Aerosol generating products

Abstract

The aerosol generating product has a two-dimensional array of aerosol generating articles. Each of the aerosol generating articles is configured to be separated from the aerosol generating product and used as an individual aerosol generating article to generate an aerosol. The two-dimensional array may be an nL × nW array, where nL is the number of aerosol generating articles over the initial length (initial product length) of the aerosol generating product, and nW is the number of aerosol generating articles over the initial width (initial product width) of the aerosol generating product.

Description

Technology Field

[0001] The present disclosure relates to an aerosol generating product, an aerosol generating article cut from said aerosol generating product, an aerosol generating device, and an aerosol generating system. Background Technology

[0002] A typical aerosol generating system includes an aerosol generating device and an aerosol generating article. The aerosol generating device may include a heater, and the aerosol generating article may include an aerosol forming substrate. When in use, the heater of the aerosol generating device heats the aerosol forming substrate of the aerosol generating article, causing volatile compounds to be released from the aerosol forming substrate. These compounds are subsequently cooled to form an aerosol that is inhaled by the user.

[0003] A typical aerosol-generating article may resemble a conventional cigarette in appearance. For example, such an aerosol-generating article may be a substantially cylindrical article comprising an aerosol-forming substrate and other components, such as a mouthpiece filter element, wrapped in cigarette paper. The dimensions of a typical aerosol-generating article are often similar to those of a conventional cigarette. Typically, such an aerosol-generating article has a circular cross-section and extends between a first open end and a second open end facing each other. Such an aerosol-generating article typically comprises a cylindrical portion of the aerosol-generating substrate corresponding to the circular cross-section of the article.

[0004] A typical aerosol generating item can be used in a single use session. For example, the aerosol generating item may be heated for a predetermined time or until other use threshold conditions are met, after which heating is stopped and the use session ends. Afterward, the aerosol generating item can be removed from the device and disposed of. To start a new use session, the user must insert another aerosol generating item into the aerosol generating device. This means that the user must carry at least one spare aerosol generating item to be inserted into the device along with the aerosol generating device. Carrying spare aerosol generating items in this manner may cause inconvenience to the user.

[0005] It is desirable to provide an aerosol generating product configured to provide an aerosol generating item that can be used in multiple usage sessions.

[0006] According to one aspect of the present disclosure, an aerosol generating product is provided in which each aerosol generating article is configured to be separable from the aerosol generating product so as to be used as an individual aerosol generating article for generating an aerosol, and the aerosol generating product is arranged in a two-dimensional array form.

[0007] The aerosol-generating product may be defined by an initial product length, an initial product width, and a product thickness. Preferably, the initial product length and the initial product width have values ​​greater than the product thickness. Thus, the aerosol-generating product may be substantially a two-dimensional product. Each individual aerosol-generating article may have an article length shorter than the initial product length of the aerosol-generating product. Each individual aerosol-generating article may have an article width shorter than the initial product width of the aerosol-generating product. Preferably, the aerosol-generating product comprises a suitable aerosol-forming substrate or aerosol-forming material for generating an aerosol.

[0008] Since the aerosol generating product is configured to be cut into multiple individual aerosol generating articles, the aerosol generating product can conveniently provide a source of articles to be used in two or more usage sessions. For example, the aerosol generating articles may be cut or otherwise separated by manual operation of the aerosol generating product. Manual operation may include a process in which the user separates articles from the aerosol generating product by bending, cutting, or breaking. The aerosol generating articles may be heated for aerosol generation, while the remainder of the aerosol generating product may not be heated. Thus, only a portion of the aerosol generating product may be consumed in a single usage session. Accordingly, the aerosol generating product can provide an aerosol generating material to be used in multiple usage sessions. Accordingly, the user may conveniently require only one aerosol generating product for multiple usage sessions, for example, at least four to six usage sessions. For example, a single aerosol generating product may be suitable for use in at least 10, 20, 30, or 40 use sessions, or more. Advantageously, the user does not need to carry multiple individual aerosol generating items that could be lost, for example, in a bag or pocket. The aerosol generating product has an initial size larger than that of a typical disposable aerosol generating item and thus may be more convenient for the user to carry than a typical disposable aerosol generating item.

[0009] An aerosol-generating article cut from the above aerosol-generating product may be configured to be used with an aerosol-generating device. For example, the aerosol-generating article may be configured to be inserted into or coupled to an aerosol-generating device. The above aerosol-generating product may include or be composed of an aerosol-forming substrate containing an aerosol-forming substance. Accordingly, the aerosol-generating article cut from the above aerosol-generating product may include an aerosol-forming substrate containing an aerosol-forming substance.

[0010] The above aerosol generating product may be configured such that, upon use, a first aerosol generating article is cut or otherwise separated from a two-dimensional array of the aerosol generating article. The first aerosol generating article may be heated by a heating element during a first use session. For example, during a first use session, the first aerosol generating article may be placed in contact with or adjacent to a heating element so that the aerosol forming substrate may be heated by the heating element. After the first aerosol generating article is heated and the first use session ends, for example, after a predetermined time has elapsed or after a predetermined condition has been met, for example, after a predetermined number of inhalations have been performed, a second aerosol generating article may be cut from the two-dimensional array of the aerosol generating article and may replace the first aerosol generating article in contact with or adjacent to the heating element, thereby allowing the aerosol forming substrate to be heated by the heating element. Now, the second aerosol generating article comes into contact with or adjacent to the heating element, for example, during a second use session. In this way, subsequent aerosol-generating articles cut from the aerosol-generating product can be configured to be heated to form an aerosol.

[0011] The above aerosol generating product is n L × n WIt can be defined as an aerosol-generating item of an array, where n L is the number of aerosol-generating articles over the initial length (initial product length) of the above aerosol-generating product, and n W is the number of aerosol-generating items across the initial width (initial product width) of the above aerosol-generating product. For example, n L can be a number between 2 and 20. For example, n W may be a number between 2 and 10. Accordingly, the aerosol-generating product may be in the form of a sheet or slab defined by the arrangement of the aerosol-generating articles, and n L and n W can have different values. For example, the aerosol generating product may be arranged in the form of a roll or coil, in which case n L can be greater than 20, for example, 50, 100, or 200. Likewise, n W It can be greater than 10, for example, 15, 20, 50, or 100.

[0012] The above aerosol-generating product can be manufactured as a continuous product that extends substantially continuously in the longitudinal direction. For example, n L can be expressed as ∞. Therefore, for a continuous product, n L can be ∞, and n W It can be a number between 2 and 50, for example, a number between 2 and 20, for example, a number between 2 and 10.

[0013] In some examples, n L n can be a number between 3 and 15, for example, between 4 and 12, or between 5 and 10. L It can be 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10.

[0014] In some examples, n W n can be a number between 2 and 15, for example, between 3 and 12, or between 4 and 10. L It can be 2, or 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10.

[0015] Advantageously, the material or physical properties of the aerosol-generating product may be configured to facilitate the separation of the product into a plurality of individual aerosol-generating articles.

[0016] In some examples, the aerosol generating product may include perforations configured to compartmentalize the aerosol generating article. Preferably, these perforations facilitate the separation of each aerosol generating article from the aerosol generating product. The perforations compartmentalizing the aerosol generating article may include perforation lines extending transversely and / or perforation lines extending longitudinally. The perforations may be uniformly spaced. The perforations of the perforations may penetrate partially or entirely in the thickness direction of the aerosol generating product.

[0017] The length and / or width of each of the plurality of aerosol-generating articles may be demarcated by perforation lines extending in the longitudinal and / or transverse directions. The perforations may be spaced at regular intervals along the longitudinal direction of the aerosol-generating product. The perforations may be spaced uniformly along the longitudinal direction. The perforations may be spaced at regular intervals along the width direction of the aerosol-generating product. The perforations may be spaced uniformly along the width direction.

[0018] Advantageously, the perforation concentrates applied stress along the perforation line extending in the transverse and / or longitudinal directions, facilitating the initiation and propagation of cracks, thereby allowing the user to more easily cut the aerosol-generating product into individual articles of predetermined dimensions.

[0019] In some examples, the aerosol generating product may include a score portion configured to facilitate the separation of an aerosol generating article from the aerosol generating product. The score portion may include a score or stress concentration portion extending in the transverse direction and / or the longitudinal direction. The score or stress concentration portion may partially penetrate in the thickness direction of the aerosol generating product. The score portion may be uniformly spaced. Preferably, the length and / or width of each aerosol generating article within an array of aerosol generating articles may be demarcated by a score line extending in the longitudinal direction and / or the transverse direction. Advantageously, the score or stress concentration portion concentrates applied stress, allowing a user to more easily cut the aerosol generating product into individual articles of predetermined dimensions.

[0020] In some examples, the length and / or width of each of the multiple aerosol-generating products is divided by one or more notches or grooves. The notches or grooves may be V-shaped. Alternatively, the notches or grooves may be U-shaped or semicircular. For example, the length and / or width of each of the multiple aerosol-generating products may be divided by grooves extending longitudinally and / or transversely, said grooves formed at the thickness dimension of the aerosol-generating products. The notches or grooves concentrate stress applied in a direction parallel to the notch depth, facilitating the initiation and propagation of cracks, thereby allowing the user to more easily cut the aerosol-generating products into individual articles of predetermined dimensions.

[0021] The aerosol generating product may include at least one stress concentration to facilitate crack initiation. For example, each article in an array of aerosol generating articles may be partitioned by one or more notches, grooves, scorelines, or perforations configured to act as stress concentrations that promote crack initiation so that individual articles can be easily separated from the aerosol generating product.

[0022] The user can cut an aerosol-generating article from an elongated strip of dispensable material in a direction across the strip length by tearing along a perforation, a score, or a laterally extending notch. Alternatively, the aerosol-generating article may be separated from the elongated strip by cutting along said perforation, a score, or a laterally extending notch, for example, by engaging the perforation, a score, or a laterally extending notch with the edge, in order to cut the aerosol-generating article from the elongated strip of dispensable material in a direction across the strip length.

[0023] Advantageously, by providing an elongated strip of distributable material having at least one of a perforation, a score, and a laterally extending notch, cutting of the strip can be facilitated in a direction across the length of the strip. This reduces damage to the strip and can also reduce damage to the aerosol-generating article when cutting the aerosol-generating article from the strip. This can also ensure that the cut aerosol-generating articles are uniform in size.

[0024] The aerosol generating product may include two or more layers. The aerosol generating product may include two or more layers stacked on top of each other. The aerosol generating product may include at least a first planar layer forming the upper surface of the aerosol generating product and a second planar layer forming the lower surface of the aerosol generating product.

[0025] The aerosol-generating product may include a first planar layer, a second planar layer, and an intermediate layer or separation layer disposed between the first planar layer and the second planar layer. One or more of the layers may include an aerosol-forming material, for example, homogenized tobacco, or may be composed of such an aerosol-forming material. The intermediate layer may form one or more air flow channels.

[0026] Preferably, a weak line partitioning each aerosol-generating article is formed in at least one of a first planar layer, a second planar layer, and, if present, an intermediate layer or a separation layer, as a weak line formed or defined, for example, by a scoreline, groove, notch, or perforation. A weak line partitioning each aerosol-generating article may be formed in each of the first planar layer, the second planar layer, and the intermediate layer or separation layer.

[0027] Preferably, one or more air flow channels are formed penetrating the aerosol-generating product, so that after separation, each of the plurality of aerosol-generating articles includes at least one air flow channel formed penetrating the interior thereof. When in use, the user can consume the article by inhaling air through the at least one air flow channel.

[0028] In some embodiments, each of the plurality of aerosol-generating articles comprises at least one cavity, for example, a cavity containing an aerosol-forming substrate. Where a cavity is present, the cavity is preferably connected to an air flow channel formed through the article.

[0029] In some embodiments, the aerosol generating product comprises a first planar layer, a second planar layer, and an intermediate layer or separation layer disposed between the first planar layer and the second planar layer, wherein at least one of the first planar layer, the second planar layer, and the intermediate layer or separation layer comprises an aerosol forming material or is composed of an aerosol forming material.

[0030] The intermediate layer or the separating layer may be a coil layer. The coil layer may include or be composed of a coil tobacco layer.

[0031] The intermediate layer or the separation layer may have a honeycomb structure. The honeycomb structure may include a number of holes penetrating the layer. The arrangement of the holes may be in all directions. The honeycomb structure layer does not need to be arranged in any specific direction with respect to the rolling direction of the aerosol-forming substrate.

[0032] The intermediate layer or separation layer may include or be composed of a porous material. The porous material may inherently contain voids. The porous material may be impregnated with an aerosol-forming material. For example, the voids may contain an aerosol-forming material.

[0033] The intermediate layer or separating layer includes or is composed of a fibrous material. The fibrous material may be impregnated with an aerosol-forming material.

[0034] The intermediate layer or separation layer may be a corrugated layer.

[0035] The aerosol generating product may include a first planar layer, a second planar layer, and a wavy element disposed between the first planar layer and the second planar layer, and, for example, at least one of the first planar layer, the second planar layer, and the wavy element may include or be made of an aerosol forming material.

[0036] The waveform of the above-mentioned waveform element may be positioned perpendicular to the longitudinal direction of the aerosol generating product and parallel to the width direction of the aerosol generating product. The waveform of the above-mentioned waveform element may be positioned perpendicular to the width direction of the aerosol generating product and parallel to the longitudinal direction of the aerosol generating product. Advantageously, an air flow path penetrating the aerosol generating product may be formed by a channel formed by the waveform of the above-mentioned waveform element extending in the longitudinal direction. For example, an air flow path penetrating each aerosol generating article may be formed by a channel formed by the waveform of the above-mentioned waveform element extending in the longitudinal direction.

[0037] The waveform can be formed with various waveform profiles. For example, the waveform may be further defined by a waveform profile, which may be a sine wave, or a triangle, or a rectangle, or a trapezoid, or a toroid, or a parabola.

[0038] Using a corrugated structure in aerosol-generating products makes it advantageous to form individual aerosol-generating articles having a very low RTD while maintaining sufficient rigidity for user handling. Furthermore, the use of a corrugated structure can enable the manufacture of aerosol-generating products with low density and low RTD by utilizing high-speed production methods similar to those used in the production of corrugated cardboard. The corrugated layer can increase the compressive strength of the aerosol-generating product.

[0039] The aerosol-generating product may further comprise at least one protective layer configured to protect the upper surface and / or lower surface of the aerosol-generating product. Preferably, the at least one protective layer forms a protective layer for each aerosol-generating article after the article is separated from the aerosol-generating product. Perforations, notches, grooves, or scores may be defined in the at least one protective layer to facilitate the separation of the aerosol-generating article from the aerosol-generating product.

[0040] In a preferred example, each article in a two-dimensional array of aerosol-generating articles has a length of 5 to 50 millimeters, and may be, for example, 10 to 45 millimeters, for example, 15 to 40 millimeters, or for example, 25 to 30 millimeters.

[0041] In a preferred example, each article in a two-dimensional array of aerosol-generating articles has a width of 3 millimeters to 50 millimeters, for example, 10 millimeters to 45 millimeters, for example, 15 millimeters to 40 millimeters, for example, 25 millimeters to 30 millimeters, preferably 5 millimeters to 17 millimeters, for example, 9 millimeters to 11 millimeters.

[0042] In a preferred example, each article in a two-dimensional array of aerosol-generating articles has a thickness of 1 millimeter to 8 millimeters, for example, 2 millimeters to 6 millimeters, for example, 2.5 millimeters to 5.5 millimeters, or for example, 3 millimeters to 3.5 millimeters. Advantageously, this thickness range can maintain a suitable balance between the aerosol-generating articles being thick enough to contain a reasonable amount of aerosol-forming material, being thin enough so that the aerosol-forming material furthest from the heater can be heated to a temperature high enough to generate an aerosol, and at the same time, the material closest to the heater can be maintained without a significant risk of combustion. This thickness can advantageously contribute to achieving uniform heating and aerosol generation while the aerosol-generating articles have sufficient strength to be used in an aerosol-generating device.

[0043] The preferred dimensions presented above can enable the formation of an aerosol-generating article comprising a sufficient aerosol-forming material to generate enough aerosol to satisfy the user during a usage session while being convenient for the user to handle.

[0044] Preferably, the width of the article is greater than the thickness of the article. Preferably, the aerosol-generating article does not have a circular or square cross-section, and the cross-section is a cross-section taken transversely or perpendicularly to the length of the article. The cross-section of the aerosol-generating article may be elliptical or rectangular, and preferably may be elliptical or rectangular having a high aspect ratio. The aerosol-generating article may have a relatively high surface area to volume ratio compared to an aerosol-generating article having a circular cross-section. A circular cross-section of a known aerosol-generating article may cause the aerosol-forming substrate to take a relatively long time to reach a temperature suitable for aerosolization. This may result in non-uniform heating of the aerosol-forming substrate.

[0045] Advantageously, the aerosol generating article can be heated in a faster and more uniform manner compared to an aerosol generating article having a circular cross-section. For example, when heated from the outside, the center of the aerosol generating article can reach the desired temperature more quickly than an article having a circular cross-section. Accordingly, heating can be more uniform throughout the aerosol generating article, and thus the formation of the aerosol can also be more uniform across the entire heated portion of the aerosol generating article.

[0046] The above aerosol-generating article may be described as flat. The above aerosol-generating article may be described as planar. The amount of material contained in the aerosol-generating article may be reduced compared to an aerosol-generating article having a circular cross-section by reducing the outer layer and other non-aerosol-forming materials present in the aerosol-generating article, thereby potentially lowering costs and reducing environmental impact.

[0047] Advantageously, this allows the aerosol generating article to be efficiently heated by a heating element and can improve the yield of aerosols generated from the aerosol-forming substrate contained in the aerosol generating article. Since the aerosol generating article has a large surface area-to-volume ratio and a reduced thickness relative to its length and width, the heating element can be positioned so that the entire aerosol generating article is located within a specific distance from the heating element. This offers the advantages of providing an improved user experience and reducing the aerosol-forming substrate wasted during use.

[0048] In some embodiments, in an initial state, the aerosol generating product comprises a two-dimensional array of 4 to 200 separable aerosol generating articles, e.g., 6 to 80 aerosol generating articles, e.g., 8 to 64 aerosol generating articles. Each aerosol generating article can be separated one by one from the aerosol generating product.

[0049] When separated from the aerosol generating product, a low-resistance airflow path may be formed through each aerosol generating article. For example, the aerosol generating article may have a suction resistance (RTD) of less than 80 mm H2O, or less than 40 mm H2O, or less than 30 mm H2O along the airflow path. Preferably, when separated from the aerosol generating product, each aerosol generating article defines an airflow path having a suction resistance of 0 mm H2O to 9.9 mm H2O. Aerosol generating articles having a low-resistance airflow path enable excellent airflow control and allow the aerosol to be extracted more efficiently from the aerosol generating substrate and delivered to the user.

[0050] An air flow path penetrating an aerosol-generating product or an aerosol-generating article may be defined by porosity, for example, as the percentage of the product or article where no material is present. In this case, the porosity is an open porosity that allows an air flow path through the product or article. Thus, an aerosol-generating article separated from an aerosol-generating product may have an air flow path defined penetrating the aerosol-generating article within the x / y plane from one side of the article to the other. The aerosol-generating article may have a porosity of more than 60%, for example, more than 80%, in the direction of the air flow path. The porosity may exceed 60%, for example, more than 80%, in at least one direction within the x / y plane of the aerosol-generating article.

[0051] The aerosol-generating product and each article of said product preferably comprise an aerosol-forming substrate. The aerosol-forming substrate may comprise an aerosol-forming material. The aerosol-forming substrate may comprise or be composed of a solid aerosol-forming material. The aerosol-forming substrate may comprise a liquid aerosol-forming material, for example, a liquid aerosol-forming material retained within a porous matrix. The aerosol-forming substrate may comprise a gel-type aerosol-forming material.

[0052] Aerosol-forming substances may include one or more organic substances, such as tobacco.

[0053] The aerosol-forming substrate may include at least one of a tobacco-based material, for example, a cast leaf or a cut filler. The aerosol-forming material may include one or more of herbal leaves, tobacco leaves, tobacco stem pieces, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco.

[0054] The aerosol-forming substrate may include a non-tobacco aerosol-forming material including an aerosol-forming agent such as glycerin or propylene glycol, and preferably may include a flavor component and / or an active component such as nicotine or cannabinol. The aerosol-forming substrate may include a wetting agent, and may include, for example, at least one of propylene glycol, glycerin / glycerol, or water.

[0055] The aerosol-forming material may comprise one or more aerosol-forming agents. Suitable aerosol-forming agents are well known in the art and include, but are not limited to, one or more aerosol-forming agents selected from polyhydric alcohols, e.g., propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols, e.g., glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids, e.g., dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable that the aerosol-forming agent is glycerin or contains glycerin.

[0056] The aerosol-forming substrate may include at least one of paper or cardboard.

[0057] The aerosol-forming material may include cellulose fibers. The aerosol-forming material may include cotton.

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

[0059] The aerosol-forming material may include a pharmacologically active component. The aerosol-forming material may include one or more cannabinoid compounds such as tetrahydrocannabinol (THC), tetrahydrocannabinol acid (THCA), cannabidiol (CBD), cannabidiol acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannavivarin (CBV), cannavivarin (CBDV), tetrahydrocannavivarin (THCV), cannabicromene (CBC), cannabicyclorol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), and cannabicitran (CBT). It may be preferable that the cannabinoid compound be CBD or THC. It may be particularly preferable that the cannabinoid compound be CBD.

[0060] The aerosol-forming material may include one or more flavoring agents. The aerosol-forming substrate may include flavoring agents, for example, at least one of menthol, L-carbon (spearmint), ethyl methylphenylglycidate (strawberry), or peppermint oil.

[0061] The above one or more flavoring agents may include one or more essential oils such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and one or more herbal materials. Suitable herbal materials include herbal leaves or other herbal materials from herbal plants, including but not limited to mints such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway. The above one or more flavoring agents may include tobacco materials.

[0062] The aerosol-forming material may include a binder. For example, the aerosol-forming material may include about 1 to 10%, preferably about 1 to 5%, of a binder such as a common gum or pectin used in the food and beverage (F&B) industry. Preferred binders may include natural pectins such as fruit, such as citrus fruits, or tobacco pectin; starches such as guar gum, locust bean gum, and their hydroxyethyl and / or hydroxypropyl derivatives; modified or derivatized starch; alginates; methyl, ethyl, ethylhydroxymethyl, and carboxymethyl cellulose; dextran; and xanthan gum. A preferred binder is guar gum.

[0063] The aerosol-forming substrate may include a gelling agent, for example, sodium alginate.

[0064] The aerosol-forming material may include organic plant glycerites. For example, the aerosol-forming material may include about 15 to 55%, preferably about 20 to 35%, of plant components such as clove, echinacea species, fennel, ginger, hawthorn berries, elderberry, monarda, mullein leaves, nettle, plantain, turmeric, yarrow, and compounds thereof.

[0065] The aerosol-forming material may include organic plant extracts. For example, the aerosol-forming material may include the aforementioned plant components, and about 1 to 15%, preferably about 2 to 7%, of secondary alcohols such as p-mentan-3-ol, which is a diastereoisomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol, such as menthol (dl-menthol, C10H20O, 2-isopropyl-5-methylcyclohexanol) obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium or other related plant species.

[0066] The aerosol-forming material may contain, for example, about 0.5 to 5%, preferably about 1 to 3% of vegetable essential oil, and said vegetable essential oil may be, for example, palm, coconut, and woody-based essential oil.

[0067] The aerosol-forming material preferably comprises an aerosol-forming agent, for example, about 5 to 35%, preferably about 10 to 25% of the aerosol-forming agent. Suitable aerosol-forming agents known in the art include glycerin; monohydric alcohols such as menthol; polyhydric alcohols such as triethylene glycol; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of these acids such as dimethyl mono-, di-, or polycarboxylic acids.

[0068] The aerosol-forming material may include particles of functional materials, for example, particles of carbon, graphite, activated carbon, or expanded graphite. These materials can, for example, increase the thermal conductivity of the aerosol-forming material and improve aerosol generation efficiency.

[0069] The aerosol-forming substrate may additionally include a thermally conductive layer, for example, an aluminum layer. The thermally conductive layer can facilitate heat transfer between a heat source and the aerosol-forming material of the aerosol-forming substrate.

[0070] The aerosol-forming substrate may additionally include a paper layer, for example, a tipping layer, said paper layer may cover at least a portion of at least one surface of the aerosol-forming substrate, for example, at least a portion of the upper surface or at least a portion of the lower surface.

[0071] The aerosol-forming substrate may include a conductive material. For example, the aerosol-forming material may include conductive particles. The conductive particles may be, for example, conductive carbon or graphite particles, or conductive metal particles, for example, particles of aluminum, stainless steel, or nickel.

[0072] The aerosol-forming substrate may include one or more susceptor materials. The one or more susceptor materials may be included within the aerosol-forming material of the aerosol-forming substrate, for example, as particles of the susceptor material dispersed within the aerosol-forming material. Due to the presence of the susceptor materials, the aerosol-forming substrate may be heated by interaction with a fluctuating electromagnetic field formed by an inductor.

[0073] Optionally, one or more susceptor materials may be included within the aerosol-forming substrate as one or more strips, threads, or wires of the susceptor material, for example, as one or more strips, threads, or wires of the susceptor material located within the air flow path of the aerosol-forming substrate.

[0074] Optionally, one or more susceptor materials may be included within the aerosol-forming substrate as one or more sheets or layers of susceptor materials, for example, as one or more sheets or layers of susceptor materials that cover an outer portion of the aerosol-forming substrate or form a structural component of the aerosol-forming substrate.

[0075] One or more sheets of the above susceptor material may be in the form of a mesh of the susceptor material.

[0076] Regardless of its form, the susceptor material may comprise one or more materials selected from the group consisting of aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0077] The aerosol-forming substrate may include at least one of an iron-based metal or an iron-based alloy. The aerosol-forming substrate may include a metal foil.

[0078] According to one aspect of the present disclosure, an aerosol generating device is provided for receiving an aerosol generating article separated from an aerosol generating product according to any example described above to form an inhalable aerosol. The aerosol generating device comprises a cavity dimensioned to receive at least a portion of the aerosol generating article, a heater or heating means, a power source for supplying power to the heater or heating means, and a controller for controlling the power supply to the heater or heating means.

[0079] According to one aspect of the present disclosure, an aerosol generating system comprising an aerosol generating device and the aerosol generating product described above is provided.

[0080] The resistance to suction (RTD) of an article or an aerosol-generating article or a component of an article or an aerosol-generating article is expressed in pressure units of 'millimeter (mm) WG', 'mm water column', or 'mm H2O'.

[0081] Unless otherwise specified, resistance to suction (RTD) is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to pass air through the entire length of a component, such as an aerosol-forming substrate. The terms “pressure drop” or “resistance to suction” of a component or article may also mean “resistance to suction.” These terms generally refer to measurements in accordance with ISO 6565-2015, which are typically performed under conditions of a volumetric flow rate of about 17.5 mm / sec at the outlet or downstream end of the component under test, a temperature of about 22°C, a pressure of about 101 kPa (about 760 Torr), and a relative humidity of about 60%.

[0082] As used in this specification, the term “aerosol-generating article” may mean an article capable of generating or releasing aerosols.

[0083] As used herein, the term “aerosol generating product” may mean a product comprising a component that can be cut to produce a plurality of individual aerosol generating articles, for example, the aerosol generating product may be an array of aerosol generating articles configured to be cut to produce a plurality of individual aerosol generating articles, or may include such an array.

[0084] As used herein, the term “aerosol-forming substrate” may mean a substrate capable of releasing an aerosol or releasing a volatile compound capable of forming an aerosol. The volatile compound may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may include an aerosol-forming material. The aerosol-forming material may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support.

[0085] As used in this specification, the term “aerosol generating device” may mean a device used in conjunction with an aerosol generating article to enable the generation or release of an aerosol.

[0086] As used herein, the term “aerosol generating system” means a combination of an aerosol generating device and one or more aerosol generating articles for use with said device. The aerosol generating system may include additional components, such as a charging unit for recharging an onboard power supply provided in an electric-driven or electric aerosol generating device.

[0087] As used herein, the term “aerosol-forming agent” may mean 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-forming article.

[0088] In relation to the present invention, the term “nicotine” as used herein refers to nicotine, nicotine base, or nicotine salt.

[0089] In relation to the present invention, the terms “proximal,” “distal,” “upstream,” and “downstream” as used herein are used to describe the relative positions of components or parts of components of a cartridge and an aerosol generating system.

[0090] As used herein, “susceptor” refers to a conductive element that heats up when exposed to a changing magnetic field. This may be the result of eddy currents and / or hysteresis losses induced in the susceptor element.

[0091] As used herein, the term “use session” refers to the operating period of an aerosol generating system having a finite duration. A use session may be a specific type of event that can be performed by the aerosol generating system. A use session may be initiated by an action of a user. A use session may be terminated after a predetermined time has elapsed from the initiation of the use session. A use session may be terminated after a parameter monitored during the use session reaches a threshold value.

[0092] The present invention is defined by the claims. However, a non-exclusive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of other examples, embodiments, or aspects described herein.

[0093] Example 1. An aerosol generating product in the form of a two-dimensional array of aerosol generating articles, wherein each of the aerosol generating articles is configured to be separable from the aerosol generating product so as to be used as an individual aerosol generating article for generating an aerosol.

[0094] Example 2. An aerosol generating product according to Example 1, wherein the aerosol generating product is defined by an initial product length, an initial product width, and a product thickness, and the initial product length and initial product width have a size greater than the product thickness.

[0095] Example 3. An aerosol generating product according to any of the examples above, wherein the aerosol generating product is n L × n W It forms an array, where n L is the number of aerosol-generating items on the initial length (initial product length) of the aerosol-generating product, and n W is the number of aerosol-generating items on the initial width (initial product width) of the aerosol-generating product, for example, n L is a number between 2 and 20, and n W is an aerosol-generating product consisting of 2 to 10 numbers.

[0096] Example 4. As an aerosol generating product according to Example 3, said aerosol generating product is a continuous product that extends continuously in the longitudinal direction, for example, n L can be expressed as ∞, for example, n L is ∞ and n W is an aerosol-generating product consisting of 2 to 10 numbers.

[0097] Example 5. As an aerosol-generating product according to Example 3, n L is a number from 3 to 15, for example, a number from 4 to 12, for example, a number from 5 to 10, for example, n L An aerosol-generating product that is 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10.

[0098] Example 6. As an aerosol-generating product according to Example 3, Example 4, or Example 5, n W is a number from 2 to 15, for example, a number from 3 to 12, for example, a number from 4 to 10, for example, n L An aerosol-generating product that is 2, or 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10.

[0099] Example 7. An aerosol generating product according to any of the examples above, wherein the material properties or physical properties of the aerosol generating product are configured to facilitate the separation of the product into a plurality of individual aerosol generating articles.

[0100] Example 8. An aerosol generating product according to any of the examples above, wherein the aerosol generating product comprises perforations configured to compartmentalize aerosol generating articles, preferably to facilitate the separation of each aerosol generating article from the aerosol generating product.

[0101] Example 9. An aerosol generating product according to Example 8, wherein the perforation comprises a perforation line extending in the transverse direction and / or a perforation line extending in the longitudinal direction.

[0102] Example 10. An aerosol generating product according to Example 9, wherein the length and / or width of each of a plurality of aerosol generating articles are partitioned by longitudinal perforations and / or transverse perforations.

[0103] Example 11. An aerosol generating product according to any one of Examples 8 to 10, wherein the perforation of the perforation portion partially or wholly penetrates in the thickness direction of the aerosol generating product.

[0104] Example 12. An aerosol generating product according to any of the examples above, wherein the aerosol generating product comprises a score portion configured to facilitate the separation of an aerosol generating article from the aerosol generating product.

[0105] Example 13. An aerosol generating product according to Example 12, wherein the score portion includes a score extending in a transverse direction or a longitudinal direction.

[0106] Example 14. An aerosol generating product according to any of the examples above, wherein the length and / or width of each of a plurality of aerosol generating articles is partitioned by a scoreline extending in the longitudinal and / or transverse directions.

[0107] Example 15. An aerosol generating product according to any of the examples above, wherein the length and / or width of each of a plurality of aerosol generating articles is partitioned by one or more notches or grooves.

[0108] Example 16. An aerosol generating product according to any of the examples above, wherein the length and / or width of each of the plurality of aerosol generating products is partitioned by a groove extending in the longitudinal and / or transverse direction, and said groove is formed in the thickness direction of the aerosol generating product.

[0109] Example 17. An aerosol generating product according to any of the examples above, comprising at least one stress concentration portion to facilitate crack initiation, wherein, for example, each of a plurality of aerosol generating articles is partitioned by one or more notches, grooves, scorelines, or perforations, and said notches, grooves, scorelines, or perforations are configured to act as stress concentration portions that facilitate crack initiation so that individual articles can be easily separated from said aerosol generating product.

[0110] Example 18. An aerosol generating product according to any of the examples above, wherein the aerosol generating product comprises two or more layers, for example, two or more layers stacked together, for example, the aerosol generating product comprises at least a first planar layer forming an upper surface and a second planar layer forming a lower surface.

[0111] Example 19. An aerosol generating product according to any of the above examples, comprising a first planar layer, a second planar layer, and an intermediate layer or separation layer disposed between the first planar layer and the second planar layer.

[0112] Example 20. An aerosol-generating product in Example 18 or Example 19, wherein each aerosol-generating article is partitioned, and a weak line formed by, for example, a scoreline, groove, notch, or perforation is formed in at least one of a first planar layer, a second planar layer, and, if present, an intermediate layer or a separation layer.

[0113] Example 21. An aerosol-generating product in Example 19 or Example 20, wherein each aerosol-generating article is partitioned, and a weak line formed by, for example, a scoreline, a groove, a notch, or a perforation is formed in each of the first planar layer, the second planar layer, and the intermediate layer or separation layer.

[0114] Example 22. An aerosol generating product according to any of the above examples, wherein one or more air flow channels are formed penetrating the aerosol generating product, and as a result therefrom, after separation, each of the plurality of aerosol generating articles comprises at least one air flow channel formed penetrating the interior thereof.

[0115] Example 23. An aerosol generating product according to any of the above examples, wherein each of the plurality of aerosol generating articles comprises at least one cavity, for example, a cavity containing an aerosol forming substrate.

[0116] Example 24. An aerosol generating product according to any of the examples described above, wherein the aerosol generating product comprises a first planar layer, a second planar layer, and an intermediate layer or separation layer disposed between the first planar layer and the second planar layer, and at least one of the first planar layer, the second planar layer, and the intermediate layer or separation layer comprises an aerosol forming material or is composed of an aerosol forming material.

[0117] Example 25. An aerosol generating product according to any of the examples described above, wherein the aerosol generating product comprises a first planar layer, a second planar layer, and a wavy element disposed between the first planar layer and the second planar layer, for example, at least one of the first planar layer, the second planar layer and the wavy element comprises an aerosol forming material or is composed of an aerosol forming material.

[0118] Example 26. An aerosol generating product according to Example 25, wherein the waveform of the waveform element is arranged perpendicular to the length direction of the aerosol generating product and parallel to the width direction of the aerosol generating product.

[0119] Example 27. An aerosol generating product according to Example 25, wherein the waveform of the waveform element is arranged perpendicular to the width direction of the aerosol generating product and parallel to the length direction of the aerosol generating product.

[0120] Example 28. An aerosol generating product according to any one of Examples 25 to 27, wherein an air flow path is formed by a channel formed by a waveform extending in the longitudinal direction of the waveform element, penetrating the aerosol generating product.

[0121] Example 29. An aerosol generating product according to any one of Examples 25 to 28, wherein an air flow path is formed by a channel formed by a waveform extending in the longitudinal direction of the waveform element, penetrating each of the aerosol generating articles.

[0122] Example 30. An aerosol generating product according to any of the examples above, wherein the aerosol generating product further comprises at least one protective layer configured to protect the upper surface and / or lower surface of the product, and preferably, the at least one protective layer forms a protective layer of each aerosol generating article after the article is separated from the aerosol generating product.

[0123] Example 31. An aerosol-forming product according to Example 30, wherein at least one protective layer has perforations, notches, grooves, or scores formed therein to facilitate separation of an aerosol-generating article from the aerosol-forming product.

[0124] Example 32. An aerosol generating product according to any of the examples above, wherein each article in a two-dimensional array of aerosol generating articles has a length of 5 to 50 mm, for example, 10 to 45 mm, for example, 15 to 40 mm, for example, 25 to 30 mm.

[0125] Example 32. An aerosol-generating product according to any of the examples above, wherein each article in a two-dimensional array of aerosol-generating articles has a width of 3 to 50 mm, for example 10 to 45 mm, for example 15 to 40 mm, for example 25 to 30 mm, preferably 5 to 17 mm, for example 9 to 11 mm.

[0126] Example 33. An aerosol-generating product according to any of the examples above, wherein each article in a two-dimensional array of aerosol-generating articles has a thickness of 1 to 8 mm, for example, 2 to 6 mm, for example, 2.5 to 5.5 mm, for example, 3 to 3.5 mm.

[0127] Example 34. An aerosol generating product according to any of the examples above, comprising a two-dimensional array of 4 to 200, e.g. 6 to 80, e.g. 8 to 64 separable aerosol generating articles.

[0128] Yes 35. An aerosol generating article according to any of the examples above, wherein each aerosol generating article forms an air flow path having a suction resistance of 0 mm H2O to 9.9 mm H2O when separated from an aerosol generating product.

[0129] Example 36. An aerosol generating device for receiving an aerosol generating article separated from an aerosol generating product according to any of the above examples to form an inhalable aerosol, wherein the aerosol generating device comprises a cavity dimensioned to receive at least a portion of the aerosol generating article, a heater or heating means, a power source for supplying power to the heater or heating means, and a control unit for controlling the power supply to the heater or heating means.

[0130] Example 37. An aerosol generating system comprising an aerosol generating device according to Example 36 and an aerosol generating product according to any one of Examples 1 to 35. Specific details for implementing the invention

[0131] Below, an example is explained in more detail with reference to the drawings:

[0132] FIG. 1 illustrates a perspective view of an aerosol-generating product according to one embodiment of the present disclosure.

[0133] FIG. 2 illustrates a perspective view of an aerosol-generating product according to one embodiment of the present disclosure.

[0134] FIG. 3 illustrates a perspective view of an aerosol-generating product and an aerosol-generating article cut from said product according to one embodiment of the present disclosure.

[0135] FIG. 4 illustrates a perspective view of an aerosol-generating product and an aerosol-generating article cut from said product according to one embodiment of the present disclosure.

[0136] FIG. 5 illustrates a perspective view of an aerosol-generating product according to one embodiment of the present disclosure.

[0137] FIG. 6 illustrates a perspective view of an aerosol-generating product according to one embodiment of the present disclosure.

[0138] FIG. 7 illustrates a schematic diagram of an apparatus used to manufacture an aerosol-generating product according to one embodiment of the present disclosure.

[0139] FIG. 8 illustrates a schematic diagram of a method used to manufacture an aerosol-generating product according to one embodiment of the present disclosure.

[0140] FIG. 9 illustrates a schematic diagram of an aerosol generating system according to one embodiment of the present disclosure.

[0141] FIG. 1 illustrates a perspective view of an aerosol generating product (10) in the form of a two-dimensional array of aerosol generating articles. The aerosol generating product (10) is defined by an initial product length (L), an initial product width (W), and a product thickness (T). The initial product length (L) and the initial product width (W) are greater than the product thickness (T). In this particular example, the aerosol generating product (10) forms a 4 × 4 array, with four aerosol generating articles arranged along the initial product length (L) of the aerosol generating product and four aerosol generating articles arranged along the initial product width (W) of the aerosol generating product. Thus, the aerosol generating product (10) is configured to be cut into 16 individual aerosol generating articles. Each aerosol generating article has an article length of 25 mm and an article width of 10 mm. The length of the article is parallel to the length (L) of the product. The width of the article is parallel to the width of the product (W). Thus, in this particular example, the aerosol-generating product (10) has an initial product length of 100 mm and an initial product width of 40 mm. The product thickness (T) is 3 mm, which is parallel to and identical to the thickness of the article. Clearly, the dimensions of the aerosol-generating product (10) and the aerosol-generating article may be changed for different specific examples.

[0142] The aerosol generating product (10) comprises a substantially flat sheet of an aerosol forming substrate (12). In this particular example, the aerosol forming substrate (12) comprises homogenized tobacco, but many other suitable aerosol forming materials may be used. The aerosol forming substrate (12) has a Young's modulus of 0.5 MPa to 5 MPa, and is generally about 0.875 MPa. The aerosol forming substrate (12) comprises a plurality of air flow channels (15) extending longitudinally, said channels extending from a distal end (13) of the substrate (12) to a proximal end (14) of the substrate (12).

[0143] A portion of each air flow channel (15) is formed by penetrating the longitudinal dimensions of each aerosol generating article. Thus, a longitudinal air flow path is formed through each aerosol generating article after being cut from the aerosol generating product (10), allowing air to be drawn through the article during use.

[0144] The above aerosol generating product (10) can be separated by tearing or cutting with a blade. Various ways in which the aerosol generating product (10) can be configured to be cut are disclosed below in relation to FIGS. 2, 3 and 4.

[0145] FIG. 2 illustrates a perspective view of an aerosol generating product (20) composed of an exemplary 4 × 4 array of aerosol generating articles (25). The aerosol generating product (20) comprises a plurality of air flow channels (250) extending longitudinally, said channels extending from a distal end (230) of the aerosol generating product (20) to a proximal end (240) of the aerosol generating product (20). The aerosol generating product (20) comprises a substantially flat sheet of an aerosol forming substrate (220), which is substantially identical to the aerosol forming substrate (12) of FIG. 1.

[0146] The aerosol generating product (20) comprises a plurality of longitudinally extending grooves (21) that divide the length of each of the plurality of aerosol generating articles (25). Each longitudinally extending groove (21) extends along the length of the aerosol generating product (20). The aerosol generating product (20) comprises a plurality of transversely extending grooves (22) that divide the width of each of the plurality of aerosol generating articles (25). Each transversely extending groove (22) extends along the width of the aerosol generating product (20).

[0147] The longitudinally extending grooves (21) are spaced evenly along the width of the aerosol generating product (20). In this exemplary embodiment, the vertical distance between the longitudinally extending grooves (21, 22) is 10 mm. In other embodiments, the vertical distance between the longitudinally extending grooves (21, 22) may be 3 mm to 50 mm. The transversely extending grooves (22) are spaced evenly along the length of the aerosol generating product (20). In this exemplary embodiment, the vertical distance between the transversely extending grooves (22) is 25 mm. In other embodiments, the vertical distance between the transversely extending grooves (22) may be 5 mm to 50 mm.

[0148] The above aerosol generating product (20) is configured to be cut into a plurality of individual aerosol generating articles (25) along grooves (21, 22, 22) extending in the longitudinal and transverse directions. The individual aerosol generating articles (25) can be cut from the aerosol generating product (20) by initiating and propagating a crack in the aerosol generating product (20) until the edges of the individual aerosol generating articles (25) are cut from the aerosol generating product (20) by tearing or bending the aerosol generating product (20) along the grooves (21, 22) extending in the longitudinal or transverse directions. Alternatively, the aerosol generating article (25) may be cut from the aerosol generating product (20) by cutting along a groove (21, 22) extending in the longitudinal or transverse direction, for example, by engaging a blade with the groove (21, 22) extending in the longitudinal or transverse direction to facilitate cutting along the groove (21, 22) extending in the longitudinal or transverse direction. When all edges of the aerosol generating article (25) are separated from the aerosol generating product (20), the aerosol generating article (25) can be completely separated from the aerosol generating product (20).

[0149] Each aerosol-generating article (25) is defined by the article length, article width, and article thickness. The article length is substantially equal to the vertical distance between the grooves (22) extending in the transverse direction. The article width is substantially equal to the vertical distance between the grooves (21) extending in the longitudinal direction. The article thickness is equal to the thickness of the aerosol-generating product (20).

[0150] FIG. 3 illustrates a perspective view of an aerosol generating product (30) and individual aerosol generating articles (35). In this exemplary embodiment, the aerosol generating product (30) initially contained 16 aerosol generating articles. As shown in FIG. 3, after one article is separated, the remaining aerosol generating product contains 15 aerosol generating articles. The aerosol generating product (30) includes a plurality of air flow channels (350) extending longitudinally, said channels extending from the distal end (330) of the aerosol generating product (30) to the proximal end (340) of the aerosol generating product (30). The aerosol generating product (30) includes a substantially flat sheet of an aerosol forming substrate (320), which is substantially identical to the aerosol forming substrate (12) of FIG. 1.

[0151] The aerosol generating product (30) comprises a plurality of perforations (31, 32). Each perforation comprises a perforation line (31) extending in the longitudinal direction or a perforation line (32) extending in the transverse direction. Each longitudinal perforation line (31) extends along the length of the aerosol generating product (30) and divides the length of each of the plurality of aerosol generating articles forming the aerosol generating product (30). Each transverse perforation line (32) extends along the width of the aerosol generating product (30) and divides the width of each of the plurality of aerosol generating articles forming the aerosol generating product (30). The perforations formed along each perforation line (31, 32) extending in the longitudinal and transverse directions are uniformly spaced apart. In this exemplary embodiment, the perforations partially penetrate the thickness dimension of the aerosol generating product (30). In other embodiments, the perforations completely penetrate the thickness dimension of the aerosol generating product (30).

[0152] The longitudinally extending perforations (31) are spaced evenly along the width of the aerosol generating product (30). In this exemplary embodiment, the vertical distance between the longitudinally extending perforations (31) is 10 mm. The transversely extending perforations (32) are spaced evenly along the length of the aerosol generating product (30). In this exemplary embodiment, the vertical distance between the transversely extending perforations (32) is 25 mm.

[0153] The above aerosol generating product (30) is configured to be cut into a plurality of individual aerosol generating articles (35) along perforation lines (31, 32) extending in the longitudinal and transverse directions. The individual aerosol generating articles (35) can be cut from the aerosol generating product (30) by initiating and propagating a crack in the aerosol generating product (30) by tearing or bending the aerosol generating product (30) along perforation lines (31, 32) extending in the longitudinal or transverse direction until the edges of the individual aerosol generating articles (35) are cut from the aerosol generating product (30). Alternatively, the aerosol generating article (35) can be cut from the aerosol generating product (30) by cutting along perforations (31, 32) extending in the longitudinal or transverse direction, for example, by engaging a blade with perforations (31, 32) extending in the longitudinal or transverse direction to facilitate cutting along perforations (31, 32) extending in the longitudinal or transverse direction.

[0154] The individual aerosol generating article (35) is completely separated from the aerosol generating product (30). The individual aerosol generating article (35) is defined by the article length (LA), article width (WA), and article thickness (TA). The article length (LA) is substantially equal to the vertical distance between two perforations (32) extending in the transverse direction. The article width (WA) is substantially equal to the vertical distance between two perforations (31) extending in the longitudinal direction. The article thickness (TA) is equal to the thickness of the aerosol generating product (30).

[0155] The individual aerosol generating article (35) includes an air flow channel (351) extending longitudinally, said channel extending from a distal end (331) of the aerosol generating article (35) to a proximal end (341) of the aerosol generating article (35).

[0156] The individual aerosol generating article (35) is configured to be inserted into an aerosol generating device to generate an aerosol during a session of use.

[0157] FIG. 4 illustrates a perspective view of an aerosol generating product (40) and individual aerosol generating articles (45). In this exemplary embodiment, the aerosol generating product (40) initially contained 16 aerosol generating articles. As shown in FIG. 4, after one article is separated, the remaining aerosol generating product contains 15 aerosol generating articles. The aerosol generating product (40) includes a plurality of air flow channels (450) extending longitudinally, said channels extending from the distal end (430) of the aerosol generating product (40) to the proximal end (440) of the aerosol generating product (40). The aerosol generating product (40) includes a substantially flat sheet of an aerosol forming substrate (420), which is substantially identical to the aerosol forming substrate (12) of FIG. 1.

[0158] The above-described aerosol generating product (40) includes a plurality of score sections (41, 42). Each score section includes a score or score line (41) extending in the longitudinal direction, or a score or score line (42) extending in the transverse direction. Each longitudinally extending score line (41) extends along the length of the aerosol generating product (40) and divides the length of each of the plurality of aerosol generating articles forming the aerosol generating product (40). Each transversely extending score line (42) extends along the width of the aerosol generating product (40) and divides the width of each of the plurality of aerosol generating articles forming the aerosol generating product (40). The score lines partially penetrate the thickness dimension of the aerosol generating product (40).

[0159] The longitudinally extending score lines (41) are spaced evenly along the width of the aerosol generating product (40). In this exemplary embodiment, the vertical distance between the longitudinally extending score lines (41) is 10 mm. The transversely extending score lines (42) are spaced evenly along the length of the aerosol generating product (40). In this exemplary embodiment, the vertical distance between the transversely extending score lines (42) is 25 mm.

[0160] The above aerosol generating product (40) is configured to be cut into a plurality of individual aerosol generating articles (45) along score lines (41, 42) extending in the longitudinal and transverse directions. The individual aerosol generating articles (45) can be cut from the aerosol generating product (40) by initiating and propagating a crack in the aerosol generating product (40) by tearing or bending the aerosol generating product (40) along score lines (41, 42) extending in the longitudinal or transverse direction until the edges of the individual aerosol generating articles (45) are cut from the aerosol generating product (40). Alternatively, the aerosol generating article (45) can be cut from the aerosol generating product (40) by cutting along score lines (41, 42) extending in the longitudinal or transverse direction, for example, by engaging a blade with score lines (41, 42) extending in the longitudinal or transverse direction to facilitate cutting along score lines (41, 42) extending in the longitudinal or transverse direction.

[0161] The individual aerosol generating article (45) is completely separated from the aerosol generating product (40). The individual aerosol generating article (45) is defined by the article length (LA), article width (WA), and article thickness (TA). The article length (LA) is substantially equal to the vertical distance between two scorelines (42) extending in the transverse direction. The article width (WA) is substantially equal to the vertical distance between two scorelines (41) extending in the longitudinal direction. The article thickness (TA) is equal to the thickness of the aerosol generating product (40).

[0162] The individual aerosol generating article (45) includes an air flow channel (451) extending longitudinally, said channel extending from a distal end (431) of the aerosol generating article (45) to a proximal end (441) of the aerosol generating article (45).

[0163] The individual aerosol generating article (45) is configured to be inserted into an aerosol generating device to generate an aerosol during a session of use.

[0164] FIG. 5 illustrates a perspective view of an aerosol generating product (50). The aerosol generating product (50) comprises a first planar layer (51), a second planar layer (52), and an intermediate layer or separation layer (53) disposed between the first planar layer (51) and the second planar layer (52). In this exemplary embodiment, the first planar layer and the second planar layer (51, 52) are formed from a cellulose acetate film sheet having a thickness of 0.05 mm. In other embodiments, the first planar layer and the second planar layer (51, 52) may have a thickness of 0.01 mm to 0.2 mm. The first planar layer and the second planar layer (51, 52) serve as a protective layer to protect the intermediate layer (53) from, for example, dust or foreign matter.

[0165] The intermediate layer (53) comprises a wavy element formed from a wavy sheet (531) made of an aerosol-forming material. A suitable aerosol-forming material may be homogenized tobacco. Accordingly, in this example, the intermediate layer (53) comprises a wavy sheet (531) made of homogenized tobacco material. The intermediate layer (53) may comprise other suitable aerosol-forming materials. The intermediate layer (53) has a thickness of 3 mm.

[0166] In this particular embodiment, the intermediate layer (53) is formed from a corrugated layer of an aerosol-forming material containing an aerosol-forming agent such as glycerin or propylene glycol. The aerosol-forming agent may be aerosolized by heating the aerosol-forming material. The corrugated sheet (531) of the aerosol-forming material may be impregnated with the aerosol-forming agent. Alternatively, or in addition thereto, the aerosol-forming agent may be present in the intermediate layer (53) between the grooves of the corrugated elements. The space between the grooves of the corrugated elements may be referred to as a channel (532, 542). The channel (532, 542) penetrates the aerosol-forming product (50) in a transverse direction.

[0167] The aerosol generating product (50) may include one or more of the grooves (21, 22), perforations (31, 32), and score portions (41, 42) as described above (not shown). The grooves (21, 22), perforations (31, 32), and score portions (41, 42) may penetrate at least one of the first planar layer (51), the second planar layer (52), and the intermediate layer (53). Accordingly, the aerosol generating product (50) may be configured to be cut according to one or more of the methods described above. The grooves (21, 22), perforations (31, 32), and score portions (41, 42) may be aligned at the intersection point (535) between the first planar layer (51) and the intermediate layer (53) and at the intersection point (545) between the second planar layer (52) and the intermediate layer (53).

[0168] The above waveform has a peak-to-trough amplitude (510) of 3 mm and a wavelength (520) of 3 mm. The intersection points (535, 545) between the first planar layer (51) and the intermediate layer (53) and between the second planar layer (52) and the intermediate layer (53) contain an adhesive that bonds the respective layers.

[0169] The waveform of the intermediate layer (53) forms a first set of transverse channels (532) defined by the first planar layer (51) and the intermediate layer (53), and forms a second set of transverse channels (542) defined by the second planar layer (52) and the intermediate layer (53). The first set and second set of transverse channels (532, 542) pass through the width of the aerosol generating product (50). The transverse channels (532, 542) define a transverse air flow path passing through the aerosol generating product (50). Thus, the air flow path passes over both sides of the corrugated sheet of the aerosol generating material. The porosity of the aerosol generating product (50) along the air flow path is approximately 90%.

[0170] FIG. 6 illustrates a perspective view of an aerosol generating product (60). The aerosol generating product (60) comprises a first planar layer (61), a second planar layer (62), and an intermediate layer or separation layer (63) disposed between the first planar layer (61) and the second planar layer (62). The first planar layer and the second planar layer (61, 62) are substantially identical to the first planar layer and the second planar layer (51, 52) of FIG. 5. The intermediate layer (63) is similar to the intermediate layer (53) of FIG. 5, but differs in that the channels (632, 642) penetrate the aerosol generating product (60) in the longitudinal direction rather than in the transverse direction as in FIG. 5.

[0171] Accordingly, the waveform of the intermediate layer (63) forms a first set of longitudinal channels (632) defined by the first planar layer (61) and the intermediate layer (63), and forms a second set of longitudinal channels (642) defined by the second planar layer (62) and the intermediate layer (63). The first set and the second set of longitudinal channels (632, 642) pass through the length of the aerosol generating product (60). The longitudinal channels (632, 642) define a longitudinal air flow path passing through the aerosol generating product (60). Accordingly, the air flow path passes over both sides of the corrugated sheet of the aerosol generating material. The porosity of the aerosol generating product along the air flow path is approximately 90%.

[0172] The aerosol generating product (60) comprises a score section (41, 42) that partially penetrates the first planar layer (61) and the second planar layer (62). In this exemplary embodiment, the score line depth is 0.01 mm. Thus, the aerosol generating product (60) can be configured to be cut as described above. The score section (41, 42) is aligned at the intersection points (635, 645) between the first planar layer (61) and the intermediate layer (63) and between the second planar layer (62) and the intermediate layer (63).

[0173] FIG. 7 is a schematic diagram of a device (710) that can be used for manufacturing an aerosol generating product (70) for forming grooves (21, 22), perforations (31, 32) or score portions (41, 42). The device includes a stamping die (71) and an anvil (72). A continuous sheet of aerosol generating product (70) is transported along a roller (73) to the stamping die (71) and the anvil (72). To form score portions (41, 42), the stamping die (71) perforates or compresses the aerosol generating product (70) against the anvil (72) to form score portions (41, 42). To form grooves (21, 22) (not shown), the stamping die (71) may be configured to have a round tip, through which the aerosol generating product (70) is compressed against the anvil (72) to form grooves (21, 22). To form perforations (31, 32) (not shown), the stamping die (71) may be configured to have a pointed tip, through which the stamping die (71) punctures the aerosol generating product (70) when the aerosol generating product (70) is compressed against the anvil (72).

[0174] FIG. 8 illustrates a schematic diagram of a process that can be used to manufacture an aerosol generating product (80). A continuous sheet of aerosol generating product (81) is cut to form an array of aerosol generating articles (82), and gaps (84) are formed between the aerosol generating articles (85). Then, a flat upper layer (83) is attached to the upper surface array of aerosol generating articles (82) using an adhesive. Then, the aerosol generating product (80) is marked with at least one of a groove (21, 22), a perforation (31, 32), and a score (41, 42) using, for example, the process of FIG. 7, so that the groove (21, 22), the perforation (31, 32), or the score (41, 42) are aligned in the gaps (84) between the aerosol generating articles (85).

[0175] FIG. 9 illustrates an aerosol generating system comprising an aerosol generating device (91) and an aerosol generating article (90). The aerosol generating device (91) may be coupled to a mouthpiece (92). The aerosol generating article (90) is configured to be coupled to the aerosol generating device (91). There is almost no gap between the outer surface of the aerosol generating article (90) and the inner surface of the cavity (950). Therefore, a tight coupling is formed between the article (90) and the device (91). When a user inserts the article (90) into the cavity (950), the device (91) can be operated. The device (91) includes two planar heaters (660). The heaters (960) heat the upper surface and the lower surface of the article (90), and as a result, the aerosol generating article (90) is heated. Volatile components of the aerosol generating article evaporate to form an aerosol. The user inhales the aerosol formed from the aerosol-generating article (100) by inhaling through the mouthpiece (92). When the volatile components of the aerosol-generating article (45) are exhausted, the article (90) is removed from the cavity (650) and disposed of.

[0176] In this specification and the appended claims, unless otherwise specified, all numerical values ​​representing amounts, quantities, percentages, etc., should be understood as being modified by the term “about” in all cases. Furthermore, all ranges include the disclosed maximum and minimum values ​​and all intermediate ranges in between that may not be specifically described in this specification. Accordingly, in this context, numerical A is understood as ±10% of A. Also in this context, numerical A may be considered to include values ​​within the general standard error range when measuring the properties defined by numerical A. Numerical A as used in the appended claims may deviate by the percentages listed above, provided that the deviation of A does not substantially affect the fundamental and novel features of the claimed invention. Also, all ranges include the disclosed maximum and minimum values ​​and all intermediate ranges in between that may not be specifically described in this specification.

Claims

Claim 1 An aerosol generating product in the form of a two-dimensional array of aerosol generating articles, wherein each of the aerosol generating articles is configured to be separable from the aerosol generating product so as to be used as an individual aerosol generating article for generating an aerosol. Claim 2 In claim 1, the aerosol generating product is defined by an initial product length, an initial product width, and a product thickness, wherein the initial product length and the initial product width are greater than the product thickness. Claim 3 In paragraph 1 or 2, the aerosol generating product is n L × n W Form an array, where n L is the number of aerosol-generating articles over the initial length (initial product length) of the above aerosol-generating product, and n W is the number of aerosol-generating items across the initial width (initial product width) of the above aerosol-generating product, for example, n L is a number between 2 and 20, and n W is an aerosol-generating product consisting of 2 to 10 numbers. Claim 4 In paragraph 3, the aerosol-generating product is a continuous product that extends continuously in the longitudinal direction, for example, n L can be expressed as ∞, for example, n L is ∞ and n W is an aerosol-generating product consisting of 2 to 10 numbers. Claim 5 In Paragraph 3, n L is a number between 3 and 15, and n W is an aerosol-generating product consisting of 2 to 15 numbers. Claim 6 An aerosol generating product according to any one of claims 1 to 5, wherein the material properties or physical properties of the aerosol generating product are configured to facilitate the separation of the product into a plurality of individual aerosol generating articles. Claim 7 An aerosol generating product according to any one of claims 1 to 6, comprising at least one stress concentration portion for facilitating crack initiation, wherein, for example, each of the plurality of aerosol generating articles is partitioned by one or more notches, grooves, scorelines, or perforations configured to act as a stress concentration portion for facilitating crack initiation, thereby facilitating the separation of individual articles from the aerosol generating product. Claim 8 An aerosol generating product comprising, in any one of claims 1 to 7, a first planar layer, a second planar layer, and an intermediate layer or separation layer disposed between the first planar layer and the second planar layer. Claim 9 In paragraph 8, an aerosol-generating product, wherein each aerosol-generating article is partitioned, and a weak line formed by, for example, a scoreline, groove, notch, or perforation is formed in at least one of a first planar layer, a second planar layer, and an intermediate layer or a separation layer. Claim 10 An aerosol generating product according to any one of claims 1 to 9, wherein one or more air flow channels are formed penetrating the aerosol generating product, and as a result therefrom, after separation, each of the plurality of aerosol generating articles comprises at least one air flow channel formed penetrating the interior thereof. Claim 11 An aerosol generating product according to any one of claims 1 to 10, wherein each of the plurality of aerosol generating articles comprises at least one cavity, for example, a cavity containing an aerosol forming substrate. Claim 12 In any one of claims 1 to 11, the aerosol generating product comprises a first planar layer, a second planar layer, and a wavy element disposed between the first planar layer and the second planar layer. Claim 13 An aerosol generating product according to any one of claims 1 to 12, further comprising at least one protective layer configured to protect the upper surface and / or lower surface of the aerosol generating product, preferably wherein the at least one protective layer forms a protective layer of each article after the aerosol generating article is separated from the aerosol generating product. Claim 14 In paragraph 13, an aerosol generating product having perforations, notches, grooves, or scores formed in at least one protective layer to facilitate separation of the aerosol generating article from the aerosol generating product. Claim 15 In any one of claims 1 to 14, each aerosol-generating article in a two-dimensional array of aerosol-generating articles has a length of 5 mm to 50 mm and a thickness of 1 mm to 8 mm, an aerosol-generating product.

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