Aerosol-generating article comprising container

Abstract

There is provided an aerosol-generating article (100) for use with an aerosol-generating device (300). The aerosol-generating article (100) comprises a container (110). The container (110) comprises a first wall (111) and a second wall (112). The first wall (111) comprises a different material to the second wall (112). The first wall (111) and second wall (112) together define a substrate compartment (113). An aerosol-generating substrate (114) is provided in the substrate compartment (113). The first wall (111) comprises a flexible cellulosic material. The second wall (112) has a higher stiffness than the first wall (111).

Description

[0001] AEROSOL-GENERATING ARTICLE COMPRISING CONTAINER

[0002] The present disclosure relates to an aerosol-generating article comprising a container. In particular, the present invention relates to an aerosol-generating article comprising a container, the container comprising a first and a second wall. The present disclosure also relates to an aerosol-generating system comprising the aerosol-generating article and an aerosol-generating device configured to heat the aerosol-generating article.

[0003] Aerosol-generating articles in which an aerosol-generating substrate, such as a tobacco containing substrate, is heated rather than combusted are known in the art. In heated aerosolgenerating articles, the aerosol is generated by heating the aerosol-generating substrate.

[0004] It is known to provide a heating element for heating an aerosol-generating substrate of an aerosol-generating article. The heating element may be provided in the article in the form of a susceptor element, which is capable of being heated when penetrated by a varying magnetic field. Alternatively or additionally, the heating element may be provided in an aerosol-generating device for generating an inhalable vapor. Such a device may heat the aerosol-generating substrate contained in the aerosol-generating article without burning the aerosol-generating substrate. In doing so, the aerosol-generating substrate may generate an aerosol which may be delivered to a user.

[0005] Such aerosol-generating articles may take the form of a conventional cigarette. Where this is the case, the aerosol-generating substrate may be wrapped in cigarette paper. This approach may be appropriate where the aerosol-generating substrate comprises strands or spaghettis of material, for example strands of cast leaf tobacco or strands of shredded tobacco. However, this approach may not effectively retain other forms of aerosol-generating substrate, such as granulated or powdered aerosol-generating substrate.

[0006] Such aerosol-generating articles may be prone to leakage of the aerosol-generating substrates during storage, handling and use thereof. Leakage of the aerosol-generating substrates may be exacerbated by high environmental temperatures and humidities. Loss of aerosol-generating substrates through leakage may disadvantageously reduce the lifespan of the aerosol-generating article comprising the aerosol-generating substrate. Leakage of aerosolgenerating substrates may negatively impact the overall performance of the aerosol-generating article. For example, leakage of aerosol-generating substrates may negatively impact the consistency of the inhalable aerosol generated by an aerosol-generating system comprising the aerosol-generating article.

[0007] There is a need to provide an aerosol-generating article in which loss or leaking of the aerosol-generating substrate is reduced or prevented. The aerosol-generating article should achieve this without compromising the ability of the aerosol-generating substrate to generate and deliver an aerosol to a user.

[0008] There is a need to provide an aerosol-generating article which is substantially stable at the temperatures required to generate an aerosol from the aerosol-generating substrate. It would be desirable that the aerosol-generating article is still able to prevent leaking or loss of the aerosolgenerating substrate even when the aerosol-generating article is heated to the temperatures required to generate an aerosol from the aerosol-generating substrate.

[0009] There is a need to provide an aerosol-generating article which is able to retain different forms of aerosol-generating substrate, such as granulated or powdered aerosol-generating substrate.

[0010] There is a need to provide an aerosol-generating article which may be readily handled and manipulated by a consumer when it is being used in combination with a suitable aerosolgenerating device.

[0011] According to a first aspect of the present disclosure, there is provided an aerosolgenerating article for use with an aerosol-generating device. The aerosol-generating article may comprise a container. The container may comprise a first wall. The container may comprise a second wall. The first wall may comprise a different material to the second wall. The first wall and second wall may together define a substrate compartment. An aerosol-generating substrate may be provided in the substrate compartment. The first wall may comprise a flexible cellulosic material. The second wall may have a higher stiffness than the first wall.

[0012] According to a first aspect of the present invention, there is provided an aerosol-generating article for use with an aerosol-generating device. The aerosol-generating article comprises a container. The container comprises a first wall and a second wall. The first wall comprises a different material to the second wall. The first wall and second wall together define a substrate compartment. An aerosol-generating substrate is provided in the substrate compartment. The first wall comprises a flexible cellulosic material. The second wall has a higher stiffness than the first wall.

[0013] Providing a substrate compartment defined by the first wall and second wall of the container may advantageously allow the aerosol-generating article to accommodate a greater variety of aerosol-generating substrate, for example granulated or powdered aerosol-generating substrate.

[0014] The first wall comprises a different material to the second wall. In other words, the first wall comprises at least one component which does not form part of the second wall, or the second wall comprises at least one component which does not form part of the first wall. This provision may advantageously allow the first and second wall to have different properties tailored for different functions. As described in more detail below, the first and second walls may be configured to have different porosities, different thermal conductivities, or different stiffnesses. By providing a container where the first wall comprises a flexible material, the first wall may be able to deform to form a substrate compartment for receiving the aerosol-generating substrate. This may advantageously allow the container to receive a sufficient quantity of aerosolgenerating substrate compared to, for example, a container formed by two stiff walls.

[0015] The provision of a second wall which has a higher stiffness than the first wall may advantageously provide a relatively rigid portion for a user to hold and manipulate the aerosolgenerating article. In addition, the provision of a second wall which has a higher stiffness may advantageously maintain the shape and structure of the aerosol-generating article. This provision may also allow the second wall to be printed with branding or information.

[0016] The provision of a first wall comprising a cellulosic material may advantageously improve the thermal stability of the container. The inventors of the present invention have identified that cellulose remains substantially thermally stable at the temperatures at which typical aerosolgenerating substrates need to be heated in order to generate an aerosol. This may advantageously prevent the generation of undesirable thermal decomposition products during heating and may also ensure that the integrity of the container is maintained during use.

[0017] Providing a substrate compartment defined by the first wall and second wall of the container may advantageously reduce or prevent loss, for example by leakage, of the aerosolgenerating substrate during storage, handling and use of aerosol-generating articles according to the present invention. This may increase the lifespan of aerosol-generating articles according to the invention compared to known aerosol-generating articles. Reducing or preventing loss of the aerosol-generating substrate during storage, handling and use may advantageously improve the consistency of the inhalable aerosol generated by aerosol-generating articles according to the present invention compared to known aerosol-generating articles. Reducing or preventing loss of the aerosol-generating substrate during storage, handling and use of aerosol-generating articles according to the present invention may advantageously reduce or prevent damage to other components of aerosol-generating systems comprising the aerosol-generating substrate.

[0018] Providing a substrate compartment defined by the first wall and second wall of the container may advantageously reduce or prevent evaporation, migration or sublimation over time of the aerosol-generating substrate. This may advantageously increase the shelf-life of aerosolgenerating articles according to the present invention compared to known aerosol-generating articles. Preventing or reducing evaporation, migration or sublimation over time of the aerosolgenerating substrate may advantageously improve the perceived quality and consistency of the inhalable aerosol generated by aerosol-generating articles according to the present invention compared to known aerosol-generating articles. For example, preventing or reducing evaporation, migration or sublimation of the aerosol-generating substrate may advantageously improve the perceived taste of the inhalable aerosol generated by aerosol-generating articles according to the present invention compared to known aerosol-generating articles. Providing a substrate compartment defined by the first wall and second wall of the container may advantageously prevent or reduce thermal degradation of components of the aerosol-generating substrate when exposed to extreme temperatures, for example, during intense heating regimes. Preventing or reducing progressive thermal degradation of components of the aerosol-generating substrate, for example during use, may advantageously improve the perceived quality and consistency of the inhalable aerosol generated by aerosol-generating articles according to the present invention compared to known aerosol-generating articles. This may also advantageously increase the lifetime of aerosol-generating articles according to the present invention compared to known aerosol-generating articles. For example, preventing or reducing progressive thermal degradation over time of the aerosol-generating substrate may advantageously improve the perceived taste of the inhalable aerosol generated by aerosolgenerating articles according to the present invention compared to known aerosol-generating articles.

[0019] Providing a substrate compartment defined by the first wall and second wall of the container may advantageously result in more energy efficient aerosol generation compared to known aerosol-generating articles. In particular, advantageously, during use of the aerosolgenerating article the aerosol-generating substrate may be heated to a sufficient temperature to generate aerosol with a reduced amount of energy required to be supplied to a heater compared to known aerosol-generating articles. As a result, advantageously, during use of the aerosolgenerating article the aerosol-generating substrate may be heated to a sufficient temperature to generate aerosol earlier in the user experience, with less of a delay following actuation of the heater, than in known aerosol-generating articles.

[0020] Providing a substrate compartment defined by the first wall and second wall of the container may advantageously improve control over aerosol generation and delivery to a user compared to known aerosol-generating articles. In particular, advantageously, the number of aerosol-generating elements provided, the surface area of the aerosol-generating elements, the composition of the aerosol-generating elements, the structure of the aerosol-generating elements and arrangement of the aerosol-generating elements can be selected to control the rate of aerosol generation as it is heated during use of an aerosol-generating article.

[0021] Providing a substrate compartment defined by the first wall and second wall of the container may advantageously increase the rate of aerosolisation through the provision of a plurality of aerosol-generating elements with a larger total surface area for aerosolisation of the aerosol-generating substrate to occur from, compared to known aerosol-generating articles.

[0022] Providing a substrate compartment defined by the first wall and second wall of the container may advantageously allow the aerosol-generating article to be manufactured using existing manufacturing equipment. In particular, although the containers of the aerosolgenerating article of the present invention have significant differences compared to known oral pouches, existing equipment used for the manufacture of known oral pouches may be used or easily adapted for the manufacture of the aerosol-generating articles of the present invention.

[0023] The container may be a pouch.

[0024] In use, the aerosol-generating article may be inserted into an aerosol-generating device, the aerosol-generating device comprising a heating element. The heating element may heat the aerosol-generating article to a temperature at which the aerosol-generating substrate may generate an aerosol. This aerosol may be delivered from the aerosol-generating device to a user.

[0025] As used herein with reference to the present invention, the term “aerosol-generating substrate” denotes a substrate capable of releasing volatile compounds upon heating, which can condense to form an aerosol.

[0026] As used herein with reference to the present invention, the term “aerosol” denotes a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. The aerosol may be visible or invisible. The aerosol may include vapours of substances that are ordinarily liquid or solid at room temperature as well as solid particles, or liquid droplets, or a combination of solid particles and liquid droplets.

[0027] As used herein with reference to the present invention, the term “aerosol-generating article” denotes an article comprising an aerosol-generating substrate that is capable of releasing volatile compounds that can form an aerosol. An aerosol-generating article may be disposable.

[0028] The aerosol-generating article of the present invention is for an aerosol-generating device. That is, the aerosol-generating article may be configured to be used with an aerosol-generating device.

[0029] As used herein with reference to the present invention, the term “aerosol-generating device” denotes a device that interacts with an aerosol-generating substrate to generate an aerosol. In some examples, the aerosol-generating device heats the aerosol-generating substrate to facilitate release of volatile compounds from the substrate.

[0030] As used herein with reference to the present invention, the term “aerosol-generating system” refers to the combination of an aerosol-generating device and an aerosol-generating article.

[0031] As used herein with reference to the present invention, the term “flexible” is used to describe the ability of a material, in particular of the first wall of the container of the aerosolgenerating article, to bend easily without breaking. That is, the first wall of the aerosol-generating article has the ability to bend easily without breaking allowing the aerosol-generating article to conform to the shape of a heating chamber of an aerosol-generating device when the aerosolgenerating article is received therein.

[0032] As used herein with reference to the present invention, the term “stiffness” refers to the extent to which an object resists deformation in response to an applied force. The greater the force required for a given deformation, the greater the stiffness of the object. The higher the stiffness of a wall, the lower the flexibility of the wall. The stiffness of a wall may depend on both the elastic modulus of the material, and the thickness and shape of the wall. Stiffness may be characterised by the force on a body in a given direction divided by the displacement produced by that force in the same direction.

[0033] As used herein with reference to the present invention, the term “cellulosic material” refers to a material which is made from or is a derivative of cellulose.

[0034] The first wall may comprise any cellulosic material. The first wall may comprise a nonwoven material.

[0035] As used herein with reference to the present invention, the term “non-woven” refers to a manufactured sheet, web or batt of directionally or randomly orientated fibres, bonded by friction, and / or cohesion and / or adhesion, excluding products which are woven, knitted, tufted, stitch- bonded incorporating binding yarns or filaments, or felted by wet-milling, whether or not additionally needled. The fibres may be of natural or man-made origin.

[0036] The non-woven material may be a non-woven material prepared by hydroentanglement.

[0037] The non-woven material may be a non-woven material prepared by needle-punching.

[0038] The non-woven cellulosic material may be a non-woven material as defined by ISO standard 9092. The non-woven cellulosic material may be a non-woven material as defined by CEN EN 29092.

[0039] The non-woven cellulosic material may comprise fibres having a length to diameter ratio of at least 300, preferably at least 600.

[0040] The provision of a non-woven material may advantageously allow the first wall to be readily moulded into a desired shape to form the substrate compartment. The provision of a nonwoven cellulosic material may advantageously remove the need to form the first wall to comprise a polymeric material. This may be particularly advantageous since containers formed from polymeric fibres may not have suitable thermal stability at a temperature at which the aerosolgenerating substrate may generate an aerosol.

[0041] The first wall may contain no synthetic fibres.

[0042] The first wall may comprise a metallic material. For example, the first wall may comprise aluminium foil.

[0043] The first wall may comprise a composite material. The first wall may comprise both a layer of non-woven cellulosic material and a layer of aluminium foil. The layer of non-woven cellulosic material and the layer of aluminium foil may be co-laminated. The layer of non-woven cellulosic material may be coated with a layer of aluminium.

[0044] The first wall may comprise paper.

[0045] The first wall may be formable or shapable. In other words, the first wall may comprise a material which my be formed into a desired shape and may hold this shape once formed. The first wall may have any basis weight or grammage. The first wall may have a grammage of at least 50 gsm, at least 75 gsm, or at least 100 gsm.

[0046] The first wall may have a grammage of no more than 300 gsm, no more than 250 gsm, or no more than 200 gsm.

[0047] The first wall may have a grammage of between about 50 gsm and about 300 gsm, or between about 100 gsm and about 200 gsm. The first wall may have a grammage of about 150 gsm.

[0048] At least a portion of the first wall may allow air to pass through it. The first wall may include a first air permeable portion. The first air permeable portion may be disposed at a first longitudinal end of the first wall. The first wall may include a second air permeable portion. The second air permeable portion may be disposed at a second longitudinal end of the aerosol-generating article.

[0049] The first wall may include both a first air permeable portion and a second air permeable portion, the first air permeable portion may be disposed at a first longitudinal end of the first wall, and the second air permeable portion may be disposed at a second longitudinal end of the aerosol-generating article. In this way, air may be able to enter the substrate compartment through the first air permeable portion, entrain the aerosol from the aerosol-generating substrate, and pass out of the substrate compartment through the second air permeable portion. The portion of the first wall between the first air permeable portion and the second air permeable portion may be air impermeable. This may advantageously help to retain the aerosol-generating substrate in the substrate compartment and ensure generated aerosol is directed towards the consumer.

[0050] The first wall may include at least one perforation. At least one of the first and second air permeable portions may include at least one perforation. Alternatively, the entire first wall may comprise perforations. The at least one perforation may be sized to allow air to pass through but to prevent aerosol-generating substrate from passing through.

[0051] The at least one perforation may be a plurality of perforations.

[0052] The at least one perforation may have a diameter of greater than or equal to 5 micrometres, greater than or equal to 50 micrometres, greater than or equal to 100 micrometres, greater than or equal to 250 micrometres, or greater than or equal to 500 micrometres.

[0053] The at least one perforation may have a diameter of less than or equal to 3 millimetres, less than or equal to 2.5 millimetres, less than or equal to 2 millimetres, less than or equal to 1 millimetre, less than or equal to 500 micrometres, less than or equal to 250 micrometres, less than or equal to 50 micrometres, or less than or equal to 5 micrometres.

[0054] At least a portion of the first wall may be porous. At least one of the first and second air permeable portions may be porous. Alternatively, the entire first wall may be porous. The provision of at least one porous first wall portion may advantageously allow airflow into and out of the substrate compartment. This may allow a mainstream airflow to pass into the substrate compartment, entrain an aerosol generated by the aerosol-generating substrate, and pass out of the substrate compartment to deliver the aerosol to a user.

[0055] As used herein with reference to the present invention, the term “porous” refers to a material, in particular the first wall of the container of the aerosol-generating article, which allows allow air to pass bidirectionally therethrough. That is, the porous first wall of the container of the aerosol-generating article may allow air to pass through the first wall into the substrate compartment, mix with aerosol generated within the substrate compartment and then pass back through the first wall to be inhaled by a user. In this way, the first wall may be considered air permeable.

[0056] The aerosol-generating article may further comprise a first side cover. The first side cover may overlay at least a portion of the first wall. The first side cover may be non-porous. The provision of a first side cover may advantageously help to retain the aerosol-generating substrate within the substrate compartment where the first wall is air permeable. The first side cover may not overlay the first longitudinal end of the first wall. The first side cover may not overlay the second longitudinal end of the first wall. In this way, the areas of the first wall remaining exposed may define the first air permeable portion and a second air permeable portion.

[0057] The first side cover may comprise paper.

[0058] Preferably, the second wall comprises paper, the first wall comprises a non-woven material, and the first side cover comprises paper.

[0059] Preferably, the first side cover defines at least part of an outer surface of the aerosolgenerating article.

[0060] Preferably, the first side cover is configured to be positioned between the first wall and a heating element of an aerosol-generating device when the aerosol-generating article is used with an aerosol-generating device.

[0061] Preferably, the first side cover overlies at least a portion of the first wall along at least part of the length of the aerosol-generating article. Preferably, the first side cover is configured to overlie at least a portion of the first wall along a part of the length of the aerosol-generating article that is greater than or equal to a length of a heating element of an aerosol-generating device suitable for use with the aerosol-generating article.

[0062] Preferably, the first side cover overlies at least a portion of the first wall covering greater than or equal to 40 percent of the surface area of the first wall, greater than or equal to 50 percent of the surface area of the first wall, greater than or equal to 60 percent of the surface area of the first wall, greater than or equal to 70 percent of the surface area of the first wall, or greater than or equal to 80 percent of the surface area of the first wall.

[0063] Preferably, the first side cover overlies at least a portion of the first wall covering less than or equal to 95 percent of the surface area of the first wall, less than or equal to 90 percent of the surface area of the first wall, or less than or equal to 80 percent of the surface area of the first wall.

[0064] Preferably, the first side cover overlies at least a portion of the first wall along greater than or equal to 40 percent of the length of the aerosol-generating article, greater than or equal to 50 percent of the length of the aerosol-generating article, or greater than or equal to 60 percent of the length of the aerosol-generating article.

[0065] Preferably, the first side cover overlies at least a portion of the first wall along less than or equal to 90 percent of the length of the aerosol-generating article, less than or equal to 80 percent of the length of the aerosol-generating article, or less than or equal to 70 percent of the length of the aerosol-generating article.

[0066] Advantageously, providing a first side cover overlying at least a portion of the first wall as described herein may reduce or prevent direct contact between the first wall and a heating element of an aerosol-generating device suitable for use with the aerosol-generating article. Advantageously, reducing or preventing direct contact between the first wall and a heating element of an aerosol-generating device may prevent thermal damage to the first wall that may be caused by direct contact between the first wall and a heating element. Advantageously, reducing or preventing direct contact between the first wall and a heating element of an aerosolgenerating device may prevent overheating of the aerosol-generating substrate provided in the substrate compartment.

[0067] Advantageously, providing a first side cover overlying at least a portion of the first wall may improve the guiding of airflow through the container, for example between the first longitudinal end of the first wall and the second longitudinal end of the first wall.

[0068] Preferably, the first wall should be thermally stable at the temperatures at which typical aerosol-generating substrates need to be heated in order to generate an aerosol.

[0069] As used herein with reference to the present invention, the term “thermally stable” denotes a material that will not substantially thermally degrade or decompose when exposed to a given temperature range. In addition, it is important that the mechanical properties of the first wall are maintained at the temperatures at which typical aerosol-generating substrates need to be heated in order to generate an aerosol.

[0070] Preferably, the first wall should be thermally stable up to 230 degrees Celsius, more preferably up to 280 degrees Celsius. This is because typical aerosol-generating substrates need to be heated to between about 100 degrees Celsius and about 280 degrees Celsius in order to generate an aerosol.

[0071] The first wall formed from cellulosic material may have any cellulose content. The first wall may have a cellulose content of greater than or equal to 50 percent by weight, optionally greater than or equal to 60 percent by weight, optionally greater than or equal to 70 percent by weight, optionally greater than or equal to 80 percent by weight, or optionally greater than or equal to 90 percent by weight.

[0072] The inventors of the present invention have identified that the provision of a first wall having a relatively high cellulose content may advantageously improve the thermal stability of the first wall. This may advantageously prevent the generation of undesirable thermal decomposition products during heating and may also ensure that the integrity of the container is maintained during use.

[0073] The first wall formed from cellulosic material may have any lignin content. The first wall may comprise a lignin content of less than or equal to 15 percent by weight, optionally less than or equal to 10 percent by weight, or optionally less than or equal to 5 percent by weight.

[0074] The inventors of the present invention have identified that the provision of a first wall having a relatively high lignin content may disadvantageously lead to softening of the first wall at the temperatures at which typical aerosol-generating substrates need to be heated in order to generate an aerosol. The inventors have also observed that thermal degradation of the lignin occurs at temperatures at which typical aerosol-generating substrates need to be heated in order to generate an aerosol. This thermal degradation may include the cleavage of p-O-aryl ether linkages, and the formation of condensed phenolic and C=O containing structures. As a result, it is advantageous to provide a first wall having a relatively small lignin content.

[0075] Preferably, the first wall contains no lignin.

[0076] The first wall formed from cellulosic material may have any hemicellulose content. The first wall may comprise a hemicellulose content of less than or equal to 20 percent by weight, optionally less than or equal to 16 percent by weight, or optionally less than or equal to 12 percent by weight.

[0077] The inventors of the present invention have identified that the provision of a first wall having a relatively high hemicellulose content may disadvantageously lead to thermal degradation of the first wall at temperatures at which typical aerosol-generating substrates need to be heated in order to generate an aerosol. This thermal degradation may include the release of C=O and O-C-O bonds and the generation of CO, CO2, and CH4.

[0078] The first wall may comprise any cellulosic material. For example, the first wall may comprise one or more of cotton, coir, jute, flax, hemp, kenaf, ramie, sisal, pineapple leaf, banana, palmyrath, bamboo, sansevieria ehrenbergii, sansevieria cylindrica, curaua, bagasse, phormium tenax, agave, sea grass, alfa, what straw, oil palm, henequen, or coconut tree leaf.

[0079] Preferably, the first wall comprises one or more of viscose, flax, hemp and cotton. The inventors have identified that these materials advantageously include a relatively high cellulose content and a relatively low lignin and hemicellulose content. This may advantageously allow these materials to be thermally stable at the temperatures at which typical aerosol-generating substrates need to be heated in order to generate an aerosol. The first wall may comprise an alginate based material. The first wall may comprise an alginate based non-woven material.

[0080] The second wall may be porous. The second wall may be non-porous.

[0081] Where the second wall is non-porous, air and aerosol is prevented from passing into and out of the substrate compartment through the second wall.

[0082] The provision of a non-porous second wall may prevent aerosol or aerosol-former from leaving the container through the second wall. This may advantageously allow the second wall to be placed in direct contact with a heating element of an aerosol-generating device without the heating element becoming contaminated with aerosol or aerosol-former. The provision of a non- porous second wall may also help to correctly direct airflow through the aerosol-generating article.

[0083] The second wall may comprise a substantially planar material.

[0084] In this way, the first wall may form the main body of the substrate compartment, with the second wall essentially closing the substrate compartment. The provision of a substantially planar second wall may advantageously maximize the contact area of the second wall with a similarly planar heating element when the second wall is brought into contact with a heating element of an aerosol-generating device. This may advantageously maximise the heat transfer between the heating element and the second wall to maximise the aerosol-generation from the aerosolgenerating substrate.

[0085] As used herein with reference to the present invention, the term “planar material” refers to a material which generally takes the form of a plane. For example, the planar material may be a sheet like material. The planar material may not include any folds or bends which cause the planar material to extend out of a single plane. The substantially planar material may nevertheless be a flexible material.

[0086] The second wall may comprise one or more of paper, non-woven cellulosic material and tobacco cast leaf. Where the second wall comprises tobacco cast leaf, the tobacco cast leaf may be in direct contact with a heating element of an aerosol-generating device when in use. In this way, the tobacco cast leaf may advantageously generate an aerosol which may be delivered to a user.

[0087] The second wall may comprise a coating. The second wall may comprise anti-staining paper.

[0088] The second wall may have any basis weight or grammage. The second wall may have a grammage of at least 15 gsm, at least 20 gsm, or at least 30 gsm.

[0089] The second wall may have a grammage of no more than 300 gsm, no more than 250 gsm, no more than 200 gsm, or no more than 150 gsm. This may be the case where the second wall comprises tobacco cast leaf.

[0090] The second wall may have a grammage of no more than 100 gsm, no more than 50 gsm, or no more than 35 gsm. The second wall may have a grammage of between 30 gsm and 35 gsm. The second wall may have an grammage of about 35 gsm.

[0091] The provision of a second wall having a grammage within this range may advantageously provide the higher stiffness required compared to the first wall. As described above, the provision of a second wall having a higher stiffness may advantageously maintain the shape and structure of the aerosol-generating article.

[0092] The first wall and the second wall may meet to define a contact region extending around the container.

[0093] The contact region may circumscribe the substrate compartment. In this way, the contact region may advantageously effectively retain the aerosol-generating substrate within the substrate compartment. The contact region has a thickness. In this way, the provision of a contact region, rather than just a contact line, may advantageously improve the security of the retention of the aerosol-generating substrate within the substrate compartment.

[0094] The contact region may have any thickness. For example, the contact region may have a thickness of at least 1 millimetre, at least 2 millimetres, or at least 3 millimetres. The contact region may have a thickness of no more than 5 millimetres, no more than 4.5 millimetres, or no more than 4 millimetres. The contact region may have a thickness of about 3.5 millimetres.

[0095] As used herein with reference to the present invention, the term “thickness of the contact region” refers to the dimension of the contact region between the radially inner edge of the contact region to the radial outer edge of the contact region when measured along the same radius.

[0096] The contact region may comprise a sealing region defined by a first wall sealing portion and a second wall sealing portion. In other words, the sealing region may be defined by at least a portion of the first wall corresponding to the first wall sealing portion and at least a portion of the second wall corresponding to the second wall sealing portion. The first wall sealing portion may have the same shape as the second wall sealing portion. The first wall sealing portion may overlay the second wall sealing portion to form the contact region. The first wall sealing portion may be in contact with the second wall sealing portion to form the contact region. The sealing region may correspond to the contact region. The sealing region may be smaller than the contact region.

[0097] The sealing region may be arranged to at least partially circumscribe the substrate compartment of the container. The sealing region may be arranged to fully circumscribe the substrate compartment of the container.

[0098] The sealing region may comprise the first wall sealing portion and the second wall sealing portion, and preferably at least a portion of the first side cover. The sealing region may be defined by the first wall sealing portion, the second wall sealing portion and at least a portion of the first side cover. In other words, the sealing region may be defined by at least a portion of the first wall corresponding to the first wall sealing portion, at least a portion of the second wall corresponding to the second wall sealing portion and at least a portion of the first side cover. In particular, the sealing region may comprise the following layers in order: at least a portion of the first side cover, at least a portion of the first wall corresponding to the first wall sealing portion and at least a portion of the second wall corresponding to the second wall sealing portion. Preferably, the sealing region comprises the following layers of material in order: paper, non-woven material and paper. At least a portion of the first side cover may overlie the first wall sealing portion, and the first wall sealing portion may overlie the second wall sealing portion to form the contact region. At least a portion of the first side cover may be in contact with the first wall sealing portion, and the first wall sealing portion may be in contact with the second wall sealing portion to form the contact region. The sealing region may correspond to the contact region. The sealing region may be smaller than the contact region.

[0099] The sealing region may have any thickness. For example, the sealing region may have a thickness of at least 1 millimetre, at least 2 millimetres, or at least 3 millimetres. The sealing region may have a thickness of no more than 5 millimetres, no more than 4.5 millimetres, or no more than 4 millimetres. The sealing region may have a thickness of about 3.5 millimetres.

[0100] The sealing region may comprise an adhesive. The adhesive may comprise polyvinyl alcohol.

[0101] The first wall sealing portion and the second wall sealing portion may be joined by the adhesive. The first wall sealing portion, the second wall sealing portion and at least a portion of the first side cover may be joined by the adhesive.

[0102] Preferably, a line extending perpendicular to the sealing region does not intersect the substrate compartment of the container.

[0103] Advantageously, providing the sealing region as described herein may allow pressure to be applied to the sealing region during manufacture, for example to bond the components of the sealing region together, whilst avoiding an application of pressure to the substrate compartment that may damage the aerosol-generating substrate received in the substrate compartment. Advantageously, providing the sealing region as described herein may allow the aerosolgenerating article to deform without damage to the sealing region.

[0104] The adhesive may comprise ethylene vinyl acetate. The adhesive may comprise a polyvinyl alcohol-ethylene vinyl acetate copolymer. The provision of an adhesive may advantageously help to retain the aerosol-generating substrate within the substrate compartment. Preferably the adhesive is thermally stable at the temperatures required to generate an aerosol from the aerosol-generating substrate. The use of a polyvinyl alcohol based adhesive is advantageous since this adhesive will remain stable at the temperatures required to generate an aerosol from the aerosol-generating substrate.

[0105] Preferably, the adhesive is food-safe. Preferably, the adhesive is non-toxic.

[0106] The adhesive may be an infused adhesive. The first wall sealing portion of the first wall and the second wall sealing portion of the second wall may be joined together with the infused adhesive. In other words, the adhesive may be infused within the first wall sealing portion and the second wall sealing portion to bond the first wall sealing portion and the second wall sealing portion together.

[0107] The first wall sealing portion, the second wall sealing portion and at least a portion of the first side cover may be joined together with the infused adhesive. In other words, the adhesive may be infused within the first wall sealing portion, the second wall sealing portion and at least a portion of the first side cover to bond the first wall sealing portion, the second wall sealing portion and at least a portion of the first side cover together.

[0108] The adhesive may have any viscosity. For example, the adhesive may have a viscosity of at least 50 centipoise (cP), at least 100 centipoise, or at least 180 centipoise.

[0109] The adhesive may have a viscosity of no more than 300 centipoise, no more than 250 centipoise, or no more than 230 centipoise.

[0110] The adhesive may have a viscosity of between about 50 centipoise and about 300 centipoise, between about 100 centipoise and about 250 centipoise, or between about 180 centipoise and about 230 centipoise.

[0111] The adhesive may have a viscosity of about 205 centipoise.

[0112] The sealing region may comprise any mass of adhesive. For example, the sealing region may comprise at least 1 milligram, at least 5 milligrams, or at least 8 milligrams of adhesive.

[0113] The sealing region may comprise no more than 30 milligrams, no more than 15 milligrams, or no more than 12 milligrams of adhesive.

[0114] The sealing region may comprise between about 1 milligram and about 30 milligrams of adhesive, between about 5 milligrams and about 15 milligrams of adhesive, or between about 8 milligrams and about 12 milligrams of adhesive.

[0115] The sealing region may comprise about 10 milligrams of adhesive.

[0116] The adhesive may be provided on only a portion of the sealing region. Preferably, the adhesive is provide on the entire sealing region. This may effectively connect the first wall to the second wall and improve the security of the retention of the aerosol-generating substrate within the substrate compartment.

[0117] Alternatively or in addition, the sealing region may comprise mechanical sealing.

[0118] The first wall sealing portion and the second wall sealing portion may be joined by mechanical sealing.

[0119] The first wall sealing portion, the second wall sealing portion and at least a portion of the first side cover may be joined by mechanical sealing.

[0120] The mechanical sealing may comprise one or both of stitching and welding. The welding may be ultrasonic welding. In other words, the first wall and the second wall, and optionally at least a portion of the first side cover, may be joined by one or both of stitching and welding, for example ultrasonic welding.

[0121] The sealing region may comprise at least one line of stitching. The row of stitching may extend along the entire sealing region to effectively connect the first wall to the second wall and improve the security of the retention of the aerosol-generating substrate within the substrate compartment.

[0122] The row of stitching may extend along the entire sealing region to effectively connect the first wall, the second wall and the first side cover, and may improve the security of the retention of the aerosol-generating substrate within the substrate compartment.

[0123] The sealing region may comprise a flavourant. The sealing region may comprise flavourant on one or more surfaces of the sealing region. The sealing region may comprise flavourant within the sealing region, for example within the infused adhesive. The flavourant of the sealing region may have a different composition to the aerosol-generating substrate provided in the substrate compartment. For example, the flavourant of the sealing region may comprise a different polyhydric alcohol content to the aerosol-generating substrate.

[0124] Advantageously, providing the sealing region comprising a flavourant may provide a more sustained flavour release profile during use of the aerosol-generating article. In particular, providing the sealing region comprising a flavourant may allow the flavourant to be heated to a lesser extent and more indirectly compared to the aerosol-generating substrate provided in the substrate compartment. Advantageously, providing the sealing region comprising a flavourant may allow the inclusion of a flavourant that is configured to be volatilised at a lower temperature than the aerosol-generating substrate.

[0125] The aerosol-generating article may further comprise a ring element extending around the contact region.

[0126] The ring element may advantageously act to strengthen the contact region and to improve the connection between the first wall sealing portion and second wall sealing portion. The ring element may also provide a relatively stiff portion to enable a user to readily hold and manipulate the aerosol-generating article.

[0127] The ring element may have a higher stiffness than the first wall. The ring element may have a higher stiffness than the second wall. The ring element may have a higher stiffness than both the first wall and the second wall.

[0128] The ring element may overlie at least a portion of the contact region. The ring element may conform to the shape of the contact region. The ring element may extend beyond the contact region.

[0129] The ring element may overlie at least a portion of the sealing region. The ring element may conform to the shape of the sealing region. The ring element may extend beyond the sealing region. The ring element may have a greater grammage than the second wall. The provision of a ring element having a higher grammage than the second wall may advantageously increase the stiffness and strength of the ring element.

[0130] The ring element may have a greater grammage than the first wall.

[0131] The ring element may have any grammage. The ring element may have a grammage of at least 20 gsm, at least 30 gsm, at least 80 gsm, at least 90 gsm, or at least 95 gsm. The ring element may have a grammage of no more than 120 gsm, no more than 1 10 gsm, or no more than 105 gsm.

[0132] The ring element may have a grammage of between about 80 gsm and about 120 gsm, between about 90 gsm and about 110 gsm, or between about 95 gsm and 105 gsm.

[0133] The ring element may have a grammage of about 100 gsm.

[0134] The ring element may comprise any material. For example, the ring element may comprise cardboard, a polymeric material, a metallic material, a non-woven material, or a non- porous wrap. The ring element may comprise paper. The ring element may comprise non-porous paper. Ring element may comprise paper having an anti-stain coating. The anti-stain coating may comprise poly vinyl alcohol.

[0135] The ring element may comprise a combination of materials. For example, the ring element may comprise a combination of paper, a non-woven material, and non-porous wrap.

[0136] The ring element may extend outwardly beyond the contact region. For example, the ring element may extend beyond the radial outer edge of the contact region. This may prevent users from coming into direct contact with the contact region. This may advantageously protect the contact region and improve the retention of the aerosol-generating substrate within the substrate compartment. The ring element may also advantageously provide a flat, stiff surface onto which adhesive may be easily applied. The ring element may also provide a flat, stiff surface onto which branding or information may be printed.

[0137] The ring element may have any thickness. For example, the ring element may have a thickness of at least 1 millimetre, at least 2 millimetres, or at least 3 millimetres. The ring element may have a thickness of no more than 5 millimetres, no more than 4.5 millimetres, or no more than 4 millimetres. The ring element may have a thickness of about 3.5 millimetres.

[0138] As used herein with reference to the present invention, the term “thickness of ring element” refers to the dimension of the ring element between the radially inner edge of the ring to the radial outer edge of the ring element when measured along the same radius.

[0139] The ring element may have a thickness of greater than equal to 1 millimetre.

[0140] The ring element may have a thickness of less than equal to 5 millimetres.

[0141] The ring element may be secured to the first wall or the second wall. Where this is the case, the ring element is on either a first or a second side of the contact region. Preferably, the ring element is secured to the first wall. The ring element may be secured to both the first wall and the second wall. Where this is the case, the ring element may be disposed between the first wall and the second wall.

[0142] The ring element may be secured to the first wall by an adhesive. The ring element may be secured to the second wall by an adhesive. The ring element may be secured to both the first wall and the second wall by an adhesive.

[0143] The ring element may be secured to one or both of the first wall and the second wall by an adhesive.

[0144] The adhesive may be any adhesive. The adhesive may be polyvinyl alcohol adhesive. As described above, the use of a polyvinyl alcohol based adhesive is advantageous since this adhesive will remain stable at the temperatures required to generate an aerosol from the aerosolgenerating substrate.

[0145] The ring element may be secured to one or both of the first wall and the second wall, and preferably the first side cover, by mechanical sealing. The mechanical sealing may comprise one or more of stitching and welding. The welding may be ultrasonic welding. In other words, the first wall and the second wall, and preferably the first side cover, may be joined to the ring element by one or more of stitching and welding, for example ultrasonic welding.

[0146] The ring element may comprise a flavourant. The ring element may comprise flavourant on one or more surfaces of the ring element. The flavourant of the ring element may have a different composition to the aerosol-generating substrate provided in the substrate compartment. For example, the flavourant of the ring element may comprise a different polyhydric alcohol content to the aerosol-generating substrate

[0147] Advantageously, providing the ring element comprising a flavourant may provide a more sustained flavour release profile during use of the aerosol-generating article. In particular, providing the ring element comprising a flavourant may allow the flavourant to be heated to a lesser extent and more indirectly compared to the aerosol-generating substrate provided in the substrate compartment. Advantageously, providing the ring element comprising a flavourant may allow the inclusion of a flavourant that is configured to be volatilised at a lower temperature than the aerosol-generating substrate.

[0148] The shape of the container may be substantially reflectively symmetrical about a plane containing the contact region.

[0149] In this way, the first wall and second wall may have substantially the same shape.

[0150] The shape of the container may be reflectively asymmetrical about a plane containing the contact region.

[0151] In this way, the first wall and second wall may not have the same shape.

[0152] As described above, the provision of an asymmetrical container may advantageously allow the first wall and second wall to serve different functions. The first wall may have a generally non-planer shape to define an open container. The second wall may be substantially flat. In this way, the second wall may close the open container formed by the first wall such that the first wall and the second wall together define the substrate compartment.

[0153] The aerosol-generating substrate may be a homogenised aerosol-generating substrate.

[0154] As used herein with reference to the present invention, the term “homogenised aerosolgenerating substrate” refers to an aerosol-generating substrate formed by agglomerating particulate material.

[0155] The aerosol-generating substrate may comprise one or more of tobacco, a botanical material and a plurality of aerosol-generating elements.

[0156] The aerosol-generating substrate may comprise homogenised tobacco material. The aerosol-generating substrate may comprise a plurality of shreds of tobacco material, such as tobacco cut filler or shreds of homogenised tobacco material.

[0157] Shreds of homogenised tobacco material may be formed from a sheet of homogenised tobacco material, for example, by cutting or shredding. Shreds of homogenised tobacco material may be formed by other methods, for example, by extrusion.

[0158] The aerosol-generating substrate may comprise botanical material. The botanical material may be a non-tobacco plant material. The botanical material may be a powder.

[0159] The botanical material may be selected from one or more of hemp flower, chrysanthemum, cardamom, star anise, red clover flower, chamomile, passionflower, lavender, rose petals, elderflower, jasmine, bay leaf, kaffir lime, orange leaves, lemon verbena, coriander, thyme, cumin, rosemary, allspice, sage, nutmeg, ginseng, clove, corn silk, garlic, garlic powder, basil, shallot, lotus leaf, curry powder, betel leaves, cayenne paper, tea leaves, palm sugar, ginger, galangal, turmeric, pangium edule, cinnamon, black paper, kaempferia galanga, pepper, jalapeno, onion, lemon grass, celery, vanilla, chives, tamarind, suji leaves, dried chili, chili powder, Mace, talas beneng, fennel, oregano, mint leaves, parsley, nipah leaves, benzoin, candlenut, and rheum officinale.

[0160] Advantageously, providing an aerosol-generating article comprising a container as described herein may allow the aerosol-generating article to effectively retain a range of forms and types of aerosol-generating substrate, such as botanical material in the form of a powder. Advantageously, the container may effectively retain botanical material in the form of a powder without requiring complex processing of the botanical material, such as a cast leaf process, that may require exposure to high temperatures or aqueous media that may result in loss or decomposition of sensitive volatile species or active ingredients that may be in the botanical material.

[0161] The sealing region may comprise a flavourant and the aerosol-generating substrate may comprise tobacco. Alternatively, the sealing region may comprise a flavourant and the aerosolgenerating substrate may comprise non-tobacco plant material, such as botanical material. The ring element may comprise a flavourant and the aerosol-generating substrate may comprise tobacco. Alternatively, the ring element may comprise a flavourant and the aerosolgenerating substrate may comprise non-tobacco plant material, such as botanical material.

[0162] The plurality of aerosol-generating elements may comprise a carrier medium and a liquid or gel sorbed in the carrier medium.

[0163] The carrier medium may comprise a solid continuous matrix structure and a solid porous substrate dispersed within the solid continuous matrix structure.

[0164] The solid continuous matrix structure may be an alginate matrix.

[0165] Alginate is a “matrix-forming polymer”, this term being used herein to denote an encapsulation material in the form of a polymer which is capable of producing a three-dimensional polymer matrix as a result of cross-linking when the matrix-forming polymer is brought into contact with a cross-linking solution of multivalent cations. The resultant polymer matrix is capable of trapping and retaining the aerosol-generating substrate within its cross-linked structure.

[0166] The aerosol-generating element may comprise an aerosol-generating substrate dispersed within the solid continuous matrix structure.

[0167] The plurality of aerosol-generating elements may have any diameter. The plurality of aerosol-generating elements may have a diameter of at least 0.25 millimetres, at least 0.5 millimetres, or at least 1 millimetre. The plurality of aerosol-generating elements may have a diameter of no more than 4 millimetres, or no more than 3 millimetres. The plurality of aerosolgenerating elements may have a diameter of between about 0.5 millimetres and 3 millimetres, or between about 1 millimetre and about 3 millimetres.

[0168] The first wall may be configured to prevent aerosol-generating substrate from passing through the first wall. The first wall may be configured to prevent the plurality of aerosol-generating elements from passing through the first wall. The first wall may be configured to prevent the plurality of aerosol-generating elements having a diameter of at least 0.25 millimetres, at least 0.5 millimetres, or at least 1 millimetre from passing through the first wall.

[0169] The first wall may be a mesh. The first wall may be a mesh that is configured to prevent the plurality of aerosol-generating elements having a diameter of at least 0.25 millimetres, at least 0.5 millimetres, or at least 1 millimetre from passing through the first wall.

[0170] The first wall may be a mesh comprising a plurality of openings each having a diameter of greater than or equal to 5 micrometres, greater than or equal to 50 micrometres, greater than or equal to 0.25 millimetres, greater than or equal to 0.5 millimetres, or greater than or equal to 1 millimetre.

[0171] The first wall may be a mesh comprising a plurality of openings each having a diameter of less than or equal to 3 millimetres, less than or equal to 2.5 millimetres, less than or equal to 2 millimetres, less than or equal to 1 millimetre, less than or equal to 0.5 millimetres, less than or equal to 0.25 millimetres, less than or equal to 50 micrometres, or less than or equal to 5 micrometres.

[0172] Advantageously, providing a first wall that is a mesh having the plurality of openings each having a diameter as described herein may allow air to pass through the first wall whilst preventing aerosol-generating substrate from passing through the first wall.

[0173] The aerosol-generating substrate may comprise at least one alkaloid.

[0174] As used herein with reference to the present invention, the term “alkaloid compound” is used to describe any one of a class of naturally occurring organic compounds that contain one or more basic nitrogen atoms. Generally, an alkaloid contains at least one nitrogen atom in an amine-type structure. This or another nitrogen atom in the molecule of the alkaloid compound can be active as a base in acid-base reactions. Most alkaloid compounds have one or more of their nitrogen atoms as part of a cyclic system, such as for example a heterocylic ring. In nature, alkaloid compounds are found primarily in plants, and are especially common in certain families of flowering plants. However, some alkaloid compounds are found in animal species and fungi. In the context of the present invention, the term “alkaloid compounds” is used to describe both naturally derived alkaloid compounds and synthetically manufactured alkaloid compounds. Suitable alkaloid compounds for use in an aerosol-generating element in accordance with the invention include, but are not limited to, nicotine and anatabine.

[0175] In preferred embodiments, the aerosol-generating substrate comprises nicotine or anatabine.

[0176] In particularly preferred embodiments, the aerosol-generating substrate comprises nicotine.

[0177] As used herein with reference to the invention, the term “nicotine” is used to describe nicotine, a nicotine base or a nicotine salt. In embodiments in which the aerosol-generating substrate comprises a nicotine base or a nicotine salt, the amounts of nicotine recited herein are the amount of free base nicotine or amount of protonated nicotine, respectively.

[0178] The aerosol-generating substrate may comprise natural nicotine or synthetic nicotine.

[0179] The aerosol-generating substrate may comprise one or more monoprotic nicotine salts.

[0180] As used herein with reference to the invention, the term “monoprotic nicotine salt” is used to describe a nicotine salt of a monoprotic acid.

[0181] The aerosol-generating substrate may comprise nicotine.

[0182] The aerosol-generating substrate may comprise an aerosol-former. The aerosolgenerating substrate may contain any amount of aerosol-former. The aerosol-generating substrate may comprise at least 50 weight percent, at least 60 weight percent, or at least 70 weight percent aerosol-former. The aerosol-generating substrate may comprise about 80 weight percent aerosol-former.

[0183] The aerosol-generating substrate may comprise a polyhydric alcohol. The polyhydric alcohol acts as the aerosol-former for the aerosol-generating substrate. Polyhydric alcohols suitable for use in the aerosol-generating substrate include, but are not limited to, propylene glycol, triethylene glycol, 1 ,3-butanediol, and glycerin. Preferably, in an aerosolgenerating substrate in accordance with the invention the polyhydric alcohol is selected from the group consisting of glycerin, propylene glycol, and combinations thereof. In particularly preferred embodiments the polyhydric alcohol is glycerin.

[0184] The aerosol-generating substrate may comprise granules. The granules may have any diameter. The aerosol-generating substrate may comprise granules with a diameter of greater than or equal to 100 micrometres, greater than or equal to 250 micrometres, or greater than or equal to 500 micrometres.

[0185] The aerosol-generating substrate may comprise granules with a diameter of less than or equal to 5 millimetres, less than or equal to 4 millimetres, or less than or equal to 3 millimetres.

[0186] The aerosol-generating substrate may comprise granules with a diameter of between 500 micrometres and 3 millimetres. The aerosol-generating substrate may comprise granules with a diameter of about 1 .5 millimetres.

[0187] The substrate compartment may contain any mass of aerosol-generating substrate. For example, the substrate compartment may contain at least 80 milligrams of aerosol-generating substrate, at least 85 milligrams of aerosol-generating substrate, or at least 90 milligrams of aerosol-generating substrate.

[0188] The substrate compartment may contain at no more than 300 milligrams of aerosolgenerating substrate, no more than 250 milligrams of aerosol-generating substrate, or no more than 200 milligrams of aerosol-generating substrate.

[0189] The substrate compartment may contain between 80 milligrams and 300 milligrams of aerosol-generating substrate, between 85 milligrams and 250 milligrams of aerosol-generating substrate, and between 100 milligrams and 200 milligrams of aerosol-generating substrate.

[0190] The substrate compartment may have any length. The substrate compartment may have a length of at least 10 millimetres, or at least 15 millimetres. The substrate compartment may have a length of no more than 30 millimetres, or no more than 20 millimetres.

[0191] The substrate compartment may have a length of between about 10 millimetres and about 30 millimetres, or between about 15 millimetres and about 20 millimetres. The substrate compartment may have a length of about 17 millimetres.

[0192] As used herein with reference to the present invention, the term “length” is used to describe the maximum dimension of elements, or portions of elements, of aerosol-generating articles according to the disclosure. The length may be defined in the longitudinal direction or along a longitudinal axis. The aerosol-generating article may have any length. The length of the aerosol-generating article may be the same as the length of the substrate compartment. The length of the aerosolgenerating article may be greater than the length of the substrate compartment.

[0193] The aerosol-generating article may have a length of at least 13 millimetres, or at least 18 millimetres. The aerosol-generating article may have a length of no more than 33 millimetres, or no more than 23 millimetres.

[0194] The aerosol-generating article may have a length of between about 13 millimetres and about 33 millimetres, or between about 18 millimetres and about 23 millimetres. The aerosolgenerating article may have a length of about 20 millimetres or about 22 millimetres.

[0195] The substrate compartment may have any width. The substrate compartment may have a width of at least 5 millimetres, or at least 6 millimetres. The substrate compartment may have a width of no more than 15 millimetres, or no more than 10 millimetres.

[0196] The substrate compartment may have a width of between about 5 millimetres and about 15 millimetres, or between about 6 millimetres and about 10 millimetres. The substrate compartment may have a width of about 8 millimetres.

[0197] As used herein with reference to the present invention, the term “width” is used to describe the second longest orthogonal dimension of elements, or portions of elements, of aerosolgenerating articles according to the disclosure. The width of the substrate compartment is perpendicular to the length of the substrate compartment.

[0198] The aerosol-generating article may have any width. The width of the aerosol-generating article may be the same as the width of the substrate compartment. The width of the aerosolgenerating article may be greater than the width of the substrate compartment.

[0199] The aerosol-generating article may have a width of at least 8 millimetres, or at least 9 millimetres. The aerosol-generating article may have a width of no more than 18 millimetres, or no more than 13 millimetres.

[0200] The aerosol-generating article may have a width of between about 8 millimetres and about 18 millimetres, or between about 9 millimetres and about 13 millimetres. The aerosol-generating article may have a width of about 11 millimetres or about 10 millimetres.

[0201] The substrate compartment may have any depth. The substrate compartment may have a depth of at least 1 millimetre, at least 2 millimetres, or at least 3 millimetres. The substrate compartment may have a depth of no more than 10 millimetres, no more than 6 millimetres, or no more than 4 millimetres.

[0202] The substrate compartment may have a depth of between about 1 millimetre and about 11 millimetres, between about 2 millimetres and about 6 millimetres, or between about 3 millimetres and about 4 millimetres. The substrate compartment may have a depth of about 3.5 millimetres. As used herein with reference to the present invention, the term “depth” is used to describe the shortest orthogonal dimension of elements, or portions of elements, of aerosol-generating articles according to the disclosure. The depth of the substrate compartment is perpendicular to the length and the width of the substrate compartment.

[0203] The depth of the aerosol-generating article may be the same as the depth of the substrate compartment.

[0204] During use, air may flow along a length of the aerosol-generating article. This may ensure that the airflow passes along the longest dimension of the substrate compartment which may advantageously ensure that the maximum quantity of aerosol is able to be entrained by the air passing through the substrate compartment.

[0205] As described above, the first wall may be thermally stable up to at least 230 degrees Celsius, more preferably up to at least 280 degrees Celsius.

[0206] The second wall may be thermally stable up to at least 230 degrees Celsius, more preferably up to at least 280 degrees Celsius.

[0207] The first wall may be thermally stable between 100 degrees Celsius and 280 degrees Celsius, optionally between 180 degrees Celsius and 230 degrees Celsius.

[0208] The second wall may be thermally stable between 100 degrees Celsius and 280 degrees Celsius, optionally between 180 degrees Celsius and 230 degrees Celsius.

[0209] The first wall and the second wall may be thermally stable between 100 degrees Celsius and 280 degrees Celsius, optionally between 180 degrees Celsius and 230 degrees Celsius.

[0210] As described above, typical aerosol-generating substrates need to be heated to between about 100 degrees Celsius and about 280 degrees Celsius in order to generate an aerosol. Ensuring that the first and second walls of the are thermally stable at this temperature may advantageously prevent the generation of undesirable thermal decomposition products during heating and may also ensure that the integrity of the container is maintained during use.

[0211] According to a second aspect of the present disclosure, there is provided an aerosolgenerating system. The aerosol-generating system may comprise an aerosol-generating article according to the first aspect of the present invention. The aerosol-generating system may comprise an aerosol-generating device configured to heat the aerosol-generating article.

[0212] According to a second aspect of the present invention, there is provided an aerosolgenerating system. The aerosol-generating system comprises an aerosol-generating article according to the first aspect of the present invention. The aerosol-generating system comprises an aerosol-generating device configured to heat the aerosol-generating article.

[0213] As used herein with reference to the present invention, the term “aerosol-generating device” denotes a device that interacts with an aerosol-generating article to generate an aerosol. In some examples, the aerosol-generating device heats the aerosol-generating substrate of the aerosol-generating article to facilitate release of volatile compounds from the substrate. Since the aerosol-generating system of this disclosure comprises an aerosol-generating article described herein, the advantages specified above for the aerosol-generating articles also apply to the system itself.

[0214] The aerosol-generating device may further comprise a heater.

[0215] The aerosol-generating device may be configured to compress the aerosol-generating article.

[0216] Below, there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0217] Example Ex 1.1. An aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article comprising: a container, the container comprising a first wall and a second wall.

[0218] Example Ex 1 .2. An aerosol-generating article according to Example Ex 1 .1 , wherein the first wall comprises a different material to the second wall.

[0219] Example Ex 1.3. An aerosol-generating article according to Example Ex 1.1 or Ex 1 .2, wherein the first wall and second wall together define a substrate compartment, an aerosolgenerating substrate provided in the substrate compartment.

[0220] Example Ex 1 .4. An aerosol-generating article according to any preceding Example, wherein the first wall comprises a flexible cellulosic material.

[0221] Example Ex 1 .5. An aerosol-generating article according to any preceding Example, wherein the second wall has a higher stiffness than the first wall.

[0222] Example Ex 1 .An aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article comprising: a container, the container comprising a first wall and a second wall, the first wall comprising a different material to the second wall, the first wall and second wall together defining a substrate compartment, and an aerosol-generating substrate provided in the substrate compartment, wherein the first wall comprises a flexible cellulosic material, and wherein the second wall has a higher stiffness than the first wall.

[0223] Example Ex 2. An aerosol-generating article according to any preceding Example, wherein the first wall comprises a non-woven material.

[0224] Example Ex 3. An aerosol-generating article according to any preceding Example, wherein at least a portion of the first wall is porous.

[0225] Example Ex 4. An aerosol-generating article according to any preceding Example, wherein the first wall has a cellulose content of greater than or equal to 50 percent by weight, optionally greater than or equal to 60 percent by weight, optionally greater than or equal to 70 percent by weight, optionally greater than or equal to 80 percent by weight, or optionally greater than or equal to 90 percent by weight. Example Ex 5. An aerosol-generating article according to any preceding Example, wherein the first wall comprises a lignin content of less than or equal to 15 percent by weight, optionally less than or equal to 10 percent by weight, or optionally less than or equal to 5 percent by weight.

[0226] Example Ex 6. An aerosol-generating article according to any preceding Example, wherein the first wall comprises a hemicellulose content of less than or equal to 20 percent by weight, optionally less than or equal to 16 percent by weight, or optionally less than or equal to 12 percent by weight.

[0227] Example Ex 7. An aerosol-generating article according to any preceding Example, wherein the first wall comprises one or more of viscose, flax, hemp and cotton.

[0228] Example Ex 8. An aerosol-generating article according to any preceding Example, wherein the second wall is non-porous.

[0229] Example Ex 9. An aerosol-generating article according to any preceding Example, wherein the second wall comprises a substantially planar material.

[0230] Example Ex 10. An aerosol-generating article according to any preceding Example, wherein the second wall comprises one or more of paper, non-woven cellulosic material and tobacco cast leaf.

[0231] Example Ex 1 1 . An aerosol-generating article according to any preceding Example, wherein the second wall has a grammage of between 30 gsm and 35 gsm.

[0232] Example Ex 12. An aerosol-generating article according to any preceding Example, wherein the first wall and the second wall meet to define a contact region extending around the container.

[0233] Example Ex 13. An aerosol-generating article according to Example Ex 12, wherein the contact region comprises a sealing region defined by a first wall sealing portion and a second wall sealing portion and optionally a first side cover that overlies at least a portion of the first wall, optionally wherein the sealing region comprises a flavourant.

[0234] Example Ex 14. An aerosol-generating article according to Example Ex 13, wherein the sealing region comprises an adhesive, the first wall sealing portion and the second wall sealing portion joined by the adhesive, optionally wherein the adhesive comprises polyvinyl alcohol, optionally wherein the first wall sealing portion, the second wall sealing portion and at least a portion of the first side cover are joined by the adhesive.

[0235] Example Ex 15. An aerosol-generating article according to Example Ex 13 or Ex 14, further comprising a ring element extending around the contact region.

[0236] Example Ex 16. An aerosol-generating article according to Example Ex 15, wherein the ring element overlies at least a portion of the sealing region.

[0237] Example Ex 17. An aerosol-generating article according to Example Ex 15 or Ex 16, wherein the ring element has a greater grammage than the second wall. Example Ex 18. An aerosol-generating article according to Example Ex 17, wherein the ring element has a grammage of between 80 gsm and 120 gsm.

[0238] Example Ex 19. An aerosol-generating article according to any one of Examples Ex 15 to Ex 18, wherein the ring element comprises paper.

[0239] Example Ex 20. An aerosol-generating article according to any one of Examples Ex 15 to Ex 19, wherein the ring element extends outwardly beyond the contact region.

[0240] Example Ex 21 . An aerosol-generating article according to any one of Examples Ex 15 to Ex 20, wherein the ring element has a thickness of greater than equal to 1 millimetre.

[0241] Example Ex 22. An aerosol-generating article according to any one of Examples Ex 15 to Ex 21 , wherein the ring element has a thickness of less than equal to 5 millimetres.

[0242] Example Ex 23. An aerosol-generating article according to any one of Examples Ex 15 to Ex 22, wherein the ring element is secured to one or both of the first wall and the second wall by an adhesive.

[0243] Example Ex 24. An aerosol-generating article according to any one of Examples Ex 12 to Ex 23, wherein the shape of the container is substantially reflectively symmetrical about a plane containing the contact region.

[0244] Example Ex 25. An aerosol-generating article according to any one of claims 12 to 23, wherein the shape of the container is reflectively asymmetrical about a plane containing the contact region.

[0245] Example Ex 26. An aerosol-generating article according to Example Ex 25, wherein the second wall is substantially flat.

[0246] Example Ex 27. An aerosol-generating article according to any preceding Example, wherein the aerosol-generating substrate is a homogenised aerosol-generating substrate.

[0247] Example Ex 28. An aerosol-generating article according to any preceding Example, wherein the aerosol-generating substrate comprises one or more of tobacco, a botanical material and a plurality of aerosol-generating elements.

[0248] Example Ex 29. An aerosol-generating article according to Example Ex 28, wherein the plurality of aerosol-generating elements comprise a carrier medium and a liquid or gel sorbed in the carrier medium.

[0249] Example Ex 30. An aerosol-generating article according to any preceding Example, wherein the aerosol-generating substrate comprises nicotine.

[0250] Example Ex 31 . An aerosol-generating article according to any preceding Example, wherein the aerosol-generating substrate comprises granules with a diameter of greater than or equal to 500 micrometres.

[0251] Example Ex 32. An aerosol-generating article according to any preceding Example, wherein the aerosol-generating substrate comprises granules with a diameter of less than or equal to 3 millimetres. Example Ex 33. An aerosol-generating article according to any preceding Example, wherein the substrate compartment contains between 80 milligrams and 300 milligrams of aerosol-generating substrate, optionally between 100 milligrams and 200 milligrams of aerosolgenerating substrate.

[0252] Example Ex 34. An aerosol-generating article according to any preceding Example, wherein the aerosol-generating article has a depth of between 2 millimetres and 6 millimetres.

[0253] Example Ex 35. An aerosol-generating article according to any preceding Example, wherein the substrate compartment has a length of between 15 millimetres and 20 millimetres.

[0254] Example Ex 36. An aerosol-generating article according to any preceding Example, wherein the substrate compartment has a width of between 6 millimetres and 10 millimetres.

[0255] Example Ex 37. An aerosol-generating article according to any preceding Example, wherein, during use, air flows along a length of the aerosol-generating article.

[0256] Example Ex 38. An aerosol-generating article according to any preceding Example, wherein the first wall and the second wall are thermally stable between 100 degrees Celsius and 280 degrees Celsius.

[0257] Example Ex 39. An aerosol-generating system comprising: an aerosol-generating article according to any preceding Example; and an aerosol-generating device configured to heat the aerosol-generating article.

[0258] Example Ex 40. An aerosol-generating system according to Example Ex 39, wherein the aerosol-generating device comprises a heater.

[0259] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:

[0260] Figure 1 is a cross-sectional view of an aerosol-generating article according to the present disclosure,

[0261] Figure 2 is an exploded perspective view of various components of the aerosol-generating article according to the present disclosure,

[0262] Figure 3 is a plan view of an aerosol-generating article according to the present disclosure along a plane including the length and width of the aerosol-generating article,

[0263] Figure 4 is a plan view of an aerosol-generating article according to the present disclosure along a plane including the length and depth of the aerosol-generating article,

[0264] Figure 5 is a plan view of an aerosol-generating article according to the present disclosure along a plane including the width and depth of the aerosol-generating article,

[0265] Figure 6 is a plan view of a further aerosol-generating article according to the present disclosure along a plane including the length and width of the aerosol-generating article,

[0266] Figure 7 is a cross-sectional view of a further aerosol-generating article according to the present disclosure, and Figure 8 is a cross-sectional view of an aerosol-generating system according to the present disclosure.

[0267] As shown in Figures 1 and 2, the aerosol-generating article 100 comprises a container 110. The container 1 10 comprises a first wall 1 11 and a second wall 1 12 which together define a substrate compartment 1 13. An aerosol-generating substrate 1 14 is provided in the substrate compartment.

[0268] The first wall 11 1 is formed from a non-woven cotton material. The first wall 11 1 comprises between 85 weight percent and 90 weight percent cellulose, between 7 weight percent and 16 weight percent hemicellulose, and between 1 weight percent and 3 weight percent lignin. The first wall 11 1 is porous.

[0269] The second wall 112 comprises paper. The second wall 1 12 has a grammage of about 35 gsm. The second wall is non-porous.

[0270] The second wall 1 12 may be substantially planar. The second wall 1 12 has a higher stiffness than the first wall 1 11. In this way, the first wall 1 11 may generally form a bag shape which is closed by the second wall 1 12.

[0271] The first wall 11 1 and the second wall 112 meet at a contact region 116. The contact region 116 extends around the circumference of the container 110. The contact region 116 has a thickness of 3.5 millimetres. The first wall 1 11 and the second wall 112 are connected at the contact region 1 16 by an adhesive to form a sealing region. The adhesive is a polyvinyl alcohol adhesive. The sealing region comprises a flavourant.

[0272] The first wall 11 1 and the second wall 112 are thermally stable up to at least 280 degrees Celsius.

[0273] The aerosol-generating article 100 further comprises a ring element 1 15 which overlies the sealing region. The ring element 115 is formed from paper having a grammage of 100 gsm. The ring element 1 15 has a higher stiffness than the first wall 1 11 and the second wall 1 12. The ring element 1 15 overlies the entire sealing region. The ring element 1 15 is adhered to the first wall 1 11. In this way, a portion of the first wall 11 1 is sandwiched between the ring element 115 and the second wall 1 12. The ring element 115 is adhered to the first wall 1 11 by a polyvinyl alcohol adhesive. The ring element 115 has a thickness of 3.5 millimetres, corresponding to the thickness of the contact region 1 16.

[0274] An aerosol-generating substrate 1 14 is provided in the substrate compartment 113. The aerosol-generating substrate 114 comprises granules of homogenised tobacco material, and an aerosol-former. The aerosol-former comprises glycerine. The substrate compartment 1 13 contains about 150 milligrams of aerosol-generating substrate 1 14.

[0275] As best seen in Figures 3 and 4, the aerosol-generating article 100 has a length of 20 millimetres, and the substrate compartment 1 13 has a length of 17 millimetres. As best seen in Figures 3 and 5, the aerosol-generating article 100 has a width of 1 1 millimetres, and the substrate compartment 1 13 has a width of 8 millimetres.

[0276] As best seen in Figures 4 and 5, the aerosol-generating article 100 has a depth of 3.5 millimetres.

[0277] Figure 6 shows a further aerosol-generating article 600. The aerosol-generating article 600 includes all of the features described above in relation to the Figure 1 example and like numerals are used to refer to identical features. In addition, the aerosol-generating article 600 includes a first side cover 601 . The first side cover 601 extends across the width of the aerosolgenerating article 600 and overlays a longitudinally central portion of the first wall 1 11. The first side cover 601 is formed from a portion of non-porous paper. The first side cover 601 does not overlay a first longitudinal end and a second longitudinal end of the first wall 11 1. In this way, the areas of the first wall 1 11 remaining exposed may define a first air permeable portion 602 and a second air permeable portion 603 of the first wall 1 11. The first wall 1 11 , the second wall 1 12 and the first side cover 601 are connected by an adhesive to form a sealing region.

[0278] Figure 7 shows a further aerosol-generating article 150. The aerosol-generating article 150 includes all of the features described above in relation to the Figure 1 example and identical numerals are used to refer to identical features. However, unlike the Figure 1 example, the first wall 151 comprises a shaped sheet of shapable paper. The first wall 151 has a grammage of about 150 gsm. The first wall 151 comprises a plurality of perforations 152 to allow air to pass into and out of the substrate compartment 113.

[0279] Figure 8 shows an aerosol-generating system 200 comprising an aerosol-generating article 100 and an aerosol-generating device 300.

[0280] The aerosol-generating device 300 comprises a first part which includes a recess 301 for receiving the substrate compartment of the aerosol-generating article 100. The first part also includes a plurality of air inlets 303 for delivering air to the recess 301 , and a plurality of air outlets 304 for allowing air and aerosol to leave the device 300. The general direction of airflow is shown by arrows 305. The aerosol-generating device includes a second part which includes a heater 302.

[0281] In use, the heater 302 is brought into contact with the second wall 1 12 of the aerosolgenerating article 100. The heater 302 is activated which heats the aerosol-generating substrate 114 leading to the generation of an aerosol. Air is drawn into the recess 301 through the air inlets 303 and passes through the porous first wall 1 11 into the substrate compartment 113 where it becomes entrained with the aerosol. The air and the aerosol then pass out of the substrate compartment 1 13 through the porous first wall 111 , and out of the aerosol-generating device 300 through the air outlets 304.

[0282] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". In this context, therefore, a number A is understood as A ± 10 percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

CLAIMS1. An aerosol-generating article for use with an aerosol-generating device, the aerosolgenerating article comprising: a container, the container comprising a first wall and a second wall, the first wall comprising a different material to the second wall, the first wall and second wall together defining a substrate compartment, and an aerosol-generating substrate provided in the substrate compartment, wherein the first wall comprises a flexible cellulosic material, and wherein the second wall has a higher stiffness than the first wall.

2. An aerosol-generating article according to claim 1 , wherein the first wall comprises a nonwoven material.

3. An aerosol-generating article according to claim 1 or 2, wherein at least a portion of the first wall is porous.

4. An aerosol-generating article according to any one of claims 1 to 3, wherein the first wall has a cellulose content of greater than or equal to 50 percent by weight, optionally greater than or equal to 60 percent by weight, optionally greater than or equal to 70 percent by weight, optionally greater than or equal to 80 percent by weight, or optionally greater than or equal to 90 percent by weight.

5. An aerosol-generating article according to any preceding claim, wherein the first wall comprises a lignin content of less than or equal to 15 percent by weight, optionally less than or equal to 10 percent by weight, or optionally less than or equal to 5 percent by weight.

6. An aerosol-generating article according to any preceding claim, wherein the first wall comprises a hemicellulose content of less than or equal to 20 percent by weight, optionally less than or equal to 16 percent by weight, or optionally less than or equal to 12 percent by weight.

7. An aerosol-generating article according to any preceding claim, wherein the second wall is non-porous.

8. An aerosol-generating article according to any preceding claim, wherein the second wall comprises one or more of paper, non-woven cellulosic material and tobacco cast leaf.

9. An aerosol-generating article according to any preceding claim, wherein the first wall and the second wall meet to define a contact region extending around the container.

10. An aerosol-generating article according to claim 9, wherein the contact region comprises a sealing region defined by a first wall sealing portion and a second wall sealing portion and optionally a first side cover that overlies at least a portion of the first wall, optionally wherein the sealing region comprises a flavourant.

11. An aerosol-generating article according to claim 10, wherein the sealing region comprises an adhesive, the first wall sealing portion and the second wall sealing portion joined by the adhesive, optionally wherein the adhesive comprises polyvinyl alcohol, optionally wherein the first wall sealing portion, the second wall sealing portion and at least a portion of the first side cover are joined by the adhesive.

12. An aerosol-generating article according to claim 10 or 11 , further comprising a ring element extending around the contact region.

13. An aerosol-generating article according to claim 12, wherein the ring element overlies at least a portion of the sealing region.

14. An aerosol-generating article according to claim 12 or 13, wherein the ring element has a greater grammage than the second wall.

15. An aerosol-generating article according to any one of claims 12 to 14, wherein the ring element comprises paper.

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