitudinal extension channels are defined by wavy folds between an upper layer and an intermediate layer and between an intermediate layer and a lower layer, and preferably, said longitudinal extension channels extend in the x / y plane between a distal end and a proximal end.

[0100] Ex8. An aerosol generating article, wherein in any one of Ex2 to Ex7, the intermediate layer is fixed to at least one of the upper layer and the lower layer by an adhesive, for example, the adhesive comprises guar gum, and optionally the adhesive comprises an aerosol-forming material such as homogenized tobacco slurry.

[0101] Ex9. An aerosol generating article, wherein in any one of Ex2 to Ex8, the intermediate layer comprises a wavy wrinkle element, for example, the intermediate layer comprises a plurality of wavy wrinkle elements, wherein two or more of the plurality of wavy wrinkle elements are arranged in a perpendicular relationship between the upper layer and the lower layer, for example, one or more of the plurality of wavy wrinkle elements comprises an aerosol forming substrate, for example, the intermediate layer further comprises a planar element located between two of the plurality of wavy wrinkle elements.

[0102] Ex10. In any one of the prior embodiments, the aerosol-forming substrate is substantially a planar substrate, and for example, the aerosol-forming substrate is substantially a parallelepiped shape, for example, substantially a rectangular parallelepiped shape, an aerosol-generating article.

[0103] Ex11. In any one of the prior embodiments, the aerosol-forming substrate is an aerosol-forming article having a length defined by an x-dimensional extending in the x direction, a width defined by a y-dimensional extending in the y direction, and a thickness defined by a z-dimensional extending in the z direction.

[0104] Ex12. An aerosol generating article, wherein in any one of the previous embodiments, the thickness of the aerosol-forming substrate is 1 mm to 5 mm, for example 1.2 mm to 4.7 mm, for example 2 mm to 4 mm, for example about 1.5 mm, or about 2.5 mm, or about 3 mm, or about 4 mm.

[0105] Ex13. An aerosol generating article, wherein in any one of the prior embodiments, the length of the aerosol-forming substrate is 10 mm to 35 mm, for example 24 mm to 31 mm, for example 20 mm to 25 mm, for example about 14 mm, or about 20 mm, or about 25 mm, or about 31 mm.

[0106] Ex14. An aerosol generating article, wherein in any one of the prior embodiments, the width of the aerosol-forming substrate is 5 mm to 25 mm, for example 9 mm to 21 mm, for example 12 mm to 16 mm, for example about 9 mm, or about 12 mm, or about 15 mm, or about 20 mm.

[0107] Ex15. In any one of the previous embodiments, the aerosol-forming substrate is an aerosol-forming article having a thickness-to-width ratio of about 0.13:1 to 0.22:1.

[0108] Ex16. In any one of the previous embodiments, the aerosol-forming substrate is an aerosol-forming article having a length-to-width ratio of about 1.55:1 to 1.48:1.

[0109] Ex17. In any one of the prior embodiments, the aerosol-forming substrate comprises two or more layers, for example, two or more layers laminated together, and for example, the aerosol-forming substrate comprises at least a first planar layer forming the upper surface of the aerosol-forming substrate and a second planar layer forming the lower surface of the aerosol-forming substrate, an aerosol-generating article.

[0110] Ex18. In Example Ex17, the aerosol-forming substrate comprises a first planar layer, a second planar layer, and an intermediate layer or separation layer disposed between the first planar layer and the second planar layer, and at least one of the first planar layer, the second planar layer, and the intermediate or separation layer comprises or is composed of an aerosol-forming material, an aerosol-generating article.

[0111] Ex19. In Example Ex18, the intermediate layer or separation layer is a wavy layer, and for example, the aerosol-forming substrate comprises a first planar layer, a second planar layer, and a wavy layer disposed between the first planar layer and the second planar layer, and at least one of the first planar layer, the second planar layer, and the wavy layer comprises or is composed of an aerosol-forming material, an aerosol-generating article.

[0112] Ex20. In Example Ex19, the aerosol generating article is arranged perpendicular to the width direction of the aerosol forming substrate and parallel to the length direction of the aerosol forming substrate.

[0113] Ex21. In any one of the prior embodiments, the airflow path is defined through an aerosol-forming substrate, for example, a low-resistance airflow path is defined through a substrate, for example, the aerosol-forming substrate has an inhalation resistance (RTD) of less than 20 mm H2O along the airflow path, an aerosol-generating article.

[0114] Ex22. In any one of the prior embodiments, the airflow path extends through the substrate from one end to another in the x dimension, for example, the airflow path extends substantially in the x direction, an aerosol generating article.

[0115] Ex23. In any one of the prior embodiments, an aerosol generating article configured to be coupled to an aerosol generating device to generate an aerosol.

[0116] Ex24. An aerosol generating article, wherein in any one of the prior embodiments, the aerosol forming substrate is configured to be received within the heating cavity of an aerosol generating device, and, for example, a part of the mouthpiece is connected to a part of the aerosol generating device to position the aerosol forming substrate within the heating cavity.

[0117] Ex25. In Ex24, the distal portion of the mouthpiece is engaged with an opening for a heating cavity of the aerosol generating device, and there is, for example, a mechanical interaction between the distal portion of the mouthpiece and the opening for the heating cavity, and for example, there is an interference fit between the distal portion of the mouthpiece and the opening for the heating cavity, and / or there is a mechanical engagement fit between the distal portion of the mouthpiece and the opening for the heating cavity.

[0118] Ex26. In any one of the prior embodiments, the aerosol generating article, wherein the aerosol forming substrate has a substantially rectangular cross section, and the cross section is a cross section taken perpendicular to the length dimension of the aerosol forming substrate.

[0119] Ex27. In any one of the prior embodiments, the mouthpiece comprises a recess having substantially the same shape as a cross section of the aerosol-forming substrate, wherein the cross section is a cross section taken perpendicular to the length dimension of the aerosol-forming substrate, and, for example, a collection chamber is defined at the proximal end of the recess.

[0120] Ex28. An aerosol generating article according to Ex27, wherein the recess is dimensioned to form a mechanical interaction with the aerosol forming substrate to join the aerosol forming substrate to the mouthpiece, for example, the recess defines a ridge or lip for engaging with the aerosol forming substrate and / or the recess is dimensioned to provide an interference fit with the aerosol forming substrate.

[0121] Ex29. An aerosol generating article in Ex27 or Ex28, wherein the airflow path through the mouthpiece is defined by an airflow channel, the inlet of the airflow channel is defined within the concave portion, and the outlet of the airflow channel is defined in the proximal portion of the mouthpiece.

[0122] Ex30. In any one of the prior embodiments, the mouthpiece is formed of a biodegradable material and / or the mouthpiece is formed of a paper material, an aerosol generating article.

[0123] Ex31. In any one of the prior embodiments, the proximal portion of the mouthpiece is shaped to fit the user's mouth ergonomically, an aerosol generating article.

[0124] Ex32. In any one of the prior embodiments, the proximal portion of the mouthpiece has a curved cross-sectional shape, for example, a curved non-circular cross-sectional shape, for example, the cross-sectional shape is oval, elliptical, or lens-shaped, an aerosol generating article.

[0125] Ex33. An aerosol generating article, wherein in any one of the prior embodiments, the proximal portion of the mouthpiece has a cross-sectional shape defined by a maximum width and a maximum height, and the maximum width is 6 mm to 26 mm, for example 11 mm to 25 mm, for example 13 mm to 23 mm, for example about 10 mm, or about 13 mm, or about 16 mm, or about 23 mm.

[0126] Ex34. An aerosol generating article, wherein in any one of the prior embodiments, the proximal portion of the mouthpiece has a cross-sectional shape defined by a maximum width and a maximum height, and the maximum height is 4 mm to 15 mm, for example 5 mm to 13 mm, for example 6 mm to 9 mm, for example about 5 mm, or about 5 mm, or about 9 mm, or about 13 mm.

[0127] Ex35. An aerosol generating article, wherein in any one of the prior embodiments, the cross-section of the proximal portion of the mouthpiece has a shape defined by a maximum width and a maximum height, and the ratio of the maximum width to the maximum height is 2:1 to 5:1, e.g. 2.5:1 to 4:1, e.g. 3:1 to 3.5:1.

[0128] Ex36. In any one of the previous embodiments, an aerosol generating article, wherein the cross-section of the mouthpiece, for example, the proximal portion of the mouthpiece, has an oval, elliptical, or lens shape, and the cross-section of the aerosol forming substrate has a rectangular cross-section.

[0129] Ex37. An aerosol generating article, wherein in any one of the prior embodiments, the cross-section of the mouthpiece, for example, the proximal portion of the mouthpiece, has a curved non-circular shape defined by the major axis and the minor axis, and the ratio of the maximum dimension of the major axis to the maximum dimension of the minor axis is 1.5:1 to 5.5:1, for example 2:1 to 5:1, for example 2.5:1 to 4:1, for example 3:1 to 3.5:1.

[0130] Ex38. An aerosol generating article, wherein in any one of the previous embodiments, the length of the mouthpiece is 10 mm to 25 mm, for example, 12 mm to 21 mm.

[0131] Ex39. In any one of the prior embodiments, the aerosol generating article comprises a mouthpiece and a planar aerosol forming substrate coupled to the mouthpiece, wherein the planar aerosol forming substrate comprises a planar frame positioned between an upper layer and a lower layer, wherein the upper surface defines the outer surface of the upper layer and the lower surface defines the outer surface of the lower layer, the planar frame defines a cavity, and an airflow path is defined through the aerosol generating article in the x / y plane, and the airflow path extends through the cavity and the mouthpiece.

[0132] Ex40. In Ex39, the upper layer and the lower layer are bonded to opposite surfaces of the frame and are placed over opposite ends of the cavity, an aerosol generating article.

[0133] Ex41. An aerosol generating article in which, in either Ex39 or Ex40, one or both of the upper layer and the lower layer comprise or are composed of an aerosol-forming substrate.

[0134] Ex42. In any one of Ex39 to Ex41, the upper layer and the lower layer are aerosol generating articles in which the aerosol forming substrate is not present.

[0135] Ex43. In any one of Ex39 to Ex42, the frame is an aerosol generating article that does not have an aerosol forming substrate.

[0136] Ex44. An aerosol generating article comprising one or more of particles, shreds, or sheets of an aerosol-forming substrate disposed within a cavity between the upper layer and the lower layer in any one of Ex39 to Ex43.

[0137] Ex45. In any one of Ex39 to Ex44, the wavy element is disposed within the cavity between the upper layer and the lower layer, an aerosol generating article.

[0138] Ex46. In Ex45, the above-mentioned wavy element comprises or is composed of an aerosol-forming substrate, an aerosol-generating article.

[0139] Ex47. In Ex45, the above-mentioned wavy element is an aerosol generating article that does not have an aerosol forming substrate.

[0140] Ex48. An aerosol generating article, wherein in any one of Ex45 to Ex47, a plurality of longitudinal extension channels are defined by ripples between the upper layer and the ripple element and between the ripple element and the lower layer.

[0141] Ex49. In Ex48, the longitudinal extension channel extends along the x / y plane between opposite ends of the frame, an aerosol generating article.

[0142] Ex50. In any one of Ex39 to Ex49, the airflow path is at least partially defined by the frame, an aerosol generating article.

[0143] Ex51. An aerosol generating article in Ex50, wherein the frame comprises an inlet airflow channel and an outlet airflow channel, the inlet airflow channel is configured to allow airflow into the cavity, and the outlet airflow channel is configured to allow airflow to exit the cavity and pass through the mouthpiece.

[0144] Ex52. In Ex51, the inlet airflow channel and the outlet airflow channel are defined on opposite ends of the frame, an aerosol generating article.

[0145] Ex53. An aerosol generating article, wherein in either Ex51 or Ex52, the inlet airflow channel is defined at the first width edge of the frame and the outlet airflow channel is defined at the second width edge of the frame.

[0146] Ex54. An aerosol generating system comprising an aerosol generating article according to any preceding embodiment, and an aerosol generating device configured to receive said aerosol generating article.

[0147] Ex55. In Ex54, the aerosol generating device is configured to generate an inhalable aerosol from at least a portion of the aerosol generating article, and, for example, the aerosol generating device is configured to heat at least a portion of the aerosol generating article to form an inhalable aerosol.

[0148] Ex56. An aerosol generating system in Ex54 or Ex55, wherein the aerosol generating device comprises a heater located within a chamber for receiving an aerosol-forming substrate of the aerosol generating article.

[0149] Ex57. In Ex56, the mouthpiece of the aerosol generating article is configured to be mechanically engaged with the aerosol generating device so that the aerosol forming substrate is received within the chamber for heating, in an aerosol generating system.

[0150] Ex58. An aerosol generating system, wherein in any one of Ex54 to Ex57, the aerosol generating device comprises an air inlet, and the airflow path is defined such that when a user inhales from the mouthpiece, air flows into the device, through the aerosol forming material, through the mouthpiece, into the user's mouth. Brief explanation of the drawing

[0151] Now, embodiments will be further described with reference to the drawings. FIG. 1 is a side perspective view of an aerosol-forming substrate suitable for use as part of an aerosol-generating article according to an embodiment of the present disclosure; FIG. 2 is a perspective view of an additional aerosol-forming substrate; FIG. 3 is a schematic end view of an additional aerosol-forming substrate; FIG. 4 is a schematic side view of the aerosol-forming substrate of FIG. 3; FIG. 5 is a schematic plan view of the aerosol-forming substrate of FIG. 3; FIG. 6 shows a schematic diagram of a wavy element used in the aerosol-forming substrate of FIG. 3; FIG. 7 shows a perspective view of an additional aerosol-forming substrate; FIG. 8 shows an exploded perspective view of the aerosol-forming substrate of FIG. 7; FIG. 9 shows an additional exploded perspective view of the aerosol-forming substrate of FIG. 7; FIG. 10 shows a schematic cross-sectional view of the aerosol-forming substrate of FIG. 7; FIG. 11 shows a schematic longitudinal cross-sectional view of the aerosol-forming substrate of FIG. 7; FIG. 12 shows an exploded perspective view of an additional aerosol-forming substrate; FIG. 13 shows a schematic cross-sectional view of the aerosol-forming substrate of FIG. 12; FIG. 14 shows a schematic side cross-sectional view of the aerosol-forming substrate of FIG. 12; FIG. 15 shows a perspective view of an aerosol-generating article viewed from the distal end according to an embodiment of the present invention; FIG. 16 shows a perspective view of the proximal end of the aerosol-generating article of FIG. 15; FIG. 17 shows a perspective view of the mouthpiece portion of the aerosol generating article of FIG. 15; FIG. 18 illustrates the aerosol generating article of FIG. 15 inserted into an aerosol generating device; FIG. 19 illustrates the aerosol generating article of FIG. 15 when inserted into an aerosol generating device; FIG. 20 shows a cross-sectional view of the aerosol generating article of FIG. 15 when inserted into an aerosol generating device; FIG. 21 shows a perspective view from the distal end of an additional aerosol-generating article according to an embodiment of the present invention; and FIG. 22 shows a perspective view of the proximal end of the aerosol-generating article of FIG. 21. Specific details for implementing the invention

[0152] Specific embodiments of an aerosol generating article substantially comprising a planar aerosol-forming substrate portion and a mouthpiece are described below. Specific embodiments of a planar aerosol-forming substrate suitable for use in such articles are described in relation to FIGS. 1 to 14 below.

[0153] FIG. 1 shows a side perspective view of a planar aerosol-forming substrate (100) for use in an aerosol-generating article according to an embodiment of the present disclosure. The aerosol-forming substrate (100) has upper and lower surfaces (110, 120) that are flat or planar.

[0154] In one embodiment, the aerosol-forming substrate (100) may be substantially composed of an aerosol-forming material. In another embodiment, the aerosol-forming material, e.g., homogenized tobacco, may be one of a plurality of component parts of the aerosol-forming substrate (100). The aerosol-forming material may be surrounded by the interior of the aerosol-forming substrate (100). The aerosol-forming substrate (100) may at least partially define the exterior of the aerosol-generating article; for example, one or both of the upper and lower surfaces (110, 120) may include or be composed of the aerosol-forming material.

[0155] Suitable aerosol-forming substances may be homogenized tobacco.

[0156] The aerosol-forming substrate (100) has a length of 80 mm extending in the x dimension, a width of 15 mm extending in the y dimension, and a height of 3.6 mm extending in the z dimension (which may also be referred to as thickness).

[0157] FIG. 2 illustrates a perspective side view of an aerosol-forming substrate (200). Features common to the aerosol-forming substrate (100) are referred to by similar reference numerals. An airflow path (230) is defined through the aerosol-forming substrate (200) between the upper surface and the lower surface (110, 120). The airflow path (230) extends between opposing first and second ends (201, 202) of the aerosol-forming substrate (200). The first end (201) may define the distal end of the aerosol-forming substrate (200), and the second end (202) may define the proximal end of the aerosol-forming substrate. The airflow path (230) may be guided toward the user's mouth so that the user can inhale an aerosol generated as a result of heating the aerosol-forming material of the aerosol-forming substrate (200).

[0158] FIGS. 3, FIGS. 4, and FIGS. 5 illustrate, respectively, an end view, a side view, and a top view of an aerosol-forming substrate (300). The aerosol-forming substrate (300) comprises a planar upper layer (310), a planar lower layer (320), and an intermediate or separating layer (340) arranged between the upper layer (310) and the lower layer (320).

[0159] The flat upper layer (310) is formed from a paper sheet having a thickness of 300 μm. The flat lower layer (320) is formed from a paper sheet having a thickness of 300 μm. The middle layer (340) is a wavy element formed from a wavy sheet of an aerosol-forming material (345). A suitable aerosol-forming material may be a homogenized tobacco. Thus, the middle layer (340) may be formed from a wavy sheet of a homogenized tobacco material (345).

[0160] FIG. 6 shows a sheet of a wavy aerosol-forming material (345). The wavy pattern has an amplitude (346) of 3 mm and a wavelength (347) of 3 mm. The sheet of aerosol-forming material (345) forming the intermediate layer (340) has a thickness of 150 μm.

[0161] The intersection points (351, 352) between the upper layer (310) and the middle layer (340) and between the lower layer (320) and the middle layer (340) contain an adhesive that bonds each layer.

[0162] The aerosol-forming substrate (300) has a length extending in the x dimension of 80 mm, a width extending in the y dimension of 15 mm, and a height (or thickness) extending in the z dimension of 3.6 mm.

[0163] The wavy folds of the intermediate layer (340) form a first set of longitudinally extending channels (361) bounded by the upper layer (310) and the intermediate layer (340), and a second set of longitudinally extending channels (362) bounded by the lower layer (320) and the intermediate layer (340). The first and second sets of longitudinally extending channels (361, 362) extend through the length of the aerosol-forming material between the proximal end (371) of the material (345) and the distal end (372) of the material (345). The longitudinally extending channels (361, 362) define an airflow path through the substrate (300). Thus, the airflow path passes through both sides of the sheet of the aerosol-forming material (345). The porosity of the aerosol-forming substrate along the airflow path is in the 90% region. This provides a very low resistance to inhalation (RTD) of less than 5 mm H2O. In fact, the RTD is close to 0.

[0164] The aerosol-forming material (345) can be any suitable aerosol-forming material sheet.

[0165] During use of an aerosol generating article comprising an aerosol forming substrate (300), the aerosol forming material (345) is heated to cause the aerosol forming material (345) to release volatile compounds, which are then entrained into air drawn into channels (361, 362) through the distal end (372). Then, the volatile compounds are cooled and condensed to form an aerosol that can be drawn from channels (361, 362) of the aerosol forming substrate (300) through the proximal end (371).

[0166] FIG. 7 illustrates an aerosol-forming substrate (400). The aerosol-forming substrate (400) comprises a first planar outer layer (424) forming a first planar outer surface (421), a second planar outer layer (425) forming a second planar outer surface (422), and a frame (450) located between the first planar outer layer (424) and the second planar outer layer (425). The second planar outer surface (422) is located parallel to the first planar outer surface (421).

[0167] FIGS. 8 and 9 show exploded views of the aerosol-forming substrate (400) of FIG. 7. A frame (450) surrounds and at least partially defines the cavity (430). FIG. 8 shows the cavity (430) in an empty state. FIG. 9 shows the cavity (430) filled with an aerosol-forming material (440). FIGS. 10 and 11 show the respective cross-sectional and longitudinal views of the aerosol-forming substrate (400) when the cavity (430) is filled with an aerosol-forming material (440).

[0168] The first planar outer layer (424) and the second planar outer layer (425) are made of cigarette paper having a thickness of 35 μm and are physically in contact with and bonded to the frame (450). The first planar outer layer (424) is placed over the first end of the cavity (430) and forms the first cavity end wall (431). The second planar outer layer (425) is placed over the second end of the cavity (430) and forms the second cavity end wall (432), and the second cavity end wall (432) faces the first cavity end wall (431). That is, the frame (450), the first planar outer layer (424), and the second planar outer layer (425) collectively define the cavity (430).

[0169] The frame (450) has a hollow rectangular shape and is made of cardboard. The frame (450) defines an aperture that extends through the height (also referred to as thickness) of the frame (450), and the aperture forms at least partially a cavity (430) of the aerosol-forming substrate (400). The frame (450) includes a periphery wall (451) surrounding the cavity (430). The periphery wall (451) includes a front wall (413) and a rear wall (414). More specifically, the periphery wall (451) is defined by an inner transverse surface (452) of the frame (450) and an outer transverse surface (453) of the frame (450). The inner transverse surface (452) of the periphery wall (451) defines at least partially the periphery of the cavity (430). The outer transverse surface (453) of the periphery wall (451) defines at least partially the periphery of the aerosol-forming substrate (400). The periphery wall (451) has a radial thickness of about 5 mm measured between the inner transverse surface (452) of the frame (450) and the outer transverse surface (453) of the frame (450).

[0170] The air inlet (411) and the air outlet (412) are defined by and extend through the peripheral wall surface (451) of the frame (450). More specifically, the air inlet (411) extends through the front wall surface (413) and the air outlet (412) extends through the rear wall surface (414). The air inlet (411) and the air outlet (412) have an equivalent diameter of 5 mm. An airflow passage extends through a cavity (430) between the air inlet (411) and the air outlet (412). As illustrated in FIGS. 9 through 11, an aerosol-forming material (440) is located within the cavity (430). The aerosol-forming material (440) comprises tobacco sticks and has an aerosol-forming agent content of 5% by weight based on dry weight. As described, the aerosol-forming material (440) fills the entire volume of the cavity (430).

[0171] The aerosol-forming substrate (400) has a rectangular shape and has a height (or thickness) of 8 mm extending in the z-dimension, a width of 40 mm extending in the y-dimension, and a length of 60 mm extending in the x-dimension, as measured between the first planar outer surface (421) and the second planar outer surface (422). The frame (450) has a height (or thickness) of 7.93 mm extending in the z-dimension, a width of 40 mm extending in the y-dimension, and a length of 60 mm extending in the x-dimension. The cavity (430) has a height (or thickness) of 7.93 mm extending in the z-dimension, a width of 39.93 mm extending in the y-dimension, and a length of 52 mm extending in the x-dimension.

[0172] FIG. 12 illustrates an additional embodiment of an aerosol-forming substrate (500). Features common to the aerosol-forming substrate (400) are referred to by similar reference numerals. The aerosol-forming substrate (500) differs from the aerosol-forming substrate (400) in that the aerosol-forming material is in the form of an aerosol-generating material sheet (540), particularly a wavy sheet of homogenized tobacco material. FIG. 13 and FIG. 14 show a cross-sectional view and a side cross-sectional view, respectively, of the aerosol-forming substrate (500) of FIG. 12.

[0173] The wavy sheet of the homogenized tobacco material (540) comprises a plurality of parallel wavy lines having a plurality of substantially parallel peaks (543) and troughs (544). The plurality of parallel wavy lines are defined by a wavy line profile that is in the form of a sinusoidal wave, as shown in FIG. 13. The plurality of parallel wavy lines have a wavy line wavelength of about 4.6 mm. The wavy line amplitude is approximately equal to the height (or thickness) of the cavity (430), as indicated by the peaks (543) and troughs (544) corresponding to the first cavity end wall (431) and the second cavity end wall (432), respectively.

[0174] A plurality of parallel wavy folds form a plurality of channels (545) between the sheet of aerosol generating material (540) and the first cavity end wall (431), and a plurality of channels (546) between the sheet of aerosol generating material (540) and the second cavity end wall (432). The plurality of channels (545, 546) extend in the longitudinal direction of the aerosol generating substrate (500) and form at least a portion of an airflow passage extending between the air inlet (411) and the air outlet (412).

[0175] During the use of each aerosol-forming substrate (400, 500), the aerosol-forming material (440, 540) is heated to release volatile compounds, which are then entrained in air drawn into the cavity (430) through the air inlet (411). Then, the volatile compounds are cooled and condensed to form an aerosol, which can be drawn from the aerosol-forming substrate (400, 500) through a mouthpiece attached to the air outlet (412).

[0176] For exemplary purposes applicable to any of the embodiments described above, the composition of a suitable aerosol-forming material may be as follows. Percentages are given as weight percentages relative to the product in the final state. The aerosol-forming material may have about 5 to 25%, preferably about 7 to 15%, of moisture in the final product state. The aerosol-forming material may further comprise the following:

[0177] 1. Tobacco leaves; for example, about 15 to 45%, preferably about 20 to 35%, of a blend of tobacco leaves, and comprising at least one of the following tobacco types: bright tobacco; dark tobacco; aromatic tobacco. The tobacco material is ground and graded to a particle size of about 100 to 380 mesh, preferably about 170 to 320 mesh.

[0178] 2. Cellulose fibers; for example, about 1 to 15%, preferably about 3 to 7%, of cellulose fibers with a length of about 10 to 250 µm, preferably about 10 to 120 µm.

[0179] 3. Tobacco fibers; for example, about 5 to 20%, preferably about 7 to 15%, of tobacco fibers as a filler of any tobacco type or blend of tobacco types. The tobacco fibers are preferably derived from stems and / or stem stalks graded into fibers of about 10 to 350 μm in length, preferably about 10 to 180 μm.

[0180] 4. Binder; for example, about 1 to 10%, preferably about 1 to 5% of a binder, such as a common gum or pectin used in the food and beverage (F&B) industry. Preferred binders may be natural pectin, such as fruit, for example, citrus or tobacco pectin; guar gum, land locust bean gum, for example, their hydroxyethyl and hydroxypropyl forms; starch, for example, modified or derived starch; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; dextran; and xanthan gum. A preferred binder is guar.

[0181] 5. Aerosol forming agent; for example, about 5 to 35%, preferably about 10 to 25% of the aerosol forming agent. Suitable aerosol forming agents known in the art include glycerin; monohydric alcohols such as menthol, polyhydric alcohols such as triethylene glycol; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids, e.g., their dimethyls.

[0182] "Tobacco type" refers to one of the different varieties of tobacco based on, for example, the unique hardening process that tobacco undergoes before being further processed into tobacco products.

[0183] For example, the composition of additional aerosol-forming materials that may also be suitable for use as an aerosol-forming substrate in any of the embodiments described above is described below. Percentages are given as weight percentages of the product in the final state. The aerosol-forming substrate may include the following.

[0184] 1. Aerosol-forming agents such as glycerin; for example, about 10 to 40%, preferably about 20 to 30%.

[0185] 2. Organic fibers; for example, about 10 to 30%, preferably about 15 to 25%, of any plant variety suitable for complying with applicable FDA F&B grade requirements and having a purity as generally available in the market. For example, the organic fibers may be derived as downproducts and downprocessed waste from cellulose, cotton, wood, and tea plant varieties of the F&B tea industry. The organic fibers are preferably about 10 to 400 μm in length, preferably about 10 to 200 μm.

[0186] 3. Organic vegetable glycerin; for example, about 15 to 55%, preferably about 20 to 35% of plants, such as cloves, echinacea species, fennel, ginger, hawthorn berries, elderberries, monada, mullet leaves, nettle, plantain, turmeric, yarrow, and compounds thereof.

[0187] 4. Organic plant extracts; for example, about 1 to 15%, preferably about 2 to 7% of any of the previously mentioned plants, as well as any secondary alcohol as a diastereomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol, as well as p-mentan-3-ol, and menthol (dl-menthol, C10H20O, 2-isopropyl-5-methylcyclohexanol) obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related plant varieties.

[0188] Alternatively, these aerosol-forming materials may also contain about 0.5 to 5%, preferably about 1 to 3%, of vegetable essential oils, such as palm essential oil, coconut essential oil, and wood essential oil.

[0189] Any one of the aerosol-forming materials described above in relation to FIGS. 1 to 14 may be combined with a mouthpiece to form an aerosol-generating article according to one or more aspects of the present invention. Such an aerosol-generating article will now be described with reference to FIGS. 15 to 20.

[0190] FIGS. 15 and 16 are schematic perspective views of an aerosol generating article (1000) according to an embodiment of the present invention. FIG. 15 shows the article (1000) viewed from a distal end, and FIG. 16 shows the same article viewed from a proximal end. FIG. 17 is a schematic perspective view of a mouthpiece (1600) of the article (1000).

[0191] The aerosol generating article (1000) comprises a flat aerosol forming substrate (1100) coupled to a mouthpiece (1600). The flat aerosol forming substrate (1100) may be any suitable substrate, for example, any one of the aforementioned substrates (100, 200, 300, 400, 500). The aerosol forming substrate (1100) comprises an aerosol forming material and has an airflow channel defined by the length of the substrate (1100) between an airflow channel inlet (1112) and an airflow channel outlet (not shown), thereby allowing air to be drawn through the substrate (1100). A specific embodiment of the aerosol forming substrate (1100) has a length of 30 mm, a width of 10 mm, and a thickness of 3 mm.

[0192] The mouthpiece (1600) has a distal portion (1601) ergonomically shaped to fit the user's lips. The mouthpiece (1600) has an airflow channel defined between the distal surface (1615) and the proximal surface (1616), and the distal portion (1601) is terminated at an airflow opening or outlet (1620) so that the user can inhale air through the mouthpiece.

[0193] As can be seen in FIG. 17, the distal surface (1615) of the mouthpiece (1600) defines a recess (1630) that is dimensioned to accommodate a portion of the aerosol-forming substrate (1100) to facilitate coupling between the substrate (1100) and the mouthpiece (1600). When the substrate (1100) and the mouthpiece (1600) are coupled, an airflow path is defined between the airflow channel inlet (1112) of the substrate (1100) and the mouthpiece outlet (1620). The recess (1630) has a rectangular cross-section and is dimensioned as a substrate carrier for holding the aerosol-forming article (1100). The recess (1630) may include a retaining feature to prevent complete insertion of the substrate (1100). For example, the concave portion (1630) may include a retaining feature on the surface to suppress displacement of the substrate (1100) along the main axis.

[0194] The connection between the substrate (1100) and the mouthpiece (1600) can be made by a simple interference fit. The connection can be facilitated by a wrapper, for example, a paper wrapper that overlaps parts of both the substrate (1100) and the mouthpiece (1600).

[0195] To consume an aerosol-forming material, the user inserts an aerosol-forming article (1000) containing a material (1100) into an aerosol generating device (1700) configured to receive the article (1000). As illustrated in FIG. 18, the aerosol-forming material portion (1100) of the article (1000) may be inserted into a material receiving cavity (1710) of the aerosol generating device (1700). FIG. 19 illustrates the article (1000) coupled to the device (1700) that is ready for use.

[0196] The engagement between the article (1000) and the device (1700) can be achieved by generally known engagement elements, such as threaded portions, snap-fits, or press-fit members, integrated within the receiving cavity (1710) and the mating surface of the article (1000). To ensure a hermetic seal between the article (1000) and the receiving cavity (1710), the article (1000) may include a seal (1655) configured to engage. For example, the seal (1655) may include material overmolded around the periphery of the distal end (1615) of the mouthpiece (1600).

[0197] FIG. 20 is a schematic cross-sectional view of an aerosol generating device (1700) when engaged with an aerosol generating article (1000). The device (1700) includes a housing (1703) for housing a battery (1701) and a control electronic device (1702). The wall of the substrate receiving cavity (1710) is thermally connected to a flat heater (1750) to heat the aerosol forming substrate (1100) received within the cavity (1710).

[0198] When the article (1000) is coupled to the device (1700), the user can activate the device, for example, by pressing an activation button. The heater (1750) is activated to heat the aerosol-forming substrate (1100) to an operating temperature sufficient to release the volatile components of the substrate. When the user inhales the distal portion of the mouthpiece (1600), air is drawn into the aerosol-generating device (1700) and through the aerosol-forming substrate (1100), entraining the volatile components of the substrate generated by heating. As air is drawn through the mouthpiece, the air is mixed and cooled, and an aerosol is generated. The aerosol is delivered to the user through the outlet of the mouthpiece (1600).

[0199] After the material (1100) is consumed, the user can remove the article (1000) from the device (1700). If the article includes a reusable mouthpiece, the user can discard the depleted aerosol-forming material (1100) from the mouthpiece and replace it with a new one. Alternatively, if the article (1000) is manufactured as a single-piece product, the user can simply discard it and replace it with a new article.

[0200] FIGS. 21 and 22 illustrate specific examples of an aerosol generating article (2000) having an ergonomically shaped mouthpiece (1800). The aerosol generating article (2000) comprises a planar aerosol forming substrate (1100) coupled to the mouthpiece (1800). The planar aerosol forming substrate (1100) may be any suitable substrate, for example, any one of the aforementioned substrates (100, 200, 300, 400, 500). The aerosol forming substrate (1100) comprises an aerosol forming material and has an airflow channel defined by the length of the substrate (1100) between an airflow channel inlet (1112) and an airflow channel outlet (not shown) so that air can be drawn through the substrate (1100). A specific embodiment of the aerosol-forming substrate (1100) has a length of 35 mm, a width of 12 mm, and a thickness of 3.5 mm.

[0201] The mouthpiece (1800) is ergonomically shaped to fit the user's lips and has a defined airflow channel through it, allowing the user to inhale air through the mouthpiece (1800). The cross-section of the mouthpiece (1800) is shaped as an ellipse having a major axis corresponding to the width dimension of the aerosol-forming substrate (1100) and a minor axis corresponding to the thickness dimension of the aerosol-forming substrate (1100). The maximum dimension of the major axis is 18 mm and the maximum dimension of the minor axis is 7 mm. The maximum dimension of the major axis of the mouthpiece (1800) is greater than the width of the substrate (1100). By using such a mouthpiece, the dimensions of the aerosol-forming substrate (1100) can be minimized while still allowing user operation.

[0202] For the purposes of this description and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, etc., shall be understood in all cases to be modified by the term “about.” Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein. Accordingly, in this context, the number “A” is understood as 10% of “A” ± “A”. In this context, the number “A” may be considered to include numerical values ​​within the general standard error for measuring the characteristic modified by the number “A”. In some cases used in the appended claims, the number “A” may deviate by the percentage listed above, provided that the amount of deviation by “A” does not substantially affect the basic and novel feature(s) of the claimed invention. Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein. The terms “here” and “the” are used as synonyms throughout this specification.

Claims

Claim 1 An aerosol generating article comprising an aerosol forming substrate and a mouthpiece, wherein the mouthpiece comprises a proximal portion for insertion into a user's mouth, the aerosol forming substrate has a length dimension greater than or equal to a width dimension and a width dimension greater than a thickness dimension, and the proximal portion of the mouthpiece has a maximum width dimension greater than at least 4% greater than the width dimension of the aerosol forming substrate. Claim 2 An aerosol generating article according to claim 1, wherein the proximal portion of the mouthpiece has a cross-section having an area larger than the cross-section of the aerosol forming substrate, and the cross-section of the substrate and the mouthpiece are cross-sections taken perpendicular to the length dimension of the aerosol forming substrate. Claim 3 An aerosol generating article according to claim 1 or 2, wherein the distal portion of the mouthpiece comprises a recess dimensioned to engage with the aerosol forming substrate, and an airflow path is defined through the mouthpiece between the distal portion and the proximal portion. Claim 4 An aerosol generating article according to any one of claims 1 to 3, wherein the aerosol-forming substrate is substantially a planar substrate, for example, the aerosol-forming substrate is substantially a parallelepiped shape, for example, substantially a rectangular parallelepiped shape. Claim 5 An aerosol generating article according to any one of claims 1 to 4, wherein the thickness of the aerosol-forming substrate is 1 mm to 5 mm, for example, 1.2 mm to 4.7 mm and / or, the length of the aerosol-forming substrate is 10 mm to 35 mm, for example, 24 mm to 31 mm and / or, and the width of the aerosol-forming substrate is 5 mm to 25 mm, for example, 9 mm to 21 mm. Claim 6 In any one of claims 1 to 5, the aerosol-forming substrate is an aerosol-forming article having a thickness-to-width ratio of about 0.13:1 to 0.22:

1. Claim 7 In any one of claims 1 to 6, the aerosol-forming substrate is an aerosol-forming article having a length-to-width ratio of about 1.55:1 to 1.48:

1. Claim 8 An aerosol generating article according to any one of claims 1 to 7, wherein the aerosol forming substrate comprises two or more layers, for example, two or more layers laminated together, for example, the aerosol forming substrate comprises at least a first planar layer forming the upper surface of the aerosol forming substrate and a second planar layer forming the lower surface of the aerosol forming substrate. Claim 9 An aerosol generating article according to any one of claims 1 to 8, wherein the aerosol forming substrate is configured to be received within a heating cavity of an aerosol generating device, and, for example, a part of the mouthpiece is configured to engage with a part of the aerosol generating device to position the aerosol forming substrate within the heating cavity. Claim 10 An aerosol generating article, wherein in any one of the prior embodiments, the cross-section of the proximal portion of the mouthpiece has a shape defined by a maximum width and a maximum height, and the ratio of the maximum width to the maximum height is 2:1 to 5:1, e.g. 2.5:1 to 4:1, e.g. 3:1 to 3.5:

1. Claim 11 An aerosol generating article, wherein in any one of the prior embodiments, the cross section of the mouthpiece, for example, the proximal portion of the mouthpiece, has a curved non-circular shape defined by a major axis and a minor axis, and the ratio of the maximum dimension of the major axis to the maximum dimension of the minor axis is 1.5:1 to 5.5:1, for example 2:1 to 5:1, for example 2.5:1 to 4:1, for example 3:1 to 3.5:

1. Claim 12 An aerosol generating article according to any one of claims 1 to 11, wherein the mouthpiece comprises a recess having substantially the same shape as the cross-section of the aerosol-forming substrate, said cross-section being a cross-section taken perpendicular to the length dimension of the aerosol-forming substrate, and preferably, an airflow path through the mouthpiece is defined by an airflow channel, said inlet of said airflow channel is defined within the recess, and said outlet of said airflow channel is defined in the proximal portion of the mouthpiece. Claim 13 An aerosol generating article according to any one of claims 1 to 12, wherein the mouthpiece is formed of a biodegradable material, e.g., paper material, and / or the proximal portion of the mouthpiece is shaped to fit ergonomically into the user's mouth. Claim 14 An aerosol generating article according to any one of claims 1 to 13, wherein the mouthpiece is separable from the aerosol forming substrate, for example, the mouthpiece may be removablely coupled to the aerosol forming substrate, for example, the mouthpiece is a reusable mouthpiece designed to be used with a plurality of different aerosol forming substrates. Claim 15 An aerosol generating article according to any one of claims 1 to 14, wherein the proximal portion of the mouthpiece has a curved cross-sectional shape, for example, a curved non-circular cross-sectional shape, for example, the cross-sectional shape is elliptical or lens-shaped.

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