Aerosol generating items
Patent Information
- Authority / Receiving Office
- KR · KR
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-12-17
- Publication Date
- 2026-08-12
Smart Images
Figure PCT00009_ABST
Abstract
Description
Technology Field
[0001] The present disclosure relates to an aerosol generating article. The present disclosure also relates to an aerosol generating device for use with an aerosol generating article. The present disclosure also relates to an aerosol generating system comprising an aerosol generating device and an aerosol generating article.
[0002] The present disclosure relates to an aerosol generating article. The present disclosure also relates to an aerosol generating device for use with an aerosol generating article. The present disclosure also relates to an aerosol generating system comprising an aerosol generating device and an aerosol generating article. The present disclosure also relates to a method for manufacturing an aerosol generating article. Background Technology
[0003] A conventional aerosol generating system comprises an aerosol generating device and an aerosol generating article comprising an aerosol generating substrate. In use, the aerosol generating device is arranged to heat a heating element positioned near or in contact with the aerosol generating substrate, causing the aerosol generating substrate to heat and release volatile compounds. These volatile compounds are then entrained into air drawn through the aerosol generating article. As the released compounds cool, they condense to form an aerosol that can be inhaled by a consumer.
[0004] Conventional aerosol generating articles may look similar to conventional cigarettes and may have similar dimensions. For example, such aerosol generating articles may be substantially cylindrical and may include an aerosol generating material in addition to other components such as a mouthpiece filter element and a cooling element arranged in the form of rods and wrapped in cigarette paper.
[0005] However, a significant portion of the aerosol generating 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 generating material contributes to the manufacturing and transportation costs of the aerosol generating article but does not contribute to the aerosol delivered to the consumer. Additionally, the components of these cylindrical aerosol generating articles generally need to have the same or very similar outer diameters so that they can be joined, positioned accurately in axial alignment, and wrapped in cigarette paper. This can increase manufacturing costs and complexity.
[0006] The object of the present disclosure is to provide an aerosol generating article in which a larger portion of the aerosol generating material is heated sufficiently to form an aerosol during use. Additionally, the object of the present disclosure is to provide an aerosol generating article that can be manufactured relatively efficiently and at a low cost.
[0007] According to the present disclosure, an aerosol generating article is provided for use with an aerosol generating device to generate an aerosol. The aerosol generating article may include a first planar outer surface. The aerosol generating article may include a second planar outer surface. The aerosol generating article may include a frame positioned between the first planar outer surface and the second planar outer surface. The aerosol generating article may include an air inlet. The aerosol generating article may include an air outlet. The frame may include a first side portion. The frame may include a second side portion. The first side portion and the second side portion may define a cavity at least partially. The first side portion and the second side portion may extend from the air inlet to the air outlet along the longitudinal axis of the aerosol generating article. The first side portion may be a support element. The second side portion may be a support element.
[0008] According to the present disclosure, an aerosol generating article is also provided for use with an aerosol generating device to generate an aerosol, wherein the aerosol generating article comprises: a first planar outer surface; a second planar outer surface; a frame positioned between the first planar outer surface and the second planar outer surface; and an air inlet and an air outlet, wherein the frame comprises a first side portion and a second side portion, the first side portion and the second side portion at least partially define a cavity and extend from the air inlet to the air outlet along the longitudinal axis of the aerosol generating article, and the first side portion is a supporting element and the second side portion is a supporting element.
[0009] Advantageously, the frame can make the aerosol-generating article relatively thin while maintaining structural rigidity.
[0010] Advantageously, providing a frame that includes separate side sections can improve the sealing of the airflow path between the air inlet and the air outlet. For example, the sealing of the airflow path between the air inlet and the air outlet can be improved because the side sections provide an increased surface area on the frame to adhesively bond the frame to a flat outer surface.
[0011] Improving the seal of the airflow path between the air inlet and the air outlet can increase the delivery of aerosols from the aerosol-generating article. Improving the seal of the airflow path between the air inlet and the air outlet can also reduce contamination of the aerosol-generating device housing the aerosol-generating article.
[0012] Advantageously, providing side parts as separate elements to other parts of the frame can reduce material waste during the manufacture of aerosol-generating articles.
[0013] Advantageously, the side portions acting as supporting elements can improve the structural rigidity of the aerosol-generating article.
[0014] An aerosol-generating article may include one or more aerosol-generating materials.
[0015] The aerosol generating article may have a length extending in the x-direction. The aerosol generating article may have a width extending in the y-direction. The aerosol generating article may have a thickness extending in the z-direction.
[0016] The aerosol generating article may be a substantially flat aerosol generating article or a substantially planar aerosol generating article. In particular, the thickness of the aerosol generating article may be less than 50% of both the length and width of the aerosol generating article. Advantageously, a thinner thickness may provide a small temperature gradient or temperature difference across the thickness of the aerosol generating substrate during heating.
[0017] The aerosol generating article may have a quadrilateral cuboid shape. The aerosol generating article may have a right-angled prism shape. The aerosol generating article may have a rectangular prism shape. The aerosol generating article may have a cylindrical shape. The aerosol generating article may have a right-angled cylindrical shape.
[0018] The aerosol generating article may have a laminated structure, for example, the aerosol generating article may include or be formed of at least two layers. In particular, as discussed in more detail below, the aerosol generating article may include at least two of a first outer layer, a second outer layer, a frame, a first frame layer, a second frame layer, a third frame layer, a first aerosol generating substrate layer, and a second aerosol generating substrate layer.
[0019] A substantial portion of the aerosol-generating article, excluding one or more aerosol-generating materials and (if present) adhesive, may be paper or cardboard.
[0020] Aerosol-generating articles may have a cellulose acetate content of less than 5%. Aerosol-generating articles may have a cellulose acetate content of less than 3%. Aerosol-generating articles may have a cellulose acetate content of less than 1%.
[0021] The frame can be a flat frame.
[0022] The frame may define frame perforations that extend through the thickness of the frame. The frame perforations may define or form airflow passages for the aerosol-generating article. The frame perforations may define or form cavities for the aerosol-generating article. For example, the frame may have a hollow rectangular shape or a square hollow tube shape. As an additional embodiment, the frame may have a cross-section that is annular in shape, and preferably, the cross-section in the x / y plane is annular in shape.
[0023] The frame may include an outer surface of the frame. The outer surface of the frame may extend transversely, for example, between a first planar outer surface and a second planar outer surface. The outer surface of the frame may at least partially define or form one or more outer surfaces of an aerosol-generating article. For example, the outer surface of the frame may at least partially define or form one or more outer wall surfaces of an aerosol-generating article. The outer surface of the frame may surround or encircle a frame perforation. The outer surface of the frame may surround or encircle a cavity.
[0024] The frame may include an inner surface of the frame. The inner surface of the frame may extend transversely, for example, between a first planar outer surface and a second planar outer surface. The inner surface of the frame may define or form an outer wall of the frame perforation. The inner surface of the frame may define or form an outer wall of the cavity. The inner surface of the frame may surround or encircle a frame perforation extending through the thickness of the frame. The inner surface of the frame may surround or encircle a cavity.
[0025] The outer surface of the frame may surround or encircle the inner surface of the frame. The inner surface of the frame and the outer surface of the frame may be concentric with each other.
[0026] The aerosol generating article may include one or more outer wall surfaces extending between a first planar outer surface and a second planar outer surface. The one or more outer wall surfaces may collectively define the entire transverse outer area of the aerosol generating article. A frame may define at least partially each of the one or more outer wall surfaces. The one or more outer wall surfaces may surround or enclose a cavity. A frame may define at least 60%, at least 70%, at least 80%, or at least 90% of the entire transverse outer area of the aerosol generating article.
[0027] The frame may include multiple parts.
[0028] Multiple parts may be separate pieces. Multiple parts may be separate pieces that can be attached to or connected to each other to form a frame.
[0029] The frame may include a first side portion and a second side portion. The frame may include a first end portion and a second end portion. The frame may include a first side portion, a second side portion, a first end portion, and a second end portion.
[0030] The first end portion may include an air inlet. The air inlet may be defined as a perforation extending through the first end portion. The air inlet may be defined as a perforation along the length of the first end portion. The first end portion may be located at the upstream end of the aerosol generating article. The first end portion may define the upstream end of the aerosol generating article.
[0031] The first end portion can physically contact the first side portion and the second side portion and can be joined thereto. The first end portion can physically contact the upstream end of the first side portion and the upstream end of the second side portion and can be joined thereto.
[0032] The second end portion may include an air outlet. The air outlet may be defined as a perforation extending through the second end portion. The air outlet may be defined as a perforation extending through the length of the second end portion. The second end portion may be located at the downstream end of the aerosol-generating article. The second end portion may define the downstream end of the aerosol-generating article.
[0033] The second end portion can physically contact the first side portion and the second side portion and can be joined thereto. The second end portion can physically contact the downstream end of the first side portion and the downstream end of the second side portion and can be joined thereto.
[0034] The first side portion and the second side portion may physically contact the downstream end of the first end portion and may be joined thereto. The first side portion and the second side portion may physically contact the upstream end of the second end portion and may be joined thereto.
[0035] At least one of the first end portion and the second end portion may comprise a cellulose material or be manufactured therefrom. The first end portion and the second end portion may comprise a cellulose material or be manufactured therefrom. The cellulose material may be paper, cigarette paper, tobacco paper, cardboard, wood, fabric, natural fiber, or artificial fiber.
[0036] The frame may include surrounding walls. The surrounding walls may surround or encircle at least a portion of the frame opening extending through the thickness of the frame. The surrounding walls may surround or encircle at least a portion of the cavity. The surrounding walls may surround or encircle the frame opening extending through the thickness of the frame. The surrounding walls may surround or encircle the cavity.
[0037] The periphery wall surface may be defined or formed by the outer surface of the frame and the inner surface of the frame. The periphery wall surface may at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The periphery wall surface may define or form the outer wall surface of the frame perforation. The periphery wall surface may define or form the outer wall surface of the cavity.
[0038] The surrounding walls may have a radial thickness. The radial thickness can be defined, for example, as the minimum distance between the outer surface of the frame and the inner surface of the frame in the x / y plane.
[0039] The surrounding wall surface may have a radial thickness of 0.5 mm or more. The surrounding wall surface may have a radial thickness of 1.5 mm or more. The surrounding wall surface may have a radial thickness of 2.5 mm or more.
[0040] The surrounding wall surface may have a radial thickness of 3.5 mm or less. The surrounding wall surface may have a radial thickness of 2.5 mm or less.
[0041] The surrounding wall surface may have a radial thickness of 0.5 mm to 3.5 mm. The surrounding wall surface may have a radial thickness of 0.5 mm to 2.5 mm.
[0042] Advantageously, a peripheral wall having a radial thickness of 0.5 mm to 3.5 mm has been found to provide good structural strength to the aerosol generating article without using an excess amount of material that could increase manufacturing costs, and can limit the amount of heat unintentionally transferred to the frame rather than the aerosol generating substrate.
[0043] The frame may be manufactured from or contain biodegradable materials. The frame may be manufactured entirely from biodegradable materials.
[0044] The frame may be manufactured from or contain a cellulose material. The cellulose material may contain a sheet of cellulose material. The cellulose material may contain cellulose fibers. The cellulose material may be paper, cardboard, or cardboard. The frame may be manufactured from or contain a plant material such as tobacco. The frame may be manufactured entirely from a cellulose material.
[0045] The aerosol generating article may include one or more susceptor materials. The frame may include one or more susceptor materials. One or more susceptor materials may be in thermal contact with the aerosol generating substrate. One or more susceptor materials may be in thermal contact with the cavity. One or more susceptor materials may be incorporated within the material of the frame. For example, one or more susceptor materials may be incorporated within the peripheral wall surface of the frame.
[0046] One or more susceptor materials may be one or more particles, strips, threads, or wires of the susceptor material. One or more susceptor materials may be one or more sheets or layers of the susceptor material. One or more sheets or layers of the susceptor material may be in the form of a mesh of the susceptor material.
[0047] The susceptor material may comprise one or more materials selected from a list consisting of aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite, in any form.
[0048] The frame may have a thickness of 50% or more of the thickness of the aerosol-generating article. The frame may have a thickness of 70% or more of the thickness of the aerosol-generating article. The frame may have a thickness of 90% or more of the thickness of the aerosol-generating article. The frame may have a thickness of 95% or more of the thickness of the aerosol-generating article.
[0049] The frame may have a thickness of 95% or less of the thickness of the aerosol-generating article. The frame may have a thickness of 90% or less of the thickness of the aerosol-generating article. The frame may have a thickness of 70% or less of the thickness of the aerosol-generating article.
[0050] The frame may have a thickness of 50% to 95% of the thickness of the aerosol-generating article. The frame may have a thickness of 70% to 95% of the thickness of the aerosol-generating article.
[0051] The frame may have a thickness of 1 mm or more, 2 mm or more, 3 mm or more, or 4 mm or more. The frame may have a thickness of 5.5 mm or less, 4.5 mm or less, 3.5 mm or less, 2.5 mm or less, or 1.5 mm or less. The frame may have a thickness of 1 mm to 5.5 mm. Preferably, the frame may have a thickness of 1.5 mm to 5.5 mm.
[0052] The frame may have a length equal to the length of the aerosol-generating article. The frame may have a length of at least 90% of the length of the aerosol-generating article. The frame may have a length of at least 95% of the length of the aerosol-generating article.
[0053] The frame may have a width equal to the width of the aerosol-generating article. The frame may have a width that is at least 90% of the width of the aerosol-generating article.
[0054] The frame may be a single component. Alternatively, the frame may include two or more layers. That is, the frame may have a laminated structure. Advantageously, the characteristics of each layer may be individually optimized according to the relative distance between the layer and the aerosol generating substrate or heater of the aerosol generating device.
[0055] A frame may include a first frame layer and a second frame layer. The first frame layer and the second frame layer may be the only layers of the frame. That is, the frame may include two or fewer layers, or exactly two layers. A frame aperture may be defined through both the first frame layer and the second frame layer.
[0056] The frame may include a first frame layer, a second frame layer, and a third frame layer. The second frame layer may be located between the first frame layer and the third frame layer. The first frame layer, the second frame layer, and the third frame layer may be the only layers of the frame. That is, the frame may include three or fewer layers, or exactly three layers.
[0057] The first side part may be separated from other pieces or parts forming the frame. The second side part may be separated from other pieces or parts forming the frame.
[0058] The first side part may be a rigid support element. The second side part may be a rigid support element. Both the first side part and the second part may be rigid support elements.
[0059] The first side part may be a wall. That is, the first side part may be a first side wall. The second side part may be a wall. That is, the second side part may be a second side wall. The first side part and the second side part may be walls. That is, the first side part may be a first side wall, and the second side part may be a second side wall.
[0060] At least one of the first side portion and the second side portion may extend from one end of the aerosol generating article to the other end of the aerosol generating article. Both the first side portion and the second side portion may extend from one end of the aerosol generating article to the other end of the aerosol generating article.
[0061] The first side part may be identical to the second side part.
[0062] The first side portion may be an elongated member. The second side portion may be an elongated member.
[0063] The first side portion may extend from the upstream end of the aerosol generating article to the downstream end of the aerosol generating article. The second side portion may extend from the upstream end of the aerosol generating article to the downstream end of the aerosol generating article.
[0064] The first side portion may extend from the first end of the frame to the second end of the frame. The second side portion may extend from the first end of the frame to the second end of the frame.
[0065] The first side portion may be located at the lateral end of the frame. The first side portion may be located at the lateral end of the aerosol-generating article. The second side portion may be located at the lateral end of the frame. The second side portion may be located at the lateral end of the aerosol-generating article.
[0066] The first side portion and the second side portion may define opposing lateral surfaces of the frame. The first side portion and the second side portion may define opposing lateral surfaces of the aerosol-generating article.
[0067] The first side part may define a lateral surface of the frame. The first part may define a lateral surface of the aerosol-generating article. The second side part may define a lateral surface of the frame. The second side part may define a lateral surface of the aerosol-generating article.
[0068] The first side portion and the second side portion may define opposing lateral surfaces of the frame. The first side portion and the second side portion may define opposing lateral surfaces of the aerosol-generating article.
[0069] The first side portion and the second side portion may define the outermost lateral surface of the aerosol-generating article.
[0070] The first side portion may have a round cross-section, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section.
[0071] The second side portion may have a round cross-section, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section.
[0072] The frame may include one or more elongated channels extending through it. Thus, one or more elongated channels are provided internally within the structure of the frame, for example, within the walls of the frame. For example, the frame may include one or more elongated channels extending longitudinally through it. Alternatively or additionally, the frame may include one or more elongated channels extending transversely through it. One or more elongated channels provide an airflow path through the frame.
[0073] The aerosol generating article may include an elongated flavor-containing element. The elongated flavor-containing element may be provided within one or more elongated channels defined within a frame. The position of the one or more elongated channels may be adjusted to control the distance between the elongated flavor-containing element and the heating element when the aerosol generating article is in place within the aerosol generating device.
[0074] The first side portion may include a first elongated channel extending longitudinally therethrough. The second side portion may include a second elongated channel extending therethrough. At least one of the first elongated channel and the second elongated channel may contain an elongated flavor-containing element. The frame may also include a first end portion and a second end portion. The first and second elongated channels may extend through the first end portion and the second end portion so that the elongated channels provide a complete airflow path through the frame between the downstream end and the upstream end.
[0075] Elongated flavor-containing elements or elements can be conveniently integrated into one or more elongated channels within the frame, which also serve as an airflow path through the frame. Positioning the elongated flavor-containing elements within the airflow path allows the flavor agent to be effectively released into the air passing through the frame, subsequently transported via an aerosol-generating article, and mixed with an aerosol generated from an aerosol-forming substrate.
[0076] The aerosol generating article may include a substrate wrapper. The substrate wrapper may surround or enclose the aerosol generating substrate. The substrate wrapper may surround or enclose the aerosol generating substrate, the first side portion, and the second side portion. The substrate wrapper may physically contact the first side portion and the second side portion and may be bonded thereto.
[0077] The substrate wrapper may contain or be manufactured from a cellulose material. The cellulose material may be paper, cigarette paper, tobacco paper, cardboard, wood, fabric, natural fiber, or artificial fiber.
[0078] At least one of the first side portion and the second side portion may include at least one wave fold. The first side portion may include at least one wave fold, and the second side portion may include at least one wave fold. At least one of the first side portion and the second side portion may include a plurality of wave folds. The first side portion may include a plurality of wave folds, and the second side portion may include a plurality of wave folds.
[0079] At least one of the first side portion and the second side portion may comprise a cellulose material or be manufactured therefrom. The first side portion and the second side portion may comprise a cellulose material or be manufactured therefrom. The cellulose material may be paper, cigarette paper, tobacco paper, cardboard, wood, fabric, natural fiber, or artificial fiber.
[0080] At least one of the first side portion and the second side portion may include one or more aerosol generating materials. The first side portion may include one or more aerosol generating sub-states, and the second side portion may include one or more aerosol generating materials.
[0081] One or more aerosol generating materials may include an aerosol generating material. Additional features of the aerosol generating material are described below.
[0082] The aerosol generating material may include homogenized tobacco material. The homogenized material may be in the form of one or more strips of tobacco material. The homogenized material may be in the form of multiple strands of homogenized tobacco material. The homogenized material may be in the form of shredded sheets of homogenized tobacco material.
[0083] Homogenized tobacco material may be formed by aggregating particles of tobacco material obtained by pulverizing, milling, or crushing one or more of plant material and optionally tobacco leaf blades and tobacco leaf stalks. Homogenized plant material may be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art.
[0084] The first side part may have a length of 20 mm or more. The first side part may have a length of 22 mm or more. The first side part may have a length of 24 mm or more. The first side part may have a length of 26 mm or more. The first side part may have a length of 28 mm or more. The first side part may have a length of 30 mm or more. The first side part may have a length of 32 mm or more.
[0085] The first side portion may have a length of less than 40 mm. The first side portion may have a length of less than 38 mm. The first side portion may have a length of less than 36 mm. The first side portion may have a length of less than 34 mm. The first side portion may have a length of less than 32 mm. The first side portion may have a length of less than 30 mm.
[0086] The first side portion may have a length of 20 mm to 40 mm. The first side portion may have a length of 22 mm to 38 mm. The first side portion may have a length of 24 mm to 36 mm. The first side portion may have a length of 26 mm to 34 mm. The first side portion may have a length of 28 mm to 32 mm.
[0087] The second side part may have a length of 20 mm or more. The second side part may have a length of 22 mm or more. The second side part may have a length of 24 mm or more. The second side part may have a length of 26 mm or more. The second side part may have a length of 28 mm or more. The second side part may have a length of 30 mm or more. The second side part may have a length of 32 mm or more.
[0088] The second side part may have a length of less than 40 mm. The second side part may have a length of less than 38 mm. The second side part may have a length of less than 36 mm. The second side part may have a length of less than 34 mm. The second side part may have a length of less than 32 mm. The second side part may have a length of less than 30 mm.
[0089] The second side portion may have a length of 20 mm to 40 mm. The second side portion may have a length of 22 mm to 38 mm. The second side portion may have a length of 24 mm to 36 mm. The second side portion may have a length of 26 mm to 34 mm. The second side portion may have a length of 28 mm to 32 mm.
[0090] The first side portion may have a length equal to the length of the aerosol-generating article. The first side portion may have a length of 90% or more of the length of the aerosol-generating article. The first side portion may have a length of 95% or more of the length of the aerosol-generating article.
[0091] The first side portion may have a length of 90% to 100% of the length of the aerosol-generating article. The first side portion may have a length of 95% to 100% of the length of the aerosol-generating article.
[0092] The second side portion may have a length equal to the length of the aerosol-generating article. The second side portion may have a length of 90% or more of the length of the aerosol-generating article. The second side portion may have a length of 95% or more of the length of the aerosol-generating article.
[0093] The second side portion may have a length of 90% of the length of the aerosol-generating article to 100% of the width of the aerosol-generating article. The second side portion may have a length of 95% of the length of the aerosol-generating article to 100% of the width of the aerosol-generating article.
[0094] The first side portion may have a width of 1.5 mm or more. The first side portion may have a width of 1.75 mm or more. The first side portion may have a width of 2 mm or more. The first side portion may have a width of 2.25 mm or more. The first side portion may have a width of 2.5 mm or more.
[0095] The first side portion may have a width of less than 3.5 mm. The first side portion may have a width of less than 3.25 mm. The first side portion may have a width of less than 3 mm. The first side portion may have a width of less than 2.75 mm. The first side portion may have a width of less than 2.5 mm.
[0096] The first side portion may have a width of 1.5 mm to 3.5 mm. The first side portion may have a width of 1.75 mm to 3.25 mm. The first side portion may have a width of 2 mm to 3 mm. The first side portion may have a width of 2.25 mm to 2.75 mm.
[0097] The second side portion may have a width of 1.5 mm or more. The second side portion may have a width of 1.75 mm or more. The second side portion may have a width of 2 mm or more. The second side portion may have a width of 2.25 mm or more. The second side portion may have a width of 2.5 mm or more.
[0098] The second side portion may have a width of less than 3.5 mm. The first side portion may have a width of less than 3.25 mm. The second side portion may have a width of less than 3 mm. The second side portion may have a width of less than 2.75 mm. The second side portion may have a width of less than 2.5 mm.
[0099] The second side portion may have a width of 1.5 mm to 3.5 mm. The second side portion may have a width of 1.75 mm to 3.25 mm. The second side portion may have a width of 2 mm to 3 mm. The second side portion may have a width of 2.25 mm to 2.75 mm.
[0100] The first side portion may have a width of 5% or more of the width of the aerosol-generating article. The first side portion may have a width of 10% or more of the width of the aerosol-generating article.
[0101] The first side portion may have a width of less than 10% of the width of the aerosol-generating article.
[0102] The first side portion may have a width of 5% to 10% of the width of the aerosol-generating article.
[0103] The second side portion may have a width of 5% or more of the width of the aerosol-generating article. The second side portion may have a width of 10% or more of the width of the aerosol-generating article.
[0104] The second side portion may have a width of less than 10% of the width of the aerosol-generating article.
[0105] The second side portion may have a width of 5% to 10% of the width of the aerosol-generating article.
[0106] The first side portion may have a thickness of 1.5 mm or more. The first side portion may have a thickness of 1.75 mm or more. The first side portion may have a thickness of 2 mm or more. The first side portion may have a thickness of 2.25 mm or more. The first side portion may have a thickness of 2.5 mm or more.
[0107] The first side portion may have a thickness of less than 3.5 mm. The first side portion may have a thickness of less than 3.25 mm. The first side portion may have a thickness of less than 3 mm. The first side portion may have a thickness of less than 2.75 mm. The first side portion may have a thickness of less than 2.5 mm.
[0108] The first side portion may have a thickness of 1.5 mm to 3.5 mm. The first side portion may have a thickness of 1.75 mm to 3.25 mm. The first side portion may have a thickness of 2 mm to 3 mm. The first side portion may have a thickness of 2.25 mm to 2.75 mm.
[0109] The second side portion may have a thickness of 1.5 mm or more. The second side portion may have a thickness of 1.75 mm or more. The second side portion may have a thickness of 2 mm or more. The second side portion may have a thickness of 2.25 mm or more. The second side portion may have a thickness of 2.5 mm or more.
[0110] The second side portion may have a thickness of less than 3.5 mm. The first side portion may have a thickness of less than 3.25 mm. The second side portion may have a thickness of less than 3 mm. The second side portion may have a thickness of less than 2.75 mm. The second side portion may have a thickness of less than 2.5 mm.
[0111] The second side portion may have a thickness of 1.5 mm to 3.5 mm. The second side portion may have a thickness of 1.75 mm to 3.25 mm. The second side portion may have a thickness of 2 mm to 3 mm. The second side portion may have a thickness of 2.25 mm to 2.75 mm.
[0112] The first side portion may have a thickness of 50% or more of the thickness of the aerosol-generating article. The first side portion may have a thickness of 70% or more of the thickness of the aerosol-generating article. The first side portion may have a thickness of 90% or more of the thickness of the aerosol-generating article. The first side portion may have a thickness of 95% or more of the thickness of the aerosol-generating article.
[0113] The first side portion may have a thickness of less than 95% of the thickness of the aerosol-generating article. The first side portion may have a thickness of less than 90% of the thickness of the aerosol-generating article. The first side portion may have a thickness of less than 70% of the thickness of the aerosol-generating article.
[0114] The first side portion may have a thickness of 50% to 95% of the thickness of the aerosol-generating article. The first side portion may have a thickness of 70% to 95% of the thickness of the aerosol-generating article.
[0115] The second side portion may have a thickness of 50% or more of the thickness of the aerosol-generating article. The second side portion may have a thickness of 70% or more of the thickness of the aerosol-generating article. The second side portion may have a thickness of 90% or more of the thickness of the aerosol-generating article. The second side portion may have a thickness of 95% or more of the thickness of the aerosol-generating article.
[0116] The second side portion may have a thickness of less than 95% of the thickness of the aerosol-generating article. The second side portion may have a thickness of less than 90% of the thickness of the aerosol-generating article. The second side portion may have a thickness of less than 70% of the thickness of the aerosol-generating article.
[0117] The second side portion may have a thickness of 50% to 95% of the thickness of the aerosol-generating article. The second side portion may have a thickness of 70% to 95% of the thickness of the aerosol-generating article.
[0118] One or more aerosol generating substrates may include an aerosol generating substrate layer. Advantageously, the aerosol generating substrate layer may be made thin so as to rapidly heat and release a volatile compound to form an aerosol. Advantageously, the aerosol generating substrate layer may be located close to a heater of an aerosol generating device.
[0119] The aerosol generating substrate layer may comprise an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. The aerosol generating material may be in the form of a sheet of aerosol generating material. The sheet of aerosol generating material may be any sheet of aerosol generating material described herein. The aerosol generating substrate layer may be a sheet of aerosol generating material and may be manufactured entirely therefrom.
[0120] The aerosol generating substrate layer may be located between the frame and the first planar outer surface. The aerosol generating substrate layer may be located between the frame and the second planar outer surface. The aerosol generating substrate layer may be in physical contact with the frame and may be bonded to the frame.
[0121] The aerosol generating substrate layer may be positioned between the frame and the outer wrapper. The outer wrapper is discussed in more detail below. The aerosol generating substrate layer may physically contact both the frame and the outer wrapper and may be bonded thereto.
[0122] The aerosol generating substrate layer may be located between the frame and the first planar outer layer. The aerosol generating substrate layer may be located between the frame and the second planar outer layer. The first planar outer layer and the second planar outer layer are discussed in more detail below. The aerosol generating substrate layer may be in physical contact with both the frame and the first planar outer layer and may be bonded thereto. The aerosol generating substrate layer may be in physical contact with both the frame and the second planar outer layer and may be bonded thereto.
[0123] The aerosol generating substrate layer may be placed over the end of the cavity. The aerosol generating substrate layer may define or form a wall surface of the cavity, such as a first cavity end wall surface or a second cavity end wall surface. Accordingly, advantageously, the aerosol generating substrate layer may be within an airflow passage or may at least partially define or form an airflow passage, thereby enabling the released volatile compound to rapidly form an aerosol.
[0124] One or more aerosol generating substrates may include a first aerosol generating substrate layer and a second aerosol generating substrate layer. Advantageously, the first and second aerosol generating substrate layers can rapidly generate a satisfactory volume of aerosol compared to using a single aerosol generating substrate layer.
[0125] The first aerosol generating substrate may include an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. The aerosol generating material may be in the form of a sheet of aerosol generating material. The sheet of aerosol generating material may be any sheet of aerosol generating material described herein. The first aerosol generating substrate layer may be a sheet of aerosol generating material and may be manufactured entirely therefrom.
[0126] The second aerosol generating substrate layer may include an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. The aerosol generating material may be in the form of a sheet of aerosol generating material. The sheet of aerosol generating material may be any sheet of aerosol generating material described herein. The second aerosol generating substrate layer may be a sheet of aerosol generating material and may be manufactured entirely therefrom.
[0127] The first aerosol generating substrate layer may be located between the frame and the first planar outer surface. The first aerosol generating substrate layer may be in physical contact with the frame and may be bonded to the frame.
[0128] The first aerosol generating substrate layer may be located between the frame and the outer wrapper. The first aerosol generating substrate layer may physically contact both the frame and the outer wrapper and may be bonded thereto.
[0129] The first aerosol generating substrate layer may be located between the frame and the first planar outer layer. The first aerosol generating substrate layer may be in physical contact with both the frame and the first planar outer layer and may be bonded thereto.
[0130] The second aerosol generating substrate layer may be located between the frame and the second planar outer surface. The second aerosol generating substrate layer may be in physical contact with the frame and may be bonded to the frame.
[0131] The second aerosol generating substrate layer may be located between the frame and the outer wrapper. The second aerosol generating substrate layer may physically contact both the frame and the outer wrapper and may be bonded thereto.
[0132] The second aerosol generating substrate layer may be located between the frame and the second planar outer layer. The second aerosol generating substrate layer may be in physical contact with both the frame and the second planar outer layer and may be bonded thereto.
[0133] The first aerosol generating substrate layer and the second aerosol generating substrate layer may be placed on opposite ends of the cavity. The first aerosol generating substrate layer and the second aerosol generating substrate layer may define or form the wall surface of the opposite ends of the cavity. That is, the frame, the first aerosol generating substrate layer, and the second aerosol generating substrate layer may collectively define the cavity.
[0134] One or more of the aerosol generating substrate layer, the first aerosol generating substrate layer, and the second aerosol generating substrate layer may have a thickness of 100㎛ or more, 200㎛ or more, 300㎛ or more, 400㎛ or more, or 500㎛ or more.
[0135] One or more of the aerosol generating substrate layer, the first aerosol generating substrate layer, and the second aerosol generating substrate layer may have a thickness of 600㎛ or less, 500㎛ or less, 400㎛ or less, 300㎛ or less, or 300㎛ or less.
[0136] One or more of the aerosol generating substrate layer, the first aerosol generating substrate layer, and the second aerosol generating substrate layer may have a thickness of 100㎛ to 600㎛, 200㎛ to 500㎛, 200㎛ to 400㎛, or 200㎛ to 300㎛.
[0137] The aerosol generating substrate layer may have a length substantially equal to the length of the frame. The aerosol generating substrate layer may have a length substantially equal to the length of the aerosol generating article.
[0138] The first aerosol generating substrate layer may have a length substantially equal to the length of the frame. The first aerosol generating substrate layer may have a length substantially equal to the length of the aerosol generating article.
[0139] The second aerosol generating substrate layer may have a length substantially equal to the length of the frame. The second aerosol generating substrate layer may have a length substantially equal to the length of the aerosol generating article.
[0140] The aerosol generating substrate layer may have a width substantially equal to the width of the frame. The aerosol generating substrate layer may have a width substantially equal to the width of the aerosol generating article.
[0141] The first aerosol generating substrate layer may have a width substantially equal to the width of the frame. The first aerosol generating substrate layer may have a width substantially equal to the width of the aerosol generating article.
[0142] The second aerosol generating substrate layer may have a width substantially equal to the width of the frame. The second aerosol generating substrate layer may have a width substantially equal to the width of the aerosol generating article.
[0143] The first planar outer surface may be a planar upper surface, and the second planar outer surface may be a planar lower surface. The first planar outer surface may be positioned parallel to the second planar outer surface. The first planar outer surface may extend in the x / y plane. The second planar outer surface may extend in the x / y plane. The second planar outer surface may be spaced apart from the first planar outer surface in the z direction or the transverse direction. The distance between the first planar outer surface and the second planar outer surface in the z direction or the transverse direction may define the thickness of the aerosol-generating article.
[0144] The aerosol-generating article may include an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may contain a hydrophobic material.
[0145] The outer wrapper may define or form a first planar outer surface. The outer wrapper may define or form a second planar outer surface. The outer wrapper may define or form both the first planar outer surface and the second planar outer surface.
[0146] The outer wrapper may surround or encircle the frame. The outer wrapper may physically contact the frame and may be bonded to the frame. The outer wrapper may be placed over the opposing end of the cavity. The outer wrapper may define or form opposing end walls of the cavity, such as a first cavity end wall and a second cavity end wall. That is, the frame and the outer wrapper may collectively define the cavity.
[0147] The outer wrapper may surround or encircle the substrate wrapper. The outer wrapper may surround or encircle the substrate wrapper, the aerosol generating substrate, and the first and second end portions. The outer wrapper may physically contact the substrate wrapper and may be bonded to the frame. The outer wrapper may physically contact the substrate wrapper, the first end portion, and the second end portion, and may be bonded thereto.
[0148] The outer wrapper may surround or encircle the frame and the aerosol generating substrate layer. The outer wrapper may physically contact both the frame and the aerosol generating substrate layer and may be bonded thereto.
[0149] The outer wrapper may surround or enclose the frame, the first aerosol generating substrate layer, and the second aerosol generating substrate layer. The outer wrapper may physically contact both the first aerosol generating substrate layer and the second aerosol generating substrate layer and may be bonded thereto.
[0150] The aerosol generating article may include a first planar outer layer and a second planar outer layer. The first planar outer layer may be an upper layer, and the second planar outer layer may be a lower layer.
[0151] The first planar outer layer may define or form a first planar outer surface. The first planar outer layer may extend in the x / y plane. The second planar outer layer may define or form a second planar outer surface. The second planar outer layer may extend in the x / y plane.
[0152] The first planar outer layer can physically contact the frame and can be bonded to the frame. The first planar outer layer can be placed over the end of the cavity. The first planar outer layer can define or form a wall surface of the cavity such as the wall surface of the first cavity end.
[0153] The second planar outer layer can physically contact the frame and can be bonded to the frame. The second planar outer layer can be placed over the end of the cavity. The second planar outer layer can define or form a wall surface of the cavity, such as the wall surface of the second cavity end.
[0154] The first planar outer layer and the second planar outer layer may be placed on the opposing ends of the cavity. The first planar outer layer and the second planar outer layer may define or form the opposing end walls of the cavity, such as the first cavity end wall and the second cavity end wall. That is, the frame, the first planar outer layer, and the second planar outer layer may collectively define the cavity.
[0155] The first planar outer layer may be spaced apart from the frame, for example, in the horizontal direction. For example, the aerosol generating substrate layer or the first aerosol generating substrate layer may be located between the first planar outer layer and the frame. The first planar outer layer may be in physical contact with the aerosol generating substrate layer or the first aerosol generating substrate layer and may be bonded thereto.
[0156] The second planar outer layer may be spaced apart from the frame, for example, in the horizontal direction. For example, the aerosol generating substrate layer or the second aerosol generating substrate layer may be located between the second planar outer layer and the frame. The second planar outer layer may be in physical contact with and bonded to the aerosol generating substrate layer or the second aerosol generating substrate layer.
[0157] The first planar outer layer may be hydrophobic. The first planar outer layer may include a hydrophobic material. The second planar outer layer may be hydrophobic. The second planar outer layer may include a hydrophobic material.
[0158] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may include a cellulose material or may be manufactured from a cellulose material. The cellulose material may be paper, cigarette paper, tobacco paper, cardboard, wood, fabric, natural fiber, or artificial fiber.
[0159] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may be an aerosol generating substrate comprising an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. In particular, the aerosol generating material may be in the form of a sheet of the aerosol generating material. The sheet of the aerosol generating material may be any sheet of the aerosol generating material described herein. Alternatively, one or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may not include any aerosol generating material, particularly in an embodiment comprising an aerosol generating substrate layer, a first aerosol generating substrate layer, a second aerosol generating substrate layer, or an aerosol generating substrate located within a cavity. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may be substantially nicotine-free.
[0160] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness of 25㎛ or more, 30㎛ or more, 35㎛ or more, 40㎛ or more, or 45㎛ or more.
[0161] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness of 55㎛ or less, 50㎛ or less, 45㎛ or less, 40㎛ or less, or 35㎛ or less.
[0162] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness of 25㎛ to 55㎛, 25㎛ to 45㎛, or 30㎛ to 45㎛.
[0163] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length substantially equal to the length of the frame. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length substantially equal to the length of the aerosol-generating article.
[0164] One or more of the first planar outer layer and the second planar outer layer may have a width substantially equal to the width of the frame. One or more of the first planar outer layer and the second planar outer layer may have a width substantially equal to the width of the aerosol-generating article.
[0165] The cavity may have a thickness of 0.5 mm or more. The cavity may have a thickness of 1.5 mm or more. The cavity may have a thickness of 2.5 mm or more. The cavity may have a thickness of 3.5 mm or more.
[0166] The cavity may have a thickness of 4.5 mm or less. The cavity may have a thickness of 3.5 mm or less. The cavity may have a thickness of 2.5 mm or less. The cavity may have a thickness of 1.5 mm or less.
[0167] The cavity may have a thickness of 0.5 mm to 4.5 mm. The cavity may have a thickness of 1 mm to 4.5 mm. Preferably, the cavity may have a thickness of 2.8 mm to 3.3 mm.
[0168] The cavity may have a length of 14 mm or more. The cavity may have a length of 18 mm or more. The cavity may have a length of 22 mm or more. The cavity may have a thickness of 30 mm or more. The cavity may have a thickness of 38 mm or more.
[0169] The cavity may have a length of 40 mm or less. The cavity may have a thickness of 34 mm or less. The cavity may have a thickness of 28 mm or less. The cavity may have a thickness of 22 mm or less. The cavity may have a thickness of 18 mm or less.
[0170] The cavity may have a length of 14 mm to 40 mm. The cavity may have a length of 14 mm to 34 mm. The cavity may have a length of 24 mm to 28 mm.
[0171] The cavity may have a width of 4.5 mm or more. The cavity may have a width of 7 mm or more. The cavity may have a width of 11 mm or more.
[0172] The cavity may have a width of 13 mm or less. The cavity may have a width of 11 mm or less. The cavity may have a width of 7 mm or less. The cavity may have a width of 5 mm or less.
[0173] The cavity may have a width of 4.5 mm to 13 mm. The cavity may have a width of 7 mm to 10 mm. The cavity may have a width of 7.5 mm to 8.5 mm.
[0174] The cavity may have a length of 14 mm to 40 mm, a width of 4.5 mm to 13 mm, and a thickness of 0.5 mm to 4.5 mm.
[0175] Preferably, the cavity may have a length of 20 mm to 30 mm, a width of 7 mm to 10 mm, and a thickness of 2.5 mm to 4 mm.
[0176] Most preferably, the cavity may have a length of 26 mm, a width of 8 mm, and a thickness of 3.1 mm.
[0177] The cavity may have a volume of 30 mm³ or more, 100 mm³ or more, 300 mm³ or more, 500 mm³ or more, 700 mm³ or more, 900 mm³ or more, 1000 mm³ or more, 2000 mm³ or more, or 30 mm³ or more.
[0178] The cavity may have a volume of 3500 mm³ or less, 2500 mm³ or less, 1500 mm³ or less, 1000 mm³ or less, 800 mm³ or less, 600 mm³ or less, 500 mm³ or less, 400 mm³ or less, or 300 mm³ or less.
[0179] The cavity may have a volume of 30 mm³ to 3500 mm³. The cavity may have a volume of 30 mm³ to 2500 mm³. The cavity may have a volume of 100 mm³ to 1500 mm³. The cavity may have a volume of 100 mm³ to 1000 mm³.
[0180] The common area can be practically empty.
[0181] One or more aerosol generating materials may include an aerosol generating material located within a cavity. The aerosol generating material located within the cavity may fill the cavity.
[0182] An aerosol generating material located within the cavity may include an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. For example, the aerosol generating material may be in the form of shredded aerosol generating material.
[0183] The aerosol generating material may be in the form of a sheet of the aerosol generating material. The sheet of the aerosol generating material may be any sheet of the aerosol generating material described herein. For example, the sheet of the aerosol generating material may be a sheet of homogenized tobacco material.
[0184] A sheet of aerosol-generating material can extend along the entire length of the cavity. A sheet of aerosol-generating material can extend along the entire width of the cavity.
[0185] The sheet of aerosol generating material may be a corrugated sheet of aerosol generating material. That is, the sheet of aerosol generating material may be wavy, folded, otherwise compressed or shrunk substantially perpendicular to the transverse direction of the aerosol generating article.
[0186] The sheet of aerosol generating material may be a crimped sheet of aerosol generating material. The sheet of aerosol generating material may be a wavy sheet of aerosol generating material. The crimped sheet of aerosol generating material or the wavy sheet of aerosol generating material may include a plurality of parallel wavy folds. For example, the crimped sheet of aerosol generating material may include a plurality of substantially parallel peaks and valleys.
[0187] Multiple parallel ripples can be defined by a ripple profile, where the ripple profile is sinusoidal, triangular, rectangular, trapezoidal, toroidal, or parabolic.
[0188] Multiple parallel wavy folds may define or form multiple channels between a sheet of aerosol-generating material and one or more walls of a cavity. The multiple channels may be multiple longitudinally extending channels. The multiple channels may be multiple laterally extending channels. The multiple channels may define or form at least a portion of an airflow passage extending between an air inlet and an air outlet of an aerosol-generating article.
[0189] The aerosol generating material may include one or more organic materials such as tobacco, mint, tea, and cloves. The aerosol generating material may include one or more of herb leaves, tobacco leaves, tobacco rib pieces, reconstituted tobacco, homogenized tobacco such as cast leaves, extruded tobacco, puffed tobacco, aerosol generating films, and gel compositions.
[0190] The aerosol generating material may be in the form of shredded aerosol generating material. The shredded aerosol generating material may include: one or more strips and strands of the aerosol generating material, such as strips and strands of tobacco or homogenized tobacco material. The shredded aerosol generating material may be in the form of shredded sheets of homogenized tobacco material.
[0191] The aerosol-generating material may be tobacco sticks. The aerosol-generating material may be tobacco sticks. Tobacco sticks may include one or more of bright tobacco, dark tobacco, flavored tobacco, and filler tobacco. Examples of bright tobacco are Brazilian yellow tobacco, Indian yellow tobacco, Chinese yellow tobacco, American yellow tobacco such as Virginia tobacco, and Tanzanian yellow tobacco. Examples of flavored tobacco include Oriental Turkish tobacco, Greek Oriental tobacco, and semi-Oriental tobacco, as well as American Burley smoked tobacco such as Perique and Rustica. Examples of dark tobacco are dark-cured Brazilian Galpao, Burley Malawi or other African Burley, and sun-cured or air-cured Indonesian Kasturi. As used herein, the term “cut-cut” is used to describe a blend of chopped plant material, such as tobacco plant material or homogenized plant material, comprising one or more of leaf blades, processed stems, and ribs.
[0192] The aerosol generating material may be in the form of a sheet of the aerosol generating material. As used herein, the term “sheet” describes a laminated element in which the width and length are substantially greater than the thickness. The sheet of the aerosol generating material may be a sheet of plant material. The sheet of the aerosol generating material may be a sheet of tobacco material. The sheet of the aerosol generating material may be a sheet of homogenized tobacco material, such as a cast leaf sheet.
[0193] The aerosol generating material may comprise one or more aerosol-forming agents. Suitable aerosol-forming agents are known in the art and include, but are not limited to, polyhydric alcohols such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable that the aerosol-forming agent be one or both of glycerin and propylene glycol, or comprise them. The aerosol-forming agent may consist of glycerin or propylene glycol, or a combination of glycerin and propylene glycol.
[0194] The aerosol generating material may have an aerosol forming agent content of 15% or more based on dry weight, for example, more than 20% based on dry weight, or more than 25% based on dry weight, or more than 30% based on dry weight, or more than 40% based on dry weight, or more than 50% based on dry weight.
[0195] The aerosol generating material may have an aerosol forming agent content of 30% by weight or less based on dry weight, 25% by weight or less based on dry weight, or 20% by weight or less based on dry weight.
[0196] The aerosol generating material may have an aerosol forming agent content of 5% to 30% by weight based on dry weight, 5% to 25% by weight based on dry weight, or 5% to 20% by weight based on dry weight.
[0197] The aerosol generating material may have an aerosol forming agent content of 10% to 30% by weight based on dry weight, 10% to 25% by weight based on dry weight, or 10% to 20% by weight based on dry weight.
[0198] The aerosol generating material may contain nicotine. The aerosol generating material may contain natural nicotine, synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.
[0199] The aerosol generating material may contain at least 0.5% by weight of nicotine, at least 1% by weight of nicotine, at least 1.5% by weight of nicotine, or at least 2% by weight of nicotine. That is, the aerosol generating material may have a nicotine content of at least 0.5% by weight, at least 1% by weight, at least 1.5% by weight, or at least 2% by weight.
[0200] The aerosol generating material may include one or more flavoring agents. One or more flavoring agents may include one or more essential oils such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and one or more herbal materials. Suitable herbal materials include, but are not limited to, mints such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway, and other herbal materials derived from herb leaves or herbal plants. One or more flavoring agents may include tobacco materials.
[0201] The aerosol generating material may contain one or more plant components. For example, the aerosol generating material may contain about 15 to 55%, preferably about 20 to 35%, of plant components, such as cloves, echinacea species, fennel, ginger, hawthorn berries, elderberries, monarda, mullein leaves, nettle, plantain, turmeric, yarrow, and compounds thereof.
[0202] An air inlet may be defined by the front wall surface of the aerosol-generating article. An air inlet may be defined by a frame and may extend through the frame. An air inlet may be defined by the periphery wall surface of the frame. An air inlet may extend through the periphery wall surface of the frame. An air outlet may be defined by the rear wall surface of the aerosol-generating article. An air outlet may be defined by a frame and may extend through the frame. An air outlet may be defined by the periphery wall surface of the frame. An outlet may extend through the periphery wall surface of the frame.
[0203] The air inlet may have a round cross-section, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section. The air outlet may have a round cross-section, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section.
[0204] An air inlet may be defined by a first planar outer surface and may extend through it. An air inlet may be defined by an outer wrapper and may extend through it. An air inlet may be defined by an outer wrapper and an aerosol generating substrate layer and may extend through it. An air inlet may be defined by an outer wrapper and a first aerosol generating substrate layer and may extend through it. An air inlet may be defined by a first planar outer layer and an aerosol generating substrate layer and may extend through it. An air inlet may be defined by a first planar outer layer and a first aerosol generating substrate layer and may extend through it.
[0205] An air inlet may be defined by a second planar outer surface and may extend through it. An air inlet may be defined by an outer wrapper and a second aerosol generating substrate layer and may extend through it. An air inlet may be defined by a second planar outer layer and an aerosol generating substrate layer and may extend through it. An air inlet may be defined by a second planar outer layer and a second aerosol generating substrate layer and may extend through it.
[0206] An air outlet can be defined by a first planar outer surface and can be extended through it. An air outlet can be defined by an outer wrapper and can be extended through it. An air outlet can be defined by an outer wrapper and an aerosol generating substrate layer and can be extended through it. An air outlet can be defined by an outer wrapper and a first aerosol generating substrate layer and can be extended through it. An air outlet can be defined by a first planar outer layer and an aerosol generating substrate layer and can be extended through it. An air outlet can be defined by a first planar outer layer and a first aerosol generating substrate layer and can be extended through it.
[0207] An air outlet may be defined by a second planar outer surface and may extend through it. An air outlet may be defined by an outer wrapper and a second aerosol generating substrate layer and may extend through it. An air outlet may be defined by a second planar outer layer and an aerosol generating substrate layer and may extend through it. An air outlet may be defined by a second planar outer layer and a second aerosol generating substrate layer and may extend through it.
[0208] One or both of the air inlet and air outlet may have an equivalent diameter of 0.1 mm or more, 0.4 mm or more, 0.7 mm or more, or 1.0 mm or more.
[0209] One or both of the air inlet and the air outlet may have an equivalent diameter of 3 mm or less, 2.7 mm or less, 2.4 mm or less, or 2.1 mm or less. The air inlet may have an equivalent diameter of 2.7 mm or less, 1.8 mm or less, or 1.5 mm or less.
[0210] One or both of the air inlet and the air outlet may have an equivalent diameter of 0.1 mm to 3 mm, 0.1 mm to 2.4 mm, 0.4 mm to 2.1 mm, 0.4 mm to 1.8 mm, 0.7 mm to 1.5 mm, or 1.0 mm to 1.5 mm.
[0211] The air inlet may have a width narrower than the width of the cavity. The air outlet may have a width narrower than the width of the cavity. The air inlet may have a thickness thinner than the thickness of the cavity. The air outlet may have a thickness thinner than the thickness of the cavity.
[0212] One or both of the air inlet and the air outlet may have a width of 0.3 mm to 3 mm or 0.5 mm to 2 mm.
[0213] One or both of the air inlet and the air outlet may have a thickness of 0.3 mm to 3 mm or 0.5 mm to 2 mm.
[0214] Preferably, the air inlet may have a width of 0.3 mm to 3 mm and a thickness of 0.3 mm to 3 mm.
[0215] Preferably, the air outlet may have a width of 0.3 mm to 3 mm and a thickness of 0.3 mm to 3 mm.
[0216] Advantageously, an aerosol generating article having an air outlet or air inlet having a width of 0.3 mm to 3 mm and a thickness of 0.3 mm to 3 mm can provide a relatively large inlet or outlet opening while allowing improved retention of the aerosol generating material within the aerosol generating article. Improved retention of the aerosol generating material within the aerosol generating article can reduce the risk of the aerosol generating material falling out of the aerosol generating article.
[0217] The ratio of the width of the air inlet to the thickness of the air inlet may be 0.33 to 3. The ratio of the width of the air inlet to the thickness of the air inlet may be 0.5 to 1.5. The ratio of the width of the air inlet to the thickness of the air inlet may be 0.75 to 1.25.
[0218] The ratio of the width of the air outlet to the thickness of the air outlet may be 0.33 to 3. The ratio of the width of the air outlet to the thickness of the air outlet may be 0.5 to 1.5. The ratio of the width of the air outlet to the thickness of the air outlet may be 0.75 to 1.25.
[0219] An aerosol generating article may include a plurality of air inlets. One or each of the air inlets may have one or more of the features of the air inlets described herein.
[0220] An aerosol generating article may include a plurality of air outlets. One or each of the air outlets may have one or more of the features of the air outlets described herein.
[0221] The aerosol generating article may include a filter element located downstream of an aerosol forming substrate. The aerosol generating article may include a filter element located downstream of a cavity. The aerosol generating article may include a filter element located at least partially within an air outlet. The aerosol generating article may include a filter element located within a cavity and may be located at the downstream end of the cavity.
[0222] The aerosol generating article may include a filter element located upstream of the aerosol forming substrate. The aerosol generating article may include a filter element located upstream of the cavity. The aerosol generating article may include a filter element located at least partially within the air inlet. The aerosol generating article may include a filter element located within the cavity and may be located at the upstream end of the cavity.
[0223] The filter element may comprise one or more filter segments of a fibrous filtration material. Suitable fibrous filtration materials will be known to those skilled in the art. The filter element may comprise cellulose acetate.
[0224] The ratio between the length and thickness of the aerosol-generating article and between the width and thickness of the aerosol-generating article may be greater than 2:1, greater than 5:1, greater than 10:1, greater than 12:1, or greater than 15:1.
[0225] The ratio between the length and thickness of the aerosol-generating article and between the width and thickness of the aerosol-generating article may be less than 15:1, less than 12:1, less than 10:1, less than 5:1, or less than 2.5:1.
[0226] The ratio between the length and thickness of the aerosol-generating article and between the width and thickness of the aerosol-generating article may be 2:1 to 15:1, 2:1 to 12:1, 2:1 to 10:1, or 5:1 to 10:1.
[0227] The ratio between the length and width of an aerosol-generating article may be greater than 1:1, greater than 2:1, greater than 3:1, greater than 4:1, or greater than 5:1.
[0228] The ratio between the length and width of an aerosol-generating article may be less than 10:1, less than 8:1, less than 5:1, less than 4:1, less than 3:1, or less than 2:1.
[0229] The ratio between the length and width of the aerosol-generating article may be 1:1 to 10:1, 1:1 to 5:1, 1:1 to 4:1, 1:1 to 3:1, 2:1 to 4:1, or 2:1 to 3:1.
[0230] Aerosol-generating articles may have a length of 15 mm or more, 20 mm or more, 25 mm or more, 30 mm or more, 35 mm or more, or 40 mm or more.
[0231] Aerosol-generating articles may have a length of 45 mm or less, 40 mm or less, 35 mm or less, or 30 mm or less.
[0232] The aerosol generating article may have a length of 15 mm to 45 mm, 20 mm to 40 mm, 20 mm to 35 mm, or 25 mm to 30 mm.
[0233] Aerosol-generating articles may have a width of 3 mm or more, greater than 5 mm, greater than 7.5 mm, greater than 9 mm, greater than 11 mm, or greater than 13 mm.
[0234] Aerosol-generating articles may have a width of 17 mm or less, 15 mm or less, 12.5 mm or less, 11 mm or less, or 9 mm or less.
[0235] The aerosol generating article may have a width of 3 mm to 17 mm, 5 mm to 15 mm, 7.5 mm to 12.5 mm, or 9 mm to 11 mm.
[0236] Aerosol-generating articles may have a thickness of 1 mm or more, 1.5 mm or more, 2 mm or more, 2.5 mm or more, 3 mm or more, 3.5 mm or more, 4 mm or more, or 4.5 mm or more.
[0237] Aerosol-generating articles may have a thickness of 5.5 mm or less, 5 mm or less, 4.5 mm or less, 4 mm or less, 3.5 mm or less, 3 mm or less, 2.5 mm or less, or 2 mm or less.
[0238] The aerosol generating article may have a thickness of 1 mm to 5 mm, 1.5 mm to 5 mm, 2 mm to 4.5 mm, 2.5 mm to 4 mm, or 3 mm to 3.5 mm.
[0239] According to the present disclosure, an aerosol generating device for receiving an aerosol generating article as described herein is provided. The aerosol generating device comprises a cavity dimensioned to receive at least a portion of the aerosol generating article. The aerosol generating device comprises 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. The aerosol generating device is configured to heat at least one of one or more aerosol generating substrates to form an aerosol, e.g., an inhalable aerosol. The aerosol generating device may be configured to heat each of one or more aerosol generating substrates to form an aerosol, e.g., an inhalable aerosol.
[0240] According to the present disclosure, an aerosol generating system comprises an aerosol generating device as disclosed herein and an aerosol generating article as disclosed herein. The system may include a plurality of such articles for use with the aerosol generating device.
[0241] As used herein, the term "aerosol generating article" refers to an article comprising an aerosol generating material. The article can be heated upon use to generate an inhalable aerosol and deliver it to a consumer.
[0242] As used herein, the term "aerosol generating material" refers to a material capable of releasing a volatile compound upon heating, for example, a compound that generates an aerosol upon cooling and condensation when in use.
[0243] As used herein, the term "aerosol generating device" refers to a device that, when in use, interacts with an aerosol generating substrate of an aerosol generating article to generate an aerosol, for example, by heating it.
[0244] As used herein, the term “planar” may generally refer to a feature formed on a single Euclidean plane that is not wrapped around a curved non-planar shape or other non-planar shape, or otherwise is not conformed to be fitted with it. A planar surface extends two dimensions in a single Euclidean plane. A planar object extends two dimensions in a single Euclidean plane substantially further than at a third dimension perpendicular to the plane. More specifically, a planar object may extend at least two, five, or ten times further to a first dimension and a second dimension perpendicular to the first dimension than to a third dimension perpendicular to the first dimension.
[0245] As used herein, the term "transverse direction" refers to the direction extending between the first planar outer surface and the second planar outer surface. The transverse direction may also be referred to as the "z direction."
[0246] As used herein, the term "longitudinal direction" refers to a direction perpendicular to the transverse direction. For example, it is the direction between the front and rear walls of an aerosol-generating article. The longitudinal direction may also be referred to as the "x-direction."
[0247] As used herein, the term "lateral direction" refers to a direction perpendicular to the transverse and longitudinal directions. For example, it is the direction from the first side wall to the second side wall of an aerosol-generating article. The lateral direction may also be referred to as the "y-direction."
[0248] As used herein, the term "thickness" refers to the maximum dimension in the transverse direction of an aerosol-generating article or a component of an aerosol-generating article.
[0249] As used herein, the term "length" refers to the maximum longitudinal dimension of an aerosol-generating article or a component of an aerosol-generating article.
[0250] As used herein, the term "width" refers to the maximum lateral dimension of an aerosol-generating article or a component of an aerosol-generating article.
[0251] As used herein, the terms “upstream” and “downstream” refer to the relative positions of a component or part of a component of an aerosol generating article with respect to the direction in which air or aerosol is transported through the aerosol generating article during use.
[0252] As used herein, the term "bulk density" may refer to the total weight of an aerosol generating material divided by the bulk volume of the aerosol generating material.
[0253] As used herein, the term "aerosol-forming agent" may refer to any suitable known compound or mixture of compounds that facilitates the formation of an aerosol upon use. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal decomposition at the operating temperature of the aerosol-generating substrate or aerosol-generating article.
[0254] As used herein, the term "aerosol-forming agent content" may refer to the aerosol-forming agent content as a percentage based on dry weight, unless otherwise specified.
[0255] As used herein, "susceptor" refers to a conductive element that heats up when affected by a variable magnetic field. This may be the result of eddy currents and / or hysteresis losses induced within the susceptor element.
[0256] As used herein, the term "hydrophobic" refers to a surface that exhibits water repellency. One useful method for determining hydrophobicity is to measure the water contact angle. The "water contact angle" is the angle at which the liquid / vapor interface meets the solid surface, typically measured through a liquid. The water contact angle quantifies the wettability of a solid surface by a liquid using Young's equation.
[0257] As used herein, the term "equivalent diameter" of an opening or perforation is used herein to denote the diameter of a circular opening or perforation having the same cross-sectional area as the opening or perforation.
[0258] The present invention is defined in the claims. However, a non-limiting, non-comprehensive list of embodiments is provided below. Any one or more features of these embodiments may be combined with any one or more features of other embodiments, embodiments, or aspects described herein.
[0259] Ex1. As an aerosol generating article for generating aerosols by use with an aerosol generating device, the aerosol generating article is:
[0260] First planar outer surface;
[0261] Second planar outer surface;
[0262] A frame located between a first planar outer surface and a second planar outer surface; and
[0263] Includes an air inlet and an air outlet,
[0264] The above frame includes a first side portion and a second side portion, wherein the first side portion and the second side portion at least partially define the cavity and extend from the air inlet to the air outlet along the longitudinal axis of the aerosol generating article, and
[0265] An aerosol generating article in which the first side portion is a supporting element and the second side portion is a supporting element.
[0266] Ex2. An aerosol generating article in Ex1, wherein the first side portion is a rigid support element and the second side portion is a rigid support element.
[0267] Ex3. An aerosol generating article in Ex1 or Ex2, wherein at least one of the first side portion and the second side portion has a length of 20 mm or more.
[0268] Ex4. In Ex3, the first side portion and the second side portion each have a length of 20 mm or more, an aerosol generating article.
[0269] Ex5. An aerosol generating article in any one of Ex1 to Ex4, wherein at least one of the first side portion and the second side portion has a length of less than 40 mm.
[0270] Ex6. In Ex5, the first side portion and the second side portion each have a length of less than 40 mm, an aerosol generating article.
[0271] Ex7. An aerosol generating article in any one of Ex1 to Ex5, wherein at least one of the first side portion and the second side portion has a length of 25 mm to 35 mm.
[0272] Ex8. An aerosol generating article in any one of Ex1 to Ex7, wherein the first side portion and the second side portion each have a length of 25 mm to 35 mm.
[0273] Ex9. An aerosol generating article in any one of Ex1 to Ex8, wherein at least one of the first side portion and the second side portion has a width of 1.5 mm or more.
[0274] Ex10. In Ex9, the first side portion and the second side portion each have a width of 1.5 mm or more, an aerosol generating article.
[0275] Ex11. An aerosol generating article in any one of Ex1 to Ex6, wherein at least one of the first side portion and the second side portion has a width of 3.5 mm or less.
[0276] Ex12. In Ex11, the first side portion and the second side portion each have a width of 3.5 mm or less, an aerosol generating article.
[0277] Ex13. An aerosol generating article according to any one of claims 1 to 7, wherein at least one of the first side portion and the second side portion has a width of 2 mm to 3 mm.
[0278] Ex14. In Ex13, the first side portion and the second side portion each have a width of 2 mm to 3 mm, an aerosol generating article.
[0279] Ex15. An aerosol generating article in any one of Ex1 to Ex14, wherein at least one of the first side portion and the second side portion has a thickness of 1.5 mm or more.
[0280] Ex16. In Ex15, the first side portion and the second side portion each have a thickness of 1.5 mm or more, an aerosol generating article.
[0281] Ex17. An aerosol generating article in any one of Ex1 to Ex16, wherein at least one of the first side portion and the second side portion has a thickness of 3.5 mm or less.
[0282] Ex18. In Ex17, the first side portion and the second side portion each have a thickness of 3.5 mm or less, an aerosol generating article.
[0283] Ex19. An aerosol generating article, wherein in any one of Ex1 to Ex18, at least one of the first side portion and the second side portion has a thickness of 2 mm to 3 mm.
[0284] Ex20. An aerosol generating article in any one of Ex1 to Ex19, wherein the first side portion and the second side portion each have a thickness of 2 mm to 3 mm.
[0285] Ex21. An aerosol generating article, wherein in any one of Ex1 to Ex20, the first side portion is a first side wall surface.
[0286] Ex22. An aerosol generating article, wherein in any one of Ex1 to Ex21, the second side portion is a second side wall surface.
[0287] Ex23. An aerosol generating article comprising one or more aerosol generating materials in any one of Ex1 to Ex22.
[0288] Ex24. In Ex23, at least one of the above-mentioned one or more aerosol generating materials is located within a cavity, an aerosol generating article.
[0289] Ex25. In Ex24, the aerosol generating material located within the above cavity is an aerosol generating article comprising a tobacco stick.
[0290] Ex26. An aerosol generating article in any one of Ex1 to Ex25, wherein at least one of the first side portion and the second side portion comprises at least one wavy fold.
[0291] Ex27. An aerosol generating article in Ex26, wherein the first side portion comprises at least one wavy fold and the second side portion comprises at least one wavy fold.
[0292] Ex28. An aerosol generating article in Ex26 or Ex27, wherein the at least one wavy fold comprises a plurality of wavy folds.
[0293] Ex29. An aerosol generating article in any one of Ex1 to Ex28, wherein at least one of the first side portion and the second side portion comprises one or more aerosol generating materials.
[0294] Ex30. An aerosol generating article in Ex29, wherein the first side portion comprises one or more aerosol generating materials and the second side portion comprises one or more aerosol generating materials.
[0295] Ex31. In Ex29 or Ex30, the one or more aerosol generating materials comprise an aerosol generating material comprising a homogenized tobacco material, an aerosol generating article.
[0296] Ex32. In Ex31, the homogenized tobacco material comprises one or more strips of homogenized tobacco material, an aerosol generating article.
[0297] Ex33. In Ex31 or Ex32, the homogenized tobacco material comprises a plurality of strips of homogenized tobacco materials, an aerosol generating article.
[0298] Ex34. An aerosol generating article in any one of Ex1 to Ex33, wherein at least one of the first side portion and the second side portion extends from one end of the aerosol generating article to the other end of the aerosol generating article.
[0299] Ex35. In any one of Ex1 to Ex34, the first side portion is identical to the second side portion, an aerosol generating article.
[0300] Ex36. An aerosol generating article in any one of Ex1 to Ex35, wherein the frame comprises one or more elongated channels extending therethrough.
[0301] Ex37. An aerosol generating article according to Ex36, wherein the first side portion comprises a first elongated channel extending longitudinally therethrough.
[0302] Ex38. An aerosol generating article in Ex36 or Ex37, wherein the second side portion comprises a second elongated channel extending therethrough. Brief explanation of the drawing
[0303] Now, embodiments will be further described with reference to the drawings. FIG. 1 shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 2 shows an exploded perspective view of the aerosol generating article of FIG. 1; FIG. 3 shows an exploded perspective view of an aerosol generating article according to the present disclosure; FIG. 4 shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 5 shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 6 shows an exploded perspective view of an aerosol-generating article according to the present disclosure; FIG. 7 shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 8 shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 9 shows an exploded perspective view of the aerosol generating article of FIG. 8; FIG. 10 shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 11 shows an exploded perspective view of the aerosol generating article of FIG. 10; FIG. 12 shows a perspective view of an aerosol-generating article according to the present disclosure in the first step of a manufacturing process; FIG. 13 shows a perspective view of the aerosol-generating article of FIG. 12 in the second stage of the manufacturing process; FIG. 14 shows a perspective view of the aerosol-generating article of FIG. 12 at the third stage of the manufacturing process; FIG. 15 shows a perspective view of the aerosol-generating article of FIG. 12 at the fourth stage of the manufacturing process; FIG. 16 shows a perspective view of an aerosol-generating article according to the present disclosure in the first step of a manufacturing process; FIG. 17 shows a perspective view of the aerosol-generating article of FIG. 16 in the second stage of the manufacturing process; FIG. 18 shows a perspective view of an aerosol-generating article according to the present disclosure in the first step of a manufacturing process; FIG. 19 shows a perspective view of the aerosol-generating article of FIG. 18 in the second stage of the manufacturing process; FIG. 20 shows a perspective view of the aerosol-generating article of FIG. 18 at the third stage of the manufacturing process; FIG. 21 shows a perspective view of the aerosol-generating article of FIG. 18 at the fourth stage of the manufacturing process; FIG. 22 shows a cross-sectional view of the aerosol-generating article illustrated in FIG. 21; FIG. 23 shows a schematic cross-sectional view of an aerosol generating device according to the present disclosure; FIG. 24 shows a schematic cross-sectional view of the aerosol generating device of FIG. 23 that engages with the aerosol generating article of the present disclosure. Specific details for implementing the invention
[0304] 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).
[0305] 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.
[0306] The aerosol generating article (10) is substantially flat or substantially planar. 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) has a shape that is generally rectangular 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 using an adhesive, in particular guar gum, as will be discussed in more detail below in relation to FIG. 2.
[0307] FIG. 2 shows an exploded view of the aerosol generating article (10) of FIG. 1.
[0308] 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.
[0309] 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 cavity outer wall. 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 (13) and a rear wall (14).
[0310] The frame (50) includes a perimeter wall (51) surrounding the cavity (30). More specifically, the perimeter wall (51) is defined by the frame inner surface (52) and the frame outer surface (53). The perimeter wall (51) has a radial thickness of about 2 mm when measured between the frame inner surface (52) and the frame outer surface (53) in the x / y plane.
[0311] 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).
[0312] 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 surface (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).
[0313] FIG. 3 illustrates 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 example 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 examples, 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 milligrams.
[0314] 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).
[0315] FIG. 5 illustrates 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 comprises 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 an 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.
[0316] 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).
[0317] The first planar outer layer (24) is physically in contact with the first aerosol generating substrate layer (41) and is 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 is bonded together with an adhesive (15).
[0318] FIG. 6 illustrates an exploded view of an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 5, except that the aerosol generating substrate (40) is located within the cavity (30) as described in relation to FIG. 3. The aerosol generating substrate (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 substrate (40) fills the entire volume of the cavity (30).
[0319] 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).
[0320] FIG. 8 illustrates an aerosol generating article 10 similar to the aerosol generating article 10 of FIG. 1 and FIG. 3, except that the frame 50 is formed in a plurality of parts. In the aerosol generating article (10) of FIG. 8, the frame (50) includes a first side part (54) and a second side part (56). The frame (50) also includes a first end part (58) and a second end part (60).
[0321] The first side portion (54) and the second side portion (56) extend along the longitudinal axis of the aerosol generating article (10) from the air inlet (11) to the air outlet (12). In the embodiment of FIG. 8, the first side portion (54) and the second side portion (56) extend from one end of the aerosol generating article (10) to the other end of the aerosol generating article (10). That is, the first side portion (54) and the second side portion (56) extend from the upstream end of the aerosol generating article (10) to the downstream end of the aerosol generating article (10).
[0322] In the embodiment of FIG. 8, the first side portion (54) and the second side portion (56) have a length of 30 mm, a width of 2 mm, and a thickness of 2.7 mm.
[0323] The first side portion (54) and the second side portion (56) are rigid. In the aerosol generating article (10) of FIG. 8, the first side portion (54) and the second side portion (56) are supporting elements that provide strength to the structure of the aerosol generating article and are formed of a rigid material, in particular corrugated cardboard.
[0324] The first end portion (58) and the second end portion (60) extend transversely along the longitudinal axis of the aerosol generating article (10). The first end portion (58) and the second end portion (60) extend between the inner surfaces of the first side portion (54) and the second side portion (56) to form a frame (50).
[0325] The air inlet (11) is defined as a perforation extending through the first end portion (58). The air outlet (12) is defined as a perforation extending through the second end portion (60).
[0326] FIG. 9 shows an exploded view of the aerosol generating article (10) of FIG. 8.
[0327] FIG. 10 illustrates an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 1 and FIG. 3, except that the frame (50) is formed in a plurality of parts. In the aerosol generating article (10) of FIG. 8, the frame (50) includes a first side part (54) and a second side part (56). The frame (50) also includes a first end part (58) and a second end part (60).
[0328] The first end portion (58) and the second end portion (60) extend transversely along the longitudinal axis of the aerosol generating article (10). In the embodiment of FIG. 10, the first end portion (58) and the second end portion (60) extend from one lateral edge of the aerosol generating article (10) to the other lateral edge of the aerosol generating article (10). An air inlet (11) is defined as a perforation extending through the first end portion (58). An air outlet (12) is defined as a perforation extending through the second end portion (60).
[0329] The first side portion (54) and the second side portion (56) extend along the longitudinal axis of the aerosol generating article (10) from the air inlet (11) to the air outlet (12). In the embodiment of FIG. 10, the first side portion (54) and the second side portion (56) extend between the inner surfaces of the first end portion (58) and the second end portion (60) to form a frame (50).
[0330] The first side portion (54) and the second side portion (56) are rigid. In the aerosol generating article (10) of FIG. 10, the first side portion (54) and the second side portion (56) are supporting elements that provide strength to the structure of the aerosol generating article (10).
[0331] FIG. 11 shows an exploded view of the aerosol generating article (10) of FIG. 10.
[0332] FIGS. 12 to 15 show the manufacture of an aerosol generating article (10) according to the present disclosure.
[0333] FIG. 12 illustrates a portion of an aerosol generating article (10). The aerosol generating article (10) comprises an aerosol generating substrate (40), a first side portion (54), and a second side portion (56). The first side portion (54) and the second side portion (56) act as supporting elements for the aerosol generating substrate (40). The first side portion (54) and the second side portion (56) are elongated members located at the lateral edge of the aerosol generating substrate (40) and extending along the longitudinal axis of the aerosol generating article (10).
[0334] The aerosol generating material (40) contains an aerosol generating material in the form of a cigarette stick and has an aerosol forming agent content of 5% by weight based on dry weight.
[0335] FIG. 13 illustrates a part of the aerosol generating article (10) of FIG. 12, comprising an aerosol generating substrate (40), a first side portion (54), and a substrate wrapper (62) wrapped around a second side portion (56).
[0336] FIG. 14 illustrates a part of the aerosol generating article (10) of FIG. 13 together with the first end portion (58) and the second end portion (60).
[0337] The first end portion (58) is located at the upstream end of the first side portion (54) and the second side portion (56). The first end portion (58) is attached to the first side portion (54) and the second side portion (56). In this embodiment, the first end portion (58) is bonded to the first side portion (54) and the second side portion (56) using an adhesive. The air inlet (11) is defined through the first end portion (58).
[0338] The second end portion (60) is located at the downstream end of the first side portion (54) and the second side portion (56). The second end portion (60) is attached to the first side portion (54) and the second side portion (56). In this embodiment, the second end portion (60) is bonded to the first side portion (54) and the second side portion (56) using an adhesive. The air outlet (12) is defined through the second end portion (60).
[0339] FIG. 15 illustrates an aerosol generating article (10) comprising a portion of the aerosol generating article (10) of FIG. 14, which is packaged in an outer wrapper (64). The outer wrapper (64) defines a first flat outer surface (21) and a second flat outer surface (22).
[0340] FIG. 16 illustrates a portion of an aerosol generating article (10). The portion of the aerosol generating article (10) is similar to the portion of the aerosol generating article (10) illustrated in FIG. 12, except that the first side portion (54) and the second side portion (56) are formed from an aerosol generating substrate, in particular a homogenized tobacco material. First side
[0341] FIG. 17 illustrates a part of the aerosol generating article (10) of FIG. 16, comprising an aerosol generating substrate (40), a first side portion (54), and a substrate wrapper (62) wrapped around a second side portion (56).
[0342] The aerosol generating article (10) can be provided by joining the first end portion (58) and the second end portion (60) to the part of the aerosol generating article (10) of FIG. 17 as described above in relation to FIG. 14, and then wrapping the generated structure with an external wrapper (62) as described above in relation to FIG. 15.
[0343] FIGS. 18 to 21 show the manufacture of an aerosol generating article (10) according to the present disclosure.
[0344] FIG. 18 illustrates a portion of an aerosol generating article (10). Except that an elongated channel extends longitudinally through each of the first side portion (54) and the second side portion (56), the portion of the aerosol generating article (10) is similar to the portion of the aerosol generating article (10) of FIG. 12.
[0345] In the embodiment of FIG. 18, the first side portion (54) includes a first elongated channel (66). The first elongated channel (66) extends longitudinally through the first side portion (54) from the upstream end of the first side portion (54) to the downstream end of the first side portion (54). The second side portion (56) includes a second elongated channel (68). The second elongated channel (68) extends longitudinally through the second side portion (56) from the upstream end of the second side portion (56) to the downstream end of the second side portion (56).
[0346] FIG. 19 illustrates a part of the aerosol generating article (10) of FIG. 18, comprising an aerosol generating substrate (40), a first side portion (54), and a substrate wrapper (62) wrapped around a second side portion (56).
[0347] FIG. 20 illustrates a portion of the aerosol generating article (10) of FIG. 19 together with a first end portion (58) and a second end portion (60). The portion of the aerosol generating article in FIG. 20 is similar to the portion of the aerosol generating article (10) of FIG. 14, except that, as previously described, an elongated channel extends longitudinally through each of the first side portion (54) and the second side portion (56).
[0348] Additionally, the first end portion (58) includes a first channel (70) and a second channel (72) that extend longitudinally from the upstream end of the first end portion (58) to the downstream end of the first end portion (58). The first channel (70) and the first elongated channel (54) are positioned to be fluidly connected to each other, allowing, for example, air to flow between the first channel (70) and the first elongated channel (54). The second channel (72) and the second elongated channel (56) are positioned to be fluidly connected to each other, allowing, for example, air to flow between the second channel (72) and the second elongated channel (56).
[0349] The air outlet (12) is defined by the second end portion (60). In the aerosol generating article of FIG. 20, the air outlet (12) is wider than the air outlet (12) of the aerosol generating article of FIG. 14. The wider air outlet (12) provides a fluid connection between the air outlet (12) and the first elongated channel (66) and the second elongated channel (68). The fluid connection between the air outlet (12) and the first elongated channel (66) and the second elongated channel (68) allows air to flow, for example, between the air outlet (12) and the first elongated channel (66), and between the air outlet (12) and the second elongated channel (68).
[0350] FIG. 21 illustrates an aerosol generating article (10) comprising a portion of the aerosol generating article (10) of FIG. 18, which is packaged in an outer wrapper (64). The outer wrapper (64) defines a first flat outer surface (21) and a second flat outer surface (22).
[0351] FIG. 22 shows a cross-sectional view of the aerosol generating article (10) of FIG. 21 taken perpendicular to the longitudinal axis of the aerosol generating article (10).
[0352] FIG. 23 shows a schematic cross-sectional view of an aerosol generating device (90) configured for use with the aerosol generating article (10) described herein. The aerosol generating device (90) is an elongated aerosol generating device extending between a proximal end (91) and a distal end (92). The aerosol generating device (90) 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 in the device (90), and the cavity (1000) has an opening (1010) defined at the proximal end (91) of the device (90). The opening (1010) is rectangular in shape and is dimensioned to accommodate a cross-section of the aerosol generating article (10). The cavity (1000) includes an upper planar surface (1020) and a lower planar surface (1030). A first heater (95) is located on the upper planar surface (1020) to heat the first planar outer surface (21) of an aerosol generating article (10) inserted into the cavity (1000), and a second heater (96) is located on the lower planar surface (1030) to heat the second planar outer surface (22) of an aerosol generating article (10) inserted into the cavity (1000). The device (90) includes an air inlet (98) that defines an airflow path configured to allow air to flow from outside the device into the cavity (1000).
[0353] FIG. 24 shows a schematic cross-sectional view of the aerosol generating device (90) of FIG. 23 that engages with the aerosol generating article (10) of FIG. 1. There is almost no tolerance between the first planar outer surface (21) and the second planar outer surface (22) of the aerosol generating article (10) and the inner surface (1020, 1030) of the cavity (1000). Therefore, there is a tight fit between the aerosol generating article (10) and the aerosol generating device (90). When a consumer inserts the aerosol generating article (10) into the cavity (1000), the device can be operated. The first heater (95) heats the first planar outer surface (21) of the aerosol generating article (10), and the second heater (96) heats the second planar outer surface (22) of the aerosol generating article, and as a result, the aerosol generating material is heated. The volatile components of the aerosol generating material evaporate and condense within the cavity (30) of the aerosol generating article (10) to form an aerosol. A consumer inhales the aerosol by sucking on the end of the aerosol generating article (10) which includes an air outlet (12). Once the volatile components in the aerosol generating material are depleted, the aerosol generating article (10) is removed from the cavity (1000) and disposed of.
[0354] 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. In 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 article for generating an aerosol by use with an aerosol generating device, wherein the aerosol generating article comprises: a first planar outer surface; a second planar outer surface; a frame positioned between the first planar outer surface and the second planar outer surface; and an air inlet and an air outlet, wherein the frame comprises a first side portion and a second side portion, wherein the first side portion and the second side portion at least partially define the cavity and extend from the air inlet to the air outlet along the longitudinal axis of the aerosol generating article, and wherein the first side portion is a support element and the second side portion is a support element. Claim 2 An aerosol generating article according to claim 1, wherein the first side portion is a rigid support element and the second side portion is a rigid support element. Claim 3 An aerosol generating article according to claim 1 or 2, wherein at least one of the first side portion and the second side portion has a length of 20 mm or more. Claim 4 An aerosol generating article according to any one of claims 1 to 3, wherein at least one of the first side portion and the second side portion has a length of less than 40 mm. Claim 5 An aerosol generating article according to any one of claims 1 to 4, wherein at least one of the first side portion and the second side portion has a length of 25 mm to 35 mm. Claim 6 An aerosol generating article according to any one of claims 1 to 5, wherein at least one of the first side portion and the second side portion has a width of 1.5 mm or more. Claim 7 An aerosol generating article according to any one of claims 1 to 6, wherein at least one of the first side portion and the second side portion has a width of 3.5 mm or less. Claim 8 An aerosol generating article according to any one of claims 1 to 7, wherein at least one of the first side portion and the second side portion has a thickness of 1.5 mm or more. Claim 9 An aerosol generating article according to any one of claims 1 to 8, wherein at least one of the first side portion and the second side portion has a thickness of 3.5 mm or less. Claim 10 An aerosol generating article according to any one of claims 1 to 9, wherein at least one of the first side portion and the second side portion comprises at least one wavy fold. Claim 11 An aerosol generating article according to any one of claims 1 to 10, wherein at least one of the first side portion and the second side portion comprises one or more aerosol generating materials. Claim 12 In claim 11, the above one or more aerosol generating materials are an aerosol generating article comprising an aerosol generating material comprising a homogenized tobacco material. Claim 13 An aerosol generating article according to any one of claims 1 to 12, wherein the frame comprises one or more elongated channels extending therethrough. Claim 14 In paragraph 13, the aerosol generating article, wherein the first side portion comprises a first elongated channel extending longitudinally through it. Claim 15 An aerosol generating article according to claim 13 or 14, wherein the second side portion comprises a second elongated channel extending therethrough.