Aerosol-generating article

Abstract

An aerosol-generating article (300) for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article (300) comprising a substrate sheet (330) comprising an aerosol-forming substrate (334) for producing an aerosol, in which the substrate sheet is rolled to form a rolled substrate sheet (332). The aerosol-generating article (300) is defined by an article length, an article width, and an article thickness, the article length and the article width being at least two times the article thickness. An aerosol-generating system is also provided.

Description

[0001] AEROSOL-GENERATING ARTICLE

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

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

[0004] However, a significant portion of the aerosol-forming substrate in these cylindrical aerosol-generating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-forming substrate contributes to the cost of manufacture and transport of the aerosol-generating article, but does not contribute to the aerosol delivered to an end user. This may be the case regardless of the way in which the aerosol-forming substrate is heated, for example regardless of whether a resistive or inductive heater is used and regardless of whether the aerosol-forming substrate is heated from the inside or the outside. Moreover, the components of these cylindrical aerosolgenerating articles normally need to have the same or very similar outer diameters so that they can be brought together, accurately positioned in co-axial alignment and wrapped in a cigarette paper. This can lead to increased cost and complexity of manufacture. During the manufacturing process, aerosol-forming substrate may be lost or wasted.

[0005] It is an aim of the present disclosure to provide an aerosol-generating article, in which a greater portion of an aerosol-forming substrate of the aerosol-generating article is sufficiently heated to form an aerosol during use. It is also an objective of the present disclosure to provide an aerosol-generating article that can be manufactured relatively efficiently and cheaply. It may be desirable to provide an aerosolgenerating article that can be manufactured with reduced loss or wastage of aerosol-forming substrate.

[0006] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article may comprise a substrate sheet comprising an aerosol-forming substrate for producing an aerosol. The substrate sheet may be a rolled substrate sheet. The aerosol-generating article may have an article length, an article width, and an article thickness. The article thickness may be less than the article length. The article thickness may be less than the article width. The article length and the article width may be at least two times the article thickness.

[0007] According to a first aspect of the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article may comprise a substrate sheet comprising an aerosol-forming substrate for producing an aerosol. The substrate sheet may be a rolled substrate sheet. The aerosol-generating article may be defined by an article length, an article width, and an article thickness, the article length and the article width being at least two times the article thickness.

[0008] 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-forming substrate of the aerosol-generating article to a temperature at which an aerosol is released, whilst minimising the risk of burning the hottest portion of the substrate closest to the heater. Alternatively, or in addition, this may reduce a time required to heat the aerosol-forming substrate sufficiently to release an aerosol.

[0009] Advantageously, providing an aerosol-generating article comprising a rolled substrate sheet may allow the aerosol-generating article to be manufactured on a high speed production line. The aerosolgenerating article may be assembled in very few steps.

[0010] Advantageously, providing an aerosol-generating article comprising a rolled substrate sheet comprising the aerosol-forming substrate, may result in less aerosol-forming substrate being lost and wasted during the manufacturing process. Advantageously, providing an aerosol-generating article comprising a rolled substrate sheet comprising the aerosol-forming substrate may reduce the risk of leakage of aerosol-forming substrate from the aerosol-generating article.

[0011] Advantageously, the rolled substrate sheet may provide a tension to the aerosol-generating article, thereby providing mechanical support to the aerosol-generating article.

[0012] For the purpose of the present disclosure, the “height” of the aerosol-generating article or rolled substrate sheet may also be referred to as the “thickness” of the aerosol-generating article or the rolled substrate sheet, respectively.

[0013] The article thickness of the aerosol-generating article may be the maximum thickness of the aerosol-generating article. In other words, the article thickness may be the thickness of the aerosolgenerating article at the thickest point aerosol-generating article. The thickness of the aerosol-generating article may vary across a cross-section of the aerosol-generating article and the article thickness may be the maximum thickness of the cross-section.

[0014] The substrate sheet may comprise or may at least partially be formed of a sheet of aerosol-forming substrate.

[0015] Preferably, the rolled substrate sheet is defined by a rolled length, and rolled width and a rolled height. Preferably, the rolled length extends parallel to the article length. Preferably, the rolled length is between 50 and 100 percent of the article length, preferably between 60 and 90 percent of the article length, preferably between 70 and 80 percent of the article length.

[0016] In some examples, the rolled length may be equal or substantially equal to the article length. The rolled width may be equal or substantially equal to the article width. The rolled height may be equal or substantially equal to the article height. The rolled width is preferably greater than the rolled thickness, preferably the rolled width is at least two time the rolled thickness. The rolled length is preferably greater than the rolled thickness, preferably the rolled length is at least two times the rolled thickness. The rolled length is preferably greater than the rolled width.

[0017] The rolled thickness of the rolled substrate sheet may be the maximum thickness of the rolled substrate sheet. In other words, the rolled thickness may be the thickness of the rolled substrate sheet at the thickest point of the rolled substrate sheet. The thickness of the rolled substrate sheet may vary across a cross-section of the rolled substrate sheet and the rolled thickness may be the maximum thickness of the cross-section.

[0018] The substrate sheet may have a Young’s modulus of between 0.5 MPa and 50 MPa, for example between 0.7 MPa and 10 MPa. The Young’s modulus of the substrate sheet may allow the substrate sheet to be rolled. The Young’s modulus of the substrate sheet may allow the substrate sheet to be rolled without breaking or becoming damaged.

[0019] As used herein "rolled" refers to a sheet that is curved, preferably without folding. So the sheet may have an elongate spiral or tubular shape. Preferably, the rolled substrate sheet may be rolled about a longitudinal axis of the aerosol-generating article. The rolled substrate sheet may be rolled about a central longitudinal axis of the aerosol-generating article. For example, the rolled substrate sheet may be rolled in an axial direction. The rolled substrate sheet may be substantially cylindrical. The rolled sheet may be rolled in an spiral, for example and Archimedean spiral. The rolled substrate sheet may be referred to as a wound substrate sheet. The rolled substrate sheet may be a helically wound substrate sheet. The term “rolled” may be used to describe a sheet that forms at least half of a full rotation or turn about an axis, preferably the longitudinal axis. For example, the angle between a start and end of the roll is greater than 180 degrees. Preferably, the sheet forms at least three quarters of a full rotation or turn about an axis, preferably the longitudinal axis. Preferably, the sheet forms at least a full rotation or turn about an axis, preferably the longitudinal axis. For example, the angle between a start and end of the roll is preferably greater than 360 degrees. A rolled substrate sheet forming one full rotation about an axis, preferably the longitudinal axis, may be referred to as a substrate sheet that is rolled once, or one time. The substrate sheet may be rolled at least once.

[0020] Preferably, the rolled substrate sheet at least partially overlaps with itself, for example when the angle between the start and end of the roll is greater than 360 degrees.

[0021] Preferably, the rolled substrate sheet is rolled at least two times, for example at least three, four or five times. For example, the rolled substrate sheet preferably forms at least 2 full turns, for example at least three, four or five full turns.

[0022] Preferably, the aerosol-generating article comprises a rolling adhesive configured to adhere at least two portions of the rolled substrate sheet to each other. Preferably, the rolling adhesive adheres at least two overlapping portions of the rolled substrate sheet to each other. Advantageously, the rolling adhesive may help prevent the rolled substrate sheet from unravelling. The rolling adhesive may comprise or consist of one or more of, for example, gum arabic, natural or synthetic resins, starches, hydroxyl propyl methyl cellulose, and varnish. Preferably, the rolling adhesive is not in contact with the aerosol-forming substrate.

[0023] The aerosol-generating article may comprise at least two of the substrate sheets. Preferably, the at least two substrate sheets are both rolled to form at least two rolled substrate sheets. The aerosolgenerating article may comprise at least two, at least three, at least four or at least five of the rolled substrate sheets. Preferably, the at least two rolled substrate sheets are sequentially rolled. Preferably, the at least two rolled substrate sheets form at least first and second concentric layers of the rolled substrate sheets.

[0024] Preferably, the aerosol-generating article comprises a layer adhesive configured to adhere the at least first and second concentric layers of the rolled substrate sheets to each other. Preferably, the aerosolgenerating article comprises a structural element at least partially encircled or at least partially circumscribed by the rolled substate sheet. Advantageously, the structural element may provide mechanical support to the aerosol-generating article. The structural element may advantageously provide an overall rigidity to the aerosol-generating article. The structural element is preferably radially central of the rolled substrate sheet.

[0025] The structural element may extend between 50 and 100 percent of the article length, preferably between 60 and 90 percent of the article length, preferably between 70 and 80 percent of the article length. Preferably, the structural element extends at least 50, 60, 70, 80, 90, 95, 98, or 99 percent, or substantially all, of the article length. Advantageously, the structural element may therefore provide structural support to the article across a large proportion of the aerosol-generating article.

[0026] Preferably, the structural element comprises a plurality of upward extending portions. Preferably, the structural element comprises a plurality of downwardly extending portions. For example, the structural element may comprise an arrangement of upwardly depending peaks and downwardly depending troughs.

[0027] The structural element may comprise at least one longitudinally extending channel or porosity forming an airflow path through the structural element. The airflow path may be defined through an airflow channel. The plurality of upwardly extending portions and the plurality of downwardly extending portions may be configured to form at least one airflow channel. The at least one airflow channel may extend between a proximal end and a distal end of the rolled substrate sheet. The at least one airflow channel may extend through a central portion of the rolled substrate sheet. Such a structure may allow for a low RTD airflow path to be defined through a passage of the rolled sheet, preferably, a central passage. Such a structure may allow for a low RTD airflow path to be defined through the aerosol-generating article.

[0028] The aerosol-generating article may comprise an air inlet, an air outlet and an airflow passage defined between the air inlet and the air outlet. The at least one airflow channel may extend between a proximal end and a distal end of the aerosol-generating article. The airflow passage may be at least partially defined by the at least one airflow channel. The at least one airflow channel may form or at least partially form the airflow passage.

[0029] Preferably, the structural element is a corrugated element comprising corrugations, for example the corrugated element may be formed of a corrugated sheet of material. Where the structural element is a corrugated element, it may be advantageous to manufacture the structural element using a process similar to that used to produced corrugated cardboard.

[0030] The use of a corrugated element may advantageously allow the production of an aerosol-forming article that has a extremely low RTD while still being sufficiently rigid to for a user to handle. Further, use of a corrugated element may allow an aerosol-forming article structural element to be produced using high speed production methods.

[0031] The corrugated element may define a plurality of longitudinally extending channels. The plurality of longitudinally extending channels may extend between a proximal end and a distal end of the corrugated element.

[0032] The corrugations of the corrugated element may be defined by a corrugation profile. Preferably, the corrugation profile is at least one of sinusoidal, or triangular, or rectangular, or trapezoidal, or toroidal, or parabolic.

[0033] The structural element may comprise cardboard, preferably corrugated cardboard. The structural element may comprise an aerosol-forming material. For example, the structural element may comprise cardboard and an aerosol-forming material. The structural element may be attached to the rolled substrate sheet. The structural element may be attached to the rolled substrate sheet by an element adhesive. The element adhesive may comprise or consist of one or more of, for example, gum arabic, natural or synthetic resins, starches, hydroxyl propyl methyl cellulose, and varnish. The element adhesive may comprise or consist of an aerosol-forming material. For example, the element adhesive may be applied to at least one of the plurality of upwardly extending portions and configured to contact a portion of the rolled sheet, for example a portion of the rolled substrate sheet facing and in contact with the structural element. The element adhesive may be applied to at least one of the plurality of downwardly extending portions and configured to contact a portion of the rolled substrate sheet, for example a portion of the rolled substrate sheet facing and in contact with the structural element.

[0034] The structural element may comprise one or more perforations or holes for air to flow through the structural element. An article air flow passage extending from an article upstream end to an article downstream end may extend through the one or more perforations or holes. The one or more perforations or holes may place adjacent longitudinally extending channels, for example longitudinally extending channels formed by corrugations of the corrugated element, in fluid communication. Advantageously, the perforations or holes may allow adjustment of the RTD of the aerosol-generating article.

[0035] The substrate sheet may comprise a first section comprising the aerosol-forming substrate and a second section comprising 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. For example, the second section may comprise or consist of paper. Preferably, the second section does not contain the aerosol-forming substrate.

[0036] The first section may be adjacent to the second section along the rolled length. The second section may be located towards the proximal end of the rolled substrate sheet, preferably at the proximal end of the rolled substrate sheet. The first section may be located towards the distal end of the rolled substrate sheet, preferably at the distal end of the rolled substrate sheet. Preferably, the first section is located between the distal end and the proximal end of the rolled substrate sheet.

[0037] The substrate sheet may comprise a third section comprising a cellulosic material. For example, the second third may comprise or consist of paper. The first section may be adjacent to the third section along the rolled length. Preferably, the first section is situated between the second section and the third section along the rolled length. Preferably, the third section is located towards the distal end of the rolled substrate sheet, preferably at the distal end of the rolled substrate sheet.

[0038] Advantageously, the provision of the section and optionally the third section may reduce the risk of loss or damage to the aerosol-forming substrate prior to use because the aerosol-forming substrate may be protected from an external environment by other sections of the rolled substrate sheet, or aerosolgenerating article.

[0039] Any rolling adhesive, layer adhesive, or element adhesive applied to rolled substrate sheet is preferably applied to at least one of the second section, third section, or both the second and third section. Preferably, no adhesive, such as the rolling adhesive, layer adhesive or element adhesive, is applied to the first section. In particular, preferably no adhesive is applied to the aerosol-forming substrate. Advantageously, the adhesive such as the rolling adhesive, layer adhesive or element adhesive, being applied to the second or third section of the rolled substrate sheet, not the aerosol-forming substrate, means that the adhesive does not interfere with aerosol formation.

[0040] The aerosol-generating article may comprise a wrapper that encircles or circumscribes the rolled substrate sheet. The wrapper may be a rolled wrapper that is rolled around the rolled substrate sheet. The wrapper may be rolled about a central longitudinal axis of the aerosol-generating article. For example, the wrapper may be rolled in an axial direction.

[0041] Preferably, the wrapper is rolled around the aerosol-forming substrate.

[0042] Advantageously, the wrapper may provide a barrier between the rolled substrate sheet, preferably the aerosol-forming substrate, and the external environment. The wrapper may therefore protect the rolled substrate sheet, preferably the aerosol-forming substrate. The wrapper may reduce the risk of damage to the aerosol-forming substrate. Advantageously, the wrapper may the reduce the risk of loss of aerosolforming substrate from the aerosol-generating article prior to use.

[0043] The wrapper may comprise or consist of a cellulosic material, for example the wrapper may be a paper wrapper.

[0044] The aerosol-generating article may comprise a wrapper adhesive configured to adhere the wrapper to the substrate sheet.

[0045] The wrapper may be integrally formed with the rolled substrate sheet. For example, the substrate sheet may comprise a fourth section, in which the fourth section comprises the wrapper. The fourth section may extend along the full rolled length. The fourth section may be adjacent to the first section of the rolled substrate sheet in an axial direction. Preferably, the fourth section may be adjacent to the first section, second section and third section of the rolled substrate sheet in an axial direction.

[0046] The wrapper adhesive may adhere the fourth section to at least one of the second or third section of the substrate sheet.

[0047] The wrapper may be separate to the substrate sheet. In other words, the wrapper may not be integrally formed with the rolled substrate sheet.

[0048] The wrapper adhesive may adhere the wrapper to at least one of the second or third section of the substrate sheet.

[0049] The wrapper adhesive may not be in contact with the aerosol-forming substrate. Advantageously, the adhesive therefore does not interfere with aerosolisation of the aerosol-forming substrate.

[0050] Optionally, the aerosol-generating article may comprise a mouthpiece element. Preferably, the mouthpiece element is located at the proximal end of the aerosol-generating article. The mouthpiece element may be a mouthpiece filter.

[0051] The aerosol-generating article may be a planar aerosol-generating article. As used herein, the term “planar” may refer to a component having two dimensions, for example a length and a width, each being at least 2, 2.5, 3, 5, or 10 times a third dimension, for example a thickness, each of those three dimensions being perpendicular to one another.

[0052] The aerosol-generating article may have a length extending in an x direction, a width extending in a y direction, and a height extending in a z direction. The aerosol-generating article may have a base defined by the length extending in the x direction, and the width extending in the y direction.

[0053] The height of the aerosol-generating article may be less than both of the length and width of the aerosol-generating article. According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising an aerosolforming substrate for producing an aerosol, the aerosol-generating article comprising a substantially planar upper surface defined by a length extending in an x direction and a width extending in a y direction, and a substantially planar lower surface defined by a length extending in an x direction and a width extending in a y direction. The substantially planar upper surface and the substantially planar lower surface may be vertically spaced from each other by a height defined in a z direction.

[0054] 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-forming substrate of the aerosol-generating article to a temperature at which an aerosol is released, whilst minimising the risk of burning the hottest portion of the substrate closest to the heater. Alternatively, or in addition, this may reduce a time required to heat the aerosol-forming substrate sufficiently to release an aerosol.

[0055] 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.

[0056] 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%.

[0057] 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-forming 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-forming substrate

[0058] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer. At least one of the first planar layer, the second planar layer and the corrugated layer may comprise or consist of an aerosol-forming substrate.

[0059] The use of a corrugated structure in the aerosol-generating article may advantageously allow the production of an aerosol-generating article that has extremely low RTD while still being sufficiently rigid to for a user to handle. Further, use of a corrugated structure may allow a low density, low RTD, aerosolgenerating article to be produced using high speed production methods similar to those used for production of corrugated cardboard.

[0060] Preferably, the corrugated layer is the structural element.

[0061] Preferably, the wrapper forms an outer surface of the aerosol-generating article. The outer surface of the aerosol-generating article comprises the first planar layer and the second planar layer.

[0062] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article may comprise a first planar external surface, a second planar external surface, a cavity and a frame. The frame may be positioned between the first planar external surface and the second planar external surface. The frame may at least partially defines the cavity. The aerosol-generating article may comprises an aerosol-forming substrate. The aerosol-generating article may comprise an air inlet and an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity.

[0063] Preferably, the rolled substrate sheet is arranged between the first planar external surface and the second planar external surface.

[0064] Preferably, the rolled substrate sheet is positioned within the cavity. Preferably, the aerosol-forming substrate is positioned within the cavity. Preferably, the aerosol-forming substrate is positioned in the airflow passage.

[0065] 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.

[0066] 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 aerosol-forming material. The cavity may be substantially empty.

[0067] Aerosol-forming substrate may be positioned within the cavity.

[0068] A corrugated layer may be positioned within the cavity.

[0069] The frame may be a planar frame.

[0070] 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.

[0071] 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.

[0072] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0073] 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.

[0074] 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.

[0075] The aerosol-generating article of any of the aspects of the present disclosure may have an article 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.

[0076] The aerosol-generating article may have an article 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.

[0077] The aerosol-generating article may have an article thickness (for example, a z dimension) of between 1 millimetres and 10 millimetres, for example between 1 .2 millimetres and 8 millimetres, for example between 1 .4 millimetres and 7 millimetres, for example between 1 .6 millimetres and 6 millimetres, for example between 1 .7 millimetres and 5 millimetres, for example about 1 .7 millimetres, or about 4.5 millimetres, or about 2 millimetres, or about 3 millimetres, or about 4 millimetres.

[0078] 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.

[0079] The aerosol-generating article may consist entirely of aerosol-forming substrate. Alternatively, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-generating article.

[0080] The aerosol-forming substrate may comprise nicotine. Nicotine may be present in the form of a tobacco material or may be in the form of a nicotine extract.

[0081] The aerosol-forming substrate may comprise one or more organic materials such as tobacco, mint, tea and cloves. The aerosol-forming substrate may comprise one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenised tobacco such as cast leaf, extruded tobacco, expanded tobacco, aerosol-generating films and gel compositions.

[0082] The aerosol-forming substrate may comprise or consist of homogenised tobacco material, for example a reconstituted tobacco material or a cast leaf tobacco material.

[0083] The aerosol-forming substrate may be in the form of shredded aerosol-generating material. The shredded aerosol-generating material may comprise one or more of: strips and strands of 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.

[0084] The aerosol-forming substrate may be cut filler. The aerosol-forming substrate may be tobacco cut filler. The cut filler may comprise one or more of bright tobacco, dark tobacco, aromatic tobacco and filler tobacco. Examples of bright tobaccos are Flue-Cured Brazil, Indian Flue-Cured, Chinese Flue-Cured, US Flue-Cured such as Virginia tobacco, and Flue-Cured from Tanzania. Examples of aromatic tobaccos are Oriental Turkey, Greek Oriental, semi-oriental tobacco but also Fire Cured, US Burley, such as Perique, and Rustica. Examples of dark tobacco are Dark Cured Brazil Galpao, Burley Malawi or other African Burley, Sun Cured or Air Cured Indonesian Kasturi. As used herein, the term “cut filler” is used to describe a blend of shredded plant material, such as tobacco plant material, including, in particular, one or more of leaf lamina, processed stems and ribs, homogenised plant material.

[0085] The aerosol-forming substrate may be in the form of a sheet of aerosol-generating material. As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenised tobacco material, such as a cast leaf sheet.

[0086] The aerosol-forming substrate may comprise a bound collection of strips, strands or particles of tobacco material. The aerosol-forming substrate may be in the form of a compressed plug of tobacco material; for example, in which a plug having a substantially circular cross-section in an initial state of the plug is compressed into a flatter cross-sectional profile in a subsequent state of the plug. The tobacco material may be enclosed by a wrapper. The aerosol-forming substrate may be in the form of strips, strands or particles of tobacco material bound together in a binder matrix.

[0087] The aerosol-forming substrate may comprise one or more aerosol-formers. Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosol-formers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosol-former to be or comprise one or both of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0088] The aerosol-forming substrate may have an aerosol-former content greater than or equal to 1 , 2, 5, 10, or 15 percent by weight on a dry weight basis. The aerosol-forming substrate may have an aerosolformer 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.

[0089] The aerosol-forming substrate may have an aerosol-former content less than or equal to 30 percent by weight on a dry weight basis, less than or equal to 25 percent by weight on a dry weight basis, or less than or equal to 20 percent by weight on a dry weight basis. That is, the aerosol-generating material may have an aerosol-former content less than or equal to 30 by weight on a dry weight basis, less than or equal to 25 by weight on a dry weight basis, or less than or equal to 20 by weight on a dry weight basis.

[0090] The aerosol-forming substrate may have an aerosol-former content between 1 percent and 30 percent by weight on a dry weight basis, between 1 percent and 25 percent by weight on a dry weight basis, or between 1 percent and 20 percent by weight on a dry weight basis.

[0091] The aerosol-forming substrate may comprise at least 50 percent by weight of aerosol former, at least 60 percent by weight of aerosol former, or at least 70 percent by weight of aerosol former.

[0092] The aerosol-forming substrate may comprise less than or equal to 85 percent by weight of aerosol former, less than or equal to 80 percent by weight of aerosol former, or less than or equal to 75 percent by weight of aerosol former.

[0093] The aerosol-forming substrate may comprise between 50 percent and 85 percent by weight of aerosol former, between 50 percent and 80 percent by weight of aerosol former, or between 50 percent and 75 percent by weight of aerosol former.

[0094] The aerosol-forming substrate may comprise nicotine. The aerosol-forming substrate may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0095] The aerosol-forming substrate may comprise at least 0.5 percent by weight of nicotine, at least 1 percent by weight of nicotine, at least 1 .5 percent by weight of nicotine, or at least 2 percent by weight of nicotine.

[0096] The aerosol-forming substrate may comprise one or more flavourants. The one or more flavourants may comprise one or more of: one or more essential oils such as eugenol, peppermint oil and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and a herbaceous material. Suitable herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavourants may comprise a tobacco material. The aerosol-forming substrate may comprise one or more botanicals. For example, the aerosolforming substrate may comprise about 1 to 90 %, for example about 15 to 55 %, preferably of about 20 to 35 %, of botanicals such as Clove, Echinacea sp., Fennel, Ginger, Hawthorn berry, Elderberry, Monarda, Mullein leaves, Nettle, Plantain, Turmeric, Yarrow, Rooibos, Star Anise, Thyme, Anethum, Chamomile and compounds of those.

[0097] The aerosol-forming substrate may have a moisture content of about 5 to 25%, preferably of about 7 to 15%, at final product state. For example, the aerosol-forming substrate may be a homogenised tobacco material with a moisture of about 5 to 25%, preferably of about 7 to 15%, at final product state.

[0098] The aerosol-forming substrate may comprise a binder. For example, the aerosol-forming substrate may comprise about 1 to 10%, preferably of about 1 to 5%, of a binder such as any of common gums or pectins used in food and beverage (F&B) industries. Preferred binders may be natural pectins, such as fruit, for example citrus, or tobacco pectins; guar gums, land locust bean gums, such as hydroxyethyl and / or hydroxypropyl of those; starches, such as modified or derivatized starches; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl, celluloses; dextran; and xanthan gum. A preferable binder is guar.

[0099] The aerosol-forming substrate may comprise, or consist of, a solid aerosol-forming material. The aerosol-forming substrate may comprise a liquid aerosol-forming material, for example a liquid aerosolforming material retained within a porous matrix. The aerosol-forming substrate may comprise a gel aerosol-forming material.

[0100] According to a second aspect of present disclosure, an aerosol-generating device for receiving an aerosol-generating article as disclosed herein, or an aerosol-forming substrate as disclosed herein, may comprise a cavity dimensioned to receive at least a portion of the aerosol-generating article or aerosolforming 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 aerosol-generating device is configured to heat an aerosol-forming substrate, for example an aerosol-forming substrate that is a component part of an aerosol-generating article, to form an aerosol, for example an inhalable aerosol.

[0101] 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.

[0102] 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.

[0103] 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. According to the present disclosure, there may be provided an aerosol-generating system. The system may comprise an aerosol-generating article as described herein, for example according to the first aspect. The system may comprise an aerosol-generating device for use with the aerosol-generating article to generate an inhalable aerosol.

[0104] According to a second aspect of the disclosure, there is provided an aerosol-generating system comprising an aerosol-generating article according to the first aspect and an aerosol-generating device for use with the aerosol-generating article to generate an inhalable aerosol. The aerosol-generating device may comprise a chamber for receiving at least a portion of the aerosol-generating article. The aerosolgenerating device may comprise an electric heater arranged to heat at least part of the aerosol-generating article when the aerosol-generating article is received within the chamber. The system may comprise an aerosol-generating device as described herein, for example according to the second aspect.

[0105] As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol.

[0106] As used herein, the term “aerosol-forming substrate” may refer to a substrate capable of releasing an aerosol or volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. An aerosol-forming substrate may comprise an aerosol-forming material. An aerosol-forming substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. An aerosol-forming substrate may conveniently be part of an aerosol-generating article or smoking article.

[0107] 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.

[0108] As used herein, the term “aerosol generating system” refers to a combination of an aerosolgenerating device and one or more aerosol-forming articles for use with the device. An aerosol-generating system may include additional components, such as a charging unit for recharging an on-board electric power supply in an electrically operated or electric aerosol-generating device.

[0109] As used herein, the term “aerosol former” may refer to any suitable known compound or mixture of compounds that, in use, facilitates formation of an aerosol. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-forming substrate or aerosol-generating article.

[0110] As used herein with reference to the invention, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.

[0111] 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.

[0112] 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.

[0113] As used herein, the term “sheet” denotes a laminar element having a width and length substantially greater than the thickness thereof. The width of a sheet may be greater than 10 mm, preferably greater than 20 mm or 30 mm. In certain embodiments, sheets of material for use in forming aerosol-forming substrates as described herein may have a thickness of between 10 irn and about 1000 pirn, for example between 10 pm and about 300 pm.

[0114] 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.

[0115] 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.

[0116] 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.

[0117] 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.

[0118] Ex1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: a substrate sheet comprising an aerosol-forming substrate for producing an aerosol, in which the substrate sheet is rolled to form a rolled substrate sheet, wherein the aerosol-generating article is defined by an article length, an article width, and an article thickness, the article length and the article width being at least two times the article thickness.

[0119] Ex1 a. The aerosol-generating article according to example Ex1 , in which the rolled substrate sheet is rolled about a longitudinal axis of the aerosol-generating article.

[0120] Ex1 b. The aerosol-generating article according to example Ex1 or Ex2, in which the rolled substrate sheet is defined by a rolled length extending parallel to the article length, in which the rolled length is between 50 and 100 percent of the article length, preferably between 60 and 90 percent of the article length, preferably between 70 and 80 percent of the article length.

[0121] Ex2. The aerosol-generating article according to any preceding example, in which the rolled substrate sheet is rolled at least two times, for example at least three, four or five times. Ex3. The aerosol-generating article according to example Ex2, comprising a rolling adhesive configured to adhere two portions of the rolled substrate sheet to each other.

[0122] Ex4. The aerosol-generating article according to any preceding example, comprising at least two rolled substrate sheets, for example at least three, four or five rolled substrate sheets.

[0123] Ex5. The aerosol-generating article according to example Ex4, in which the rolled substrate sheets are sequentially rolled to form at least first and second concentric layers of the rolled substrate sheets.

[0124] Ex6. The aerosol-generating article according to example Ex5, comprising a layer adhesive configured to adhere the first and second concentric layers of the rolled substrate sheets to each other.

[0125] Ex7. The aerosol-generating article according to any preceding example, comprising a structural element at least partially circumscribed by the rolled substrate sheet.

[0126] Ex8. The aerosol-generating article according to example Ex7, in which the structural element comprises a plurality of upwardly extending portions and downwardly extending portions configured to allow at least one airflow channel to extend between a proximal end and a distal end of the rolled substrate sheet.

[0127] Ex9. The aerosol-generating article according to example Ex7 or Ex8, wherein the structural element is a corrugated element comprising corrugations.

[0128] Ex10. The aerosol-generating article according to example Ex9, in which the corrugations are defined by a corrugation profile, in which the corrugation profile is at least one of sinusoidal, or triangular, or rectangular, or trapezoidal, or toroidal, or parabolic.

[0129] Ex1 1 . The aerosol-generating article according to any one of examples Ex7 to Ex10, in which the structural element comprises cardboard.

[0130] Ex12. The aerosol-generating article according to any one of examples Ex7 to Ex1 1 , in which the structural element extends between 50 and 100 percent of the article length, preferably between 60 and 90 percent of the article length, preferably between 70 and 80 percent of the article length.

[0131] Ex13. The aerosol-generating article according to any preceding example, in which the rolled substrate sheet comprises a first section comprising the aerosol-forming substrate and a second section comprising a cellulosic material, for example paper.

[0132] Ex14. The aerosol-generating article according to example Ex13, in which the first section is adjacent to the second section along the rolled length.

[0133] Ex15. The aerosol-generating article according to example Ex13 or Ex14, comprising a third section comprising a cellulosic material, for example paper.

[0134] Ex16. The aerosol-generating article according to example Ex15, and in which the first section is adjacent to the third section along the rolled length, such that the first section is situated between the second section and the third section along the rolled length.

[0135] Ex17. The aerosol-generating article according to any preceding example, comprising a wrapper that circumscribes the rolled substrate sheet.

[0136] Ex18. The aerosol-generating article according to example Ex17, in which the wrapper comprises or consists of a cellulosic material, for example paper.

[0137] Ex19. The aerosol-generating article according to example Ex17 or Ex18, in which the wrapper is integrally formed with the rolled substrate sheet.

[0138] Ex20. The aerosol-generating article according to example Ex17 or Ex18, in which the wrapper is separate to the rolled substrate sheet. Ex21 . The aerosol-generating article according to any of examples Ex17 to Ex20, comprising a wrapper adhesive configured to adhere the wrapper to the rolled substrate sheet.

[0139] Ex22. The aerosol-generating article according to any of examples Ex17 to Ex21 , in which the wrapper forms an outer surface of the aerosol-generating article.

[0140] Ex23. The aerosol-generating article according to example Ex22, in which the outer surface of the aerosol-generating article comprises a first planar layer and a second planar layer.

[0141] Ex24. The aerosol-generating article according to any one of examples Ex1 to Ex21 , comprising a first planar external surface and a second planar external surface, in which the rolled substrate sheet is arranged between the first planar external surface and the second planar external surface.

[0142] Ex25. The aerosol-generating article according to example Ex24, comprising a frame positioned between the planar upper external layer and the planar lower external layer.

[0143] Ex26. The aerosol-generating article according to example Ex25, in which the frame at least partially defines a cavity, wherein the rolled substrate sheet is positioned within the cavity.

[0144] Ex27. The aerosol-generating article according to any preceding example, comprising an air inlet, an air outlet, and an airflow passage extending between the air inlet and the air outlet.

[0145] Ex28. The aerosol-generating article according to any preceding example, comprising a mouthpiece element.

[0146] Ex29. An aerosol-generating system comprising: an aerosol-generating article according to any preceding example; and an aerosol-generating device, the aerosol-generating device comprising: a chamber for receiving at least a portion of the aerosol-generating article; and an electric heater arranged to heat at least part of the aerosol-generating article when the aerosol-generating article is received within the chamber.

[0147] Examples will now be further described with reference to the figures in which:

[0148] Figure 1 is a perspective side view of an aerosol-generating article according to a first embodiment of the present disclosure;

[0149] Figure 2 is a perspective side view of an aerosol-generating article according to a second embodiment of the present disclosure;

[0150] Figure 3 is a schematic end view of an aerosol-generating article according to a third embodiment of the present disclosure;

[0151] Figure 4 is a schematic side view of the aerosol-generating article of figure 3;

[0152] Figure 5 is a schematic plan view of the aerosol-generating article of figure 3;

[0153] Figure 6 shows a schematic illustration of a corrugated element as used in the aerosol-generating article of figure 3;

[0154] Figure 7 shows a perspective view of an aerosol-generating article according to a fourth embodiment of the present disclosure;

[0155] Figure 8 shows an exploded perspective view of the aerosol-generating article of figure 7;

[0156] Figure 9 shows a further exploded perspective view of the aerosol-generating article of figure 7;

[0157] Figure 10 shows a schematic transverse cross-sectional view of the aerosol-generating article of figure 7; Figure 1 1 shows a schematic longitudinal cross-sectional view of the aerosol-generating article of figure 7;

[0158] Figure 12 shows a schematic transverse cross-sectional view of an aerosol-generating article according to a fifth embodiment of the present disclosure;

[0159] Figure 13 shows a schematic side view of an aerosol-generating article according to a sixth embodiment of the present disclosure;

[0160] Figure 14 shows a schematic transverse cross-sectional view of an aerosol-generating article according to a seventh embodiment of the present disclosure;

[0161] Figure 15A shows a schematic transverse cross-sectional view of a rolled substrate sheet according to an eighth embodiment of the present disclosure;

[0162] Figure 15B shows a schematic plan view of the rolled substrate sheet of figure 15A;

[0163] Figure 15C shows a schematic perspective view of the rolled substrate sheet of figure 15A;

[0164] Figure 16 shows a schematic transverse cross-sectional view of an aerosol-generating article comprising the rolled substrate sheet of figures 15A-15C;

[0165] Figure 17 shows a schematic view of an aerosol-generating device according to an embodiment of the present disclosure, the device configured to engage with an aerosol-generating article, for example the aerosol-generating article of any of figures 1 to 14 or figure 16;

[0166] Figure 18 shows a schematic end view of the aerosol-generating device of figure 17;

[0167] Figure 19 is a schematic view showing an aerosol-generating article (for example, the aerosolgenerating article of any of figures 1 to 14 or figure 16) in engagement with the aerosol-generating device of figure 17; and

[0168] Figure 20 is a schematic view of an alternative embodiment to that of figures 17 to 19, showing an aerosol-generating article in engagement with an aerosol-generating device.

[0169] Figure 1 illustrates a perspective side view of an aerosol-generating article 100 according to a first embodiment of the present disclosure. The aerosol-generating article 100 has upper and lower surfaces 1 10, 120 which are flat or planar.

[0170] The aerosol-generating article 100 comprises an aerosol-forming substrate (not shown). In one embodiment, the aerosol-generating article 100 may consist substantially of aerosol-forming substrate. In another embodiment, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-generating article 100. The aerosol-forming substrate may be enclosed within an interior of the aerosol-generating article 100. The aerosol-forming substrate may at least partially define an exterior of the aerosol-generating article 100; for example, one or both of the upper and lower surfaces 1 10, 120 may comprise or consist of aerosol-forming substrate.

[0171] A suitable aerosol-forming substrate may be homogenised tobacco.

[0172] 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.

[0173] Figure 2 illustrates a perspective side view of an aerosol-generating article 200 according to a second embodiment of the present disclosure, being a variant of aerosol-generating article 100. Features in common with aerosol-generating article 100 are referred to with like reference signs but commencing with numeral 2 instead of numeral 1 . An air flow path 230 is defined through the aerosol-generating article 200 between the upper and lower surfaces 210, 220. The air flow path 230 extends between opposed first and second ends 201 , 202 of the aerosol-generating article 200. The first end 201 may define a distal end of the aerosol-generating article 200, and the second end 202 may define a proximal or mouth end of the aerosol-generating article. The air flow path 230 may be directed towards a mouth of a user to allow a user to inhale aerosol generated in consequence of heating of aerosol-forming substrate of the aerosolgenerating article 200.

[0174] Figures 3, 4, and 5 illustrate respectively an end view, a side view, and a plan view of an aerosolgenerating article 300 according to a third embodiment of the present disclosure. The aerosol-generating article 300 comprises a planar upper layer 310, a planar lower layer 320, and an intermediate or separation layer 340, which in this element may be a structural element 348 arranged between the upper layer 310 and lower layer 320.

[0175] The planar upper layer 310 and planar lower layer 320 are formed from a substrate sheet 330 comprising an aerosol-forming substrate 334. The substrate sheet 330 forms a rolled substrate sheet 332, rolled about the longitudinal x-axis of the aerosol-generating article 300. In this example, the rolled substrate sheet 332 is rolled one full turn about the x-axis and partially overlaps itself. The aerosol-generating article comprises an adhesive (not shown) to adhere the planar upper layer 310 to an overlapping portion of the rolled substrate sheet 332.

[0176] The substrate sheet 330 has a sheet thickness of between 30 and 150 microns. The rolled substrate sheet 332 circumscribes the structural element 348. The rolled substrate sheet 332 has a rolled thickness of between 3000 and 3750 micrometres.

[0177] The aerosol-forming substrate 334 may be any suitable aerosol-forming substrate. A suitable aerosol-forming substrate may be homogenised tobacco. The structural element 348 is a corrugated element formed from a corrugated sheet of cardboard 345, having a plurality of substantially parallel peaks and troughs. The plurality of parallel corrugations are defined by a corrugation profile which, as seen in figure 6, is approximately sinusoidal.

[0178] Figure 6 illustrates the corrugated sheet of cardboard 345. The corrugations have an amplitude 346 of 3 millimetres and a wavelength 347 of 3 millimetres. The sheet of cardboard 345 forming the intermediate layer 340 has a thickness of 300 microns.

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

[0180] The aerosol-generating article 300 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (or thickness), extending in a z dimension, of between 3 and 4 millimetres, preferably 3.6 millimetres.

[0181] The rolled substrate sheet 332 has a rolled length that is equal to the article length. The rolled substrate sheet 332 has a rolled thickness that is equal to the article thickness. The rolled substrate sheet 332 has a rolled width that is equal to the article width.

[0182] Corrugations of the intermediate layer 340 form a first set of longitudinally extending channels 361 that are bounded by the upper layer 310 and the intermediate layer 340, and a second set of longitudinally extending channels 362 bounded by the lower layer 320 and the intermediate layer 340. The first and second sets of longitudinally extending channels 361 , 362 extend through the length of the corrugated element 348 between a proximal end 371 of the corrugated element 348 and a distal end 372 of the corrugated element 348. The longitudinally extending channels 361 , 362 define an air-flow path through the corrugated element 348. The air-flow path, therefore, passes over both sides of the corrugated element 348. The porosity of the aerosol-generating article along the air-flow path is in the region of 90 %. This provides a very low resistance to draw (RTD) of less than 5 mm H2O. In fact, the RTD is close to zero.

[0183] During use of the aerosol-generating article 300, the aerosol-forming substrate 334 is heated up to cause the aerosol-forming substrate 334 to release volatile compounds, which are then entrained in air drawn into the channels 361 , 362 via the distal end 372. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the channels 361 , 362 of the aerosol-generating article 300 via the proximal end 371 .

[0184] Figure 7 shows an aerosol-generating article 400 according to a fourth embodiment of the present disclosure. The aerosol-generating article 400 comprises a first planar external layer 424 forming a first planar external surface 421 , a second planar external layer 425 forming a second planar external surface 422, and a frame 450 positioned between the first planar external layer 424 and the second planar external layer 425. The second planar external surface 422 is positioned parallel to the first planar external surface 421 .

[0185] Figures 8 and 9 show exploded views of the aerosol-generating article 400 of figure 7. The frame 450 circumscribes and at least partially defines a cavity 430. Figure 8 shows the cavity 430 in an empty state. Figure 9 shows the aerosol-generating article 400 with a rolled substrate sheet 432 and structural element 448 positioned in the cavity 430. Figures 10 and 1 1 show respective transverse and longitudinal cross-sectional views of the aerosol-generating article 400 when the rolled substrate sheet 432 and structural element 448 are positioned in the cavity 430.

[0186] The first planar external layer 424 and the second planar external layer 425 are made from cigarette paper having a thickness of 35 micrometres and are in physical contact, with and bonded to, the frame 450. The first planar external layer 424 overlies a first end of the cavity 430 and forms a first cavity end wall. The second planar external layer 425 overlies a second end of the cavity 430 and forms a second cavity end wall, the second cavity end wall being opposite to the first cavity end wall. That is, the frame 450, the first planar external layer 424 and the second planar external layer 425 collectively define the cavity 430.

[0187] The frame 450 has a hollow cuboid shape and is made from cardboard. The frame 450 defines an aperture extending through the height (also referred to as the thickness) of the frame 450 and the aperture at least partially forms the cavity 430 of the aerosol-generating article 400. The frame 450 comprises a peripheral wall 451 that circumscribes the cavity 430. The peripheral wall 451 includes a front wall 413 and a back wall 414. In more detail, the peripheral wall 451 is defined by an inner transverse surface 452 of the frame 450 and an outer transverse surface 453 of the frame 450. The inner transverse surface 452 of the peripheral wall 451 at least partially defines a perimeter of the cavity 430. The outer transverse surface 453 of the peripheral wall 451 at least partially defines a perimeter of the aerosol-generating article 400. The peripheral wall 451 has a radial thickness measured between the inner transverse surface 452 of the frame 450 and the outer transverse surface 453 of the frame 450 of about 5 millimetres.

[0188] An air inlet 41 1 and an air outlet 412 are defined by, and extend through, the peripheral wall 451 of the frame 450. More specifically, the air inlet 41 1 extends through the front wall 413 and the air outlet 412 extends through the back wall 414. The air inlet 41 1 and the air outlet 412 have an equivalent diameter of 5 millimetres. An airflow passage extends between the air inlet 41 1 and the air outlet 412 through the cavity

[0189] 430.

[0190] As shown in figures 9 to 1 1 , a substrate sheet comprising an aerosol-forming substrate 434 forms a rolled substrate sheet 432. The aerosol-forming substrate 434 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.

[0191] As shown in Figure 10, the rolled substrate sheet 432 circumscribes a structural element 448. The rolled substrate sheet 432 and the structural element 448 are positioned within the cavity 430. The structural element 448 comprises a plurality of parallel corrugations. Features in common with aerosol-generating article 300 are referred to with like reference signs but commencing with numeral 4 instead of numeral 3. The structural element 448 is substantially the same as the structural element 348, except where described below.

[0192] The structural element 448 comprises a corrugated element 445 comprising a plurality of parallel corrugations, which have a corrugation wavelength of about 4.6 millimetres. The corrugation amplitude is approximately the same as the height (or thickness) as in interior passage of the rolled substrate sheet, as shown by the peaks and troughs coinciding with the rolled substrate sheet 432.

[0193] The plurality of parallel corrugations form a plurality of longitudinally extending channels in a central portion or the rolled substrate sheet 432. The plurality of channels extend in a longitudinal direction of the aerosol-generating article 400 and form at least a portion of the airflow passage extending between the air inlet 41 1 and the air outlet 412.

[0194] The aerosol-generating article 400 has a cuboid shape and has a height (or thickness) extending in a z dimension, as measured between the first planar external surface 421 and the second planar external surface 422, of 8 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The frame 450 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The cavity 430 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 30 millimetres and a length extending in an x dimension of 50 millimetres.

[0195] The rolled substrate sheet 432 has a rolled length that is equal to the cavity length. The rolled substrate sheet 432 has a rolled thickness that is equal to the cavity thickness. The rolled substrate sheet 432 has a rolled width that is equal to the cavity width.

[0196] During use the aerosol-generating article 400, the aerosol-forming substrate 434 is heated up to cause the aerosol-forming substrate 434 to release volatile compounds, which are then entrained in air drawn through the air inlet 41 1 into the cavity 430. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the aerosol-generating article 400 through the air outlet 412.

[0197] Figure 12 shows a schematic transverse cross-sectional view of an aerosol-generating article 500 according to a fifth embodiment of the present disclosure. Features in common with aerosol-generating article 300 are referred to with like reference signs but commencing with numeral 5 instead of numeral 3.

[0198] The aerosol-generating article 500 comprises a rolled substrate sheet 532 comprising an aerosolforming substrate 534. A structural element 548 is circumscribed by the rolled substrate sheet 532. In this embodiment, the rolled substrate sheet 532 is rolled over two complete turns about the longitudinal axis of the aerosol-generating article 500. The rolled substrate sheet 532 therefore forms multiple layers of substrate sheet circumscribing the structural element 545. The aerosol-generating article 500 comprises a rolling adhesive (not shown) configured to adhere two portions of the rolled substrate sheet 532 to each other. The rolling adhesive adheres two radially adjacent portions of the rolled substrate sheet 532 to each other. The rolling adhesive may be any suitable adhesive.

[0199] Figure 13 shows a side view of an aerosol-generating article 600 according to a sixth embodiment of the present disclosure. In this embodiment, the aerosol-generating article 600 may be identical to the article 300 or 500, except where described below.

[0200] The aerosol-generating article 600 comprises a rolled substrate sheet 632 comprising a first section 635 comprising the aerosol-forming substrate 634.

[0201] The rolled substrate sheet 632 comprises a second section 637 comprising paper 636. The second section 637 is adjacent to the first section 635 along the rolled length and is positioned downstream of the first section 635, at the proximal end of the rolled substrate sheet 632 at the proximal end of the aerosolgenerating article 600. The first section 635 is located between the distal end and the proximal end of the rolled substrate sheet 632.

[0202] The rolled substrate sheet 632 comprises a third section 639 comprising paper 638. The first section 635 is located between the second section 637 and the third section 639.

[0203] The third section is adjacent to the first section 635 along the rolled length and is positioned upstream of the first section 635, at the distal end of the rolled substrate sheet 632 at the distal end of the aerosolgenerating article 600.

[0204] In this embodiment, any adhesive used in the aerosol-generating article 600, for example a rolled adhesive, layer adhesive, or element adhesive, is adhered to the second section 637 and the third section 639 of the rolled substrate sheet 632.

[0205] Figure 14 shows a schematic transverse cross-sectional view of an aerosol-generating article 700 according to a seventh embodiment of the present disclosure. In this embodiment, the aerosol-generating article 700 is a variant of aerosol-generating article 300. Features in common with aerosol-generating article 300 are referred to with like reference signs but commencing with numeral 7 instead of numeral 3. The aerosol-generating article 700 is identical to the aerosol-generating article 300, except where described below.

[0206] The aerosol-generating article 700 comprises a rolled substrate sheet 732 comprising an aerosolforming substrate 734. The rolled substrate sheet 732 circumscribes a structural element 745. In this embodiment, the rolled substrate sheet 732 completes over one full rotation around the structural element 745. As shown in Figure 14, the rolled substrate sheet 732 overlaps itself.

[0207] The aerosol-generating article 700 further comprises a wrapper 770. The wrapper 770 is a paper wrapper that encircles the rolled substrate sheet 732. The wrapper 770 is rolled about a central longitudinal axis of the aerosol-generating article 700.

[0208] The aerosol-generating article comprises a wrapper adhesive (not shown) that adheres the wrapper 770 to the rolled substrate sheet 732. The wrapper adhesive may also be applied to the wrapper 770 to adhere the wrapper 770 to itself, to hold the wrapper 770 and the rolled substrate 732 together. The wrapper adhesive is applied to a paper section of the rolled substrate sheet, and not to the aerosol-forming substrate 734.

[0209] In this embodiment, the wrapper 770 is not integrally formed with the rolled substrate sheet 732. However, it should be appreciated in other embodiments the wrapper and rolled substrate sheet may be integrally formed.

[0210] Figure 15A shows a schematic transverse cross-sectional view of a rolled substrate sheet 832 according to an eighth embodiment of the present disclosure. Features in common with rolled substrate sheet 332 are referred to with like reference signs but commencing with numeral 8 instead of numeral 3.

[0211] The rolled substrate sheet 832 comprises an aerosol-forming substrate 834.

[0212] In this embodiment, the rolled substrate sheet 832 is rolled over three complete turns about the longitudinal axis of the rolled substrate sheet 832, approximately 3 and a half complete turns. The rolled substrate sheet 832 therefore forms multiple layers of substrate sheet. A rolling adhesive (not shown) is configured to adhere two portions of the rolled substrate sheet 832 to each other. The rolling adhesive adheres two radially adjacent portions of the rolled substrate sheet 832 to each other. The rolling adhesive may be any suitable adhesive.

[0213] Figure 15B shows a schematic plan view of the rolled substrate sheet 832 of Figure 15A.

[0214] Figure 15C shows a schematic perspective view of the rolled substrate sheet 832 of Figure 15A. As shown in Figure 15A, 15B and 15C, the rolled substrate sheet 832 has a substantially stadium shaped cross-section. The rolled substrate sheet 832 has a rolled length LR. In this example, the rolled length LR is at least two times greater than a rolled width WR of the rolled substrate 832. The rolled substrate 832 also has a rolled height HR that is less than the rolled width WR. In this example, the rolled width WR is about least two times greater than the rolled height HR. However, it should be appreciated that in other examples the rolled substrate sheet may have any suitable cross-section such as a circular or oval cross section.

[0215] The rolled substrate 832 may form part of any aerosol-generating article described herein.

[0216] Figure 16 shows a schematic transverse cross-sectional view of an aerosol-generating article 800 comprising the rolled substrate sheet 832 of figures 15A-15C. Features in common with aerosol-generating article 400 are referred to with like reference signs but commencing with numeral 8 instead of numeral 4.

[0217] The rolled substrate sheet 832 is configured to form part of the aerosol-generating article 800 without requiring a structural element. For example, the rolled substrate sheet 832 is situated in the cavity 830 without the presence of a structural element.

[0218] An airflow passage extends between the air inlet and the air outlet of the aerosol-generating article 800 and through the cavity 830. At least a portion of the airflow passage is defined through a central region of the rolled substrate sheet 832, which may be referred to as an airflow channel 860. The airflow channel 860 extends from a first end of the rolled substrate sheet 832 to a second, opposing, end of the rolled substrate sheet 832 such that air that passing through the cavity 830 is able to contact the rolled substrate sheet 832 and in particular the aerosol-forming substrate 834.

[0219] In use of the article, air may flow between the article air inlet and the article air outlet. The aerosolforming substrate 834 is heated up to cause the aerosol-forming substrate 834 to release volatile compounds, which are then entrained in air drawn through the air inlet into the cavity 830 and through the airflow channel 860. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the aerosol-generating article 800 through the air outlet 812. Figures 17 and 18 illustrate an aerosol-generating device 6000 configured for use with an aerosolgenerating article 900 comprising or consisting of aerosol-forming substrate 940. 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 900. 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 900 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.

[0220] Figure 19 illustrates the device 6000 of figure 17 in engagement with the aerosol-generating article 900. There is little tolerance between outer surfaces of the aerosol-generating article 900 and the internal surfaces of the cavity 6050. Thus, there is a snug fit between the aerosol-generating article 900 and the device 6000. As the RTD of the aerosol-generating article 900 is negligible, the RTD of the system formed by the combination of aerosol-generating article 900 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 900 into the cavity 6050, the device 6000 can be operated. The heater 6030 heats a lower surface of the aerosolgenerating article 900, and as a result the aerosol-forming substrate 940 of the aerosol-generating article 900 is heated. Volatile components of the aerosol-forming substrate 940 are evaporated and condense in longitudinal air-flow channels defined within the aerosol-generating article 900 to form an aerosol. The user inhales the aerosol by drawing on the proximal end 901 of the aerosol-generating article 900. Once the aerosol-generating substrate 940 of the aerosol-generating article 900 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 900 may be any one of the aerosol-generating articles 100, 200, 300, 400, 500, 600 , 700 or 800 previously described or any other aerosol-generating article of the present disclosure.

[0221] Although figure 19 shows part of the aerosol-generating article 900 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 20 illustrates an alternative embodiment to that of figure 19, with like features referred to by the same reference numbers but with the addition of a prime symbol ’. For the alternative embodiment of figure 20, the entirety of aerosol-generating article 900’ is enclosed within the interior of aerosol-generating device 6000’.

[0222] 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 comprising: a substrate sheet comprising an aerosol-forming substrate for producing an aerosol, in which the substrate sheet is rolled to form a rolled substrate sheet, wherein the aerosol-generating article is defined by an article length, an article width, and an article thickness, the article length and the article width being at least two times the article thickness.

2. The aerosol-generating article according to claim 1 , in which the rolled substrate sheet is rolled about a longitudinal axis of the aerosol-generating article.

3. The aerosol-generating article according to claim 1 or 2, in which the rolled substrate sheet is defined by a rolled length extending parallel to the article length, in which the rolled length is between 50 and 100 percent of the article length, preferably between 60 and 90 percent of the article length, preferably between 70 and 80 percent of the article length.

4. The aerosol-generating article according to any preceding claim, in which the rolled substrate sheet is rolled at least two times, for example at least three, four or five times.

5. The aerosol-generating article according to any preceding claim, comprising a rolling adhesive configured to adhere at least two portions of the rolled substrate sheet to each other.

6. The aerosol-generating article according to any preceding claim, comprising at least two rolled substrate sheets, for example at least three, four or five rolled substrate sheets.

7. The aerosol-generating article according to claim 6, in which the rolled substrate sheets are sequentially rolled to form at least first and second concentric layers of the rolled substrate sheets.

8. The aerosol-generating article according to claim 7, comprising a layer adhesive configured to adhere the first and second concentric layers of the rolled substrate sheets to each other.

9. The aerosol-generating article according to any preceding claim, comprising a structural element at least partially circumscribed by the rolled substrate sheet.

10. The aerosol-generating article according to claim 9, in which the structural element comprises a plurality of upwardly extending portions and downwardly extending portions configured to allow at least one airflow channel to extend between a proximal end and a distal end of the rolled substrate sheet.1 1. The aerosol-generating article according to claim 9 or 10, wherein the structural element is a corrugated element comprising corrugations.

12. The aerosol-generating article according to any of claims 3 to 1 1 , in which the rolled substrate sheet comprises a first section comprising the aerosol-forming substrate and a second section comprising a cellulosic material, for example paper, in which the first section is adjacent to the second section along the rolled length.

13. The aerosol-generating article according to any preceding claim, comprising a wrapper that circumscribes the rolled substrate sheet.

14. The aerosol-generating article according to claim 13, in which the wrapper forms an outer surface of the aerosol-generating article.

15. An aerosol-generating system comprising: an aerosol-generating article according to any preceding claim; andan aerosol-generating device, the aerosol-generating device comprising: a chamber for receiving at least a portion of the aerosol-generating article; and an electric heater arranged to heat at least part of the aerosol-generating article when the aerosol-generating article is received within the chamber.

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