Aerosol-generating article with aerosol-generating substrate

Abstract

There is provided an aerosol-generating article 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 and a second external surface facing in substantially the opposite direction to the first external surface. The aerosol-generating article further comprises a cavity between the first external surface and the second external surface. An airflow path is defined through the aerosol-generating article between an air inlet and an air outlet, the airflow path extending through the cavity. An aerosol-generating element is located in the cavity, the aerosol-generating element having at least one longitudinal surface, a first end surface, and a second end surface. The angle between the at least one longitudinal surface and at least one of the first and second end surfaces is less than 90 degrees.

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. This may be the case regardless of the way in which the aerosol-generating 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] 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 in which the delay between heating and aerosol delivery is reduced, and which produces a consistent aerosol over the full duration of the experience. It is also an objective of the present disclosure to provide an aerosol-generating article that can be manufactured relatively efficiently and cheaply.

[0006] 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 have at least one longitudinal surface, a first end surface, and a second end surface. The angle between the at least one longitudinal surface and at least one of the first and second end surfaces may be less than 90 degrees. 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 has at least one longitudinal surface, a first end surface, and a second end surface. The angle between the at least one longitudinal surface and at least one of the first and second end surfaces is less than 90 degrees.

[0007] The provision of an aerosol-generating element in which the angle between the at least one longitudinal surface and at least one of the first and second end surfaces is less than 90 degrees means that on at least one corner of the aerosol-generating element narrows to an edge more acute than 90 degrees. As a result, the mass of aerosol-generating substrate in the vicinity of the edge more acute than 90 degrees is reduced. The reduced mass of aerosol-generating substrate in this region may be more readily heated during the early stages of heating of the aerosol-generating element during use. As a result, during use aerosol may first be generated from the portion of aerosol-generating substrate near the edge more acute than 90 degrees. As the remainder of the aerosol-generating element warms up to a temperature required to generate an aerosol, more aerosol is progressively released from the remainder of the aerosol-generating element, the area of the aerosol-generating element generating an aerosol generally progressing away from the edge more acute than 90 degrees. 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.

[0008] The surface area of at least one of the first and second end surfaces may be greater than the transverse cross sectional area of the aerosol-generating article.

[0009] The angle between the at least one longitudinal surface and each of the first and second end surfaces may be less than 90 degrees.

[0010] This provision may provides a plurality of edges more acute than 90 degrees. This may further advantageously ensure that there is little or no delay between heating and aerosol delivery and may ensure that aerosol generation is more consistent over the full duration of the experience.

[0011] The angle between the at least one longitudinal surface and each of the first and second end surfaces may be between 30 degrees and 60 degrees. The angle between the at least one longitudinal surface and each of the first and second end surfaces may be about 45 degrees.

[0012] The first end surface may be parallel to the second end surface such that the aerosol-generating article has a constant length in the longitudinal direction.

[0013] This may ensure that the aerosol-generating element has a constant resistance to draw in the transverse direction. This may advantageously ensure that the entire mass of aerosol-generating substrate becomes depleted evenly.

[0014] The first end surface may be nonparallel to the second end surface such that the length of the aerosol-generating element varies in the longitudinal direction. This may result in the aerosol-generating element having a short portion and a long portion. In use, the short portion may heat up quicker than the long portion due to reduced thermal inertia. 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] The resistance to draw of the aerosol-generating element may vary in the transverse direction across the aerosol-generating element.

[0016] The aerosol-generating element is reflectively symmetrical about a longitudinally central transverse plane.

[0017] The first and second end surfaces may be flat surfaces. The provision of flat surfaces may advantageously simplify manufacture since the aerosol-generating element may be cut using a straight blade.

[0018] At least one of the first and second end surfaces may not be flat. For example, at least one of the first and second end surfaces may include one or more undulations, peaks, or troughs. At least one of the first and second end surfaces may include a plurality of faces, the faces not being co-planar. For example, the first end surface may include a first face and a second face, the first face and the second face not being co-planar. The angle between the at least one longitudinal surface and at least one of the first face and the second face of the first end surface may be less than 90 degrees. The angle between the at least one longitudinal surface and both of the first face and the second face of the first end surface may be less than 90 degrees.

[0019] The second end surface may include a first face and a second face, the first face and the second face not being co-planar. The angle between the at least one longitudinal surface and at least one of the first face and the second face of the second end surface may be less than 90 degrees. The angle between the at least one longitudinal surface and both of the first face and the second face of the second end surface may be less than 90 degrees.

[0020] This may lead to the aerosol-generating element having a short portion proximal to the central longitudinal axis of the aerosol-generating element. Where the air inlet and air outlet are aligned with the central longitudinal axis of the aerosol-generating article, the air inlet and air outlet are close to the shortest portion of the aerosol-generating element. This may advantageously ensure that the aerosol generated early during the experience is delivered to a user as soon as possible. This may also advantageously reduce the resistance to draw of the aerosol-generating article.

[0021] The aerosol-generating element may have a circular cross sectional shape such that the aerosolgenerating element has a single longitudinal surface.

[0022] The aerosol-generating element may have a polygonal cross sectional shape such that the aerosolgenerating element has a plurality of longitudinal surfaces. For example, the aerosol-generating element may have a rectangular cross sectional shape such that the aerosol-generating element has four longitudinal surfaces.

[0023] The provision of an aerosol-generating element having a rectangular cross sectional shape may advantageously ensure that the aerosol-generating element fills the cavity of the aerosol-generating article. In addition, the provision of an aerosol-generating element having a rectangular cross sectional shape may advantageously ensure that the aerosol-generating element is correctly orientated within the cavity of the aerosol-generating article. The aerosol-generating element may have a cross sectional shape which corresponds to the cross sectional shape of the interior of the cavity such that the aerosol-generating element substantially fills the cavity in a transverse direction.

[0024] The resistance to draw of the aerosol-generating article is greater than zero at all points in the transverse direction across the cavity.

[0025] In this way, the aerosol-generating element fills the cavity in the transverse direction such that there is not an unobstructed airflow path from the air inlet to the air outlet. This may advantageously ensure that the mainstream airflow is forced through the aerosol-generating article such that it is entrained with the generated aerosol. This may advantageously improve aerosol delivery.

[0026] The air inlet and air outlet may be aligned with the central longitudinal axis of the aerosol-generating article. Alternatively, at least one of the ait inlet and air outlet may not be aligned with the central longitudinal axis of the aerosol-generating article. For example, at least one of the air inlet and air outlet may be located closer to the side of the cavity which includes the angle between the at least one longitudinal surface and at least one of the first and second end surfaces which is less than 90 degrees. In some cases, both the air inlet and air outlet are located closer to the side of the cavity which includes the angle between the at least one longitudinal surface and at least one of the first and second end surfaces which is less than 90 degrees. This may mean that the air inlet and air outlet are close to the longest portion of the aerosolgenerating element. This may advantageously promote the mainstream airflow to pass through the longest portion of the aerosol-generating element which may improve the aerosol delivery from the aerosolgenerating element.

[0027] At least one of the air inlet and air outlet may be located closer to the side of the cavity does not include the angle between the at least one longitudinal surface and at least one of the first and second end surfaces which is less than 90 degrees. In some cases, both the air inlet and air outlet are located closer to the side of the cavity which does not include the angle between the at least one longitudinal surface and at least one of the first and second end surfaces which is less than 90 degrees. This may mean that the air inlet and air outlet are close to the shortest portion of the aerosol-generating element. This may advantageously ensure that the aerosol generated early during the experience is delivered to a user as soon as possible. This may also advantageously reduce the resistance to draw of the aerosol-generating article.

[0028] The aerosol-generating element may be compressible. This may advantageously ensure that the aerosol-generating element fills the cavity in the transverse direction.

[0029] 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.

[0030] 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.

[0031] 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.

[0032] The aerosol-generating article according to any of the aspects disclosed herein may have an airflow 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.

[0033] 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%.

[0034] 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 airflow 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

[0035] 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. The first external surface may be a planar surface. The second external surface may be a planar surface.

[0036] 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.

[0037] 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.

[0038] An aerosol-generating element is located in the cavity.

[0039] A corrugated layer may be positioned within the cavity.

[0040] The frame may be a planar frame.

[0041] 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.

[0042] 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.

[0043] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] The aerosol-generating element may comprise an aerosol-generating substrate.

[0052] 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.

[0053] 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.

[0054] The aerosol-generating substrate may comprise or consist of homogenised tobacco material, for example a reconstituted tobacco material or a cast leaf tobacco material.

[0055] 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.

[0056] 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.

[0057] The aerosol-generating substrate may be in the form of a sheet of aerosol-generating material. As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenised tobacco material, such as a cast leaf sheet. The aerosol-generating element may comprise a plug of aerosol-generating substrate circumscribed about the at least one longitudinal surface by a wrapper.

[0058] The aerosol-generating substrate may comprise a bound collection of strips, strands or particles of tobacco material. The aerosol-generating substrate may be in the form of a compressed plug of tobacco material; for example, in which a plug having a substantially circular cross-section in an initial state of the plug is compressed into a flatter cross-sectional profile in a subsequent state of the plug. The tobacco material may be enclosed by a wrapper. The aerosol-generating substrate may be in the form of strips, strands or particles of tobacco material bound together in a binder matrix.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] 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. 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.

[0067] 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.

[0068] 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.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] The aerosol-generating element may be a porous aerosol-generating element. 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.

[0077] 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.

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

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

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

[0081] As used herein, the term “aerosol-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.

[0082] 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.

[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-generating substrate or aerosol-generating article. As used herein with reference to the invention, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.

[0085] 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.

[0086] 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. A longitudinal direction may also be defined through the aerosol-generating element in which the longitudinal direction of the aerosol-generating element is parallel to the longitudinal direction of the aerosol-generating article.

[0087] As used herein, the term “transverse” refers to the direction which is perpendicular to the longitudinal direction of either the aerosol-generating article or aerosol-generating element.

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

[0089] As used herein, the term “homogenised tobacco material” encompasses any tobacco material formed by the agglomeration of particles of tobacco material. Sheets or webs of homogenised tobacco material are formed by agglomerating particulate tobacco obtained by grinding or otherwise powdering of one or both of tobacco leaf lamina and tobacco leaf stems. In addition, homogenised tobacco material may comprise a minor quantity of one or more of tobacco dust, tobacco fines, and other particulate tobacco 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.

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

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

[0092] 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 having at least one longitudinal surface, a first end surface, and a second end surface, wherein the angle between the at least one longitudinal surface and at least one of the first and second end surfaces is less than 90 degrees.

[0093] Example Ex2: An aerosol-generating article according to Ex1 , wherein the surface area of at least one of the first and second end surfaces is greater than the transverse cross sectional area of the aerosolgenerating article.

[0094] Example Ex3: An aerosol-generating article according to Ex1 or Ex2, wherein the angle between the at least one longitudinal surface and each of the first and second end surfaces is less than 90 degrees.

[0095] Example Ex4: An aerosol-generating article according to any preceding Example, wherein the angle between the at least one longitudinal surface and each of the first and second end surfaces is between 30 degrees and 60 degrees.

[0096] Example Ex5: An aerosol-generating article according to Ex4, wherein the angle between the at least one longitudinal surface and each of the first and second end surfaces is about 45 degrees.

[0097] Example Ex6: An aerosol-generating article according to any preceding Example, wherein the first end surface is parallel to the second end surface such that the aerosol-generating element has a constant length in the longitudinal direction.

[0098] Example Ex7: An aerosol-generating article according to any one of Examples Ex1 to Ex5, wherein the first end surface is nonparallel to the second end surface such that the length of the aerosol-generating element varies in the longitudinal direction.

[0099] Example Ex8: An aerosol-generating article according to Ex7, wherein the aerosol-generating element is reflectively symmetrical about a longitudinally central transverse plane.

[0100] Example Ex9: An aerosol-generating article according to any preceding Example, wherein the resistance to draw of the aerosol-generating element varies in the transverse direction across the aerosolgenerating element.

[0101] Example Ex10: An aerosol-generating article according to any preceding Example, wherein the first and second end surfaces are flat surfaces.

[0102] Example Ex1 1 : An aerosol-generating article according to any preceding Example, wherein the aerosol-generating element has a circular cross sectional shape such that the aerosol-generating element has a single longitudinal surface.

[0103] Example Ex12: An aerosol-generating article according to any one of Examples Ex1 to Ex10, wherein the aerosol-generating element has a polygonal cross sectional shape such that the aerosol-generating element has a plurality of longitudinal surfaces. Example Ex13: An aerosol-generating article according to Ex12, wherein the aerosol-generating element has a rectangular cross sectional shape such that the aerosol-generating element has four longitudinal surfaces.

[0104] Example Ex14: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating element has a cross sectional shape which corresponds to the cross sectional shape of the interior of the cavity such that the aerosol-generating element substantially fills the cavity in a transverse direction.

[0105] Example Ex15: An aerosol-generating article according to any preceding Example, wherein the resistance to draw of the aerosol-generating article is greater than zero at all points in the transverse direction across the cavity.

[0106] Example Ex16: An aerosol-generating article according to Ex15, wherein the resistance to draw of the aerosol-generating article between the air inlet and air outlet is at least 5 millimetre H2O.

[0107] Example Ex17: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating element is compressible.

[0108] Example Ex18: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating element comprises at least one aerosol-generating material, the at least one aerosolgenerating material comprising one or more organic materials.

[0109] Example Ex19: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating element comprises a plug of aerosol-generating material circumscribed about the at least one longitudinal surface by a wrapper.

[0110] Example Ex20: An aerosol-generating article according to Ex18 or Ex19, wherein the aerosolgenerating material comprises at least one aerosol former.

[0111] Example Ex21 : 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.

[0112] Example Ex22: 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.

[0113] Example Ex23: 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.

[0114] Example Ex24: 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.

[0115] Example Ex25: 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.

[0116] Example Ex26: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating element is a porous aerosol-generating element.

[0117] Examples will now be further described with reference to the figures in which: Figure 1 is a perspective side view of an aerosol-generating article according to a first embodiment of the present disclosure;

[0118] Figure 2 is a perspective side view of an aerosol-generating article according to a second embodiment of the present disclosure;

[0119] Figure 3 shows a perspective view of an aerosol-generating article according to a third embodiment of the present disclosure;

[0120] Figure 4 shows an exploded perspective view of the aerosol-generating article of Figure 3;

[0121] Figure 5 shows a cross sectional plan view of the aerosol-generating article of Figure 3;

[0122] Figure 6 shows a cross sectional plan view of an aerosol-generating article according to a further embodiment of the present disclosure;

[0123] Figure 7 shows a cross sectional plan view of an aerosol-generating article according to a further embodiment of the present disclosure;

[0124] Figure 8 shows a cross sectional plan view of an aerosol-generating article according to a further embodiment of the present disclosure;

[0125] Figure 9 shows a cross sectional plan view of an aerosol-generating article according to a further embodiment of the present disclosure;

[0126] Figure 10 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 9;

[0127] Figure 1 1 shows a schematic end view of the aerosol-generating device of Figure 10;

[0128] Figure 12 is a schematic view showing an aerosol-generating article (for example, the aerosolgenerating article of any of Figures 1 to 9) in engagement with the aerosol-generating device of Figure 8.

[0129] Figure 13 is a schematic view of an alternative embodiment to that of Figures 10 to 12, showing an aerosol-generating article in engagement with an aerosol-generating device.

[0130] 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 1 10 and a second external surface 120. The first and second external surfaces 1 10, 120 are flat or planar.

[0131] 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 120 may comprise or consist of aerosol-generating substrate.

[0132] A suitable aerosol-generating substrate may be homogenised tobacco.

[0133] 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.

[0134] 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 airflow path 230 is defined through the aerosol-generating article 200 between the first external surface 210 and a second external surface 220. The airflow path 230 extends between opposed first and second ends 201 , 202 of the aerosol-generating article 200. The first end 201 may define a distal end of the aerosol-generating article 200, and the second end 202 may define a proximal or mouth end of the aerosol-generating article. The airflow 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 an exploded view 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 430. 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 an aerosol-generating material in the form of tobacco cut filler and has an aerosol former content of 5 percent by weight on a dry weight basis.

[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 includes a longitudinal surface 360, a first end surface 361 , and a second end surface 362. The cross sectional shape of the aerosol-generating element 340 corresponds to the cross sectional shape of the cavity 330 such that the aerosol-generating element 340 fills the cavity 330 in the transverse direction. The aerosol-generating element 340 has a rectangular cross sectional shape when viewed in the x direction such that it includes four longitudinal surfaces 360. The angle 363 between a longitudinal surface 360 and the first end surface 361 is less than 90 degrees. The angle 363 between the longitudinal surface 360 and the first end surface 361 is about 45 degrees. In this way, the aerosol-generating element 340 includes a narrow portion in the region near the edge between the longitudinal surface 360 and the first end surface 361 . The angle between the longitudinal surface 360 and the second end surface 362 is 90 degrees.

[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. As with the aerosol-generating article 300 in Figure 5, the angle 463 between a longitudinal surface 460 and the first end surface 461 is less than 90 degrees. The angle 463 between the longitudinal surface 460 and the first end surface 461 is about 45 degrees. Unlike the aerosol-generating article 300 in Figure 5, the angle 464 between the longitudinal surface 460 and the second end surface 462 is less than 90 degrees. The angle 464 between the longitudinal surface 460 and the second end surface 462 is about 45 degrees. In this way, the aerosol-generating element 440 is reflectively symmetrical about a longitudinally central transverse plane such that the aerosol-generating element 440 includes a short side and a long side in the transverse direction.

[0142] Figure 7 shows a sectional plan view of a further aerosol-generating article 500. The aerosolgenerating article 500 is similar to aerosol-generating article 400. Features in common with aerosolgenerating article 400 are referred to with like reference signs but commencing with numeral 5 instead of numeral 4. The aerosol-generating element 540 in Figure 7 is the same shape as the aerosol-generating element 440 in Figure 6. Unlike in the examples shown in Figures 3 to 6, the air inlet 51 1 and air outlet 512 are not aligned with the central longitudinal axis of the aerosol-generating article 500. The air inlet 51 1 and air outlet 512 are longitudinally aligned with each other and are located closer to the side of the cavity which does not include the angle 563, 564 between the at least one longitudinal surface 560 and at least one of the first 561 and second end 562 surfaces which is less than 90 degrees. In this way, the air inlet 51 1 and air outlet 512 are located close to the shortest portion of the aerosol-generating element 540.

[0143] Figure 8 shows a sectional plan view of a further aerosol-generating article 600. The aerosolgenerating article 600 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 6 instead of numeral 3. As with the aerosol-generating article 300 in Figure 5, the angle 663 between a first longitudinal surface 660 and the first end surface 661 is less than 90 degrees. The angle 663 between the first longitudinal surface 660 and the first end surface 661 is about 45 degrees. Unlike the aerosol-generating article 300 in Figure 5, the angle 664 between a second longitudinal surface 670 and the second end surface 662 is less than 90 degrees. The angle 664 between the second longitudinal surface 670 and the second end surface 662 is about 45 degrees. The angle 663 between the first longitudinal surface 660 and the first end surface 661 is the same as the angle 664 between the second longitudinal surface 670 and the second end surface 662. In this way, the first end surface 661 and the second end surface 662 are parallel. The aerosol-generating element 640 therefore has a constant length in the longitudinal direction.

[0144] Figure 9 shows a sectional plan view of a further aerosol-generating article 700. The aerosolgenerating article 700 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 7 instead of numeral 3. The first end surface 761 comprises a first face 771 and a second face 772. The first face 771 and the second face 772 are not co-planar. The angle 763 between the angle 763, 773 between the at least one longitudinal surface 760 and each of the first face 771 and the second face 772 of the first end surface 761 is less than 90 degrees.

[0145] The second end surface 762 comprises a first face 774 and a second face 775. The first face 774 and the second face 775 are not co-planar. The angle 764, 776 between the at least one longitudinal surface 760 and each of the first face 775 and the second face 774 of the second end surface 766 is less than 90 degrees. Angles 763, 773, 764, and 776 are all 45 degrees. The result of this is that the aerosolgenerating element 740 has a short portion proximal to the central longitudinal axis of the aerosolgenerating element.

[0146] 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.

[0147] During use of each of the aerosol-generating articles 300, 400, and 500, the aerosol-generating element 340, 440, and 540 is 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 , and 51 1 into the cavity 330, 430, and 530. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the aerosol-generating article 300, 400, and 500 through the air outlet 312, 412, and 512.

[0148] Figures 10 and 1 1 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.

[0149] Figure 12 illustrates the device 6000 of Figure 10 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.

[0150] Although Figure 12 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 13 illustrates an alternative embodiment to that of Figure 12, with like features referred to by the same reference numbers but with the addition of a prime symbol ’. For the alternative embodiment of Figure 13, the entirety of aerosol-generating article 600’ is enclosed within the interior of aerosol-generating device 6000’.

[0151] 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 having at least one longitudinal surface, a first end surface, and a second end surface, wherein the angle between the at least one longitudinal surface and at least one of the first and second end surfaces is less than 90 degrees.

2. An aerosol-generating article according to claim 1 , wherein the surface area of at least one of the first and second end surfaces is greater than the transverse cross sectional area of the aerosol-generating article.

3. An aerosol-generating article according to claim 1 or claim 2, wherein the angle between the at least one longitudinal surface and each of the first and second end surfaces is less than 90 degrees.

4. An aerosol-generating article according to any preceding claim, wherein the angle between the at least one longitudinal surface and each of the first and second end surfaces is between 30 degrees and 60 degrees.

5. An aerosol-generating article according to claim 4, wherein the angle between the at least one longitudinal surface and each of the first and second end surfaces is about 45 degrees.

6. An aerosol-generating article according to any preceding claim, wherein the first end surface is parallel to the second end surface such that the aerosol-generating element has a constant length in the longitudinal direction.

7. An aerosol-generating article according to any one of claims 1 to 5, wherein the first end surface is nonparallel to the second end surface such that the length of the aerosol-generating element varies in the longitudinal direction.

8. An aerosol-generating article according to claim 7, wherein the aerosol-generating element is reflectively symmetrical about a longitudinally central transverse plane.

9. An aerosol-generating article according to any preceding claim, wherein the resistance to draw of the aerosol-generating element varies in the transverse direction across the aerosol-generating element.

10. An aerosol-generating article according to any preceding claim, wherein the first and second end surfaces are flat surfaces.1 1. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating element has a circular cross sectional shape such that the aerosol-generating element has a single longitudinal surface.

12. An aerosol-generating article according to any one of claims 1 to 10, wherein the aerosolgenerating element has a polygonal cross sectional shape such that the aerosol-generating element has a plurality of longitudinal surfaces.

13. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating element has a cross sectional shape which corresponds to the cross sectional shape of the interior of the cavity such that the aerosol-generating element substantially fills the cavity in a transverse direction.

14. An aerosol-generating article according to any preceding claim, wherein the resistance to draw of the aerosol-generating article is greater than zero at all points in the transverse direction across the cavity.

15. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating element is a porous aerosol-generating element.

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