Aerosol generating article having a chamber-type mouthpiece

Abstract

The aerosol generating article comprises a planar aerosol forming substrate and a mouthpiece. The mouthpiece comprises a proximal portion for insertion into a user's mouth and a distal portion configured for engagement with the aerosol forming substrate. An airflow path is defined by an airflow channel passing between the distal portion and the proximal portion through the mouthpiece. The airflow channel includes a first constricted portion and a first expanded portion located downstream of the first constricted portion to facilitate mixing and aerosol formation.

Description

Technology Field

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

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

[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. The aerosol generating article is preferably a substantially planar aerosol generating article. 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 integral with the aerosol forming substrate. Preferably, an airflow path is defined through the aerosol forming substrate and the mouthpiece.

[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 engage with the aerosol-forming substrate. The mouthpiece may be configured for engaging with the aerosol-forming substrate. An airflow path is defined by an airflow channel passing through the mouthpiece between the distal portion and the proximal portion. The airflow channel comprises a first constricted portion and a first expanded portion downstream of the first constricted portion.

[0008] When in use, air may be inhaled through the aerosol generating material by the user inhaling through the mouthpiece. The air is introduced into and passes through the aerosol forming material, enters the mouthpiece through the first constricted portion and the first expanded portion, and then enters the user's mouth. When in use, the airflow carries volatile components of the aerosol forming material released from the material, for example, by heating. As the airflow passes through the constricted portion and into the expanded portion, it may experience a Venturi effect in which the pressure of the airflow decreases and its velocity increases as it passes through the constricted portion, and its pressure increases and its velocity decreases as it passes into the expanded portion. Turbulence within the airflow is generated in the expanded portion. The turbulence facilitates the mixing of the volatile components of the aerosol forming material accompanied by the air, thereby homogenizing the mixture. The expanded portion also slows down the airflow, allowing for the cooling of the airflow and the subsequent formation of an aerosol.

[0009] The airflow channel may gradually taper inward toward the first constriction portion or narrow into a funnel shape. The airflow channel may gradually taper outward toward the first expansion portion or narrow into a funnel shape.

[0010] Advantageously, the airflow path may further include a second constricted portion downstream of the first expanded portion. The airflow channel may taper inwardly toward the second constricted portion or narrow in a funnel shape. The airflow channel may taper outwardly from the second constricted portion or narrow in a funnel shape. The airflow path may further include a second expanded portion downstream of the second constricted portion.

[0011] By providing alternative contraction and expansion of the airflow path, the homogenization and cooling of the airflow path can be improved, and a highly homogenized and optimally cooled aerosol can be produced.

[0012] An airflow outlet may be defined in the second expansion portion. An aerosol collection chamber may be defined by a mouthpiece, and the aerosol collection chamber is located downstream of the aerosol-forming substrate and upstream of the first contraction portion. The aerosol collection chamber may be a space where volatile components of the aerosol-forming substrate accompanied by the airflow can condense to form an aerosol.

[0013] 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.

[0014] The proximal portion of the mouthpiece may have a major axis dimension larger than the width dimension of the aerosol-forming substrate.

[0015] 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-sections of the substrate and the mouthpiece are cross-sections taken perpendicular to the length dimension of the aerosol-forming substrate.

[0016] The mouthpiece may have a distal portion including a dimensioned recess for engaging with an aerosol-forming substrate. An airflow path passing between the distal and proximal portions through the mouthpiece may be defined.

[0017] Non-rod-shaped aerosol generating articles, particularly thin planar and flat consumables, have an overall shape that may be uncomfortable for a user to inhale directly. While planar 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 planar aerosol generating material to provide an aerosol generating article with a comfortable shape that allows a user to inhale while still maintaining the advantages of the planar 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.

[0018] 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 engaging with the aerosol-forming substrate. The recess may be dimensioned to provide an interference fit with the aerosol-forming substrate.

[0019] The mouthpiece may form an integral part of the aerosol-generating article. That is, the mouthpiece may be an indetachable part of the article. However, advantageously, the mouthpiece may be detachably 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 may be separated from the aerosol-generating substrate.

[0020] The proximal portion of the mouthpiece can be shaped to provide an ergonomic fit to the user's mouth. 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 elliptical or lens-shaped.

[0021] The proximal portion of the mouthpiece may have a cross-sectional shape defined by a maximum width and a maximum height. 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 6 mm to 9 mm, for example about 5 mm, or about 5 mm, or about 9 mm, or about 13 mm.

[0022] The cross-section of the proximal portion of the mouthpiece may have a shape defined by the maximum width and maximum height, where the ratio of the maximum width to the maximum height is 2:1 to 5:1, for example 2.5:1 to 4:1, for example 3:1 to 3.5:1. The cross-section of the mouthpiece, for example, the proximal portion of the mouthpiece, may have an oval, elliptical, or lens-shaped shape, and the cross-section of the aerosol-forming substrate may have a rectangular cross-section.

[0023] 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.

[0024] Preferably, the mouthpiece has a length of 10 mm to 25 mm, for example, 12 mm to 21 mm. The airflow path is preferably defined along the length dimension of the mouthpiece and may include one or more chambers and / or airflow constrictions.

[0025] 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.

[0026] 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 over the height of the aerosol generating article during heating. For example, if the base of the aerosol generating article is in contact with a planar heater and heated by it, a smaller gap or height between the base and the upper surface may result in a smaller temperature difference between the base and the upper surface facing the base. Advantageously, this may minimize the risk of the hottest part of the substrate closest to the heater burning while enabling a greater proportion of the aerosol-forming substrate of the aerosol generating article to be heated to the temperature at which the aerosol is released. Alternatively or additionally, this can reduce the time required to heat the aerosol-forming substrate sufficiently to release the aerosol.

[0027] 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, e.g., 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, e.g., 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 enables excellent airflow control and can allow aerosols to be extracted more efficiently from the aerosol generating article and delivered to the user. Free airflow through the material may result in a lack of mixing between the volatile components accompanying the airflow. A lack of mixing may result in heterogeneous aerosols. The use of a mouthpiece as described herein may be particularly advantageous for aerosol generating articles in which the substrate is a planar substrate, in particular in the case of a planar substrate having a free airflow path and a low RTD. The benefits of using a planar substrate can still be obtained while achieving a homogeneous aerosol.

[0028] 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 the output or downstream end of the component at a volumetric flow rate of approximately 17.5 mm per second.

[0029] An aerosol generating article according to any one of the embodiments disclosed herein may comprise an upper surface and a lower surface that are 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 surface and the lower surface may comprise an aerosol-forming substrate. The aerosol generating article may comprise an upper layer and a lower layer, at least one of the upper layer and the 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.

[0030] According to the present disclosure, an aerosol generating article may be provided comprising a substrate portion having a first planar layer, a second planar layer, and a wavy layer arranged between the first planar layer and the second planar layer, and a mouthpiece coupled to the 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.

[0031] The use of a corrugated structure in 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 a 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.

[0032] According to the present disclosure, an aerosol generating article may be provided, wherein the aerosol generating article comprises a first planar outer surface, a second planar outer surface, a cavity, a frame positioned between the first planar outer surface and the second planar outer surface and defining the cavity at least partially, an aerosol forming substrate positioned 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.

[0033] The frame may include a surrounding wall that at least partially surrounds or encloses the cavity. The frame may include a surrounding wall that completely surrounds or encloses the cavity.

[0034] 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.

[0035] The common area can be practically empty.

[0036] The aerosol-forming substrate can be located within the cavity.

[0037] The wavy fold layer can be located within the cavity.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] At least a portion of an aerosol generating article according to any one of the embodiments of the present disclosure may have a shape that defines a polygon, a square (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof when viewed in a planar view. Where the aerosol generating article comprises an upper surface and a lower surface that are substantially planar, one or both of the upper surface and the lower surface may have a shape that defines a polygon, a square (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 when viewed in a planar view 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 an upper surface and a lower surface that are substantially planar, the perimeter of one or both of the upper surface and the lower surface when viewed in a planar view may have a shape that defines a polygon, a square (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof.

[0042] 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 components of the aerosol generating article and may be detachably coupled to the mouthpiece. The substrate may be described as being separable from the mouthpiece.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] The aerosol-forming material may include 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.

[0049] The aerosol-forming material may include 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.

[0050] The aerosol-forming material may include 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.

[0051] The aerosol-forming material may include 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.

[0052] The aerosol-forming material may include 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] The aerosol-forming material may contain nicotine. The aerosol-forming material may contain natural nicotine, synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0059] 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%.

[0060] 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), cannabidivarin (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 be particularly preferably CBD.

[0061] 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.

[0062] 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 a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state.

[0063] 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 materials such as tobacco leaves are preferably crushed and graded to a particle size of about 100 to 380 mesh, preferably about 170 to 320 mesh.

[0064] "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.

[0065] 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.

[0066] 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.

[0067] Examples of dark tobacco are fumigated Brazilian gaupão, Burleigh Malawi or other African burleigh, and sun-dried or air-dried Indonesian kasturi.

[0068] 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.

[0069] 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.

[0070] 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.

[0071] The aerosol-forming material may include organic vegetable 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.

[0072] 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.

[0073] 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.

[0074] 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 mono-, di-, or polycarboxylic acids, for example, aliphatic esters of their dimethyl.

[0075] 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.

[0076] As used herein, the term “aerosol-forming substrate” may refer to a component of an aerosol-generating article comprising a material capable of releasing an aerosol or releasing 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 the aerosol-forming material or may consist entirely of the 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salt.

[0081] 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 airflow when a user inhales the aerosol-generating article or device.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] The present invention is defined in the claims. However, a non-limiting, non-comprehensive list of embodiments is provided below. Any one or more features of these embodiments may be combined with any one or more features of other embodiments, embodiments, or aspects described herein.

[0088] Example i. An aerosol generating article comprising a substantially flat aerosol forming substrate coupled to a mouthpiece.

[0089] Example ii. An aerosol generating article comprising a substantially flat aerosol forming substrate that can be detachably coupled to a mouthpiece or separated from a mouthpiece.

[0090] Example iii. An aerosol generating article comprising a substantially planar aerosol forming substrate coupled to a mouthpiece, wherein an airflow path is defined through the aerosol forming substrate and the mouthpiece.

[0091] Example iv. An aerosol generating article comprising a substantially planar aerosol forming substrate coupled to a mouthpiece, wherein an airflow path is defined through the aerosol forming substrate and the mouthpiece, and the airflow path through the mouthpiece passes through a channel having a first contracted portion and a first expanded portion located downstream of the first contracted portion.

[0092] Example v. An aerosol generating article, for example, an aerosol generating article according to any one of the prior examples, 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 the width dimension and a width dimension greater than the thickness dimension, and the proximal portion of the mouthpiece has a main axis dimension greater than the width dimension of the aerosol forming substrate.

[0093] Example vi. An aerosol generating article, for example, an aerosol generating article according to any one of the prior examples, 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, 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 aerosol forming substrate and the mouthpiece is a cross-section taken perpendicular to the length dimension of the aerosol forming substrate.

[0094] Example vii. An aerosol generating article, for example, an aerosol generating article according to any one of the prior examples, 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 concave portion with dimensions set for interlocking with the aerosol forming substrate, an airflow path is defined between the distal portion and the proximal portion through the mouthpiece, 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.

[0095] Example 1. An aerosol generating article, for example, an aerosol generating article according to any one of the prior examples, 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 for interlocking with the aerosol forming substrate, and an airflow path is defined by an airflow channel passing between the distal portion and the proximal portion through the mouthpiece, and the airflow channel comprises a first constricted portion and a first expanded portion located downstream of the first constricted portion.

[0096] Example 2. An aerosol generating article in Example 1, wherein the airflow channel gradually tapers inward toward the first contracted portion or narrows into a funnel shape.

[0097] Example 3. An aerosol generating article in Example 1 or Example 2, wherein the airflow channel gradually tapers outwardly from the first contracted portion toward the first expanded portion or narrows into a funnel shape.

[0098] Example 4. An aerosol generating article in any one of Examples 1 to 3, wherein the airflow path further comprises a second contracted portion downstream of the first expanded portion.

[0099] Example 5. An aerosol generating article in Example 4, wherein the airflow channel gradually tapers inward toward the second contracted portion or narrows into a funnel shape.

[0100] Example 6. An aerosol generating article in Example 4 or Example 5, wherein the airflow channel gradually tapers outward from the second contracted portion or narrows into a funnel shape.

[0101] Example 7. An aerosol generating article in any one of Examples 4 to 6, wherein the airflow path further comprises a second expansion portion downstream of the second contraction portion.

[0102] Example 8. In Example 7, the airflow outlet is an aerosol generating article defined in the second extension portion.

[0103] Example 9. An aerosol generating article in any one of Examples 1 to 8, wherein the collection chamber is defined by a mouthpiece, and the collection chamber is located downstream of the aerosol forming substrate and upstream of the first contracted portion.

[0104] Example 10. In any one of the prior examples, the aerosol-forming substrate is substantially planar, for example, the aerosol-forming substrate is substantially parallelepiped in shape, for example, substantially rectangular in shape, an aerosol-generating article.

[0105] Example 11. In any one of the prior examples, the aerosol-forming substrate has 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.

[0106] Example 12. An aerosol generating article, wherein, in any one of the prior examples, 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.

[0107] Example 13. An aerosol generating article, wherein in any one of the prior examples, 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.

[0108] Example 14. An aerosol generating article, wherein in any one of the prior examples, 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.

[0109] Example 15. In any one of the prior examples, the aerosol-forming substrate is an aerosol-forming article having a thickness-to-width ratio of about 0.13:1 to 0.22:1.

[0110] Example 16. In any one of the prior examples, the aerosol-forming substrate is an aerosol-forming article having a length-to-width ratio of about 1.55:1 to 1.48:1.

[0111] Example 17. An aerosol generating article, wherein in any one of the prior examples, the aerosol forming substrate comprises two or more layers, for example, two or more layers are laminated, 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.

[0112] Example 18. The aerosol-forming substrate of Example 17, wherein the aerosol-forming substrate comprises a first planar layer, a second planar layer, and an intermediate layer or separation layer arranged 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 layer or separation layer comprises an aerosol-forming material or is composed of an aerosol-forming material.

[0113] Example 19. The intermediate layer or separation layer of Example 18 is a wavy layer, for example, the aerosol forming substrate comprises a first planar layer, a second planar layer, and a wavy layer arranged 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 an aerosol forming material or is made of an aerosol forming material.

[0114] Example 20. An aerosol generating article in Example 19, wherein the wavy folds are arranged perpendicular to the width direction of the aerosol forming substrate and parallel to the length direction of the aerosol forming substrate.

[0115] Example 21. In any one of the prior examples, the airflow path is defined through an aerosol-forming substrate, for example, a low-resistance airflow path is defined through the 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.

[0116] Example 22. An aerosol generating article, wherein in any one of the prior examples, the airflow path extends from one end to the other in the x-dimensional direction of the substrate, for example, the airflow path extends substantially in the x-direction.

[0117] Example 23. An aerosol generating device configured to be coupled to an aerosol generating device for generating an aerosol, in any one of the prior examples.

[0118] Example 24. An aerosol generating article, wherein in any one of the prior examples, the aerosol forming substrate is configured to be received within the heating cavity of an aerosol generating device, 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.

[0119] Example 25. An aerosol generating article according to Example 24, wherein the distal portion of the mouthpiece engages with the opening of the heating cavity of the aerosol generating device, for example, there is a mechanical interaction between the distal portion of the mouthpiece and the opening of the heating cavity, for example, there is an interference fit between the distal portion of the mouthpiece and the opening of the heating cavity and / or there is a mechanical fastening fit between the distal portion of the mouthpiece and the opening of the heating cavity.

[0120] Example 26. An aerosol generating article, wherein in any one of the prior examples, 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.

[0121] Example 27. In any one of the prior examples, 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, an aerosol collection chamber is defined at the proximal end of the recess, an aerosol-generating article.

[0122] Example 28. An aerosol generating article according to Example 27, wherein the recess is dimensioned to form a mechanical interaction with the aerosol forming substrate to bond 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.

[0123] Example 29. An aerosol generating article in Example 27 or Example 28, wherein the airflow path through the mouthpiece is defined by an airflow channel, the inlet of the airflow channel is defined within a recess, and the outlet of the airflow channel is defined in a proximal part of the mouthpiece, for example, air passing along the airflow path passes through a first constricted portion between the inlet and the outlet, then passes through a first expanded portion, and then passes through the outlet.

[0124] Example 30. An aerosol generating article in any one of the prior examples, wherein the mouthpiece is formed of a biodegradable material and / or the mouthpiece is formed of a paper material.

[0125] Example 31. An aerosol generating article in any one of the prior examples, wherein the proximal portion of the mouthpiece is shaped to provide an ergonomic fit to the user's mouth.

[0126] Example 32. An aerosol generating article in any one of the prior examples, 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.

[0127] Example 33. An aerosol generating article, wherein, in any one of the prior examples, 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, e.g. 11 mm to 25 mm, e.g. 13 mm to 23 mm, e.g. about 10 mm, or about 13 mm, or about 16 mm, or about 23 mm.

[0128] Example 34. An aerosol generating article, wherein, in any one of the prior examples, 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, e.g. 5 mm to 13 mm, e.g. 6 mm to 9 mm, e.g. about 5 mm, or about 5 mm, or about 9 mm, or about 13 mm.

[0129] Example 35. An aerosol generating article, wherein, in any one of the prior examples, 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.

[0130] Example 36. An aerosol generating article, wherein in any one of the prior examples, the cross-section of the mouthpiece, for example, the proximal portion of the mouthpiece, has an elliptical or lens-shaped shape, and the cross-section of the aerosol forming substrate has a rectangular cross-section.

[0131] Example 37. An aerosol generating article, wherein in any one of the prior examples, 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.

[0132] Example 38. In any one of the prior examples, the mouthpiece has a length of 10 mm to 25 mm, for example, 12 mm to 21 mm, an aerosol generating article.

[0133] Example 39. An aerosol generating article, wherein, in any one of the prior examples, 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, 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, the 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.

[0134] Example 40. An aerosol generating article in Example 39, wherein the upper layer and the lower layer are bonded to opposite surfaces of the frame and placed over opposite ends of the cavity.

[0135] Example 41. An aerosol generating article in Example 39 or Example 40, wherein one or both of the upper layer and the lower layer comprise an aerosol-forming substrate or are composed of an aerosol-forming substrate.

[0136] Example 42. An aerosol generating article in any one of Examples 39 to 41, wherein the upper layer and the lower layer do not have an aerosol-forming substrate.

[0137] Example 43. In any one of Examples 39 to 42, the frame is an aerosol generating article that does not have an aerosol-forming substrate.

[0138] Example 44. An aerosol generating article comprising one or more of particles, cut pieces, or sheets of an aerosol-forming substrate disposed within a cavity between an upper layer and a lower layer, in any one of Examples 39 to 43.

[0139] Example 45. An aerosol generating article in any one of Examples 39 to 44, wherein the wavy element is disposed within a cavity between an upper layer and a lower layer.

[0140] Example 46. The aerosol generating article of Example 45, wherein the wavy element comprises an aerosol-forming substrate or is composed of an aerosol-forming substrate.

[0141] Example 47. In Example 45, the wavy element is an aerosol generating article that does not have an aerosol forming substrate.

[0142] Example 48. An aerosol generating article in any one of Examples 45 to 47, wherein a plurality of longitudinally extending channels are defined by ripples between an upper layer and a ripple element and between a ripple element and a lower layer.

[0143] Example 49. The aerosol generating article of Example 48, wherein the longitudinally extending channel extends along the x / y plane between opposing ends of the frame.

[0144] Example 50. An aerosol generating article in any one of Examples 39 to 49, wherein the airflow path is at least partially defined by a frame.

[0145] Example 51. An aerosol generating article according to Example 50, wherein the frame includes an inlet airflow channel and an outlet airflow channel, the inlet airflow channel is configured to allow airflow into a cavity, and the outlet airflow channel is configured to allow airflow to exit the cavity and pass through a mouthpiece.

[0146] Example 52. The aerosol generating article of Example 51, wherein the inlet airflow channel and the outlet airflow channel are defined on opposite ends of the frame.

[0147] Example 53. An aerosol generating article in Example 51 or Example 52, wherein 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.

[0148] Example 54. An aerosol generating article, wherein in any one of Examples i to 38, the mouthpiece and a planar aerosol forming substrate coupled to the mouthpiece, the planar aerosol forming substrate comprises an intermediate layer arranged between an upper layer and a lower layer, 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 in the x / y plane between the distal end and the proximal end of the aerosol generating article.

[0149] Example 55. The aerosol generating article of Example 54, wherein the resistance to suction (RTD) along the airflow path of the aerosol generating article is less than 20 mm H2O, e.g., less than 15 mm H2O, or less than 10 mm H2O.

[0150] Example 56. An aerosol generating article in Example 54 or Example 55, wherein one or more of the upper layer, the middle layer, and the lower layer comprise an aerosol-forming substrate or are composed of an aerosol-forming substrate.

[0151] Example 57. An aerosol generating article according to Example 56, wherein one or both of the upper layer and the lower layer comprise an aerosol-forming substrate or are composed of an aerosol-forming substrate, and the intermediate layer does not have an aerosol-forming substrate.

[0152] Example 58. An aerosol generating article according to Example 56, wherein the intermediate layer comprises an aerosol-forming substrate or is composed of an aerosol-forming substrate, and the upper layer and lower layer do not have an aerosol-forming substrate.

[0153] Example 59. An aerosol generating article in any one of Examples 54 to 58, wherein a plurality of longitudinally extending channels are defined by wavy folds between an upper layer and an intermediate layer and between an intermediate layer and a lower layer.

[0154] Example 60. The aerosol generating article of Example 59, wherein the longitudinally extending channel extends along the x / y plane between the distal end and the proximal end.

[0155] Example 61. An aerosol generating article in any one of Examples 54 to 60, wherein 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.

[0156] Example 62. An aerosol generating article in any one of Examples 54 to 61, wherein the intermediate layer comprises a wavy element.

[0157] Example 63. An aerosol generating article according to Example 62, wherein the intermediate layer comprises a plurality of wavy elements, and at least two of the plurality of wavy elements are arranged in a perpendicular relationship between the upper layer and the lower layer.

[0158] Example 64. An aerosol generating article according to Example 63, wherein one or more of the plurality of wavy elements comprises an aerosol-forming substrate.

[0159] Example 65. An aerosol generating article in Example 63 or Example 64, wherein the intermediate layer further comprises a planar element located between two of a plurality of wavy elements.

[0160] Example 66. An aerosol generating system comprising an aerosol generating article according to any one of the prior examples and an aerosol generating device configured to receive the aerosol generating article.

[0161] Example 67. The aerosol generating system of Example 66, wherein the aerosol generating device is configured to generate an inhalable aerosol from at least a portion of an aerosol generating article, for example, the aerosol generating device is configured to form an inhalable aerosol by heating at least a portion of an aerosol generating article.

[0162] Example 68. The aerosol generating system of Example 66 or Example 67, wherein the aerosol generating device comprises a heater disposed within a chamber for receiving an aerosol-forming substrate of an aerosol generating article.

[0163] Example 69. An aerosol generating system according to Example 68, wherein the mouthpiece of the aerosol generating article is configured to be mechanically engaged with an aerosol generating device, and an aerosol forming substrate is received within a chamber for heating.

[0164] Example 70. An aerosol generating system in any one of Examples 66 to 69, wherein the aerosol generating device includes an air inlet, and when a user inhales the mouthpiece, air is introduced into the device, passes through an aerosol forming substrate, passes through a first contracted portion of the mouthpiece, passes through a first expanded portion of the mouthpiece, and is introduced into the user's mouth. Brief explanation of the drawing

[0165] Now, embodiments will be further described with reference to the drawings. FIG. 1 is a perspective side 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 side view of an additional aerosol-forming substrate; FIG. 3 is a schematic cross-sectional 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 illustrates 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 illustrates an additional exploded perspective view of the aerosol-forming substrate of FIG. 7; FIG. 10 illustrates a schematic cross-sectional view of the aerosol-forming substrate of FIG. 7; FIG. 11 illustrates a schematic 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 illustrates a schematic cross-sectional view of the aerosol-forming substrate of FIG. 12; FIG. 14 illustrates a schematic side cross-sectional view of the aerosol-forming substrate of FIG. 12; FIG. 15 illustrates a perspective view from the distal end of an aerosol-generating article according to an embodiment of the present invention; FIG. 16 shows a perspective view from 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 shows a cross-sectional view of the aerosol-generating article of FIG. 15; FIG. 19 illustrates the state in which the aerosol generating article of FIG. 15 is inserted into an aerosol generating device; FIG. 20 illustrates the state in which the aerosol generating article of FIG. 15 is inserted into an aerosol generating device; FIG. 21 shows a cross-sectional view of the aerosol generating article of FIG. 15 inserted into an aerosol generating device; FIG. 22 illustrates a perspective view from the distal end of an additional aerosol-generating article according to an embodiment of the present invention; and FIG. 23 shows a perspective view from the proximal end of the aerosol-generating article of FIG. 22. Specific details for implementing the invention

[0166] Specific embodiments of an aerosol generating article comprising a substantially 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.

[0167] FIG. 1 illustrates a perspective side 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 an upper surface (110) and a lower surface (120) that are flat or planar.

[0168] In one embodiment, the aerosol forming substrate (100) may be substantially composed of an aerosol forming material. In another embodiment, an aerosol forming material, such as homogenized tobacco, may be one of a plurality of components of the aerosol forming substrate (100). The aerosol forming material may be contained within 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 surface (110) and the lower surface (120) may comprise the aerosol forming material or be made of the aerosol forming material.

[0169] Suitable aerosol-forming materials may be homogenized tobacco.

[0170] 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).

[0171] 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 (110) and the lower surface (120). The airflow path (230) extends between the opposing first end (201) and second end (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 the aerosol generated as a result of heating the aerosol-forming material of the aerosol-forming substrate (200).

[0172] FIGS. 3, FIGS. 4, and FIGS. 5 illustrate a cross-sectional view, a side view, and a top view, respectively, 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 layer or separation layer (340) arranged between the upper layer (310) and the lower layer (320).

[0173] 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).

[0174] FIG. 6 illustrates a wavy sheet of an aerosol-forming material (345). The wavy lines have an amplitude (346) of 3 mm and a wavelength (347) of 3 mm. The sheet of the aerosol-forming material (345) forming the intermediate layer (340) has a thickness of 150 μm.

[0175] 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.

[0176] 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.

[0177] 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 along 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 passing 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.

[0178] The aerosol forming material (345) can be any suitable aerosol forming material sheet.

[0179] 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 a volatile compound, which is then carried along with air drawn into the channels (361, 362) through the distal end (372). Then, the volatile compound is cooled and condensed to form an aerosol that can be drawn from the channels (361, 362) of the aerosol forming substrate (300) through the proximal end (371).

[0180] 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) positioned between the first planar outer layer (424) and the second planar outer layer (425). The second planar outer surface (422) is positioned parallel to the first planar outer surface (421).

[0181] FIGS. 8 and 9 illustrate exploded views of the aerosol-forming substrate (400) of FIG. 7. A frame (450) surrounds and defines at least partially the cavity (430). FIG. 8 illustrates the cavity (430) in an empty state. FIG. 9 illustrates the cavity (430) filled with an aerosol-forming material (440). FIGS. 10 and 11 illustrate the respective cross-sectional and longitudinal views of the aerosol-forming substrate (400) when the cavity (430) is filled with the aerosol-forming material (440).

[0182] 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).

[0183] The frame (450) has a hollow rectangular shape and is made of cardboard. The frame (450) defines an aperture extending 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).

[0184] The air inlet (411) and the air outlet (412) are defined by and extend through the peripheral wall (451) of the frame (450). More specifically, the air inlet (411) extends through the front wall (413) and the air outlet (412) extends through the rear wall (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 leaves and has an aerosol-forming agent content of 5% by weight based on dry weight. As illustrated, the aerosol-forming material (440) fills the entire volume of the cavity (430).

[0185] 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.

[0186] 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 substrate is in the form of a sheet of aerosol-generating material (540), particularly a wavy sheet of homogenized tobacco material. FIG. 13 and FIG. 14 illustrate a cross-sectional view and a side cross-sectional view, respectively, of the aerosol-forming substrate (500) of FIG. 12.

[0187] 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.

[0188] 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).

[0189] 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 accompanied by 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).

[0190] For exemplary purposes applicable to any of the aforementioned embodiments, 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:

[0191] 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.

[0192] 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.

[0193] 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 leaf stalks graded into fibers of about 10 to 350 μm, preferably about 10 to 180 μm in length.

[0194] 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.

[0195] 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 mono-, di-, or polycarboxylic acids, such as aliphatic esters of their dimethyl.

[0196] "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.

[0197] For the purpose of illustration, the composition of an additional aerosol-forming material that may also be suitable for use as an aerosol-forming substrate in any one 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.

[0198] Aerosol-forming agents such as glycerin; for example, about 10 to 40%, preferably about 20 to 30%.

[0199] 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.

[0200] 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.

[0201] 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.

[0202] 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.

[0203] With reference to FIGS. 1 to 14, any one of the aforementioned aerosol-forming materials may be combined with a mouthpiece to form an aerosol-generating article according to one or more embodiments of the present invention. Such an aerosol-generating article will now be described with reference to FIGS. 15 to 20.

[0204] FIGS. 15 and 16 are schematic perspective views of an aerosol generating article (1000) according to 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).

[0205] The aerosol generating article (1000) comprises a planar aerosol forming substrate (1100) coupled to a mouthpiece (1600). 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 30 mm, a width of 10 mm, and a thickness of 3 mm.

[0206] 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) terminates at an airflow opening or outlet (1620) to allow the user to inhale air through the mouthpiece.

[0207] 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 to hold the aerosol-forming substrate (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 its surface to suppress displacement of the substrate (1100) along the main axis.

[0208] The connection between the substrate (1100) and the mouthpiece (1600) can be achieved 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).

[0209] The airflow channel through the mouthpiece can be configured to cause turbulence in the airflow. FIG. 18 illustrates an aerosol generating article (1000) having a cut mouthpiece (1600) showing the structure of the airflow channel. A substrate (1100) is coupled to the concave portion (1630) of the mouthpiece (1600).

[0210] The airflow path through the formed mouthpiece will be described from upstream to downstream from the recess (1630) to the outlet (1620). When the material is attached to the mouthpiece, the space between the proximal surface of the material and the rear portion of the recess (1630) forms a chamber that may be called an aerosol collection chamber (1640). In use, the aerosol collection chamber (1640) is a space where the volatile components of the aerosol-forming material (1100), which are entrained by the airflow passing through the aerosol-forming material, can be cooled and begin to condense into an aerosol. Then, the airflow path narrows at the first constriction (1650). Air drawn in through the first constriction has its speed increased due to the constriction, and consequently, the pressure is lower. As soon as it passes through the first constriction (1650), the airflow path enters the expansion chamber (1660). The expansion chamber has a larger cross-sectional area than the first contraction section (1650). Air passing into the expansion chamber (1660) slows down, increases pressure, and experiences severe turbulence. As a result, the airflow containing associated volatile components undergoes significant mixing. Additionally, the continuous cooling of the airflow and rapid changes in pressure create conditions for the nucleation and formation of aerosols. Upstream of the expansion chamber (1660), the airflow path passes through the second contraction section (1670). The second contraction section (1670) contracts and accelerates the airflow again before the airflow channel expands once more over the mouthpiece outlet (1620) where the aerosol can be released.

[0211] The first constriction section (1650) and the second constriction section (1670) may be the narrowest sections along the airflow path. However, the relative dimensions of the first constriction section (1650) and the second constriction section (1670) may be selected to provide a specific pressure difference along the airflow path. In particular, the relative dimensions of the first constriction section (1650) and the second constriction section (1670) may affect the airflow velocity and particle size of the aerosol reaching the outlet (1620) to be delivered to the user's mouth.

[0212] 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. 19, 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. 20 illustrates an article (1000) coupled to a device (1700) that is ready for use.

[0213] The engagement between the article (1000) and the device (1700) can be achieved by generally known engagement elements, such as threads, snap-fits, or pressure-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 with the device (1700). For example, the seal (1655) may include a material overmolded on the periphery of the distal end (1615) of the mouthpiece (1600).

[0214] FIG. 21 is a schematic cross-sectional view of an aerosol generating device (1700) when coupled with an aerosol generating article (1000). The device (1700) includes a housing (1703) that accommodates a battery (1701) and a control electronic device (1702). The wall of the substrate receiving cavity (1710) is in thermal communication with a planar heater (1750) to heat the aerosol forming substrate (1100) contained in the cavity (1710).

[0215] When the article (1000) is coupled to the device (1700), the user may 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), carrying the volatile components of the substrate released 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).

[0216] 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, integrated product, the user can simply discard it and replace it with a new article.

[0217] FIGS. 22 and 23 illustrate specific embodiments of an aerosol generating article (2000) having an ergonomically shaped mouthpiece (1800). The aerosol generating article (2000) comprises an 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 through 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.

[0218] The mouthpiece (1800) is ergonomically shaped to fit the user's lips and has a defined airflow channel, allowing the user to inhale air through the mouthpiece (1800). The cross-section of the mouthpiece (1800) is shaped as an ellipse having a main 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 main axis is 18 mm and the maximum dimension of the minor axis is 7 mm. The maximum dimension of the main 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.

[0219] 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 and a distal portion configured for interlocking with the aerosol forming substrate, and an airflow path is defined by an airflow channel passing between the distal portion and the proximal portion through the mouthpiece, and the airflow channel comprises a first constricted portion and a first expanded portion located downstream of the first constricted portion. Claim 2 An aerosol generating article according to claim 1, wherein the airflow path further comprises a second contraction portion downstream of the first expansion portion. Claim 3 An aerosol generating article according to claim 1 or 2, wherein the airflow path further comprises a second expansion portion downstream of the second contraction portion. Claim 4 In paragraph 3, the airflow outlet is an aerosol generating article defined in the second extension portion. Claim 5 An aerosol generating article according to any one of claims 1 to 4, wherein the collection chamber is defined by the mouthpiece, and the collection chamber is located downstream of the aerosol forming substrate and upstream of the first contraction portion. Claim 6 In any one of claims 1 to 5, the aerosol-forming substrate is substantially planar, for example, the aerosol-forming substrate is substantially parallelepiped in shape, for example, substantially rectangular in shape, an aerosol-generating article. Claim 7 An aerosol generating article according to any one of claims 1 to 6, wherein the airflow path is defined through the aerosol-forming substrate, for example, a low-resistance airflow path is defined through the substrate, for example, the aerosol-forming substrate has an inhalation resistance (RTD) of less than 20 mm H2O along the airflow path. Claim 8 An aerosol generating article according to any one of claims 1 to 7, wherein the aerosol forming substrate is configured to be received within the heating cavity of an aerosol generating device, 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 9 An aerosol generating article according to any one of claims 1 to 8, wherein the mouthpiece comprises a concave portion having substantially the same shape as the cross-section of the aerosol-forming substrate, and the cross-section is a cross-section taken perpendicular to the length dimension of the aerosol-forming substrate. Claim 10 In paragraph 9, the collection chamber is an aerosol generating article defined at the proximal end of the concave portion. Claim 11 An aerosol generating article according to claim 9 or 10, 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. Claim 12 An aerosol generating article according to any one of claims 9 to 11, 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, for example, air passing along the airflow path passes through the first constricted portion between the inlet and the outlet, then passes through the first expanded portion, and then passes through the outlet. Claim 13 An aerosol generating article according to any one of claims 1 to 12, wherein the mouthpiece is formed of a biodegradable material and / or the mouthpiece is formed of a paper material. 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 configured to receive said aerosol generating article. Claim 15 An aerosol generating system according to claim 14, wherein the aerosol generating device includes an air inlet, and when a user inhales the mouthpiece, air is introduced into the device, passes through the aerosol forming material, passes through the first contracted portion of the mouthpiece, passes through the first expanded portion of the mouthpiece, and is introduced into the user's mouth. Claim 16 An aerosol generating article according to any one of claims 1 to 15, wherein the mouthpiece may be detachably 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.

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