Aerosol generating article having an asymmetric external shape

Abstract

An aerosol generating system is provided, comprising an aerosol generating article and an aerosol generating device configured to receive the aerosol generating article and generate an aerosol. The aerosol generating article has a length extending in the x-direction between a distal end and a proximal end, a width extending in the y-direction between a left side and a right side, and a thickness extending in the z-direction between an upper side and a lower side. The length and width are larger than the thickness. The aerosol generating device includes an article receiving cavity for receiving the aerosol generating article for use. The article has an asymmetrical shape such that the distal end of the article can operably engage with the article receiving cavity, while the proximal end cannot.

Description

Technology Field

[0001] The present disclosure relates to an aerosol generating article and an aerosol generating system comprising the aerosol generating article and an aerosol generating device. Background Technology

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

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

[0004] A relatively "thin" aerosol generating article can provide advantages over conventional aerosol generating articles. The objective of the present disclosure is to provide an improved aerosol generating article, wherein a larger portion of the aerosol-forming substrate of the aerosol generating article is heated sufficiently to form an aerosol during use. Additionally, the objective of the present disclosure is to provide an aerosol generating article that can be manufactured relatively efficiently and at a low cost. Furthermore, the objective of the present disclosure is to provide an aerosol generating article optimized for use with an aerosol generating device.

[0005] 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 has a length extending in the x-direction between a distal end and a proximal end. The aerosol generating article has a width extending in the y-direction between a left side and a right side. The aerosol generating article has a thickness extending in the z-direction between an upper side and a lower side. The length and width of the aerosol generating article may be larger than the thickness. The aerosol generating article may include an upper surface. The aerosol generating article may include a lower surface. The aerosol generating article may include a substrate cavity located between the upper surface and the lower surface. The substrate cavity may extend longitudinally within the article. The midpoint of the substrate cavity may be located closer to the distal end of the article than to the proximal end of the article. The volume of the substrate cavity may be 150 mm³ to 400 mm³.

[0006] In a preferred example, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol, the aerosol generating article having a length extending in the x direction between a distal end and a proximal end, a width extending in the y direction between a left side and a right side, and a thickness extending in the z direction between an upper side and a lower side, the length and width being larger than the thickness, the aerosol generating article comprising an upper surface; a lower surface; and a substrate cavity located between the upper surface and the lower surface, the substrate cavity extending longitudinally within the article, the midpoint of the substrate cavity being located closer to the distal end of the article than to the proximal end of the article, and the volume of the substrate cavity being 150 mm³ to 400 mm³.

[0007] According to the present disclosure, an aerosol generating system may be provided comprising an aerosol generating article and an aerosol generating device configured to receive the aerosol generating article and generate an aerosol. The aerosol generating article has a length extending in the x-direction between a distal end and a proximal end. The aerosol generating article has a width extending in the y-direction between a left side and a right side. The aerosol generating article has a thickness extending in the z-direction between an upper side and a lower side. The length and width may be larger than the thickness.

[0008] The aerosol generating device may have an article receiving cavity for receiving an aerosol generating article for use. The aerosol generating article may have an asymmetric shape such that the distal end of the article can operably engage with the article receiving cavity, while the proximal end cannot.

[0009] In a preferred example, an aerosol generating system may be provided comprising an aerosol generating article and an aerosol generating device configured to receive the aerosol generating article and generate an aerosol, wherein the aerosol generating article has a length extending in the x direction between a distal end and a proximal end, a width extending in the y direction between a left side and a right side, and a thickness extending in the z direction between an upper side and a lower side, the length and width being larger than the thickness, and the aerosol generating device having an article receiving cavity for receiving the aerosol generating article for use, and the article has an asymmetrical shape such that the distal end of the article can be operably engaged with the article receiving cavity while the proximal end cannot.

[0010] 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 has a length extending in the x-direction between a distal end and a proximal end. The aerosol generating article has a width extending in the y-direction between a left side and a right side. The aerosol generating article has a thickness extending in the z-direction between an upper side and a lower side. The length and width of the article may be greater than the thickness of the article. The aerosol generating article may include an upper surface. The aerosol generating article may include a lower surface. The aerosol generating article may include a substrate cavity located between the upper surface and the lower surface. A first airflow passage may extend between the distal end of the article and the cavity. A second airflow passage may extend between the cavity and the proximal end of the article. The length of the second airflow passage may be greater than the length of the first airflow passage. The minimum cross-sectional area of ​​the first airflow passage (in the yz plane) may be smaller than the minimum cross-sectional area of ​​the second airflow passage (in the yz plane).

[0011] In a preferred example, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article has a length extending in the x direction between a distal end and a proximal end, a width extending in the y direction between a left side and a right side, and a thickness extending in the z direction between an upper side and a lower side, wherein the length and width of the article are greater than the thickness of the article, and the aerosol generating article comprises an upper surface; a lower surface; and a substrate cavity located between the upper surface and the lower surface, wherein a first airflow passage extends between the distal end of the article and the cavity, and a second airflow passage extends between the cavity and the proximal end of the article, wherein the length of the second airflow passage is greater than the length of the first airflow passage, and the minimum cross-sectional area of ​​the first airflow passage (in the yz plane) is smaller than the minimum cross-sectional area of ​​the second airflow passage (in the yz plane).

[0012] An aerosol-generating article according to the present disclosure may comprise a first planar outer surface; and a second planar outer surface. An aerosol-generating article according to the present disclosure may be referred to as a planar article and may be relatively “thin.” The thickness of the article may be significantly smaller than the length or width of the article.

[0013] Advantageously, such an article enables good contact with an external heater of an aerosol generating device, particularly a flat external heater, thereby providing optimal heating of the aerosol generating material.

[0014] Advantageously, such articles can provide a large surface area for heating by an external heater of an aerosol generator, thereby enabling the aerosol generating substrate to be rapidly heated to a temperature sufficient to generate aerosols.

[0015] Advantageously, a specific example of the aerosol-generating article of the present disclosure can be manufactured by laminating sheet materials that can be achieved through a continuous manufacturing process, thereby enabling the aerosol-generating article to be manufactured easily and inexpensively.

[0016] The described cavity may be positioned asymmetrically within the article. The cavity may include a distal end of the described cavity and a proximal end of the described cavity. The cavity may include a midpoint of the described cavity located midway between the distal end of the described cavity and the proximal end of the described cavity. The described cavity may be positioned asymmetrically with respect to the x-direction of the article such that the midpoint of the described cavity is located closer to the distal end of the article than to the proximal end of the article. The midpoint of the described cavity is the midpoint of the cavity with respect to both the length and the width of the cavity.

[0017] Therefore, the material cavity may be positioned closer to the distal end of the article than to the proximal end of the article. When the distal end of the article is inserted into the article receiving cavity of the aerosol generator, it becomes easier for the entire material cavity to be aligned with the heater and thus heated compared to when the cavity is positioned symmetrically with respect to the length of the article.

[0018] The distance between the proximal end of the base cavity and the proximal end of the article may be greater than 10 mm, for example, greater than 12 mm, for example, greater than 15 mm, preferably 11 mm to 16 mm. The distance between the distal end of the base cavity and the distal end of the article may be less than 4 mm, for example, less than 3 mm, for example, less than 2 mm, preferably 4 mm to 2 mm.

[0019] Advantageously, the asymmetric position of the cavity can facilitate the handling of the aerosol generating article during or after heating. This is because the asymmetric position of the cavity can extend the distance from the proximal end of the aerosol generating article to a portion of the aerosol generating article being heated. Thus, a larger portion of the aerosol generating article can be easily grasped during or after heating. In particular, this can facilitate the removal of the aerosol generating article after use. Furthermore, the proximal end of the article is less likely to be heated to high temperatures due to the distance from the cavity, which means that the proximal end of the article is more comfortable to handle immediately after use.

[0020] Advantageously, the asymmetric positioning of the cavity having a cavity midpoint located closer to the distal end of the aerosol generating article may enable the aerosol generating device configured to accommodate the article to have at least one heating element having a reduced length compared to the case where the cavity is located in the center of the article. This is because the distance between the proximal end of the cavity and the distal end of the aerosol generating article is smaller than when the cavity is located in the center, and accordingly, the heating element having a reduced length can still heat the entire length of the cavity. This can improve the efficiency of the aerosol generating device because the smaller heating element can be used to heat the aerosol generating material within the cavity of the aerosol generating article.

[0021] The volume of the substrate cavity may be 150 mm³ to 400 mm³, for example, 200 mm³ to 380 mm³, for example, 220 mm³ to 370 mm³, for example, 250 mm³ to 350 mm³. The length of the substrate cavity may be 10 mm to 20 mm, for example, 12 mm to 15 mm, for example, about 12 mm, or about 13 mm, or about 14 mm, or about 15 mm. The maximum width of the substrate cavity may be 6 mm to 10 mm, for example, 7 mm to 8 mm, for example, about 7 mm or about 8 mm. The average width of the substrate cavity may be 6 mm to 10 mm, for example, 7 mm to 8 mm, for example, about 7 mm or about 8 mm. The thickness of the substrate cavity may be 2.5 mm to 3.5 mm, for example 2.8 mm to 3.2 mm, for example about 2.0 mm, or about 3 mm, or about 3.1 mm.

[0022] Advantageously, the cavity dimensions can provide a cavity large relative to the size of the aerosol-generating article without compromising the structural integrity of the aerosol-generating article.

[0023] The width of the distal end of the material cavity may be smaller than the width of the proximal end of the cavity. Alternatively, the width of the distal end of the material cavity may be larger than the width of the proximal end of the cavity. The material cavity may include rounded corners. The radius of the rounded corners may be 0.5 millimeters to 2 millimeters, for example, 1.5 millimeters.

[0024] An aerosol-generating article may include a frame positioned between an upper surface and a lower surface. The frame may have an inner surface extending in the z-direction or transverse direction between the upper surface and the lower surface. The frame may have an outer surface extending in the z-direction or transverse direction between the upper surface and the lower surface. The frame may include a periphery wall surrounding or enclosing a substrate cavity. The periphery wall may be formed by the inner surface of the frame and the outer surface of the frame. The inner surface of the frame may define the outer wall of the cavity. The outer surface of the frame may at least partially define one or more outer walls of the aerosol-generating article.

[0025] The frame may have a thickness of at least 80 percent of the thickness of the aerosol-generating article. The frame may have a thickness of 80 percent to 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness of 1 mm to 4 mm, for example, 2 mm to 3 mm.

[0026] The distance between the sidewall of the article, for example, the left sidewall or the right sidewall, and the side surface of the article, for example, the left side surface or the right side surface, may be less than 2 mm, for example, less than 1.5 mm, for example, less than 1 mm, preferably 0.5 mm to 1.5 mm.

[0027] Advantageously, the distance between the sidewall of the cavity and the side surface of the article is small without compromising the structural integrity of the article. Thus, the aerosol-generating article may have a thin perimeter wall around the cavity. This allows for a cavity larger than the dimensions of the aerosol-generating article without compromising the structural integrity of the article.

[0028] The aerosol-generating article may include a first airflow passage and a second airflow passage. The first airflow passage may extend between the distal end of the article and the substrate cavity. The second airflow passage may extend between the substrate cavity and the proximal end of the article. The first airflow passage may be an air inlet, and the second airflow passage may be an air outlet. Alternatively, the first airflow passage may be an air outlet, and the second airflow passage may be an air inlet.

[0029] The lengths of the first and second airflow passages may be extended to the x dimension of the aerosol generating article. The widths of the first and second airflow passages may be extended to the y dimension of the aerosol generating article. The thicknesses of the first and second airflow passages may be extended to the z dimension of the aerosol generating article.

[0030] The length of the second airflow passage may be greater than the length of the first airflow passage. For example, the length of the second airflow passage may be at least twice as large as the length of the first airflow passage, and for example, at least three times, at least four times, or at least five times larger than the length of the first airflow passage.

[0031] The length of the first airflow passage may be 1.5 mm to 6 mm, for example, 2 mm to 4 mm. The average width of the first airflow passage may be 2 mm to 6 mm, for example, 3 mm to 5 mm. The minimum width of the first airflow passage may be 2 mm to 6 mm, for example, 3 mm to 5 mm. The average thickness of the first airflow passage may be 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm. The minimum thickness of the first airflow passage may be 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm.

[0032] The length of the second airflow passage may be 10 mm to 20 mm, for example, 11 mm to 16 mm. The average width of the second airflow passage may be 2 mm to 6 mm, for example, 3 mm to 5 mm. The minimum width of the second airflow passage may be 2 mm to 6 mm, for example, 3 mm to 5 mm. The average thickness of the second airflow passage may be 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm. The minimum thickness of the second airflow passage may be 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm. The first airflow passage may be an air inlet. The second airflow passage may be an air outlet. Alternatively, the first airflow passage may be an air outlet and the second airflow passage may be an air inlet.

[0033] The aerosol generating article may include an air inlet and an air outlet. The air inlet may extend between the distal end of the article and the substrate cavity. The air outlet may extend between the substrate cavity and the proximal end of the article. For example, the air inlet may be a first airflow passage and the airflow outlet may be a second airflow passage.

[0034] The length of the air outlet and the length of the air inlet may be extended to the x dimension of the aerosol generating article. The width of the air outlet and the width of the air inlet may be extended to the y dimension of the aerosol generating article. The thickness of the air outlet and the thickness of the air inlet may be extended to the z dimension of the aerosol generating article.

[0035] The length of the air inlet may be 1.5 mm to 6 mm, for example, 2 mm to 4 mm. The average width of the air inlet may be 2 mm to 6 mm, for example, 3 mm to 5 mm. The minimum width of the air inlet may be 2 mm to 6 mm, for example, 3 mm to 5 mm. The average thickness of the air inlet may be 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm. The minimum thickness of the air inlet may be 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm. The volume of the air inlet may be 6 mm³ to 40 mm³.

[0036] The length of the air outlet may be 10 mm to 20 mm, for example, 11 mm to 16 mm. The average width of the air outlet may be 2 mm to 6 mm, for example, 3 mm to 5 mm. The minimum width of the air outlet may be 2 mm to 6 mm, for example, 3 mm to 5 mm. The average thickness of the air outlet may be 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm. The minimum thickness of the air outlet may be 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm. The volume of the air outlet may be 33 mm³ to 160 mm³.

[0037] The length of the air outlet is preferably greater than the length of the air inlet. The length of the air outlet may be at least twice as large as the length of the air inlet, and, for example, may be at least three times larger, at least four times larger, or at least five times larger than the length of the air outlet.

[0038] Advantageously, a longer air outlet enables greater cooling of the aerosol before it enters the user's mouth. This is because a longer air outlet increases the surface area of ​​the outlet through which heat can be dissipated, extending the time for heat to dissipate from the aerosol between exiting the material cavity and entering the user's mouth.

[0039] Heating an aerosol-forming substrate can lead to the formation of aerosols, which may result in the generation of moisture and slurry. This moisture and slurry may be drawn toward the user during the use of the article. If a relatively long air outlet channel is provided between the substrate cavity and the user, some of this moisture and slurry may be retained by the wall of the air outlet and thus not delivered to the user.

[0040] The average width of the air outlet may be greater than the average width of the air inlet. The minimum width of the air outlet may be greater than the minimum width of the air inlet. The maximum width of the air outlet may be greater than the maximum width of the air inlet. The average thickness of the air outlet may be greater than the average thickness of the air inlet. The minimum thickness of the air outlet may be greater than the minimum thickness of the air inlet. The maximum thickness of the air outlet may be greater than the maximum thickness of the air inlet. Therefore, the average cross-sectional area of ​​the air inlet may be smaller than the average cross-sectional area of ​​the air outlet.

[0041] Advantageously, having a smaller average air inlet cross-sectional area enables reduced leakage of the aerosol-generating substrate from the substrate cavity to the inner surface of the air inlet. Although air is drawn into the inlet and out of the outlet, there is also a possibility of moisture and slurry leaking from the air inlet into the device during use. Therefore, a smaller average air inlet cross-sectional area can help prevent unwanted leakage through the air inlet.

[0042] An air inlet may have a distal end located at the distal end of the article and a proximal end located at the entrance of the cavity. The cross-sectional area of ​​the proximal end of the air inlet may be smaller than the cross-sectional area of ​​the distal end of the air inlet. In other words, the cross-sectional area of ​​the air inlet may be smaller in the cavity than at the distal end of the article. The width of the proximal end of the air inlet may be smaller than the width of the distal end of the air inlet. Alternatively or additionally, the thickness of the proximal end of the air inlet may be smaller than the thickness of the distal end of the air inlet. The width of the air inlet may decrease between the distal end of the air inlet and the proximal end of the air inlet. The width of the air inlet may decrease continuously or linearly. The thickness of the air inlet may decrease between the distal end of the air inlet and the proximal end of the air inlet. The thickness of the air inlet may decrease continuously or linearly.

[0043] Alternatively, the cross-sectional area of ​​the proximal end of the air inlet may be larger than the cross-sectional area of ​​the distal end of the air inlet. In other words, the cross-sectional area of ​​the air inlet may be larger in the cavity than at the distal end of the article. The width of the proximal end of the air inlet may be larger than the width of the distal end of the air inlet. Alternatively or additionally, the thickness of the proximal end of the air inlet may be greater than the thickness of the distal end of the air inlet. The width of the air inlet may increase between the distal end of the air inlet and the proximal end of the air inlet. The width of the air inlet may increase continuously or linearly. The thickness of the air inlet may increase between the distal end of the air inlet and the proximal end of the air inlet. The thickness of the air inlet may increase continuously or linearly.

[0044] An air outlet may have a proximal end located at the proximal end of the article and a distal end located at the exit from the cavity. The cross-sectional area of ​​the proximal end of the air outlet may be smaller than the cross-sectional area of ​​the distal end of the air outlet. In other words, the cross-sectional area of ​​the air outlet may be larger in the cavity than at the proximal end of the article. The width of the proximal end of the air outlet may be smaller than the width of the distal end of the air outlet. The thickness of the proximal end of the air outlet may be smaller than the thickness of the distal end of the air outlet. The width of the air outlet may decrease between the distal end of the air outlet and the proximal end of the air outlet. The width of the air outlet may decrease continuously or linearly. The thickness of the air outlet may decrease between the distal end of the air outlet and the proximal end of the air outlet. The thickness of the air outlet may decrease continuously or linearly.

[0045] The cross-sectional area of ​​the proximal end of the air outlet may be larger than the cross-sectional area of ​​the distal end of the air outlet. In other words, the cross-sectional area of ​​the air outlet may be smaller in the cavity than at the proximal end of the article. The width of the proximal end of the air outlet may be larger than the width of the distal end of the air outlet. The thickness of the proximal end of the air outlet may be larger than the thickness of the distal end of the air outlet. The width of the air outlet may increase between the distal end of the air outlet and the proximal end of the air outlet. The width of the air outlet may increase continuously or linearly. The thickness of the air outlet may increase between the distal end of the air outlet and the proximal end of the air outlet. The thickness of the air outlet may increase continuously or linearly.

[0046] The volume-to-length ratio of the air outlet may be within 20% of the volume-to-length ratio of the air inlet, for example, within 10%, or within 5%, or within 1%. The volume-to-length ratio of the air outlet may be the same as the volume-to-length ratio of the air inlet. The average cross-sectional area of ​​the air outlet may be within 20% of the average cross-sectional area of ​​the air inlet, for example, within 10%, or within 5%, or within 1%. The average cross-sectional area of ​​the air outlet may be the same as the average cross-sectional area of ​​the air inlet.

[0047] Alternatively, the average cross-sectional area of ​​the air outlet may be larger than the average cross-sectional area of ​​the air inlet. The volume-to-average cross-sectional area ratio of the air outlet may be within 20% of the volume-to-average cross-sectional area ratio of the air inlet, for example, within 10%, or within 5%, or within 1%. The volume-to-average cross-sectional area ratio of the air outlet may be the same as the volume-to-average cross-sectional area ratio of the air inlet.

[0048] The external shape of an aerosol-generating article may be asymmetric. The external shape of the article may be asymmetric in the x-direction. For example, the distal portion of the article may have a shape different from the proximal portion of the article. The distal portion of the article may be tapered. The distal portion of the article may be tapered in its width dimension. For example, the minimum width at the proximal portion of the article may be greater than the minimum width at the distal portion of the article.

[0049] The width of an article measured by the y-dimension at a point 3 mm from the distal end of the article may be smaller than the width measured by the y-dimension at a point 3 mm from the proximal end of the article, for example, 1% to 15% smaller, and for example, 2% to 10% smaller.

[0050] Advantageously, having the width at a point 3 mm from the distal end of the aerosol generating article within 15% of the width at a point 3 mm from the proximal end of the aerosol generating article makes it possible to manufacture the aerosol generating article more easily. Thus, the side of the article can taper slightly as it approaches the distal end. By providing asymmetry to the slight taper of the distal part of the article, the volume of the substrate cavity located within the distal part of the article may not be significantly damaged. Thus, the load of the aerosol generating substrate cam can be maximized while still providing unidirectional insertion of the article into the device. Furthermore, if the width of the article at the distal end is, for example, 15% or more of the width of the article at the proximal end, the ability to manufacture the article in a cost- and material-efficient manner can be optimized.

[0051] The external shape of the article may be mechanically configured such that the distal end of the article can be inserted into the aerosol generator while the proximal end cannot. Advantageously, this facilitates the insertion of the article into the aerosol generator with a correct orientation. The aerosol generating article may include a left side face and a right side face. A cavity may be located between the left side face and the right side face. The article may include a proximal end surface and a distal end surface, and a cavity is located between the proximal end surface and the distal end surface.

[0052] The aerosol-generating article may include a first distal corner and a second distal corner. The first and second distal corners may be defined, respectively, between the distal end surface and the left side surface and the right side surface. The first and second distal corners may be rounded corners. The aerosol-generating article may include a first proximal corner and a second proximal corner. The first and second proximal corners may be defined, respectively, between the proximal end surface and the left side surface and the right side surface. The first and second proximal corners may be rounded corners. The first and second distal corners may have a smaller radius than the first and second proximal corners. The first and second distal corners may have a radius of 0.5 mm to 2 mm, for example, about 1 mm. The first and second proximal corners may have a radius of 1 mm to 3 mm, for example, about 2 mm. The first and second distal corners may have a smaller radius than the first and second proximal corners. Therefore, the proximal end surface may be wider than the distal end surface. This can advantageously prevent the user from inserting the proximal end of the article into the aerosol generator first.

[0053] Air can flow into the aerosol-generating article through the distal end surface, through the substrate cavity, and out of the article through the proximal end surface. For example, air can exit through an inlet defined within the distal end surface, through the substrate cavity, and out of an outlet defined through the proximal end surface.

[0054] The aerosol generating article may comprise one or more aerosol generating materials. At least one of the one or more aerosol generating materials may be located within a cavity. The aerosol generating material located within the cavity may comprise a tobacco stick. Alternatively or additionally, the aerosol generating material located within the cavity may be in the form of a plurality of free-flowing beads of an aerosol-forming material, for example, a plurality of distinct free-flowing beads having an average bead diameter of 0.1 mm to 4 mm, preferably 1 mm to 2 mm, for example 1.2 mm to 1.7 mm.

[0055] The term "bead" refers to distinct solid particles formed from an aerosol-generating substrate. Beads may have a round shape, typically spherical. Round or spherical beads have a small contact area with other beads, and multiple such beads may possess good fluidity. This implies that the mass or volume of these beads can flow freely. The ability of multiple beads to flow or pour can be highly advantageous for providing a consistent volume of substrate during manufacturing. Other terms may be used to define the substrate, such as "granules," for example.

[0056] Beads can be handled more easily than other aerosol-forming materials, such as fine powder or shavings. Since beads flow easily, they can reliably and consistently fill the cavity of an aerosol-generating article during manufacturing. In particular, shavings cannot be reliably and repeatedly poured into the cavity of an article. This can enable a consistent and reproducible amount of aerosol-forming material to be loaded into each article during manufacturing. Beads can also be cleaner to handle than powders and shavings, which can cause dust in the factory and leak from the aerosol-generating article during transport or use. By selecting beads having an appropriate bead size and an appropriate particle size distribution, the airflow through the cavity of the aerosol-generating article can be controlled more reproducibly, so to speak, than in the case of shavings. It is noted that the plurality of beads referred to herein are a plurality of distinct beads, that is, the beads are not bonded to each other on a binder or matrix.

[0057] When a particle is not perfectly spherical but its diameter is referred to, the term "diameter" may refer to the largest dimension of the particle. Alternatively, the term "diameter" may refer to the diameter of a perfectly spherical particle having the same volume as a non-perfectly spherical particle.

[0058] As used herein, the term "average particle diameter" may refer to the number average particle diameter. Other methods for determining the average particle diameter are known. Thus, the average particle diameter may be, for example, the volume average particle diameter.

[0059] Unless otherwise noted, values ​​given for average particle diameter in this specification refer to "number average particle diameter." Specifically, "number average particle diameter" is calculated as the sum of the diameters of particles within a group divided by the number of particles within the group. Mathematically, this can be expressed as follows:

[0060]

[0061] In the above equation, N is the total number of particles, and is the diameter of the nth particle.

[0062] Each of the multiple beads has a maximum dimension (d max ) and minimum dimension (d min It can be defined in terms of ). Preferably, the plurality of beads have an average d of less than 4 mm, for example, less than 3 mm. max It has. Preferably, the plurality of beads have an average d greater than 0.5 mm, for example, greater than 0.75 mm. min It has. The bead dimensions are selected so that the beads flow easily and the volume of the beads is not too large, so that volatile components cannot be substantially completely released from each bead when heated for a short duration. The beads may be substantially spherical. The beads may be non-spherical, but in this case, the beads preferably have a low aspect ratio, e.g., oval, and thus still flow easily.

[0063] The aerosol generating substrate may include an aerosol generating material. The aerosol generating material may be in the form of shredded aerosol generating material. The shredded aerosol generating material may include one or more of strips and strands of aerosol generating material, such as strips and strands of tobacco or homogenized tobacco material.

[0064] The aerosol generating material located within the cavity may have a mass of 50 mg to 500 mg. For example, the aerosol generating material located within the cavity may have a mass of 100 mg to 350 mg, for example, 130 mg to 230 mg.

[0065] The length of the article may be greater than or equal to the width of the article. The width of the article may be at least twice the thickness of the article, for example, at least three times the thickness, for example, at least 3.5 times the thickness, or at least four times the thickness. Thus, the thickness of the aerosol-generating article may be less than 50 percent of both the length and width of the aerosol-generating article. Advantageously, this increases the heating surface area of ​​the aerosol-generating article in the xy plane, which can enable a more uniform heat distribution through the article.

[0066] The length of the article may be 25 mm to 35 mm, for example, 29 mm to 31 mm, for example, about 30 mm. The width of the article may be 8 mm to 15 mm, for example, 10 mm to 12 mm, for example, about 11 mm. The thickness of the article may be 2.5 mm to 3.5 mm, for example, 2.9 mm to 3.3 mm, for example, about 3.1 mm, or 3.2 mm, or 3.3 mm.

[0067] According to the present disclosure, an aerosol generating system may be provided comprising an aerosol generating article as described above, and an aerosol generating device configured to receive the aerosol generating article and generate an aerosol. The aerosol generating device includes an article receiving cavity. The aerosol generating article may have an asymmetrical shape such that the distal end of the article may be operablely engaged with the article receiving cavity, while the proximal end may not. The width of the distal portion of the article may be smaller than the width of the proximal portion of the article. The article receiving cavity may be dimensioned such that it may receive the article when the distal end of the article is inserted, but not when the proximal end of the article is inserted. The internal shape of the article receiving cavity may be configured to match the external shape of the proximal portion of the aerosol generating article when the article is operablely engaged with the article receiving cavity. The article may have a rounded distal corner, and the article receiving cavity may include a distal end having a rounded corner to engage with the distal end of the aerosol generating article.

[0068] As used herein, the term "aerosol generating article" may refer to an article capable of generating or releasing aerosols.

[0069] 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.

[0070] 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.

[0071] As used herein, the term “aerosol generating system” refers to a combination of an aerosol generating device and one or more aerosol forming articles for use with a device. The aerosol generating system may include additional components, such as a charging unit for recharging an embedded power supply within an electrically operated or electric aerosol generating device.

[0072] 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.

[0073] As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salt.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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 fine particulate plant material.

[0079] As used herein, the term "particle size" may refer to a single dimension and may be used to characterize the size of a given particle. The dimension may be the diameter of a spherical particle that occupies the same volume as the given particle. All particle sizes and particle size distributions described herein may be obtained using standard laser diffraction techniques. Particle sizes and particle size distributions as described herein may be obtained using commercially available sensors, for example, Sympatec HELOS laser diffraction sensors.

[0080] As used herein, unless otherwise specified, the term "density" may be used to refer to true density. Thus, unless otherwise specified, the density of a powder or a plurality of particles may refer to the true density of the powder or a plurality of particles (not the bulk density of the powder or a plurality of particles, which may vary significantly depending on how the powder or a plurality of particles are handled). The measurement of true density may be performed using a number of standard methods, which are generally based on Archimedes' principle. The most widely used method involves placing the powder inside a container of known volume (pycnometer) and weighing it when used to measure the true density of the powder. Then, the pycnometer is filled with a fluid of known density in which the powder does not dissolve. The volume of the powder is determined by the difference between the volume indicated by the pycnometer and the volume of the added liquid (i.e., the volume of displaced air).

[0081] The present invention is defined in the claims. However, a non-limiting, non-comprehensive list of embodiments is provided below. Any one or more of the features of these embodiments may be combined with any one or more features of other embodiments, embodiments, or aspects described herein.

[0082] Exi. An aerosol generating article for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article has a length extending in the x-direction between a distal end and a proximal end, a width extending in the y-direction between a left side and a right side, and a thickness extending in the z-direction between an upper side and a lower side, wherein the length and width are greater than the thickness, and the aerosol generating article includes a substrate cavity,

[0083] The listed cavity is an aerosol-generating article that extends vertically within the article.

[0084] Exii. An aerosol generating article for use with an aerosol generating device to generate an aerosol, for example, an aerosol generating article according to Exi, wherein the aerosol generating article comprises: a first planar outer surface; a second planar outer surface; and a cavity located between the first planar outer surface and the second planar outer surface.

[0085] Exiii. An aerosol generating article for use with an aerosol generating device to generate an aerosol, for example, an aerosol generating article according to Exi or Exii, wherein the aerosol generating article comprises one or more aerosol forming substrates located within a substrate cavity, and the aerosol generating article comprises a first planar outer surface and a second planar outer surface.

[0086] Exiv. An aerosol generating article for use with an aerosol generating device to generate an aerosol, for example, an aerosol generating article according to any one of the prior embodiments, wherein the aerosol generating article has a base defined by an x ​​dimension extending in the x direction and a y dimension extending in the y direction, and a height defined by a z dimension extending in the z direction, and a cavity located within the article.

[0087] Exv. An aerosol generating article for use with an aerosol generating device to generate an inhalable aerosol, for example, an aerosol generating article according to any one of the prior embodiments, wherein the aerosol generating article comprises an upstream end or distal end and a downstream end or proximal end, and the article airflow path and article length extend from the upstream end / distal end of the article to the downstream end / proximal end of the article.

[0088] Exvi. An aerosol generating article for use with an aerosol generating device to generate an aerosol, for example, an aerosol generating article according to any one of the prior embodiments, 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, the frame defining at least partially the cavity; one or more aerosol generating materials; and an air inlet and an air outlet, an airflow passage extending between the air inlet and the air outlet through the cavity.

[0089] Exvii. An aerosol generating article for use with an aerosol generating device to generate an aerosol, for example, an aerosol generating article according to any one of the prior embodiments, wherein the aerosol generating article has a length extending in the x-direction between a distal end and a proximal end, a width extending in the y-direction between a left side and a right side, and a thickness extending in the z-direction between an upper side and a lower side, wherein the length and width are greater than the thickness, and the aerosol generating article comprises a substrate cavity,

[0090] An aerosol generating article, wherein the material cavity extends longitudinally within the article, and the midpoint of the material cavity is located closer to the distal end of the article than to the proximal end of the article.

[0091] Ex1. An aerosol generating article for use with an aerosol generating device, for example, an aerosol generating device according to any one of the prior embodiments, to generate an aerosol, wherein the aerosol generating article has a length extending in the x-direction between a distal end and a proximal end, a width extending in the y-direction between a left side and a right side, and a thickness extending in the z-direction between an upper side and a lower side, wherein the length and width are greater than the thickness, and the aerosol generating article

[0092] Upper surface;

[0093] lower surface; and

[0094] It includes a substrate cavity located between an upper surface and a lower surface, and

[0095] An aerosol generating article, wherein the material cavity extends longitudinally within the article, and the midpoint of the material cavity is located closer to the distal end of the article than to the proximal end of the article.

[0096] Ex2. An aerosol generating article for use with an aerosol generating device, for example, an aerosol generating device according to any one of the prior embodiments, to generate an aerosol, wherein the aerosol generating article has a length extending in the x-direction between a distal end and a proximal end, a width extending in the y-direction between a left side and a right side, and a thickness extending in the z-direction between an upper side and a lower side, and the aerosol generating article

[0097] Upper surface;

[0098] lower surface; and

[0099] It includes a substrate cavity located between an upper surface and a lower surface, and

[0100] The recording cavity is an aerosol-generating article located asymmetrically within the article.

[0101] Ex3. An aerosol generating article for use with an aerosol generating device, for example, an aerosol generating device according to any one of the prior embodiments, to generate an aerosol, or an aerosol generating article having a length extending in the x-direction between a distal end and a proximal end, a width extending in the y-direction between a left side and a right side, and a thickness extending in the z-direction between an upper side and a lower side, wherein the aerosol generating article

[0102] Upper surface;

[0103] lower surface; and

[0104] It includes a substrate cavity located between an upper surface and a lower surface, and

[0105] The material cavity extends longitudinally within the article in the x-direction between the distal end of the material cavity and the proximal end of the material cavity, and the midpoint of the material cavity is located in the middle between the distal end of the material cavity and the proximal end of the material cavity, and

[0106] An aerosol generating article, wherein the material cavity is positioned asymmetrically with respect to the x-direction of the article such that the midpoint of the material cavity is located closer to the distal end of the article than to the proximal end of the article.

[0107] Ex3A. An aerosol generating article for use with an aerosol generating device, for example, an aerosol generating device according to any one of the prior embodiments, to generate an aerosol, wherein the aerosol generating article has a length extending in the x-direction between a distal end and a proximal end, a width extending in the y-direction between a left side and a right side, and a thickness extending in the z-direction between an upper side and a lower side, wherein the length and width of the article are greater than the thickness of the article, and the aerosol generating article

[0108] Upper surface;

[0109] lower surface; and

[0110] It includes a substrate cavity located between an upper surface and a lower surface, and

[0111] A first airflow passage extends between the distal end of the article and the cavity, and a second airflow passage extends between the cavity and the proximal end of the article, and the length of the second airflow passage is greater than the length of the first airflow passage, and

[0112] An aerosol generating article in which the minimum cross-sectional area of ​​the first airflow path (i.e., within the yz plane) is smaller than the minimum cross-sectional area of ​​the second airflow path (i.e., within the yz plane).

[0113] Ex4. An aerosol generating article, wherein in any one of the previous embodiments, the volume of the substrate cavity is 150 mm³ to 400 mm³, for example 200 mm³ to 380 mm³, for example 220 mm³ to 370 mm³, for example 250 mm³ to 350 mm³.

[0114] Ex5. An aerosol generating article, wherein in any one of the prior embodiments, the length of the substrate cavity is 10 mm to 20 mm, for example 12 mm to 15 mm, for example about 12 mm, or about 13 mm, or about 14 mm, or about 15 mm.

[0115] Ex6. An aerosol generating article, wherein in any one of the previous embodiments, the maximum width of the substrate cavity is 6 mm to 10 mm, for example 7 mm to 8 mm, for example about 7 mm or about 8 mm.

[0116] Ex7. An aerosol generating article, wherein in any one of the previous embodiments, the average width of the substrate cavity is 6 mm to 10 mm, for example 7 mm to 8 mm, for example about 7 mm or about 8 mm.

[0117] Ex8. An aerosol generating article, wherein in any one of the previous embodiments, the thickness of the substrate cavity is 2.5 mm to 3.5 mm, for example 2.8 mm to 3.2 mm, for example about 2.0 mm, or about 3 mm, or about 3.1 mm.

[0118] Ex9. In any one of the previous embodiments, the aerosol generating article comprises a proximal end and a distal end, wherein the substrate cavity comprises a proximal end and a distal end.

[0119] Ex10. In Ex9, the width of the distal end of the cavity is smaller than the width of the proximal end of the cavity, an aerosol generating article.

[0120] Ex11. In Ex9, the width of the distal end of the cavity is greater than the width of the proximal end of the cavity, in an aerosol generating article.

[0121] Ex12. In any one of the prior embodiments, the article comprises an aerosol generating article comprising an upper surface, a lower surface, and a frame positioned between the upper surface and the lower surface.

[0122] Ex13. In Ex12, the frame has an inner frame surface extending in the z-direction or transverse direction between the upper surface and the lower surface, an aerosol generating article.

[0123] Ex14. An aerosol generating article in Ex12 or Ex13, wherein the frame has an outer frame surface extending in the z-direction or transverse direction between the upper surface and the lower surface.

[0124] Ex15. In any one of Examples 12 to 14, the aerosol generating article, wherein the frame includes a peripheral wall that surrounds or encloses a substrate cavity.

[0125] Ex16. An aerosol generating article, wherein in any one of Examples 12 to 15, the peripheral wall is formed by an inner surface of a frame and an outer surface of a frame, the inner surface of the frame defines a cavity outer wall, and the outer surface of the frame defines at least one or more outer walls of the aerosol generating article.

[0126] Ex17. In any one of Examples 12 to 16, the frame has a thickness of at least 80 percent of the thickness of the aerosol generating article.

[0127] Ex18. In any one of Examples 12 to 17, the frame has a thickness of 80 percent to 95 percent of the thickness of the aerosol generating article.

[0128] Ex19. In any one of Examples 12 to 18, the frame has a thickness of 1 mm to 4 mm, for example, 2 mm to 3 mm, an aerosol generating article.

[0129] Ex20. An aerosol generating article, wherein in any one of the previous embodiments, the distance between the proximal end of the substrate cavity and the proximal end of the article is greater than 10 mm, for example, greater than 12 mm, for example, greater than 15 mm, preferably 11 mm to 16 mm.

[0130] Ex20A. An aerosol generating article, wherein in any one of the prior embodiments, the distance between the sidewall of the substrate cavity, e.g., the left sidewall or the right sidewall, and the side surface of the article, e.g., the left side surface or the right side surface, is less than 2 mm, e.g., less than 1.5 mm, e.g., less than 1 mm, preferably 0.5 mm to 1.5 mm.

[0131] Ex21. An aerosol generating article, wherein in any one of the previous embodiments, the distance between the distal end of the substrate cavity and the distal end of the article is less than 4 mm, for example less than 3 mm, for example less than 2 mm, preferably 4 mm to 2 mm.

[0132] Ex21A. In any one of the prior embodiments, the article comprises a first airflow passage (the first airflow passage extends between the distal end of the article and the substrate cavity) and a second airflow passage (the second airflow passage extends between the substrate cavity and the proximal end of the article), an aerosol generating article.

[0133] Ex21B. An aerosol generating article, wherein in any one of the previous embodiments, the first airflow passage is an air inlet and the second airflow passage is an air outlet.

[0134] Ex21C. An aerosol generating article, wherein in any one of the previous embodiments, the first airflow passage is an air outlet and the second airflow passage is an air inlet.

[0135] Ex21D. An aerosol generating article, wherein in any one of Ex21A to Ex21C, the length of the second airflow passage is greater than the length of the first airflow passage, for example, the length of the second airflow passage is at least twice as large as the length of the first airflow passage, for example, at least three times larger, at least four times larger, or at least five times larger than the length of the first airflow passage.

[0136] Ex21E. An aerosol generating article in any one of Examples Ex21A to Ex21D, wherein the length of the first airflow passage is 1.5 mm to 6 mm, for example, 2 mm to 4 mm.

[0137] Ex21F. An aerosol generating article in any one of Examples Ex21A to Ex21E, wherein the average width of the first airflow passage is 2 mm to 6 mm, for example, 3 mm to 5 mm.

[0138] Ex21G. An aerosol generating article in any one of Examples Ex21A to Ex21F, wherein the minimum width of the first airflow passage is 2 mm to 6 mm, for example, 3 mm to 5 mm.

[0139] Ex21H. An aerosol generating article in any one of Examples Ex21A to Ex21G, wherein the average thickness of the first airflow passage is 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm.

[0140] Ex21I. An aerosol generating article in any one of Examples Ex21A to Ex21H, wherein the minimum thickness of the first airflow passage is 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm.

[0141] Ex21J. An aerosol generating article in any one of Examples Ex21A to Ex21I, wherein the length of the second airflow passage is 10 mm to 20 mm, for example, 11 mm to 16 mm.

[0142] Ex21K. An aerosol generating article in any one of Examples Ex21A to Ex21J, wherein the average width of the second airflow passage is 2 mm to 6 mm, for example, 3 mm to 5 mm.

[0143] Ex21L. An aerosol generating article in any one of Examples Ex21A to Ex21K, wherein the minimum width of the second airflow passage measured by the y-dimension of the aerosol generating article is 2 mm to 6 mm, for example, 3 mm to 5 mm.

[0144] Ex21M. An aerosol generating article in any one of Examples Ex21A to Ex21L, wherein the average thickness of the second airflow passage is 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm.

[0145] Ex21J. An aerosol generating article in any one of Examples Ex21A to Ex21I, wherein the minimum thickness of the second airflow passage measured by the z-dimension of the aerosol generating article is 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm.

[0146] Ex22. In any one of the prior embodiments, the article comprises an air inlet (the air inlet extends between the distal end of the article and the substrate cavity) and an air outlet (the air outlet extends between the substrate cavity and the proximal end of the article), for example, the air inlet is the first airflow passage of Ex21A and the airflow outlet is the second airflow passage of Ex21A, an aerosol generating article.

[0147] Ex23. In Ex22, the length of the air outlet is greater than the length of the air inlet, for example, the length of the air outlet and the length of the air inlet extend to the x dimension of the aerosol generating article.

[0148] Ex24. In Ex22 or Ex23, the length of the air outlet is at least twice as large as the length of the air inlet, for example, at least three times larger, at least four times larger, or at least five times larger than the length of the air outlet, an aerosol generating article.

[0149] Ex25. An aerosol generating article in any one of Examples Ex22 to Ex24, wherein the length of the air inlet is 1.5 mm to 6 mm, for example, 2 mm to 4 mm.

[0150] Ex26. In any one of Examples Ex22 to Ex25, the average width of the air inlet is 2 mm to 6 mm, for example, 3 mm to 5 mm, and the width of the air outlet and the width of the air inlet extend to the y dimension of the aerosol generating article.

[0151] Ex26A. An aerosol generating article in any one of Examples Ex22 to Ex25, wherein the minimum width of the air inlet measured by the y-dimension of the aerosol generating article is 2 mm to 6 mm, for example, 3 mm to 5 mm.

[0152] Ex27. In any one of Examples Ex22 to Ex26A, the average thickness of the air inlet is 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm, and the thickness of the air outlet and the thickness of the air inlet extend to the z-dimension of the aerosol generating article.

[0153] Ex27A. An aerosol generating article in any one of Examples Ex22 to Ex26A, wherein the minimum thickness of the air inlet measured by the z-dimension of the aerosol generating article is 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm.

[0154] Ex28. An aerosol generating article in any one of Examples Ex22 to Ex27A, wherein the length of the air outlet is 10 mm to 20 mm, for example, 11 mm to 16 mm.

[0155] Ex29. An aerosol generating article in any one of Examples Ex22 to Ex28, wherein the average width of the air outlet is 2 mm to 6 mm, for example, 3 mm to 5 mm.

[0156] Ex29A. An aerosol generating article in any one of Examples Ex22 to Ex29, wherein the minimum width of the air outlet measured by the y-dimension of the aerosol generating article is 2 mm to 6 mm, for example, 3 mm to 5 mm.

[0157] Ex30. An aerosol generating article in any one of Examples Ex22 to Ex29A, wherein the volume of the air outlet is 33 mm3 to 160 mm3.

[0158] Ex31. An aerosol generating article in any one of Examples Ex22 to Ex30, wherein the volume of the air inlet is 6 mm3 to 40 mm3.

[0159] Ex32. An aerosol generating article in any one of Examples Ex22 to Ex31, wherein the average thickness of the air outlet is 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm.

[0160] Ex32A. An aerosol generating article in any one of Examples Ex22 to Ex32, wherein the minimum thickness of the air outlet measured by the z-dimension of the aerosol generating article is 0.75 mm to 2.5 mm, for example, 1 mm to 2 mm.

[0161] Ex33. An aerosol generating article in any one of Examples Ex22 to Ex32A, wherein the average width of the air outlet is greater than the average width of the air inlet.

[0162] Ex33A. An aerosol generating article in any one of Examples Ex22 to Ex33, wherein the minimum width of the air outlet is greater than the minimum width of the air inlet.

[0163] Ex34. An aerosol generating article in any one of Examples Ex22 to Ex33A, wherein the maximum width of the air outlet is greater than the maximum width of the air inlet.

[0164] Ex35. An aerosol generating article in any one of Examples Ex22 to Ex34, wherein the average thickness of the air outlet is greater than the average thickness of the air inlet.

[0165] Ex35A. An aerosol generating article in any one of Examples Ex22 to Ex35, wherein the minimum thickness of the air outlet is greater than the minimum thickness of the air inlet.

[0166] Ex36. An aerosol generating article in any one of Examples Ex22 to Ex35A, wherein the maximum thickness of the air outlet is greater than the maximum thickness of the air inlet.

[0167] Ex37. In any one of Examples Ex22 to Ex36, the air inlet has a distal end located at the distal end of the article and a proximal end located at the entrance of the cavity, an aerosol generating article.

[0168] Ex37A. In Ex37, the cross-sectional area of ​​the proximal end of the air inlet is smaller than the cross-sectional area of ​​the distal end of the air inlet, that is, the cross-sectional area of ​​the air inlet is smaller in the cavity than in the distal end of the article, an aerosol generating article.

[0169] Ex37B. An aerosol generating article in Ex37 or Ex37A, wherein the width of the proximal end of the air inlet is smaller than the width of the distal end of the air inlet.

[0170] Ex37C. In Ex37 or Ex37A, an aerosol generating article in which the thickness of the proximal end of the air inlet is smaller than the thickness of the distal end of the air inlet.

[0171] Ex38. In Ex37 to Ex37C, the width of the air inlet increases between the distal end of the air inlet and the proximal end of the air inlet, for example, increasing continuously or linearly, an aerosol generating article.

[0172] Ex39. In Ex37 to Ex38, the thickness of the air inlet increases between the distal end of the air inlet and the proximal end of the air inlet, for example, increasing continuously or linearly, an aerosol generating article.

[0173] Ex40. In Ex37, the cross-sectional area of ​​the proximal end of the air inlet is larger than the cross-sectional area of ​​the distal end of the air inlet, that is, the cross-sectional area of ​​the air inlet is larger in the cavity than in the distal end of the article, an aerosol generating article.

[0174] Ex40A. An aerosol generating article in Ex37 or Ex40, wherein the width of the proximal end of the air inlet is greater than the width of the distal end of the air inlet.

[0175] Ex40B. In Ex37, Ex40, or Ex40A, an aerosol generating article in which the thickness of the proximal end of the air inlet is greater than the thickness of the distal end of the air inlet.

[0176] Ex41. In Ex37, the width of the air inlet decreases between the distal end of the air inlet and the proximal end of the air inlet, for example, decreasing continuously or linearly, an aerosol generating article.

[0177] Ex42. In Ex37 or Ex41, the thickness of the air inlet decreases between the distal end of the air inlet and the proximal end of the air inlet, for example, decreasing continuously or linearly, an aerosol generating article.

[0178] Ex43. In any one of Examples Ex22 to Ex42, an aerosol generating article having an air outlet having a proximal end located at the proximal end of the article and a distal end located at the outlet exiting from the cavity.

[0179] Ex44. In Ex43, the cross-sectional area of ​​the proximal end of the air outlet is smaller than the cross-sectional area of ​​the distal end of the air outlet, that is, the cross-sectional area of ​​the air outlet is larger in the cavity than in the proximal end of the article, an aerosol generating article.

[0180] Ex44B. An aerosol generating article in Ex43 or Ex44, wherein the width of the proximal end of the air outlet is smaller than the width of the distal end of the air outlet.

[0181] Ex44C. An aerosol generating article in any one of Examples Ex43 to Ex44B, wherein the thickness of the proximal end of the air outlet is smaller than the thickness of the distal end of the air outlet.

[0182] Ex45. In Ex43 to Ex44C, the width of the air outlet increases between the proximal end of the air outlet and the distal end of the air outlet, for example, increasing continuously or linearly, an aerosol generating article.

[0183] Ex46. In Ex43 to Ex45, the thickness of the air outlet increases between the proximal end of the air outlet and the distal end of the air outlet, for example, increasing continuously or linearly, an aerosol generating article.

[0184] Ex47. In Ex43, the cross-sectional area of ​​the proximal end of the air outlet is larger than the cross-sectional area of ​​the distal end of the air outlet, that is, the cross-sectional area of ​​the air outlet is smaller in the cavity than in the proximal end of the article, an aerosol generating article.

[0185] Ex47A. In Ex43 or Ex47, an aerosol generating article in which the width of the proximal end of the air outlet is greater than the width of the distal end of the air outlet.

[0186] Ex47B. In Ex43, Ex47, or Ex47A, an aerosol generating article in which the thickness of the proximal end of the air outlet is greater than the thickness of the distal end of the air outlet.

[0187] Ex48. In Ex43, the width of the air outlet decreases between the proximal end of the air outlet and the distal end of the air outlet, for example, decreasing continuously or linearly, an aerosol generating article.

[0188] Ex48A. In Ex43 or Ex48, the thickness of the air outlet decreases between the proximal end of the air outlet and the distal end of the air outlet, for example, decreasing continuously or linearly, an aerosol generating article.

[0189] Ex49. An aerosol generating article in any one of Ex21A to Ex48A, wherein the volume-to-length ratio of the air outlet is within 20% of the volume-to-length ratio of the air inlet, for example, within 10%, or within 5%, or within 1%.

[0190] Ex50. An aerosol generating article in any one of Ex21A to Ex49, wherein the volume-to-length ratio of the air outlet is the same as the volume-to-length ratio of the air inlet.

[0191] Ex51. An aerosol generating article in any one of Ex21A to Ex50, wherein the average cross-sectional area of ​​the air outlet is within 20% of the average cross-sectional area of ​​the air inlet, for example, within 10%, or within 5%, or within 1%.

[0192] Ex52. An aerosol generating article in any one of Ex21A to Ex51, wherein the average cross-sectional area of ​​the air outlet is the same as the average cross-sectional area of ​​the air inlet.

[0193] Ex53. An aerosol generating article in any one of Ex21A to Ex52, wherein the average cross-sectional area of ​​the air outlet is larger than the average cross-sectional area of ​​the air inlet.

[0194] Ex54. An aerosol generating article in any one of Ex21A to Ex53, wherein the ratio of the volume to the average cross-sectional area of ​​the air outlet is within 20% of the ratio of the volume to the average cross-sectional area of ​​the air inlet, for example, within 10%, or within 5%, or within 1%.

[0195] Ex55. An aerosol generating article in any one of Ex21A to Ex54, wherein the ratio of the volume to the average cross-sectional area of ​​the air outlet is the same as the ratio of the volume to the average cross-sectional area of ​​the air inlet.

[0196] Ex56. In any one of the previous embodiments, an aerosol generating article in which the external shape of the article is asymmetric.

[0197] Ex57. In any one of the prior embodiments, the external shape of the article is asymmetric in the x-direction, and for example, the distal part of the article has a shape different from the proximal part of the article, an aerosol generating article.

[0198] Ex58. In Ex57, an aerosol generating article, wherein the distal portion of the article is tapered, for example, in its width dimension, and for example, the minimum width at the proximal portion of the article is greater than the minimum width at the distal portion of the article.

[0199] Ex59. An aerosol generating article in Ex57 or Ex58, wherein the width of the article measured by the y-dimension at a point 3 mm from the distal end of the article is smaller than the width measured by the y-dimension at a point 3 mm from the proximal end of the article, for example, 1% to 15% smaller, for example, 2% to 10% smaller.

[0200] Ex60. In any one of the prior embodiments, an aerosol generating article, wherein the external shape of the article is mechanically configured such that the distal end of the article can be inserted into an aerosol generating device while the proximal end cannot.

[0201] Ex61. In any one of the prior embodiments, the article comprises a left side surface and a right side surface, and the cavity is located between the left side surface and the right side surface, an aerosol generating article.

[0202] Ex62. In any one of the prior embodiments, the article comprises a proximal end surface and a distal end surface, and the cavity is located between the proximal end surface and the distal end surface, an aerosol generating article.

[0203] Ex63. An aerosol generating article in Ex61 and Ex62, wherein the first and second distal corners defined respectively between the distal end surface and the left side surface and the right side surface are rounded corners.

[0204] Ex64. In Ex61 and Ex62, the first and second proximal corners defined respectively between the proximal end surface and the left side surface and the right side surface are rounded corners, an aerosol generating article.

[0205] Ex65. In Ex63 and Ex64, the first and second distal corners have a smaller radius than the first and second proximal corners, an aerosol generating article.

[0206] Ex66. An aerosol generating article in any one of Ex63 to Ex65, wherein the first and second distal corners have a radius of 0.5 mm to 2 mm, for example, about 1 mm.

[0207] Ex67. An aerosol generating article in any one of Ex63 to Ex66, wherein the first and second proximal corners have a radius of 1 mm to 3 mm, for example, about 2 mm.

[0208] Ex68. An aerosol generating article comprising one or more aerosol generating materials in any one of the prior embodiments.

[0209] Ex69. In Ex68, at least one of the one or more aerosol generating materials is located within a cavity, an aerosol generating article.

[0210] Ex70. In Ex69, the aerosol generating material located within the cavity is an aerosol generating article comprising tobacco sticks.

[0211] Ex71. In Ex69, the aerosol generating material located within the cavity is an aerosol generating article in the form of a plurality of free-flowing beads of an aerosol forming material, for example, having an average bead diameter of 0.1 mm to 4 mm, preferably 1 mm to 2 mm, for example 1.2 mm to 1.7 mm.

[0212] Ex72. In Ex69, the aerosol generating material is an aerosol generating article in the form of shredded aerosol generating material.

[0213] Ex73. In Ex72, the shredded aerosol generating material comprises one or more of strips and strands of aerosol generating material, such as strips and strands of tobacco or homogenized tobacco material.

[0214] Ex74. In any one of the previous embodiments, an aerosol generating article, wherein the thickness of the aerosol generating article is less than 50 percent of both the length and width of the aerosol generating article.

[0215] Ex75. In any one of the previous embodiments, the aerosol generating material located within the cavity is an aerosol generating article having a mass of 50 mg to 500 mg.

[0216] Ex76. In any one of the previous embodiments, the aerosol generating material located within the cavity is an aerosol generating article having a mass of 100 mg to 350 mg, for example, 130 mg to 230 mg.

[0217] Ex77. An aerosol generating article for use with an aerosol generating device to generate an aerosol, for example, an aerosol generating article according to any one of the prior embodiments, wherein the aerosol generating article comprises a first planar outer surface; and a second planar outer surface, a left side surface and a right side surface, a proximal end surface and a distal end surface, wherein a substrate cavity is located within the article, and first and second distal corners defined respectively between the distal end surface and the left side surface and the distal end surface and the right side surface are rounded corners.

[0218] Ex78. In Ex77, the first and second proximal corners defined between the proximal end surface and the left side surface and between the proximal end surface and the right side surface, respectively, are rounded corners, in an aerosol generating article.

[0219] Ex79. In Ex77 and Ex78, the first and second distal corners have a smaller radius than the first and second proximal corners, an aerosol generating article.

[0220] Ex80. An aerosol generating article in any one of Ex77 to Ex79, wherein the first and second distal corners have a radius of 0.5 mm to 2 mm.

[0221] Ex81. An aerosol generating article in any one of Ex77 to Ex80, wherein the first and second proximal corners have a radius of 1 mm to 3 mm.

[0222] Ex82. An aerosol generating article in any one of Ex77 to Ex81, wherein the proximal end surface is wider than the distal end surface.

[0223] Ex83. An aerosol generating article in any one of Ex77 to Ex82, wherein air flows into the article through a distal end surface, for example, through an inlet defined within the distal end surface, through a substrate cavity, and out of the article through a proximal end surface, for example, through an outlet defined within the proximal end surface.

[0224] Ex83A. An aerosol generating article, wherein in any one of the prior embodiments, the length of the article is greater than or equal to the width of the article, and the width of the article is at least twice the thickness of the article, for example, at least three times the thickness, for example, at least 3.5 times the thickness, or at least four times the thickness.

[0225] Ex83B. In any one of the previous embodiments, an aerosol generating article having a length of 25 mm to 35 mm, for example 29 mm to 31 mm, for example about 30 mm.

[0226] Ex83C. In any one of the previous embodiments, an aerosol generating article, wherein the width of the article is 8 mm to 15 mm, for example 10 mm to 12 mm, for example about 11 mm.

[0227] Ex83D. An aerosol generating article, wherein in any one of the previous embodiments, the thickness of the article is 2.5 mm to 3.5 mm, for example 2.9 mm to 3.3 mm, for example about 3.1 mm, or 3.2 mm, or 3.3 mm.

[0228] Ex84. An aerosol generating system comprising an aerosol generating article and an aerosol generating device configured to receive the aerosol generating article and generate an aerosol, wherein the aerosol generating article is an article as defined in any one of the prior embodiments.

[0229] Ex85. An aerosol generating system comprising an aerosol generating article and an aerosol generating device configured to receive the aerosol generating article and generate an aerosol, for example, an aerosol generating system according to Example Ex84,

[0230] The aerosol-generating article has a length extending in the x-direction between the distal end and the proximal end, a width extending in the y-direction between the left side and the right side, and a thickness extending in the z-direction between the upper side and the lower side, wherein the length and width are larger than the thickness,

[0231] The aerosol generating device includes an article receiving cavity for receiving an aerosol generating article for use, and

[0232] An aerosol generating article having an asymmetric shape such that the distal end of the article can operably engage with an article receiving cavity, while the proximal end cannot.

[0233] Ex86. An aerosol generating system in which, in Ex85, the width of the distal part of the article is smaller than the width of the proximal part of the article, and the article receiving cavity is dimensioned such that it can receive the article when the distal end of the article is inserted but not when the proximal end of the article is inserted.

[0234] Ex87. An aerosol generating system in Ex85 or Ex86, wherein the internal shape of the article receiving cavity is configured to match the external shape of the proximal part of the aerosol generating article when the article is operably engaged with the article receiving cavity.

[0235] Ex88. An aerosol generating system, wherein in any one of Examples Ex85 to Ex87, the article is an article as defined in Ex63 having a rounded distal corner, and the aerosol receiving cavity comprises a distal end having a rounded corner to engage with the distal end of the aerosol generating article. Brief explanation of the drawing

[0236] Now, embodiments will be further described with reference to the drawings. : FIG. 1 shows a perspective view of one embodiment of an aerosol-generating article; FIG. 2 shows an exploded perspective view of the aerosol generating article of FIG. 1; FIG. 3 illustrates an exploded perspective view of an additional embodiment of an aerosol-generating article; FIG. 4 illustrates an exploded perspective view of an additional embodiment of an aerosol-generating article; FIG. 5 illustrates an exploded perspective view of an additional embodiment of an aerosol-generating article; FIG. 6 illustrates an exploded perspective view of an additional embodiment of an aerosol-generating article; FIG. 7 illustrates an exploded perspective view of an additional embodiment of an aerosol-generating article; FIG. 8 illustrates a perspective view of an aerosol-generating article according to an embodiment of the present disclosure; FIG. 9 illustrates an exploded perspective view of the aerosol generating article of FIG. 8; FIG. 10 illustrates a cross-sectional plan view of the article of FIG. 9, drawn in an XY plane; FIG. 11 illustrates an exploded perspective view of an article according to another embodiment of the present disclosure; FIG. 12 illustrates a cross-sectional plan view of the article of FIG. 11, drawn in an XY plane; FIG. 13 shows a cross-sectional view of the proximal part of the article of FIG. 11 (taken along line AA), drawn in the YZ plane; FIG. 14 shows a cross-sectional view of the distal portion of the article of FIG. 11 (taken along line BB), drawn in the YZ plane; FIG. 15 illustrates an exploded perspective view of an article according to another embodiment of the present disclosure; FIG. 16 illustrates a cross-sectional plan view of the article of FIG. 15, drawn in an XY plane; FIG. 17 illustrates a perspective view of an aerosol-generating article according to another embodiment of the present disclosure; FIG. 18 shows an exploded perspective view of the aerosol generating article of FIG. 17; FIG. 19 illustrates an exploded perspective view of an article according to another embodiment of the present disclosure; FIG. 20 illustrates an exploded perspective view of an article according to another embodiment of the present disclosure; FIG. 21 illustrates a schematic side cross-sectional view of an aerosol generating device used as part of an aerosol generating system according to the present disclosure; FIG. 22 illustrates a schematic side cross-sectional view of the aerosol generating device of FIG. 21 that is operably engaged with the aerosol generating article of FIG. 8; FIG. 23 shows a schematic cross-sectional plan of the aerosol generating device of FIG. 21 that is operably engaged with the aerosol generating article of FIG. 8. Specific details for implementing the invention

[0237] FIGS. 1 through 7 illustrate embodiments of an aerosol generating article for use with an aerosol generating device to generate an aerosol. FIGS. 8 through 23 illustrate various embodiments of an aerosol generating article and an aerosol generating system, the understanding of which is aided by the description of FIGS. 1 through 7.

[0238] FIG. 1 illustrates an aerosol generating article (10) comprising a first planar outer layer (24) forming a first planar outer surface (21), a second planar outer layer (25) forming a second planar outer surface (22), and a frame (50) positioned between the first planar outer layer (24) and the second planar outer layer (25). Both the first planar outer layer (24) and the second planar outer layer (25) comprise an aerosol generating substrate comprising an aerosol generating material, namely tobacco. However, it will be understood that in some embodiments, only one of the first planar outer layer (24) and the second planar outer layer (25) may comprise an aerosol generating substrate. Alternatively or additionally, the aerosol generating substrate may be located elsewhere within the aerosol generating article (10).

[0239] The aerosol generating article (10) has a length extending in the x direction, a width extending in the y direction, and a thickness extending in the z direction. The aerosol generating article (10) has a length of 30 mm, a width of 10 mm, and a thickness of 3.1 mm.

[0240] The aerosol generating article (10) is substantially flat or substantially planar aerosol generating article. In particular, the thickness of the aerosol generating article (10) is less than 50% of both the length and width of the aerosol generating article. The aerosol generating article (10) generally has a rectangular cuboid shape and has a laminated structure formed by a first planar outer layer (24), a frame (50), and a second planar outer layer (25). The first planar outer layer (24), the frame (50), and the second planar outer layer (25) are bonded together with an adhesive, in particular guar gum, as will be discussed in more detail below in relation to FIG. 2.

[0241] Figure 2 shows an exploded view of the aerosol generating article (10) of Figure 1.

[0242] The frame (50) has a length of 30 mm, a width of 10 mm, and a thickness of 2.7 mm. The frame (50) is made of cardboard and defines a frame aperture that extends through the thickness of the frame (50). The frame aperture forms at least partially a cavity (30). The cavity (30) has a length of 26 mm, a width of 6 mm, and a thickness of 2.7 mm. Thus, the cavity (30) has a volume of approximately 421.2 mm³. In this embodiment, the cavity (30) is substantially empty.

[0243] The frame (50) has an inner frame surface (52) extending in the z-direction or transverse direction between the first planar outer surface (21) and the second planar outer surface (22). The inner frame surface (52) defines a joint outer wall surface. The frame (50) has an outer frame surface (53) extending in the z-direction or transverse direction between the first planar outer surface (21) and the second planar outer surface (22). The outer frame surface (53) defines at least one or more outer surfaces of an aerosol generating article, such as a front wall surface (13) and a rear wall surface (14).

[0244] The frame (50) includes a perimeter wall surface (51) surrounding the cavity (30). More specifically, the perimeter wall surface (51) is defined by an inner surface (52) of the frame and an outer surface (53) of the frame. The perimeter wall surface (51) has a radial thickness of about 2 mm when measured between the inner surface (52) of the frame and the outer surface (53) of the frame in the x / y plane.

[0245] The first planar outer layer (24) and the second planar outer layer (25) have a thickness of 200 μm and are in physical contact with the frame (50). The first planar outer layer (24) and the second planar outer layer (25) are bonded to the frame with an adhesive (15). The first planar outer layer (24) defines at least a portion of the cavity (30). The second planar outer layer (25) defines at least a portion of the cavity (30).

[0246] The aerosol generating article (10) includes an air inlet (11) and an air outlet (12). The air inlet (11) and the air outlet (12) are defined by and extend through the peripheral wall (51) of the frame (50). The air inlet (11) and the air outlet (12) each have a rectangular cross-section, a width of 2 mm, and a thickness of 0.9 mm. An airflow passage extends through a cavity (30) between the air inlet (11) and the air outlet (12).

[0247] FIG. 3 shows an exploded view of an aerosol generating article similar to the aerosol generating article (10) of FIG. 1, except that the first planar outer layer (24) and the second planar outer layer (25) do not contain an aerosol generating substrate. Instead, the aerosol generating substrate (40) is located within the cavity (30). The aerosol generating substrate (40) contains an aerosol generating material in the form of a tobacco stick and has an aerosol forming agent content of 5% by weight based on dry weight. As illustrated, the aerosol generating substrate (40) fills the entire volume of the cavity (30). In the embodiment of FIG. 3, the aerosol generating substrate (40) has a packing density of about 0.87, a density of about 0.3 g / cm³, and a mass of about 110 mg. In other embodiments, the aerosol generating substrate (40) may have a different packing density, a different density, and a different mass. For example, the aerosol generating material may have a packing density of 0.64, a density of 0.35 grams / cubic centimeter, and a mass of about 95 mg. In another example, the aerosol generating material may be in the form of aerosol generating beads, for example, distinct free-flowing beads having an average bead diameter of 0.1 mm to 4 mm.

[0248] FIG. 4 illustrates an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 1 and FIG. 3, except that the aerosol generating article (10) of FIG. 4 includes an outer wrapper (23) defining a first planar outer surface (21) and a second planar outer surface (22) instead of a first planar outer layer (24) and a second planar outer layer (25).

[0249] FIG. 5 shows an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 1, except that the aerosol generating article (10) of FIG. 5 further includes a first aerosol generating substrate layer (41) and a second aerosol generating substrate layer (42). The first aerosol generating substrate layer (41) and the second aerosol generating substrate layer (42) are formed from sheets of aerosol generating material. In particular, the sheets of homogenized tobacco material have an aerosol forming agent content of 5% by weight based on dry weight. The first aerosol generating substrate layer (41) and the second aerosol generating substrate layer (42) each have a length equal to the length of the aerosol generating article (10), a width equal to the width of the aerosol generating article (10), and a thickness of 200 μm. That is, the aerosol generating article (10) has a length of 30 mm, a width of 10 mm, and a thickness of 3.5 mm.

[0250] The first aerosol generating substrate layer (41) and the second aerosol generating substrate layer (42) are in physical contact with the frame (50) and are bonded to the frame with an adhesive (15). The first aerosol generating substrate layer (41) defines at least a portion of the cavity (30). The second aerosol generating layer (42) defines at least a portion of the cavity (30).

[0251] The first planar outer layer (24) is physically in contact with the first aerosol generating substrate layer (41) and bonded together with an adhesive (15). The second planar outer layer (25) is physically in contact with the second aerosol generating substrate layer (42) and bonded together with an adhesive (15).

[0252] FIG. 6 shows an exploded view of an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 5, except that the aerosol generating material (40) is located within the cavity (30) as described in relation to FIG. 3. The aerosol generating material (40) comprises an aerosol generating material in the form of a tobacco stick and has an aerosol forming agent content of 5% by weight based on dry weight. As illustrated, the aerosol generating material (40) fills the entire volume of the cavity (30).

[0253] FIG. 7 illustrates an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 5, except that the aerosol generating article (10) of FIG. 7 includes an outer wrapper (23) defining a first planar outer surface (21) and a second planar outer surface (22) instead of a first planar outer layer (24) and a second planar outer layer (25).

[0254] FIG. 8 shows a perspective view of an aerosol generating article (80) similar to the aerosol generating article of FIG. 1, except that the geometric structure of the first planar outer layer (824), the second planar outer layer (825), and the frame (850) of FIG. 8 has a geometric structure different from that of the first planar outer layer (24), the second planar outer layer (25), and the frame (50) of FIG. 1. FIG. 9 shows an exploded view of the aerosol generating article (80) of FIG. 8.

[0255] Similar to FIG. 1, the first planar outer layer (824) forms the first planar outer surface (821), the second planar outer layer (825) forms the second planar outer surface (822), and the frame (850) is located between the first planar outer layer (824) and the second planar outer layer (825).

[0256] The aerosol generating article (80) has a length extending in the x direction, a width extending in the y direction, and a thickness extending in the z direction. The aerosol generating article (80) has a length of 30 millimeters, a maximum width of 11 millimeters, and a thickness of 3.1 millimeters.

[0257] The aerosol generating article (80) comprises a proximal end surface (814), a distal end surface (813), a left side surface (817), and a right side surface (818). The aerosol generating article (80) has a first proximal corner (847) defined between the left side surface (817) and the proximal end surface (814); a second proximal corner (848) defined between the right side surface (818) and the proximal end surface (814); a first distal corner (837) defined between the left side surface (817) and the distal end surface (813); and a second distal corner (838) defined between the right side surface (818) and the distal end surface (813). In this embodiment, the first proximal corner (847) and the second proximal corner (848) are round corners having a radius of 2 millimeters; The first distal corner (837) and the second distal corner (838) are round corners having a radius of 1 millimeter. Thus, the first and second distal corners (837, 838) have smaller radii than the first and second proximal corners (847, 848), and the external shape of the aerosol generating article (80) is asymmetric in the x-direction.

[0258] The distance between the left side surface (817) and the right side surface (818) decreases toward the distal end surface (813). The distance between the left side surface (817) and the right side surface (818) begins to decrease from the point 2 / 3 of the length between the proximal end surface (814) and the distal end surface (813). In other words, the external shape of the aerosol generating article (80) begins to tapere at a distance of 10 millimeters from the distal end surface (813), that is, along the distal 1 / 3 section of the article (80). By having a distal end that is narrower than the proximal end, the aerosol generating article (80) can be configured so that only the distal end can be inserted into the aerosol generating device first.

[0259] The frame (850) has a length of 30 millimeters, a maximum width of 11 millimeters, and a thickness of 2.8 millimeters. The maximum width is the transverse width at the widest point of the article. The frame (850) has substantially the same external profile in the XY plane as the first and second outer layers (824, 825) in the XY plane. The frame (850) defines a frame aperture extending through the thickness of the frame (850). The frame aperture forms at least partially a cavity (830). The cavity (830) has a length of 14 millimeters, a maximum width of 8 millimeters, and a thickness of 2.8 millimeters. The maximum width of the cavity is the transverse width of the cavity at its widest point. The cavity (830) includes a proximal end (833) and a distal end (834). At the proximal end (833), the width of the cavity (830) is 7 millimeters. The width of the cavity (830) at the distal end (834) is 8 millimeters. Thus, the cavity (830) is narrower at the distal end (833) compared to the proximal end (834) of the cavity, and the cavity (830) is asymmetric in the x-direction.

[0260] The asymmetry of the cavity reflects the asymmetry of the article. In this embodiment, the four inner corners of the cavity (830) are four rounded corners each having a radius of 1.5 millimeters. In this embodiment, the midpoint (801) of the cavity (830) is located closer to the distal end face (813) than to the proximal end face (814). The midpoint (801) of the cavity is the midpoint of the cavity for both length and width. Thus, the cavity (830) is asymmetrically located within the article (80). The cavity is configured to hold an aerosol generating substrate, for example, an aerosol generating substrate formed of a plurality of distinct beads of an aerosol forming material.

[0261] The frame (850) has an inner frame surface (852) extending in the z-direction or transverse direction between the first planar outer surface (821) and the second planar outer surface (822). The inner frame surface (852) defines a cavity wall. The frame (850) has an outer frame surface (853) extending in the z-direction or transverse direction between the first planar outer surface (821) and the second planar outer surface (822). The outer frame surface (853) partially defines one or more outer surfaces of an aerosol-generating article, such as a distal end surface (813) and a proximal end surface (814).

[0262] The first planar outer layer (824) and the second planar outer layer (825) each have a thickness of 150 micrometers and are in physical contact with the frame (850) in FIG. 8. The first planar outer layer (824) and the second planar outer layer (825) are bonded to the frame using an adhesive (not shown). The first planar outer layer (824) defines at least a portion of the cavity (830). The second planar outer layer (825) defines at least a portion of the cavity (830). The cavity (830) is located between the first planar outer layer (824) and the second planar outer layer (825); between the proximal end surface (814) and the distal end surface (813); and between the left side surface (817) and the right side surface (818).

[0263] The aerosol generating article (80) includes an air inlet (811) and an air outlet (812). The air inlet (811) extends between the distal end surface (813) and the distal end (833) of the cavity (830). The air inlet (811) has a length of 3 millimeters. The air outlet (812) extends between the proximal end (834) of the cavity (830) and the proximal end surface (814). The air outlet (812) has a length of 12 millimeters. In this embodiment, the air inlet (811) and the air outlet (812) each define a hollow channel with a rectangular cross section, a width of 4 millimeters, and a thickness of 2 millimeters. An airflow path extends through the cavity (830) between the air inlet (811) and the air outlet (812). Therefore, air can enter the article through the air inlet, pass through the cavity containing the aerosol-forming agent, and exit the article through the air outlet. The air outlet is longer than the air inlet.

[0264] The material cavity (830) is positioned asymmetrically toward the distal end of the article. This allows the entire material cavity to be inserted into the aerosol generator to be heated, while allowing a sufficient portion of the article to protrude from the device so that the user can grasp the article for extraction.

[0265] A longer air outlet also enables greater cooling of the aerosol after it exits the heating zone of the material cavity and before it enters the user's mouth. This is because a longer air outlet extends the time for heat to dissipate from the aerosol and provides a larger surface area of ​​the outlet through which heat can be dissipated before it enters the user's mouth.

[0266] Heating an aerosol-forming substrate can lead to the formation of aerosols, which may result in the generation of moisture and slurry. This moisture and slurry may be drawn toward the user during the use of the article. If a relatively long air outlet channel is provided between the substrate cavity and the user, some of this moisture and slurry may be retained by the wall of the air outlet and thus not delivered to the user.

[0267] In a specific embodiment, the aerosol-forming substrate is in the form of a plurality of distinct free-flowing beads of an aerosol-forming material. The beads are substantially spherical beads. The beads have an average diameter of 1 mm to 2 mm, preferably about 1.5 mm, and a density of 1.3 grams / cubic centimeter. The total weight of the beads within the substrate cavity is about 150 mg. The beads are formed from an aerosol-generating substrate comprising plant particles, an aerosol-forming agent, and a hydrocolloid binder. Examples of suitable compositions of the aerosol-generating substrate forming the beads are provided below.

[0268] Examples of bead compositions

[0269] Suitable compositions for forming beads of an aerosol generating substrate according to the present invention are presented in Table 1 below:

[0270]

[0271] All amounts are presented as weight percentages on a dry weight basis, based on the total weight of the aerosol generating element.

[0272] To manufacture beads, tobacco particles are first mixed with glycerin. An HPMC or CMC binder is dispersed in the glycerin, and then water is added to form an aqueous binder solution. The binder solution is added to the mixture of tobacco particles and glycerin, and all components are mixed to form a dough. The dough is extruded to form multiple distinct elements, and then the distinct elements are spherical at low speed to form spherical beads with an average diameter of 1.5 millimeters. The beads are dried in an oven to a desired moisture content. Then, the dried beads can be incorporated into various aerosol generating articles as described above.

[0273] When these beads were incorporated into an aerosol generating article as described herein and heated, an aerosol containing nicotine and glycerin was generated from the aerosol generating substrate. It was found that the ratio of nicotine to glycerin in each puff of the aerosol remained consistent over the duration of heating. This contrasts with aerosols generated from articles having a similar composition but in which the aerosol generating substrate is in the form of a tobacco cast leaf. Aerosols generated by the tobacco cast leaf substrate under the same conditions were found to have a much more variable ratio of nicotine to glycerin per puff. Providing an aerosol with a more consistent ratio of nicotine to glycerin throughout the puff provides the consumer with an optimal sensory experience over the duration of heating.

[0274] For exemplary purposes applicable to any of the embodiments described herein, the composition of an aerosol-forming material that can be used to form a plurality of aerosol-forming beads may be as follows. Percentages are given as weight percentages relative to the product in the final state. The aerosol-forming substrate may have about 5 to 25%, preferably about 7 to 15%, of moisture in the final product state. The aerosol-forming substrate may further comprise the following:

[0275] 1. Tobacco leaves; for example, about 15 to 45%, preferably about 20 to 35%, of a blend of tobacco leaves, which comprises at least one of the following tobacco types: bright tobacco; dark tobacco; flavored tobacco. The tobacco material is ground and graded to a particle size of about 100 to 380 mesh, preferably about 170 to 320 mesh.

[0276] 2. Cellulose fibers; for example, about 1 to 15%, preferably about 3 to 7%, of cellulose fibers having a length of about 10 to 250 μm, preferably about 10 to 120 μm.

[0277] 3. Tobacco fibers; for example, about 5 to 20%, preferably about 7 to 15%, of tobacco fibers as a filler in 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.

[0278] 4. Binder; for example, about 1 to 10%, preferably about 1 to 5% of a binder, such as any of common gums or pectins used in the food and beverage (F&B) industry. Preferred binders may be natural pectins, such as fruit, for example, citrus or tobacco pectins; guar gum, land locust bean gum, for example, their hydroxyethyl and hydroxypropyl; starch, for example, modified or derivatized starch; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; dextran; and xanthan gum. A preferred binder is guar.

[0279] 5. Aerosol forming agent; for example, about 5 to 35%, preferably about 10 to 25%, of the aerosol forming agent. Suitable aerosol forming agents known in the art include glycerin; monohydric alcohols such as menthol, polyhydric alcohols such as triethylene glycol; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and mono-, di-, or polycarboxylic acids, such as aliphatic esters of their dimethyl.

[0280] "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.

[0281] For exemplary purposes, the composition of additional aerosol-forming substrates that may be suitable for use as aerosol-forming substrates in any of the embodiments described above is described below. Percentages are given as weight percentages of the product in the final state. The aerosol-forming substrates may comprise the following:

[0282] 1. Aerosol-forming agents such as glycerin; for example, about 10 to 40%, preferably about 20 to 30%.

[0283] 2. Organic fibers; for example, any plant variety suitable for compliance having a purity that complies with applicable FDA F&B grade requirements, such as generally available on the market, of about 10 to 30%, preferably about 15 to 25%. For example, the organic fibers may be derived as downproducts and sub-processed waste from cellulose, cotton, wood, and tea plant varieties of the F&B tea industry. The organic fibers preferably have a length of about 10 to 400 μm, preferably about 10 to 200 μm.

[0284] 3. Organic vegetable glycerin preparations; for example, about 15 to 55%, preferably about 20 to 35% of plant materials, such as cloves, Echinacea species, fennel, ginger, hawthorn berries, elderberries, monada, mullein leaves, nettle, plantain, turmeric, yarrow, and compounds thereof.

[0285] 4. Organic plant extracts; for example, about 1 to 15%, preferably about 2 to 7% of any of the previously mentioned plant species, as well as any secondary alcohol as a diastereomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol, p-mentan-3-ol, and menthol (dl-menthol, C) obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related plant varieties. 10 H 20 O, 2-isopropyl-5-methylcyclohexanol).

[0286] Alternatively, such aerosol-forming substrates may also contain about 0.5 to 5%, preferably about 1 to 3%, of vegetable essential oils, such as palm, coconut, and wood essential oils.

[0287] A dough formed from any of these aerosol-forming materials may be extruded to form a plurality of distinct elements, and the distinct elements may then be spherical at low speed to form substantially spherical beads having an average diameter of 0.5 to 4 millimeters. The beads are dried in an oven to a desired moisture content. Then, the dried beads may be incorporated into various aerosol-generating articles as described herein.

[0288] FIG. 10 illustrates a cross-sectional plan view in the XY plane of the article (80) of FIG. 8 and 9, which not only illustrates the shape of the article in the XY plane but also the shape of the air inlet (811), the air outlet (812), and the cavity (830). An intermediate point (801) of the cavity is shown. In this embodiment, the air inlet (811) and the air outlet (812) have the same width and thickness but different lengths.

[0289] FIG. 11 is an exploded perspective view of an alternative embodiment of an aerosol generating article (80A) according to the present disclosure. The article is very similar to the article (80) of FIG. 8, and similar features have similar reference numbers distinguished from the features of FIG. 8 by the suffix "A". In FIG. 11, the air inlet (811A) has a rectangular cross-section, a length of 3 millimeters, a width of 2.5 millimeters, and a thickness of 1 millimeter. The air outlet (812A) has a rectangular cross-section, a length of 12 millimeters, a width of 4 millimeters, and a thickness of 2 millimeters. Thus, the air inlet (811A) has a smaller cross-section than the air outlet (812A).

[0290] FIG. 12 illustrates a cross-sectional plan view in the XY plane of the article (80A) of FIG. 11, which not only illustrates the shape of the article in the XY plane but also the shapes of the air inlet (811A), the air outlet (812A), and the cavity (830A). The midpoint (801A) of the cavity is shown.

[0291] FIG. 13 shows a cross-sectional view of the article (80A) of FIG. 11 and FIG. 12 in the YZ plane. The cross section is taken along the line marked AA in FIG. 12, 3 millimeters away from the proximal end face (814).

[0292] FIG. 14 shows a cross-sectional view of the article (80A) of FIG. 11 and FIG. 12 in the YZ plane. The cross section is taken along the line marked BB in FIG. 12, 3 millimeters away from the distal end face (813).

[0293] It can be seen that the air inlet (811A) shown in the cross-section of FIG. 14 has a smaller width, a smaller thickness, and therefore a smaller cross-sectional area than the air outlet (812A) shown in the cross-section of FIG. 13. Furthermore, due to a slight tapering toward the distal end of the article, the cross-sectional width (10 mm) of the article (80A) taken along line BB is slightly smaller than the cross-sectional width (11 mm) of the article (80A) taken along line AA. By providing asymmetry to the slight taper of the distal part of the article, the volume of the substrate cavity located within the distal part of the article may not be significantly compromised. Thus, the load of the aerosol-generating substrate cam can be maximized while still providing unidirectional insertion of the article into the device. Furthermore, if the width of the article at the distal end is, for example, 15% or more of the width of the article at the proximal end, the ability to manufacture the article in a cost- and material-efficient manner can be optimized.

[0294] FIG. 15 is an exploded perspective view of an alternative embodiment of an aerosol generating article (80B) according to the present disclosure. The article (80B) is very similar to the article (80) of FIG. 8, and similar features have similar reference numbers distinguished from the features of FIG. 8 by the suffix “B”. In FIG. 15, the air inlet (811B) has a length of 4 millimeters and the air outlet (812B) has a length of 12 millimeters. The air inlet (811B) has a smaller cross-section at the distal end surface (813B) than at the distal end (833B) of the cavity (830B). Similarly, the air outlet (812B) has a smaller cross-sectional area at the proximal end surface (814B) than at the proximal end (834B) of the cavity. Specifically, the air inlet (811B) has a width of 2.5 millimeters and a thickness of 1 millimeter at the distal end surface (813B); and a width of 4 millimeters and a thickness of 2 millimeters at the distal end (833B) of the cavity (830B). The air outlet (12) has a width of 3 millimeters and a thickness of 1.5 mm at the proximal end surface (814B); and a width of 4 mm and a thickness of 2 mm at the proximal end (834B) of the cavity (830B). Thus, the air inlet (811B) and the air outlet (812B) have different minimum cross-sectional areas and different average cross-sectional areas in the YZ plane. The air inlet is shorter than the air outlet. Although air is drawn into the inlet and out of the outlet, there is still a possibility that moisture and slurry may leak from the air inlet into the device during use. Therefore, a smaller average air inlet cross-sectional area can help prevent unwanted leakage through the air inlet.

[0295] FIG. 16 illustrates a cross-sectional view of the article (80B) of FIG. 15, which not only illustrates the shape of the article in the XY plane but also the shapes of the air inlet (811B), the air outlet (812B), and the cavity (830B). The midpoint (801B) of the cavity is shown.

[0296] In another embodiment, the air inlet may have a larger cross-sectional area at the distal end surface than at the distal end of the cavity; and the air outlet may have a larger cross-sectional area at the proximal end surface than at the proximal end of the cavity.

[0297] FIGS. 17 and 18 illustrate an aerosol generating article (90) similar to the aerosol generating article (80) of FIGS. 8 and 9, except that the geometric structure of the first planar outer layer (924), the second planar outer layer (925), and the frame (950) of FIGS. 17 and 18 has a geometric structure different from that of the first planar outer layer (824), the second planar outer layer (825), and the frame (850) of FIG. 1. Accordingly, FIGS. 15 and 16 will be described only with respect to the differences from FIGS. 8 and 9. FIG. 18 illustrates an exploded view of the aerosol generating article (90) of FIG. 17.

[0298] In FIGS. 17 and 18, the first and second distal corners (937, 938) are rounded corners, and the first and second proximal corners (947, 948) are right angles. Thus, the aerosol generating article (90) can be more easily inserted into the device by first inserting the distal end face (913) into the aerosol generating device. Each of the four corners of the cavity (930) is rounded and has the same radius. In this embodiment, the profile of the cavity (930) in the XY plane has a rounded rectangular shape. The air inlet (911) is shorter than the air outlet (912), but both the inlet (911) and the outlet (912) have the same cross-sectional area.

[0299] FIG. 19 is an exploded perspective view of an alternative embodiment of an aerosol generating article (90A) according to the present disclosure. The article (90A) is very similar to the article (90) of FIG. 17, and similar features have similar reference numbers distinguished from the features of FIG. 17 by the suffix “A”. The article (90A) of FIG. 19 has an air inlet (911A) that is shorter than the air outlet (912A). The cross-sectional area of ​​the air inlet (911A) is smaller than the cross-sectional area of ​​the air outlet (912A).

[0300] FIG. 20 is an exploded perspective view of an alternative embodiment of an aerosol-generating article (90B) according to the present disclosure. The article (90B) is very similar to the article (90) of FIG. 17, and similar features have similar reference numbers distinguished from the features of FIG. 17 by the suffix "B". The article (90B) of FIG. 20 has an air inlet (911B) that is shorter than the air outlet (912B). Both the air inlet (911B) and the air outlet (912B) of the article (90B) are tapered channels having a minimum width at the distal and proximal ends of the article, respectively. The tapering of the inlet and outlet is substantially the same as described in relation to the article (80B) of FIG. 15 described above.

[0301] FIG. 21 illustrates a schematic cross-sectional view of an aerosol generating device (900) configured for use with the aerosol generating article (80) described herein. The aerosol generating device (900) is an elongated aerosol generating device extending between a proximal end (91) and a distal end (92). The aerosol generating device (900) includes a battery (93), a controller (94), a first heater (95), and a second heater (96) located within a housing (97). The controller (94) controls the power supply from the battery (93) to the first heater (95) and the second heater (96). A cavity (1000) is defined within the device (900), and the cavity (1000) has an opening (1010) defined within the proximal end (91) of the device (900). The opening (1010) is rectangular in shape and is dimensioned to accommodate the maximum cross-section of the aerosol generating article (80). The cavity (1000) includes an upper planar surface (1020) and a lower planar surface (1030). A first heater (95) is located within the upper planar surface (1020) to heat the first planar outer surface (821) of the aerosol generating article (80) inserted into the cavity (1000), and a second heater (96) is located within the lower planar surface (1030) to heat the second planar outer surface (822) of the aerosol generating article (80) inserted into the cavity (1000). The first heater (95) extends partially along the upper planar surface (1020). The second heater (96) extends partially along the lower planar surface (1030). The device (900) includes an air inlet (98) that defines an airflow path configured to enable air to flow from the outside of the device into the cavity (1000).

[0302] FIG. 22 illustrates a schematic cross-sectional view of the aerosol generating device (900) of FIG. 21 that engages with the aerosol generating article (80) of FIG. 8. There is almost no tolerance between the first planar outer surface (821) and the second planar outer surface (822) of the aerosol generating article (80) and the inner surfaces (1020, 1030) of the cavity (1000). Therefore, a snug pit exists between the aerosol generating article (80) and the aerosol generating device (900). When a consumer inserts the aerosol generating article (80) into the cavity (1000), the device can be operated. The first heater (95) heats the first flat outer surface (821) of the aerosol generating article (80), and the second heater (96) heats the second flat outer surface (822) of the aerosol generating article, and as a result, the aerosol generating material within the aerosol generating article (80) is heated. The volatile components of the aerosol generating material evaporate and condense within the cavity (830) of the aerosol generating article (80) to form an aerosol. A consumer inhales the aerosol by inhaling from the end of the aerosol generating article (80) which includes an air outlet (812). When the volatile components in the aerosol generating material are depleted, the aerosol generating article (80) is removed from the cavity (1000) and disposed of.

[0303] FIG. 23 illustrates a schematic cross-sectional plan of an aerosol generating device (900) engaged with an aerosol generating article (80). The cavity (1000) includes a left side surface (1040), a right side surface (1050), and a distal surface (1060). The distance between the left side surface (1040) and the right side surface (1050) decreases toward the distal surface (1060). In other words, the cavity (1000) tapers toward the distal surface (1060) so that only the distal end of the aerosol generating article (80) can be inserted into the cavity (1000) first.

[0304] The dimensions of the distal end (813) of the article, and the corresponding shapes of the article (80) and the device cavity (1000), mean that the article (80) can be operably engaged with the device (900) only when the distal end (813) of the article is inserted into the cavity (1000). This ensures that the air inlet (811) is inserted into the device so as to engage with an airflow channel defined within the device (900). When operably engaged, it is preferable that a portion of the proximal end of the article (80) may protrude from or become accessible from the cavity (1000) to enable a user to remove the article from the cavity.

[0305] 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 contain any intermediate ranges that may or may not be specifically enumerated herein. Accordingly, in this context, the number A is understood as 10% of A ± A. Within this context, the number A may be considered to include numerical values ​​within the general standard error for measuring the characteristic that the number A modifies. In some examples used in the appended claims, the number A may deviate by the percentages listed above, provided that the amount of deviation from 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 contain any intermediate ranges that may or may not be specifically enumerated herein.

Claims

Claim 1 An aerosol generating system comprising an aerosol generating article and an aerosol generating device configured to receive the aerosol generating article and generate an aerosol, wherein the aerosol generating article has a length extending in the x-direction between a distal end and a proximal end, a width extending in the y-direction between a left side and a right side, and a thickness extending in the z-direction between an upper side and a lower side, wherein the length and the width are larger than the thickness, and the aerosol generating device comprises an article receiving cavity for receiving the aerosol generating article for use, and the article has an asymmetrical shape such that the distal end of the article can be operably engaged with the article receiving cavity while the proximal end cannot. Claim 2 An aerosol generating system according to claim 1, wherein the width of the distal end of the article is smaller than the width of the proximal end of the article. Claim 3 An aerosol generating system according to claim 1 or 2, wherein the article receiving cavity is sized such that it engages operably with the article when the distal end of the article is inserted into the cavity, but not when the proximal end of the article is inserted into the cavity. Claim 4 An aerosol generating system according to any one of claims 1 to 3, wherein the internal shape of the article receiving cavity is configured to match the external shape of the proximal part of the aerosol generating article when the article is operably engaged with the article receiving cavity. Claim 5 An aerosol generating system according to any one of claims 1 to 4, wherein the external shape of the aerosol generating article is asymmetric in the x-direction, and, for example, the distal portion of the article has a shape different from the proximal portion of the article. Claim 6 In paragraph 5, the distal portion of the above article is tapered, for example, tapered by a width dimension, an aerosol generating system. Claim 7 In paragraph 6, an aerosol generating system in which the minimum width of the proximal portion of the article is greater than the minimum width of the distal portion of the article. Claim 8 An aerosol generating system according to claim 6 or 7, wherein the transverse width of the article at a point 3 mm from the distal end of the article is smaller than the transverse width in y-dimension at a point 3 mm from the proximal end of the article, for example, 1% to 15% smaller, for example, 2% to 10% smaller. Claim 9 An aerosol generating system according to any one of claims 1 to 8, wherein the article comprises a proximal end surface and a distal end surface, the cavity is located between the proximal end surface and the distal end surface, and the first and second distal corners defined between the distal end surface and the left side and between the distal end surface and the right side, respectively, are rounded corners. Claim 10 An aerosol generating system according to claim 9, wherein the first and second proximal corners defined respectively between the proximal end surface and the left side surface and the proximal end surface and the right side surface are rounded corners, and the first and second distal corners have a radius smaller than the first and second proximal corners. Claim 11 An aerosol generating system according to claim 9 or 10, wherein the first and second distal corners have a radius of 0.5 mm to 2 mm, for example, about 1 mm. Claim 12 An aerosol generating system according to claim 9, 10, or 11, wherein the first and second proximal corners have a radius of 1 mm to 3 mm, for example, about 2 mm. Claim 13 An aerosol generating article configured for use in an aerosol generating system according to any one of claims 1 to 12, for example, having a length extending in the x-direction between a distal end and a proximal end, a width extending in the y-direction between a left side and a right side, and a thickness extending in the z-direction between an upper side and a lower side, wherein the length and the width are larger than the thickness, the aerosol generating article includes a substrate cavity, and the article has an asymmetrical shape such that the distal part of the article has a shape different from the proximal part of the article. Claim 14 An aerosol generating article for use with an aerosol generating device to generate an aerosol, e.g., an aerosol generating article according to claim 13, wherein the aerosol generating article comprises a first planar outer surface; and a second planar outer surface, a left side surface and a right side surface, a proximal end surface and a distal end surface, wherein a substrate cavity is located within the article, and the first and second distal corners are rounded corners, respectively defined between the distal end surface and the left side surface and the distal end surface and the right side surface. Claim 15 An aerosol generating article according to claim 14, wherein the first and second proximal corners defined respectively between the proximal end surface and the left side surface and the proximal end surface and the right side surface are rounded corners, and the first and second distal corners have a radius smaller than the first and second proximal corners.

Images