Aerosol-generating system

Abstract

There is provided an aerosol-generating system comprising an aerosol-generating article (100, 200, 300, 400, 500, 600, 600') and an aerosol-generating device (6000). The aerosol-generating article comprises at least one aerosol-forming substrate (340, 440, 540, 640, 640'). The aerosol-generating article is defined by an article length, an article width, and an article thickness, the article length and the article width being at least two times the article thickness. The aerosol-generating device comprises a heating chamber (6050, 6050') for receiving the aerosol-generating article. The aerosol-generating device comprises at least one heater (6030, 6030'), the at least one heater defining a heating zone (6100, 6100') in the heating chamber. When the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, between 20 and 80 percent of a total mass of the at least one aerosol-forming substrate is located within the heating zone.

Description

[0001] AEROSOL-GENERATING SYSTEM

[0002] The present disclosure relates to an aerosol-generating system. The system comprises an aerosolgenerating device and an aerosol-generating article comprising an aerosol-forming substrate.

[0003] A typical aerosol-generating article may appear similar to a conventional cigarette. For example, such an aerosol-generating article may be substantially cylindrical and comprise an aerosol-forming substrate and other components such as a mouthpiece filter element and a cooling element, all arranged together in the form of a rod and wrapped in a cigarette paper. Dimensions of typical aerosol-generating articles are often similar to the dimensions of conventional cigarettes.

[0004] During use, an aerosol-generating article is typically engaged with an aerosol-generating device and then the aerosol-forming substrate is heated by the aerosol-generating device.

[0005] However, a significant portion of the aerosol-forming substrate in these cylindrical aerosol-generating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-forming substrate contributes to the cost of manufacture and transport of the aerosol-generating article, but does not contribute to the aerosol delivered to an end user. This may be the case regardless of the way in which the aerosol-forming substrate is heated, for example regardless of whether a resistive or inductive heater is used and regardless of whether the aerosol-forming substrate is heated from the inside or the outside. Moreover, the components of these cylindrical aerosolgenerating articles normally need to have the same or very similar outer diameters so that they can be brought together, accurately positioned in co-axial alignment and wrapped in a cigarette paper. This can lead to increased cost and complexity of manufacture.

[0006] Further, in some aerosol-generating systems, a time between first activating the heater and the aerosol-forming substrate reaching a sufficiently high temperature to form an aerosol, sometimes referred to as a time to first puff, is too long. Alternatively, or in addition, in some aerosol-generating systems, after the aerosol-forming substrate reaches a sufficiently high temperature to form an aerosol, too much of the aerosol-forming substrate is depleted too quickly. This can mean that the flavour of the aerosol delivered to a user diminishes rapidly after the first puff or first few puffs.

[0007] It is an aim of the present disclosure to provide an aerosol-generating system in which a greater portion of an aerosol-forming substrate of the aerosol-generating article is sufficiently heated to form an aerosol during use. It is also an objective of the present disclosure to provide an aerosol-generating article that can be manufactured relatively efficiently and cheaply. It is also an objective of the present disclosure to provide an aerosol-generating system in which a time to first puff is reduced. It is also an objective of the present disclosure to provide an aerosol-generating system in which the aerosol-forming substrate is not depleted too quickly.

[0008] According to the present disclosure, there is provided an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device. The aerosol-generating article may comprise at least one aerosol-forming substrate. The aerosol-generating article may have or be defined by an article length, an article width, and an article thickness. The article length may be at least two times the article thickness. The article width may be at least two times the article thickness. The aerosol-generating device may comprise a heating chamber for receiving at least a portion of the aerosol-generating article. The aerosol-generating device may comprise at least one heater. The at least one heater may define a heating zone in the heating chamber. When the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, between 10 and 90 percent, preferably between 20 and 80 percent, of a total mass of the at least one aerosol-forming substrate may be located within the heating zone.

[0009] Thus, according to a first aspect of the present disclosure, there is provided an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device. The aerosol-generating article comprises an at least one aerosol-forming substrate. The aerosol-generating article is defined by an article length, an article width, and an article thickness, the article length and the article width being at least two times the article thickness. The aerosol-generating device comprises a heating chamber for receiving at least a portion of the aerosol-generating article. The aerosol-generating device comprises at least one heater, the at least one heater defining a heating zone in the heating chamber. When the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, between 10 and 90 percent, preferably between 20 and 80 percent, of a total mass of the at least one aerosol-forming substrate is located within the heating zone.

[0010] Advantageously, by having only up to 80 percent of the total mass of the at least one aerosolforming substrate located within the heating zone when the aerosol-generating article is fully received in the heating chamber, when the heater is first switched on, a greater proportion of the heat energy provided by the heater is transferred to a smaller mass of aerosol-forming material, compared with a system where 100 percent of the total mass of the at least one aerosol-forming substrate is located within the heating zone. This means that the portion of the aerosol-forming substrate in the heating zone is able to reach a sufficiently high temperature to form an aerosol sooner. In addition, the portion of the at least one aerosolforming substrate outside the heating zone may take longer to reach a sufficiently high temperature to form an aerosol. Thus, this portion of the at least one aerosol-forming substrate outside the heating zone may be able to release a high quality aerosol later during a usage session of the aerosol-generating system. Thus, the system may reduce a time to first puff and delay depletion of the aerosol-forming substrate.

[0011] As set out above, the device comprises a heating chamber for receiving at least a portion of the article. The heating chamber may, or may not, receive an entirety of the article. Therefore, as the skilled person would understand after reading this disclosure, references to the article being fully received in the heating chamber do not refer to the entirety of the article being received in the heating chamber. Rather, as the skilled person would understand after reading this disclosure, references to the article being fully received in the heating chamber may refer to the article being received in the heating chamber to the greatest extent the article can be received in the heating chamber. This may be when the upstream end of the article abuts a stop surface of the heating chamber as discussed later. This stop surface may be an upstream end of the heating chamber or a surface of another component within the heating chamber to prevent the aerosol-generating article moving any further into the heating chamber. When the aerosol generating article is “fully received” in the heating chamber, a portion of the aerosol-generating article may protrude out of a heating chamber opening of the heating chamber. This may be the case where, for example, the length of the aerosol-generating article is greater than the length of the heating chamber, or when length of the aerosol-generating article is greater than a distance between the downstream end of the heating chamber and a surface within the heating chamber preventing the article from moving any further into the heating chamber. The at least one heater may comprise all heaters of the device, or all heaters of the device which are configured to heat the at least one aerosol-forming substrate to form an aerosol. The heating zone may be defined by all heaters of the device, or all heaters of the device which are configured to heat the at least one aerosol-forming substrate to form an aerosol. The at least one aerosol-forming substrate may comprise all aerosol-forming material in the article, or all of the aerosol-forming material in the article which is configured to be heated during a usage session. The only aerosol-forming material in the article may be the at least one aerosol-forming substrate. There may be no aerosol-forming material in the article other than the at least one aerosol-forming substrate. The total mass of the at least one aerosol-forming substrate may be the total mass of all of the mass of the aerosol-forming material in the article, or all of the mass of the aerosol-forming material in the article that is configured to be heated during a usage session.

[0012] According to a second aspect of the present disclosure, there is also provided an aerosolgenerating article. The article may be for use in an aerosol-generating system, such as the system described above or of the first aspect. The article may be for use with an aerosol-generating device, for example to generate an aerosol.

[0013] According to a third aspect of the present disclosure, there is also provided an aerosol-generating device. The device may be for use in an aerosol-generating system, such as the system described above or of the first aspect. The device may be for use with an aerosol-generating article such as the article according to the second aspect, for example to generate an aerosol.

[0014] Features described in relation to one aspect may be applicable to another aspect. For example, features described in relation to the article of the system of the first aspect may be applicable to the article of the second aspect. Similarly, features described in relation to the device of the system of the first aspect may be applicable to the device of the third aspect.

[0015] The system may be configured such that, during use, for example over the course of an entire usage session, a portion of the at least one aerosol-forming substrate, for example at least 20 or 30 percent of the total mass of the aerosol-forming substrate, is never located within the heating zone.

[0016] The heating chamber may define a heating chamber opening. The article may be received in the heating chamber through the heating chamber opening. The heating chamber opening may be substantially rectangular in shape. An area of the heating chamber opening may be no more than 20 or 10 percent greater than an area defined by the article width and article thickness. When the article is fully received in the heating chamber, the article may be held in position by friction. Advantageously, a friction or snug fit like this may allow efficient heat transfer from the at least one heater to the at least one substrate.

[0017] The heating chamber may have or define an at least partially closed end. The closed end may oppose the heating chamber opening. The heating chamber may comprise a stop surface. The at least partially closed end may comprise the stop surface. The stop surface may prevent receipt of the article in the heating chamber beyond a fully received position. When the article is fully received in the heating chamber, the stop surface may abut the article, for example an upstream end of the article. Advantageously, the use of a stop surface may ensure that a desired percent of the total mass of the aerosol-forming substrate is located within the heating zone when the article is fully received in the heating chamber.

[0018] Optionally, the at least one heater is or comprises at least one substantially flat or planar heater. Optionally, the at least one heater comprises a heating surface, for example a substantially flat or planar heating surface. Advantageously, a flat or planar heating surface may efficiently transfer heat to a substantially flat or planar aerosol-forming substrate.

[0019] The heating surface may be defined by a heating surface length and a heating surface width. Optionally, an internal surface of the heating chamber is or comprises at least a portion of the heating surface. Advantageously, an internal surface of the heating chamber being or comprising at least a portion of the heating surface may allow contact between, or minimise a distance between, the article or substrate and the heating surface. Advantageously, this may allow efficient transfer of heat.

[0020] Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, the heating surface length is substantially aligned with the article length. Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosolgenerating device, the heating surface width is substantially aligned with the article width. Advantageously, this alignment may allow efficient transfer of heat from the at least one heater to the article. Alternatively, or in addition, this alignment may minimise overheating or underheating an outer periphery of the article or substrate due to the at least one heater extending beyond, or not reaching, that outer periphery.

[0021] Optionally, the at least one aerosol-forming substrate comprises or consists of a first aerosolforming substrate. The first aerosol-forming substrate may have or be defined by a first substrate length, a first substrate width, and a first substrate thickness. Optionally, the first substrate length is at least two times the first substrate thickness. Optionally, the first substrate width is at least two times the first substrate thickness. The first aerosol-forming substrate may be a plug comprising aerosol-forming material. The first aerosol-forming substrate may be substantially prismatic in shape, for example cuboid or cylindrical.

[0022] Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, the heating surface length is substantially aligned with the first substrate length. Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosolgenerating device, the heating surface width is substantially aligned with the first substrate width.

[0023] Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosolgenerating device, the first substrate thickness extends in a direction that is substantially perpendicular to one or both of the heating surface length and the heating surface width. Advantageously, this alignment may allow efficient transfer of heat from the at least one heater to the first substrate. Alternatively, or in addition, this alignment may minimise overheating or underheating an outer periphery of the first substrate due to the at least one heater extending beyond, or not reaching, that outer periphery.

[0024] Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, at least 30, 40, 50, or 60 percent of the total mass of the at least one aerosolforming substrate is located within the heating zone. Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, nor more than 70, 60, 50 or 40 percent of the total mass of the at least one aerosol-forming substrate is located within the heating zone. Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, the percent of the total mass of the at least one aerosol-forming substrate located within the heating zone is between: 30 and 80, or 40 and 80, or 50 and 80, or 60 and 80, or 30 and 70, or 40 and 70, or 50 and 70, or 60 and 70, or 30 and 60, or 40 and 60, or 50 and 60, or 30 and 50, or 40 and 50, or 30 and 40, percent. It may be particularly preferable that, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, at least 55 percent, for example between 55 and 70 percent, of the total mass of the at least one aerosol-forming substrate is located within the heating zone. It has been found that this range may provide a quick time to first puff and a suitable delay to the formation of aerosol from the substrate outside of the heating zone.

[0025] Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device at least 80 or 90 percent, for example 100 percent, of a most upstream half of the total mass of the at least one aerosol-forming substrate is located within the heating zone. Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device at least 80 or 90 percent, for example 100 percent, of a most upstream quarter of the total mass of the at least one aerosol-forming substrate is located within the heating zone. Optionally, when the aerosolgenerating article is fully received in the heating chamber of the aerosol-generating device at least 80 or 90 percent, for example 100 percent, of a most downstream quarter of the total mass of the at least one aerosol-forming substrate is located outside the heating zone. It may be preferable to locate an upstream portion of the substrate in the heating zone because it is most likely that the portion of the substrate in the heating zone will reach the highest temperature in use, and by choosing this portion to be an upstream portion, the aerosol generated from this portion will have more time and distance to cool before reaching a user downstream. Alternatively, or in addition, warm air or aerosol from upstream may flow through or past a downstream portion of the substrate. This may advantageously help to warm the downstream portion of the substrate, particularly if that portion is located outside the heating zone.

[0026] Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, a most upstream end of any one, two or all three of the at least one heater, the heating zone, and the heating surface is aligned with a location no more than 20 or 10 or 5 millimetres from an upstream end of the at least one aerosol-forming substrate. Optionally, the most upstream end of any one, two or all three of the at least one heater, the heating zone, and the heating surface is substantially aligned with the upstream end of the at least one aerosol-forming substrate. Optionally, when the aerosolgenerating article is fully received in the heating chamber of the aerosol-generating device, a most downstream end of any one, two or all three of the at least one heater, the heating zone, and the heating surface is aligned with a location at least 2, 5, 10 or 20 millimetres from a downstream end of the aerosolforming substrate. Advantageously, this arrangement may allow efficient transfer of heat to the substrate whilst positioning an upstream portion of the substrate in the heating zone and positioning a downstream portion of the substrate outside the heating zone.

[0027] Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device at least 80 or 90 percent, for example 100 percent, of a most downstream half of the total mass of the at least one aerosol-forming substrate is located within the heating zone. Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device at least 80 or 90 percent, for example 100 percent, of a most downstream quarter of the total mass of the at least one aerosol-forming substrate is located within the heating zone. Optionally, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device at least 80 or 90 percent, for example 100 percent, of a most upstream quarter of the total mass of the at least one aerosol-forming substrate is located outside the heating zone. It may be preferable to locate a downstream portion of the substrate in the heating zone because this may reduce a time to first puff. This may be because there is little, or no, substrate further downstream which could absorb heat or aerosol droplets as generated aerosol flows to a user. Alternatively, or in addition, cool air flowing through the article may flow through or past an upstream portion of the substrate. This may advantageously further delay a spread of heat from the downstream portion to the upstream portion. This may advantageously allow more aerosol or flavour to be formed later in the usage session.

[0028] The at least one heater may be configured to heat portions of the heating zone separately, or to heat portions of the heating zone to an operating temperature separately. The at least one heater may be configured to heat a first portion of the heating zone, for example heat a first portion of the heating zone to an operating temperature, but not heat a second portion of the heating zone, for example not heat a second portion of the heating zone to an operating temperature, during a first stage. The at least one heater may be configured to heat the second portion of the heating zone, for example heat the second portion of the heating zone to an operating temperature, during a second stage. The least one heater may comprise at least two, three or five heaters or heating surfaces. Each heater or heating surface may be activated, or heated to an operating temperature, individually. A first heater or heating surface of the at least one heater may be configured to heat the first portion of the heating zone. A second heater or heating surface of the at least one heater may be configured to heat the second portion of the heating zone.

[0029] In the context of the above paragraph, the term “operating temperature” may refer to a temperature sufficiently high for an aerosol-forming substrate, for example the aerosol-forming substrate of the article, to form an aerosol. The term “operating temperature” may refer to a temperature of at least 100, 150, 200, or 250 degrees Celsius. The term “operating temperature” may refer to a temperature of no more than 800, 500, or 300 degrees Celsius. The term “operating temperature” may refer to a temperature of between 100 and 800, or between 100 and 500, or between 100 and 300, or between 150 and 800, or between 150 and 500, or between 150 and 300, degrees Celsius.

[0030] The second stage may be subsequent to the first stage. The first stage and second stage may occur during the same usage session. The first portion may comprise between 30 and 70 percent of the heating zone. The second portion may comprise between 30 and 70 percent of the heating zone.

[0031] Advantageously, heating portions of the heating zone as set out above may further reduce the time to first puff as an even smaller mass of substrate is being heated initially. Alternatively, or in addition, this may allow aerosol or flavour to be generated for longer during a usage session as heating some portions of the substrate to a sufficiently high temperature to form an aerosol is delayed.

[0032] Optionally, the at least one aerosol-forming substrate comprises or consists of a positionable aerosol-forming substrate. Optionally, the article comprises a cavity, for example a cavity for the positionable aerosol-forming substrate. Optionally, the positionable aerosol-forming substrate is positionable in the article, for example in the cavity of the article. Optionally, the positionable aerosolforming substrate is positionable in the aerosol-generating article relative to at least one other component of the aerosol-generating article, for example relative to the cavity of the aerosol-generating article. Advantageously, this may allow adjustment the percent of the total mass of the at least one substrate within the heating zone when the article is fully received in the heating chamber. This may affect aerosol generation during use, for example a time to first puff or how long the substrate is able to continue producing high quality aerosol and flavour. Optionally, the positionable aerosol-forming substrate is positionable in the aerosol-generating article by a user, for example before the aerosol-generating article is received in the heating chamber. Optionally, the positionable aerosol-forming substrate is positionable in the aerosol-generating article to vary a percentage of the positionable aerosol-forming substrate located within the heating zone when the aerosol-generating article is fully received in the heating chamber. Advantageously, this may allow a user to adjust the percent of the total mass of the at least one substrate within the heating zone when the article is fully received in the heating chamber.

[0033] Optionally, the positionable aerosol-forming substrate is positionable in the aerosol-generating article in at least a first position and a second position different to the first position. Optionally, when the aerosol-generating article is fully received in the heating chamber and the positionable aerosol-forming substrate is in the first position, a first position percentage of the positionable aerosol-forming substrate is located within the heating zone. Optionally, when the aerosol-generating article is fully received in the heating chamber and the positionable aerosol-forming substrate is in the second position, a second position percentage of the positionable aerosol-forming substrate is located within the heating zone. The first position percentage may be different to the second position percentage. Optionally, the first position percentage differs from the second position percentage by at least 10, 20, or 30 percent. Advantageously, this may allow adjustment the percent of the total mass of the at least one substrate within the heating zone when the article is fully received in the heating chamber.

[0034] The article may comprise a retaining means for retaining the positionable aerosol-forming substrate in a particular position. For example, the article may comprise an adhesive area for adhering to a surface of the positionable aerosol-forming substrate. The adhesive area may be located in or adjacent to the cavity of the article. The adhesive area may be located on a surface defining a boundary of the cavity. The adhesive area may be located on an upper surface of a base of the article. The adhesive area may be larger than an area of the surface of the positionable aerosol-forming substrate. Advantageously, this may provide an easy way for a user to position the positionable aerosol-forming substrate.

[0035] Optionally, the aerosol-generating article comprises at least one indicator configured to indicate where the positionable aerosol-forming substrate is positionable in the aerosol-generating article. Advantageously, this may reduce a risk of the positionable substrate being incorrectly positioned.

[0036] Optionally, the aerosol-generating article comprises at least one indicator configured to indicate that a position, or a change of position, of the positionable aerosol-forming substrate in the aerosolgenerating article affects use of the aerosol-generating article in the aerosol-generating system. Optionally, the aerosol-generating article comprises at least one indicator configured to indicate how the position, or the change of position, of the positionable aerosol-forming substrate in the aerosol-generating article affects use of the aerosol-generating article in the aerosol-generating system. Advantageously, this may inform a user how a position or change of position of the positionable substrate may affect use. Thus, a user may advantageously be able to position the positionable substrate in a position that will provide a more desirable experience for them during use.

[0037] Optionally, the aerosol-generating device is configured to estimate or determine a position of the positionable aerosol-forming substrate in the aerosol-generating article. Optionally, the aerosol-generating device is configured to control a heating profile of the at least one heater at least partly based on a position, or an estimated or determined position, of the positionable aerosol-forming substrate in the aerosol- generating article. Advantageously, this may allow tailoring of an experience depending on where the substrate is positioned. This may be a straightforward way for a user to tailor their experience.

[0038] A user may input a position of the positionable aerosol-forming substrate into the aerosolgenerating device. Or the device may be configured to determine a position of the positionable aerosolforming substrate in the aerosol-generating article in any suitable manner. The skilled person would be aware of suitable ways to detect a position of the positionable aerosol-forming substrate in the article.

[0039] As one example, the substrate may comprise a taggant and the device may comprise a plurality of detectors configured to detect that taggant. The plurality of detectors may be positioned along the heating chamber. The detector or detectors which receive a strongest signal from the taggant may be those closest to the substrate. This information may thus be used to estimate or determine a position of the positionable aerosol-forming substrate in the aerosol-generating article. Any suitable taggant could be used.

[0040] As another example, the device may comprise a one or more light emitters and one or more light detectors. The one or more light emitters and one or more light detectors may be positioned around the heating chamber. The one or more light detectors may be positioned on an opposite side of the heating chamber to the one or more light detectors. The one or more light emitters may emit light into the heating chamber after an article is received in the heating chamber. Analysis of light detected by the one or more light detectors may indicate a position of the positionable aerosol-forming substrate. For example, each light emitter may attempt to shine light through the article to a corresponding, opposing light detector. Less light from a given emitter may reach the corresponding detector if the positionable aerosol-forming substrate is between the given emitter and corresponding detector. Thus, analysis of the light detected at the light detectors may indicate a position of the positionable aerosol-forming substrate.

[0041] In accordance with the above few paragraphs, in an aspect of the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device, for example to generate an aerosol. The article comprises: a cavity and a positionable aerosol-forming substrate which is positionable in the cavity in at least two different positions. The article preferably comprises at least one indicator configured to indicate that, and particularly preferably how, a position, or a change of position, of the positionable aerosol-forming substrate in the aerosol-generating article affects use of the aerosolgenerating article with the aerosol-generating device.

[0042] Optionally, the aerosol-generating article is receivable in the heating chamber of the aerosolgenerating device in at least a first orientation and a second orientation different to the first orientation.

[0043] Optionally, when the aerosol-generating article is fully received in the heating chamber in the first orientation, a first orientation percentage of the at least one aerosol-forming substrate is located within the heating zone. Optionally, when the aerosol-generating article is fully received in the heating chamber in the second orientation, a second orientation percentage of the at least one aerosol-forming substrate is located within the heating zone. Optionally, the first orientation percentage is different to the second orientation percentage. Optionally, the first orientation percentage differs from the second orientation percentage by at least 10, 20, or 30 percent. Advantageously, this may allow a user to choose the percent of the total mass of the at least one substrate within the heating zone when the article is fully received in the heating chamber by choosing the orientation in which the article is received in the heating chamber. This may provide a straightforward way for a user to tailor their experience. Optionally, the aerosol-generating article comprises at least one indicator configured to indicate that the aerosol-generating article is receivable in the heating chamber of the aerosol-generating device in at least two different orientations, for example in the first orientation and in the second orientation.

[0044] Optionally, the aerosol-generating article comprises at least one indicator configured to indicate that an orientation in which the aerosol-generating article is received in the heating chamber affects use of the aerosol-generating article in the aerosol-generating system. Optionally, the aerosol-generating article comprises at least one indicator configured to indicate how the orientation in which the aerosol-generating article is received in the heating chamber affects use of the aerosol-generating article in the aerosolgenerating system. Advantageously, this may inform a user how an orientation of the article may affect use. Thus, a user may advantageously be able to orient the article in a way that will provide a more desirable experience for them during use.

[0045] Optionally, the aerosol-generating device is configured to determine an orientation in which the aerosol-generating article is received in the heating chamber. Optionally, the aerosol-generating device is configured to determine whether the aerosol-generating article is received in the heating chamber in one of the first and second orientations. Optionally, the aerosol-generating device is configured to control a heating profile of the at least one heater at least partly based on the orientation, or a determination of the orientation, in which the aerosol-generating article is received in the heating chamber. Advantageously, this may allow tailoring of an experience depending on the orientation of the article. This may be a straightforward way for a user to tailor their experience.

[0046] A user may input the orientation of the article into the device. Or the aerosol-generating device may be configured to determine the orientation of the aerosol-generating article in any suitable manner. The skilled person would be aware of suitable ways to detect the orientation of the article.

[0047] As one example, the article may have a first end at one end of the article length and a second end at an opposing end of the article length. The first and second ends may be interchangeable such that either can be the mouth end and either can be the distal end. The first end may comprise a first taggant and the second end may comprise a second taggant. The first and second taggants may be any suitable taggants, such as physical or chemical taggants. For example, the first taggant may be a first barcode and the second taggant may be a second barcode. The device may comprise a detector. The detector may be configured to detect the taggant at the distal end of the article, for example after the article is fully inserted into the heating chamber. Thus, depending on whether the first taggant or the second taggant is detected, the device may be able to determine which of the first end and the second end has been inserted into the heating chamber, and thus determine the orientation of the article.

[0048] In accordance with the above few paragraphs, in an aspect of the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device, for example to generate an aerosol. The aerosol-generating article is configured to be received in a heating chamber of the aerosolgenerating device. The article comprises at least one indicator configured to indicate that, and preferably how, an orientation of the aerosol-generating article affects use of the aerosol-generating article with the aerosol-generating device.

[0049] As the skilled person would understand after reading this disclosure, the article may comprise the positionable aerosol-forming substrate as describe above, and be receivable in the heating chamber of the aerosol-generating device in at least the first orientation and the second orientation different to the first orientation as described above. Other features described in relation to the positionable substrate or the orientation of the article may also be applicable. Advantageously, combining these features may give a user even more ways to customise or tailor their experience with a single article.

[0050] The following paragraphs explain some optional features of the aerosol-generating article. Below, the at least one aerosol-forming substrate may be referred to as the aerosol-forming substrate.

[0051] The article length may be greater than, for example at least 2, 3 or 5 times, the article thickness. The article width may be greater than, for example at least 2, 3 or 5 times, the article thickness. The article length may be greater than the article width. Advantageously, the article thickness being relatively small may reduce a temperature gradient across the article, or across the substrate of the article, during use. This may mean that a greater proportion of the substrate is able to reach a sufficiently high temperature to form an aerosol, without a significant risk of burning the substrate, compared with a thicker article or substrate.

[0052] The terms height and thickness may be used interchangeably herein. Thus, the terms article height and article thickness may be used interchangeably and the terms substrate height and substrate thickness may be used interchangeably.

[0053] Optionally, the article length extends in an article length direction. Optionally, the article width extends in an article width direction. Optionally, the article thickness extends in an article thickness direction. Optionally, the article length direction is perpendicular to the article width direction. Optionally, the article length direction is perpendicular to the article thickness direction. Optionally, the article width direction is perpendicular to the article thickness direction. Optionally, the article length direction, the article width direction, and the article thickness direction are mutually perpendicular. The article length direction may be referred to as the x direction. The article width direction may be referred to as the y direction. The article thickness direction may be referred to as the z direction. The article length may extend from an upstream end to a downstream end of the article.

[0054] Optionally, the article is substantially planar in shape. Optionally, the article is substantially cuboid in shape.

[0055] The aerosol-generating article may comprise an upper surface, for example a substantially planar upper surface. The upper surface may be defined by a length extending in an x direction, for example the article length, and a width extending in a y direction, for example the article width. The article may comprise a lower surface, for example a substantially planar lower surface. The lower surface may be defined by a length extending in an x direction, for example the article length, and a width extending in a y direction, for example the article width. The upper surface and lower surface may be external surfaces of the article. The upper surface and the lower surface may be vertically spaced from each other by a height defined in a z direction, for example the article thickness or article height.

[0056] The at least one aerosol-forming substrate may have, or be defined by, a substrate length, a substrate width, and a substrate thickness. The substrate length may extend in a substrate length direction. The substrate width may extend in a substrate width direction. The substrate thickness may extend in a substrate thickness direction. The substrate length direction, substrate width direction and substrate thickness direction may be mutually perpendicular. The substrate length may be greater than, for example at least 2, 3 or 5 times, the substrate thickness. The substrate width may be greater than, for example at least 2, 3 or 5 times, the substrate thickness. The substrate length may be greater than the substrate width. Advantageously, the substrate thickness being relatively small may reduce a temperature gradient across the substrate during use. This may mean that a greater proportion of the substrate is able to reach a sufficiently high temperature to form an aerosol, without a significant risk of burning the substrate, compared with a thicker substrate.

[0057] The substrate length may extend from an upstream end of the substrate to a downstream end of the at least one substrate. The substrate length direction may align, or be substantially parallel to, the article length direction. The substrate width direction may align, or be substantially parallel to, the article width direction. The substrate thickness direction may align, or be substantially parallel to, the article thickness direction.

[0058] Features described in the above two paragraphs in relation to the substrate may apply to the first substrate introduced earlier. For example the features relating to the relative sizes and directions of the substrate length, width and thickness may apply to the first substrate length, width and thickness of the first substrate introduced earlier.

[0059] Aerosol-generating articles according to the present disclosure may preferably be substantially flat articles or substantially planar articles. Such articles may have a large base area relative to the volume of the article. In particular, the height of the aerosol-generating article may be less than 50 or 25 percent of both the length and width ofthe aerosol-generating 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 aerosolgenerating article during heating. For example, where the base ofthe 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.

[0060] The aerosol-generating article may have an air flow path extending through the aerosol-generating article. The aerosol-generating article may have an air-flow path 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 aerosolgenerating 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 airflow path. Preferably, the aerosol-generating 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.

[0061] 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 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%.

[0062] The aerosol-generating article may comprise substantially planar upper and lower surfaces. A vertical separation between the substantially planar upper and lower surfaces may define a height (for example, a z dimension) of the aerosol-generating article. An air flow channel may be defined between the substantially planar upper and lower surfaces. The height of the aerosol-generating article may be less than 5 millimetres, for example between 1 .5 millimetres and 5 millimetres, for example between 1 .5 millimetres and 4 millimetres, for example between 1.5 millimetres and 3 millimetres, for example between 1.5 millimetres and 2 millimetres. One or both of the substantially planar upper and lower surfaces may comprise aerosol-forming material. The aerosol-generating article may comprise upper and lower layers, the upper layer forming the substantially planar upper surface and the lower layer forming the substantially planar lower surface. One or both of the upper and lower layers may comprise or consist of aerosol-forming material. In this case, the at least one aerosol-forming substrate may comprise one or both of the substantially planar upper and lower layers.

[0063] The aerosol-generating article may comprise a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer. At least one of the first planar layer, the second planar layer and the corrugated layer may comprise or consist of aerosolforming material. In this case, the at least one aerosol-forming substrate may comprise at least one of the first planar layer, the second planar layer and the corrugated layer.

[0064] The use of a corrugated structure in the aerosol-generating article may advantageously allow the production of an aerosol-generating article that has extremely low RTD while still being sufficiently rigid to for a user to handle. Further, use of a corrugated structure may allow a low density, low RTD, aerosolgenerating article to be produced using high speed production methods similar to those used for production of corrugated cardboard.

[0065] The aerosol-generating article may comprise a first external surface, a second external surface, a cavity and a frame. One or both of the first and second external surfaces may be planar. The frame may be positioned between the first external surface and the second external surface. The frame may at least partially define the cavity. The aerosol-generating article may comprise an air inlet and an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity.

[0066] Preferably, the at least one aerosol-forming substrate is positioned between the first external surface and the second external surface.

[0067] 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. Advantageously, the frame may allow the aerosol-generating article to be relatively thin whilst maintaining structural rigidity.

[0068] The aerosol-generating article may comprise a first external layer and a second external layer, in which the first external layer forms the first external surface and the second external layer forms the second external surface. Optionally, at least one of the first external layer, the second external layer, and the frame may comprise or consist of aerosol-forming material. In this case, the at least one aerosol-forming substrate may comprise at least one of the first external layer, the second external layer and the frame.

[0069] The cavity may be substantially empty. So the at least one aerosol-forming substrate may be positioned outside the cavity. Alternatively, the at least one aerosol-forming substrate may be positioned within the cavity.

[0070] The corrugated layer or element may be positioned within the cavity.

[0071] The frame may be a planar frame. The frame may have a height between 50 percent and 95 percent of the height of the aerosol-generating article. The frame may have a height between 60 percent and 95 percent of the height of the aerosol-generating article. The frame may have a height between 70 percent and 95 percent of the height of the aerosol-generating article. The frame may have a height between 80 percent and 95 percent of the height of the aerosol-generating article.

[0072] The frame may have a height between 1 millimetre and 5.5 millimetres. The frame may have a height between 1 millimetre and 5 millimetres. Preferably, the frame may have a height between 1 .5 millimetres and 5 millimetres.

[0073] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0074] The frame may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may comprise cellulose fibres. The cellulosic material may be paper, paperboard, or cardboard. The frame may be made from or comprise a plant material, such as tobacco. The frame may be made entirely from a cellulosic material.

[0075] The frame may be a unitary component. Alternatively, the frame may comprise two or more layers. That is, the frame may have a laminated structure.

[0076] The article length (for example, an x dimension) may be between 10 millimetres and 100 millimetres, or between 10 millimetres and 50 millimetres, for example between 10 millimetres and 40 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.

[0077] The article width (for example, a y dimension) may be 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.

[0078] The article height (for example, a z dimension) may be 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.

[0079] The aerosol-generating article when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof. Where the aerosol-generating article comprises substantially planar upper and lower surfaces, one or both of the upper and lower surfaces when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof. A perimeter of the aerosol-generating article when viewed in plan may be formed of a plurality of straight sides, a plurality of curved sides, or a combination of straight and curved sides. Where the aerosol-generating article comprises substantially planar upper and lower surfaces, a perimeter of one or both of the upper and lower surfaces when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof.

[0080] The aerosol-generating article may consist entirely of aerosol-forming substrate. Alternatively, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-generating article.

[0081] The aerosol-forming substrate may comprise nicotine. Nicotine may be present in the form of a tobacco material or may be in the form of a nicotine extract.

[0082] The at least one aerosol-forming substrate may comprise one or more organic materials such as tobacco, mint, tea and cloves. The at least one aerosol-forming substrate may comprise one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenised tobacco such as cast leaf, extruded tobacco, expanded tobacco, aerosol-generating films and gel compositions.

[0083] The at least one aerosol-forming substrate may comprise or consist of homogenised tobacco material, for example a reconstituted tobacco material or a cast leaf tobacco material.

[0084] The at least one aerosol-forming substrate may be in the form of shredded aerosol-generating material. The shredded aerosol-generating material may comprise one or more of: strips and strands of aerosol-generating material, such as strips and strands of tobacco or homogenised tobacco material. The shredded aerosol-generating material may be in the form of a shredded sheet of homogenised tobacco material.

[0085] The at least one aerosol-forming substrate may be cut filler. The at least one aerosol-forming substrate may be tobacco cut filler. The cut filler may comprise one or more of bright tobacco, dark tobacco, aromatic tobacco and filler tobacco. Examples of bright tobaccos are Flue-Cured Brazil, Indian Flue-Cured, Chinese Flue-Cured, US Flue-Cured such as Virginia tobacco, and Flue-Cured from Tanzania. Examples of aromatic tobaccos are Oriental Turkey, Greek Oriental, semi-oriental tobacco but also Fire Cured, US Burley, such as Perique, and Rustica. Examples of dark tobacco are Dark Cured Brazil Galpao, Burley Malawi or other African Burley, Sun Cured or Air Cured Indonesian Kasturi. As used herein, the term “cut filler” is used to describe a blend of shredded plant material, such as tobacco plant material, including, in particular, one or more of leaf lamina, processed stems and ribs, homogenised plant material.

[0086] The at least one aerosol-forming substrate may be in the form of a sheet of aerosol-generating material. As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenised tobacco material, such as a cast leaf sheet.

[0087] The at least one aerosol-forming substrate may comprise a bound collection of strips, strands or particles of tobacco material. The aerosol-forming substrate may be in the form of a compressed plug of tobacco material; for example, in which a plug having a substantially circular cross-section in an initial state of the plug is compressed into a flatter cross-sectional profile in a subsequent state ofthe plug. The tobacco material may be enclosed by a wrapper. The at least one aerosol-forming substrate may be in the form of strips, strands or particles of tobacco material bound together in a binder matrix.

[0088] The at least one aerosol-forming substrate may comprise one or more aerosol-formers. 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 aerosol-former to be or comprise one or both of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0089] The at least one aerosol-forming substrate may have an aerosol-former content greater than or equal to 1 , 2, 5, 10, or 15 percent by weight on a dry weight basis. The aerosol-forming substrate may have an aerosol-former content greater than or equal to 15 percent by weight on a dry weight basis, for example greater than 20 by weight on a dry weight basis, or greater than 25 by weight on a dry weight basis, or greater than 30 by weight on a dry weight basis, or greater than 40 by weight on a dry weight basis, or greater than 50 by weight on a dry weight basis.

[0090] The at least one aerosol-forming substrate may have an aerosol-former content less than or equal to 30 percent by weight on a dry weight basis, less than or equal to 25 percent by weight on a dry weight basis, or less than or equal to 20 percent by weight on a dry weight basis. That is, the aerosol-generating material may have an aerosol-former content less than or equal to 30 by weight on a dry weight basis, less than or equal to 25 by weight on a dry weight basis, or less than or equal to 20 by weight on a dry weight basis.

[0091] The at least one aerosol-forming substrate may have an aerosol-former content between 1 percent and 30 percent by weight on a dry weight basis, between 1 percent and 25 percent by weight on a dry weight basis, or between 1 percent and 20 percent by weight on a dry weight basis.

[0092] The at least one aerosol-forming substrate may comprise at least 50 percent by weight of aerosol former, at least 60 percent by weight of aerosol former, or at least 70 percent by weight of aerosol former.

[0093] The at least one aerosol-forming substrate may comprise less than or equal to 85 percent by weight of aerosol former, less than or equal to 80 percent by weight of aerosol former, or less than or equal to 75 percent by weight of aerosol former.

[0094] The at least one aerosol-forming substrate may comprise between 50 percent and 85 percent by weight of aerosol former, between 50 percent and 80 percent by weight of aerosol former, or between 50 percent and 75 percent by weight of aerosol former.

[0095] The at least one aerosol-forming substrate may comprise nicotine. The at least one aerosol-forming substrate may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0096] The at least one 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.

[0097] The at least one 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. The at least one aerosol-forming substrate may comprise one or more botanicals. For example, the aerosol-forming 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.

[0098] The at least one aerosol-forming substrate may have a moisture content of about 5 to 25%, preferably of about 7 to 15%, af 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.

[0099] The at least one 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.

[0100] The at least one aerosol-forming substrate may comprise, or consist of, a solid aerosol-forming material. The aerosol-forming substrate may comprise a liquid aerosol-forming material, for example a liquid aerosol-forming material retained within a porous matrix. The aerosol-forming substrate may comprise a gel aerosol-forming material.

[0101] According to the present disclosure, there is provided an aerosol-generating device. The device may be for receiving an aerosol-generating article, for example as disclosed herein, or an aerosol-forming substrate, for example as disclosed herein. The device may be for use in the system described above or in the system of the first aspect.

[0102] The heating chamber may be dimensioned to receive at least a portion of the aerosol-generating article or aerosol-forming substrate. The device may comprise the at least one heater, a power source for supplying power to the at least one heater, and a controller to control supply of power to the at least one heater. The aerosol-generating device may be configured to heat the at least one aerosol-forming substrate of the article in use.

[0103] The aerosol-generating device may preferably be configured to receive the entirety of the aerosolgenerating article such that the aerosol-generating article is wholly enclosed within the aerosol-generating device.

[0104] The heating chamber may comprise the heating chamber opening mentioned earlier. The heating chamber may have a length extending in a heating chamber length direction. A distal end of the aerosolgenerating article may be insertable into the heating chamber opening, for example in the heating chamber length direction. The heating chamber may have any suitable cross-sectional shape. For example, the heating chamber 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.

[0105] Preferably, at least one internal surface of the heating chamber 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, of the at least one heater. 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.

[0106] According to the present disclosure, there is also provided a method of using an aerosol-generating system, for example the system as described above or according to the first aspect. The method may comprise steps corresponding to any features set out above, for example any features described in relation to any system, article or device described above.

[0107] The method may comprise inserting the aerosol-generating article into the heating chamber such that the aerosol-generating article is fully received in the heating chamber and between 20 and 80 percent of the total mass of the at least one aerosol-forming substrate is located within the heating zone.

[0108] The method may comprise heating at least a portion of the heating zone to an operational temperature with the at least one heater to form an aerosol from the at least one aerosol-forming substrate.

[0109] The method may comprise, during a first stage, heating a first portion of the heating zone to an operating temperature with the at least one heater, for example to form an aerosol from the at least one aerosol-forming substrate. The method may comprise, during a second stage after the first stage, heating a second portion of the heating zone to an operating temperature with the at least one heater, for example to form an aerosol from the at least one aerosol-forming substrate. The method may comprise, during a third stage after the second stage, heating a third portion of the heating zone to an operating temperature with the at least one heater, for example to form an aerosol from the at least one aerosol-forming substrate. Features set out with respect to the first, second and third stages when discussing the system may be applicable to the first, second and third stages of this method. Similarly, features set out with respect to the operating temperature when discussing the system may be applicable to the operating temperature of this method.

[0110] As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol.

[0111] 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.

[0112] As used herein, the term “aerosol-generating device” may refer to a device for use with an aerosolgenerating article to enable the generation, or release, of an aerosol.

[0113] 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 aerosol-generating system may include additional components, such as a charging unit for recharging an on-board electric power supply in an electrically operated or electric aerosol-generating device.

[0114] 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.

[0115] As used herein with reference to the invention, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.

[0116] 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.

[0117] 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 aerosol-generating article in the longitudinal direction.

[0118] 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.

[0119] 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 byproducts 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.

[0120] 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.

[0121] 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.

[0122] As used herein, the term “heating zone” may refer to a portion of the heating chamber which is aligned with a heater or heating surface of the at least one heater. This alignment may be in a direction parallel to the article thickness direction when the article is fully received in the heating chamber. The heating zone may be a single continuous zone. Alternatively, the heating zone may comprise multiple, separated zones.

[0123] As used herein, the term “usage session” may refer to a period or session in which a plurality of puffs are applied by a user on the aerosol-generating system to extract aerosol from the aerosolforming substrate. The usage session may be a finite usage session; that is a usage session having a start and an end. The duration of the usage session as measured by time may be influenced by use during the usage session. The duration of the usage session may have a maximum duration determined by a maximum time from the start of the usage session. The duration of the usage session may be less than the maximum time if one or more monitored parameters reaches a predetermined threshold before the maximum time from the start of the usage session. By way of example, the one or more monitored parameters may comprise one or more of: i) a cumulative puff count of a series of puffs drawn by a user since the start of the usage session, and ii) a cumulative volume of aerosol evolved from the aerosol-forming substrate since the start of the usage session. The usage session may comprise at least 2 or 5 puffs on the system. The usage session may comprise no more than 20 or 15 puffs on the system. The usage session may last at least 2 or 5 minutes. The usage session may last no more than 20 or 15 minutes.

[0124] The invention is defined in the claims. However, below there is provided a non-exhaustive list of nonlimiting 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.

[0125] Example Ex1 . An aerosol-generating system comprising an aerosol-generating article and an aerosolgenerating device, wherein: the aerosol-generating article comprises at least one aerosol-forming substrate; the aerosol-generating article is defined by an article length, an article width, and an article thickness, the article length and the article width being at least two times the article thickness; the aerosol-generating device comprises a heating chamber for receiving at least a portion of the aerosolgenerating article; the aerosol-generating device comprises at least one heater, the at least one heater defining a heating zone in the heating chamber; wherein, when the aerosol-generating article is fully received in the heating chamber of the aerosolgenerating device, between 20 and 80 percent of a total mass of the at least one aerosol-forming substrate is located within the heating zone.

[0126] Example Ex2. An aerosol-generating system according to any preceding example, wherein the at least one heater comprises a substantially planar heating surface, the heating surface being defined by a heating surface length and a heating surface width.

[0127] Example Ex3. An aerosol-generating system according to example Ex2, wherein an internal surface of the heating chamber is or comprises at least a portion of the heating surface.

[0128] Example Ex4. An aerosol-generating system according to example Ex2 or Ex3, wherein, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, the heating surface length is substantially aligned with the article length and the heating surface width is substantially aligned with the article width. Example Ex5. An aerosol-generating system according to any preceding example, wherein the at least one aerosol-forming substrate comprises or consists of a first aerosol-forming substrate defined by a first substrate length, a first substrate width, and a first substrate thickness, the first substrate length and the first substrate width being at least two times the first substrate thickness.

[0129] Example Ex6. An aerosol-generating system according to example Ex5, when dependent on example Ex2, wherein, when the aerosol-generating article is fully received in the heating chamber of the aerosolgenerating device, the heating surface length is substantially aligned with the first substrate length and the heating surface width is substantially aligned with the first substrate width.

[0130] Example Ex7. An aerosol-generating system according to any preceding example, wherein when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, a most upstream end of the at least one heater or heating zone is aligned with a location no more than 20 or 10 or 5 millimetres from an upstream end of the at least one aerosol-forming substrate.

[0131] Example Ex8. An aerosol-generating system according to any preceding example, wherein when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, a most downstream end of the at least one heater or heating zone is aligned with a location at least 2, 5, 10 or 20 millimetres from a downstream end of the aerosol-forming substrate.

[0132] Example Ex9. An aerosol-generating system according to example Ex5 or Ex6, when dependent on example Ex2, wherein, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, a most upstream end of the heating surface is aligned with a location no more than 20 or 10 or 5 millimetres from an upstream end of the at least one aerosol-forming substrate.

[0133] Example Ex10. An aerosol-generating system according to example Ex9, wherein the most upstream end of the heating surface is substantially aligned with the upstream end of the at least one aerosol-forming substrate.

[0134] Example Ex11 . An aerosol-generating system according to any of examples Ex5 to Ex10, when dependent on example Ex2, wherein, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, a most downstream end of the heating surface is aligned with a location at least 2, 5, 10 or 20 millimetres from a downstream end of the at least one aerosol-forming substrate.

[0135] Example Ex12. An aerosol-generating system according to any preceding example, wherein when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, between 50 and 70 percent of the total mass of the at least one aerosol-forming substrate is located within the heating zone.

[0136] Example Ex13. An aerosol-generating system according to any preceding example, wherein the at least one aerosol-forming substrate comprises or consists of a positionable aerosol-forming substrate that is positionable in the aerosol-generating article.

[0137] Example Ex14. An aerosol-generating system according to example Ex13, wherein the positionable aerosol-forming substrate is positionable in the aerosol-generating article, for example by a user before the aerosol-generating article is received in the heating chamber, to vary a percentage of the positionable aerosol-forming substrate located within the heating zone when the aerosol-generating article is fully received in the heating chamber. Example Ex15. An aerosol-generating system according to example Ex13 or Ex14, wherein the positionable aerosol-forming substrate is positionable in the aerosol-generating article in at least a first position and a second position different to the first position, optionally wherein: when the aerosol-generating article is fully received in the heating chamber and the positionable aerosolforming substrate is in the first position, a first position percentage of the positionable aerosol-forming substrate is located within the heating zone; and when the aerosol-generating article is fully received in the heating chamber and the positionable aerosolforming substrate is in the second position, a second position percentage of the positionable aerosolforming substrate is located within the heating zone, wherein the first position percentage is different to the second position percentage.

[0138] Example Ex16. An aerosol-generating system according to example Ex15, wherein the first position percentage differs from the second position percentage by at least 10, 20, or 30 percent.

[0139] Example Ex17. An aerosol-generating system according to any preceding example, wherein the aerosolgenerating article comprises at least one indicator configured to indicate where the positionable aerosolforming substrate is positionable in the aerosol-generating article.

[0140] Example Ex18. An aerosol-generating system according to any preceding example, wherein the aerosolgenerating article comprises at least one indicator configured to indicate that a position, or a change of position, of the positionable aerosol-forming substrate in the aerosol-generating article affects use of the aerosol-generating article in the aerosol-generating system.

[0141] Example Ex19. An aerosol-generating system according to example Ex18, wherein the aerosol-generating article comprises at least one indicator configured to indicate how the position, or the change of position, of the positionable aerosol-forming substrate in the aerosol-generating article affects use of the aerosolgenerating article in the aerosol-generating system.

[0142] Example Ex20. An aerosol-generating system according to any of examples Ex13 to Ex19, wherein the aerosol-generating device is configured to determine a position of the positionable aerosol-forming substrate in the aerosol-generating article.

[0143] Example Ex21. An aerosol-generating system according to any preceding example, wherein the aerosolgenerating device is configured to control a heating profile of the at least one heater at least partly based on a determination of a position of the positionable aerosol-forming substrate in the aerosol-generating article.

[0144] Example Ex22. An aerosol-generating system according to any preceding example, wherein the aerosolgenerating article is receivable in the heating chamber of the aerosol-generating device in at least a first orientation and a second orientation different to the first orientation.

[0145] Example Ex23. An aerosol-generating system according to example Ex22, wherein: when the aerosol-generating article is fully received in the heating chamber in the first orientation, a first orientation percentage of the at least one aerosol-forming substrate is located within the heating zone; and when the aerosol-generating article is fully received in the heating chamber in the second orientation, a second orientation percentage of the at least one aerosol-forming substrate is located within the heating zone, wherein the first orientation percentage is different to the second orientation percentage. Example Ex24. An aerosol-generating system according to example Ex23, wherein the first orientation percentage differs from the second orientation percentage by at least 10, 20, or 30 percent.

[0146] Example Ex25. An aerosol-generating system according to any of examples Ex22 to Ex24, wherein the aerosol-generating article comprises at least one indicator configured to indicate that the aerosolgenerating article is receivable in the heating chamber of the aerosol-generating device in at least two different orientations, for example in the first orientation and in the second orientation.

[0147] Example Ex26. An aerosol-generating system according to any preceding example, wherein the aerosolgenerating article comprises at least one indicator configured to indicate that an orientation in which the aerosol-generating article is received in the heating chamber affects use of the aerosol-generating article in the aerosol-generating system.

[0148] Example Ex27. An aerosol-generating system according to example Ex26, wherein the aerosol-generating article comprises at least one indicator configured to indicate how the orientation in which the aerosolgenerating article is received in the heating chamber affects use of the aerosol-generating article in the aerosol-generating system.

[0149] Example Ex28. An aerosol-generating system according to any preceding example, wherein the aerosolgenerating device is configured to determine an orientation in which the aerosol-generating article is received in the heating chamber.

[0150] Example Ex29. An aerosol-generating system according to any preceding example, wherein the aerosolgenerating device is configured to control a heating profile of the at least one heater at least partly based on an orientation, or a determination of an orientation, in which the aerosol-generating article is received in the heating chamber.

[0151] Example Ex30. An aerosol-generating article for use with an aerosol-generating device, the aerosolgenerating article comprising: a cavity; a positionable aerosol-forming substrate positionable in the cavity in at least two different positions; and at least one indicator configured to indicate that a position, or a change of position, of the positionable aerosol-forming substrate in the aerosol-generating article affects use of the aerosol-generating article with the aerosol-generating device.

[0152] Example Ex31 . An aerosol-generating article for use with an aerosol-generating device wherein the aerosol-generating article is configured to be received in a heating chamber of the aerosol-generating device and the aerosol-generating article comprises at least one indicator configured to indicate that, and preferably how, an orientation of the aerosol-generating article affects use of the aerosol-generating article with the aerosol-generating device.

[0153] Examples will now be further described with reference to the figures in which:

[0154] Figure 1 is a perspective side view of an aerosol-generating article according to a first embodiment of the present disclosure;

[0155] Figure 2 is a perspective side view of an aerosol-generating article according to a second embodiment of the present disclosure;

[0156] Figure 3 is a schematic end view of an aerosol-generating article according to a third embodiment of the present disclosure;

[0157] Figure 4 is a schematic side view of the aerosol-generating article of figure 3;

[0158] Figure 5 is a schematic plan view of the aerosol-generating article of figure 3; Figure 6 shows a schematic illustration of a corrugated element as used in the aerosol-generating article of figure 3;

[0159] Figure 7 shows an exploded perspective view of an aerosol-generating article according to a fourth embodiment of the present disclosure;

[0160] Figure 8 shows a perspective view of the aerosol-generating article of figure 7;

[0161] Figure 9 shows a partially exploded perspective view of the aerosol-generating article of figure 7;

[0162] Figure 10 shows a schematic transverse cross-sectional view of the aerosol-generating article of figure 7;

[0163] Figure 11 shows a schematic longitudinal cross-sectional view of the aerosol-generating article of figure 7;

[0164] Figure 12 shows an exploded perspective view of an aerosol-generating article according to a fifth embodiment of the present disclosure;

[0165] Figure 13 shows a schematic transverse cross-sectional view of the aerosol-generating article of figure 12;

[0166] Figure 14 shows a schematic lateral cross-sectional view of the aerosol-generating article of figure 12.

[0167] 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;

[0168] Figure 16 shows a schematic end view of the aerosol-generating device of figure 15;

[0169] 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.

[0170] 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.

[0171] Figure 1 illustrates a perspective side view of an aerosol-generating article 100 according to a first embodiment of the present disclosure. The aerosol-generating article 100 has upper and lower surfaces 110, 120 which are flat or planar.

[0172] The aerosol-generating article 100 comprises an aerosol-forming substrate (not shown). In one embodiment, the aerosol-generating article 100 may consist substantially of aerosol-forming substrate. In another embodiment, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-generating article 100. The aerosol-forming substrate may be enclosed within an interior of the aerosol-generating article 100. The aerosol-forming substrate may at least partially define an exterior of the aerosol-generating article 100; for example, one or both of the upper and lower surfaces 110, 120 may comprise or consist of aerosol-forming substrate.

[0173] A suitable aerosol-forming substrate may be homogenised tobacco.

[0174] The aerosol-generating article 100 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (which may also be referred to as a thickness), extending in a z dimension, of 3.6 millimetres.

[0175] Figure 2 illustrates a perspective side view of an aerosol-generating article 200 according to a second embodiment of the present disclosure, being a variant of aerosol-generating article 100. Features in common with aerosol-generating article 100 are referred to with like reference signs but commencing with numeral 2 instead of numeral 1 . An air flow path 230 is defined through the aerosol-generating article 200 between the upper and lower surfaces 210, 220. The air flow path 230 extends between opposed first and second ends 201 , 202 of the aerosol-generating article 200. The first end 201 may define a distal end of the aerosol-generating article 200, and the second end 202 may define a proximal or mouth end of the aerosol-generating article. The air flow path 230 may be directed towards a mouth of a user to allow a user to inhale aerosol generated in consequence of heating of aerosol-forming substrate of the aerosolgenerating article 200.

[0176] Figures 3, 4, and 5 illustrate respectively an end view, a side view, and a plan view of an aerosolgenerating article 300 according to a third embodiment of the present disclosure. The aerosol-generating article 300 comprises a planar upper layer 310, a planar lower layer 320, and an intermediate or separation layer 340 arranged between the upper layer 310 and lower layer 320.

[0177] The planar upper layer 310 is formed from a sheet of paper having a thickness of 300 microns. The planar lower layer 320 is formed from a sheet of paper having a thickness of 300 microns. The intermediate layer 340 is a corrugated element formed from a corrugated sheet of aerosol-forming substrate 345. A suitable aerosol-forming substrate may be homogenised tobacco. Thus, the intermediate layer 340 may be formed from a corrugated sheet of homogenised tobacco material 345.

[0178] Figure 6 illustrates the corrugated sheet of aerosol-forming substrate 345. The corrugations have an amplitude 346 of 3 millimetres and a wavelength 347 of 3 millimetres. The sheet of aerosol-forming substrate 345 forming the intermediate layer 340 has a thickness of 150 microns.

[0179] Points of intersection 351 , 352 between the upper layer 310 and the intermediate layer 340 and between the lower layer 320 and the intermediate layer 340 comprise an adhesive that joins the respective layers.

[0180] The aerosol-generating article 300 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (or thickness), extending in a z dimension, of 3.6 millimetres.

[0181] Corrugations of the intermediate layer 340 form a first set of longitudinally extending channels 361 that are bounded by the upper layer 310 and the intermediate layer 340, and a second set of longitudinally extending channels 362 bounded by the lower layer 320 and the intermediate layer 340. The first and second sets of longitudinally extending channels 361 , 362 extend through the length of the aerosol-forming substrate between a proximal end 371 of the substrate 345 and a distal end 372 of the substrate 345. The longitudinally extending channels 361 , 362 define an air-flow path through the substrate 345. The air-flow path, therefore, passes over both sides of the sheet of aerosol-forming substrate 345. The porosity of the aerosol-generating article along the air-flow path is in the region of 90 %. This provides a very low resistance to draw (RTD) of less than 5 mm H2O. In fact, the RTD is close to zero.

[0182] The aerosol-forming substrate 345 may be a sheet of any suitable aerosol-forming substrate.

[0183] During use of the aerosol-generating article 300, the aerosol-forming substrate 345 is heated up to cause the aerosol-forming substrate 345 to release volatile compounds, which are then entrained in air drawn into the channels 361 , 362 via the distal end 372. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the channels 361 , 362 of the aerosol-generating article 300 via the proximal end 371 . Figure 7 shows an exploded perspective view of an aerosol-generating article 400 according to a fourth embodiment of the present disclosure. The aerosol-generating article 400 comprises a first planar external layer 424 forming a first planar external surface 421 , a second planar external layer 425 forming a second planar external surface 422, and a frame 450 positioned between the first planar external layer 424 and the second planar external layer 425. The second planar external surface 422 is positioned parallel to the first planar external surface 421 . The first planar external layer 424 is optional but is present in this embodiment. The frame 450 circumscribes and at least partially defines a cavity 430. The article also comprises a substantially cuboid plug of aerosol-forming substrate 440. On an upper surface of the second planer external layer 425, there is a first indicator 470, a second indicator 472, and an adhesive area 474 therebetween.

[0184] The adhesive area 474 is a substantially rectangular area of adhesive for adhering to the plug of aerosol-forming substrate 440. The adhesive area 474 has roughly the same width, or y dimension, as the plug of aerosol-forming substrate 440, but has a length, or x dimension, greater than a length of the plug of aerosol-forming substrate 440. The article 400 is supplied to the user with the second planar external layer 425 in physical contact with, and bonded to, the frame 450, but with the first planar external layer 424 and the plug of aerosol-forming substrate 440 separate. Thus, the user is able to position the plug of aerosolforming substrate 440 on the adhesive area 474 in their desired position in the cavity 430, then optionally attach the first planar external layer 424 to the frame 450, for example with a suitable adhesive, to make the article 400 ready for use.

[0185] In this embodiment, the first indicator 470 is printed onto the second planar external layer 425 and reads “Insertion end. Position the substrate closer to this end for a more intense experience.”. In this embodiment, the second indicator 470 is printed onto the second planar external layer 425 and reads “Mouth end. Position the substrate closer to this end for a more mild experience.”. Thus, the first and second indicators indicate how the position of the aerosol-forming substrate 440 in the aerosol-generating article 400 affects use of the aerosol-generating article 400.

[0186] In use, the experience may be inherently altered by the position of the substrate in the article. This is because the position of the substrate may affect how much of the substrate is positioned within a heating zone of a device for use with the article when the article is received in a heating chamber of the device. And, as an example of how the experience may differ, if less of the substrate is in the heating zone of the device, then less of the substrate may be directly heated, and more of the substrate may rely on conduction through the substrate to reach a sufficiently high temperature to form an aerosol. This may result in the substrate being depleted less quickly. This may result in a more mild experience.

[0187] With an article like that shown in Figure 7, the experience may be inherently altered by the position of the substrate in the article if, for example, the article is to be received in only one orientation in the heating chamber of a device, or if the article is receivable in the heating chamber of the device in multiple orientations, but those orientations do not affect how much of the substrate is in the heating zone. The former option could be the case for the article shown in Figure 7 if the article is to be inserted into a device in one specific orientation. The latter option could be the case for the article shown in Figure 7 if the article had fixed upstream and downstream ends but could still be received in the heating chamber in at least two orientations - the orientation shown and an orientation in which the article is rotated 180 degrees about the x axis from the orientation shown. Alternatively, or in addition, to the experience being inherently altered by the position of the substrate in the article, the device may be able to determine or estimate the position of the substrate 440, or a user may input the position of the substrate 440 into the device, and the device may then choose a heating profile for one or more heaters of the device to alter the experience at least partly based on the position of the substrate 440.

[0188] The first planar external layer 424 and the second planar external layer 425 are made from cigarette paper having a thickness of 35 micrometres. The second planar external layer 425 is in physical contact with and bonded to, the frame 450. The first planar external layer 424 is optional and, after a user has positioned the plug of aerosol-forming substrate 440 in the cavity 430 as discussed in more detail later, may be placed in contact with, and bonded to, the frame 450, for example by a user. Then, the first planar external layer 424 overlies a first, upper end of the cavity 430 and forms a first cavity end wall. The second planar external layer 425 overlies a second, lower end of the cavity 430 and forms a second cavity end wall, the second cavity end wall being opposite to the first cavity end wall. That is, the frame 450, the first planar external layer 424 and the second planar external layer 425 collectively define boundaries of the cavity 430. In the case where the first planar external layer 424 is not present, the cavity would be an open cavity, not bounded on the side where the first planar external layer 424 is in the embodiment shown in Figure 7.

[0189] The frame 450 has a hollow cuboid shape and is made from cardboard. The frame 450 defines an aperture extending through the height (also referred to as the thickness) of the frame 450 and the aperture at least partially forms the cavity 430 of the aerosol-generating article 400. The frame 450 comprises a peripheral wall 451 that circumscribes the cavity 430. The peripheral wall 451 includes a front wall 413 and a back wall 414. In more detail, the peripheral wall 451 is defined by an inner transverse surface 452 of the frame 450 and an outer transverse surface 453 of the frame 450. The inner transverse surface 452 of the peripheral wall 451 at least partially defines a perimeter of the cavity 430. The outer transverse surface 453 of the peripheral wall 451 at least partially defines a perimeter of the aerosol-generating article 400. The peripheral wall 451 has a radial thickness measured between the inner transverse surface 452 of the frame 450 and the outer transverse surface 453 of the frame 450 of about 5 millimetres.

[0190] An air inlet 411 and an air outlet 412 are defined by, and extend through, the peripheral wall 451 of the frame 450. More specifically, the air inlet 411 extends through the front wall 413 and the air outlet 412 extends through the back wall 414. The air inlet 411 and the air outlet 412 have an equivalent diameter of 5 millimetres. An airflow passage extends between the air inlet 411 and the air outlet 412 through the cavity 430. As shown in figures 9 to 11 , an aerosol-forming substrate 440 is positioned within the cavity 430. The aerosol-forming substrate 440 comprises an aerosol-generating material in the form of homogenised tobacco-containing material and has an aerosol-former content of 5 percent by weight on a dry weight basis. As shown, the aerosol-forming substrate 440 fills part of the volume of the cavity 430.

[0191] On an outer surface of the peripheral wall 451 of the frame 450, the surface being in the x-z plane, near the end with the first air aperture.

[0192] The aerosol-generating article 400 has a cuboid shape and has a height (or thickness) extending in a z dimension, as measured between the first planar external surface 421 and the second planar external surface 422, 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 450 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 430 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 30 millimetres and a length extending in an x dimension of 50 millimetres.

[0193] Figure 8 shows the article 400 after the first and second planar external layers 424, 425 have been bonded to the frame 450 and the article 400 is ready for use.

[0194] Figure 9 shows the article 400 after the second planar external layer 425 has been bonded to the lower surface of the frame 450, and the substrate 440 has then been position on and adhered to the adhesive layer 474. But the first planar external layer 424 has not been bonded to the upper surface of the frame 450. This is optional. The first planar external layer 424 could be discarded or bonded to the upper surface of the frame 450 at this point. In this embodiment, the plug of aerosol-forming substrate 440 has been positioned closer to the first indicator 470 than the second indicator 472.

[0195] Figures 10 and 11 show respective transverse and longitudinal cross-sectional views of the aerosolgenerating article 400 when the cavity 430 contains the aerosol-forming substrate 440.

[0196] Figure 12 shows an aerosol-generating article 500 according to a fifth embodiment of the present disclosure. Features in common with aerosol-generating article 400 are referred to with like reference signs but commencing with numeral 5 instead of numeral 4. Aerosol-generating article 500 differs from aerosolgenerating article 400 in that the aerosol-forming substrate is in the form of a sheet of aerosol-generating material 540, in particular a corrugated sheet of homogenised tobacco material, and in that there are no first and second indicators 470, 472, nor an adhesive area 474. Aerosol-generating article 500 also differs from aerosol-generating article 400 in that on a peripheral wall of the frame 550, there is a third indicator 580 and a fourth indicator 582. Figures 13 and 14 show respective transverse and lateral cross-section views of the aerosol-generating article 500 of figure 12.

[0197] The corrugated sheet of homogenised tobacco material 540 comprises a plurality of parallel corrugations having a plurality of substantially parallel peaks 543 and troughs 544. The plurality of parallel corrugations are defined by a corrugation profile which, as seen in figure 13, is sinusoidal. The plurality of parallel corrugations have a corrugation wavelength of about 4.6 millimetres. The corrugation amplitude is approximately the same as the height (or thickness) of the cavity 430, as shown by the peaks 543 and troughs 544 coinciding with the first cavity end wall 531 and the second cavity end wall 532, respectively.

[0198] The plurality of parallel corrugations form a plurality of channels 545 between the sheet of aerosolgenerating material 540 and the first cavity end wall 531 , and a plurality of channels 546 between the sheet of aerosol-generating material 540 and the second cavity end wall 532. The plurality of channels 545, 546 extend in a longitudinal direction of the aerosol-generating article 500 and form at least a portion of the airflow passage extending between the air inlet 511 and the air outlet 512.

[0199] The article 500 is substantially symmetrical from a structural point of view. This means that either end of the article 500 could serve as an upstream end, with the other end serving as the downstream end. Thus, the air inlet and air outlet could be reversed, depending on an orientation in which the article 500 is received in a heating chamber of a device.

[0200] The frame 550 comprises a third indicator 580 and a fourth indicator 582. The third indicator 580 is positioned near a first longitudinal end of the article 500, and thus near one of the air inlet and the air outlet. The fourth indicator 582 is positioned near a second, opposing longitudinal end of the article 500, and thus near the other of the air inlet and the air outlet.

[0201] The third indicator 580 comprises a statement which reads “Insert this end into the device for a shorter, more intense experience” and a third indicator barcode. The fourth indicator 582 comprises a statement which reads “Insert this end into the device for a longer, less intense experience” and a fourth indicator barcode different to the third indicator barcode.

[0202] A user is able to choose which end of the article 500 to insert into a heating chamber of a device. The device may include one or more barcode scanners able to scan the barcode at the distal end of the article 500 when the article is received in the heating chamber and thus determine the orientation in which the article 500 has been inserted into the device. The device may then control a heating profile of at least one heater of the device so as to affect the experience during use. For example, in this case, if the user inserts the end with the third indicator 580 into the heating chamber first, then the device would scan the third indicator barcode and determine that the user would like a shorter, more intense experience. As such, an operating temperature of at least one heater of the device may be set higher compared to if the device has scanned the fourth barcode and determined that the user would like a longer, less intense experience. With a higher operational temperature, more aerosol may be formed more quickly during use. This may result in a more intense experience for the user. In addition, the aerosol-forming substrate may be depleted more quickly. This may result in a shorter experience for the user.

[0203] During use of each of the aerosol-generating articles 400, 500, the aerosol-forming substrate 440, 540 is heated up to cause the aerosol-forming substrate 440, 540 to release volatile compounds, which are then entrained in air drawn through the air inlet 411 , 511 into the cavity 430, 530. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the aerosol-generating article 400, 500 through the air outlet 412, 512.

[0204] Figures 15 and 16 illustrate an aerosol-generating device 6000 configured for use with an aerosolgenerating article 600, and Figure 17 illustrates the aerosol-generating device 6000 in engagement with the aerosol-generating article 600.

[0205] In this embodiment, the article 600 is similar to the article 400 of Figure 7. However, the article 600 could be any of the articles 100, 200, 300, 400, 500 described previously. The article 600 comprises a plug of aerosol-forming substrate 640 similar to the plug of aerosol-forming substrate 440 of the article 400 of Figure 7.

[0206] The device 6000 is an elongate aerosol-generating device extending between a proximal end 6001 and a distal end 6002. The device 6000 comprises a battery 6010, a controller 6020 and at least one heater 6030 located within a housing 6040. The controller 6020 controls supply of power from the battery 6010 to the at least one heater 6030. A cavity 6050, which may also be referred to as a heating chamber 6050, is defined in the device 6000, the heating chamber 6050 having an opening 6051 defined in the proximal end 6001 of the device. The opening 6051 is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosol-generating article 600. The heating chamber 6050 comprises an upper planar surface 6052 and a lower planar surface 6053. The at least one heater 6030 may form or be located adjacent to the lower planar surface 6053 to heat a lower surface of the aerosol-generating article 600 inserted into the heating chamber 6050. The at least one heater 6030 defines a heating zone 6100 in the heating chamber 6050. The heating zone 6100 is entirely within the heating chamber 6050. The upstream and downstream boundaries of the heating zone 6100, indicated with dashed lines, coincide with the upstream and downstream boundaries of the at least one heater 6030. The device 6000 also comprises a component 6102 at a base of the heating chamber 6050. The component 6102 has a stop surface at its rightmost end. An air-flow path is configured to allow air to flow into the heating chamber 6050 from outside the device 6000.

[0207] Figure 17 illustrates the device 6000 of figure 15 in engagement with the aerosol-generating article 600. There is little tolerance between outer surfaces of the aerosol-generating article 600 and the internal surfaces of the heating chamber 6050. Thus, there is a snug fit between the aerosol-generating article 600 and the device 6000.

[0208] When the article 600 is inserted into the heating chamber 6050 and an upstream end of the article 600 abuts the stop surface of the component 6102, the article 600 is fully received in the device 6000 and the stop surface prevents the article 600 from being inserted further into the heating chamber 6050. In this position, an upstream end of the substrate 640 is within 10 millimetres of an upstream end of the heater 6030 coinciding with an upstream end of the heating zone, and around 70 percent of a total mass of the aerosol-forming substrate 640 is within the heating zone 6100.

[0209] As the RTD of the aerosol-generating article 600 is negligible, the RTD of the system formed by the combination of aerosol-generating article 600 and aerosol-generating device 6000 is controlled by the airflow path defined within the device.

[0210] When a user has inserted the aerosol-generating article 600 into the heating chamber 6050, the device 6000 can be operated. The at least one heater 6030 heats a lower surface of the aerosol-generating article 600, and as a result the aerosol-forming substrate 640 of the aerosol-generating article 600 is heated. Volatile components of the aerosol-forming substrate 640 are evaporated and condense to form an aerosol. The user inhales the aerosol by drawing on the proximal end 601 of the aerosol-generating article 600. Once the aerosol-generating substrate 640 of the aerosol-generating article 600 has been depleted of volatile components, the aerosol-generating article is removed from the heating chamber 6050 of the device 6000 and disposed of. The aerosol-generating article 600 may be any one of the aerosol-generating articles 100, 200, 300, 400, 500 previously described or any other aerosol-generating article of the present disclosure.

[0211] Although figure 17 shows part of the aerosol-generating article 600 extending outside of the aerosolgenerating device 6000, 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 600’ is enclosed within the interior of aerosol-generating device 6000’ and the heater 6030’ is shorter so that still between 20 and 80 percent of a total mass of the substrate 640’ is in the heating zone.

[0212] In some embodiments that may appear identical to those shown in Figures 15 to 17, the at least one heater 6030, 6030’ may heat portions of the aerosol-forming substrate 640, 640’ at different times. For example, the at least one heater 6030, 6030’ may comprise three structurally identical heaters - a first heater located along an upstream third of the at least one heater 6030, 6030’, a second heater located along a middle third of the at least one heater 6030, 6030’, and a third heater located along a downstream third of the at least one heater 6030, 6030’. In use, when the device 6000, 6000’ is activated, only one of the three heaters may be activated at first, for example the first heater. Then, later during the usage session, the second heater may be activated. At this point, the first heater may be deactivated or remain activated. Then, later during the usage session, the third heater may be activated. At this point, the first heater and second heaters may be deactivated or remain activated. An advantage of this staggered activation of the heaters is that it may reduce a risk of a relatively large portion of the substrate 640, 640’ reaching a sufficiently high temperature to form an aerosol at this same time which could mean that much of the flavour of the substrate 640, 640’ is depleted over the course of very few puffs.

[0213] 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

CLAIMS1 . An aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device, wherein: the aerosol-generating article comprises at least one aerosol-forming substrate; the aerosol-generating article is defined by an article length, an article width, and an article thickness, the article length and the article width being at least two times the article thickness; the aerosol-generating device comprises a heating chamber for receiving the aerosolgenerating article; the aerosol-generating device comprises at least one heater, the at least one heater defining a heating zone in the heating chamber; and wherein, when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, between 20 and 80 percent of a total mass of the at least one aerosolforming substrate is located within the heating zone.

2. An aerosol-generating system according to claim 1 , wherein the at least one heater comprises a substantially planar heating surface, the heating surface being defined by a heating surface length and a heating surface width.

3. An aerosol-generating system according to claim 2, wherein an internal surface of the heating chamber is or comprises at least a portion of the heating surface.

4. An aerosol-generating system according to claim 2 or 3, wherein when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, the heating surface length is substantially aligned with the article length and the heating surface width is substantially aligned with the article width.

5. An aerosol-generating system according to claim 2 or 3 or 4, wherein the at least one aerosolforming substrate comprises or consists of a first aerosol-forming substrate defined by a first substrate length, a first substrate width, and a first substrate thickness, the first substrate length and the first substrate width being at least two times the first substrate thickness, and wherein when the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, the heating surface length is substantially aligned with the first substrate length and the heating surface width is substantially aligned with the first substrate width.

6. An aerosol-generating system according to any preceding claim, wherein when the aerosolgenerating article is fully received in the heating chamber of the aerosol-generating device, at least 80 percent of a most upstream quarter of the total mass of the at least one aerosol-forming substrate is located within the heating zone.

7. An aerosol-generating system according to any of claims 1 to 5, wherein when the aerosolgenerating article is fully received in the heating chamber of the aerosol-generating device, at least80 percent of a most downstream quarter of the total mass of the at least one aerosol-forming substrate is located within the heating zone.

8. An aerosol-generating system according to any preceding claim, wherein when the aerosolgenerating article is fully received in the heating chamber of the aerosol-generating device, between 55 and 80 percent of the total mass of the at least one aerosol-forming substrate is located within the heating zone.

9. An aerosol-generating system according to any preceding claim, wherein the at least one aerosolforming substrate comprises or consists of a positionable aerosol-forming substrate that is positionable in the aerosol-generating article in at least a first position and a second position different to the first position, and wherein: when the aerosol-generating article is fully received in the heating chamber and the positionable aerosol-forming substrate is in the first position, a first position percentage of the positionable aerosol-forming substrate is located within the heating zone; and when the aerosol-generating article is fully received in the heating chamber and the positionable aerosol-forming substrate is in the second position, a second position percentage of the positionable aerosol-forming substrate is located within the heating zone, wherein the first position percentage is different to the second position percentage.

10. An aerosol-generating system according to claim 9, wherein the aerosol-generating device is configured to estimate or determine a position of the positionable aerosol-forming substrate in the aerosol-generating article and is configured to control a heating profile of the at least one heater at least partly based on an estimated or determined position of the positionable aerosol-forming substrate in the aerosol-generating article.

11. An aerosol-generating system according to any preceding claim, wherein the aerosol-generating article is receivable in the heating chamber of the aerosol-generating device in at least a first orientation and a second orientation different to the first orientation, wherein: when the aerosol-generating article is fully received in the heating chamber in the first orientation, a first orientation percentage of the at least one aerosol-forming substrate is located within the heating zone; and when the aerosol-generating article is fully received in the heating chamber in the second orientation, a second orientation percentage ofthe at least one aerosol-forming substrate is located within the heating zone, wherein the first orientation percentage is different to the second orientation percentage.

12. An aerosol-generating system according to claim 11 , wherein the aerosol-generating device is configured to estimate or determine an orientation in which the aerosol-generating article is received in the heating chamber and is configured to control a heating profile of the at least one heater at least partly based on an estimated or determined orientation in which the aerosolgenerating article is received in the heating chamber.

13. An aerosol-generating system according to any preceding claim, wherein the at least one heater the at least one heater is configured to heat a first portion of the heating zone but not a second portion of the heating zone during a first stage, and the at least one heater is configured to heat the second portion of the heating zone during a second stage subsequent to the first stage.

14. An aerosol-generating system according to claim 13, wherein the first portion comprises between 30 and 70 percent of the heating zone and the second portion comprises between 30 and 70 percent of the heating zone.

15. A method of using an aerosol-generating system according to any preceding claim, the method comprising: inserting the aerosol-generating article into the heating chamber such that the aerosolgenerating article is fully received in the heating chamber and between 20 and 80 percent of the total mass of the at least one aerosol-forming substrate is located within the heating zone; and heating at least a portion of the heating zone to an operating temperature with the at least one heater to form an aerosol from the at least one aerosol-forming substrate.

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