Aerosol-generating article

Abstract

There is provided an aerosol-generating article (100) for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article comprises a wrapper (101) encapsulating at least an aerosol-forming substrate (102) to define a wrapped body. The wrapper (101) is formed of a foldable material. The wrapper (101) is configured to inhibit or prevent passage of moisture across a thickness of the wrapper.

Description

[0001] AEROSOL-GENERATING ARTICLE

[0002] The present disclosure relates to an aerosol-generating article for use with an aerosolgenerating device to generate an aerosol.

[0003] A challenge faced by a typical aerosol-generating article configured for the generation of aerosol through heating rather than burning of an aerosol-forming substrate is ensuring that the aerosol-forming substrate does not contain excessive levels of moisture prior to use of the aerosolgenerating article. Excessive moisture content may reduce the shelf life of the aerosol-generating article.

[0004] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article may comprise a wrapper encapsulating at least an aerosol-forming substrate to define a wrapped body. The wrapper may be formed of a foldable material. The wrapper may be configured to inhibit or prevent passage of moisture across a thickness of the wrapper.

[0005] By “encapsulate” is meant to fully enclose. So, where the wrapper is stated to encapsulate at least an aerosol-forming substrate means that the wrapper fully encloses at least the aerosol-forming substrate of the aerosol-generating article.

[0006] By a “foldable material” is meant a material which is capable of being deformed into a folded state to define one or more fold lines therein, the fold lines remaining on removal of the force responsible for causing the deformation into the folded state.

[0007] Having the wrapper configured to inhibit or prevent passage of moisture across a thickness of the wrapper helps to reduce or prevent the aerosol-forming substrate from absorbing moisture during transportation and storage of the aerosol-generating article. Avoiding excessive absorption of moisture by the aerosol-forming substrate may help to ensure that compounds evolved from the aerosol-forming substrate under heating do not contain excessive levels of moisture and / or reduce the likelihood of water vapour being evolved from the aerosol-forming substrate in preference to desired volatile compounds present in the aerosol-forming substrate. So, avoiding excessive absorption of moisture by the aerosol-forming substrate may provide a user of the aerosol-generating article with an improved user experience. The wrapper may also help to reduce or prevent loss of volatile compounds of the aerosol-forming substrate from within the aerosol-generating article prior to use of the article. Further, during use of the aerosol-generating article (for example, on heating of the aerosol-generating article during a usage session to evolve volatile compounds from the aerosolforming substrate), the wrapper may help to reduce or prevent unwanted loss of aerosol from within the aerosol-generating article.

[0008] The wrapper may have a polymer content of less than 25%, or less than 15%, or less than 10%, or less than 5%. Preferably, the wrapper is substantially free of polymer content. Reduced levels of polymer content in the wrapper may facilitate ensuring that the wrapper is foldable, as well as enhancing the sustainability of the aerosol-generating article and its manufacture.

[0009] Preferably, the wrapper may have an unbreached first state and a breached second state. In the breached second state an air flow path may be defined through the wrapped body between an air inlet and an air outlet defined in the wrapper. In the unbreached first state the wrapper lacks the air inlet and the air outlet. The unbreached first state and the breached second state of the aerosolgenerating article are two different states of the wrapper which cannot simultaneously exist at the same instant in time. The unbreached first state is a state in which the wrapper’s ability to prevent or inhibit passage of moisture across the wrapper is greater than for the breached second state. The breached second state allows an air flow to be introduced through the wrapped body. In the breached second state, the aerosol-generating article may have a resistance to draw between 0 millimetres H2O and 9.9 millimetres H2O.

[0010] The wrapper of the aerosol-generating article may preferably be adapted and configured to facilitate breaching of the wrapper to define the air inlet and air outlet associated with the breached second state. For example, the wrapper may have a thickness which facilitates piercing of the wrapper by an object, such as a protrusion of an aerosol-generating device designed for use with the aerosol-generating article. The protrusion may be a blade, a pin, or an annular member. One or more score lines may be defined in a surface of the wrapper at locations corresponding to the air inlet and air outlet. The one or more score lines may define locally thinned regions of the wrapper, thereby facilitating breaching of the wrapper to define the air inlet and air outlet.

[0011] The wrapped body may be configured such that on breaching of the wrapper at predetermined first and second locations axially spaced from each other in a length direction of the wrapped body, an air flow path is defined through the wrapped body between the predetermined first and second locations.

[0012] The air flow path may be defined through the aerosol-generating article in an x / y plane from one side of the aerosol-generating article to the other side of the aerosol-generating article. The aerosol-generating article preferably has a resistance to draw (RTD) of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in the direction of the air flow path. Preferably, the aerosolgenerating article has a RTD of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in at least one direction in an x / y plane of the aerosol-generating article. An aerosol-generating article with a low resistance air-flow path may allow for superior air-flow management and allow aerosol to be extracted more efficiently from the aerosol-generating article and guided to a user.

[0013] Unless otherwise specified, the resistance to draw (RTD) is measured in accordance with ISO 6565-2015. The RTD refers to the pressure required to force air through the full length of a component, such as the wrapped body or the aerosol-generating article. The terms “pressure drop’’ or “draw resistance” of a component or article may also refer to the “resistance to draw”. Such terms generally refer to the measurements made in accordance with ISO 6565-2015 and are normally carried out at under test at a volumetric flow rate of about 17.5 millilitres per second at the output or downstream end of the measured component at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr) and a relative humidity of about 60%.

[0014] The wrapped body may extend longitudinally between opposed first and second axial end faces. The predetermined first location may be located on the first axial end face and the predetermined second location located on the second axial end face. The first axial end face may be located at a distal end of the aerosol-generating article and the second axial end face located at a proximal end of the aerosol-generating article. In this manner, the separation between the first axial end face and the second axial end face may correspond to the length of the aerosol-generating article. The first and second axial end faces may be planar.

[0015] Preferably, the wrapper may be impermeable to water. In this manner, the wrapper is able to avoid the aerosol-forming substrate encapsulated within the wrapper from absorbing moisture from outside of the wrapper and / or loss of moisture content from the aerosol-forming substrate to outside of the aerosol-generating article.

[0016] The wrapper may have a permeability of between 1 to 10 Coresta units, for example between 1 to 5 Coresta units, for example between 1 to 3 Coresta units.

[0017] Advantageously, the wrapper may be impervious to light, for example to light having a wavelength associated with any one or more of infrared radiation, visible light and ultraviolet light. In this manner, the wrapper may avoid photodegradation caused by exposure to light, such as sunlight.

[0018] The wrapper may be a single wrapper. Alternatively, the wrapper may be formed of a plurality of wrappers or wrapper portions. The plurality of wrappers or wrapper portions may be arranged relative to each other to collectively encapsulate at least the aerosol-forming substrate.

[0019] Preferably, the wrapper may comprise one or a combination of materials selected from a group consisting of parchment paper, supercalendered paper (for example glassine), tracing paper, cellulose films, coated paper (for example PVOH paper), and metal foil. These specified materials facilitate limiting or preventing the passage of moisture across the thickness of the wrapper.

[0020] The materials of the above-mentioned group are preferably in sheet form.

[0021] The wrapper may comprise or consist of aluminium foil having a thickness of at least 4 microns, for example at least 6.3 microns, for example at least 9 microns. This use of aluminium foil with such a thickness provides the wrapper with the ability to be impervious to moisture and light, whilst ensuring a low mass for the wrapper.

[0022] The wrapper may comprise or consist of a laminate of a metal first layer and a second layer. The metal first layer may comprise or consist of aluminium. The metal first layer may comprise or consist of aluminium foil having a thickness of at least 4 microns, for example at least 6.3 microns, for example at least 9 microns. The second layer may be one of a cellulosic layer and a polymer film. The cellulosic layer may comprise or consist of paper, paperboard or cardboard.

[0023] In some embodiments, the wrapper may encapsulate only aerosol-forming substrate. In other embodiments, the aerosol-generating article may further comprise at least one additional element encapsulated within the wrapper along with the aerosol-forming substrate. By way of example, the at least one additional element may comprise one or more of a filter (for example, for filtering of aerosol generated within the wrapped body prior to being inhaled by a user), a spacer element and a frame.

[0024] Advantageously, the aerosol-forming substrate may comprise discrete first and second portions of aerosol-forming substrate. Preferably, the composition of the first portion of aerosol-forming substrate may be different to the composition of the second portion of aerosol-forming substrate. In this manner, the aerosol inhaled by a user of the aerosol-generating article in a usage session may be formed of combinations of different volatile compounds evolved from the different compositions of the first and second portions of aerosol-forming substrate, thereby providing a more varied user experience. In some examples, the first and second portions of aerosol-forming substrate may be spaced apart from each other along a length direction of the aerosol-generating article; for example the first and second portions may be separated from each other by a spacer element. In some other examples, the first and second portions of aerosol-forming substrate may be spaced apart from each other along a width direction of the aerosol-generating article; for example the first and second portions may be separated from each other by a spacer element. In some other examples, the first and second portions of aerosol-forming substrate may be spaced apart from each other along a thickness direction of the aerosol-generating article; for example the first and second portions may be separated from each other by a spacer element.

[0025] The aerosol-generating article may have a circular cross-section, an oval cross-section, a lenticular cross-section, a square cross-section, or a rectangular cross-section.

[0026] The wrapper may define at least part of an exterior surface of the aerosol-generating article.

[0027] Conveniently, the wrapped body may be the aerosol-generating article. Where the wrapped body is the aerosol-generating article, the length, width and thickness of the wrapped body define the length, width and thickness of the aerosol-generating article.

[0028] The aerosol-generating article may comprise an additional wrapper, the wrapped body enclosed by the additional wrapper. Preferably, the outer wrapper may define an exterior surface of the aerosol-generating article. By “additional wrapper” is meant a wrapper distinct from and in addition to the wrapper of the wrapped body.

[0029] The aerosol-generating article may be defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness. The length may extend in an x-direction. The width may extend in a y-direction. The thickness may extend in a z-direction.

[0030] Preferably, the aerosol-generating article may be of uniform cross-section along the entirety of the length of the aerosol-generating article.

[0031] The aerosol-generating article may comprise upper and lower external surfaces. The upper and lower external surfaces may preferably be separated from each other to define a thickness of the aerosol-generating article. The upper and lower external surfaces may collectively define all or a majority of a perimeter of the aerosol-generating article.

[0032] Aerosol-generating articles according to the present disclosure may preferably be substantially flat articles or substantially planar articles. Such articles have a large base area relative to the volume of the article. Advantageously, a larger base area may provide greater surface area for heating by a planar heater of an aerosol-generating device. Advantageously, a smaller height may allow a smaller temperature gradient or difference across the height of the aerosol-generating article during heating. The terms “height” and “thickness” have the same meaning for the purposes of the present disclosure, for example when used in reference to the aerosol-generating article. For example, where the base of the aerosol-generating article is in contact with, and heated by, a planar heater, there may be a smaller temperature difference between the base and an upper surface opposing the base if the spacing, or height, between the base and the upper surface is smaller. Advantageously, this may allow heating of a greater proportion of the aerosol-forming substrate of the aerosol-generating article to a temperature at which an aerosol is released, whilst minimising the risk of burning the hottest portion of the substrate closest to the heater. Alternatively, or in addition, this may reduce a time required to heat the aerosol-forming substrate sufficiently to release an aerosol.

[0033] Preferably, the upper and lower external surfaces may be planar. In this manner, the aerosolgenerating article may be generally flat.

[0034] Alternatively, the upper and lower external surfaces may be outwardly convex. The upper and lower external surfaces may collectively define a round, circular, ovoid or lenticular profile.

[0035] The upper and lower external surfaces may be defined by the wrapper. Alternatively, the upper and lower external surfaces may be defined by an additional wrapper of the aerosol-generating article, the wrapped body enclosed by the additional wrapper.

[0036] The aerosol-generating article may further comprise a cavity and a frame. The cavity may be located within the aerosol-generating article between the upper external surface and the lower external surface. The frame may be positioned between the upper external surface and the lower external surface. The frame may at least partially define the cavity. An air-flow path may be defined through the aerosol-generating article between an air inlet and an air outlet. The air-flow path may extend through the cavity.

[0037] The wrapped body may be disposed within the cavity. The upper and lower external surfaces may be defined by an additional wrapper of the aerosol-generating article, the wrapped body and the frame enclosed by the additional wrapper.

[0038] Preferably, the aerosol-forming substrate may be disposed within the cavity, the wrapper configured to encapsulate the frame in addition to the aerosol-forming substrate. Advantageously, one or more apertures may be formed in opposing walls of the frame to provide for passage of an air flow through the cavity when the wrapper is breached at locations corresponding to the locations of the one or more apertures.

[0039] The cavity may be defined by internal dimensions, the internal dimensions being a cavity length, a cavity width, and a cavity height, the cavity width being greater than the cavity height.

[0040] The frame may comprise a peripheral wall at least partially circumscribing or encircling the cavity. The frame may comprise a peripheral wall wholly circumscribing or encircling the cavity. The peripheral wall may be formed by a frame inner surface and a frame outer surface. The peripheral wall may have a radial thickness between 1 millimetre and 3 millimetres.

[0041] The frame may have a thickness greater than or equal to 80 percent of the thickness of the aerosol-generating article.

[0042] The frame may have a thickness between 80 percent and 95 percent of the thickness of the aerosol-generating article.

[0043] The frame may have a thickness between 1 millimetre and 5.5 millimetres.

[0044] The frame may comprise a cellulosic material. The cellulosic material may have a grammage between 300 grams per square metre and 900 grams per square metre. The cellulosic material may be paper, paperboard, or cardboard.

[0045] The frame may be a unitary component.

[0046] The frame may comprise a first frame layer and a second frame layer. The first frame layer may be bonded to the second frame layer with an adhesive. The frame may comprise a third frame layer. The second frame layer may be positioned between the first frame layer and the third frame layer. The second frame layer may be bonded to the third frame layer with an adhesive.

[0047] The cavity may have a width between 30 percent and 95 percent of the width of the aerosolgenerating article.

[0048] The cavity may have a length between 30 percent and 95 percent of the length of the aerosolgenerating article.

[0049] The cavity may have a thickness between 30 percent and 95 percent of the thickness of the aerosol-generating article.

[0050] The cavity may have a length between 14 millimetres and 40 millimetres, a width between 4.5 millimetres and 13 millimetres, and a thickness between 0.5 millimetres and 4.5 millimetres.

[0051] The cavity may have a length between 20 millimetres and 30 millimetres, a width between 7 millimetres and 10 millimetres, and a thickness between 2.5 millimetres and 4 millimetres.

[0052] Preferably, a thickness of the aerosol-generating article may be less than 50 percent of both a length and a width of the aerosol-generating article.

[0053] The aerosol-forming substrate may comprise one or more aerosol-formers. The use of an aerosol former may facilitate the evolving of desired volatile compounds from the aerosol-forming substrate through heating rather than burning of the substrate. However, substrates containing aerosol formers can tend to attract moisture. So, the wrapper of the present disclosure facilitates the use of an aerosol-forming substrate adapted for generating aerosol through heating rather than burning of the substrate, whilst helping to reduce the likelihood of the substrate absorbing water during storage and transportation of the aerosol-generating article.

[0054] Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosol-formers selected from polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosolformer to be or comprise glycerine or propylene glycol.

[0055] Preferably, the aerosol-forming substrate may have an aerosol-former content of greater than 20 wt % on a dry weight basis, for example greater than 25 wt %, or greater than 30 wt %, for example greater than 35 wt %.

[0056] The aerosol-forming substrate may comprise tobacco, for example tobacco cut filler, cast leaf tobacco, or homogenised tobacco.

[0057] The aerosol-forming substrate may comprise any one or more of nicotine, botanicals, cannabinoid, and a flavouring agent.

[0058] Where the aerosol-forming substrate comprises nicotine, the nicotine may comprise or consist of natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0059] The aerosol-forming substrate may comprise at least 0.5 percent by weight of nicotine, at least 1 percent by weight of nicotine, at least 1 .5 percent by weight of nicotine, or at least 2 percent by weight of nicotine. That is, the aerosol-forming substrate may have a nicotine content of at least 0.5 percent by weight, at least 1 percent by weight, at least 1 .5 percent by weight, or at least 2 percent by weight.

[0060] The aerosol-forming substrate may comprise one or more cannabinoid compounds such as one or more of: tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannabivarin (CBV), cannabidivarin (CBDV), tetrahydrocannabivarin (THCV), cannabichromene (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), cannabicitran (CBT). It may be preferable that the cannabinoid compound is CBD or THC. It may be particularly preferable that the cannabinoid compound is CBD.

[0061] The aerosol-forming substrate may comprise one or more flavourants. The one or more flavourants may comprise one or more of: one or more essential oils such as eugenol, peppermint oil and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and a herbaceous material. Suitable herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavourants may comprise a tobacco material.

[0062] The aerosol-forming substrate may comprise one or more botanicals. For example, the aerosolforming substrate may comprise about 1 to 90 %, for example about 15 to 55 %, preferably of about 20 to 35 %, of botanicals such as Clove, Echinacea sp., Fennel, Ginger, Hawthorn berry, Elderberry, Monarda, Mullein leaves, Nettle, Plantain, Turmeric, Yarrow, Rooibos, Star Anise, Thyme, Anethum, Chamomile and compounds of those.

[0063] The aerosol-forming substrate may have a moisture content of about 5 to 25%, preferably of about 7 to 15%, at final product state. For example, the aerosol-forming substrate may be a homogenised tobacco material with a moisture of about 5 to 25%, preferably of about 7 to 15%, at final product state.

[0064] The aerosol-forming substrate may comprise a binder. For example, the aerosol-forming substrate may comprise about 1 to 10%, preferably of about 1 to 5%, of a binder such as any of common gums or pectins used in food and beverage (F&B) industries. Preferred binders may be natural pectins, such as fruit, for example citrus, or tobacco pectins; guar gums, land locust bean gums, such as hydroxyethyl and / or hydroxypropyl of those; starches, such as modified or derivatized starches; alginate; methyl, ethyl, ethylhydroxymethyl and carboxy methyl, celluloses; dextran; and xanthan gum. A preferable binder is guar.

[0065] Preferably, the aerosol-forming substrate may comprise or consist of a solid aerosol-forming material. Where the aerosol-forming substrate comprises or consists of a solid aerosol-forming material, the ability of the wrapper to inhibit or prevent the passage of moisture across the thickness of the wrapper reduces the likelihood of ingress of moisture across the wrapper and a consequent reduction in flexural stiffness of the aerosol-generating article. Alternatively, the aerosol-forming substrate may have a liquid or gel composition, or have a composition of two or more of solid, liquid or gel phases. Where the aerosol-forming substrate has a liquid or gel composition, the ability of the wrapper to inhibit or prevent the passage of moisture across the thickness of the wrapper may avoid the escape of liquid content of the aerosol-forming substrate from inside of the wrapped body and / or the ingress of additional moisture content into the substrate from outside of the wrapped body.

[0066] The aerosol-forming substrate encapsulated by the wrapper may have a bulk density in a range of between 150 mg per cubic centimetre and 500 mg per cubic centimetre. The aerosol-forming substrate encapsulated by the wrapper may have a bulk density of between 175 mg per cubic centimetre and 475 mg per cubic centimetre. The aerosol-forming substrate encapsulated by the wrapper may have a bulk density of between 200 mg per cubic centimetre and 450 mg per cubic centimetre. The aerosol-forming substrate encapsulated by the wrapper may have a bulk density of between 225 mg per cubic centimetre and 425 mg per cubic centimetre. The aerosol-forming substrate encapsulated by the wrapper may have a bulk density of between 250 mg per cubic centimetre and 400 mg per cubic centimetre. The aerosol-forming substrate encapsulated by the wrapper may have a bulk density of between 275 mg per cubic centimetre and 375 mg per cubic centimetre. The aerosol-forming substrate encapsulated by the wrapper may have a bulk density of between 300 mg per cubic centimetre and 350 mg per cubic centimetre.

[0067] The aerosol-forming substrate encapsulated by the wrapper may have a bulk density of between 50 mg per cubic centimetre and 900 mg per cubic centimetre. The aerosol-forming substrate encapsulated by the wrapper may have a bulk density of between 100 mg per cubic centimetre and 800 mg per cubic centimetre. The aerosol-forming substrate encapsulated by the wrapper may have a bulk density of between 200 mg per cubic centimetre and 700 mg per cubic centimetre. The aerosolforming substrate encapsulated by the wrapper may have a bulk density of between 200 mg per cubic centimetre and 600 mg per cubic centimetre. The aerosol-forming substrate encapsulated by the wrapper may have a bulk density of between 200 mg per cubic centimetre and 500 mg per cubic centimetre. The aerosol-forming substrate encapsulated by the wrapper may have a bulk density of between 200 mg per cubic centimetre and 400 mg per cubic centimetre.

[0068] For the aerosol-generating article of any of the aspects of the present disclosure, a ratio between the length and the thickness of the aerosol-generating article and a ratio between the width and the thickness of the aerosol-generating article may be between 2:1 and 15:1.

[0069] For the aerosol-generating article of any of the aspects of the present disclosure, a ratio between the length and the width of the aerosol-generating article may be between 1 :1 and 10:1 .

[0070] The aerosol-generating article of any of the aspects of the present disclosure may have a length (for example, an x dimension) of between 10 millimetres and 100 millimetres, or between 10 millimetres and 50 millimetres, for example between 12 millimetres and 30 millimetres, for example between 14 millimetres and 26 millimetres, for example between 16 millimetres and 24 millimetres, for example between 18 millimetres and 22 millimetres, for example about 18 millimetres, or about 19 millimetres, or about 20 millimetres, or about 21 millimetres, or about 22 millimetres.

[0071] The aerosol-generating article may have a length between 15 millimetres and 45 millimetres, for example between 25 millimetres and 30 millimetres.

[0072] The aerosol-generating article may have a width (for example, a y dimension) of between 5 millimetres and 20 millimetres, for example between 8 millimetres and 18 millimetres, for example between 10 millimetres and 16 millimetres, for example between 11 millimetres and 15 millimetres, for example between 12 millimetres and 14 millimetres, for example about 13 millimetres.

[0073] The aerosol-generating article may have a width between 3 millimetres and 17 millimetres, for example between 9 millimetres and 11 millimetres.

[0074] The aerosol-generating article may have a height or thickness (for example, a z dimension) of between 1 millimetres and 10 millimetres, for example between 1.2 millimetres and 8 millimetres, for example between 1 .4 millimetres and 7 millimetres, for example between 1.6 millimetres and 6 millimetres, for example between 1.7 millimetres and 5 millimetres, for example about 1 .7 millimetres, or about 4.5 millimetres, or about 2 millimetres, or about 3 millimetres, or about 4 millimetres.

[0075] The aerosol-generating article may have a thickness or height of between 1 millimetres and 5.5 millimetres, for example between 3 millimetres and 3.5 millimetres.

[0076] According to the present disclosure, an aerosol-generating device for receiving an aerosolgenerating article as disclosed herein, may comprise a cavity dimensioned to receive at least a portion of the aerosol-generating article, a heater or heating means, a power source for supplying power to the heater or heating means, and a controller to control supply of power to the heater or heating means. The aerosol-generating device is configured to heat an aerosol-forming substrate, for example an aerosol-forming substrate that is a component part of an aerosol-generating article, to form an aerosol, for example an inhalable aerosol.

[0077] The aerosol-generating device may preferably be configured to receive the entirety of the aerosol-generating article such that the aerosol-generating article is wholly enclosed within the aerosol-generating device.

[0078] The cavity may comprise an opening into which a distal end of the aerosol-generating article can be inserted. The cavity may have any suitable cross-sectional shape. For example, the cavity may have a rectangular transverse cross-section, for example a rectangular cross-section having opposing top and bottom sides that are greater in length than left and right sides.

[0079] Preferably, at least one internal surface of the cavity is a heating surface configured to heat an aerosol-generating article. The heating surface may comprise a heater, for example a resistance heater, or an infra-red heater, or a susceptor configured to be heated by engagement with an inductor. The heating surface may comprise an inductor, for example the surface may comprise a coil arranged to generate a fluctuating electromagnetic field within a space of the cavity. The heating surface may be a surface that is permeable to a fluctuating electromagnetic field, such that an inductor arranged outside the cavity can project a fluctuating electromagnetic field through the heating surface to engage with a susceptor arranged within the cavity.

[0080] As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol.

[0081] As used herein, the term “aerosol-forming substrate” may refer to a substrate capable of releasing an aerosol or volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. An aerosol-forming substrate may comprise an aerosol-forming material. An aerosol-forming substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. An aerosol-forming substrate may conveniently be part of an aerosol-generating article or smoking article.

[0082] As used herein, the term “aerosol-generating device” may refer to a device for use with an aerosol-generating article to enable the generation, or release, of an aerosol.

[0083] As used herein, the term “aerosol generating system” refers to a combination of an aerosolgenerating device and one or more aerosol-forming articles for use with the device. An aerosolgenerating system may include additional components, such as a charging unit for recharging an onboard electric power supply in an electrically operated or electric aerosol-generating device.

[0084] As used herein, the term “aerosol former” may refer to any suitable known compound or mixture of compounds that, in use, facilitates formation of an aerosol. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-forming substrate or aerosol-generating article.

[0085] As used herein with reference to the invention, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.

[0086] As used herein with reference to the invention, the terms “proximal”, “distal”, “upstream” and “downstream” are used to describe the relative positions of components, or portions of components, of the aerosol-generating article.

[0087] As used herein, the term “longitudinal” refers to the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. During use, air may be drawn through the aerosolgenerating article in the longitudinal direction.

[0088] As used herein, the term “sheet” denotes a laminar element having a width and length substantially greater than the thickness thereof. The width of a sheet may be greater than 10 mm, preferably greater than 20 mm or 30 mm. In certain embodiments, sheets of material for use in forming aerosol-forming substrates as described herein may have a thickness of between 10 pm and about 1000 pm, for example between 10 pm and about 300 pm.

[0089] As used herein, the term “homogenised tobacco material” encompasses any tobacco material formed by the agglomeration of particles of tobacco material. Sheets or webs of homogenised tobacco material are formed by agglomerating particulate tobacco obtained by grinding or otherwise powdering of one or both of tobacco leaf lamina and tobacco leaf stems. In addition, homogenised tobacco material may comprise a minor quantity of one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during the treating, handling and shipping of tobacco. The sheets of homogenised tobacco material may be produced by casting, extrusion, paper making processes or other any other suitable processes known in the art.

[0090] The term “cast leaf” is used herein to refer to a product made by a casting process that is based on casting a slurry comprising plant particles (for example, clove particles or tobacco particles and clove particles in a mixture) and a binder (for example, guar gum) onto a supportive surface, such as a belt conveyor, drying the slurry and removing the dried sheet from the supportive surface. An example of the casting or cast leaf process is described in, for example, US-A-5,724,998 for making cast leaf tobacco. In a cast leaf process, particulate plant materials are produced by pulverizing, grinding, or comminuting parts of the plant. The particles produced from one or more plants are mixed with a liquid component, typically water, to form a slurry. Other components in the slurry may include fibres, a binder and an aerosol former. The particulate plant materials may be agglomerated in the presence of the binder. The slurry is cast onto a supportive surface and dried into a sheet of homogenized plant material. Preferably, homogenized plant material used in articles according to the present invention may be produced by casting. Such homogenized plant material may comprise agglomerated particulate plant material.

[0091] As used herein, resistance to draw is expressed with the units of pressure “mm H2O" or “mm WG” or “mm of water gauge’’ and may be measured in accordance with ISO 6565:2002.

[0092] The invention is defined in the claims. However, 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.

[0093] Example Ex1 : An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising a wrapper encapsulating at least an aerosol-forming substrate to define a wrapped body, wherein the wrapper is formed of a foldable material, the wrapper configured to inhibit or prevent passage of moisture across a thickness of the wrapper.

[0094] Example Ex2: An aerosol-generating article according to Ex1 , wherein the wrapper has a polymer content of less than 25%, or less than 15%, or less than 10%, or less than 5%.

[0095] Example Ex3: An aerosol-generating article according to either one of Ex1 or Ex2, wherein the wrapper is substantially free of polymer content.

[0096] Example Ex4: An aerosol-generating article according to any one of Ex1 to Ex3, the wrapper having an unbreached first state and a breached second state, wherein in the breached second state an air flow path is defined through the wrapped body between an air inlet and an air outlet defined in the wrapper, the wrapper lacking the air inlet and the air outlet in the unbreached first state.

[0097] Example Ex5: An aerosol-generating article according to Ex4, wherein in the unbreached first state one or more score lines are defined in a surface of the wrapper at locations corresponding to the air inlet and the air outlet.

[0098] Example Ex6: An aerosol-generating article according to any one of Ex1 to Ex5, wherein the wrapped body is configured such that on breaching of the wrapper at predetermined first and second locations axially spaced from each other in a length direction of the wrapped body, an air flow path is defined through the wrapped body between the predetermined first and second locations.

[0099] Example Ex7: An aerosol-generating article according to Ex6, the wrapped body extending longitudinally between opposed first and second axial end faces, the predetermined first location located on the first axial end face and the predetermined second location located on the second axial end face.

[0100] Example Ex8: An aerosol-generating article according to Ex7, wherein the first axial end face is at a distal end of the aerosol-generating article and the second axial end face is at a proximal end of the aerosol-generating article. Example Ex9: An aerosol-generating article according to either one of Ex7 or Ex8, wherein the first and second axial end faces are planar.

[0101] Example Ex10: An aerosol-generating article according to any one of Ex1 to Ex9, wherein the wrapper is impermeable to water.

[0102] Example Ex11 : An aerosol-generating article according to any one of Ex1 to Ex10, wherein the wrapper has a permeability of between 1 to 10 Coresta units, for example between 1 to 5 Coresta units, for example between 1 to 3 Coresta units.

[0103] Example Ex12: An aerosol-generating article according to any one of Ex1 to Ex11 , wherein the wrapper is impervious to light, for example impervious to light having a wavelength associated with one or more of infrared radiation, visible light and ultraviolet light.

[0104] Example Ex13: An aerosol-generating article according to any one of Ex1 to Ex12, wherein the wrapper comprises one or a combination of materials selected from a group consisting of parchment paper, supercalendered paper (for example glassine), tracing paper, cellulose films, coated paper (for example PVOH paper), and metal foil.

[0105] Example Ex14: An aerosol-generating article according to Ex13, wherein the materials of the group are in sheet form.

[0106] Example Ex15: An aerosol-generating article according to either one of Ex13 or Ex14, wherein the wrapper comprises or consists of aluminium foil having a thickness of at least 4 microns, for example at least 6.3 microns, for example at least 9 microns.

[0107] Example Ex16: An aerosol-generating article according to any one of Ex1 to Ex15, wherein the wrapper comprises or consists of a laminate of a metal first layer and a second layer.

[0108] Example Ex17: An aerosol-generating article according to Ex16, wherein the metal first layer comprises or consists of aluminium.

[0109] Example Ex18: An aerosol-generating article according to Ex17, wherein the metal first layer comprises or consists of aluminium foil having a thickness of at least 4 microns, for example at least 6.3 microns, for example at least 9 microns.

[0110] Example Ex19: An aerosol-generating article according to any one of Ex16 to Ex18, wherein the second layer is one of a cellulosic layer and a polymer film.

[0111] Example Ex20: An aerosol-generating article according to Ex19, wherein the cellulosic layer comprises or consists of paper, paperboard or cardboard.

[0112] Example Ex21 : An aerosol-generating article according to any one of Ex1 to Ex20, wherein the wrapper encapsulates only aerosol-forming substrate.

[0113] Example Ex22: An aerosol-generating article according to any one of Ex1 to Ex20, wherein the aerosol-generating article further comprises at least one additional element encapsulated within the wrapper along with the aerosol-forming substrate.

[0114] Example Ex23: An aerosol-generating article according to Ex22, wherein the least one additional element comprises one or more of a filter, a spacer element and a frame.

[0115] Example Ex24: An aerosol-generating article according to any one of Ex1 to Ex23, wherein the aerosol-forming substrate comprises discrete first and second portions of aerosol-forming substrate. Example Ex25: An aerosol-generating article according to Ex24, wherein the composition of the first portion of aerosol-forming substrate is different to the composition of the second portion of aerosol-forming substrate.

[0116] Example Ex26: An aerosol-generating article according to either one of Ex24 or Ex25, wherein the first and second portions of aerosol-forming substrate are spaced apart from each other along a length direction of the aerosol-generating article, for example the first and second portions being separated from each other by a spacer element.

[0117] Example Ex27: An aerosol-generating article according to any one of Ex24 to Ex26, wherein the first and second portions of aerosol-forming substrate are spaced apart from each other along a width direction of the aerosol-generating article, for example the first and second portions being separated from each other by a spacer element.

[0118] Example Ex28: An aerosol-generating article according to any one of Ex24 to Ex27, wherein the first and second portions of aerosol-forming substrate are spaced apart from each other along a thickness direction of the aerosol-generating article, for example the first and second portions being separated from each other by a spacer element.

[0119] Example Ex29: An aerosol-generating article according to any one of Ex1 to Ex28, wherein the aerosol-generating article has a circular cross-section, an oval cross-section, a lenticular crosssection, a square cross-section, or a rectangular cross-section.

[0120] Example Ex30: An aerosol-generating article according to any one of Ex1 to Ex29, wherein the wrapper defines at least part of an exterior surface of the aerosol-generating article.

[0121] Example Ex31 : An aerosol-generating article according to any one of Ex1 to Ex30, wherein the wrapped body is the aerosol-generating article.

[0122] Example Ex32: An aerosol-generating article according to any one of Ex1 to Ex29, the aerosolgenerating article comprising an additional wrapper, the wrapped body enclosed by the additional wrapper.

[0123] Example Ex33: An aerosol-generating article according to Ex32, wherein the additional wrapper defines an exterior surface of the aerosol-generating article.

[0124] Example Ex34: An aerosol-generating article according to any one of Ex1 to Ex33, the aerosolgenerating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness.

[0125] Example Ex35: An aerosol-generating article according to any one of Ex1 to Ex34, wherein the aerosol-generating article comprises upper and lower external surfaces, the upper and lower external surfaces separated from each other to define a thickness of the aerosol-generating article.

[0126] Example Ex36: An aerosol-generating article according to Ex35, wherein the upper and lower external surfaces are planar.

[0127] Example Ex37: An aerosol-generating article according to Ex35, wherein the upper and lower external surfaces are outwardly convex, for example the upper and lower external surfaces collectively defining a round, circular, ovoid or lenticular profile.

[0128] Example Ex38: An aerosol-generating article according to any one of Ex35 to Ex37, wherein the upper and lower external surfaces are defined by the wrapper. Example Ex39: An aerosol-generating article according to any one of Ex35 to Ex37, wherein the upper and lower external surfaces are defined by an additional wrapper of the aerosol-generating article, the wrapped body enclosed by the additional wrapper.

[0129] Example Ex40: An aerosol-generating article according to any one of Ex35 to Ex39, wherein the aerosol-generating article further comprises: a cavity located within the aerosol-generating article between the upper external surface and the lower external surface; a frame positioned between the upper external surface and the lower external surface, the frame at least partially defining the cavity; an airflow path defined through the aerosol-generating article between an air inlet and an air outlet, the airflow path extending through the cavity.

[0130] Example Ex41 : An aerosol-generating article according to Ex40, wherein the wrapped body is disposed within the cavity.

[0131] Example Ex42: An aerosol-generating article according to Ex41 , wherein the upper and lower external surfaces are defined by an additional wrapper of the aerosol-generating article, the wrapped body and the frame enclosed by the additional wrapper.

[0132] Example Ex43: An aerosol-generating article according to Ex40, wherein the aerosol-forming substrate is disposed within the cavity, the wrapper configured to encapsulate the frame in addition to the aerosol-forming substrate.

[0133] Example Ex44: An aerosol-generating article according to Ex43, wherein one or more apertures may be formed in opposing walls of the frame to provide for passage of an air flow through the cavity when the wrapper is breached at locations corresponding to the locations of the one or more apertures

[0134] Example Ex45: An aerosol-generating article according to any one of Ex1 to Ex44, wherein the aerosol-forming substrate comprises an aerosol-former, for example an aerosol former selected from the list consisting of glycerine and propylene glycol, for example in which the aerosol-forming substrate has an aerosol-former content of greater than 20 wt % on a dry weight basis, for example greater than 25 wt %, or greater than 30 wt %, for example greater than 35 wt %.

[0135] Example Ex46: An aerosol-generating article according to any one of Ex1 to Ex45, wherein the aerosol-forming substrate comprises tobacco, for example tobacco cut filler, cast leaf tobacco, or homogenised tobacco.

[0136] Example Ex47: An aerosol-generating article according to any one of Ex1 to Ex46, wherein the aerosol-forming substrate comprises any one or more of nicotine, botanicals, cannabinoid, and a flavouring agent.

[0137] Example Ex48: An aerosol-generating article according to any one of Ex1 to Ex47, wherein the aerosol-forming substrate comprises or consists of a solid aerosol-forming substrate.

[0138] Example Ex49: An aerosol-generating article according to any one of Ex1 to Ex47, wherein the aerosol-forming substrate has a liquid or gel composition, or a composition of two or more of solid, liquid or gel phases.

[0139] Examples will now be further described with reference to the figures in which: Figure 1 is a perspective view of an aerosol-generating article according to a first embodiment of the present disclosure in an unbreached first state, including a transverse cross-sectional view through the article;

[0140] Figure 2 is a perspective view of the aerosol-generating article of figure 1 in a breached second state;

[0141] Figure 3 is a perspective view of an aerosol-generating article according to a second embodiment of the present disclosure, including a transverse cross-sectional view through the article;

[0142] Figure 4 is a perspective view of the aerosol-generating article of figure 3 in a breached second state;

[0143] Figures 5(a)-(f) are perspective views illustrating a first example of how a wrapper may be folded about a body of aerosol-forming substrate;

[0144] Figures 6(a)-(f) are perspective views illustrating a second example of how a wrapper may be folded about a body of aerosol-forming substrate;

[0145] Figures 7(a)-(f) are perspective views illustrating a third example of how a wrapper may be folded about a body of aerosol-forming substrate;

[0146] Figures 8(a)-(f) are perspective views illustrating a fourth example of how a wrapper may be folded about a body of aerosol-forming substrate;

[0147] Figure 9 is an exploded perspective view showing the components of an aerosol-generating article according to a further embodiment of the present disclosure;

[0148] Figure 10 is a perspective view of the aerosol-generating article of figure 9 when partially assembled;

[0149] Figure 1 1 is a perspective view of the aerosol-generating article of figures 9 and 10 when fully assembled, a wrapper of the aerosol-generating article being in an unbreached first state;

[0150] Figure 12 shows a schematic transverse cross-sectional view of the assembled aerosolgenerating article of figure 11 ;

[0151] Figure 13 shows a schematic longitudinal cross-sectional view of the assembled aerosolgenerating article of figure 11 ;

[0152] Figure 14 is a perspective view of the assembled aerosol-generating article of figures 11 to 13, with the wrapper of the aerosol-generating article being in a breached second state.

[0153] Figure 15 shows a schematic view of an aerosol-generating device according to an embodiment of the present disclosure, the device configured to engage with an aerosol-generating article, for example the aerosol-generating article of any of figures 1 to 14;

[0154] Figure 16 shows a schematic end view of the aerosol-generating device of figure 15;

[0155] Figure 17 is a schematic view showing an aerosol-generating article (for example, the aerosolgenerating article of any of figures 1 to 14) in engagement with the aerosol-generating device of figure 15.

[0156] Figure 18 is a schematic view of an alternative embodiment to that of figures 15 to 17, showing an aerosol-generating article in engagement with an aerosol-generating device.

[0157] Figures 1 and 2 illustrate a perspective view of an aerosol-generating article 100 according to a first embodiment of the present disclosure. The aerosol-generating article 100 has a wrapper 101 encapsulating a body of aerosol-forming substrate 102. The body of aerosol-forming substrate 102 is shown in broken outline in figures 1 and 2 to be indicative of the wrapper 101 enclosing the entirety of the body of aerosol-forming substrate. Figure 1 also includes a view through section A-A of the aerosol-generating article 100, illustrating how the wrapper 101 encapsulates the body of aerosolforming substrate 102. The aerosol-generating article 100 of figure 1 is cuboid in shape, with the wrapper 101 defining the exterior of the aerosol-generating article. The aerosol-generating article 100 has a length extending in an x direction, a width extending in a y-direction and a thickness (or height) extending in a z direction. Upper and lower external surfaces 103, 104 of the article 100 are planar and flat. In a similar manner, opposing external side surfaces 105, 106 of the article 100 are also planar and flat. The aerosol-forming substrate 102 is in the form of homogenised tobacco having an aerosol-former content of 25 percent by weight on a dry weight basis.

[0158] The wrapper 101 is formed of a material configured to inhibit or prevent passage of moisture across a thickness of the wrapper. Further, the wrapper 101 is formed of a foldable material, by which is meant a material capable of being deformed into a folded state to define one or more fold lines therein, the fold lines remaining on removal of the force responsible for causing deformation of the wrapper into the folded state. In the illustrated embodiment of figure 1 , the wrapper 101 is formed of a coated paper, such as PVOH paper, and has a thickness of 35 microns. In another embodiment, the wrapper 101 may instead be formed from an aluminium foil of 7 microns in thickness, or a foil made of a different metal. In a further embodiment, the wrapper 101 may instead be formed having a laminate structure; for example, having a metal first layer (for example, a layer of aluminium) overlaid by or overlying a paper-based second layer, with the wrapper having a thickness of between 10 and 200 microns.

[0159] The encapsulation of the body of aerosol-forming substrate 102 by the wrapper 101 serves to fully enclose the substrate.

[0160] Figure 1 illustrates the aerosol-generating article 100 in an unbreached first state, in which the wrapper 101 substantially prevents any air flow and / or moisture entering the body of aerosol-forming substrate 102 from outside of the aerosol-generating article. Similarly, the unbreached first state of the wrapper 101 helps to avoid or reduce loss of moisture content from the body of aerosol-forming substrate 102.

[0161] Figure 2 illustrates the aerosol-generating article 100 in a breached second state, in which the wrapper 101 has been breached at opposed axial end faces 107, 108 of the aerosol-generating article to define respective apertures 109, 110 through the wrapper in the opposed axial end faces. Aperture 109 defines an air inlet and aperture 1 10 defines an air outlet. The homogenised tobacco forming the body of aerosol-forming substrate 102 has a porous structure. The apertures 109, 110 provide for an air flow into the aerosol-generating article 100, through the aerosol-forming substrate 102 and then out from the aerosol-generating article. The path 11 1 taken by the air flow through the interior of the aerosol-generating article 100 is indicated by arrows in figure 2.

[0162] The wrapper 101 may be breached to form the apertures 109, 1 10 by a consumer prior to insertion of the aerosol-generating article 100 into an aerosol-generating device (not shown), for example, by using a pin, blade or other suitable sharp or pointed implement. Alternatively, the aerosol-generating article 100 may instead be breached as a consequence of the aerosol-generating article being inserted within a cavity of an aerosol-generating device. For example, the cavity of the aerosol-generating device may be adapted to breach the wrapper 101 on or after insertion of the aerosol-generating article 100 into the cavity. The aerosol-generating device may be provided with a heating arrangement (for example, an electrically-powered heating element) for heating the aerosolforming substrate 102 of the aerosol-generating article 100 to vaporise volatile constituents of the aerosol-forming substrate, with the vapour cooling and becoming entrained in an air flow through the aerosol-generating article along air flow path 1 11 to form an aerosol.

[0163] Figures 3 and 4 illustrate a perspective view of an aerosol-generating article 200 according to a second embodiment of the present disclosure. Features in common with aerosol-generating article 100 are referred to with like reference signs, but starting with numeral 2 instead of 1 . In common with the article 100 of figures 1 and 2, the aerosol-generating article 200 has a wrapper 201 encapsulating a body of aerosol-forming substrate 202. The body of aerosol-forming substrate 202 is shown in broken outline in figures 3 and 4 to be indicative of the wrapper 201 enclosing the entirety of the body of aerosol-forming substrate. Figure 3 also includes a view through section B-B of aerosolgenerating article 200, illustrating how the wrapper 201 encapsulates the body of aerosol-forming substrate 202. The aerosol-generating article 200 differs from the article 100 of figures 1 and 2 in defining a round cylindrical rod shape, with the wrapper 201 defining the exterior of the aerosolgenerating article. The aerosol-generating article 200 has a length extending in an x direction, a width extending in a y-direction and a thickness (or height) extending in a z direction. In common with article 100, the aerosol-forming substrate 202 of the article 200 is in the form of homogenised tobacco.

[0164] The wrapper 201 is formed of the same materials as described above for wrapper 101 .

[0165] The encapsulation of the body of aerosol-forming substrate 202 by the wrapper 201 serves to fully enclose the substrate.

[0166] Figure 3 illustrates the aerosol-generating article 200 in an unbreached first state, in which the wrapper 201 substantially prevents any air flow and / or moisture entering the body of aerosol-forming substrate 202 from outside of the aerosol-generating article. Figure 4 illustrates the aerosolgenerating article 200 in a breached second state, in which the wrapper 201 has been breached at opposed axial end faces 207, 208 of the aerosol-generating article to define respective apertures 209, 210 through the wrapper in the opposed axial end faces. Aperture 209 defines an air inlet and aperture 210 defines an air outlet. The homogenised tobacco forming the body of aerosol-forming substrate 202 has a porous structure. The apertures 209, 210 provide for an air flow into the aerosolgenerating article 200, through the aerosol-forming substrate 202 and then out from the aerosolgenerating article. The path 211 taken by the air flow through the interior of the aerosol-generating article 200 is indicated by arrows in figure 4. The wrapper 201 may be breached in the same manner as the wrapper 101 of the aerosol-generating article 100 described above.

[0167] In a variant of the aerosol-generating article 200 of figures 3 and 4, the aerosol-generating article may instead have a lenticular cross-section with upper and lower external surfaces of the article defined by convex upper and lower portions of the wrapper enclosing a correspondingly shaped body of aerosol-forming substrate. Such a lenticular cross-section defines a profile corresponding to that of a bi-convex lens.

[0168] For the aerosol-generating articles 100, 200 illustrated in figures 1 to 4, the body of aerosolforming substrate 102, 202 is the sole entity encapsulated by the respective wrapper 101 , 201 . However, in other embodiments, one or more additional elements may be encapsulated by the wrapper 101 , 201 in addition to the body of aerosol-forming substrate 102, 202.

[0169] Figures 5(a)-(e) are perspective views illustrating a first example of how a wrapper 301 may be folded about a body of aerosol-forming substrate 302 to form a wrapped body 300 of aerosol-forming substrate. Figure 5(a) shows the body of aerosol-forming substrate 302 placed on a wrapper 301 . Figure 5(a) shows the wrapper 301 being in the form of a sheet. Opposing longitudinally-extending ends 312a, 312b of the wrapper 301 are folded in the direction of the arrows shown in figure 5(a) around opposed side faces of the body of aerosol-forming substrate 302 to adopt the state shown in figure 5(b). The opposing longitudinally-extending ends 312a, 312b of the wrapper 301 are then aligned with each other to define a fin seal portion 313 of the wrapper (see figure 5(c)), with opposing inside surfaces of the fin seal portion bonded to each other by an adhesive or other sealing means. As also shown in figure 5(c), the wrapper 301 is folded to enclose a periphery of the body of aerosolforming substrate 302, but with portions 314a, 314b of the wrapper extending beyond opposed axial end faces of the body of aerosol-forming substrate 302 to leave the opposed axial end faces of the body of aerosol-forming substrate uncovered and exposed. The outline of the body of aerosol-forming substrate 302 is shown in broken outline in figures 5(c) and 5(d). The fin seal portion 313 of the wrapper 301 is then folded downwards in the direction of the arrow shown in figure 5(c) to overlie one of the exterior side walls of the wrapper and adopt the state shown in figure 5(d). Upper and lower surfaces of the portion 314a of the wrapper 301 are then pressed together and flattened, with the same being performed for the upper and lower surfaces of portion 314b - as shown in figure 5(e). The flattened portions 314a, 314b are then folded upwardly in the direction of the arrows shown in figure 5(e) to overlie the upper wall of the wrapper 301 , thereby forming the wrapped body 300 of figure 5(f). A consumer may prepare the wrapped body 300 for consumption by unfolding the flattened portions 314a, 314b of the wrapper 301 back into the state shown in figure 5(e) and then removing the flattened portions from the wrapper by cutting with scissors or a knife to thereby expose the aerosolforming substrate 302. The wrapped body 300 may form an aerosol-generating article in its own right, or may be a component part of an aerosol-generating article.

[0170] Figures 6(a)-(e) are perspective views illustrating a second example of how a wrapper 401 may be folded about a body of aerosol-forming substrate 402 to form a wrapped body 400 of aerosolforming substrate. Figure 6(a) shows the body of aerosol-forming substrate 402 placed on a wrapper 401 . Figure 6(a) shows the wrapper 401 being in the form of a sheet. Opposing laterally-extending ends 412a, 412b of the wrapper 401 are folded in the direction of the arrows shown in figure 6(a) around opposed axial end faces of the body of aerosol-forming substrate 402 to adopt the state shown in figure 6(b). The opposing laterally-extending ends 412a, 412b of the wrapper 401 are then aligned with each other to define a fin seal portion 413 of the wrapper (see figure 6(c)), with opposing inside surfaces of the fin seal portion bonded to each other by an adhesive or other sealing means. As also shown in figure 6(c), the wrapper 401 is folded to enclose a periphery of the body of aerosolforming substrate 402, but with portions 414a, 414b of the wrapper extending beyond opposed side faces of the body of aerosol-forming substrate 402 to leave the opposed side faces of the body of aerosol-forming substrate uncovered and exposed. The outline of the body of aerosol-forming substrate 402 is shown in broken outline in figures 6(c) and 6(d). The fin seal portion 413 of the wrapper 401 is then folded upwards in the direction of the arrow shown in figure 6(c) to overlie the upper wall of the wrapper and adopt the state shown in figure 6(d). The upper surface of the portion 414a of the wrapper 401 is then folded downwards in the direction of the arrow in figure 6(d) to overlie one of the side surfaces of the body of aerosol-forming substrate 402, with the same being performed for the upper surface of portion 414b - as shown in figure 6(e). The lower surface of portion 414a is then folded upwardly in the direction of the arrow shown in figure 6(e) to overlie the folded upper surface of portion 414a, with the same being performed for the lower surface of portion 414b - , thereby forming the wrapped body 400 of figure 6(f). A consumer may prepare the wrapped body 400 for consumption by piercing the wrapper 401 in each of opposed axial end faces 407, 408 of the wrapper. The wrapped body 400 may form an aerosol-generating article in its own right, or may be a component part of an aerosol-generating article.

[0171] Figures 7(a)-(e) are perspective views illustrating a third example of how a wrapper 501 may be folded about a body of aerosol-forming substrate 502 to form a wrapped body 500 of aerosol-forming substrate. Figure 7(a) shows the body of aerosol-forming substrate 502 placed on a wrapper 501 . Figure 7(a) shows the wrapper 501 being in the form of a sheet. Opposing laterally-extending ends 512a, 512b of the wrapper 501 are folded in the direction of the arrows shown in figure 7(a) around opposed axial end faces of the body of aerosol-forming substrate 502 to adopt the state shown in figure 7(b). The opposing laterally-extending ends 512a, 512b of the wrapper 501 are then aligned with each other to define a fin seal portion 513 of the wrapper (see figure 7(c)), with opposing inside surfaces of the fin seal portion bonded to each other by an adhesive or other sealing means. As also shown in figure 7(c), the wrapper 501 is folded to enclose a periphery of the body of aerosol-forming substrate 502, but with portions 514a, 514b of the wrapper extending beyond opposed side faces of the body of aerosol-forming substrate 502 to leave the opposed side faces of the body of aerosolforming substrate uncovered and exposed. The outline of the body of aerosol-forming substrate 502 is shown in broken outline in figures 7(c) and 7(d). The fin seal portion 513 of the wrapper 501 is then folded in the direction of the arrow shown in figure 7(c) to overlie the upper wall of the wrapper and adopt the state shown in figure 7(d). The upper surface of the portion 514a of the wrapper 501 is then folded downwards in the direction of the arrow in figure 7(d) to overlie one of the side surfaces of the body of aerosol-forming substrate 502, with the same being performed for the upper surface of portion 514b - as shown in figure 7(e). The lower surface of portion 514a is then folded upwardly in the direction of the arrow shown in figure 7(e) to overlie the folded upper surface of portion 514a, with the same being performed for the lower surface of portion 514b - thereby forming the wrapped body 500 of figure 7(f). A consumer may prepare the wrapped body 500 for consumption by piercing the wrapper 501 in each of opposed axial end faces 507, 508 of the wrapper. The wrapped body 500 may form an aerosol-generating article in its own right, or may be a component part of an aerosolgenerating article.

[0172] Figures 8(a)-(e) are perspective views illustrating a fourth example of how a wrapper 601 may be folded about a body of aerosol-forming substrate 602 to form a wrapped body 600 of aerosolforming substrate. Figure 8(a) shows the body of aerosol-forming substrate 602 placed on a wrapper 601 . Figure 8(a) shows the wrapper 601 being in the form of a sheet. Opposing longitudinally- extending ends 612a, 612b of the wrapper 601 are folded in the direction of the arrows shown in figure 8(a) around opposed side faces of the body of aerosol-forming substrate 602 to adopt the state shown in figure 8(b). The opposing longitudinally-extending ends 612a, 612b of the wrapper 601 are then aligned with each other to define a fin seal portion 613 of the wrapper (see figure 8(c)), with opposing inside surfaces of the fin seal portion bonded to each other by an adhesive or other sealing means. As also shown in figure 8(c), the wrapper 601 is folded to enclose a periphery of the body of aerosol-forming substrate 602, but with portions 614a, 614b of the wrapper extending beyond opposed axial end faces of the body of aerosol-forming substrate 602 to leave the opposed axial end faces of the body of aerosol-forming substrate uncovered and exposed. The outline of the body of aerosol-forming substrate 602 is shown in broken outline in figures 8(c) and 8(d). The fin seal portion 613 of the wrapper 601 is then folded in the direction of the arrow shown in figure 8(c) to overlie the upper wall of the wrapper and adopt the state shown in figure 8(d). Upper and lower surfaces of the portion 614a of the wrapper 601 are then pressed together and flattened, with the same being performed for the upper and lower surfaces of portion 614b - as shown in figure 8(e). The flattened portions 614a, 614b are then folded upwardly in the direction of the arrows shown in figure 6(e) to overlie the upper wall of the wrapper 601 , thereby forming the wrapped body 600 of figure 8(f). A consumer may prepare the wrapped body 600 for consumption by unfolding the flattened portions 614a, 614b of the wrapper 601 back into the state shown in figure 8(e) and then removing the flattened portions from the wrapper by cutting with scissors or a knife. The wrapped body 600 may form an aerosol-generating article in its own right, or may be a component part of an aerosolgenerating article.

[0173] Figure 9 shows the components of a further embodiment of an aerosol-generating article 700. The components of the aerosol-generating article 700 include a wrapper 701 and a body of aerosolforming substrate 702. The wrapper 701 is a laminated sheet formed of a layer of aluminium overlaid onto a layer of a paper-based substrate, the aluminium layer being 6 microns thickness and the paper-based substrate layer being of 40 microns thickness. The body of aerosol-forming substrate 702 is in the form of a portion of cut filler tobacco having an aerosol-former content of 5 percent by weight on a dry weight basis. The components of the aerosol-generating article 700 also include a frame 715, a first planar layer 716 forming a first planar surface 717, and a second planar layer 718 forming a second planar surface 719. The frame 715 circumscribes and at least partially defines a cavity 720. The body of aerosol-forming substrate 702 is dimensioned to fit within the cavity 720.

[0174] The first planar layer 716 and the second planar layer 718 are made from cigarette paper having a thickness of 35 micrometres. The frame 715 has a hollow cuboid shape and is made from cardboard. The frame 715 defines an aperture extending through the thickness of the frame and the aperture at least partially forms the cavity 720. The frame 715 comprises a peripheral wall 721 that circumscribes the cavity 720. The peripheral wall 721 includes a front wall 722 and a back wall 723. In more detail, the peripheral wall

[0175] 721 is defined by an inner transverse surface 724 of the frame 715 and an outer transverse surface 725 of the frame. The inner transverse surface 724 of the frame 715 at least partially defines a perimeter of the cavity 720. The peripheral wall 721 has a radial thickness measured between the inner transverse surface 724 of the frame 715 and the outer transverse surface 725 of the frame of about 5 millimetres. An air inlet 726 and an air outlet 727 are defined by, and extend through, the peripheral wall 721 of the frame 715. More specifically, the air inlet 726 extends through the front wall

[0176] 722 and the air outlet 727 extends through the back wall 723. The air inlet 726 and the air outlet 727 have an equivalent diameter of 5 millimetres. An air flow passage extends between the air inlet 726 and the air outlet 727 through the cavity 720.

[0177] The components of the aerosol-generating article 700 are partially assembled in a first series of steps to form an intermediate structure 700a (shown in figure 10) positioned on a surface of the wrapper 701 , as described below.

[0178] The first planar layer 716 is bonded to a first planar annular surface of the peripheral wall 721 of the frame 715 using an adhesive. The body of aerosol-forming substrate 702 is then positioned within the cavity 720 defined by the frame 715 to rest upon a surface of the first planar layer 716. In the illustrated embodiment, the body of aerosol-forming substrate 702 fills the entire volume of the cavity 720. In other embodiments, the body of aerosol-forming substrate 702 may only partially fill the cavity 720; for example the body of aerosol-forming substrate 702 may extend along only part of the length (in an x-direction) of the cavity, and / or only part of the width (in a y-direction) of the cavity, and / or only part of the thickness (in a z-direction) of the cavity.

[0179] The second planar layer 718 is then bonded to a second planar annular surface of the peripheral wall 721 of the frame 715 using an adhesive. The second planar layer 718 is positioned parallel to the first planar layer 716. The first planar layer 716 overlies a first end of the cavity 720 and forms a first cavity end wall 728. The second planar layer 718 overlies a second end of the cavity 720 and forms a second cavity end wall 729, the second cavity end wall being opposite to the first cavity end wall. That is, the frame 715, the first planar external layer 716 and the second planar external layer 718 collectively enclose and define the cavity 720. The structure formed by the combination of the frame 715, first and second planar layers 716, 718 and body of aerosol-forming substrate 702 defines the intermediate structure 700a. Figure 10 shows this intermediate structure 700a positioned on a surface of the wrapper 701 . The first planar surface 717 of the first planar layer 716 defines a lower external surface of the intermediate structure 700a. The second planar surface 719 of the second planar layer 718 defines an upper external surface of the intermediate structure 700a.

[0180] Assembly of the aerosol-generating article 700 is then completed in a second series of steps. In this second series of steps, the wrapper 701 is folded around the intermediate structure 700a so as to encapsulate the intermediate structure, thereby forming assembled aerosol-generating article 700 (as shown in figure 11 ). Figure 1 1 shows the intermediate structure 700a in broken outline, the intermediate structure fully enclosed by and within the wrapper 701 . The precise manner in which the wrapper 701 is folded around the intermediate structure 700a is not illustrated in the figures relating to the aerosol-generating article 700, but it will be appreciated that the wrapper 701 may be folded so as to encapsulate the intermediate structure 700a in the same manner in which the wrapper 301 , 401 , 501 , 601 is folded so as to encapsulate the body of aerosol-forming substrate 302, 402, 502, 602 for the embodiments of figures 5(a) to (f), 6(a) to (f), 7(a) to (f) and 8(a) to (f).

[0181] Figure 11 shows the wrapper 701 of the assembled aerosol-generating article 700 in an unbreached first state. In the unbreached first state, the wrapper 701 substantially prevents the passage of moisture across the wrapper to or from the intermediate structure 700a. In this manner, the aerosol-generating article 700 may be stored or transported in damp or humid environments without the body of aerosol-forming substrate 702 absorbing any moisture from the environment in which the article is stored or transported.

[0182] Figures 12 and 13 show respective transverse and longitudinal cross-sectional views of the fully assembled aerosol-generating article 700.

[0183] A consumer will receive the aerosol-generating article 700 with the wrapper 701 in the unbreached first state of figure 1 1 . However, to enable the user to inhale aerosol containing vapours evolved from heating of the aerosol-forming substrate 702, the user may transform the aerosolgenerating article 700 into a breached second state by piercing the wrapper 701 at locations adjacent to the air inlet 726 and air outlet 727 in the frame 715 to define an inlet aperture 732 and an outlet aperture 733 through the wrapper - as shown in figure 14. The user may use a blade, needle or other pointed or sharp object to manually breach the wrapper 701 to create the inlet and outlet apertures 732, 733. Alternatively, the wrapper 701 may be breached by features of an aerosol-generating device in consequence of or subsequent to coupling of the aerosol-generating article 700 with the device. The inlet aperture 732 and outlet aperture 733 of the wrapper 701 in combination with the air inlet and air outlet 726, 727 of the frame 715 define part of an air flow path 711 through the interior of the aerosol-generating article 700. The air flow path 711 extends through the body of aerosol-forming substrate 702 by virtue of the strands of cut filler which form the aerosol-forming substrate defining an inherently porous structure.

[0184] The aerosol-generating article 700 has a cuboid shape and has a height (or thickness) extending in a z dimension, of 8 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The frame 715 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The cavity 720 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 35 millimetres and a length extending in an x dimension of 52 millimetres.

[0185] In an alternative embodiment to the aerosol-generating article 700 of figures 9 to 14, the body of aerosol-forming substrate 702 may instead be encapsulated within a wrapper to define a wrapped body, with the wrapped body inserted into the cavity 720. By way of example, the wrapped body may be in the form of any of the wrapped bodies 300, 400, 500, 600 described above in relation to figures 5(a) to (f), figures 6(a) to (f), figures 7(a) to (f) and figures 8(a) to (f). In such an alternative embodiment, the wrapper 701 may define an additional wrapper of the aerosol-generating article 700, or may be dispensed with entirely.

[0186] Figures 15 and 16 illustrate an aerosol-generating device 8000 configured for use with an aerosol-generating article 800 comprising or consisting of aerosol-forming substrate 840. The device 8000 is an elongate aerosol-generating device extending between a proximal end 8001 and a distal end 8002. The device 8000 comprises a battery 8010, a controller 8020 and a heater 8030 located within a housing 8040. The controller 8020 controls supply of power from the battery 8010 to the heater 8030. A cavity 8050 is defined in the device 8000, the cavity having an opening 8051 defined in the proximal end 8001 of the device. The opening 8051 is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosol-generating article 800. The cavity 8050 comprises an upper planar surface 8052 and a lower planar surface 8053. The heater 8030 is located in the lower planar surface 8053 to heat a lower surface of the aerosol-generating article 800 inserted into the cavity 8050. An air-flow path is configured to allow air to flow into the cavity 8050 from outside the device 8000.

[0187] Figure 17 illustrates the device 8000 of figure 15 in engagement with the aerosol-generating article 800. There is little tolerance between outer surfaces of the aerosol-generating article 800 and the internal surfaces of the cavity 8050. Thus, there is a snug fit between the aerosol-generating article 800 and the device 8000. As the RTD of the aerosol-generating article 800 is negligible, the RTD of the system formed by the combination of aerosol-generating article 800 and aerosolgenerating device 8000 is controlled by the air-flow path defined within the device. When a user has inserted the aerosol-generating article 800 into the cavity 8050, the device 8000 can be operated. The heater 8030 heats a lower surface of the aerosol-generating article 800, and as a result the aerosolforming substrate 840 of the aerosol-generating article 800 is heated. Volatile components of the aerosol-forming substrate 840 are evaporated and condense in longitudinal air-flow channels defined within the aerosol-generating article 800 to form an aerosol. The user inhales the aerosol by drawing on the proximal end 801 of the aerosol-generating article 800. Once the aerosol-generating substrate 840 of the aerosol-generating article 800 has been depleted of volatile components, the aerosolgenerating article is removed from the cavity 8050 of the device 8000 and disposed of. The aerosolgenerating article 800 may be any one of the aerosol-generating articles 100, 200, 300, 400, 500, 600, 700 previously described or any other aerosol-generating article of the present disclosure.

[0188] Although figure 17 shows part of the aerosol-generating article 800 extending outside of the aerosol-generating device 8000, in other embodiments the entirety of an aerosol-generating article may be wholly enclosed within an aerosol-generating device. By way of example, figure 18 illustrates an alternative embodiment to that of figure 17, with like features referred to by the same reference numbers but with the addition of a prime symbol '. For the alternative embodiment of figure 18, the entirety of aerosol-generating article 800’ is enclosed within the interior of aerosol-generating device 8000’.

[0189] 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”. 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. In this context, therefore, a number “A” is understood as “A” ± 10% 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. The terms “in which” and “wherein” are used synonymously through this specification.

Claims

CLAIMS:

1. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising a wrapper encapsulating at least an aerosolforming substrate to define a wrapped body, wherein the wrapper is formed of a foldable material, the wrapper configured to inhibit or prevent passage of moisture across a thickness of the wrapper.

2. An aerosol-generating article according to claim 1 , wherein the wrapper has a polymer content of less than 25%, or less than 15%, or less than 10%, or less than 5%, for example wherein the wrapper is substantially free of polymer content.

3. An aerosol-generating article according to any one of claims 1 to 2, the wrapper having an unbreached first state and a breached second state, wherein in the breached second state an air flow path is defined through the wrapped body between an air inlet and an air outlet defined in the wrapper, the wrapper lacking the air inlet and the air outlet in the unbreached first state.

4. An aerosol-generating article according to any one of claims 1 to 3, wherein the wrapped body is configured such that on breaching of the wrapper at predetermined first and second locations axially spaced from each other in a length direction of the wrapped body, an air flow path is defined through the wrapped body between the predetermined first and second locations.

5. An aerosol-generating article according to any one of claims 1 to 4, wherein the wrapper is impermeable to water.

6. An aerosol-generating article according to any one of claims 1 to 5, wherein the wrapper has a permeability of between 1 to 10 Coresta units, for example between 1 to 5 Coresta units, for example between 1 to 3 Coresta units.

7. An aerosol-generating article according to any one of claims 1 to 6, wherein the wrapper is impervious to light, for example impervious to light having a wavelength associated with one or more of infrared radiation, visible light and ultraviolet light.

8. An aerosol-generating article according to any one of claims 1 to 7, wherein the wrapper comprises one or a combination of materials selected from a group consisting of parchment paper, supercalendered paper (for example glassine), tracing paper, cellulose films, coated paper (for example PVOH paper), and metal foil.An aerosol-generating article according to any one of claims 1 to 8, wherein the wrapper comprises or consists of a laminate of a metal first layer and a second layer.

10. An aerosol-generating article according to any one of claims 1 to 9, wherein the wrapper encapsulates only aerosol-forming substrate.

11. An aerosol-generating article according to any one of claims 1 to 9, wherein the aerosol- generating article further comprises at least one additional element encapsulated within the wrapper along with the aerosol-forming substrate, for example wherein the least one additional element comprises one or more of a filter, a spacer element and a frame.

12. An aerosol-generating article according to any one of claims 1 to 11 , wherein the aerosolforming substrate comprises discrete first and second portions of aerosol-forming substrate, for example wherein the composition of the first portion of aerosol-forming substrate is different to the composition of the second portion of aerosol-forming substrate.

13. An aerosol-generating article according to any one of claims 1 to 12, wherein the wrapped body is the aerosol-generating article.

14. An aerosol-generating article according to any one of claims 1 to 13, wherein the aerosolgenerating article comprises upper and lower external surfaces, the upper and lower external surfaces separated from each other to define a thickness of the aerosol-generating article, for example wherein the upper and lower external surfaces are planar, or for example wherein the upper and lower external surfaces are outwardly convex, for example the upper and lower external surfaces collectively define a round, circular, ovoid or lenticular profile.

15. An aerosol-generating article according to claim 14, wherein the aerosol-generating article further comprises: a cavity located within the aerosol-generating article between the upper external surface and the lower external surface; a frame positioned between the upper external surface and the lower external surface, the frame at least partially defining the cavity; an airflow path defined through the aerosol-generating article between an air inlet and an air outlet, the airflow path extending through the cavity; for example wherein the aerosol-forming substrate is disposed within the cavity, the wrapper configured to encapsulate the frame in addition to the aerosol-forming substrate.

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