Aerosol-generating product

Abstract

An aerosol-generating product has the form of a two-dimensional array of aerosol- generating articles. Each of the aerosol-generating articles is configured to be separable from the aerosol-generating product to be used as a discrete aerosol-generating article to generate an aerosol. The two-dimensional array may be a nL x nw array, in which nL is the number of aerosol-generating articles over an initial length of the aerosol-generating product (initial product length) and nW is the number of aerosol-generating articles over an initial width of the aerosol- generating product (initial product width).

Description

[0001] AEROSOL-GENERATING PRODUCT

[0002] The present disclosure relates to an aerosol-generating product, aerosol-generating articles severed from the aerosol-generating product, an aerosol-generating device, and an aerosolgenerating system.

[0003] A typical aerosol-generating system comprises an aerosol-generating device and an aerosol-generating article. The aerosol-generating device may comprise a heater, and the aerosol-generating article may comprise an aerosol-forming substrate. In use, the heater of the aerosol-generating device heats the aerosol-forming substrate of the aerosol-generating article causing the release of volatile compounds from the aerosol-forming substrate. These compounds then cool to form an aerosol that is inhaled by a user.

[0004] A typical aerosol-generating article may appear similar to a conventional cigarette. For example, such an aerosol-generating article may be a substantially cylindrical article comprising an aerosol-forming substrate and other components such as mouthpiece filter element, all wrapped in a cigarette paper. Dimensions of typical aerosol-generating articles are often similar to the dimensions of conventional cigarettes. Typically, such aerosol-generating articles are circular in cross-section and extend between opposed first and second open ends. Such an aerosol-generating article typically contains a portion of aerosol-forming substrate having a cylindrical shape corresponding to the circular cross-section of the article.

[0005] Typical aerosol-generating articles are usable in a single usage session. For example, the aerosol-generating article is heated for a predetermined amount of time, or until another usage threshold is met, and then heating may be stopped and the usage session ends. The aerosolgenerating article may be removed from the device and disposed of. To start a new usage session, a user must insert another aerosol-generating article into the aerosol-forming device. This requires a user to carry an aerosol generating device and at least one spare aerosolgenerating article for insertion into the device. Carrying a supply of spare aerosol-generating articles may inconvenience the user.

[0006] It is desirable to provide an aerosol-generating product that is configured to provide aerosolgenerating articles for use in multiple usage sessions.

[0007] According to an aspect of the present disclosure, there is provided an aerosol-generating product in the form of a two-dimensional array of aerosol-generating articles, each of the aerosol-generating articles configured to be separable from the aerosol-generating product to be used as a discrete aerosol-generating article to generate an aerosol.

[0008] The aerosol-generating product may be defined by an initial product length, an initial product width, and a product thickness. Preferably, the initial product length and the initial product width are greater in magnitude than the product thickness. Thus, the aerosol-generating product may be a substantially 2-dimensional product. Each of the discrete aerosol-generating articles may have an article length that is shorter than the initial product length of the aerosol-generating product. Each of the discrete aerosol-generating articles may have an article width that is shorter than the initial product width of the aerosol-generating product. Preferably the aerosol-generating product comprises a suitable aerosol-forming substrate or aerosol-forming material for producing an aerosol.

[0009] As the aerosol-generating product is configured to be severable into a plurality of discrete aerosol-generating articles, the aerosol-generating product may conveniently provide a source of articles for use in more than one usage session. For example, an aerosol-generating article may be severed, or otherwise separated, by manual manipulation of the aerosol-generating product. Manual manipulation may involve a user separating an article from the aerosol-generating product by a process of bending, cutting, or tearing the article from the product. The aerosol-generating article may be heatable for aerosol generation, without the remaining portion of the aerosolgenerating product being heated. In this way, only a portion of the aerosol-generating product may be consumed in any single usage session. Therefore, the aerosol-generating product may provide aerosol-generating substrate for use in multiple usage sessions. As such, a user may conveniently only require one aerosol-generating product for use in multiple usage sessions, for example in at least four to six usage sessions. For example, one aerosol-generating product may be suitable for use in at least ten, twenty, thirty or forty usage sessions, or more. Advantageously, a user is not required to carry multiple discrete aerosol-generating articles, which may for example become lost in a bag or a pocket. The aerosol-generating product has a larger initial size than an aerosol-generating article and, thus, may be more convenient for the user to carry than typical single use disposable aerosol-generating articles.

[0010] An aerosol-generating article severed from the aerosol-generating product may be configured for use with an aerosol-generating device. For example, the aerosol-generating article may be configured to be inserted into or engaged with the aerosol-generating device. The aerosolgenerating product may comprise or consist of an aerosol-forming substrate comprising an aerosol-forming material. Thus, an aerosol-generating article severed from the aerosolgenerating product may comprise an aerosol-forming substrate comprising an aerosol-forming material.

[0011] The aerosol-generating product may be configured such that, in use, a first aerosolgenerating article is severed, or otherwise separated, from the two-dimensional array of aerosolgenerating articles. The first aerosol-generating article is heatable by a heating element in a first usage session. For example, in the first usage session, the first aerosol-generating article is in contact with, or adjacent to a heating element, such that the aerosol-forming substrate is heatable by the heating element. After the first aerosol-generating article has been heated and the first usage session is finished, for example, after a predetermined amount of time or a predetermined condition has been met, for example after a predetermined number of puffs have been taken, a second aerosol-generating article may be severed from the two-dimensional array of aerosolgenerating articles and may replace the first aerosol-generating article in contact with, or adjacent to a heating element, such that the aerosol-forming substrate is heatable by the heating element. A second aerosol-generating article is now in contact with, or adjacent to a heating element, for example in a second usage session. In this way subsequent aerosol-generating articles severed from the aerosol-generating product are configured to be heatable to form an aerosol.

[0012] The aerosol-generating product may define a nLx nwarray of aerosol-generating articles, in which nds the number of aerosol-generating articles over an initial length of the aerosolgenerating product (initial product length) and nwis the number of aerosol-generating articles over an initial width of the aerosol-generating product (initial product width). For example, n may be a number between 2 and 20. For example, nw may be a number between 2 and 10. The aerosol-forming product may, therefore, be in the form of a sheet or slab defined by the array of aerosol-generating articles. n and nwmay have different values. For example, the aerosolgenerating product may be arranged in a roll or coil, in which case n may be greater than 20, for example 50, or 100, or 200. Likewise, nwmay be greater than 10, for example 15, or 20, or 50, or 100.

[0013] The aerosol-generating product may be produced as a continuous product, effectively extending continuously in the length direction. For example, ni_ may be represented as °°. Thus, for a continuous product n may be00and nwmay be a number between 2 and 50, for example between 2 and 20, for example between 2 and 10.

[0014] In some examples, ni_ may be a number between 3 and 15, for example between 4 and 12, for example between 5 and 10. ni_ may be 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10.

[0015] In some examples, nw may be a number between 2 and 15, for example between 3 and 12, for example between 4 and 10. ni_ may be 2, or 3, or 4, or, 5, or 6, or 7, or 8, or 9, or 10.

[0016] Advantageously, material properties or physical properties of the aerosol-generating product may be configured to facilitate separation of the product into the plurality of discrete aerosol-generating articles.

[0017] In some examples, the aerosol-generating product may comprise perforated portions configured to delineate the aerosol-generating articles. Preferably, such perforated portions facilitate separation of each of the aerosol-generating articles from the aerosol-generating product. A perforated portion delineating an aerosol-generating article may comprise a transversely extending line of perforations and / or a longitudinally extending line of perforations. The perforations may be uniformly spaced. Perforations of the perforated portions may extend partially or entirely through the thickness dimension of the aerosol-generating product. A length and / or width of each of the plurality of aerosol-generating articles may be delineated by longitudinal and / or transverse lines of perforations. Perforated portions may be spaced at intervals along the length of the aerosol-generating product. The perforated portions may be uniformly spaced lengthwise. Perforated portions may be spaced at intervals along the width of the aerosol-generating product. The perforated portions may be uniformly spaced width wise.

[0018] Advantageously, perforations may concentrate applied stress along the transversely and / or longitudinally extending lines of perforations to facilitate crack initiation and propagation, such that a user may more easily sever the aerosol-generating product into individual articles of predetermined dimensions.

[0019] In some examples, the aerosol-generating product may comprise scored portions configured to facilitate separation of the aerosol-generating articles from the aerosol-generating product. A scored portion may comprise a transversely and / or longitudinally extending score or stress concentrator. A score or stress concentrator may extend partially through the thickness dimension of the aerosol-generating product. The scored portions may be uniformly spaced. Preferably, a length and / or width of each of the aerosol-generating articles in the array of aerosolgenerating articles may be delineated by longitudinally and / or transversely extending scorelines. Advantageously, a score or stress concentrator may concentrate applied stress such that a user may more easily sever the aerosol-generating product into individual articles of predetermined dimensions.

[0020] In some examples, a length and / or width of each of the plurality of aerosol-generating products is delineated by one or more notches or grooves. The notches or grooves may be V- shaped. Alternatively, the notches or grooves may be U-shaped or semi-circular. For example, a length and / or width of each of the plurality of aerosol-generating products may be delineated by longitudinally and / or transversely extending grooves, the grooves being defined in the thickness dimension of the aerosol-generating product. Notches or grooves may concentrate applied stress in a parallel direction to the notch depth to facilitate crack initiation and propagation, such that a user may more easily sever the aerosol-generating product into individual articles of predetermined dimensions.

[0021] An aerosol-generating product may comprise at least one stress concentrator to facilitate crack initiation. For example, each article of the array of aerosol-generating articles may be delineated by one or more notches, grooves, scorelines, or perforations configured to act as stress concentrators to facilitate crack initiation to facilitate separation of individual articles from the aerosol-generating product.

[0022] A user may be able to tear along a perforated portion, scored portion or laterally extending notch to sever an aerosol-generating article from the elongated strip of dispensable material in a direction transverse to the strip length. Alternatively, an aerosol-generating article may be severed from the elongated strip of dispensable material by cutting along a perforation portion, scored portion or laterally extending notch to sever an aerosol-generating article from the elongated strip of dispensable material in a direction transverse to the strip length, for example by engaging the perforation portion, scored portion or laterally extending notch with an edge.

[0023] Advantageously, providing an elongated strip of dispensable material with at least one of perforated portions, scored portions and laterally extending notches may facilitate severing of the strip in a direction transverse to the strip length. This may result in less damage to the strip and less damage to an aerosol-generating article when severing the aerosol-generating article from the strip. This may also ensure that severed aerosol-generating articles are uniform in size.

[0024] The aerosol-generating product may comprise two or more layers. The aerosol-generating product may comprise two or more layers laminated together. The aerosol-generating product may comprise at least a first planar layer forming an upper surface of the aerosol-generating product and a second planar layer forming a lower surface of the aerosol-generating product.

[0025] The aerosol-generating product may comprise a first planar layer, a second planar layer, and an intermediate layer or separation layer arranged between the first planar layer and the second planar layer. Any one or more of the layers may comprise or consist of an aerosolforming material, for example homogenised tobacco. The intermediate layer may define one or more air flow channels.

[0026] Preferably, lines of weakness, for example lines of weakness as formed or defined by scorelines, groves, notches, or perforations, delineating each of the aerosol-generating articles are defined in at least one of the first planar layer, the second planar layer, and, where present, the intermediate layer or separation layer. Lines of weakness, delineating each of the aerosolgenerating articles may be defined in each of the first planar layer, the second planar layer, and the intermediate layer or separation layer.

[0027] Preferably, one or more airflow channels are defined through the aerosol-generating product such that, after separation, each of the plurality of aerosol-generating articles comprises at least one airflow channel defined therethrough. In use, a user may draw air through the at least one airflow channel to consume the article.

[0028] In some embodiments, each of the plurality of aerosol-generating articles comprises at least one cavity, for example a cavity containing an aerosol-forming substrate. A cavity, where present, is preferably connected to an air flow channel defined through the article.

[0029] In some embodiments, the aerosol-generating product comprises a first planar layer, a second planar layer, and an intermediate layer or separation 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 intermediate or separation layer comprising, or consisting of, an aerosol-forming material.

[0030] The intermediate layer or the separation layer may be a crimped layer. The crimped layer may comprise or consist of a crimped tobacco layer.

[0031] The intermediate layer or the separation layer may have a honeycomb structure. The honeycomb structure may comprise numerous holes through the layer. The arrangement of the holes may be omnidirectional. The honeycomb layer does not need to be arranged in any particular direction in relation to the rolling direction of the aerosol-forming substrate.

[0032] The intermediate layer or the separation layer may comprise or consist of a porous material. The porous material may inherently contain voids. The porous material may be impregnated with an aerosol-forming material. For example, the voids may contain an aerosol-forming material.

[0033] The intermediate layer or the separation layer comprise or consist of a fibrous material. The fibrous material may be impregnated with an aerosol-forming material.

[0034] The intermediate layer or the separation layer may comprise a corrugated layer.

[0035] The aerosol-generating product may comprise a first planar layer, a second planar layer, and a corrugated element arranged between the first planar layer and the second planar layer, for example in which at least one of the first planar layer, the second planar layer and the corrugated element comprises or consists of an aerosol-forming material.

[0036] Corrugations of the corrugated element may be arranged perpendicular to the length direction of the aerosol-generating product and parallel to the width direction of the aerosolgenerating product. Corrugations of the corrugated element may be arranged perpendicular to the width direction of the aerosol-generating product and parallel to the length direction of the aerosol-generating product. Advantageously, an air-flow path may be defined through the aerosol-generating product by channels formed by longitudinally extending corrugations of the corrugated element. For example, an air-flow path may be defined through each of the aerosolgenerating articles by channels formed by longitudinally extending corrugations of the corrugated element.

[0037] Corrugations may be formed in a number of different corrugation profiles. For example, the corrugations may be further defined by a corrugation profile, in which the corrugation profile is sinusoidal, or triangular, or rectangular, or trapezoidal, or toroidal, or parabolic.

[0038] The use of a corrugated structure in the aerosol-generating product may advantageously allow the formation of individual aerosol-generating articles that have extremely low RTD while still being sufficiently rigid for a user to handle. Further, use of a corrugated structure may allow a low density, low RTD, aerosol-generating product to be produced using high speed production methods similar to those used for production of corrugated cardboard. The corrugated layer may increase the compressive strength of the aerosol-generating product. The aerosol-generating product may further comprise at least one protective layer configured to protect an upper and / or lower surface of the aerosol-generating product. Preferably the at least one protective layer forms a protective layer of each aerosol-generating article after the article is separated from the aerosol-generating product. Perforations, notches, grooves, or scores may be defined in the at least one protective layer to facilitate separation of aerosol-generating articles from the aerosol-forming product.

[0039] In preferred examples, each aerosol-generating article in the two-dimensional array of aerosol-generating articles has a length of between 5 millimetres and 50 millimetres, for example between 10 millimetres and 45 millimetres, for example between 15 millimetres and 40 millimetres, for example between 25 millimetres and 30 millimetres.

[0040] In preferred examples, each aerosol-generating article in the two-dimensional array of aerosol-generating articles has a width of between 3 millimetres and 50 millimetres, for example between 10 millimetres and 45 millimetres, for example between 15 millimetres and 40 millimetres, for example between 25 millimetres and 30 millimetres, preferably between 5 millimetres and 17 millimetres, for example between 9 millimetres and 11 millimetres.

[0041] In preferred examples, each aerosol-generating article in the two-dimensional array of aerosol-generating articles has a thickness of between 1 millimetres and 8 millimetres, for example between 2 millimetres and 6 millimetres for example between 2.5 millimetres and 5.5 millimetres for example between 3 millimetres and 3.5 millimetres. Advantageously, this range of thicknesses may provide a good compromise between the aerosol-generating article being sufficiently thick to contain a reasonable quantity of aerosol-forming material, but sufficiently thin to allow aerosol-forming material furthest from a heater to be heated to a sufficiently high temperature to generate an aerosol without a significant risk of burning the material closest to the heater. This thickness advantageously contributes to the aerosol-generating article being sufficiently robust for use in an aerosol-generating device, while achieving uniform heating and aerosol-generation.

[0042] Preferred dimension provided above may enable aerosol-generating articles to be formed that are convenient for a user to handle while also containing sufficient aerosol-forming substrate to generate enough aerosol to satisfy a user during a usage session.

[0043] Preferably, the article width is greater than the article thickness. Preferably, the aerosolgenerating article does not have a circular or square transverse cross-section, the transverse cross-section being a cross-section taken transverse or perpendicular to the length of the article. The transverse cross-section of the aerosol-generating article may be oval or rectangular, preferably an oval or rectangle having a high aspect ratio. The aerosol-generating article may have a relatively high surface area to volume ratio compared to an aerosol-generating article having a circular cross-section. The circular cross-section of known aerosol-generating articles can lead to a relatively long time to reach adequate temperature for aerosolisation of the aerosolforming substrate. This may result in non-uniform heating of the aerosol-forming substrate.

[0044] Advantageously, the aerosol-generating article may be heated more quickly and in a more uniform manner compared with an aerosol-generating article having a circular cross-section. For example, if being externally heated, a centre portion of the aerosol-generating article may reach a desired temperature more quickly than in an article with a circular cross-section. As such, heating across the aerosol-generating article may be more uniform and thus formation of aerosol may be more uniform throughout the heated portion of the aerosol-generating article.

[0045] The aerosol-generating article may be described as flat. The aerosol-generating article may be described as planar. The amount of material in the aerosol-generating article may be reduced compared with an aerosol-generating article having a circular cross-section through reduction of outer papers and other non-aerosol forming material present in the aerosol-generating article thereby potentially lowering costs and reducing environmental impact.

[0046] Advantageously, this may allow the aerosol-generating article to be efficiently heated by a heating element and improves the yield of aerosol generated from aerosol-forming substrate comprised in the aerosol-generating article. By having a large surface area to volume ratio, and by having a reduced thickness compared to its length and width, a heating element can be located such that all of the aerosol-generating article is within a specified distance from the heating element. This has the advantage of providing an improved user experience and reducing wasted aerosol-forming substrate in use.

[0047] In some embodiments, in its initial state the aerosol-generating product comprises a two- dimensional array of between 4 and 200 separable aerosol-generating articles, for example between 6 and 80 aerosol-generating articles, for example between 8 and 64 aerosolgenerating articles. Each of the aerosol-generating articles may be separated, one by one, from the aerosol-forming product.

[0048] A low resistance air flow path may be defined through each aerosol-generating article when separated from the aerosol-generating product. For example, the aerosol-generating article may have a resistance to draw (RTD), along the air flow path, of less than 80 millimetre H2O, or less than 40 millimetre H2O, or less than 30 millimetre H2O. Preferably, each aerosol-generating article, when separated from the aerosol-generating product, defines an air-flow path having a resistance to draw of between 0 millimetres H2O and 9.9 millimetres H2O. 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-forming substrate and guided to a user.

[0049] An air flow path through the aerosol-generating product or an aerosol-generating article may be defined in terms of porosity, for example a percentage of the product or article that is free of material. The porosity in this case is open porosity, allowing an air flow path through the product or article. Thus, an aerosol-generating article separated from the aerosol-forming product may have an air flow path defined through the aerosol-generating article in an x / y plane from one side of the article to the other. The aerosol-generating article may have a porosity of greater than 60 percent, for example greater than 80 percent, in the direction of the air flow path. The porosity may be greater than 60 percent, for example greater than 80 percent, in at least one direction in an x / y plane of the aerosol-generating article.

[0050] The aerosol-generating product, and each article of the product, preferably contains an aerosol-forming substrate. The aerosol-forming substrate may comprise an aerosol-forming material. The 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.

[0051] The aerosol-forming material may comprise one or more organic materials such as tobacco.

[0052] The aerosol-forming substrate may comprise a tobacco based material, for example at least one of cast leaf or cut filler. The aerosol-forming material may comprise one or more of herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenised tobacco, extruded tobacco and expanded tobacco.

[0053] The aerosol-forming substrate may comprise a non-tobacco aerosol forming material comprising an aerosol former, such as glycerine or propylene glycol, preferably including a flavour component and or an active component such as nicotine or a cannabinol. The aerosol-forming substrate may comprise a humectant, for example at least one of propylene glycol, glycerine / glycerol or water.

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

[0055] The aerosol-forming substrate may comprise at least one of paper or paperboard.

[0056] The aerosol-forming material may comprise cellulose fibres. The aerosol-forming material may comprise cotton.

[0057] The aerosol-forming material may comprise nicotine. The aerosol-forming material may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine. The aerosol-forming substrate may comprise a pharmacologically active ingredient. The aerosol-forming material may comprise one or more cannabinoid compounds such as one or more of: tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannabivarin (CBV), cannabidivarin (CBDV), tetrahydrocannabivarin (THCV), cannabichromene (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), cannabicitran (CBT). It may be preferable that the cannabinoid compound is CBD or THC. It may be particularly preferable that the cannabinoid compound is CBD.

[0058] The aerosol-forming material may comprise one or more flavourants. The aerosol-forming substrate may comprise a flavourant, for example at least one of menthol, L-Carvone (spearmint), ethyl methylphenylglycidate (strawberry), or peppermint oil.

[0059] 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.

[0060] The aerosol-forming material may comprise a binder. For example, the aerosol-forming material 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 carboxymethyl, celluloses; dextran; and xanthan gum. A preferable binder is guar.

[0061] The aerosol-forming substrate may comprise a gelling agent, for example sodium alginate.

[0062] The aerosol-forming material may comprise an organic botanical glycerite. For example, the aerosol-forming material may comprise 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, and compounds of those.

[0063] The aerosol-forming material may comprise organic botanical extracts. For example, the aerosol-forming material may comprise about 1 to 15 %, preferably of about 2 to 7 %, of any of the previously referred botanicals, as well as menthol (dl-Menthol, C10H20G, 2-lsopropyl-5- methylcyclohexanol) such as obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related botanic varieties, as well as P-menthan-3-ol, as any secondary alcohol as diastereoisomers of 5-methyl-2-(propan-2-yl)cyclohexan-1 -ol.

[0064] The aerosol-forming material may comprise botanical essential oils, for example about 0.5 to 5 %, preferably of about 1 to 3 %, of a botanical essential oil, for example a botanical essential oil such as of palm, coconut, and wooden-based essential oils.

[0065] The aerosol-forming material preferably comprises an aerosol-former, for example about 5 to 35%, preferably of about 10 to 25%, of an aerosol former. Suitable aerosol-formers known in the art include: glycerine; monohydric alcohols like menthol, polyhydric alcohols, such as triethylene glycol; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyls of those.

[0066] The aerosol-forming material may comprise particles of a functional material, for example particles of carbon, graphite, activated carbon, or expanded graphite. Such materials may, for example, increase the thermal conductivity of the aerosol-forming material and improve efficiency of aerosol generation.

[0067] The aerosol-forming substrate may further comprise a thermally conductive layer, for example an aluminium layer. A thermally conductive layer may facilitate thermal transfer between a heat source and the aerosol-forming material of the aerosol-forming substrate.

[0068] The aerosol-forming substrate may further comprise a paper layer, for example a tipping paper layer, covering at least a portion of at least one surface of the aerosol-forming substrate, for example at least a portion of an upper surface, or at least a portion of a lower surface.

[0069] The aerosol-forming substrate may comprise conductive materials. For example, the aerosol-forming material may comprise conductive particles. Conductive particles may be, for example, conductive carbon or graphite particles, or conductive metallic particles, for example particles of aluminium, or stainless steel, or nickel.

[0070] The aerosol-forming substrate may comprise one or more susceptor materials. The one or more susceptor materials may be incorporated within an aerosol-forming material of the aerosolforming substrate, for example as particles of susceptor material distributed within the aerosolforming material. The presence of susceptor materials may allow the aerosol-forming substrate to be heated by engagement with a fluctuating electromagnetic field formed by an inductor.

[0071] Optionally, one or more susceptor materials may be incorporated within the aerosol-forming substrate as one or more strips, threads, or wires of susceptor material, for example one or more strips, threads, or wires of susceptor material located within an airflow path of the aerosol-forming substrate.

[0072] Optionally, one or more susceptor materials may be incorporated within the aerosol-forming substrate as one or more sheets or layers of susceptor material, for example one or more sheets or layers of susceptor material covering an external portion of the aerosol-forming substrate or forming a structural component of the aerosol-forming substrate.

[0073] The one of more sheets of susceptor material may be in the form of a mesh of susceptor material.

[0074] The susceptor material, in whatever form, may comprise one or more materials selected from the list consisting of: aluminium, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0075] The aerosol-forming substrate may comprise at least one of a ferrous metal, or a ferrous metal alloy. The aerosol-forming substrate may comprise a metal foil.

[0076] According to an aspect of the present disclosure, there is provided an aerosol-generating device for receiving an aerosol-generating article separated from an aerosol-generating product according to any preceding example to form an inhalable aerosol. The aerosol-generating device comprises a cavity dimensioned to receive at least a portion of the aerosol-generating article, a heater or heating means, a power source for supplying power to the heater or heating means, and a controller to control supply of power to the heater or heating means.

[0077] According to an aspect of the present disclosure, there is provided an aerosol-generating system comprising an aerosol-generating device and an aerosol-generating product as described above.

[0078] The resistance to draw (RTD) of the article or aerosol-generating article or a component of the article or aerosol-generating article is expressed with the units of pressure ‘millimetres WG’ or ‘millimetres of water gauge’ or ‘millimetres H2O’.

[0079] 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-forming substrate. 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 in accordance with ISO 6565-2015 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%.

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

[0081] As used herein, the term “aerosol-generating product” may refer to a product comprising a component capable of being severed to produce a plurality of discrete aerosol-generating articles, for example an aerosol-generating product may be or comprise an array of aerosol-generating articles configured to be able to be severed to produce a plurality of discrete aerosol-generating articles. 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 material may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support.

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

[0083] As used herein, the term “aerosol-generating system” refers to a combination of an aerosolgenerating device and one or more aerosol-generating articles for use with the device. An aerosolgenerating 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.

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

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

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

[0087] As used herein, a “susceptor” means a conductive element that heats up when subjected to a changing magnetic field. This may be the result of eddy currents induced in the susceptor element and / or hysteresis losses.

[0088] As used herein, the term “usage session” refers to an operational period of the aerosolgenerating system having a finite duration. A usage session may be a specific type of event that can be performed by the aerosol-generating system. A usage session may be initiated by the action of a user. A usage session may be terminated after a predetermined period of time has elapsed from the initiation of the usage session. A usage session may be terminated after a monitored parameter has reached a threshold during the usage session.

[0089] The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0090] Ex1 . An aerosol-generating product in the form of a two-dimensional array of aerosolgenerating articles, each of the aerosol-generating articles configured to be separable from the aerosol-generating product to be used as a discrete aerosol-generating article to generate an aerosol. Ex2. An aerosol-generating product according to Ex1 in which the aerosol-generating product is defined by an initial product length, an initial product width, and a product thickness, the initial product length and the initial product width being greater in magnitude than the product thickness.

[0091] Ex3. An aerosol-generating product according to any preceding example in which the aerosol-generating product defines a n x nwarray, in which n is the number of aerosolgenerating articles over an initial length of the aerosol-generating product (initial product length) and nwis the number of aerosol-generating articles over an initial width of the aerosolgenerating product (initial product width), for example in which n is a number between 2 and 20 and nw is a number between 2 and 10.

[0092] Ex4. An aerosol-generating product according to Ex3 in which the aerosol-generating product is a continuous product extending continuously in the length direction, for example in which nL can be represented as °°, for example in which OL is00and nw is a number between 2 and 10.

[0093] Ex5. An aerosol-generating product according to Ex3 in which OL is a number between 3 and 15, for example between 4 and 12, for example between 5 and 10, for example in which OL is 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10.

[0094] Ex6. An aerosol-generating product according to Ex3, Ex4, or Ex5 in which nw is a number between 2 and 15, for example between 3 and 12, for example between 4 and 10, for example in which ni is 2, or 3, or 4, or, 5, or 6, or 7, or 8, or 9 , or 10.

[0095] Ex7. An aerosol-generating product according to any preceding example in which material properties or physical properties of the aerosol-generating product are configured to facilitate separation of the product into the plurality of discrete aerosol-generating articles.

[0096] Ex8. An aerosol-generating product according to any preceding example in which the aerosol-generating product comprises perforated portions configured to delineate the aerosolgenerating articles, and preferably to facilitate separation of each of the aerosol-generating articles from the aerosol-generating product.

[0097] Ex9. An aerosol-generating product according to Ex8 in which a perforated portion comprises a transversely extending line of perforations and / or a longitudinally extending line of perforations.

[0098] Ex10. An aerosol-generating product according to Ex9 in which a length and / or width of each of the plurality of aerosol-generating articles is delineated by longitudinal and / or transverse lines of perforations.

[0099] Ex11 . An aerosol-generating product according to any of Ex8 to Ex10 in which perforations of the perforated portions extend partially or entirely through the thickness dimension of the aerosol-generating product. Ex12. An aerosol-generating product according to any preceding example in which the aerosol-generating product comprises scored portions configured to facilitate separation of the aerosol-generating articles from the aerosol-generating product.

[0100] Ex13. An aerosol-generating product according to Ex12 in which a scored portion comprises a transversely or longitudinally extending score.

[0101] Ex14. An aerosol-generating product according to any preceding example in which a length and / or width of each of the plurality of aerosol-generating articles is delineated by longitudinally and / or transversely extending scorelines.

[0102] Ex15. An aerosol-generating product according to any preceding example in which a length and / or width of each of the plurality of aerosol-generating articles is delineated by one or more notches or grooves.

[0103] Ex16. An aerosol-generating product according to any preceding example in which a length and / or width of each of the plurality of aerosol-generating products is delineated by longitudinally and / or transversely extending grooves, the grooves being defined in the thickness dimension of the aerosol-generating product.

[0104] Ex17. An aerosol-generating product according to any preceding example comprising at least one stress concentrator to facilitate crack initiation, for example in which each of the plurality of aerosol-generating articles is delineated by one or more notches, grooves, scorelines, or perforations configured to act as stress concentrators to facilitate crack initiation to facilitate separation of individual articles from the aerosol-generating product.

[0105] Ex18. An aerosol-generating product according to any preceding example in which the aerosol-generating product comprises two or more layers, for example two or more layers laminated together, for example in which the aerosol-generating product comprises at least a first planar layer forming an upper surface of the aerosol-generating product and a second planar layer forming a lower surface of the aerosol-generating product.

[0106] Ex19. An aerosol-generating product according to any preceding example comprising a first planar layer, a second planar layer, and an intermediate layer or separation layer arranged between the first planar layer and the second planar layer.

[0107] Ex20. An aerosol-generating product according to example Ex18 or Ex19 in which lines of weakness, for example formed by scorelines, groves, notches, or perforations, delineating each of the aerosol-generating articles are defined in at least one of the first planar layer, the second planar layer, and, where present, the intermediate layer or separation layer.

[0108] Ex21 . An aerosol-generating product according to Ex19 or Ex20 in which lines of weakness, for example formed by scorelines, groves, notches, or perforations, delineating each of the aerosol-generating articles are defined in each of the first planar layer, the second planar layer, and the intermediate layer or separation layer. Ex22. An aerosol-generating product according to any preceding example in which one or more airflow channels are defined through the aerosol-generating product such that, after separation, each of the plurality of aerosol-generating articles comprises at least one airflow channel defined therethrough.

[0109] Ex23. An aerosol-generating product according to any preceding example in which each of the plurality of aerosol-generating articles comprises at least one cavity, for example a cavity containing an aerosol-forming substrate.

[0110] Ex24. An aerosol-generating product according to any preceding example in which the aerosol-generating product comprises a first planar layer, a second planar layer, and an intermediate layer or separation 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 intermediate or separation layer comprising, or consisting of, an aerosol-forming material.

[0111] Ex25. An aerosol-generating product according to any preceding example in which the aerosol-generating product comprises a first planar layer, a second planar layer, and a corrugated element arranged between the first planar layer and the second planar layer, for example in which at least one of the first planar layer, the second planar layer and the corrugated element comprises or consists of an aerosol-forming material.

[0112] Ex26. An aerosol-generating product according to example Ex25 in which corrugations of the corrugated element are arranged perpendicular to the length direction of the aerosolgenerating product and parallel to the width direction of the aerosol-generating product.

[0113] Ex27. An aerosol-generating product according to example Ex25 in which corrugations of the corrugated element are arranged perpendicular to the width direction of the aerosolgenerating product and parallel to the length direction of the aerosol-generating product.

[0114] Ex28. An aerosol-generating product according to any of examples Ex25 to Ex27 in which an air-flow path is defined through the aerosol-generating product by channels formed by longitudinally extending corrugations of the corrugated element.

[0115] Ex29. An aerosol-generating product according to any of examples Ex25 to Ex28 in which an air-flow path is defined through each of the aerosol-generating articles by channels formed by longitudinally extending corrugations of the corrugated element.

[0116] Ex30. An aerosol-generating product according to any preceding example further comprising at least one protective layer configured to protect an upper and / or lower surface of the aerosol-generating product, preferably in which the at least one protective layer forms a protective layer of each aerosol-generating article after the article is separated from the aerosolgenerating product. Ex31 . An aerosol-forming product according to Ex30 in which perforations, notches, grooves, or scores are defined in the at least one protective layer to facilitate separation of aerosol-generating articles from the aerosol-forming product.

[0117] Ex32. An aerosol-generating product according to any preceding example, wherein each aerosol-generating article in the two-dimensional array of aerosol-generating articles has a length between 5 millimetres and 50 millimetres, for example between 10 millimetres and 45 millimetres, for example between 15 millimetres and 40 millimetres, for example between 25 millimetres and 30 millimetres.

[0118] Ex32. An aerosol-generating product according to any preceding example, wherein each aerosol-generating article in the two-dimensional array of aerosol-generating articles has a width of between 3 millimetres and 50 millimetres, for example between 10 millimetres and 45 millimetres, for example between 15 millimetres and 40 millimetres, for example between 25 millimetres and 30 millimetres, preferably between 5 millimetres and 17 millimetres, for example between 9 millimetres and 11 millimetres.

[0119] Ex33. An aerosol-generating product according to any preceding example, wherein each aerosol-generating article in the two-dimensional array of aerosol-generating articles has a thickness of between 1 millimetres and 8 millimetres, for example between 2 millimetres and 6 millimetres for example between 2.5 millimetres and 5.5 millimetres for example between 3 millimetres and 3.5 millimetres.

[0120] Ex34. An aerosol-generating product according to any preceding example comprising a two-dimensional array of between 4 and 200 separable aerosol-generating articles, for example between 6 and 80, for example between 8 and 64.

[0121] Ex35. An aerosol-generating article according to any preceding example, wherein each aerosol-generating article, when separated from the aerosol-generating product, defines an airflow path having a resistance to draw of between 0 millimetres H2O and 9.9 millimetres H2O.

[0122] Ex36. An aerosol-generating device for receiving an aerosol-generating article separated from an aerosol-generating product according to any preceding example to form an inhalable aerosol, the aerosol-generating device comprising a cavity dimensioned to receive at least a portion of the aerosol-generating article, a heater or heating means, a power source for supplying power to the heater or heating means, and a controller to control supply of power to the heater or heating means.

[0123] Ex37. An aerosol-generating system comprising an aerosol-generating device according to Ex36 and an aerosol-generating product according to any of examples Ex1 to Ex35.

[0124] Examples will now be further described with reference to the figures in which: Figure 1 shows a perspective view of an aerosol-generating product according to an embodiment of the present disclosure;

[0125] Figure 2 shows a perspective view of an aerosol-generating product according to an embodiment of the present disclosure;

[0126] Figure 3 shows a perspective view of an aerosol-generating product according to an embodiment of the present disclosure, and an aerosol-generating article severed from the product;

[0127] Figure 4 shows a perspective view of an aerosol-generating product according to an embodiment of the present disclosure, and an aerosol-generating article severed from the product;

[0128] Figure 5 shows a perspective view of an aerosol-generating product according to an embodiment of the present disclosure;

[0129] Figure 6 shows a perspective view of an aerosol-generating product according to an embodiment of the present disclosure;

[0130] Figure 7 shows a schematic illustration of an apparatus used in the manufacture of an aerosol-generating product according to an embodiment of the present disclosure;

[0131] Figure 8 shows a schematic illustration of method used in the manufacture of an aerosolgenerating product according to an embodiment of the present disclosure; and

[0132] Figure 9 shows a schematic illustration of an aerosol-generating system according to an embodiment of the present disclosure.

[0133] Figure 1 illustrates a perspective view of an aerosol-generating product 10 in the form of a two-dimensional array of aerosol-generating articles. The aerosol-generating product 10 is defined by an initial product length (L), an initial product width (W), and a product thickness (T). The initial product length (L) and the initial product width (W) are greater in magnitude than the product thickness. In this specific example, the aerosol-generating product 10 defines a 4 x 4 array, in which there are four aerosol-generating articles over an initial product length (L) of the aerosol-generating product and four aerosol-generating articles over an initial width (W) of the aerosol-generating product. The aerosol-generating product 10 is thus configured to be severable into sixteen discrete aerosol generating articles. Each aerosol-generating article has an article length of 25 millimetres and an article width of 10 millimetres. The article length is parallel to the product length (L). The article width is parallel to the product width (W). Thus, the aerosolgenerating product 10 in this specific example has an initial product length of 100 millimetres and an initial product width of 40 millimetres. The product thickness (T) is 3 millimetres, which is parallel and equal to an article thickness. Clearly, the aerosol-generating product 10 and aerosolgenerating article dimensions may be varied for different specific examples. The aerosol-generating product 10 comprises a substantially planar sheet of aerosolforming substrate 12. In this specific example, the aerosol-forming substrate 12 comprises homogenised tobacco, however, many other suitable aerosol-forming materials may be used. The aerosol-forming substrate 12 has a Youngs modulus of between 0.5 MPa and 5 MPa, typically in the region of 0.875 MPa. The aerosol-forming substrate 12 comprises a plurality of longitudinally extending air flow channels 15 extending from a distal end 13 of the substrate 12 to a proximal end 14 of the substrate 12.

[0134] A portion of each air flow channel 15 is defined through a longitudinal dimension of each of the aerosol-generating articles. Thus, a longitudinal air flow path is defined through each aerosolgenerating article after it has been severed from the aerosol-generating product 10, in order to allow air to be drawn through the article during use.

[0135] The aerosol-generating product 10 may be severed by being torn or cut using a blade. Different ways in which the aerosol-generating product 10 may be configured to be severable are disclosed below in relation to Figure 2, Figure 3 and Figure 4.

[0136] Figure 2 illustrates a perspective view of an aerosol-generating product 20 consisting of an exemplary 4 x 4 array of aerosol-generating articles 25. The aerosol-generating product 20 comprises a plurality of longitudinally extending air flow channels 250 extending from a distal end 230 of the aerosol-generating product 20 to a proximal end 240 of the aerosol-generating product 20. The aerosol-generating product 20 comprises a substantially planar sheet of aerosol-forming substrate 220, which is substantially the same as the aerosol-forming substrate 12 of Figure 1.

[0137] The aerosol-generating product 20 comprises a plurality of longitudinally extending grooves 21 delineating a length of each of the plurality of aerosol-generating articles 25. Each longitudinally extending groove 21 extends along the length of the aerosol-generating product 20. The aerosol-generating product 20 comprises a plurality of transversely extending grooves 22 delineating a width of each of the plurality of aerosol-generating articles 25. Each transversely extending groove 22 extends along the width of the aerosol-generating product 20.

[0138] The longitudinally extending grooves 21 are uniformed spaced at intervals along the width of the aerosol-generating product 20. In this exemplary embodiment, a perpendicular distance between longitudinally extending grooves 21 , 22 is 10 millimetres. In other embodiments, the perpendicular distance between longitudinally extending grooves 21 , 22 may be between 3 millimetres and 50 millimetres. The transversely extending grooves 22 are uniformed spaced at intervals along the length of the aerosol-generating product 20. In this exemplary embodiment, a perpendicular distance between transversely extending grooves 22 is 25 millimetres. In other embodiments, the perpendicular distance between transversely extending grooves 22 may be between 5 millimetres and 50 millimetres. The aerosol-generating product 20 is configured to be severable into a plurality of discrete aerosol-generating articles 25 along the longitudinally and transversely extending grooves 21 , 22, 22. A discrete aerosol-generating article 25 may be severed from the aerosol-generating product 20 by tearing or bending the aerosol-generating product 20 along a longitudinally or transversely extending groove 21 , 22 to initiate and propagate a crack in the aerosol-generating product 20 until an edge of the discrete aerosol-generating article 25 is severed from the aerosol-generating product 20. Alternatively, an aerosol-generating article 25 may be severed from the aerosolgenerating product 20 by cutting along a longitudinally or transversely extending groove 21 , 22, for example by engaging a longitudinally or transversely extending groove 21 , 22 with a blade to facilitate severing along the longitudinally or transversely extending groove 21 , 22. An aerosolgenerating article 25 may be fully separated from the aerosol-generating product 20 once all edges of the aerosol-generating article 25 are separated from the aerosol-generating product 20.

[0139] Each aerosol-generating article 25 is defined by an article length, an article width and an article thickness. The article length is substantially equal to the perpendicular distance between transversely extending grooves 22. The article width is substantially equal to the perpendicular distance between longitudinally extending grooves 21. The article thickness is equal to the thickness of the aerosol-generating product 20.

[0140] Figure 3 illustrates a perspective view of an aerosol-generating product 30 and a discrete aerosol-generating article 35. In this exemplary embodiment, the aerosol-generating product 30 initially comprised sixteen aerosol-generating articles. After the separation of an article, as illustrated in Figure 3, the remaining aerosol-generating product comprises fifteen aerosolgenerating articles. The aerosol-generating product 30 comprises a plurality of longitudinally extending air flow channels 350 extending from a distal end 330 of the aerosol-generating product 30 to a proximal end 340 of the aerosol-generating product 30. The aerosol-generating product 30 comprises a substantially planar sheet of aerosol-forming substrate 320, which is substantially the same as the aerosol-forming substrate 12 of Figure 1 .

[0141] The aerosol-generating product 30 comprises a plurality of perforated portions 31 , 32. Each perforated portion comprises a longitudinally extending line of perforations 31 , or a transversely extending line of perforations 32. Each longitudinally extending line of perforations 31 extends along the length of the aerosol-generating product 30 and delineates a length of each of the plurality of aerosol-generating articles forming the aerosol-generating product 30. Each transversely extending line of perforations 32 extends along the width of the aerosol-generating product 30 and delineates a width of each of the plurality of aerosol-generating articles forming the aerosol-generating product 30. The perforations along each longitudinally and transversely extending line of perforations 31 , 32 are uniformly spaced. In this exemplary embodiment, the perforations extend partially through the thickness dimension of the aerosol-generating product 30. In other embodiments, the perforations may extend fully through the thickness dimension of the aerosol-generating product 30.

[0142] The longitudinally extending lines of perforations 31 are uniformed spaced at intervals along the width of the aerosol-generating product 30. In this exemplary embodiment, a perpendicular distance between longitudinally extending lines of perforations 31 is 10 millimetres. The transversely extending lines of perforations 32 are uniformed spaced at intervals along the length of the aerosol-generating product 30. In this exemplary embodiment, a perpendicular distance between transversely extending lines of perforations 32 is 25 millimetres.

[0143] The aerosol-generating product 30 is configured to be severable into a plurality of discrete aerosol-generating articles 35 along the longitudinally and transversely extending lines of perforations 31 , 32. A discrete aerosol-generating article 35 may be severed from the aerosolgenerating product 30 by tearing or bending the aerosol-generating product 30 along a longitudinally or transversely extending line of perforations 31 , 32 to initiate and propagate a crack in the aerosol-generating product 30 until an edge of the discrete aerosol-generating article 35 is severed from the aerosol-generating product 30. Alternatively, an aerosol-generating article 35 may be severed from the aerosol-generating product 30 by cutting along a longitudinally or transversely extending line of perforations 31 , 32, for example by engaging a longitudinally or transversely extending line of perforations 31 , 32 with a blade to facilitate severing along the longitudinally or transversely extending line of perforations 31 , 32.

[0144] The discrete aerosol-generating article 35 is fully separated from the aerosol-generating product 30. The discrete aerosol-generating article 35 is defined by an article length (LA), an article width (WA) and article thickness (TA). The article length (LA) is substantially equal to the perpendicular distance between two transversely extending lines of perforations 32. The article width (WA) is substantially equal to the perpendicular distance between two longitudinally extending lines of perforations 31. The article thickness (TA) is equal to the thickness of the aerosol-generating product 30.

[0145] The discrete aerosol-generating article 35 comprises a longitudinally extending air flow channel 351 extending from a distal end 331 of the aerosol-generating article 35 to a proximal end 341 of the aerosol-generating article 35.

[0146] The discrete aerosol-generating article 35 is configured to be inserted into an aerosolgenerating device to generate aerosol during a usage session.

[0147] Figure 4 illustrates a perspective view of an aerosol-generating product 40 and a discrete aerosol-generating article 45. In this exemplary embodiment, the aerosol-generating product 40 initially comprised sixteen aerosol-generating articles. After the separation of an article, as illustrated in Figure 4, the remaining aerosol-generating product comprises fifteen aerosolgenerating articles. The aerosol-generating product 40 comprises a plurality of longitudinally extending air flow channels 450 extending from a distal end 430 of the aerosol-generating product 40 to a proximal end 440 of the aerosol-generating product 40. The aerosol-generating product 40 comprises a substantially planar sheet of aerosol-forming substrate 420, which is substantially the same as the aerosol-forming substrate 12 of Figure 1 .

[0148] The aerosol-generating product 40 comprises a plurality of scored portions 41 , 42. Each scored portion comprises a longitudinally extending score or scoreline 41 , or a transversely extending score or scoreline 42. Each longitudinally extending scoreline 41 extends along the length of the aerosol-generating product 40 and delineates a length of each of the plurality of aerosol-generating articles forming the aerosol-generating product 40. Each transversely extending scoreline 42 extends along the width of the aerosol-generating product 40 and delineates a width of each of the plurality of aerosol-generating articles forming the aerosolgenerating product 40. The scorelines extend partially through the thickness dimension of the aerosol-generating product 40.

[0149] The longitudinally extending scorelines 41 are uniformed spaced at intervals along the width of the aerosol-generating product 40. In this exemplary embodiment, a perpendicular distance between longitudinally extending scorelines 41 is 10 millimetres. The transversely extending scorelines 42 are uniformed spaced at intervals along the length of the aerosol-generating product 40. In this exemplary embodiment, a perpendicular distance between transversely extending scorelines 42 is 25 millimetres.

[0150] The aerosol-generating product 40 is configured to be severable into a plurality of discrete aerosol-generating articles 45 along the longitudinally and transversely extending scorelines 41 , 42. A discrete aerosol-generating article 45 may be severed from the aerosol-generating product 40 by tearing or bending the aerosol-generating product 40 along a longitudinally or transversely extending scoreline 41 , 42 to initiate and propagate a crack in the aerosol-generating product 40 until an edge of the discrete aerosol-generating article 45 is severed from the aerosol-generating product 40. Alternatively, an aerosol-generating article 45 may be severed from the aerosolgenerating product 40 by cutting along a longitudinally or transversely extending scoreline 41 , 42, for example by engaging a longitudinally or transversely extending scoreline 41 , 42 with a blade to facilitate severing along the longitudinally or transversely extending scoreline 41 , 42.

[0151] The discrete aerosol-generating article 45 is fully separated from the aerosol-generating product 40. The discrete aerosol-generating article 45 is defined by an article length (LA), an article width (WA) and article thickness (TA). The article length (LA) is substantially equal to the perpendicular distance between two transversely extending scorelines 42. The article width (WA) is substantially equal to the perpendicular distance between two longitudinally extending scorelines 41. The article thickness (TA) is equal to the thickness of the aerosol-generating product 40. The discrete aerosol-generating article 45 comprises a longitudinally extending air flow channel 451 extending from a distal end 431 of the aerosol-generating article 45 to a proximal end 441 of the aerosol-generating article 45.

[0152] The discrete aerosol-generating article 45 is configured to be inserted into an aerosolgenerating device to generate aerosol during a usage session.

[0153] Figure 5 illustrates a perspective view of an aerosol-generating product 50. The aerosolgenerating product 50 comprises a first planar layer 51 , a second planar layer 52, and an intermediate layer or separation layer 53 arranged between the first planar layer 51 and the second planar layer 52. In this exemplary embodiment, the first and second planar layers 51 , 52 are formed from a sheet of cellulose acetate film having a thickness of 0.05 millimetres. In other embodiments, the first and second planar layers 51 , 52 may have a thickness of between 0.01 millimetres and 0.2 millimetres. The first and second planar layers 51 , 52 act as protective layers to protect the intermediate layer 53, for example from dust or debris.

[0154] The intermediate layer 53 comprises a corrugated element formed from a corrugated sheet 531 of aerosol-forming material. A suitable aerosol-forming material may be homogenised tobacco. Thus, in this example, the intermediate layer 53 comprises a corrugated sheet of homogenised tobacco material 531. The intermediate layer 53 may comprise other suitable aerosol-forming material. The intermediate layer 53 has a thickness of 3 millimetres.

[0155] In this specific embodiment, the intermediate layer 53 is formed from a corrugated layer of aerosol-forming material, which comprises an aerosol-former such as glycerin or propylene glycol. The aerosol-former can be aerosolised by heating of the aerosol-forming material. The corrugated sheet of aerosol-forming material 531 may be impregnated with the aerosol-former. Alternatively, or in addition, the aerosol-former may be present in the intermediate layer 53 between the flutes of the corrugated element. The space between the flutes of the corrugated element may be referred to as channels 532, 542. The channels 532, 542 extend transversely through the aerosol-generating product 50.

[0156] The aerosol-generating product 50 may comprise one or more of the grooves 21 , 22, perforated portions 31 , 32, and scored portions 41 , 42 as described above (not shown). The grooves 21 , 22, perforated portions 31 , 32, and scored portions 41 , 42 may extend through at least one of the first planar layer 51 , the second planar layer 52 and the intermediate layer 53. Thus, the aerosol-generating product 50 may be configured to be severable according to one or more of the ways described above. The grooves 21 , 22, perforated portions 31 , 32, and scored portions 41 , 42 may be aligned to the points of intersection 535, 545 between the first planar layer 51 and the intermediate layer 53 and between the second planar layer 52 and the intermediate layer 53. The corrugations have a peak-to-trough amplitude 510 of 3 millimetres and a wavelength 520 of 3 millimetres. Points of intersection 535, 545 between the first planar layer 51 and the intermediate layer 53 and between the second planar layer 52 and the intermediate layer 53 comprise an adhesive that joins the respective layers.

[0157] Corrugations of the intermediate layer 53 form a first set of transverse channels 532 that are bounded by the first planar layer 51 and the intermediate layer 53, and a second set of transverse channels 542 bounded by the second planar layer 52 and the intermediate layer 53. The first and second set of transverse channels 532, 542 extend through the width of the aerosolgenerating product 50. The transverse channels 532, 542 define a lateral air flow path through the aerosol-generating product 50. The air flow path, therefore, passes over both sides of the corrugated sheet of aerosol-forming material. The porosity of the aerosol-generating product 50 along the air flow path is in the region of 90%.

[0158] Figure 6 illustrates a perspective view of an aerosol-generating product 60. The aerosolgenerating product 60 comprises a first planar layer 61 , a second planar layer 62, and an intermediate layer or separation layer 63 arranged between the first planar layer 61 and the second planar layer 62. The first and second planar layers 61 , 62 are substantially the same as the first and second planar layers 51 , 52 of Figure 5. The intermediate layer 63 is similar to the intermediate layer 53 of Figure 5, with the difference that the channels 632, 642 extend longitudinally through the aerosol-generating product 60, instead of transversely as in Figure 5.

[0159] Thus, corrugations of the intermediate layer 63 form a first set of longitudinal channels 632 that are bounded by the first planar layer 61 and the intermediate layer 63, and a second set of longitudinal channels 642 bounded by the second planar layer 62 and the intermediate layer 63. The first and second set of longitudinal channels 632, 642 extend through the length of the aerosol-generating product 60. The longitudinal channels 632, 642 define a longitudinal air flow path through the aerosol-generating product 60. The air flow path, therefore, passes over both sides of the corrugated sheet of aerosol-forming material. The porosity of the aerosol-generating product along the air flow path is in the region of 90%.

[0160] The aerosol-generating product 60 comprises scored portions 41 , 42 which extend partially through the first planar layer 61 and second planar layer 62. In this exemplary embodiment, the scoreline depth is 0.01 millimetres. Thus, the aerosol-generating product 60 may be configured to be severable as described above. The scored portions 41 , 42 are aligned to the points of intersection 635, 645 between the first planar layer 61 and the intermediate layer 63 and between the second planar layer 62 and the intermediate layer 63.

[0161] Figure 7 is a schematic illustration of an apparatus 710 that may be used for the manufacture of the aerosol-generating product 70 to create grooves 21 , 22, perforated portions 31 , 32, or scored portions 41 , 42. The apparatus comprises a stamping die 71 and an anvil 72. A continuous sheet of aerosol-generating product 70 is conveyed along rollers 73 to the stamping die 71 and anvil 72. To create scored portions 41 , 42, the stamping die 71 pierces or compresses the aerosol-generating product 70 against the anvil 72 to form a scored portion 41 , 42. To create grooves 21 , 22 (not shown), the stamping die 71 may configured with a rounded tip to compress the aerosol-generating product 70 against the anvil 72 to form a groove 21 , 22. To create perforated portions 31 , 32 (not shown), the stamping die 71 may configured with a pointed tip to perforate the aerosol-generating product 70 when the stamping die 71 compresses the aerosolgenerating product 70 against the anvil 72.

[0162] Figure 8 is a schematic illustration of a process that may be used for the manufacture of aerosol-generating product 80. A continuous sheet of aerosol-generating product 81 is sectioned to form an array of aerosol-generating articles 82 with gaps 84 between the aerosol-generating articles 85. A planar upper layer 83 is then affixed to an upper surface array of the aerosolgenerating articles 82 using an adhesive. The aerosol-generating product 80 is then marked with at least one of grooves 21 , 22, perforated portions 31 , 32, and scored portions 41 , 42, for example by using the process of Figure 7, such that the grooves 21 , 22, perforated portions 31 , 32, or scored portions 41 , 42 align with the gaps 84 between aerosol-generating articles 85.

[0163] Figure 9 illustrates an aerosol-generating system comprising an aerosol-generating device 91 and an aerosol-generating article 90. The aerosol-generating device 91 may be coupled to a mouthpiece 92. The aerosol-generating article 90 is configured to engage with the aerosolgenerating device 91. There is little tolerance between outer surfaces of the aerosol-generating article 90 and the internal surfaces of the cavity 950. Thus, there is a snug fit between the article 90 and the device 91 . When a user has inserted the article 90 into the cavity 950, the device 91 can be operated. The device 91 comprises two planar heaters 660. The heaters 960 heat an upper and lower surface of the article 90, and as a result the aerosol-generating article 90 is heated. Volatile components of the aerosol-generating article are evaporated and form an aerosol. The user inhales the aerosol formed from the aerosol-generating article 100 by drawing on the mouthpiece 92. Once the aerosol-generating article 45 has been depleted of volatile components, the article 90 is removed from the cavity 650 and disposed of.

[0164] 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 percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

CLAIMS1 . An aerosol-generating product in the form of a two-dimensional array of aerosolgenerating articles, each of the aerosol-generating articles configured to be separable from the aerosol-generating product to be used as a discrete aerosol-generating article to generate an aerosol.

2. An aerosol-generating product according to claim 1 in which the aerosol-generating product is defined by an initial product length, an initial product width, and a product thickness, the initial product length and the initial product width being greater in magnitude than the product thickness.

3. An aerosol-generating product according to any preceding claim in which the aerosolgenerating product defines a n x nwarray, in which n is the number of aerosol-generating articles over an initial length of the aerosol-generating product (initial product length) and nwis the number of aerosol-generating articles over an initial width of the aerosol-generating product (initial product width), for example in which ni_ is a number between 2 and 20 and nw is a number between 2 and 10.

4. An aerosol-generating product according to claim 3 in which the aerosol-generating product is a continuous product extending continuously in the length direction, for example in which CL can be represented as °°, for example in which OL is00and nw is a number between 2 and 10.

5. An aerosol-generating product according to claim 3 in which n is a number between 3 and 15 and nwis a number between 2 and 15.

6. An aerosol-generating product according to any preceding claim in which material properties or physical properties of the aerosol-generating product are configured to facilitate separation of the product into the plurality of discrete aerosol-generating articles.

7. An aerosol-generating product according to any preceding claim comprising at least one stress concentrator to facilitate crack initiation, for example in which each of the plurality of aerosol-generating articles is delineated by one or more notches, grooves, scorelines, or perforations configured to act as stress concentrators to facilitate crack initiation to facilitate separation of individual articles from the aerosol-generating product.

8. An aerosol-generating product according to any preceding claim comprising a first planar layer, a second planar layer, and an intermediate layer or separation layer arranged between the first planar layer and the second planar layer.

9. An aerosol-generating product according to claim 8 in which lines of weakness, for example formed by scorelines, groves, notches, or perforations, delineating each of the aerosol-generating articles are defined in at least one of the first planar layer, the second planar layer, and the intermediate layer or separation layer.

10. An aerosol-generating product according to any preceding claim in which one or more airflow channels are defined through the aerosol-generating product such that, after separation, each of the plurality of aerosol-generating articles comprises at least one airflow channel defined therethrough.11 . An aerosol-generating product according to any preceding claim in which each of the plurality of aerosol-generating articles comprises at least one cavity, for example a cavity containing an aerosol-forming substrate.

12. An aerosol-generating product according to any preceding claim in which the aerosolgenerating product comprises a first planar layer, a second planar layer, and a corrugated element arranged between the first planar layer and the second planar layer.

13. An aerosol-generating product according to any preceding claim further comprising at least one protective layer configured to protect an upper and / or lower surface of the aerosolgenerating product, preferably in which the at least one protective layer forms a protective layer of each aerosol-generating article after the article is separated from the aerosol-generating product.

14. An aerosol-generating product according to claim 13 in which perforations, notches, grooves, or scores are defined in the at least one protective layer to facilitate separation of aerosol-generating articles from the aerosol-generating product.

15. An aerosol-generating product according to any preceding claim, wherein each aerosol-generating article in the two-dimensional array of aerosol-generating articles has a length between 5 millimetres and 50 millimetres, and a thickness of between 1 millimetres and 8 millimetres.

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