Aerosol-generating article with aerosol-generating substrate

Abstract

There is provided an aerosol-generating article (300) for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article (300) being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness. The aerosol-generating article (300) comprises a first external surface (321) and a second external surface (322) facing in substantially the opposite direction to the first external surface (321). The aerosol-generating article (300) further comprises a cavity (330) between the first external surface (321) and the second external surface (322). An airflow path is defined through the aerosol-generating article (300) between an air inlet (311) and an air outlet (312), the airflow path extending through the cavity (330). An aerosol-generating element (340) is located in the cavity (330), the aerosol-generating element (340) comprising a rope formed from a plurality of twisted or braided fibres of aerosol-generating material.

Description

[0001] AEROSOL-GENERATING ARTICLE WITH AEROSOL-GENERATING SUBSTRATE

[0002] The present disclosure relates to an aerosol-generating article comprising an aerosol-generating 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-generating 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] However, a significant portion of the aerosol-generating substrate in these cylindrical aerosolgenerating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-generating 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. Moreover, even if a portion of the aerosol-generating substrate is sufficiently heated to form an aerosol during use, this can take time due to the thermal inertia. As a result, there can be a significant delay between beginning heating and aerosol generation. In addition, the initial inhalations from the aerosol-generating article may have a low concentration of aerosol compared to the later inhalations. More broadly, typical aerosol-generating substrates of the prior art may not produce sufficient aerosol without a very high density of aerosol-generating substrate. However, where the density of aerosol-generating substrate is increases, this is typically accompanied by a corresponding increase in resistance to draw which can make the aerosol-generating article difficult to use. This may be the case regardless of the way in which the aerosolgenerating substrate is heated, for example regardless of whether a resistive or inductive heater is used and regardless of whether the aerosol-generating substrate is heated from the inside or the outside. Moreover, the components of these cylindrical aerosol-generating 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.

[0005] Furthermore, many aerosol-generating articles of the prior art comprise a particulate aerosolgenerating substrate. However, it has been found that adding the particulate aerosol-generating substrate to the body of the article at high speed during manufacturing may lead to particles of aerosol-generating substrate flying out of the article. In addition, depending on their size, the particulate aerosol-generating substrate may escape the article through one or more air inlets and air outlets. This may disadvantageously reduce the volume of aerosol-generating substrate in the aerosol-generating article, block the one or more air inlets and air outlets, and create mess.

[0006] It is an aim of the present disclosure to provide an aerosol-generating article, in which a greater portion of an aerosol-generating 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 disclose to provide an aerosol-generating article which is easier to manufacture and transport without damage. It is also an objective of the present disclosure to provide an aerosol-generating article in which the delay between heating and aerosol delivery is reduced, and which produces a consistent aerosol over the full duration of the experience. In addition, it would be desirable to provide an increases aerosol delivery without increasing the resistance to draw of the aerosol-generating article to an unacceptably high level.

[0007] According to the present disclosure there is provided an aerosol-generating article. The aerosolgenerating article may be for use with an aerosol-generating device to generate an aerosol. The aerosolgenerating article may be defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness. The aerosol-generating article may comprise a first external surface. The aerosol-generating article may comprise a second external surface facing in substantially the opposite direction to the first external surface. The aerosol-generating article may comprise a cavity between the first external surface and the second external surface. The aerosol-generating article may comprise an airflow path defined through the aerosol-generating article between an air inlet and an air outlet. The airflow path may extend through the cavity. The aerosol-generating article may comprise an aerosol-generating element located in the cavity. The aerosol-generating element may comprise a rope formed from a plurality of twisted or braided fibres of aerosol-generating material.

[0008] According to a first aspect of the present invention, there is provided an aerosol-generating article. The aerosol-generating article is for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article is defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness. The aerosol-generating article comprises a first external surface. The aerosol-generating article comprises a second external surface facing in substantially the opposite direction to the first external surface. The aerosol-generating article comprises a cavity between the first external surface and the second external surface. The aerosol-generating article comprises an airflow path defined through the aerosol-generating article between an air inlet and an air outlet. The airflow path extends through the cavity. The aerosol-generating article comprises an aerosol-generating element located in the cavity. The aerosol-generating element comprises a rope formed from a plurality of twisted or braided fibres of aerosol-generating material.

[0009] The provision of an aerosol-generating element comprising a rope formed from a plurality of twisted or braided fibres may advantageously allow for simple handling of the aerosol-generating element during manufacture and assembly of the aerosol-generating article. For example, aerosol-generating elements of the prior art may comprise tobacco cut filler or tobacco cast leaf gathered and wrapped into a plug. Where this is the case, the tobacco may become detached from the aerosol-generating element if it is not handled with care. In addition, the arrangement of the prior art requires a separate paper wrapper to keep the tobacco substrate together. This adds a further material to the aerosol-generating element which does not contribute to aerosol-generation. This adds cost and may prevent or reduce heat conduction to the tobacco aerosol-generating substrate. Furthermore, the provision of an aerosol-generating element comprising a rope formed from a plurality of twisted or braided fibres may advantageously allow the aerosol-generating substrate to be added to the cavity at high speed with reduced risk that some or all of the aerosol-generating substrate may leave the cavity during manufacture. This may be a particular problem where the aerosolgenerating substrate comprises loose particulate aerosol-generating substrate. In addition, the provision of an aerosol-generating element comprising a rope formed from a plurality of twisted or braided fibres of aerosol-generating material may make it easier to control the parameters of the aerosol-generating substrate including the resistance to draw, the porosity, density, and the heat conductivity of the aerosolgenerating substrate compared to, for example, loose particulate aerosol-generating substrate. In addition, an aerosol-generating article including an aerosol-generating element comprising a rope may be stronger than and more resilient to handling than an aerosol-generating article including loose particulate aerosolgenerating substrate.

[0010] The provision of an aerosol-generating element comprising a rope formed from a plurality of twisted or braided fibres may advantageously also prevent aerosol-generating substrate from leaving the aerosolgenerating article through one or more of the air inlet or air outlet.

[0011] By contrast, the provision of a rope of the present invention may advantageously keep the aerosolgenerating substrate together without the need for a separate paper wrapper. This may advantageously help to simplify manufacture while also making the aerosol-generating element more robust for assembly and transport. In addition, the removal of the paper wrapper may advantageously improve heat conduction from the aerosol-generating device to the aerosol-generating material of the aerosol-generating element. This may in turn improve aerosol generation.

[0012] The removal of the need for a paper wrapper may also advantageously remove the need for a glue or adhesive which is typically used to stick the wrapper together. This may make the aerosol-generating element more sustainable and potentially even biodegradable. In addition, the absence of a paper wrapper may visually distinguish the aerosol-generating element of the present invention from conventional cigarettes. This may advantageously remind users that the aerosol-generating element of the present invention must be used differently to conventional cigarettes.

[0013] Furthermore, the provision of a plurality of twisted or braided fibres of aerosol-generating material may allow for an aerosol-generating element having a higher density of aerosol-generating substrate compared to traditional gathered and wrapped arrangements. This may advantageously improve the aerosol delivery of the aerosol-generating article during use. Typically, a high density aerosol-generating element may result in an unacceptably high resistance to draw. However, where aerosol-generating element comprises a rope formed from a plurality of twisted or braided fibres, small spaces between the twisted or braided fibres may provide air passages which keep the resistance to draw of the aerosolgenerating element at an acceptable level.

[0014] The provision of an aerosol-generating element comprising a rope formed from a plurality of twisted or braided fibres of aerosol-generating material may mean that the density of aerosol-generating material varies across the aerosol-generating element. As a result, the thermal inertia of the aerosol-generating material varies across the aerosol-generating element. This may mean that different portions of the aerosolgenerating material heating up at different rates when the aerosol-generating element is heated. This may advantageously ensure that there is little or no delay between heating and aerosol delivery. This may further advantageously ensure that aerosol generation is more consistent over the full duration of the experience.

[0015] As used herein, the term “rope” refers to a group of yarns, plies, fibres, or strands which are twisted or braided together. The term “rope” does not imply any particular length, diameter, strength or number of strands. It is understood that in this context, the term “rope” covers arrangements of aerosol-generating material which may be described as cords, strings, or twines provided they are still formed from a plurality of twisted or braided fibres of aerosol-generating material.

[0016] The rope may comprise any number of strands. The rope may comprise at least 2 strands of aerosolgenerating material. For example, the rope may comprise at least 3, at least 4 strands of aerosol-generating material, at least 6 strands of aerosol-generating material, at least 10 strands of aerosol-generating material, at least 15 strands of aerosol-generating material, or at least 20 strands of aerosol-generating material.

[0017] The provision of a rope comprising at least 2 strands of aerosol-generating material may advantageously improve the structure of the aerosol-generating element meaning that the aerosolgenerating material may be better retained in the aerosol-generating element.

[0018] The rope may comprise no more than 6 strands of aerosol-generating material. For example, the rope may comprise no more than 5 strands of aerosol-generating material.

[0019] The provision of a rope comprising no more than 6 strands of aerosol-generating material may advantageously keep the aerosol-generating element from becoming too complicated to manufacture.

[0020] The aerosol-generating element may have a diameter which is the same as the diameter of the cavity. This may advantageously force the mainstream airflow to pass through the aerosol-generating element to entrain the aerosol generated by the aerosol-generating element. This may also maximise the mass of aerosol-generating material in the aerosol-generating article.

[0021] The aerosol-generating article may comprise a plurality of aerosol-generating elements located in the cavity, each aerosol-generating element comprising a rope formed from a plurality of twisted or braided fibres of aerosol-generating material. For example, the aerosol-generating article may comprise may comprise at least 2, at least 3, at least 4, at least 5, or at least 6 aerosol-generating elements.

[0022] The provision of a plurality of aerosol-generating elements may advantageously allow the cavity to be more effectively filled by the aerosol-generating element where the shape of one aerosol-generating elements does not conform to the shape of the cavity.

[0023] Each of the plurality of aerosol-generating elements may comprise the same aerosol-generating material. Each of the plurality of aerosol-generating elements may comprise different aerosol-generating materials. For example, a first aerosol-generating element may comprise nicotine and a second aerosolgenerating element may comprise an aerosol former.

[0024] Each of the plurality of aerosol-generating elements may have the same diameter. Each of the plurality of aerosol-generating elements may comprise a rope being formed from the same number of strands.

[0025] The aerosol-generating element may be compressible. This may advantageously ensure that the aerosol-generating element fills the cavity in the transverse direction.

[0026] The longitudinal axis of the rope may be aligned with the longitudinal axis of the cavity. This may advantageously ensure that the small spaces or air passages between the twisted or braided fibres are generally aligned with the longitudinal axis of the cavity such that air may easily pass through the aerosolgenerating article.

[0027] The aerosol-generating article may not include a wrapper. As described above, the absence of a wrapper may advantageously simplify manufacture, remove the need for an adhesive, and improve heat conduction to the aerosol-generating material.

[0028] The cavity may comprise between 50 mg and 300 mg of the aerosol-generating element, for example between 100 mg and 200 mg, for example between 125 mg and 175 mg, for example between 140 mg and 160 mg, for example about 140 mg, or about 150 mg or about 160 mg.

[0029] The aerosol-generating element may have a length of between 10 mm and 25 mm, for example between 15 mm and 20 mm, for example about 15 mm or about 17 mm, or about 20 mm. The aerosol-generating element may have a width of between 5 mm and 15 mm, for example between 6 mm and 10 mm, for example between 7 mm and 8 mm, for example about 6 mm or about 7 mm, or about 8 mm.

[0030] The aerosol-generating element may have a thickness of between 1 mm and 5 mm, for example between 1 .5 mm and 4 mm, for example between 2 mm and 3 mm, for example about 2.5 mm or about 3 mm, or about 3.5 mm.

[0031] The aerosol-generating element may be a porous aerosol-generating element.

[0032] According to the present disclosure, the aerosol-generating article may be a planar aerosolgenerating article having a base defined by a length extending in an x direction, a width extending in a y direction, and a height extending in a z direction.

[0033] The height of the aerosol-generating article may be less than both of the length and width of the aerosol-generating article. For the purpose of the present disclosure, the “height” of the aerosol-generating article may also be referred to as the “thickness” of the aerosol-generating article.

[0034] Aerosol-generating articles according to the present disclosure may preferably be substantially flat articles or substantially planar articles. Such articles have a large base area relative to the volume of the article. In particular, the height of the aerosol-generating article may be less than 50 percent of both the length and width of the 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 aerosol-generating article during heating. For example, where the base of the aerosol-generating article is in contact with, and heated by, a planar heater, there may be a smaller temperature difference between the base and an upper surface opposing the base if the spacing, or height, between the base and the upper surface is smaller. Advantageously, this may allow heating of a greater proportion of the aerosol-generating 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-generating substrate sufficiently to release an aerosol.

[0035] The aerosol-generating article according to any of the aspects disclosed herein 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 aerosol-generating article. The aerosol-generating article preferably has a resistance to draw (RTD) of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in the direction of the 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 aerosolgenerating 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. The resistance to draw of the aerosol-generating article between the air inlet and air outlet is at least 5 millimetre H2O.

[0036] The air inlet may have any diameter. The air inlet may have a diameter of at least 4 millimetres, at least 5 millimetres, at least 6 millimetres, or at least 8 millimetres.

[0037] The air outlet may have any diameter. The air outlet may have a diameter of at least 4 millimetres, at least 5 millimetres, at least 6 millimetres, or at least 8 millimetres. As used herein, the “diameter” of the air inlet and air outlet refers to the longest dimension of the air inlet and air outlet.

[0038] The provision of at least one of the air inlet and air outlet having a relatively large diameter may advantageously improve the airflow through the cavity. This may reduce the overall resistance to draw of the aerosol-generating article. Moreover, the provision of an aerosol-generating element comprising a rope formed from a plurality of twisted or braided fibres of aerosol-generating material allows for an enlarged air inlet and air outlet since the aerosol-generating material is not free to move around the cavity but is bound in the rope. As a result, the risk that aerosol-generating substrate may escape the article through one or more air inlets and air outlets is reduced, even where the air inlets and air outlets have large diameters.

[0039] The air inlet and air outlet may have the same diameter.

[0040] The aerosol-generating element may be loose in the cavity. The aerosol-generating element may be attached to the interior of the cavity. This may advantageously help to retain the aerosol-generating element in the correct position in the cavity. This may also advantageously prevent the aerosol-generating element from falling out of the cavity where the air inlet and air outlet have diameters larger than the diameter of the aerosol-generating element.

[0041] For example, the aerosol-generating element may be attached to the interior of the cavity by a glue or an adhesive.

[0042] 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%.

[0043] The aerosol-generating article according to any of the aspects disclosed herein 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 an aerosol-generating substrate. 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. At least one of the upper and lower layers may comprise or consist of aerosol-generating substrate

[0044] According to the present disclosure, the aerosol-generating article may comprise a frame positioned between the first external surface and the second external surface. The frame at least partially defines the cavity.

[0045] The first external surface may be a planar surface. The second external surface may be a planar surface. 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.

[0046] The aerosol-generating article may comprise a first planar external layer and a second planar external layer, in which the first planar external layer forms the first planar external surface and the second planar external layer forms the second planar external surface. Optionally, at least one of the first planar external layer, the second planar external layer, and the frame may comprise or consist of aerosolgenerating substrate.

[0047] An aerosol-generating element is located in the cavity.

[0048] A corrugated layer may be positioned within the cavity.

[0049] The frame may be a planar frame.

[0050] The frame may have a height between 50 percent and 95 percent of the height of the aerosolgenerating 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.

[0051] 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.

[0052] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0053] 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.

[0054] 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.

[0055] The aerosol-generating article of any of the aspects of the present disclosure may have a length (for example, an x dimension) of between 10 millimetres and 100 millimetres, or between 10 millimetres and 50 millimetres, for example between 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.

[0056] The aerosol-generating article may have a width (for example, a y dimension) of between 5 millimetres and 20 millimetres, for example between 8 millimetres and 18 millimetres, for example between 10 millimetres and 16 millimetres, for example between 1 1 millimetres and 15 millimetres, for example between 12 millimetres and 14 millimetres, for example about 13 millimetres.

[0057] The aerosol-generating article may have a height (for example, a z dimension) of between 1 millimetres and 10 millimetres, for example between 1 .2 millimetres and 8 millimetres, for example between 1 .4 millimetres and 7 millimetres, for example between 1 .6 millimetres and 6 millimetres, for example between 1 .7 millimetres and 5 millimetres, for example about 1 .7 millimetres, or about 4.5 millimetres, or about 2 millimetres, or about 3 millimetres, or about 4 millimetres.

[0058] The aerosol-generating article of any of the aspects of the present disclosure 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 aerosolgenerating 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.

[0059] The aerosol-generating article may consist entirely of aerosol-generating substrate. Alternatively, the aerosol-generating substrate may be one of a plurality of component parts of the aerosol-generating article.

[0060] The aerosol-generating material may comprise at least one aerosol-generating substrate.

[0061] The aerosol-generating 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.

[0062] The aerosol-generating substrate may comprise one or more organic materials such as tobacco, mint, tea and cloves. The aerosol-generating 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. The aerosol-generating material may comprise shredded organic material. The aerosol-generating material may comprise shredded tobacco cast leaf filaments.

[0063] The aerosol-generating substrate may comprise or consist of homogenised tobacco material, for example a reconstituted tobacco material or a cast leaf tobacco material.

[0064] The aerosol-generating 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 aerosolgenerating 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.

[0065] The aerosol-generating substrate may be cut filler. The aerosol-generating 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.

[0066] The aerosol-generating substrate may comprise a bound collection of strips, strands of tobacco material. The aerosol-generating 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.

[0067] The aerosol-generating 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-generating 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.

[0068] The aerosol-generating 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.

[0069] The aerosol-generating 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.

[0070] The aerosol-generating 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.

[0071] The aerosol-generating 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.

[0072] The aerosol-generating 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.

[0073] The aerosol-generating substrate may comprise nicotine. The aerosol-generating substrate may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0074] The aerosol-generating 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.

[0075] The aerosol-generating 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.

[0076] The aerosol-generating substrate may comprise one or more botanicals. For example, the aerosolgenerating 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.

[0077] The aerosol-generating substrate may have a moisture content of about 5 to 25%, preferably of about 7 to 15%, at final product state. For example, the aerosol-generating 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.

[0078] The aerosol-generating substrate may comprise a binder. For example, the aerosol-generating 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 carboxymethyl, celluloses; dextran; and xanthan gum. A preferable binder is guar.

[0079] The aerosol-generating substrate may comprise, or consist of, a solid aerosol-generating material. The aerosol-generating substrate may comprise a liquid aerosol-generating material, for example a liquid aerosol-generating material retained within a porous matrix. The aerosol-generating substrate may comprise a gel aerosol-generating material.

[0080] The aerosol-generating material may comprise fibres of absorbent material with an aerosolgenerating substrate sorbed on the absorbent material.

[0081] The absorbent material may comprise at least one of cotton, nylon, or paper.

[0082] The absorbent material may comprise filter material. The absorbent material may comprise cellulose acetate fibres. Where this is the case, the aerosol-generating substrate may comprise a liquid aerosolgenerating substrate.

[0083] According to the present disclosure, an aerosol-generating device for receiving an aerosolgenerating article as disclosed herein, or an aerosol-generating substrate as disclosed herein, may comprise a cavity dimensioned to receive at least a portion of the aerosol-generating article or aerosolgenerating substrate, a heater or heating means, a power source for supplying power to the heater or heating means, and a controller to control supply of power to the heater or heating means. The aerosolgenerating device is configured to heat an aerosol-generating substrate, for example an aerosol-generating substrate that is a component part of an aerosol-generating article, to form an aerosol, for example an inhalable aerosol.

[0084] 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.

[0085] The cavity may comprise an opening into which a distal end of the aerosol-generating article can be inserted. The cavity may have any suitable cross-sectional shape. For example, the cavity may have a rectangular transverse cross-section, for example a rectangular cross-section having opposing top and bottom sides that are greater in length than left and right sides.

[0086] Preferably, at least one internal surface of the cavity is a heating surface configured to heat an aerosol-generating article. The heating surface may comprise a heater, for example a resistance heater, or an infra-red heater, or a susceptor configured to be heated by engagement with an inductor. The heating surface may comprise an inductor, for example the surface may comprise a coil arranged to generate a fluctuating electromagnetic field within a space of the cavity. The heating surface may be a surface that is permeable to a fluctuating electromagnetic field, such that an inductor arranged outside the cavity can project a fluctuating electromagnetic field through the heating surface to engage with a susceptor arranged within the cavity.

[0087] As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol.

[0088] As used herein, the term “aerosol-generating 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-generating substrate. An aerosol-generating substrate may comprise an aerosolgenerating material. An aerosol-generating substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. An aerosol-generating substrate may conveniently be part of an aerosolgenerating article or smoking article.

[0089] 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.

[0090] 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.

[0091] 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-generating substrate or aerosol-generating article.

[0092] As used herein with reference to the invention, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.

[0093] 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.

[0094] 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.

[0095] 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-generating substrates as described herein may have a thickness of between 10 irn and about 1000 pirn, for example between 10 pm and about 300 pm.

[0096] 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.

[0097] 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.

[0098] 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.

[0099] According to the present disclosure, there is further provided an aerosol-generating element, the aerosol-generating element comprises a rope formed from a plurality of twisted or braided fibres of aerosolgenerating material. Further features for the aerosol-generating element are described above in reference to the disclosure related to the aerosol-generating article.

[0100] According to the present disclosure, there is further provided a method for forming an aerosolgenerating element. The method comprises steps of: providing a fibrous aerosol-generating material; gathering the fibres and passing the fibres of aerosol-generating material through a funnel and onto a spinning mandrel to form strands of aerosol-generating material; twisting at least two strands of aerosolgenerating material together to form a rope.

[0101] 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.

[0102] Example Ex1 : An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: a first external surface and a second external surface facing in substantially the opposite direction to the first external surface; a cavity between the first external surface and the second external surface; an airflow path defined through the aerosol-generating article between an air inlet and an air outlet, the airflow path extending through the cavity, and an aerosol-generating element located in the cavity, the aerosol-generating element comprising a rope formed from a plurality of twisted or braided fibres of aerosolgenerating material.

[0103] Example Ex2: An aerosol-generating article according to Ex1 , wherein the rope comprises at least 2 strands of aerosol-generating material.

[0104] Example Ex3: An aerosol-generating article according to Ex1 or Ex2, wherein the rope comprises no more than 6 strands of aerosol-generating material.

[0105] Example Ex4: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating material comprises at least one aerosol-generating substrate.

[0106] Example Ex5: An aerosol-generating article according to Ex4, wherein the aerosol-generating substrate comprises tobacco.

[0107] Example Ex6: An aerosol-generating article according to Ex5, wherein the aerosol-generating substrate comprises at least one of cast leaf tobacco material, extruded tobacco material, or tobacco cut filler material.

[0108] Example Ex7: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating material comprises fibres of absorbent material with an aerosol-generating substrate sorbed on the absorbent material.

[0109] Example Ex8: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating material comprises an aerosol former.

[0110] Example Ex9: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating element comprises at least 10 percent by weight of aerosol former on a dry weight basis.

[0111] Example Ex10: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating element has a diameter which is the same as the diameter of the cavity.

[0112] Example Ex1 1 : An aerosol-generating article according to any preceding Example, wherein the aerosol-generating element is compressible.

[0113] Example Ex12: An aerosol-generating article according to any preceding Example, wherein the longitudinal axis of the rope is aligned with the longitudinal axis of the cavity.

[0114] Example Ex13: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating article does not include a wrapper.

[0115] Example Ex14: An aerosol-generating article according to any preceding Example, wherein the cavity comprises between 50 mg and 300 mg of the aerosol-generating element, for example between 100 mg and 200 mg, for example between 125 mg and 175 mg, for example between 140 mg and 160 mg, for example about 140 mg, or about 150 mg or about 160 mg.

[0116] Example Ex15: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating element has a length of between 10 mm and 25 mm, for example between 15 mm and 20 mm, for example about 15 mm or about 17 mm, or about 20 mm.

[0117] Example Ex16: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating element has a width of between 5 mm and 15 mm, for example between 6 mm and 10 mm, for example between 7 mm and 8 mm, for example about 6 mm or about 7 mm, or about 8 mm. Example Ex17: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating element has a thickness of between 1 mm and 5 mm, for example between 1 .5 mm and 4 mm, for example between 2 mm and 3 mm, for example about 2.5 mm or about 3 mm, or about 3.5 mm.

[0118] Example Ex18: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating element is a porous aerosol-generating element.

[0119] Example Ex19: An aerosol-generating element, the aerosol-generating element comprising a rope formed from a plurality of twisted or braided fibres of aerosol-generating material.

[0120] Examples will now be further described with reference to the figures in which:

[0121] Figure 1 is a perspective side view of an aerosol-generating article according to a first embodiment of the present disclosure;

[0122] Figure 2 is a perspective side view of an aerosol-generating article according to a second embodiment of the present disclosure;

[0123] Figure 3 shows a perspective view of an aerosol-generating article according to a third embodiment of the present disclosure;

[0124] Figure 4 shows an exploded perspective view of the aerosol-generating article of Figure 3;

[0125] Figure 5 shows a cross sectional plan view of the aerosol-generating article of Figure 3;

[0126] Figure 6 shows a cross sectional plan view of an aerosol-generating article according to a further embodiment of the present disclosure;

[0127] Figure 7 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 6;

[0128] Figure 8 shows a schematic end view of the aerosol-generating device of Figure 7;

[0129] Figure 9 is a schematic view showing an aerosol-generating article (for example, the aerosolgenerating article of any of Figures 1 to 6) in engagement with the aerosol-generating device of Figure 7.

[0130] Figure 10 is a schematic view of an alternative embodiment to that of Figures 7 to 9, showing an aerosol-generating article in engagement with an aerosol-generating device.

[0131] 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 a first external surface 110 and a second external surface 120. The first and second external surfaces 1 10, 120 are flat or planar.

[0132] The aerosol-generating article 100 comprises an aerosol-generating substrate (not shown). In one embodiment, the aerosol-generating article 100 may consist substantially of aerosol-generating substrate. In another embodiment, the aerosol-generating substrate may be one of a plurality of component parts of the aerosol-generating article 100. The aerosol-generating substrate may be enclosed within an interior of the aerosol-generating article 100. The aerosol-generating substrate may at least partially define an exterior of the aerosol-generating article 100; for example, one or both of the first external surface 1 10 and a second external surface 120may comprise or consist of aerosol-generating substrate.

[0133] A suitable aerosol-generating substrate may be homogenised tobacco.

[0134] 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. 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 first external surface 210 and a second external surface 220 upper and lower surfaces 210, 220. The airflow path 230 extends between opposed first and second ends 201 , 202 of the aerosolgenerating 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-generating substrate of the aerosol-generating article 200.

[0135] Figure 3 shows an aerosol-generating article 300 according to a third embodiment of the present disclosure. The aerosol-generating article 300 comprises a first planar external layer 324 forming a first planar external surface 321 , a second planar external layer 325 forming a second planar external surface 322, and a frame 350 positioned between the first planar external layer 324 and the second planar external layer 325. The second planar external surface 322 is positioned parallel to the first planar external surface 321 .

[0136] Figure 4 shows exploded views of the aerosol-generating article 300 of Figure 3. The frame 350 circumscribes and at least partially defines a cavity 330.

[0137] The first planar external layer 324 and the second planar external layer 325 are made from cigarette paper having a thickness of 35 micrometres and are in physical contact, with and bonded to, the frame 350. The frame 350, the first planar external layer 324 and the second planar external layer 325 collectively define the cavity 330.

[0138] The frame 350 has a hollow cuboid shape and is made from cardboard. The frame 350 defines an aperture extending through the height (also referred to as the thickness) of the frame 350 and the aperture at least partially forms the cavity 330 of the aerosol-generating article 300. The frame 350 comprises a peripheral wall 351 that circumscribes the cavity 330. The peripheral wall 351 includes a front wall 313 and a back wall 314. In more detail, the peripheral wall 351 is defined by an inner transverse surface 352 of the frame 350 and an outer transverse surface 353 of the frame 350. The inner transverse surface 352 of the peripheral wall 351 at least partially defines a perimeter of the cavity 330. The outer transverse surface 353 of the peripheral wall 351 at least partially defines a perimeter of the aerosol-generating article 300. The peripheral wall 351 has a radial thickness measured between the inner transverse surface 352 of the frame 350 and the outer transverse surface 353 of the frame 350 of about 5 millimetres.

[0139] An air inlet 31 1 and an air outlet 312 are defined by, and extend through, the peripheral wall 351 of the frame 350. More specifically, the air inlet 31 1 extends through the front wall 313 and the air outlet 312 extends through the back wall 314. The air inlet 31 1 and the air outlet 312 have an equivalent diameter of 5 millimetres. The air inlet 31 1 and air outlet 312 are aligned with the central longitudinal axis of the aerosolgenerating article 300. An airflow path extends between the air inlet 31 1 and the air outlet 312 through the cavity 330. An aerosol-generating element 340 is positioned within the cavity 330. The aerosol-generating element 340 comprises a rope formed from a plurality of twisted fibres of aerosol-generating material.

[0140] Figure 5 shows a sectional plan view of the aerosol-generating article 300 of Figures 3 and 4 in the z direction. The aerosol-generating element 340 comprises a rope formed from a plurality of twisted fibres of tobacco material. The tobacco material comprises shredded cast leaf filaments. The aerosol-generating element 340 comprises a rope formed from three twisted strands of aerosol-generating material.

[0141] Figure 6 shows a sectional plan view of a further aerosol-generating article 400. The aerosolgenerating article 400 is similar to aerosol-generating article 300. Features in common with aerosolgenerating article 300 are referred to with like reference signs but commencing with numeral 4 instead of numeral 3. The aerosol-generating article 400 includes a first aerosol-generating element 440 comprising a rope formed from a plurality of twisted or braided fibres of aerosol-generating material, and a second aerosol-generating element 460 comprising a rope formed from a plurality of twisted or braided fibres of aerosol-generating material. The aerosol-generating material from which the first aerosol-generating element 440 is formed is different from the aerosol-generating material from which the second aerosolgenerating element 460 is formed.

[0142] Referring again to Figure 3, the aerosol-generating article 300 has a cuboid shape and has a height (or thickness) extending in a z dimension, as measured between the first planar external surface 321 and the second planar external surface 322, 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 350 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 330 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.

[0143] During use of each of the aerosol-generating articles 300, and 400 the aerosol-generating elements 340, 440, and 460 are heated up to cause the aerosol-generating substrate to release volatile compounds, which are then entrained in air drawn through the air inlet 31 1 , 41 1 into the cavity 330, 430. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the aerosol-generating article 300, 400 through the air outlet 312, 412.

[0144] Figures 7 and 8 illustrate an aerosol-generating device 6000 configured for use with an aerosolgenerating article 600 comprising or consisting of aerosol-generating element 640. 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 a heater 6030 located within a housing 6040. The controller 6020 controls supply of power from the battery 6010 to the heater 6030. A cavity 6050 is defined in the device 6000, the cavity 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 cavity 6050 comprises an upper planar surface 6052 and a lower planar surface 6053. The heater 6030 is located in the lower planar surface 6053 to heat a lower surface of the aerosol-generating article 600 inserted into the cavity 6050. An air-flow path is configured to allow air to flow into the cavity 6050 from outside the device 6000.

[0145] Figure 10 illustrates the device 6000 of Figure 7 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 cavity 6050. Thus, there is a snug fit between the aerosol-generating article 600 and the device 6000. 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 air-flow path defined within the device. When a user has inserted the aerosol-generating article 600 into the cavity 6050, the device 6000 can be operated. The heater 6030 heats a lower surface of the aerosolgenerating article 600, and as a result the aerosol-generating element 640 of the aerosol-generating article 600 is heated. Volatile components of the aerosol-generating element 640 are evaporated and condense in longitudinal air-flow channels defined within the aerosol-generating article 600 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 cavity 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.

[0146] Although Figure 9 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 10 illustrates an alternative embodiment to that of Figure 9, with like features referred to by the same reference numbers but with the addition of a prime symbol ’. For the alternative embodiment of Figure 10, the entirety of aerosol-generating article 600’ is enclosed within the interior of aerosol-generating device 6000’.

[0147] 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 article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: a first external surface and a second external surface facing in substantially the opposite direction to the first external surface; a cavity between the first external surface and the second external surface; an airflow path defined through the aerosol-generating article between an air inlet and an air outlet, the airflow path extending through the cavity, and an aerosol-generating element located in the cavity, the aerosol-generating element comprising a rope formed from a plurality of twisted or braided fibres of aerosol-generating material.

2. An aerosol-generating article according to claim 1 , wherein the rope comprises at least 2 strands of aerosol-generating material.

3. An aerosol-generating article according to claim 1 or claim 2, wherein the rope comprises no more than 6 strands of aerosol-generating material.

4. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating material comprises at least one aerosol-generating substrate.

5. An aerosol-generating article according to claim 4, wherein the aerosol-generating substrate comprises tobacco.

6. An aerosol-generating article according to claim 5, wherein the aerosol-generating substrate comprises at least one of cast leaf tobacco material, extruded tobacco material, or tobacco cut filler material.

7. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating material comprises fibres of absorbent material with an aerosol-generating substrate sorbed on the absorbent material.

8. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating material comprises an aerosol former.

9. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating element comprises at least 10 percent by weight of aerosol former on a dry weight basis.

10. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating element has a diameter which is the same as the diameter of the cavity.1 1. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating element is compressible.

12. An aerosol-generating article according to any preceding claim, wherein the longitudinal axis of the rope is aligned with the longitudinal axis of the cavity.

13. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating article does not include a wrapper.

14. An aerosol-generating article according to any preceding claim, wherein the cavity comprises between 50 mg and 300 mg of the aerosol-generating element, for example between 100 mg and 200 mg, for example between 125 mg and 175 mg, for example between 140 mg and 160 mg, for example about 140 mg, or about 150 mg or about 160 mg.

15. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating element has a length of between 10 mm and 25 mm, for example between 15 mm and 20 mm, for example about 15 mm or about 17 mm, or about 20 mm.

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