Aerosol generating items

Abstract

An aerosol generating article (300) for use with an aerosol generating device to generate an aerosol. The aerosol generating article (300) comprises a substrate sheet (330) comprising an aerosol forming substrate (334) for generating an aerosol, wherein the substrate sheet is rolled to form a roll-type substrate sheet (332). The aerosol generating article (300) is defined by an article length, an article width, and an article thickness, wherein the article length and article width are at least twice the article thickness. An aerosol generating system is also provided.

Description

Technology Field

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

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

[0003] However, a significant portion of the aerosol-forming material within these cylindrical aerosol-generating articles may not be heated sufficiently to form an aerosol during use. This is undesirable because the insufficiently heated portion of the aerosol-forming material increases the manufacturing and transportation costs of the aerosol-generating article but does not contribute to the aerosol delivered to the end user. This may apply regardless of how the aerosol-forming material is heated, for example, whether a resistive or inductive heater is used, and whether the aerosol-forming material is heated from the inside or the outside. 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. During the manufacturing process, the aerosol-forming material may be lost or wasted.

[0004] The object of the present disclosure is to provide an aerosol generating article, wherein a larger portion of the aerosol-forming substrate of the aerosol generating article is heated sufficiently to form an aerosol during use. Additionally, the object of the present disclosure is to provide an aerosol generating article that can be manufactured relatively efficiently and inexpensively. It may be desirable to provide an aerosol generating article that can be manufactured with reduced loss or waste of the aerosol-forming substrate.

[0005] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol. The aerosol generating article may include a substrate sheet comprising an aerosol forming substrate for generating an aerosol. The substrate sheet may be a roll-type substrate sheet. The aerosol generating article may have an article length, an article width, and an article thickness. The article thickness may be smaller than the article length. The article thickness may be smaller than the article width. The article length and article width may be at least twice the article thickness.

[0006] According to a first aspect of 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 substrate sheet comprising an aerosol forming substrate for generating an aerosol. The substrate sheet may be a roll-type substrate sheet. The aerosol generating article may be defined by an article length, an article width, and an article thickness, wherein the article length and article width are at least twice the article thickness.

[0007] Advantageously, a smaller height may allow for a smaller temperature gradient or difference across the height of the aerosol-generating article during heating. For example, if the base of the aerosol-generating article is in contact with a flat heater and heated by it, a smaller gap or height between the base and the upper surface may result in a smaller temperature difference between the base and the upper surface facing the base. Advantageously, this may minimize the risk of the hottest part of the material closest to the heater burning, while enabling a greater proportion of the aerosol-forming material of the aerosol-generating article to be heated to the temperature at which the aerosol is released. Alternatively, or additionally, this may reduce the time required to heat the aerosol-forming material sufficiently to release the aerosol.

[0008] Advantageously, providing an aerosol generating article comprising a roll-type substrate sheet enables the aerosol generating article to be manufactured on a high-speed production line. The aerosol generating article can be assembled in very few steps.

[0009] Advantageously, providing an aerosol generating article comprising a roll-type substrate sheet containing an aerosol-forming substrate can cause the aerosol-forming substrate to be less lost and less wasted during the manufacturing process. Advantageously, providing an aerosol generating article comprising a roll-type substrate sheet containing an aerosol-forming substrate can reduce the risk of leakage of the aerosol-forming substrate from the aerosol generating article.

[0010] Advantageously, the roll-type substrate sheet can provide tension to the aerosol-generating article, thereby providing mechanical support to the aerosol-generating article.

[0011] For the purposes of the present disclosure, the “height” of an aerosol-generating article or a roll-type base sheet may also be referred to as the “thickness” of the aerosol-generating article or the roll-type base sheet, respectively.

[0012] The thickness of the aerosol-generating article may be the maximum thickness of the aerosol-generating article. That is, the article thickness may be the thickness of the aerosol-generating article at its thickest point. The thickness of the aerosol-generating article may vary across the cross-section of the aerosol-generating article, and the article thickness may be the maximum thickness of the cross-section.

[0013] The substrate sheet may include a sheet of aerosol-forming substrate or at least be partially formed therefrom.

[0014] Preferably, the roll-type substrate sheet is defined by a roll-type length, a roll-type width, and a roll-type height. Preferably, the roll-type length extends parallel to the length of the article. Preferably, the roll-type length is 50 to 100% of the length of the article, preferably 60 to 90% of the length of the article, and preferably 70 to 80% of the length of the article.

[0015] In some examples, the roll length may be equal to or substantially equal to the article length. The roll width may be equal to or substantially equal to the article width. The roll height may be equal to or substantially equal to the article height. The roll width is preferably greater than the roll thickness, and preferably the roll width is at least twice the roll thickness. The roll length is preferably greater than the roll thickness, and preferably the roll length is at least twice the roll thickness. The roll length is preferably greater than the roll width.

[0016] The roll thickness of the roll-type substrate sheet may be the maximum thickness of the roll-type substrate sheet. That is, the roll thickness may be the thickness of the roll-type substrate sheet at its thickest point. The thickness of the roll-type substrate sheet may vary across the cross-section of the roll-type substrate sheet, and the roll thickness may be the maximum thickness of the cross-section.

[0017] The base sheet may have a Young's modulus of 0.5 MPa to 50 MPa, for example, 0.7 MPa to 10 MPa. The Young's modulus of the base sheet may allow the base sheet to be rolled. The Young's modulus of the base sheet may allow the base sheet to be rolled without breaking or being damaged.

[0018] As used herein, "rolled" preferably refers to a curved sheet without folding. Thus, the sheet may have an elongated spiral or tubular shape. Preferably, the rolled base sheet may be rolled about the longitudinal axis of the aerosol generating article. The rolled base sheet may be rolled about the central longitudinal axis of the aerosol generating article. For example, the rolled base sheet may be rolled axially. The rolled base sheet may be substantially cylindrical. The rolled sheet may be rolled spirally, for example, in an Archimedes spiral. The rolled base sheet may be referred to as a wound base sheet. The rolled base sheet may be a spirally wound base sheet. The term "rolling" may be used to describe a sheet forming at least half of a complete rotation or turn about an axis, preferably the longitudinal axis. For example, the angle between the beginning and end of the roll may be greater than 180 degrees. Preferably, the sheet forms at least 3 / 4 of a complete rotation or turn around an axis, preferably a longitudinal axis. Preferably, the sheet forms at least a complete rotation or turn around an axis, preferably a longitudinal axis. For example, the angle between the beginning and end of the roll is preferably greater than 360 degrees. A roll-type substrate sheet forming one complete rotation around an axis, preferably a longitudinal axis, may be referred to as a substrate sheet rolled once or once. The substrate sheet may be rolled at least once.

[0019] Preferably, the roll-type substrate sheet overlaps at least partially with itself, for example, when the angle between the start point and the end point of the roll is greater than 360 degrees.

[0020] Preferably, the roll-type substrate sheet is rolled at least twice, for example, at least three, four, or five times. For example, the roll-type substrate sheet preferably forms at least two complete turns, for example, at least three, four, or five complete turns.

[0021] Preferably, the aerosol-generating article comprises a rolling adhesive configured to bond at least two portions of a roll-type substrate sheet together. Preferably, the rolling adhesive bonds at least two overlapping portions of the roll-type substrate sheet together. Advantageously, the rolling adhesive may help prevent the roll-type substrate sheet from unraveling. The rolling adhesive may comprise or consist of one or more of, for example, gum arabic, natural or synthetic resins, starch, hydroxylpropyl methylcellulose, and varnish. Preferably, the rolling adhesive does not come into contact with the aerosol-forming substrate.

[0022] The aerosol generating article may include at least two of the substrate sheets. Preferably, at least two substrate sheets are all rolled to form at least two rolled substrate sheets. The aerosol generating article may include at least two, at least three, at least four, or at least five roll-type substrate sheets. Preferably, at least two roll-type substrate sheets are rolled sequentially. Preferably, at least two rolled substrate sheets form at least first and second concentric layers of the rolled substrate sheets.

[0023] Preferably, the aerosol generating article comprises a layer adhesive configured to bond at least first and second concentric layers of a roll-type substrate sheet together. Preferably, the aerosol generating article comprises a structural element that is at least partially wrapped or at least partially enclosed by the roll-type substrate sheet. Advantageously, the structural element may provide mechanical support for the aerosol generating article. Advantageously, the structural element may provide overall rigidity to the aerosol generating article. The structural element is preferably located at the radial center of the roll-type substrate sheet.

[0024] The structural element may extend for 50 to 100% of the length of the article, preferably 60 to 90% of the length of the article, preferably 70 to 80% of the length of the article. Preferably, the structural element extends for at least 50, 60, 70, 80, 90, 95, 98, or 99% of the length of the article, or substantially the entire length. Advantageously, thus, the structural element may provide structural support to the article over a significant proportion of the aerosol-generating article.

[0025] Preferably, the structural element includes a plurality of upwardly extending portions. Preferably, the structural element includes a plurality of downwardly extending portions. For example, the structural element may include an arrangement of upwardly leaning peaks and downwardly leaning valleys.

[0026] The structural element may include at least one longitudinally extending channel or porosity forming an airflow path through the structural element. The airflow path may be defined through the airflow channel. A plurality of upwardly extending portions and a plurality of downwardly extending portions may be configured to form at least one airflow channel. At least one airflow channel may extend between the proximal and distal ends of the roll-type substrate sheet. At least one airflow channel may extend through the central portion of the roll-type substrate sheet. This structure may allow a low RTD airflow path to be defined through the passages of the roll-type sheet, preferably the central passages. This structure may allow a low RTD airflow path to be defined through an aerosol-generating article.

[0027] An aerosol generating article may include an air inlet, an air outlet, and an airflow passage defined between the air inlet and the air outlet. At least one airflow channel may extend between the proximal end and the distal end of the aerosol generating article. The airflow passage may be at least partially defined by at least one airflow channel. At least one airflow channel may form or at least partially form the airflow passage.

[0028] Preferably, the structural element is a corrugated element containing wrinkles, and, for example, the corrugated element may be formed from a corrugated sheet material. If the structural element includes a corrugated element, it may be advantageous to manufacture the structural element using a process similar to that used to produce corrugated cardboard.

[0029] The use of corrugated elements makes it advantageous to produce aerosol-forming articles that have a very low RTD while remaining sufficiently rigid for user handling. Additionally, the use of corrugated elements enables the production of aerosol-forming article structural elements using high-speed production methods.

[0030] The corrugated element can define multiple channels extending longitudinally. The multiple longitudinally extending channels can extend between the proximal and distal ends of the corrugated element.

[0031] The wrinkles of the wrinkled element can be defined by a wrinkle profile. Preferably, the wrinkle profile is at least one of a sine wave, a triangle, a rectangle, a trapezoid, a toroid, or a parabola.

[0032] The structural element may include cardboard, preferably corrugated cardboard. The structural element may include an aerosol-forming material. For example, the structural element may include cardboard and an aerosol-forming material.

[0033] A structural element may be attached to a roll-type substrate sheet. A structural element may be attached to a roll-type substrate sheet by an element adhesive. The element adhesive may comprise or consist of one or more of, for example, gum arabic, natural or synthetic resins, starch, hydroxylpropyl methylcellulose, and varnish. The element adhesive may comprise or consist of an aerosol-forming material. For example, the element adhesive may be applied to at least one of a plurality of upward extensions and configured to contact a portion of the roll-type sheet, for example, a portion of the roll-type substrate sheet facing and in contact with the structural element. The element adhesive may be applied to at least one of a plurality of downward extensions and configured to contact a portion of the roll-type substrate sheet, for example, a portion of the roll-type substrate sheet facing and in contact with the structural element.

[0034] The structural element may include one or more perforations or holes to allow air to flow through the structural element. An article airflow passage extending from an upstream end of the article to a downstream end of the article may extend through one or more perforations or holes. One or more perforations or holes may fluidly communicate with an adjacent longitudinally extended channel, for example, a longitudinally extended channel formed by the corrugations of a corrugated element. Advantageously, the perforations or holes may adjust the RTD of the aerosol-generating article.

[0035] The substrate sheet may comprise a first section comprising an aerosol-forming substrate and a second section comprising a cellulose material. The cellulose material may comprise a sheet of cellulose material. The cellulose material may comprise cellulose fibers. The cellulose material may be paper, paperboard, or cardboard. For example, the second section may comprise or be composed of paper. Preferably, the second section does not contain an aerosol-forming substrate.

[0036] The first section may be adjacent to the second section along the length of the roll. The second section may be positioned toward the proximal end of the roll-type substrate sheet, preferably at the proximal end of the roll-type substrate sheet. The first section may be positioned toward the distal end of the roll-type substrate sheet, preferably at the distal end of the roll-type substrate sheet. Preferably, the first section is positioned between the distal end and the proximal end of the roll-type substrate sheet.

[0037] The base sheet may include a third section comprising a cellulose material. For example, the second and third may comprise or be composed of paper. The first section may be adjacent to the third section along the roll length. Preferably, the first section is located between the second and third sections along the roll length. Preferably, the third section is located toward the distal end of the roll base sheet, preferably at the distal end of the roll base sheet.

[0038] Advantageously, the provision of a section and optionally a third section can reduce the risk of loss or damage to the aerosol-forming substrate before use, because the aerosol-forming substrate can be protected from the external environment by a roll-type substrate sheet or another section of the aerosol-generating article.

[0039] Any rolling adhesive, layer adhesive, or elemental adhesive applied to the roll-type substrate sheet is preferably applied to at least one of the second section, the third section, or both the second and third sections. Preferably, an adhesive such as a rolling adhesive, layer adhesive, or elemental adhesive is not applied to the first section. In particular, preferably, the adhesive is not applied to the aerosol-forming substrate. Advantageously, applying an adhesive such as a rolling adhesive, layer adhesive, or elemental adhesive to the second or third section of the roll-type substrate sheet, rather than to the aerosol-forming substrate, means that the adhesive does not interfere with aerosol formation.

[0040] The aerosol-generating article may include a wrapper that wraps or surrounds a roll-type substrate sheet. The wrapper may be a roll-type wrapper that rolls around the roll-type substrate sheet. The wrapper may be rolled around the central longitudinal axis of the aerosol-generating article. For example, the wrapper may be rolled axially.

[0041] Preferably, the wrapper is rolled around the aerosol-forming substrate.

[0042] Advantageously, the wrapper can provide a barrier between the roll-type substrate sheet, preferably the aerosol-forming substrate, and the external environment. Thus, the wrapper can protect the roll-type substrate sheet, preferably the aerosol-forming substrate. The wrapper can reduce the risk of damage to the aerosol-forming substrate. Advantageously, the wrapper can reduce the risk of loss of the aerosol-forming substrate from the aerosol-generating article before use.

[0043] The wrapper may contain or be made of cellulose material, for example, the wrapper may be a paper wrapper.

[0044] The aerosol generating article may include a wrapper adhesive configured to adhere the wrapper to the substrate sheet.

[0045] The wrapper may be formed integrally with the roll-type substrate sheet. For example, the substrate sheet may include a fourth section, wherein the fourth section includes the wrapper. The fourth section may extend along the entire roll length. The fourth section may be axially adjacent to the first section of the roll-type substrate sheet. Preferably, the fourth section may be axially adjacent to the first, second, and third sections of the roll-type substrate sheet.

[0046] The wrapper adhesive can bond the fourth section to at least one of the second or third sections of the substrate sheet.

[0047] The wrapper can be separated from the substrate sheet. That is, the wrapper may not be formed integrally with the roll-type substrate sheet.

[0048] The wrapper adhesive can adhere the wrapper to at least one of the second or third sections of the substrate sheet.

[0049] The wrapper adhesive may not come into contact with the aerosol-forming substrate. Therefore, advantageously, the adhesive does not interfere with the aerosolization of the aerosol-forming substrate.

[0050] Optionally, the aerosol generating article may include a mouthpiece element. Preferably, the mouthpiece element is located at the proximal end of the aerosol generating article. The mouthpiece element may be a mouthpiece filter.

[0051] The aerosol generating article may be a planar aerosol generating article. As used herein, the term “planar” may refer to a component having two dimensions, e.g., length and width, each being at least 2, 2.5, 3, 5, or 10 times a third dimension, e.g. thickness, and each of these three dimensions is perpendicular to each other.

[0052] An aerosol-generating article may have a length extending in the x-direction, a width extending in the y-direction, and a height extending in the z-direction. An aerosol-generating article may have a base defined by a length extending in the x-direction and a width extending in the y-direction.

[0053] The height of the aerosol-generating item may be smaller than both the length and width of the aerosol-generating item.

[0054] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol, the aerosol generating article comprises an aerosol forming substrate for generating an aerosol, and the aerosol generating article comprises a substantially flat upper surface defined by a length extending in the x-direction and a width extending in the y-direction, and a substantially flat lower surface defined by a length extending in the x-direction and a width extending in the y-direction. The substantially flat upper surface and the substantially flat lower surface may be spaced perpendicularly apart from each other by a height defined in the z-direction.

[0055] The aerosol generating article according to the present disclosure may preferably be a substantially flat article or a substantially planar article. Such an article has a large base area relative to the volume of the article. In particular, the height of the aerosol generating article may be less than 50% of both the length and width of the aerosol generating article. Advantageously, a larger base area may provide a larger surface area for heating by a planar heater of the aerosol generating device. Advantageously, a smaller height may allow for a smaller temperature gradient or difference across the height of the aerosol generating article during heating. For example, if the base of the aerosol generating article is in contact with a planar heater and heated by it, a smaller gap or height between the base and the upper surface may result in a smaller temperature difference between the base and the upper surface facing the base. Advantageously, this may minimize the risk of the hottest part of the substrate closest to the heater burning while enabling a greater proportion of the aerosol-forming substrate of the aerosol generating article to be heated to the temperature at which the aerosol is released. Alternatively or additionally, this can reduce the time required to heat the aerosol-forming substrate sufficiently to release the aerosol.

[0056] An aerosol generating article according to any one of the embodiments disclosed herein may have an airflow path extending through the aerosol generating article. The aerosol generating article may have an airflow path defined through the aerosol generating article in the x / y plane from one side of the aerosol generating article to another side of the aerosol generating article. The aerosol generating article preferably has a resistance to suction (RTD) of less than 20 mm H2O, for example, less than 10 mm H2O, in the direction of the airflow path. Preferably, the aerosol generating article has an RTD of less than 20 mm H2O, for example, less than 10 mm H2O, in at least one direction in the x / y plane of the aerosol generating article. An aerosol generating article having a low resistance airflow path can enable excellent airflow management and allow aerosols to be extracted more efficiently from the aerosol generating article and delivered to the user.

[0057] Unless otherwise specified, resistance to suction (RTD) is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through the entire length of a component, such as in an aerosol-generating article. The terms "pressure drop" or "resistance to suction" with respect to a component or article may also refer to "resistance to suction." These terms generally refer to measurements performed under testing in accordance with ISO 6565-2015 at a volumetric flow rate of about 17.5 mm / s at the output or downstream end of the component, measured at a temperature of about 22°C, a pressure of about 101 kPa (about 760 Torr), and a relative humidity of about 60%.

[0058] An aerosol generating article according to any one of the embodiments disclosed herein may comprise an upper and lower surface that is substantially planar. A vertical separation between the substantially planar upper surface and the lower surface may define the height (e.g., z-dimension) of the aerosol generating article. An airflow channel may be defined between the substantially planar upper surface and the lower surface. The aerosol generating article may have a height of less than 5 mm, e.g., 1.5 mm to 5 mm, e.g., 1.5 mm to 4 mm, e.g., 1.5 mm to 3 mm, e.g., 1.5 mm to 2 mm. One or both of the substantially planar upper and lower surfaces may comprise an aerosol-forming substrate. The aerosol generating article may comprise an upper layer and a lower layer, wherein the upper layer forms a substantially planar upper surface and the lower layer forms a substantially planar lower surface. At least one of the upper layer and the lower layer may comprise or be made of an aerosol-forming substrate.

[0059] According to the present disclosure, an aerosol generating article for use with an aerosol generating device to generate an aerosol may be provided, and the aerosol generating article comprises a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer. At least one of the first planar layer, the second planar layer, and the corrugated layer may comprise or be made of an aerosol forming substrate.

[0060] The use of a corrugated structure within aerosol-generating articles advantageously enables the production of articles with a very low RTD while remaining sufficiently rigid for user handling. Furthermore, the use of a corrugated structure allows for the production of low-density, low-RTD, aerosol-generating articles using high-speed manufacturing methods similar to those used in the production of corrugated cardboard.

[0061] Preferably, the corrugated layer is a structural element.

[0062] Preferably, the wrapper forms the outer surface of the aerosol-generating article. The outer surface of the aerosol-generating article includes a first planar layer and a second planar layer.

[0063] According to the present disclosure, an aerosol generating article may be provided for use with an aerosol generating device to generate an aerosol. The aerosol generating article may comprise a first planar outer surface, a second planar outer surface, a cavity, and a frame. The frame may be positioned between the first planar outer surface and the second planar outer surface. The frame may define the cavity at least partially. The aerosol generating article may comprise an aerosol forming substrate. The aerosol generating article may comprise an air inlet, an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity.

[0064] Preferably, the roll-type substrate sheet is positioned between the first planar outer surface and the second planar outer surface.

[0065] Preferably, the roll-type substrate sheet is located within the cavity. Preferably, the aerosol-forming substrate is located within the cavity. Preferably, the aerosol-forming substrate is located in the airflow passage.

[0066] The frame may include a periphery wall that at least partially surrounds or encloses the cavity. The frame may include a periphery wall that completely surrounds or encloses the cavity. Advantageously, the frame can make the aerosol-generating article relatively thin while maintaining structural rigidity.

[0067] The aerosol generating article may include a first planar outer layer and a second planar outer layer, wherein the first planar outer layer forms a first planar outer surface and the second planar outer layer forms a second planar outer surface. Optionally, at least one of the first planar outer layer, the second planar outer layer, and the frame may include or be made of an aerosol-forming material.

[0068] The common area can be practically empty.

[0069] The aerosol-forming substrate can be located within the cavity.

[0070] The wrinkled layer can be located within the cavity.

[0071] The frame can be a flat frame.

[0072] The frame may have a height of 50% to 95% of the height of the aerosol-generating article. The frame may have a height of 60% to 95% of the height of the aerosol-generating article. The frame may have a height of 70% to 95% of the height of the aerosol-generating article. The frame may have a height of 80% to 95% of the height of the aerosol-generating article.

[0073] The frame may have a height of 1 mm to 5.5 mm. The frame may have a height of 1 mm to 5 mm. Preferably, the frame may have a height of 1.5 mm to 5 mm.

[0074] The frame may be manufactured from or contain biodegradable materials. The frame may be manufactured entirely from biodegradable materials.

[0075] 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, paperboard, 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.

[0076] The frame may be a single component. Alternatively, the frame may include two or more layers. That is, the frame may have a stacked structure.

[0077] An aerosol-generating article of any embodiment of the present disclosure may have an article length (e.g., x-dimension) of 10 mm to 100 mm, or 10 mm to 50 mm, for example 10 mm to 40 mm, for example 12 mm to 30 mm, for example 14 mm to 26 mm, for example 16 mm to 24 mm, for example 18 mm to 22 mm, for example about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.

[0078] The aerosol-generating article may have an article width (e.g., y dimension) of 5 mm to 20 mm, e.g. 8 mm to 18 mm, e.g. 10 mm to 16 mm, e.g. 11 mm to 15 mm, e.g. 12 mm to 14 mm, e.g. about 13 mm.

[0079] The aerosol-generating article may have an article thickness (e.g., z-dimension) of 1 mm to 10 mm, e.g. 1.2 mm to 8 mm, e.g. 1.4 mm to 7 mm, e.g. 1.6 mm to 6 mm, e.g. 1.7 mm to 5 mm, e.g. about 1.7 mm, or about 4.5 mm, or about 2 mm, or about 3 mm, or about 4 mm.

[0080] When viewed in a plan view, an aerosol generating article of any embodiment of the present disclosure may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof. Where the aerosol generating article comprises upper and lower surfaces that are substantially planar, when viewed in a plan view, one or both of the upper and lower surfaces may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof. When viewed in a plan view, the perimeter of the aerosol generating article may be formed by a plurality of straight sides, a plurality of curved sides, or a combination of straight sides and curved sides. Where the aerosol generating article comprises upper and lower surfaces that are substantially planar, when viewed in a plan view, the perimeter of one or both of the upper and lower surfaces may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an ellipse, a circle, or a combination thereof.

[0081] An aerosol-generating article may be entirely composed of an aerosol-forming substrate. Alternatively, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-generating article.

[0082] The aerosol-forming material may contain nicotine. Nicotine may exist in the form of a tobacco substance or in the form of a nicotine extract.

[0083] The aerosol-forming substrate may include one or more organic materials such as tobacco, mint, tea, and cloves. The aerosol-forming substrate may include one or more of homogenized tobacco such as herb leaves, tobacco leaves, tobacco rib pieces, reconstituted tobacco, cast leaves, extruded tobacco, puffed tobacco, aerosol-generating films, and gel compositions.

[0084] The aerosol-forming material may include or be composed of homogenized tobacco material, for example, reconstituted tobacco material or cast leaf tobacco material.

[0085] The aerosol-forming substrate may be in the form of a 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.

[0086] The aerosol-forming material may be a cut herb. The aerosol-forming material may be a tobacco cut herb. The cut herb may include one or more of bright tobacco, dark tobacco, flavored tobacco, and filler tobacco. Examples of bright tobacco are Brazilian yellow, Indian yellow, Chinese yellow, 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 fumigated Brazilian Gaufão, Burley Malawi or other African Burley, and sun-dried or air-dried Indonesian Kasturi. As used herein, the term “cut herb” is used to describe a blend of shredded plant material, such as tobacco plant material and homogenized plant material, comprising one or more of leaf blades, processed stems, and ribs.

[0087] The aerosol-forming substrate may be in the form of a sheet of 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 aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenized tobacco material, such as a cast leaf sheet.

[0088] The aerosol-forming material may comprise a combined aggregate of strips, strands, or particles of tobacco material. The aerosol-forming material may be in the form of a compressed plug of tobacco material; for example, a plug having a substantially circular cross-section in the initial state of the plug is compressed into a flatter cross-sectional profile in a subsequent state of the plug. The tobacco material may be surrounded by a wrapper. The aerosol-forming material may be in the form of strips, strands, or particles of tobacco material bonded together in a binder matrix.

[0089] The aerosol-forming substrate may comprise one or more aerosol-forming agents. Suitable aerosol-forming agents are known in the art and include, but are not limited to, polyhydric alcohols such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable that the aerosol-forming agent 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.

[0090] The aerosol-forming substrate may have an aerosol-forming agent content of 1, 2, 5, 10, or 15 weight% or more based on dry weight. The aerosol-forming substrate may have an aerosol-forming agent content of 15 weight% or more based on dry weight, for example, exceeding 20 weight% based on dry weight, or exceeding 25 weight% based on dry weight, or exceeding 30 weight% based on dry weight, or exceeding 40 weight% based on dry weight, or exceeding 50 weight% based on dry weight.

[0091] The aerosol-forming material may have an aerosol-forming agent content of 30% by weight or less, 25% by weight or less, or 20% by weight or less based on dry weight. That is, the aerosol-generating material may have an aerosol-forming agent content of 30% by weight or less, 25% by weight or less based on dry weight, or 20% by weight or less based on dry weight.

[0092] The aerosol-forming substrate may have an aerosol-forming agent content of 1% to 30% by weight based on dry weight, 1% to 25% by weight based on dry weight, or 1% to 20% by weight based on dry weight.

[0093] The aerosol-forming substrate may comprise at least 50 weight% of an aerosol-forming agent, at least 60 weight% of an aerosol-forming agent, or at least 70 weight% of an aerosol-forming agent.

[0094] The aerosol-forming material may include 85% by weight or less of an aerosol-forming agent, 80% by weight or less of an aerosol-forming agent, or 75% by weight or less of an aerosol-forming agent.

[0095] The aerosol-forming substrate may comprise 50% to 85% by weight of an aerosol-forming agent, 50% to 80% by weight of an aerosol-forming agent, or 50% to 75% by weight of an aerosol-forming agent.

[0096] The aerosol-forming material may include nicotine. The aerosol-forming material may include natural nicotine, synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0097] The aerosol-forming substrate may contain at least 0.5% by weight of nicotine, at least 1% by weight of nicotine, at least 1.5% by weight of nicotine, or at least 2% by weight of nicotine.

[0098] The aerosol-forming material may include one or more flavoring agents. One or more flavoring agents may include one or more essential oils such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and one or more herbal substances. Suitable herbal substances include, 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 substances derived from herb leaves or herbal plants. One or more flavoring agents may include tobacco substances.

[0099] The aerosol-forming substrate may include one or more plant components. For example, the aerosol-forming substrate may include plant components such as clove, echinacea species, fennel, ginger, hawthorn berry, elderberry, monarda, mullein leaf, nettle, plantain, turmeric, yarrow, rooibos, star anise, thyme, anethum, chamomile, and compounds thereof in an amount of about 1 to 90%, for example, about 15 to 55%, preferably about 20 to 35%.

[0100] The aerosol-forming substrate may have a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state. For example, the aerosol-forming substrate may be a homogenized tobacco material having a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state.

[0101] The aerosol-forming substrate may include a binder. For example, the aerosol-forming substrate may include about 1 to 10%, preferably about 1 to 5%, of a binder such as either a common gum or pectin used in the food and beverage (F&B) industry. Preferred binders may be natural pectins, e.g., fruit, e.g., citrus or tobacco pectins; guar gum, land locust bean gum, e.g., their hydroxyethyl and hydroxypropyl; starch, e.g., modified or derived starch; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; dextran; and xanthan gum. A preferred binder is guar.

[0102] The aerosol-forming substrate may include or be composed of an aerosol-forming material. The aerosol-forming substrate may include a liquid aerosol-forming material, for example, a liquid aerosol-forming material retained within a porous matrix. The aerosol-forming substrate may include a gel aerosol-forming material.

[0103] According to a second aspect of the present disclosure, an aerosol generating device for receiving an aerosol generating article as disclosed herein or an aerosol forming substrate as disclosed herein may comprise a cavity having dimensions for receiving at least a portion of the aerosol generating article or the aerosol forming substrate, 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 the aerosol forming substrate, for example, the aerosol forming substrate which is a component part of the aerosol generating article, to form an aerosol, for example, an inhalable aerosol.

[0104] The aerosol generating device may preferably be configured to accommodate the entire aerosol generating article so that the aerosol generating article is completely surrounded within the aerosol generating device.

[0105] The cavity may include an opening into which the distal end of an aerosol-generating article can be inserted. The cavity may have any suitable cross-sectional shape. For example, the cavity may have a rectangular cross section, for example, a rectangular cross section having opposing top and bottom sides that are longer than the left and right sides.

[0106] Preferably, at least one internal surface of the cavity is a heating surface configured to heat an aerosol generating article. The heating surface may include a heater, for example, a resistance heater or an infrared heater, or a susceptor configured to be heated by coupling with an inductor. The heating surface may include an inductor, and for example, the surface may include a coil disposed to generate a fluctuating electromagnetic field within the cavity space. The heating surface may be a surface permeable to the fluctuating electromagnetic field so that an inductor disposed outside the cavity can project the fluctuating electromagnetic field through the heating surface and couple with a susceptor disposed inside the cavity.

[0107] According to the present disclosure, an aerosol generating system may be provided. The system may include an aerosol generating article as described herein, for example, according to a first embodiment. The system may include an aerosol generating device for use with the aerosol generating article to generate an inhalable article.

[0108] According to a second aspect of the present disclosure, an aerosol generating system is provided comprising an aerosol generating article according to a first aspect of the present invention and an aerosol generating device for use with the aerosol generating article to generate an inhalable aerosol. The aerosol generating device may include a chamber for receiving at least a portion of the aerosol generating article. The aerosol generating device may include an electric heater disposed to heat at least a portion of the aerosol generating article when the aerosol generating article is received within the chamber. The system may include an aerosol generating device, for example according to the second aspect, as described herein.

[0109] As used herein, the term "aerosol generating article" may refer to an article capable of generating or releasing aerosols.

[0110] As used herein, the term "aerosol-forming substrate" may refer to a substrate capable of releasing an aerosol or a volatile compound capable of forming an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may comprise an aerosol-forming material. The aerosol-forming substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. For convenience, the aerosol-forming substrate may be part of an aerosol-generating article or a smoking article.

[0111] As used herein, the term "aerosol generating device" may refer to a device for use with an aerosol generating article to enable the generation or release of an aerosol.

[0112] As used herein, the term 'aerosol generating system' refers to a combination of an aerosol generating device and one or more aerosol forming articles for use with the device. The aerosol generating system may include additional components, such as a charging unit for recharging an on-board electric power supply to an electrically operated or electric aerosol generating device.

[0113] As used herein, the term "aerosol-forming agent" may refer to any suitable known compound or mixture of compounds that facilitates the formation of an aerosol upon use. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal decomposition at the operating temperature of the aerosol-forming substrate or the aerosol-generating article.

[0114] As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salt.

[0115] As used herein with respect to the present invention, the terms "proximal," "distal," "upstream," and "downstream" are used to describe the relative positions of a component or a part of a component of an aerosol-generating article.

[0116] As used herein, the term "longitudinal" refers to a direction corresponding to the main longitudinal axis of the aerosol generating article extending between the upstream and downstream ends of the aerosol generating article. During use, air may be drawn longitudinally through the aerosol generating article.

[0117] As used herein, the term “sheet” refers to a laminated element in which the width and length are substantially greater than the thickness. The width of the sheet is greater than 10 mm, and preferably greater than 20 mm or 30 mm. In certain embodiments, the sheet of material to be used to form an aerosol-forming substrate as described herein may have a thickness of 10 μm to about 1000 μm, for example, 10 μm to about 300 μm.

[0118] As used herein, the term “homogenized tobacco material” comprises any tobacco material formed by the aggregation of particles of tobacco material. A sheet or web of homogenized tobacco material is formed by aggregating particulate tobacco obtained by crushing or pulverizing one or both of tobacco leaf lamina and tobacco leaf stem. Additionally, the homogenized tobacco material may contain trace amounts of one or more of tobacco powder, tobacco fines, and other particulate tobacco by-products formed during the processing, handling, and delivery of tobacco. A sheet of homogenized tobacco material may be manufactured by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0119] The term “cast leaf” is used herein to refer to a product produced by a casting process based on casting a slurry containing plant particles (e.g., clove particles, or a mixture of tobacco particles and clove particles) and a binder (e.g., guar gum) onto a supporting surface, such as a belt conveyor, drying the slurry, and removing the dried sheet from the supporting surface. Examples of casting or cast leaf processes are described, for instance, in US-A-5,724,998 for the manufacture of cast leaf tobacco. In a cast leaf process, particulate plant material is produced by pulverizing, grinding, or crushing a portion of a plant. Particles produced from one or more plants are mixed with a liquid component, typically water, to form a slurry. Other components within the slurry may include fibers, a binder, and an aerosol-forming agent. The particulate plant material may aggregate in the presence of a binder. The slurry is cast onto a supporting surface and dried into a sheet of homogenized plant material. Preferably, the homogenized plant material used in the article according to the present invention can be produced by casting. Such homogenized plant material may comprise aggregated particulate plant material.

[0120] As used herein, suction resistance is expressed as "mm H2O" or "mm WG" or "mm water level gauge" and is measured according to ISO 6565:2002.

[0121] 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.

[0122] Ex1. As an aerosol generating article for generating aerosols by use with an aerosol generating device, the aerosol generating article is,

[0123] A substrate sheet comprising an aerosol-forming substrate for generating an aerosol, wherein the substrate sheet comprises a substrate sheet that is rolled to form a roll-type substrate sheet.

[0124] An aerosol-generating article is defined by the length of the article, the width of the article, and the thickness of the article, wherein the length of the article and the width of the article are at least twice the thickness of the article.

[0125] Ex1a. In Example Ex1, the roll-type substrate sheet is an aerosol generating article that is rolled around the longitudinal axis of the aerosol generating article.

[0126] Ex1b. An aerosol generating article in Example Ex1 or Ex2, wherein the roll-type substrate sheet is defined by a roll-type length extending parallel to the length of the article, and the roll-type length is 50 to 100% of the length of the article, preferably 60 to 90% of the length of the article, preferably 70 to 80% of the length of the article.

[0127] Ex2. In any one of the prior embodiments, the aerosol generating article, wherein the roll-type substrate sheet is rolled at least twice, for example at least three times, four times, or five times.

[0128] Ex3. An aerosol generating article comprising a rolling adhesive configured to bond two parts of a roll-type substrate sheet together, in Example Ex2.

[0129] Ex4. An aerosol generating article comprising, in any one of the prior embodiments, at least two roll-type substrate sheets, for example, at least three, four, or five roll-type substrate sheets.

[0130] Ex5. In Example Ex4, an aerosol generating article in which a roll-type substrate sheet is sequentially rolled to form at least first and second concentric layers of the roll-type substrate sheet.

[0131] Ex6. An aerosol generating article comprising a layer adhesive configured to bond the first and second concentric layers of a roll-type substrate sheet together, in Example Ex5.

[0132] Ex7. An aerosol generating article comprising a structural element at least partially enclosed by a roll-type substrate sheet in any one of the prior embodiments.

[0133] Ex8. In Example Ex7, the aerosol generating article comprises a plurality of upwardly extending and downwardly extending portions configured such that at least one airflow channel can extend between the proximal end and the distal end of the roll-type substrate sheet.

[0134] Ex9. An aerosol generating article in Example Ex7 or Ex8, wherein the structural element is a corrugated element including a corrugation.

[0135] Ex10. In Example Ex9, the wrinkles are defined by a wrinkle profile, and the wrinkle profile is at least one of a sinusoidal, triangular, rectangular, trapezoidal, toroidal, or parabolic shape, an aerosol generating article.

[0136] Ex11. An aerosol generating article in any one of Examples Ex7 to Ex10, wherein the structural element comprises cardboard.

[0137] Ex12. An aerosol generating article in any one of Examples Ex7 to Ex11, wherein the structural element extends to 50 to 100% of the length of the article, preferably 60 to 90% of the length of the article, preferably 70 to 80% of the length of the article.

[0138] Ex13. In any one of the prior embodiments, the roll-type substrate sheet comprises an aerosol-generating article comprising a first section including an aerosol-forming substrate and a second section including a cellulose material, e.g., paper.

[0139] Ex14. In Example Ex13, the first section is an aerosol generating article adjacent to the second section along the roll length.

[0140] Ex15. An aerosol generating article comprising a third section comprising a cellulose material, e.g., paper, in Example Ex13 or Ex14.

[0141] Ex16. In Example Ex15, the first section is adjacent to the third section along the roll length, and accordingly, the first section is located between the second section and the third section along the roll length, an aerosol generating article.

[0142] Ex17. An aerosol generating article comprising a wrapper surrounding a roll-type substrate sheet in any one of the prior embodiments.

[0143] Ex18. In Example Ex17, the wrapper is an aerosol-generating article comprising or made of a cellulose material, e.g., paper.

[0144] Ex19. In Example Ex17 or Ex18, the wrapper is formed integrally with the roll-type substrate sheet, an aerosol-generating article.

[0145] Ex20. In Example Ex17 or Ex18, the wrapper is an aerosol-generating article separated from the roll-type substrate sheet.

[0146] Ex21. An aerosol generating article comprising a wrapper adhesive configured to adhere a wrapper to a roll-type substrate sheet, in any one of Examples Ex17 to Ex20.

[0147] Ex22. In any one of Examples Ex17 to Ex21, the wrapper forms the outer surface of the aerosol generating article.

[0148] Ex23. In Example Ex22, the outer surface of the aerosol generating article comprises a first planar layer and a second planar layer.

[0149] Ex24. An aerosol generating article in any one of Examples Ex1 to Ex21, comprising a first planar outer surface and a second planar outer surface, wherein a roll-type substrate sheet is arranged between the first planar outer surface and the second planar outer surface.

[0150] Ex25. An aerosol generating article according to Example Ex24, comprising a frame positioned between a planar upper outer layer and a planar lower outer layer.

[0151] Ex26. In Example Ex25, the frame defines at least partially the cavity, and the roll-type substrate sheet is positioned within the cavity, an aerosol-generating article.

[0152] Ex27. An aerosol generating article comprising, in any one of the prior embodiments, an air inlet, an air outlet, and an airflow passage extending between the air inlet and the air outlet.

[0153] Ex28. An aerosol generating article comprising a mouthpiece element in any one of the prior embodiments.

[0154] Ex29. As an aerosol generation system,

[0155] Aerosol generating article according to any one of the prior embodiments; and

[0156] The aerosol generating device includes, wherein the aerosol generating device

[0157] A chamber for accommodating at least a portion of an aerosol-generating article; and

[0158] An aerosol generating system comprising an electric heater arranged to heat at least a portion of an aerosol generating article when the aerosol generating article is contained within a chamber. Brief explanation of the drawing

[0159] Now, embodiments will be further described with reference to the drawings. FIG. 1 is a side perspective view of an aerosol generating article according to a first embodiment of the present disclosure. FIG. 2 is a side perspective view of an aerosol generating article according to a second embodiment of the present disclosure. FIG. 3 is a schematic end view of an aerosol article according to a third embodiment of the present disclosure. Figure 4 is a schematic side view of the aerosol generating article of Figure 3. Figure 5 is a schematic plan view of the aerosol generating article of Figure 3. Figure 6 illustrates a schematic diagram of a corrugated element used in the aerosol generating article of Figure 3. FIG. 7 illustrates a perspective view of an aerosol generating article according to a fourth embodiment of the present disclosure. FIG. 8 shows an exploded perspective view of the aerosol generating article of FIG. 7. FIG. 9 shows an additional exploded perspective view of the aerosol generating article of FIG. 7. FIG. 10 illustrates a schematic cross-sectional view of the aerosol-generating article of FIG. 7. FIG. 11 illustrates a schematic longitudinal cross-sectional view of the aerosol-generating article of FIG. 7. FIG. 12 illustrates a schematic cross-sectional view of an aerosol-generating article according to a fifth embodiment of the present disclosure. FIG. 13 illustrates a schematic side view of an aerosol generating article according to a sixth embodiment of the present disclosure. FIG. 14 illustrates a schematic cross-sectional view of an aerosol generating article according to the seventh embodiment of the present disclosure. FIG. 15 illustrates a schematic cross-sectional view of an aerosol generating article according to the eighth embodiment of the present disclosure. FIG. 15b shows a schematic plan view of the roll-type substrate sheet of FIG. 15a. FIG. 15c shows a schematic perspective view of the roll-type substrate sheet of FIG. 15a. FIG. 16 illustrates a schematic cross-sectional view of an aerosol generating article comprising the roll-type substrate sheets of FIG. 15a to 15c. FIG. 17 illustrates a schematic diagram of an aerosol generating device according to one embodiment of the present disclosure, and the device is configured to engage with an aerosol generating article, for example, any one of FIG. 1 to 14 or FIG. 16. FIG. 18 shows a schematic end view of the aerosol generating device of FIG. 17. FIG. 19 is a schematic diagram showing an aerosol generating article (e.g., an aerosol generating article of any one of FIG. 1 to 14 or FIG. 16) that engages with the aerosol generating device of FIG. 17. FIG. 20 is a schematic diagram of an alternative embodiment of FIG. 17 to 19, showing an aerosol generating article coupled with an aerosol generating device. Specific details for implementing the invention

[0160] FIG. 1 illustrates a side perspective view of an aerosol generating article (100) according to a first embodiment of the present disclosure. The aerosol generating article (100) has upper and lower surfaces (110, 120) that are flat or planar.

[0161] The aerosol generating article (100) comprises an aerosol forming substrate (not shown). In one embodiment, the aerosol generating article (100) may be substantially made of an aerosol forming substrate. In another embodiment, the aerosol forming substrate may be one of a plurality of component parts of the aerosol generating article (100). The aerosol forming substrate may be surrounded inside the aerosol generating article (100). The aerosol forming substrate may at least partially define the exterior of the aerosol generating article (100); for example, one or both of the upper and lower surfaces (110, 120) may comprise or be made of the aerosol forming substrate.

[0162] A suitable aerosol-forming substrate may be a homogenized tobacco.

[0163] The aerosol generating article (100) has a length of 80 mm extending in the x dimension, a width of 15 mm extending in the y dimension, and a height of 3.6 mm extending in the z dimension (which may also be referred to as thickness).

[0164] FIG. 2 shows a side perspective view of an aerosol generating article (200) according to a second embodiment of the present disclosure, which is a variation of the aerosol generating article (100). Features common to the aerosol generating article (100) are referred to by similar reference numerals, but start with the number 2 instead of the number 1. An airflow path (230) is defined through the aerosol generating article (200) between the upper surface and the lower surface (210, 220). The airflow path (230) extends between opposing first and second ends (201, 202) of the aerosol generating article (200). The first end (201) may define the distal end of the aerosol generating article (200), and the second end (202) may define the proximal or mouse end of the aerosol generating article. The airflow path (230) can be guided toward the user's mouth so that the user can inhale the aerosol generated as a result of heating the aerosol forming substrate of the aerosol generating article (200).

[0165] FIGS. 3, FIGS. 4, and FIGS. 5 respectively illustrate an end view, a side view, and a top view of an aerosol generating article (300) according to a third embodiment of the present disclosure. The aerosol generating article (300) comprises a planar upper layer (310), a planar lower layer (320), and an intermediate layer or a separation layer (340), which may be a structural element (348) arranged between the upper layer (310) and the lower layer (320) in this element.

[0166] The flat upper layer (310) and the flat lower layer (320) are formed from a substrate sheet (330) comprising an aerosol-forming substrate (334). The substrate sheet (330) forms a roll-type substrate sheet (332) rolled along the longitudinal x-axis of the aerosol-generating article (300). In this example, the roll-type substrate sheet (332) is rolled in one complete turn around the x-axis and partially overlaps itself. The aerosol-generating article includes an adhesive (not shown) for bonding the flat upper layer (310) to the overlap of the roll-type substrate sheet (332).

[0167] The substrate sheet (330) has a sheet thickness of 30 to 150 μm. The roll-type substrate sheet (332) surrounds the structural element (348). The roll-type substrate sheet (332) has a roll thickness of 3000 to 3750 μm.

[0168] The aerosol-forming substrate (334) may be any suitable aerosol-forming substrate. A suitable aerosol-forming substrate may be a homogenized tobacco. The structural element (348) is a corrugated element formed from a corrugated sheet of cardboard (345) having a plurality of substantially parallel peaks and valleys. The plurality of parallel corrugations are defined by a corrugation profile, which is approximately sinusoidal in shape as shown in FIG. 6.

[0169] FIG. 6 illustrates a corrugated sheet of cardboard (345). The corrugations have an amplitude (346) of 3 mm and a wavelength (347) of 3 mm. The cardboard sheet (345) forming the intermediate layer (340) has a thickness of 300 μm.

[0170] The intersection points (351, 352) between the upper layer (310) and the middle layer (340) and between the lower layer (320) and the middle layer (340) contain an adhesive that bonds each layer.

[0171] The aerosol generating article (300) has a length extending in an x ​​dimension of 80 mm, a width extending in a y dimension of 15 mm, and a height (or thickness) extending in a z dimension of 3 to 4 mm, preferably 3.6 mm.

[0172] The roll-type base sheet (332) has a roll-type length equal to the length of the article. The roll-type base sheet (332) has a roll-type thickness equal to the thickness of the article. The roll-type base sheet (332) has a roll-type width equal to the width of the article.

[0173] The folds of the intermediate layer (340) form a first set of longitudinally extending channels (361) bounded by the upper layer (310) and the intermediate layer (340), and a second set of longitudinally extending channels (362) bounded by the lower layer (320) and the intermediate layer (340). The first and second sets of longitudinally extending channels (361, 362) extend through the length of the corrugated element (348) between the proximal end (371) and the distal end (372) of the corrugated element (348). The longitudinally extending channels (361, 362) define an airflow path through the corrugated element (348). Thus, the airflow path passes through both sides of the corrugated element (348). The porosity of the aerosol-generating article along the airflow path is within 90% of the area. This provides a very low resistance to inhalation (RTD) of less than 5 mm H2O. In fact, the RTD is close to 0.

[0174] While using the aerosol generating article (300), the aerosol forming substrate (334) is heated to cause the aerosol forming substrate (334) to release a volatile compound, and the volatile compound is then entrained in air drawn into the channels (361, 362) through the distal end (372). Then, the volatile compound is cooled and condensed to form an aerosol, and the aerosol can be drawn from the channels (361, 362) of the aerosol generating article (300) through the proximal end (371).

[0175] FIG. 7 shows an aerosol generating article (400) according to a fourth embodiment of the present disclosure. The aerosol generating article (400) comprises a first planar outer layer (424) forming a first planar outer surface (421), a second planar outer layer (425) forming a second planar outer surface (422), and a frame (450) located between the first planar outer layer (424) and the second planar outer layer (425). The second planar outer surface (422) is located parallel to the first planar outer surface (421).

[0176] FIGS. 8 and 9 show exploded views of the aerosol generating article (400) of FIG. 7. A frame (450) surrounds and defines at least partially the cavity (430). FIG. 8 shows the cavity (430) in an empty state. FIG. 9 shows the aerosol generating article (400) having a roll-type substrate sheet (432) and a structural element (448) positioned within the cavity (430). FIGS. 10 and 11 show a cross-sectional view and a longitudinal cross-sectional view, respectively, of the aerosol generating article (400) when the roll-type substrate sheet (432) and the structural element (448) are positioned within the cavity (430).

[0177] The first planar outer layer (424) and the second planar outer layer (425) are made of cigarette paper having a thickness of 35 μm and are physically in contact with and bonded to the frame (450). The first planar outer layer (424) is placed over the first end of the cavity (430) and forms the first cavity end wall. The second planar outer layer (425) is placed over the second end of the cavity (430) and forms the second cavity end wall, and the second cavity end wall faces the first cavity end wall. That is, the frame (450), the first planar outer layer (424), and the second planar outer layer (425) collectively define the cavity (430).

[0178] The frame (450) has a hollow rectangular shape and is made of cardboard. The frame (450) defines a perforation extending through the height (also referred to as thickness) of the frame (450), and the perforation forms at least partially a cavity (430) of the aerosol generating article (400). The frame (450) includes a periphery wall (451) surrounding the cavity (430). The periphery wall (451) includes a front wall (413) and a rear wall (414). More specifically, the periphery wall (451) is defined by an inner transverse surface (452) of the frame (450) and an outer transverse surface (453) of the frame (450). The inner transverse surface (452) of the periphery wall (451) defines at least partially the periphery of the cavity (430). The outer transverse surface (453) of the periphery wall (451) defines at least partially the periphery of the aerosol generating article (400). The periphery wall (451) has a radial thickness of about 5 mm measured between the inner transverse surface (452) of the frame (450) and the outer transverse surface (453) of the frame (450).

[0179] The air inlet (411) and air outlet (412) are defined by and extend through the peripheral wall surface (451) of the frame (450). More specifically, the air inlet (411) extends through the front wall surface (413) and the air outlet (412) extends through the rear wall surface (414). The air inlet (411) and the air outlet (412) have an equivalent diameter of 5 mm. An airflow passage extends through a cavity (430) between the air inlet (411) and the air outlet (412).

[0180] As illustrated in FIGS. 9 to 11, a substrate sheet comprising an aerosol-forming substrate (434) forms a roll-type substrate sheet (432). The aerosol-forming substrate (434) 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.

[0181] As illustrated in FIG. 10, a roll-type substrate sheet (432) surrounds a structural element (448). The roll-type substrate sheet (432) and the structural element (448) are located within a cavity (430). The structural element (448) includes a plurality of parallel folds. Features common to the aerosol generating article (300) are referred to by similar reference numerals, except that they begin with the number 4 instead of the number 3. The structural element (448) is substantially identical to the structural element (348), except as described below.

[0182] The structural element (448) includes a corrugated element (445) comprising a plurality of parallel corrugations having a corrugation wavelength of about 4.6 mm. The corrugation amplitude is approximately equal to the height (or thickness) in the internal passage of the roll-type substrate sheet, as illustrated by the peaks and valleys corresponding to the roll-type substrate sheet (432).

[0183] A plurality of parallel folds form a plurality of longitudinally extending channels in the central portion or the roll-type substrate sheet (432). The plurality of channels extend in the longitudinal direction of the aerosol generating article (400) and form at least a portion of an airflow passage extending between the air inlet (411) and the air outlet (412).

[0184] The aerosol generating article (400) has a rectangular shape and has a height (or thickness) of 8 mm extending in the z-dimension, a width of 40 mm extending in the y-dimension, and a length of 60 mm extending in the x-dimension, as measured between the first planar outer surface (421) and the second planar outer surface (422). The frame (450) has a height (or thickness) of 7.93 mm extending in the z-dimension, a width of 40 mm extending in the y-dimension, and a length of 60 mm extending in the x-dimension. The cavity (430) has a height (or thickness) of 7.93 mm extending in the z-dimension, a width of 30 mm extending in the y-dimension, and a length of 50 mm extending in the x-dimension.

[0185] The roll-type substrate sheet (432) has a roll-type length equal to the cavity length. The roll-type substrate sheet (432) has a roll-type thickness equal to the cavity thickness. The roll-type substrate sheet (432) has a roll-type width equal to the cavity width.

[0186] During use of the aerosol generating article (400), the aerosol forming material (434) is heated to cause the aerosol forming material (434) to release a volatile compound, and then the volatile compound is entrained in the air drawn into the cavity (430) through the air inlet (411). Then, the volatile compound is cooled and condensed to form an aerosol, which can be drawn from the aerosol generating article (400) through the air outlet (412).

[0187] FIG. 12 illustrates a schematic cross-sectional view of an aerosol generating article (500) according to a fifth embodiment of the present disclosure. Features common to the aerosol generating article (300) are referred to by similar reference numerals, but start with the number 5 instead of the number 3.

[0188] The aerosol generating article (500) comprises a roll-type substrate sheet (532) containing an aerosol-forming substrate (534). A structural element (548) is surrounded by the roll-type substrate sheet (532).

[0189] In this embodiment, the roll-type substrate sheet (532) is rolled over more than two full turns around the longitudinal axis of the aerosol generating article (500). Thus, the roll-type substrate sheet (532) forms a plurality of layers of substrate sheets surrounding the structural element (545). The aerosol generating article (500) includes a rolling adhesive (not shown) configured to bond two portions of the roll-type substrate sheet (532) together. The rolling adhesive bonds radially adjacent portions of the roll-type substrate sheet (532) together. The rolling adhesive may be any suitable adhesive.

[0190] FIG. 13 shows a side view of an aerosol generating article (600) according to a sixth embodiment of the present disclosure. In this embodiment, the aerosol generating article (600) may be identical to article (300 or 500), except as described below.

[0191] The aerosol generating article (600) includes a roll-type substrate sheet (632) comprising a first section (635) comprising an aerosol-forming substrate (634).

[0192] The roll-type substrate sheet (632) includes a second section (637) comprising paper (636). The second section (637) is adjacent to the first section (635) along the roll length and is located downstream of the first section (635) at the proximal end of the roll-type substrate sheet (632) at the proximal end of the aerosol generating article (600). The first section (635) is located between the distal end and the proximal end of the roll-type substrate sheet (632).

[0193] The roll-type substrate sheet (632) includes a third section (639) containing paper (638). The first section (635) is located between the second section (637) and the third section (639).

[0194] The third section is adjacent to the first section (635) along the roll length and is located upstream of the first section (635) at the distal end of the roll base sheet (632) at the distal end of the aerosol generating article (600).

[0195] In this embodiment, any adhesive used in the aerosol generating article (600), such as a roll adhesive, a layer adhesive, or an element adhesive, is adhered to the second section (637) and the third section (639) of the roll substrate sheet (632).

[0196] FIG. 14 illustrates a schematic cross-sectional view of an aerosol generating article (700) according to a seventh embodiment of the present disclosure. In this embodiment, the aerosol generating article (700) is a variation of the aerosol generating article (300). Features common to the aerosol generating article (300) are referred to by similar reference numerals, but start with the number 7 instead of the number 3. The aerosol generating article (700) is identical to the aerosol generating article (300) except as described below.

[0197] The aerosol generating article (700) comprises a roll-type substrate sheet (732) comprising an aerosol-forming substrate (734). The roll-type substrate sheet (732) surrounds a structural element (745). In this embodiment, the roll-type substrate sheet (732) completes more than one full rotation around the structural element (745). As shown in FIG. 14, the roll-type substrate sheet (732) overlaps itself.

[0198] The aerosol generating article (700) further includes a wrapper (770). The wrapper (770) is a paper wrapper that surrounds a roll-type substrate sheet (732). The wrapper (770) is rolled around the central longitudinal axis of the aerosol generating article (700).

[0199] The aerosol-generating article includes a wrapper adhesive (not shown) that attaches a wrapper (770) to a roll-type substrate sheet (732). The wrapper adhesive is also applied to the wrapper (770) to attach the wrapper (770) to itself and to hold the wrapper (770) and the roll-type substrate sheet (732) together. The wrapper adhesive is applied to a paper section of the roll-type substrate sheet, rather than to the aerosol-forming substrate (734).

[0200] In this embodiment, the wrapper (770) is not formed integrally with the roll-type substrate sheet (732). However, it should be understood that in other embodiments, the wrapper and the roll-type substrate sheet may be formed integrally.

[0201] FIG. 15a illustrates a schematic cross-sectional view of a roll-type substrate sheet (832) according to the eighth embodiment of the present disclosure. Features common to the roll-type substrate sheet (332) are referred to by similar reference numerals, but start with the number 8 instead of the number 3.

[0202] The roll-type substrate sheet (832) includes an aerosol-forming substrate (834).

[0203] In this embodiment, the roll-type substrate sheet (832) is rolled in approximately three and a half complete turns, exceeding three complete turns around the longitudinal axis of the roll-type substrate sheet (832). Thus, the roll-type substrate sheet (832) forms multiple layers of substrate sheets. A rolling adhesive (not shown) is configured to bond two parts of the roll-type substrate sheet (832) together. The rolling adhesive bonds radially adjacent parts of the roll-type substrate sheet (832) together. The rolling adhesive may be any suitable adhesive.

[0204] FIG. 15b shows a schematic plan view of the roll-type substrate sheet (832) of FIG. 15a.

[0205] FIG. 15c illustrates a schematic perspective view of the roll-type substrate sheet (832) of FIG. 15a. As shown in FIG. 15a, 15b, and 15c, the roll-type substrate sheet (832) has a substantially stadium-shaped cross-section. The roll-type substrate sheet (832) has a roll-type length L R It has. In this example, the roll length L R The roll width W of the roll-type material (832) R It is at least twice as large. The roll-type material (832) also has a roll-type width W R Smaller roll-type height H R It has. In this example, the roll width W R Silver roll type height H R It is at least about 2 times larger than. However, in other examples, it should be understood that the roll-type substrate sheet can have any suitable cross-section, such as a circular or elliptical cross-section.

[0206] The roll-type material (832) can form part of any aerosol-generating article described herein.

[0207] FIG. 16 illustrates a schematic cross-sectional view of an aerosol generating article (800) comprising the roll-type substrate sheet (832) of FIG. 15a through 15c. Features common to the aerosol generating article (400) are referred to by similar reference numerals, but start with the number 8 instead of the number 4.

[0208] The roll-type substrate sheet (832) is configured to form part of the aerosol generating article (800) without requiring structural elements. For example, the roll-type substrate sheet (832) is located within the cavity (830) without the presence of structural elements.

[0209] The airflow passage extends through the cavity (830) between the air inlet and the air outlet of the aerosol generating article (800). At least a portion of the airflow passage is defined through the central region of the roll-type substrate sheet (832), which may be referred to as the airflow channel (860). The airflow channel (860) extends from the first end of the roll-type substrate sheet (832) to the second opposite end of the roll-type substrate sheet (832), so that air passing through the cavity (830) can come into contact with the roll-type substrate sheet (832) and, in particular, the aerosol forming material (834).

[0210] When the article is used, air may flow between the article air inlet and the article air outlet. The aerosol-forming material (834) is heated to cause the aerosol-forming material (834) to release a volatile compound, and then the volatile compound is entrained into the cavity (830) through the air inlet and into the air drawn through the airflow channel (860). Then, the volatile compound is cooled and condensed to form an aerosol, which can be drawn from the aerosol-generating article (800) through the air outlet (812).

[0211] FIGS. 17 and 18 illustrate an aerosol generating device (6000) configured for use with an aerosol generating article (900) comprising or made of an aerosol forming material (940). The device (6000) is an elongated aerosol generating device extending between a proximal end (6001) and a distal end (6002). The device (6000) includes a battery (6010), a controller (6020), and a heater (6030) located within a housing (6040). The controller (6020) controls the power supply from the battery (6010) to the heater (6030). A cavity (6050) is defined in the device (6000), and the cavity has an opening (6051) defined at the proximal end (6001) of the device. The opening (6051) is rectangular in shape and is dimensioned to accommodate a cross section of the aerosol generating article (900). The cavity (6050) includes an upper flat surface (6052) and a lower flat surface (6053). A heater (6030) is located within the lower flat surface (6053) to heat the lower surface of the aerosol generating article (900) inserted into the cavity (6050). An airflow path is configured so that air can flow from outside the device (6000) into the cavity (6050).

[0212] FIG. 19 illustrates the device (6000) of FIG. 17 engaging with an aerosol generating article (900). There is almost no tolerance between the outer surface of the aerosol generating article (900) and the inner surface of the cavity (6050). Therefore, there is a tight fit between the aerosol generating article (900) and the device (6000). Since the RTD of the aerosol generating article (900) is negligible, the RTD of the system formed by the combination of the aerosol generating article (900) and the aerosol generating device (6000) is controlled by an airflow path defined within the device. When a user inserts the aerosol generating article (900) into the cavity (6050), the device (6000) can be operated. A heater (6030) heats the lower surface of the aerosol generating article (900), and as a result, the aerosol forming substrate (940) of the aerosol generating article (900) is heated. The volatile component of the aerosol-forming substrate (940) evaporates and condenses into a longitudinal airflow channel defined within the aerosol-generating article (900) to form an aerosol. The user inhales the aerosol by inhaling the proximal end (901) of the aerosol-generating article (900). Once the volatile component in the aerosol-generating substrate (940) of the aerosol-generating article (900) is depleted, the aerosol-generating article is removed from the cavity (6050) of the device (6000) and disposed of. The aerosol-generating article (900) may be any one of the aerosol-generating articles (100, 200, 300, 400, 500, 600, 700, or 800) previously described in this disclosure or any other aerosol-generating article.

[0213] FIG. 19 illustrates a portion of an aerosol generating article (900) extending outside of an aerosol generating device (6000), but in other embodiments, the entire aerosol generating article may be completely enclosed within the aerosol generating device. As an example, FIG. 20 illustrates an alternative embodiment of FIG. 19, in which similar features are referred to by the same reference numeral but with the addition of the prime symbol '. In the alternative embodiment of FIG. 20, the entire aerosol generating article (900') is enclosed within the aerosol generating device (6000').

[0214] For the purposes of this description and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, etc., shall be understood in all cases to be modified by the term “about.” Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein. Accordingly, in this context, the number “A” is understood as 10% of “A” ± “A”. In this context, the number “A” may be considered to include numerical values ​​within the general standard error for measuring the characteristic modified by the number “A”. In some cases used in the appended claims, the number “A” may deviate by the percentage listed above, provided that the amount of deviation by “A” does not substantially affect the basic and novel feature(s) of the claimed invention. Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein. The terms “among them” and “here” are used as synonyms throughout this specification.

Claims

Claim 1 An aerosol generating article for generating an aerosol by using it in conjunction with an aerosol generating device, wherein the aerosol generating article comprises a substrate sheet including an aerosol forming substrate for generating an aerosol, wherein the substrate sheet is rolled to form a roll-type substrate sheet, and wherein the aerosol generating article is defined by an article length, an article width, and an article thickness, wherein the article length and article width are at least twice the article thickness. Claim 2 In claim 1, the roll-type substrate sheet is an aerosol generating article that is rolled around the longitudinal axis of the aerosol generating article. Claim 3 An aerosol generating article according to claim 1 or 2, wherein the roll-type substrate sheet is defined by a roll-type length extending parallel to the length of the article, and the roll-type length is 50 to 100% of the length of the article, preferably 60 to 90% of the length of the article, preferably 70 to 80% of the length of the article. Claim 4 An aerosol generating article according to any one of claims 1 to 3, wherein the roll-type substrate sheet is rolled at least twice, for example at least three times, four times, or five times. Claim 5 An aerosol generating article comprising a rolling adhesive configured to bond at least two portions of the roll-type substrate sheet together, in any one of claims 1 to 4. Claim 6 An aerosol generating article according to any one of claims 1 to 5, comprising at least two roll-type substrate sheets, for example, at least three, four, or five roll-type substrate sheets. Claim 7 In claim 6, the aerosol generating article wherein the roll-type substrate sheet is sequentially rolled to form at least first and second concentric layers of the roll-type substrate sheet. Claim 8 An aerosol generating article according to claim 7, comprising a layer adhesive configured to bond the first and second concentric layers of the roll-type substrate sheet together. Claim 9 An aerosol generating article comprising a structural element at least partially surrounded by the roll-type substrate sheet in any one of claims 1 to 8. Claim 10 In claim 9, the above structural element comprises a plurality of upwardly extending and downwardly extending portions configured such that at least one airflow channel extends between the proximal end and the distal end of the roll-type substrate sheet, an aerosol generating article. Claim 11 An aerosol generating article according to claim 9 or 10, wherein the structural element is a corrugated element including a corrugation. Claim 12 In any one of claims 3 to 11, the roll-type substrate sheet comprises a first section comprising the aerosol-forming substrate and a second section comprising a cellulose material, e.g., paper, wherein the first section is an aerosol-generating article adjacent to the second section along the roll-type length. Claim 13 An aerosol generating article comprising a wrapper surrounding the roll-type substrate sheet in any one of claims 1 to 12. Claim 14 In paragraph 13, the above wrapper forms the outer surface of the aerosol generating article. Claim 15 An aerosol generating system comprising: an aerosol generating article according to any one of claims 1 to 14; and an aerosol generating device, wherein the aerosol generating device A chamber for accommodating at least a portion of the above-mentioned aerosol generating article; and An aerosol generating system comprising an electric heater arranged to heat at least a portion of the aerosol generating article when the aerosol generating article is received within the chamber.

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