Aerosol generating items

Abstract

An aerosol generating article (100) for use with an aerosol generating device to generate an aerosol is provided. The aerosol generating article includes a wrapper (101) that defines a body portion wrapped around at least an aerosol forming substrate (102). The wrapper (101) is formed of a foldable material. The wrapper (101) is configured to inhibit or prevent moisture from passing across the thickness of the wrapper.

Description

Technology Field

[0001] The present disclosure relates to an aerosol generating article for use with an aerosol generating device to generate an aerosol. Background Technology

[0002] A challenge faced by conventional aerosol generating articles configured to generate aerosols through heating rather than combustion of the aerosol-forming substrate is to ensure that the aerosol-forming substrate does not contain excessive levels of moisture before use. Excessive moisture content can reduce the shelf life of the aerosol generating article.

[0003] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol. The aerosol generating article may include a wrapper defining a body portion that wraps and packages at least an aerosol forming substrate. The wrapper may be formed of a foldable material. The wrapper may be configured to inhibit or prevent the passage of moisture across the thickness of the wrapper.

[0004] "To wrap" means to completely encircle. Therefore, when a wrapper is mentioned to wrap at least an aerosol-forming substrate, it means that the wrapper completely encircles at least the aerosol-forming substrate of the aerosol-generating article.

[0005] "Foldable material" means a material that can be deformed into a folded state to define one or more fold lines within it, and the fold lines remain when the force responsible for causing the deformation into a folded state is removed.

[0006] Having a wrapper configured to inhibit or prevent the passage of moisture across the thickness of the wrapper helps reduce or prevent the aerosol-forming substrate from absorbing moisture during the transport and storage of the aerosol-generating article. Avoiding excessive moisture absorption by the aerosol-forming substrate can help ensure that compounds released from the aerosol-forming substrate under heating do not contain excessive levels of moisture and / or reduce the likelihood that water vapor will be released from the aerosol-forming substrate in preference to the desired volatile compounds present in the aerosol-forming substrate. Therefore, avoiding excessive moisture absorption by the aerosol-forming substrate can provide an improved user experience for the user of the aerosol-generating article. The wrapper can also help reduce or prevent the loss of volatile compounds from the aerosol-forming substrate from within the aerosol-generating article before use. Additionally, during the use of an aerosol generating article (e.g., when heating the aerosol generating article during a use session to release volatile compounds from the aerosol-forming substrate), the wrapper can help reduce or prevent unwanted loss of aerosol from within the aerosol generating article.

[0007] The wrapper may have a polymer content of less than 25%, or less than 15%, or less than 10%, or less than 5%. Preferably, the wrapper has substantially no polymer content. A reduced level of polymer content in the wrapper not only ensures that the wrapper can be folded, but can also facilitate improving the sustainability of the aerosol-generating article and its manufacture.

[0008] Preferably, the wrapper may have a first unperforated state and a second perforated state. In the second perforated state, an airflow path may be defined through a packaged body portion between an air inlet and an air outlet defined in the wrapper. In the first unperforated state, the wrapper does not have an air inlet or an air outlet. The first unperforated state and the second perforated state of the aerosol generating article are two different states of the wrapper that cannot exist simultaneously at the same time. In the first unperforated state, the ability of the wrapper to prevent or inhibit the passage of moisture across the wrapper is greater than in the second perforated state. The second perforated state allows airflow to be introduced through the packaged body portion. In the second perforated state, the aerosol generating article may have an inhalation resistance (RTD) of 0 mm H2O to 9.9 mm H2O.

[0009] The wrapper of the aerosol generating article may preferably be configured to facilitate perforation of the wrapper and to define air inlets and air outlets associated with a second perforated state. For example, the wrapper may have a thickness that facilitates perforation of the wrapper by an object, such as a protrusion of an aerosol generating device designed for use with the aerosol generating article. The protrusion may be a blade, a pin, or an annular member. One or more engravings may be defined on the surface of the wrapper at locations corresponding to the air inlets and air outlets. One or more engravings may define a locally thinned area of ​​the wrapper, thereby facilitating perforation of the wrapper to define the air inlets and air outlets.

[0010] When perforating a wrapper at preset first and second positions axially spaced apart from each other along the length of the packaged body, the packaged body may be configured so that an airflow path is defined through the packaged body between the preset first and second positions.

[0011] An airflow path can be defined through an aerosol generating article from one side of the aerosol generating article to another side of the aerosol generating article in the x / y plane. The aerosol generating article preferably has a resistance to suction (RTD) of less than 20 mm H2O, for example, less than 10 mm H2O, in the direction of the airflow path. Preferably, the aerosol generating article has an RTD of less than 20 mm H2O, for example, less than 10 mm H2O, in at least one direction in the x / y plane of the aerosol generating article. An aerosol generating article having a low resistance airflow path enables excellent airflow management and allows aerosols to be extracted more efficiently from the aerosol generating article and delivered to the user.

[0012] Unless otherwise specified, resistance to suction (RTD) is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air to pass along the entire length of a component, such as a packaged body or an aerosol-generating article. Additionally, the terms "pressure drop" or "resistance to suction" with respect to a component or article may refer to "resistance to suction." These terms generally refer to measurements performed under test in accordance with ISO 6565-2015 at a volumetric flow rate of about 17.5 ml per second at the output or downstream end of the component, measured at a temperature of about 22°C, a pressure of about 101 kPa (about 760 Torr), and a relative humidity of about 60%.

[0013] The packaged body portion may extend longitudinally between opposing first and second axial end faces. A preset first position may be located on the first axial end face, and a preset second position may be located on the second axial end face. The first axial end face may be located at the distal end of the aerosol-generating article, and the second axial end face may be located at the proximal end of the aerosol-generating article. In this way, the separation between the first axial end face and the second axial end face may correspond to the length of the aerosol-generating article. The first and second axial end faces may be planar.

[0014] Preferably, the wrapper may be impermeable to water. In this way, the wrapper can prevent the aerosol-forming substrate wrapped within the wrapper from absorbing / absorbing moisture from the outside of the wrapper or the loss of moisture content from the aerosol-forming substrate to the outside of the aerosol-generating article.

[0015] The wrapper may have a permeability of 1 to 10 coresta units, for example 1 to 5 coresta units, for example 1 to 3 coresta units.

[0016] Advantageously, the wrapper may be impermeable to light having wavelengths associated with any one or more of infrared radiation, visible light, and ultraviolet light. In this way, the wrapper can avoid photodegradation caused by exposure to light such as sunlight.

[0017] The wrapper may be a single wrapper. Alternatively, the wrapper may be formed of multiple wrappers or wrapper parts. The multiple wrappers or wrapper parts may be arranged relative to one another to collectively wrap at least the aerosol-forming substrate.

[0018] Preferably, the wrapper may comprise one or a combination of materials selected from the group consisting of parchment, ultra-abrasive paper (e.g., glassine), tracing paper, cellulose film, coated paper (e.g., PVOH paper), and metal foil. These specified materials facilitate limiting or preventing moisture from passing through the thickness of the wrapper.

[0019] The material of the aforementioned group is preferably in the form of a sheet.

[0020] The wrapper may include or be made of aluminum foil having a thickness of at least 4 μm, e.g., at least 6.3 μm, e.g., at least 9 μm. The use of aluminum foil having such thickness provides the wrapper with the ability to be impermeable to moisture and light while ensuring low mass for the wrapper.

[0021] The wrapper may comprise or be made of a thin film of a first metal layer and a second metal layer. The first metal layer may comprise or be made of aluminum. The first metal layer may comprise or be made of aluminum foil having a thickness of at least 4 μm, for example, at least 6.3 μm, for example, at least 9 μm. The second layer may be one of a cellulose layer and a polymer film. The cellulose layer may comprise or be made of paper, cardboard, or cardboard.

[0022] In some embodiments, the wrapper may wrap only the aerosol-forming substrate. In other embodiments, the aerosol-generating article may further include at least one additional element wrapped within the wrapper along the aerosol-forming substrate. For example, the at least one additional element may include one or more of a filter (e.g., for filtering aerosols generated within the packaged body before being inhaled by a user), a spacer element, and a frame.

[0023] Advantageously, the aerosol-forming substrate may comprise distinct first and second portions of the aerosol-forming substrate. Preferably, the composition of the first portion of the aerosol-forming substrate may differ from the composition of the second portion of the aerosol-forming substrate. In this way, the aerosol inhaled by the user of the aerosol-generating article during a usage session may be formed from a combination of different volatile compounds released from the different compositions of the first and second portions of the aerosol-forming substrate, thereby providing a more diverse user experience. In some examples, the first and second portions of the aerosol-forming substrate may be spaced apart from each other along the longitudinal direction of the aerosol-generating article, for example, the first and second portions may be separated from each other by a spacer element. In some other examples, the first and second portions of the aerosol-generating substrate may be spaced apart from each other along the width direction of the aerosol-generating article, for example, the first and second portions may be separated from each other by a spacer element. In some other examples, the first and second portions of the aerosol-forming substrate may be spaced apart from each other along the thickness direction of the aerosol-generating article, for example, the first and second portions may be separated from each other by a spacer element.

[0024] Aerosol-generating articles may have a circular cross-section, an oval cross-section, a lens-shaped cross-section, a square cross-section, or a rectangular cross-section.

[0025] The wrapper can define at least a portion of the outer surface of the aerosol-generating article.

[0026] For convenience, the packaged body may be an aerosol-generating article. If the packaged body is an aerosol-generating article, the length, width, and thickness of the packaged body define the length, width, and thickness of the aerosol-generating article.

[0027] The aerosol-generating article may include an additional wrapper, and the packaged body is surrounded by the additional wrapper. Preferably, an outer wrapper may define the outer surface of the aerosol-generating article. "Additional wrapper" means a wrapper that is distinct from and added to the wrapper of the packaged body.

[0028] An aerosol-generating article can be defined by the article length, article width, and article thickness, where the article width is greater than the article thickness. The length may extend in the x-direction. The width may extend in the y-direction. The thickness may extend in the z-direction.

[0029] Preferably, the aerosol generating article may have a uniform cross-section along the entire length of the aerosol generating article.

[0030] The aerosol-generating article may include upper and lower outer surfaces. The upper and lower outer surfaces are preferably separated from each other to define the thickness of the aerosol-generating article. The upper and lower outer surfaces may collectively define all or most of the periphery of the aerosol-generating article.

[0031] 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. Advantageously, a larger base area may provide a larger surface area for heating by a planar heater of the aerosol generating device. Advantageously, a smaller height may allow for a smaller temperature gradient or difference across the height of the aerosol generating article during heating. The terms “height” and “thickness” have the same meaning for the purposes of the present disclosure when used, for example, in relation to an aerosol generating article. 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.

[0032] Preferably, the upper and lower outer surfaces may be flat. In this way, the aerosol-generating article may generally be flat.

[0033] Alternatively, the upper and lower outer surfaces may be outwardly convex. The upper and lower outer surfaces may collectively define a circular, circular, oval, or lens-shaped profile.

[0034] The upper and lower outer surfaces may be defined by a wrapper. Alternatively, the upper and lower outer surfaces may be defined by an additional wrapper of the aerosol-generating article, and the packaged body is surrounded by the additional wrapper.

[0035] The aerosol generating article may further include a cavity and a frame. The cavity may be located within the aerosol generating article between the upper outer surface and the lower outer surface. The article may be located between the upper outer surface and the lower outer surface. The frame may define the cavity at least partially. An airflow path may be defined through the aerosol generating article between the air inlet and the air outlet. The airflow path may extend through the cavity.

[0036] The packaged body part may be placed inside the cavity. The upper and lower outer surfaces may be defined by an additional wrapper of the aerosol-generating article, the packaged body part, and a frame surrounded by the additional wrapper.

[0037] Preferably, the aerosol-forming material may be disposed within the cavity, and the wrapper is configured to wrap the frame in addition to the aerosol-forming material. Advantageously, one or more holes may be formed on the opposing walls of the frame so that airflow passes through the cavity when the wrapper is perforated at a location corresponding to the location of one or more holes.

[0038] A cavity can be defined by internal dimensions, which are cavity length, cavity width, and cavity height, and the cavity width is greater than the cavity height.

[0039] The frame may include a periphery wall surface that at least partially surrounds or encloses the cavity. The frame may include a periphery wall surface that completely surrounds or encloses the cavity. The periphery wall surface may be formed by an inner surface of the frame and an outer surface of the frame. The periphery wall surface may have a radial thickness of 1 mm to 3 mm.

[0040] The frame can have a thickness of 80% or more of the thickness of the aerosol-generating article.

[0041] The frame may have a thickness of 80% to 95% of the thickness of the aerosol-generating article.

[0042] The frame can have a thickness of 1 mm to 5.5 mm.

[0043] The frame may contain cellulose material. The cellulose material is 300 g / m² 2 Up to 900 g / m² 2 It can have a basis weight. The cellulose material can be paper, cardboard, or cardboard.

[0044] The frame can be an integral component.

[0045] The frame may include a first frame layer and a second frame layer. The first frame layer may be bonded to the second frame layer with an adhesive. The frame may include a third frame layer. The second frame layer may be located between the first frame layer and the third frame layer. The second frame layer may be bonded to the third frame layer with an adhesive.

[0046] The cavity may have a width of 30% to 95% of the width of the aerosol-generating article.

[0047] The cavity may have a length of 30% to 95% of the length of the aerosol-generating article.

[0048] The cavity may have a thickness of 30% to 95% of the thickness of the aerosol-generating article.

[0049] The cavity may have a length of 14 mm to 40 mm, a width of 4.5 mm to 13 mm, and a thickness of 0.5 mm to 4.5 mm.

[0050] The cavity may have a length of 20 mm to 30 mm, a width of 7 mm to 10 mm, and a thickness of 2.5 mm to 4 mm.

[0051] Preferably, the thickness of the aerosol-generating article may be less than 50% of both the length and width of the aerosol-generating article.

[0052] An aerosol-forming substrate may comprise one or more aerosol-forming agents. The use of aerosol-forming agents can facilitate the release of desired volatile compounds from the aerosol-forming substrate through heating rather than combustion of the substrate. However, substrates containing aerosol-forming agents may have a tendency to attract moisture. Accordingly, the wrapper of the present disclosure facilitates the use of an aerosol-forming substrate configured to be suitable for generating aerosols through heating rather than combustion of the substrate, while helping to reduce the likelihood of the substrate absorbing water during the storage and transport of the aerosol-generating article.

[0053] Suitable aerosol-forming agents are widely 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 desirable for the aerosol-forming agent to be glycerin or propylene glycol or to include the same.

[0054] Preferably, the aerosol-forming substrate may have an aerosol-forming agent content of more than 20% by weight, for example, more than 25% by weight, or more than 30% by weight, for example, more than 35% by weight, based on dry weight.

[0055] The aerosol-forming material may include tobacco, for example, tobacco sticks, cast-leaf tobacco, or homogenized tobacco.

[0056] The aerosol-forming material may include any one or more of nicotine, plant components, cannabinoids, and flavoring agents.

[0057] When the aerosol-forming material contains nicotine, the nicotine may include or consist of natural nicotine, synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0058] The aerosol-forming substrate may contain at least 0.5% by weight of nicotine, at least 1% by weight of nicotine, at least 1.5% by weight of nicotine, or at least 2% by weight of nicotine. That is, the aerosol-forming substrate may have a nicotine content of at least 0.5% by weight, at least 1% by weight, at least 1.5% by weight, or at least 2% by weight.

[0059] The aerosol-forming substrate may comprise one or more cannabinoid compounds such as tetrahydrocannabinol (THC), tetrahydrocannabinol acid (THCA), cannabidiol (CBD), cannabidiol acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannavivarin (CBV), cannavivarin (CBDV), tetrahydrocannavivarin (THCV), cannabicromin (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), and cannabicitran (CBT). The cannabinoid compound may preferably be CBD or THC. The cannabinoid compound may particularly preferably be CBD.

[0060] 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 substances. Suitable herbal substances include herb leaves or other herbal substances from herbal plants including, but not limited to, mints such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway. One or more flavoring agents may include tobacco substances.

[0061] The aerosol-forming substrate may include one or more plant components. For example, the aerosol-forming substrate may include plant components such as clove, echinacea species, fennel, ginger, hawthorn berry, elderberry, monarda, mullein leaf, nettle, plantain, turmeric, yarrow, rooibos, star anise, thyme, anethum, chamomile, and compounds thereof in an amount of about 1 to 90%, for example, about 15 to 55%, preferably about 20 to 35%.

[0062] The aerosol-forming substrate may have a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state. For example, the aerosol-forming substrate may be a homogenized tobacco material having a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state.

[0063] The aerosol-forming substrate may include a binder. For example, the aerosol-forming substrate may include about 1 to 10%, preferably about 1 to 5%, of a binder such as any of the common gums or pectins 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; alginates; methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; dextran; and xanthan gum. A preferred binder is guar.

[0064] Preferably, the aerosol-forming substrate may comprise or be made of a solid aerosol-forming material. If the aerosol-forming substrate comprises or is made of a solid aerosol-forming material, the ability of the wrapper to inhibit or prevent moisture from passing across the thickness of the wrapper reduces the likelihood of moisture entering across the wrapper and, consequently, the likelihood of reduced flexural stiffness of the aerosol-generating article. Alternatively, the aerosol-forming substrate may have a liquid or gel composition, or may have a composition of two or more of solid, liquid, or gel phases. If the aerosol-forming substrate has a liquid or gel composition, the ability of the wrapper to inhibit or prevent moisture from passing across the thickness of the wrapper prevents the liquid content of the aerosol-forming substrate from escaping from the interior of the packaged body and / or the additional moisture content from entering into the substrate from the exterior of the packaged body.

[0065] The aerosol-forming substrate wrapped by a wrapper is 150 mg / cm² 3 up to 500 mg / cm² 3 It can have a bulk density in the range. The aerosol-forming substrate wrapped by a wrapper has a density of 175 mg / cm². 3 Up to 475 mg / cm² 3It can have a bulk density of . The aerosol-forming substrate wrapped by a wrapper has a density of 200 mg / cm². 3 up to 450 mg / cm² 3 It can have a bulk density of . The aerosol-forming substrate wrapped by a wrapper has a density of 225 mg / cm². 3 to 425 mg / cm² 3 It can have a bulk density of . The aerosol-forming substrate wrapped by a wrapper has a density of 250 mg / cm². 3 to 400 mg / cm² 3 It can have a bulk density of . The aerosol-forming substrate wrapped by a wrapper has a density of 275 mg / cm². 3 to 375 mg / cm² 3 It can have a bulk density of . The aerosol-forming substrate wrapped by a wrapper has a density of 300 mg / cm². 3 up to 350 mg / cm² 3 It can have a volume density of

[0066] The aerosol-forming substrate wrapped by a wrapper is 50 mg / cm² 3 to 900 mg / cm² 3 It can have a bulk density of . The aerosol-forming substrate wrapped by a wrapper has a volume of 100 mg / cm². 3 up to 800 mg / cm² 3 It can have a bulk density of . The aerosol-forming substrate wrapped by a wrapper has a density of 200 mg / cm². 3 up to 700 mg / cm² 3 It can have a bulk density of . The aerosol-forming substrate wrapped by a wrapper has a density of 200 mg / cm². 3 to 600 mg / cm² 3 It can have a bulk density of . The aerosol-forming substrate wrapped by a wrapper has a density of 200 mg / cm². 3 up to 500 mg / cm² 3 It can have a bulk density of . The aerosol-forming substrate wrapped by a wrapper has a density of 200 mg / cm². 3 to 400 mg / cm² 3It can have a volume density of

[0067] In the case of an aerosol generating article of any embodiment of the present disclosure, the ratio between the length and thickness of the aerosol generating article and the ratio between the width and thickness of the aerosol generating article may be 2:1 to 15:1.

[0068] In the case of an aerosol generating article of any embodiment of the present disclosure, the ratio between the length and width of the aerosol generating article may be 1:1 to 10:1.

[0069] An aerosol generating article of any embodiment of the present disclosure may have a length (e.g., 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.

[0070] The aerosol-generating article may have a length of 15 mm to 45 mm, for example, 25 mm to 30 mm.

[0071] The aerosol generating article may have a width (e.g., 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.

[0072] The aerosol-generating article may have a width of 3 mm to 17 mm, for example, 9 mm to 11 mm.

[0073] The aerosol generating article may have a height or thickness (e.g., 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.

[0074] The aerosol-generating article may have a thickness or height of 1 mm to 5.5 mm, for example, 3 mm to about 3.5 mm.

[0075] According to the present disclosure, an aerosol generating device for receiving an aerosol generating article as disclosed herein may include a cavity having dimensions for receiving at least a portion of the aerosol generating article, a heater or heating means, a power source for supplying power to the heater or heating means, and a controller for controlling the supply of power to the heater or heating means. The aerosol generating device is configured to heat an aerosol forming substrate, for example, an aerosol forming substrate that is a component part of the aerosol generating article, to form an aerosol, for example, an inhalable aerosol.

[0076] The aerosol generating device may preferably be configured to accommodate the entire aerosol generating article so that the aerosol generating article is entirely surrounded within the aerosol generating device.

[0077] The cavity may include an opening into which the distal end of an aerosol-generating article can be inserted. The cavity may have any suitable cross-sectional shape. For example, the cavity may have a rectangular cross section, for example, a rectangular cross section having opposing top and bottom sides that are longer than the left and right sides.

[0078] Preferably, at least one internal surface of the cavity is a heating surface configured to heat an aerosol generating article. The heating surface may include a heater, for example, a resistance heater or an infrared heater, or a susceptor configured to be heated by coupling with an inductor. The heating surface may include an inductor, and for example, the surface may include a coil disposed to generate a fluctuating electromagnetic field within the cavity space. The heating surface may be a surface permeable to the fluctuating electromagnetic field so that an inductor disposed outside the cavity can project the fluctuating electromagnetic field through the heating surface and couple with a susceptor disposed inside the cavity.

[0079] As used herein, the term "aerosol generating article" may refer to an article capable of generating or releasing aerosols.

[0080] As used herein, the term "aerosol-forming substrate" may refer to a substrate capable of releasing an aerosol or a volatile compound capable of forming an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may comprise an aerosol-forming material. The aerosol-forming substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. For convenience, the aerosol-forming substrate may be part of an aerosol-generating article or a smoking article.

[0081] 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.

[0082] 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 on-board electric power supply to an electrically operated or electric aerosol generating device.

[0083] As used herein, the term "aerosol-forming agent" may refer to any suitable known compound or mixture of compounds that facilitates the formation of an aerosol upon use. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal decomposition at the operating temperature of the aerosol-forming substrate or the aerosol-generating article.

[0084] As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salt.

[0085] 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 or a part of a component of an aerosol-generating article.

[0086] 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.

[0087] As used herein, the term “sheet” refers to a laminated element in which the width and length are substantially greater than the thickness. The width of the sheet is greater than 10 mm, and 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.

[0088] As used herein, the term “homogenized tobacco material” includes 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 pulverizing one or both of tobacco leaf lamina and tobacco leaf stem. 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.

[0089] 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 manufacture 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 into a sheet of homogenized plant material. Preferably, the homogenized plant material used in the article according to the present invention can be produced by casting. Such homogenized plant material may comprise aggregated fine particulate plant material.

[0090] As used herein, suction resistance is expressed as "mm H2O" or "mm WG" or "mm water level gauge" and can be measured according to ISO 6565:2002.

[0091] The present invention is defined in the claims. However, a non-limiting, non-comprehensive list of examples is provided below. Any one or more features of these examples may be combined with any one or more features of other examples, embodiments, or modes described herein.

[0092] Example Ex1: An aerosol generating article for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article comprises a wrapper defining a body portion that surrounds and packages an aerosol forming substrate, wherein the wrapper is formed of a foldable material and the wrapper is configured to inhibit or prevent moisture from passing across the thickness of the wrapper.

[0093] Example Ex2: In Ex1, the wrapper is an aerosol generating article having a polymer content of less than 25%, or less than 15%, or less than 10%, or less than 5%.

[0094] Example Ex3: An aerosol-generating article in Ex1 or Ex2, wherein the wrapper substantially has no polymer content.

[0095] Example Ex4: An aerosol generating article, wherein in any one of Ex1 to Ex3, the wrapper has a first state that is not perforated and a second state that is perforated, wherein in the second state that is perforated, the airflow path is defined through a body portion that is wrapped between an air inlet and an air outlet defined in the wrapper, and in the first state that is not perforated, the wrapper does not have an air inlet and an air outlet.

[0096] Example Ex5: An aerosol generating article in which, in the first unperforated state of Ex4, one or more engraving lines are defined on the surface of the wrapper at positions corresponding to the air inlet and air outlet.

[0097] Example Ex6: An aerosol generating article in any one of Ex1 to Ex5, wherein when a wrapper is perforated at a preset first and second position axially spaced apart from each other in the longitudinal direction of the packaged body, the airflow path is defined through the packaged body between the preset first and second positions.

[0098] Example Ex7: In Ex6, the packaged body portion extends longitudinally between opposing first and second axial end faces, a preset first position is located on the first axial end face, and a preset second position is located on the second axial end face, an aerosol generating article.

[0099] Example Ex8: An aerosol generating article in which, in Ex7, the first axial end surface is at the distal end of the aerosol generating article and the second axial end surface is at the proximal end of the aerosol generating article.

[0100] Example Ex9: An aerosol generating article in which, in Ex7 or Ex8, the first and second axial end faces are planar.

[0101] Example Ex10: In any one of Ex1 to Ex9, the wrapper is an aerosol-generating article that is impermeable to water.

[0102] Example Ex11: In any one of Ex1 to Ex10, the wrapper is an aerosol generating article having a permeability of 1 to 10 Coresta units, for example 1 to 5 Coresta units, for example 1 to 3 Coresta units.

[0103] Example Ex12: In any one of Ex1 to Ex11, the wrapper is opaque to light and is opaque to light having a wavelength associated with, for example, one or more of infrared radiation, visible light and ultraviolet light, an aerosol generating article.

[0104] Example Ex13: In any one of Ex1 to Ex12, the wrapper comprises one or a combination of materials selected from the group consisting of parchment, ultra-abrasive paper (e.g., glassine), tracing paper, cellulose film, coated paper (e.g., PVOH paper) and metal foil, an aerosol generating article.

[0105] Example Ex14: In Ex13, the material of the above group is an aerosol-generating article in the form of a sheet.

[0106] Example Ex15: In Ex13 or Ex14, the wrapper comprises or is made of aluminum foil having a thickness of at least 4 μm, e.g. at least 6.3 μm, e.g. at least 9 μm. an aerosol generating article.

[0107] Example Ex16: In any one of Ex1 to Ex15, the wrapper comprises or is composed of a thin layer of a first metal layer and a second metal layer, an aerosol generating article.

[0108] Example Ex17: An aerosol generating article in Ex16, wherein the first metal layer comprises or is made of aluminum.

[0109] Example Ex18: An aerosol generating article in Ex17, wherein the metal first layer comprises or is made of aluminum foil having a thickness of at least 4 μm, e.g. at least 6.3 μm, e.g. at least 9 μm.

[0110] Example Ex19: An aerosol generating article in any one of Ex16 to Ex18, wherein the second layer is one of a cellulose layer and a polymer film.

[0111] Example Ex20: An aerosol-generating article in Ex19, wherein the cellulose layer comprises or is made of paper, cardboard or cardboard.

[0112] Example Ex21: In any one of Ex1 to Ex20, the wrapper is an aerosol generating article that wraps only the aerosol-forming substrate.

[0113] Example Ex22: In any one of Ex1 to Ex20, the aerosol generating article further comprises at least one additional element wrapped within a wrapper along an aerosol forming substrate.

[0114] Example Ex23: In Ex22, at least one additional element comprises one or more of a filter, a spacer element, and a frame, an aerosol generating article.

[0115] Example Ex24: In any one of Ex1 to Ex23, the aerosol-forming substrate comprises separated first and second portions of the aerosol-forming substrate, an aerosol-generating article.

[0116] Example Ex25: An aerosol generating article in which the composition of the first part of the aerosol-forming substrate in Ex24 is different from the composition of the second part of the aerosol-forming substrate.

[0117] Example Ex26: In Ex24 or Ex25, the first and second portions of the aerosol-forming substrate are spaced apart from each other along the longitudinal direction of the aerosol-generating article, for example, the first and second portions are separated from each other by a spacer element, an aerosol-generating article.

[0118] Example Ex27: In any one of Ex24 to Ex26, the first and second portions of the aerosol-forming substrate are spaced apart from each other along the width direction of the aerosol-generating article, for example, the first and second portions are separated from each other by a spacer element.

[0119] Example Ex28: In any one of Ex24 to Ex27, the first and second portions of the aerosol-forming substrate are spaced apart from each other along the thickness direction of the aerosol-generating article, for example, the first and second portions are separated from each other by a spacer element.

[0120] Example Ex29: In any one of Ex1 to Ex28, the aerosol generating article has a circular cross section, an oval cross section, a lens-shaped cross section, a square cross section, or a rectangular cross section.

[0121] Example Ex30: In any one of Ex1 to Ex29, the wrapper defines at least a portion of the outer surface of the aerosol-generating article.

[0122] Example Ex31: In any one of Ex1 to Ex30, the packaged body is an aerosol generating article.

[0123] Example Ex32: In any one of Ex1 to Ex29, the aerosol generating article comprises an additional wrapper, and the packaged body is surrounded by the additional wrapper.

[0124] Example Ex33: In Ex32, an additional wrapper defines the outer surface of the aerosol generating article.

[0125] Example Ex34: In any one of Ex1 to Ex33, the aerosol generating article is defined by the article length, article width and article thickness, and the article width is greater than the article thickness.

[0126] Example Ex35: In any one of Ex1 to Ex34, the aerosol generating article comprises upper and lower outer surfaces, and the upper and lower outer surfaces are separated from each other to define the thickness of the aerosol generating article.

[0127] Example Ex36: An aerosol generating article in which the upper and lower outer surfaces of Ex35 are flat.

[0128] Example Ex37: An aerosol generating article in which, in Ex35, the upper and lower outer surfaces are convex outwardly, for example, the upper and lower outer surfaces collectively define a round, circular, oval, or lens-shaped profile.

[0129] Example Ex38: An aerosol generating article in any one of Ex35 to Ex37, wherein the upper and lower outer surfaces are defined by a wrapper.

[0130] Example Ex39: In any one of Ex35 to Ex37, the upper and lower outer surfaces are defined by an additional wrapper of the aerosol-generating article, and the packaged body is surrounded by an additional wrapper.

[0131] Example Ex40: In any one of Ex35 to Ex39, the aerosol-generating article is

[0132] A cavity located within an aerosol-generating article between an upper outer surface and a lower outer surface;

[0133] A frame located between an upper outer surface and a lower outer surface, defining at least partially a cavity;

[0134] An aerosol generating article defined through an aerosol generating article between an air inlet and an air outlet, and further comprising an airflow passage extending through a cavity.

[0135] Example Ex41: In Ex40, the packaged body part is disposed within the cavity, an aerosol-generating article.

[0136] Example Ex42: In Ex41, the upper and lower outer surfaces are defined by an additional wrapper of the aerosol-generating article, a packaged body, and a frame surrounded by the additional wrapper.

[0137] Example Ex43: An aerosol generating article in which, in Ex40, the aerosol forming material is disposed within a cavity, and the wrapper is configured to wrap the frame in addition to the aerosol forming material.

[0138] Example Ex44: An aerosol generating article in which, in Ex43, one or more holes are formed in opposing wall surfaces of the frame, so that airflow can pass through the cavity when a wrapper is perforated at a position corresponding to the location of one or more holes.

[0139] Example Ex45: In any one of Ex1 to Ex44, the aerosol-forming substrate comprises an aerosol-forming agent selected from a list consisting of, for example, glycerin and propylene glycol, and, for example, the aerosol-forming substrate has an aerosol-forming agent content of more than 20% by weight, for example, more than 25% by weight, or more than 30% by weight, for example, more than 35% by weight, based on dry weight, an aerosol-generating article.

[0140] Example Ex46: In any one of Examples Ex1 to Ex45, the aerosol-forming substrate comprises an aerosol-generating article, for example, tobacco, tobacco sticks, cast leaf tobacco, or homogenized tobacco.

[0141] Example Ex47: In any one of Ex1 to Ex46, the aerosol-forming material comprises any one or more of nicotine, plant components, cannabinoids, and flavoring agents, an aerosol-generating article.

[0142] Example Ex48: An aerosol generating article in any one of Ex1 to Ex47, wherein the aerosol forming substrate comprises or is composed of a solid aerosol forming substrate.

[0143] Example Ex49: In any one of Ex1 to Ex47, the aerosol-forming substrate is an aerosol-generating article having a liquid or gel composition, or a composition of two or more of a solid, liquid, or gel phase. Brief explanation of the drawing

[0144] Now, additional examples will be explained with reference to the drawings. FIG. 1 is a perspective view of an aerosol-generating article in an unperforated first state according to a first embodiment of the present disclosure, including a cross-sectional view through the article; FIG. 2 is a perspective view of a perforated second state of the aerosol-generating article of FIG. 1; FIG. 3 is a perspective view of an aerosol-generating article according to a second embodiment of the present disclosure, including a cross-sectional view through the article; FIG. 4 is a perspective view of a perforated second state of the aerosol-generating article of FIG. 3; FIGS. 5(a) to 5(f) are perspective views illustrating a first example of a method in which a wrapper can be folded around a body portion of an aerosol-forming substrate; FIGS. 6(a) to 6(f) are perspective views illustrating a second example of a method in which a wrapper can be folded around a body portion of an aerosol-forming substrate; FIGS. 7(a) to 7(f) are perspective views illustrating a third example of a method in which a wrapper can be folded around the body portion of an aerosol-forming substrate; FIGS. 8(a) to 8(f) are perspective views illustrating a fourth example of a method in which a wrapper can be folded around a body portion of an aerosol-forming substrate; FIG. 9 is an exploded perspective view illustrating components of an aerosol generating article according to an additional embodiment of the present disclosure; FIG. 10 is a perspective view of the aerosol generating article of FIG. 9 when partially assembled; FIG. 11 is a perspective view of the aerosol generating article of FIG. 9 and FIG. 10 when fully assembled, wherein the wrapper of the aerosol generating article is in a first state that is not perforated; FIG. 12 illustrates a schematic cross-sectional view of the assembled aerosol generating article of FIG. 11; FIG. 13 illustrates a schematic cross-sectional view of the assembled aerosol generating article of FIG. 11; FIG. 14 is a perspective view of the assembled aerosol generating article of FIG. 11 to FIG. 13, and the wrapper of the aerosol generating article is in a perforated second state. FIG. 15 illustrates a schematic diagram of an aerosol generating device according to one embodiment of the present disclosure, wherein the device is configured to engage with an aerosol generating article, for example, any of FIG. 1 to FIG. 14; FIG. 16 illustrates a schematic end view of the aerosol generator of FIG. 15; FIG. 17 is a schematic diagram illustrating an aerosol generating article (e.g., any aerosol generating article among FIG. 1 to FIG. 14) that engages with the aerosol generating device of FIG. 15. FIG. 18 is a schematic diagram of an alternative embodiment of FIG. 15 to 17, illustrating an aerosol generating article coupled with an aerosol generating device. Specific details for implementing the invention

[0145] FIGS. 1 and 2 show a side perspective view of an aerosol generating article (100) according to a first embodiment of the present disclosure. The aerosol generating article (100) has a wrapper (101) that wraps around a body portion of an aerosol forming substrate (102). The body portion of the aerosol forming substrate (102) is shown as a dashed outline in FIGS. 1 and 2 to indicate the wrapper (101) that encloses the entire body portion of the aerosol forming substrate. FIG. 1 also includes a view through section AA of the aerosol generating article (100) showing how the wrapper (101) wraps around the body portion of the aerosol forming substrate (102). The aerosol generating article (100) of FIG. 1 has a rectangular shape, and the wrapper (101) defines the exterior of the aerosol generating article. The aerosol generating article (100) has a length extending in the x direction, a width extending in the y direction, and a thickness (or height) extending in the z direction. The upper and lower outer surfaces (103, 104) of the article (100) are planar and flat. In a similar manner, the opposing outer side surfaces (105, 106) of the article (100) are also planar and flat. The aerosol forming substrate (102) is in the form of a homogenized tobacco having an aerosol forming agent content of 25% by weight based on dry weight.

[0146] The wrapper (101) is formed of a material configured to inhibit or prevent moisture from passing across the thickness of the wrapper. Additionally, the wrapper (101) is formed of a foldable material, meaning a material that can be deformed into a folded state to define one or more fold lines within it, and the fold lines remain intact upon removal of the corresponding force causing the wrapper to deform into a folded state. In the embodiment shown in FIG. 1, the wrapper (101) is formed of coated paper, such as PVOH paper, and has a thickness of 35 μm. In another embodiment, the wrapper (101) may instead be formed of aluminum foil or foil made of other metal with a thickness of 7 μm. In a further embodiment, the wrapper (101) may instead be formed having a thin-layer structure, e.g., a paper-based second layer placed on top or a metal first layer (e.g., an aluminum layer) placed on top of the paper-based second layer; and the wrapper has a thickness of 10 to 200 μm.

[0147] Wrapping the body portion of the aerosol-forming substrate (102) by the wrapper (101) serves to completely enclose the substrate.

[0148] FIG. 1 shows an aerosol generating article (100) in a first state without perforations, wherein the wrapper (101) substantially prevents any airflow and / or moisture from entering the body portion of the aerosol forming substrate (102) from the outside of the aerosol generating article. Similarly, the first state without perforations of the wrapper (101) helps to avoid or reduce the loss of moisture content from the body portion of the aerosol forming substrate (102).

[0149] FIG. 2 shows a perforated aerosol generating article (100) in a second state, wherein a wrapper (101) is perforated at opposing axial end surfaces (107, 108) of the aerosol generating article, and each hole (109, 110) is defined through the wrapper within the opposing axial end surfaces. The hole (109) defines an air inlet, and the hole (110) defines an air outlet. The homogenized tobacco forming the body portion of the aerosol forming substrate (102) has a porous structure. The holes (109, 110) provide an airflow into the aerosol generating article (100), pass through the aerosol forming substrate (102), and then discharge it out of the aerosol generating article. The path (111) through which the airflow proceeds through the interior of the aerosol generating article (100) is indicated by an arrow in FIG. 2.

[0150] The wrapper (101) may be perforated using, for example, a pin, a blade, or other suitable sharp or pointed tool to form a hole (109, 110) before the consumer inserts the aerosol generating article (100) into the aerosol generating device (not shown). Alternatively, the aerosol generating article (100) may instead be perforated as a result of the aerosol generating article being inserted into the cavity of the aerosol generating device. For example, the cavity of the aerosol generating device may be configured to be suitable for perforating the wrapper (101) at or after the insertion of the aerosol generating article (100) into the cavity. The aerosol generating device may be equipped with a heating array (e.g., an electric-driven heating element) for heating the aerosol-forming substrate (102) of the aerosol generating article (100) to vaporize the volatile components of the aerosol-forming substrate, and as the steam passes through the aerosol-forming article along the airflow path (111), it cools and is entrained by the airflow to form an aerosol.

[0151] FIGS. 3 and 4 show perspective views of an aerosol generating article (200) according to a second embodiment of the present disclosure. Features common to the aerosol generating article (100) are referred to by similar reference numerals, except that they start with 2 instead of the number 1. Common to the article (100) of FIGS. 1 and 2, the aerosol generating article (200) has a wrapper (201) that wraps around a body portion of an aerosol forming substrate (202). The body portion of the aerosol forming substrate (202) is shown as a dashed outline in FIGS. 3 and 4 to indicate the wrapper (201) that encloses the entire body portion of the aerosol forming substrate. FIG. 3 also includes a cross-sectional view of section BB of the aerosol generating article (200) showing how the wrapper (201) wraps around the body portion of the aerosol forming substrate (202). The aerosol generating article (200) differs from the article (100) of FIGS. 1 and 2 in that it defines a round cylindrical rod shape, and the wrapper (201) defines the exterior of the aerosol generating article. The aerosol generating article (200) has a length extending in the x direction, a width extending in the y direction, and a thickness (or height) extending in the z direction. Common to the article (100), the aerosol forming substrate (202) of the article (200) is in the form of a homogenized cigarette.

[0152] The wrapper (201) is formed of the same material as described above for the wrapper (101).

[0153] Wrapping the body portion of the aerosol-forming substrate (202) by the wrapper (201) serves to completely enclose the substrate.

[0154] FIG. 3 illustrates an aerosol generating article (200) in a first state that is not perforated, wherein the wrapper (201) substantially prevents any airflow and / or moisture from entering the body portion of the aerosol forming substrate (202) from the outside of the aerosol generating article. FIG. 4 illustrates an aerosol generating article (200) in a second state that is perforated, wherein the wrapper (201) is perforated at opposing axial end surfaces (207, 208) of the aerosol generating article, and each hole (209, 210) is defined through the wrapper within the opposing axial end surfaces. The hole (209) defines an air inlet, and the hole (210) defines an air outlet. The homogenized tobacco forming the body portion of the aerosol forming substrate (202) has a porous structure. The holes (209, 210) provide airflow into the aerosol generating article (200), pass through the aerosol forming substrate (202), and then discharge it out of the aerosol generating article. The path (211) through which the airflow proceeds through the interior of the aerosol generating article (200) is indicated by an arrow in FIG. 4. The wrapper (201) can be perforated in the same manner as the wrapper (101) of the aerosol generating article (100) described above.

[0155] In a modified example of the aerosol generating article (200) of FIGS. 3 and 4, the aerosol generating article may instead have a lens-shaped cross-section, so as to have upper and lower outer surfaces of the article defined by convex upper and lower portions of a wrapper that surround a body portion of the corresponding shape of the aerosol forming substrate. This lens-shaped cross-section defines a profile corresponding to a double convex lens.

[0156] In the case of the aerosol generating article (100, 200) shown in FIGS. 1 to 4, the body portion of the aerosol forming substrate (102, 202) is the only entity wrapped by each wrapper (101, 201). However, in other embodiments, in addition to the body portion of the aerosol forming substrate (102, 202), one or more additional elements may be wrapped by the wrapper (101, 201).

[0157] FIGS. 5(a) to 5(e) are perspective views illustrating a first example of a method in which a wrapper (301) is folded around the body portion of an aerosol-forming substrate (302) to form a packaged body portion (300) of an aerosol-forming substrate. FIG. 5(a) shows the body portion of an aerosol-forming substrate (302) placed on the wrapper (301). FIG. 5(a) shows that the wrapper (301) is in the form of a sheet. The ends (312a, 312b) extending in the opposite longitudinal direction of the wrapper (301) are folded around the opposite side surface of the body portion of the aerosol-forming substrate (302) in the direction of the arrow shown in FIG. 5(a) to form the state shown in FIG. 5(b). Then, the opposing longitudinally extending ends (312a, 312b) of the wrapper (301) are aligned with each other to define a fin seal portion (313) of the wrapper (see FIG. 5(c)), and the opposing inner surfaces of the fin seal portion are joined together by an adhesive or other sealing means. Also, as shown in FIG. 5(c), the wrapper (301) is folded to surround the periphery of the body portion of the aerosol forming substrate (302), but the portions (314a, 314b) of the wrapper extend beyond the opposing axial end surfaces of the body portion of the aerosol forming substrate (302), leaving the opposing axial end surfaces of the body portion of the aerosol forming substrate exposed without covering them. The contour of the body portion of the aerosol forming substrate (302) is shown as a dashed outline in FIG. 5(c) and FIG. 5(d). Then, the pin seal portion (313) of the wrapper (301) is folded downward in the direction of the arrow shown in FIG. 5(c) and placed over one of the outer side walls of the wrapper to form the state shown in FIG. 5(d). Then, the upper and lower surfaces of part (314a) of the wrapper (301) are pressed together and flattened, and the same is done for the upper and lower surfaces of part (314b) as shown in FIG. 5(e).Then, the flattened portions (314a, 314b) are folded upward in the direction of the arrow shown in FIG. 5(e) and placed on the upper wall of the wrapper (301) to form the packaged body portion (300) of FIG. 5(f). The consumer can prepare the packaged body portion (300) for consumption by unfolding the flattened portions (314a, 314b) of the wrapper (301) back to the state shown in FIG. 5(e) and then cutting with scissors or a knife to remove the flattened portions from the wrapper, thereby exposing the aerosol-forming material (302). The packaged body portion (300) may itself form an aerosol-generating article or may be part of a component of an aerosol-generating article.

[0158] FIGS. 6(a) to 6(e) are perspective views illustrating a second example of a method in which a wrapper (401) is folded around the body portion of an aerosol-forming substrate (402) to form a packaged body portion (400) of an aerosol-forming substrate. FIG. 6(a) shows the body portion of an aerosol-forming substrate (402) placed on the wrapper (401). FIG. 6(a) shows that the wrapper (401) is in the form of a sheet. The opposing laterally extending ends (412a, 412b) of the wrapper (401) are folded around the opposing axial end surface of the body portion of the aerosol-forming substrate (402) in the direction of the arrow shown in FIG. 6(a) to form the state shown in FIG. 6(b). Then, the opposing laterally extending ends (412a, 412b) of the wrapper (401) are aligned with each other to define the pin seal portion (413) of the wrapper (see FIG. 6(c)), and the opposing inner surfaces of the pin seal portion are joined together by an adhesive or other sealing means. Also, as shown in FIG. 6(c), the wrapper (401) is folded to surround the periphery of the body portion of the aerosol forming substrate (402), but parts (414a, 414b) of the wrapper extend beyond the opposing lateral surface of the body portion of the aerosol forming substrate (402), leaving the opposing lateral surface of the body portion of the aerosol forming substrate exposed without covering it. The contour of the body portion of the aerosol forming substrate (402) is shown as a dashed line contour in FIG. 6(c) and FIG. 6(d). Then, the pin seal portion (413) of the wrapper (401) is folded upward in the direction of the arrow shown in FIG. 6(c) and placed over the upper wall surface of the wrapper to form the state shown in FIG. 6(d). Then, the upper surface of portion (414a) of the wrapper (401) is folded downward in the direction of the arrow in FIG. 6(d) and placed over one of the side surfaces of the body portion of the aerosol-forming substrate (402), and the same is done for the upper surface of portion (414b) as shown in FIG. 6(e).Then, the lower surface of part (414a) is folded upward in the direction of the arrow shown in FIG. 6(e) and placed over the folded upper surface of part (414a), and the same is done for the lower surface of part (414b) to form the packaged body part (400) of FIG. 6(f). A consumer can prepare the packaged body part (400) for consumption by piercing the wrapper (401) at each of the opposing axial end surfaces (407, 408) of the wrapper. The packaged body part (400) may itself form an aerosol generating article or may be part of a component of an aerosol generating article.

[0159] FIGS. 7(a) to 7(e) are perspective views illustrating a third example of a method in which a wrapper (501) is folded around the body portion of an aerosol-forming substrate (502) to form a packaged body portion (500) of an aerosol-forming substrate. FIG. 7(a) shows the body portion of an aerosol-forming substrate (502) placed on the wrapper (501). FIG. 7(a) shows that the wrapper (501) is in the form of a sheet. The opposing laterally extending ends (512a, 512b) of the wrapper (501) are folded around the opposing axial end surface of the body portion of the aerosol-forming substrate (502) in the direction of the arrow shown in FIG. 7(a) to form the state shown in FIG. 7(b). Then, the opposing laterally extending ends (512a, 512b) of the wrapper (501) are aligned with each other to define the pin seal portion (513) of the wrapper (see FIG. 7(c)), and the opposing inner surfaces of the pin seal portion are joined together by an adhesive or other sealing means. Also, as shown in FIG. 7(c), the wrapper (501) is folded to surround the periphery of the body portion of the aerosol forming substrate (502), but parts (514a, 514b) of the wrapper extend beyond the opposing lateral surface of the body portion of the aerosol forming substrate (502), leaving the opposing lateral surface of the body portion of the aerosol forming substrate exposed without covering it. The contour of the body portion of the aerosol forming substrate (502) is shown as a dashed line contour in FIG. 7(c) and FIG. 7(d). Then, the pin seal portion (513) of the wrapper (501) is folded in the direction of the arrow shown in FIG. 7(c) and placed over the upper wall surface of the wrapper to form the state shown in FIG. 7(d). Then, the upper surface of portion (514a) of the wrapper (501) is folded downward in the direction of the arrow in FIG. 7(d) and placed over one of the side surfaces of the body portion of the aerosol-forming substrate (502), and the same is done for the upper surface of portion (514b) as shown in FIG. 7(e).Then, the lower surface of part (514a) is folded upward in the direction of the arrow shown in FIG. 7(e) and placed over the folded upper surface of part (514a), and the same is done for the lower surface of part (514b) to form the packaged body part (500) of FIG. 7(f). A consumer can prepare the packaged body part (500) for consumption by piercing the wrapper (501) at each of the opposing axial end surfaces (507, 508) of the wrapper. The packaged body part (500) may itself form an aerosol generating article or may be part of a component of an aerosol generating article.

[0160] FIGS. 8(a) to 8(e) are perspective views illustrating a fourth example of a method in which a wrapper (601) is folded around the body portion of an aerosol-forming substrate (602) to form a packaged body portion (600) of an aerosol-forming substrate. FIG. 8(a) shows the body portion of an aerosol-forming substrate (602) placed on the wrapper (601). FIG. 8(a) shows that the wrapper (601) is in the form of a sheet. The ends (612a, 612b) extending in the opposite longitudinal direction of the wrapper (601) are folded around the opposite side surface of the body portion of the aerosol-forming substrate (602) in the direction of the arrow shown in FIG. 8(a) to form the state shown in FIG. 8(b). Then, the opposing longitudinally extending ends (612a, 612b) of the wrapper (601) are aligned with each other to define the pin seal portion (613) of the wrapper (see FIG. 8(c)), and the opposing inner surfaces of the pin seal portion are joined together by an adhesive or other sealing means. Also, as shown in FIG. 8(c), the wrapper (601) is folded to surround the periphery of the body portion of the aerosol forming substrate (602), but the portions (614a, 614b) of the wrapper extend beyond the opposing axial end surfaces of the body portion of the aerosol forming substrate (602), leaving the opposing axial end surfaces of the body portion of the aerosol forming substrate exposed without covering them. The contour of the body portion of the aerosol forming substrate (602) is shown as a dashed line in FIG. 8(c) and FIG. 8(d). Then, the pin seal portion (613) of the wrapper (601) is folded in the direction of the arrow shown in FIG. 8(c) and placed on the upper wall surface of the wrapper to form the state shown in FIG. 8(d). Then, the upper and lower surfaces of part (614a) of the wrapper (601) are pressed together and flattened, and the same is done for the upper and lower surfaces of part (614b) as shown in FIG. 8(e).Then, the flattened portions (614a, 614b) are folded upward in the direction of the arrow shown in FIG. 6(e) and placed on the upper wall of the wrapper (601) to form the packaged body portion (600) of FIG. 8(f). The consumer can prepare the packaged body portion (600) for consumption by unfolding the flattened portions (614a, 614b) of the wrapper (601) back to the state shown in FIG. 8(e) and then removing the flattened portions from the wrapper by cutting with scissors or a knife. The packaged body portion (600) may itself form an aerosol-generating article or may be part of a component of an aerosol-generating article.

[0161] FIG. 9 illustrates the components of an additional embodiment of an aerosol generating article (700). The components of the aerosol generating article (700) include a wrapper (701) and a body portion of an aerosol forming substrate (702). The wrapper (701) is a thin sheet formed of an aluminum layer placed on a layer of a paper-based substrate, the aluminum layer being 6 μm thick and the paper-based substrate layer being 40 μm thick. The body portion of the aerosol forming substrate (702) is in the form of a part of a cigarette with an aerosol forming agent content of 5 wt% based on dry weight. Additionally, the components of the aerosol generating article (700) include a frame (715), a first planar layer (716) forming a first flat surface (717), and a second planar layer (718) forming a second flat surface (719). The frame (715) surrounds and at least partially defines the cavity (720). The body portion of the aerosol-forming substrate (702) has dimensions that allow it to be fitted into the cavity (720).

[0162] The first flat layer (716) and the second flat layer (718) are made of cigarette paper having a thickness of 35 μm.

[0163] The frame (715) has a hollow rectangular shape and is made of cardboard. The frame (715) defines a hole extending through the thickness of the frame, and the hole forms at least partially a cavity (720). The frame (715) includes a periphery wall (721) surrounding the cavity (720). The periphery wall (721) includes a front wall (722) and a rear wall (723). More specifically, the periphery wall (721) is defined by an inner transverse surface (724) of the frame (715) and an outer transverse surface (725) of the frame. The inner transverse surface (724) of the frame (715) defines at least partially the periphery of the cavity (720). The periphery wall (721) has a radial thickness of about 5 mm measured between the inner transverse surface (724) of the frame (715) and the outer transverse surface (725) of the frame. The air inlet (726) and air outlet (727) are defined by and extend through the peripheral wall surface (721) of the frame (715). More specifically, the air inlet (726) extends through the front wall surface (722) and the air outlet (727) extends through the rear wall surface (723). The air inlet (726) and the air outlet (727) have an equivalent diameter of 5 mm. An airflow passage extends through a cavity (720) between the air inlet (726) and the air outlet (727).

[0164] The components of the aerosol generating article (700) are partially assembled in a first series of steps to form an intermediate structure (700a) (shown in FIG. 10) located on the surface of the wrapper (701), as described below.

[0165] The first planar layer (716) is bonded to the first planar annular surface of the peripheral wall (721) of the frame (715) using an adhesive. Then, the body portion of the aerosol-forming substrate (702) is positioned within the cavity (720) defined by the frame (715) and rests on the surface of the first planar layer (716). In the illustrated embodiment, the body portion of the aerosol-forming substrate (702) fills the entire volume of the cavity (720). In another embodiment, the body portion of the aerosol-forming substrate (702) may only partially fill the cavity (720); for example, the body portion of the aerosol-forming substrate (702) may extend only along a portion of the length (x-direction) of the cavity and / or only along a portion of the width (y-direction) of the cavity and / or only along a portion of the thickness (z-direction) of the cavity.

[0166] Then, a second planar layer (718) is bonded to a second planar annular surface of the peripheral wall (721) of the frame (715) using adhesive. The second planar layer (718) is positioned parallel to the first planar layer (716). The first planar layer (716) is placed over the first end of the cavity (720) and forms the first cavity end wall (728). The second planar layer (718) is placed over the second end of the cavity (720) and forms the second cavity end wall (729), and the second cavity end wall faces the first cavity end wall. That is, the frame (715), the first planar outer layer (716), and the second planar outer layer (718) collectively surround and define the cavity (720). A structure formed by a combination of a frame (715), first and second planar layers (716, 718) and a body portion of an aerosol-forming substrate (702) defines an intermediate structure (700a). FIG. 10 illustrates this intermediate structure (700a) located on the surface of a wrapper (701). A first flat surface (717) of the first planar layer (716) defines the lower outer surface of the intermediate structure (700a). A second flat surface (719) of the second planar layer (718) defines the upper outer surface of the intermediate structure (700a).

[0167] Then, the assembly of the aerosol generating article (700) is completed in a second series of steps. In this second series of steps, the wrapper (701) is folded around the intermediate structure (700a) to wrap the intermediate structure, thereby forming the assembled aerosol generating article (700) (as shown in FIG. 11). FIG. 11 shows the intermediate structure (700a) in dashed lines, which is completely surrounded by the wrapper (701) and contained within it. Although the exact manner in which the wrapper (701) is folded around the intermediate structure (700a) is not illustrated in the drawings relating to the aerosol generating article (700), it is understood that the wrapper (701) can be folded to wrap the intermediate structure (700a) in the same manner as the wrapper (301, 401, 501, 601) is folded to wrap the body portion of the aerosol forming substrate (302, 402, 502, 602) in the embodiments of FIGS. 5(a) to 5(f), FIGS. 6(a) to 6(f), FIGS. 7(a) to 7(f) and FIGS. 8(a) to 8(f).

[0168] FIG. 11 illustrates a wrapper (701) of an assembled aerosol generating article (700) in a first, unperforated state. In the first, unperforated state, the wrapper (701) substantially prevents moisture from passing through the wrapper to or from the intermediate structure (700a). In this way, the aerosol generating article (700) can be stored or transported in a damp or humid environment without the body of the aerosol forming substrate (702) absorbing any moisture from the environment in which the article is stored or transported.

[0169] FIGS. 12 and FIGS. 13 respectively show a cross-sectional view and a longitudinal section of a fully assembled aerosol generating article (700).

[0170] The consumer receives the aerosol generating article (700) with the wrapper (701) in the first unperforated state of FIG. 11. However, in order to enable the user to inhale the vapor-containing aerosol released from the heating of the aerosol forming substrate (702), the user may transform the aerosol generating article (700) into a second perforated state by perforating the wrapper (701) at a location adjacent to the air inlet (726) and air outlet (727) within the frame (715), as shown in FIG. 14, thereby defining the air inlet (732) and outlet hole (733) through the wrapper. The user may form the inlet and outlet holes (732, 733) by manually perforating the wrapper (701) using a blade, needle, or other pointed or sharp object. Alternatively, the wrapper (701) may be perforated by a feature of the aerosol generating device as a result of combining the aerosol generating article (700) and the device, or subsequently. The inlet hole (732) and outlet hole (733) of the wrapper (701), combined with the air inlet and air outlet (726, 727) of the frame (715), define a part of the airflow path (711) passing through the interior of the aerosol generating article (700). The airflow path (711) extends through the body of the aerosol generating material (702) by a strand of a spore forming an aerosol generating material that essentially defines a porous structure.

[0171] The aerosol generating article (700) 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. The frame (715) 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 (720) has a height (or thickness) of 7.93 mm extending in the z-dimension, a width of 35 mm extending in the y-dimension, and a length of 52 mm extending in the x-dimension.

[0172] In an alternative embodiment of the aerosol generating article (700) of FIGS. 9 through 14, the body portion of the aerosol forming substrate (702) may instead define a body portion wrapped within a wrapper and the body portion wrapped within the wrapper is inserted into the cavity (720). For example, the body portion wrapped within the wrapper may be any form of the body portion (300, 400, 500, 600) described above in relation to FIGS. 5(a) through 5(f), FIGS. 6(a) through 6(f), FIGS. 7(a) through 7(f) and FIGS. 8(a) through 8(f). In this alternative embodiment, the wrapper (701) may define additional wrappers of the aerosol generating article (700) or may be distributed as a whole.

[0173] FIGS. 15 and 16 illustrate an aerosol generating device (8000) configured for use with an aerosol generating article (800) comprising or made of an aerosol forming material (840). The device (8000) is an elongated aerosol generating device extending between a proximal end (8001) and a distal end (8002). The device (8000) includes a battery (8010), a controller (8020), and a heater (8030) located within a housing (8040). The controller (8020) controls the supply of power from the battery (8010) to the heater (8030). A cavity (8050) is defined in the device (8000), and the cavity has an opening (8051) defined at the proximal end (8001) of the device. The opening (8051) is rectangular in shape and has dimensions to accommodate a cross-section of an aerosol generating article (800). The cavity (8050) includes an upper flat surface (8052) and a lower flat surface (8053). A heater (8030) is located within the lower flat surface (8053) to heat the lower surface of the aerosol generating article (800) inserted into the cavity (8050). An airflow path is configured so that air can flow from outside the device (8000) into the cavity (8050).

[0174] FIG. 17 shows the device (8000) of FIG. 15 engaging with the aerosol generating article (800). There is almost no tolerance between the outer surface of the aerosol generating article (800) and the inner surface of the cavity (8050). Therefore, there is a tight fit between the aerosol generating article (800) and the device (8000). Since the RTD of the aerosol generating article (800) can be ignored, the RTD of the system formed by the combination of the aerosol generating article (800) and the aerosol generating device (8000) is controlled by an airflow path defined within the device. When a user inserts the aerosol generating article (800) into the cavity (8050), the device (8000) can be operated. A heater (8030) heats the lower surface of the aerosol generating article (800), and as a result, the aerosol forming substrate (840) of the aerosol generating article (800) is heated. The volatile component of the aerosol-forming substrate (840) vaporizes and condenses in a longitudinal airflow channel defined within the aerosol-generating article (800) to form an aerosol. The user inhales the aerosol by suction at the proximal end (801) of the aerosol-generating article (800). Once the volatile component in the aerosol-generating substrate (840) of the aerosol-generating article (800) is depleted, the aerosol-generating article is removed from the cavity (8050) of the device (8000) and disposed of. The aerosol-generating article (800) may be any one of the previously described aerosol-generating articles (100, 200, 300, 400, 500, 600, 700) or any other aerosol-generating article of the present disclosure.

[0175] FIG. 17 illustrates a portion of an aerosol generating article (800) extending outside of an aerosol generating device (8000), but in other embodiments, the entire aerosol generating article may be completely enclosed within the aerosol generating device. As an example, FIG. 18 illustrates an alternative embodiment of FIG. 17, in which similar features are referred to by the same reference numeral except that the prime symbol ' is added. In the alternative embodiment of FIG. 18, the entire aerosol generating article (800') is enclosed within the aerosol generating device (8000').

[0176] 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 “in which” and “wherein” are used as synonyms throughout this specification.

Claims

Claim 1 An aerosol generating article for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article comprises a wrapper defining a body portion that surrounds and packages an aerosol forming substrate, wherein the wrapper is formed of a foldable material and the wrapper is configured to inhibit or prevent moisture from passing across the thickness of the wrapper. Claim 2 An aerosol generating article according to claim 1, wherein the wrapper has a polymer content of less than 25%, or less than 15%, or less than 10%, or less than 5%, for example, the wrapper has substantially no polymer content. Claim 3 An aerosol generating article according to claim 1 or 2, wherein the wrapper has a first unperforated state and a second perforated state, wherein in the second perforated state, an airflow path is defined through the packaged body portion between an air inlet and an air outlet defined in the wrapper, and in the first unperforated state, the wrapper does not have the air inlet and the air outlet. Claim 4 An aerosol generating article according to any one of claims 1 to 3, wherein, when a wrapper is perforated at a preset first and second position axially spaced apart from each other in the longitudinal direction of the packaged body, the airflow path is defined through the packaged body between the preset first and second positions. Claim 5 In any one of paragraphs 1 to 4, the wrapper is an aerosol-generating article that is impermeable to water. Claim 6 An aerosol generating article according to any one of claims 1 to 5, wherein the wrapper has a permeability of 1 to 10 Coresta units, for example 1 to 5 Coresta units, for example 1 to 3 Coresta units. Claim 7 An aerosol generating article according to any one of claims 1 to 6, wherein the wrapper is opaque to light and is opaque to light having a wavelength associated with, for example, one or more of infrared radiation, visible light and ultraviolet light. Claim 8 An aerosol generating article according to any one of claims 1 to 7, wherein the wrapper comprises one or a combination of materials selected from the group consisting of parchment, ultra-abrasive paper (e.g., glassine), tracing paper, cellulose film, coated paper (e.g., PVOH paper) and metal foil. Claim 9 An aerosol generating article according to any one of claims 1 to 8, wherein the wrapper comprises or is composed of a thin layer of a metal first layer and a second layer. Claim 10 An aerosol generating article according to any one of claims 1 to 9, wherein the wrapper covers only the aerosol-forming substrate. Claim 11 In any one of claims 1 to 9, the aerosol generating article further comprises at least one additional element wrapped within the wrapper along the aerosol forming substrate, for example, the at least one additional element comprises one or more of a filter, a spacer element, and a frame. Claim 12 An aerosol generating article according to any one of claims 1 to 11, wherein the aerosol forming substrate comprises separated first and second portions of the aerosol forming substrate, for example, the composition of the first portion of the aerosol forming substrate is different from the composition of the second portion of the aerosol forming substrate. Claim 13 In any one of paragraphs 1 to 12, the packaged body part is an aerosol generating article. Claim 14 An aerosol generating article according to any one of claims 1 to 13, wherein the aerosol generating article comprises upper and lower outer surfaces, and the upper and lower outer surfaces are separated from each other to define the thickness of the aerosol generating article, for example, the upper and lower outer surfaces are flat, for example, the upper and lower outer surfaces are convex outward, for example, the upper and lower outer surfaces collectively define a round, circular, oval, or lens-shaped profile. Claim 15 In claim 14, the aerosol generating article comprises: a cavity located within the aerosol generating article between the upper outer surface and the lower outer surface; a frame located between the upper outer surface and the lower outer surface and at least partially defining the cavity; and an airflow passage further defined through the aerosol generating article between an air inlet and an air outlet and extending through the cavity, for example, the aerosol forming material is disposed within the cavity, and the wrapper is configured to wrap the frame in addition to the aerosol forming material.

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