Aerosol-generating article

Abstract

There is provided an aerosol-generating article (100) for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article (100) has a length extending in an x direction, a width extending in a y direction and a height extending in a z direction, the height being less than each of the length and the width. The aerosol-generating article (100) comprises first and second cavities (104, 105), an aerosol-forming substrate (115, 116) disposed in each of the first and second cavities, and a third cavity (106) positioned between the first and second cavities.

Description

[0001] AEROSOL-GENERATING ARTICLE

[0002] The present disclosure relates to an aerosol-generating article comprising an aerosolforming 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 a portion of 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 portion of 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 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 capable of two user experiences.

[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 have a length extending in an x direction, a width extending in a y direction and a height extending in a z direction, the height being less than each of the length and the width. The aerosolgenerating article may comprise first and second cavities. An aerosol-forming substrate may be disposed in each of the first and second cavities. The aerosol-generating article may further comprise a third cavity positioned between the first and second cavities.

[0007] 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.

[0008] The positioning of the third cavity between the first and second cavities facilitates thermally isolating the first and second cavities from each other. The presence of the third cavity facilitates impeding heat imparted to aerosol-forming substrate in one of the first and second cavities from also acting on aerosol-forming substrate in the other of the first and second cavities. So, the third cavity helps to ensure that substrate in the first cavity can be heated for one usage session without inadvertently heating and depleting aerosol-forming substrate in the second cavity intended for use in a second usage session.

[0009] Each of the first and second cavities may comprise a respective air inlet and air outlet. In this manner, each of the first and second cavities may be adapted for the channelling of air into and out of the respective cavity. By way of example, a first air flow path may be defined between the air inlet and air outlet of the first cavity, and a second air flow path defined between the air inlet and air outlet of the second cavity.

[0010] Preferably, the third cavity may be hermetically isolated from outside of the aerosolgenerating article.

[0011] Preferably, the third cavity may be hermetically isolated from each of the first and second cavities. In this manner, thermal isolation of the first and second cavities from each other may be enhanced.

[0012] The third cavity is preferably free of aerosol-forming substrate.

[0013] Although the third cavity may contain a thermally insulative filling material, advantageously the third cavity may instead define an empty void. The use of an empty void provides for efficiently thermally isolating the first and second cavities from each other, whilst also helping to minimise the mass of the aerosol-generating article compared to if the third cavity contained a filling material. By “empty void” is meant empty other than for the presence of air.

[0014] Preferably, the first and second cavities may be arranged relative to each other in opposing halves of the aerosol-generating article. Where the first cavity is for use in a first usage session and the second cavity is for use in a second usage session, each of the two halves of the article may thereby be associated with a different one of the first and second usage sessions. By way of example, in a first usage session heat may be applied to the half of the article containing the first cavity and in a second usage session heat may be applied to the other half of the article containing the second cavity.

[0015] Preferably, the first and second cavities may be arranged relative to each other in opposing halves of the length of the aerosol-generating article. Advantageously, the first and second cavities may be symmetrically arranged relative to each other in the opposing halves of the length of the aerosol-generating article. The use of a symmetric arrangement of the first and second cavities over the length of the article may allow for either end of the article to be inserted into a receiving section of an aerosol-generating device for the application of heat to the aerosol-forming substrate in a given one of the first and second cavities. The third cavity may extend through at least 75%, for example at least 85%, for example at least 95% of a width of the aerosol-generating article. An increase in the proportion of the width of the article occupied by the third cavity may provide a corresponding increase in the level of thermal isolation between the first and second cavities arising from the third cavity. Each of the first and second cavities may comprise a respective air inlet and air outlet, wherein for each of the first and second cavities the respective air inlet and air outlet are arranged on opposite sides of the width of the aerosol-generating article. In this manner, a first air flow path may be defined through the first cavity extending in a widthwise (or y) direction of the article between the air inlet and air outlet of the first cavity. Similarly, a second air flow path may be defined through the second cavity extending in a width-wise (or y) direction of the article between the air inlet and air outlet of the second cavity.

[0016] The first and second cavities may be arranged relative to each other in opposing halves of the width of the aerosol-generating article. Advantageously, the first and second cavities may be symmetrically arranged relative to each other in the opposing halves of the width of the aerosolgenerating article. The use of a symmetric arrangement of the first and second cavities over the width of the article may allow for either side of the article to be inserted into a receiving section of an aerosol-generating device for the application of heat to the aerosol-forming substrate in a given one of the first and second cavities. The third cavity may extend through at least 75%, for example at least 85%, for example at least 95% of a length of the aerosol-generating article. An increase in the proportion of the length of the article occupied by the third cavity may provide a corresponding increase in the level of thermal isolation between the first and second cavities arising from the third cavity. Each of the first and second cavities may comprise a respective air inlet and air outlet, wherein for each of the first and second cavities the respective air inlet and air outlet are arranged on opposite ends of the length of the aerosol-generating article. In this manner, a first air flow path may be defined through the first cavity extending in a length-wise (or x) direction of the article between the air inlet and air outlet of the first cavity. Similarly, a second air flow path may be defined through the second cavity extending in a length-wise (or x) direction of the article between the air inlet and air outlet of the second cavity.

[0017] Preferably, the aerosol-generating article may be symmetric along any one or more of the length, width and height of the aerosol-generating article. The symmetry may be a symmetry in the profile defined by the exterior surface(s) of the article. Alternatively or additionally, the symmetry may be a symmetry in the interior structure of the aerosol-generating article. Such symmetry may allow the article to be inserted into a receiving section of an aerosol-generating device in different orientations to allow the application of heat to the aerosol-forming substrate in one of the first and second cavities for a given usage session. The aerosol-generating article may be symmetric along each of the length, width and height of the aerosol-generating article.

[0018] Preferably, substantially the entirety of each of the first and second cavities is filled with aerosol-forming substrate. Filling the first and second cavities with aerosol-forming substrate may reduce the likelihood of substrate settling at one side or end of the first and second cavities during manufacture and / or transportation of the aerosol-generating articles. Having the entire volume of the first and second cavities filled with aerosol-forming substrate may facilitate providing a consistent user experience for different ones of the aerosol-generating articles.

[0019] Where it is desired for the first and second cavities to provide an identical user experience to a consumer of the aerosol-generating article in different usage sessions, the first and second cavities may contain the same composition of aerosol-forming substrate. Alternatively however, the composition of the aerosol-forming substrate in the first cavity may be different to the composition of the aerosol-forming substrate in the second cavity. Such a difference in the composition of the aerosol-forming substrates in the first and second cavities may provide a consumer of the aerosol-generating article with variety and choice in the user experience in different usage sessions.

[0020] The ratio of the volume of the third cavity to the volume of each of the first and second cavities may be less than 0.5:1 , for example less than 0.25:1 , for example less than 0.1 :1. Minimising the volume of the third cavity may help to minimise the physical size of the aerosolgenerating article and / or maximise the space available within the article for the first and second cavities and their respective aerosol-forming substrates.

[0021] The ratio of the volume of the first cavity to the volume of the second cavity may be between 0.9 and 1 .11 , for example between 0.95 and 1 .05. Preferably, the first and second cavities are of equal volume, thereby providing the same amount of space for containing aerosol-forming substrate.

[0022] The ratio of the mass of aerosol-forming substrate in the first cavity to the mass of aerosolforming substrate in the second cavity may be between 0.9 and 1 .1 1 , for example between 0.95 and 1.05.

[0023] The aerosol-forming substrate employed in either or both of the first and second cavities may be in the form of any one or more of shredded aerosol-forming substrate, strips of aerosolforming substrate, strands of aerosol-forming substrate, particles of aerosol-forming substrate, one or more sheets of aerosol-forming substrate, one or more gathered sheets of aerosol-forming substrate, cut filler dispersed within a solid binder matrix, a plurality of beads or granules of aerosol-forming substrate.

[0024] The aerosol-forming substrate may comprise a free-flowing aerosol-forming substrate. For example, the aerosol-forming substrate may comprise or consist of a plurality of beads or granules.

[0025] The aerosol-forming substrate may preferably comprise tobacco, for example, tobacco particles, tobacco cut filler or cast leaf tobacco. The aerosol-forming substrate may comprise homogenised tobacco.

[0026] The aerosol-forming substrate may comprise an aerosol-former, for example an aerosol former selected from the list consisting of glycerine and propylene glycol, for example in which the aerosol-forming substrate has an aerosol-former content of greater than 20 wt % on a dry weight basis, for example greater than 25 wt %, or greater than 30 wt %, for example greater than 35 wt %. The use of an aerosol former may facilitate the promote the generation of aerosol from the aerosol-forming substrate through heating rather than burning of the substrate.

[0027] The aerosol-forming substrate may comprise one or more flavour compounds.

[0028] The aerosol-generating article may comprise opposed planar upper and lower external surfaces, the opposed planar upper and lower external surfaces spaced apart from each other in the z direction. Preferably, the planar upper external surface and the planar lower external surface may be parallel to each other.

[0029] Alternatively, the aerosol-generating article may comprise opposed outwardly-convex upper and lower external surfaces, the opposed outwardly-convex upper and lower external surfaces spaced apart from each other in the z direction.

[0030] The aerosol-generating article may comprise a frame, the frame at least partially defining each of the first, second and third cavities.

[0031] The frame may enhance the flexural stiffness of the aerosol-generating article and may provide the majority of the flexural stiffness of the aerosol-generating article.

[0032] The frame may comprise one or both of an air inlet and an air outlet for each of the first and second cavities.

[0033] Preferably, each of the first and second cavities may extend through a full height of the frame to define opposed upper and lower openings through corresponding upper and lower surfaces of the frame. Conveniently, the aerosol-generating article may further comprise upper and lower sheets coupled to the respective upper and lower surfaces of the frame to cover the opposed upper and lower openings of the first and second cavities. The upper and lower sheets may thereby help to retain the aerosol-forming substrate within the first and second cavities.

[0034] The upper and lower sheets may be formed of paper, a metallic foil or a laminate of paper and metallic foil layers.

[0035] The upper and lower sheets may be substantially impermeable, for example being water impermeable. The upper and lower sheets may have a permeability of between 1 and 5 Coresta units.

[0036] Alternatively, one or both of the upper and lower sheets may be porous to permit passage of air flow into and / or out of the first and second cavities.

[0037] The third cavity may extend through a full height of the frame. Alternatively, the third cavity may only extend through part of the height of the frame; for example, the third cavity may extend through between 50% and 95% of the height of the frame. By having the third cavity extending only part of the height of the frame, the frame has a greater level of flexural rigidity than if the third cavity extends through the full height of the frame.

[0038] The frame may comprise a plurality of layers successively arranged over each other. Each of the plurality of layers may extend over the length of the aerosol-generating article.

[0039] The frame may comprise a cellulosic material. The cellulosic material may have a grammage between 300 grams per square metre and 900 grams per square metre. The cellulosic material may be paper, paperboard, or cardboard.

[0040] The aerosol-generating article may comprise one or more surface regions configured to change in colour on heating. The change in colour may be irreversible. The one or more surface regions may comprise a first surface region associated with the first cavity and a second surface region associated with the second cavity. In this manner, a change in colour of the first surface region may indicate if the aerosol-forming substrate in the first cavity has already been consumed, whereas a change in colour of the second surface region may indicate if the aerosol-forming substrate in the second cavity has already been consumed. The one or more surface regions may comprise a heat sensitive ink or heat sensitive coating. The one or more surface regions may preferably form part of an exterior surface of the aerosol-generating article.

[0041] According to another aspect of the present disclosure, there may be provided an aerosolgenerating article for use with an aerosol-generating device to generate an aerosol, the aerosolgenerating article having a length extending in an x direction, a width extending in a y direction and a height extending in a z direction, the height being less than each of the length and the width. The aerosol-generating article may comprise an aerosol-forming substrate and a cavity. The cavity may be free of aerosol-forming substrate and hermetically isolated from outside of the aerosol-generating article.

[0042] The cavity may serve as a means of finger access for a user to allow them to engage their finger with the article; for example during or after completion of heating of the article, with the empty cavity allowing the user to avoid their fingers being burnt from contact with hot aerosolforming substrate.

[0043] The aerosol-generating article may comprise at least one additional cavity, wherein aerosolforming substrate is disposed in the additional cavity. The additional cavity may be distinct from and hermetically isolated from the cavity free of aerosol-forming substrate.

[0044] As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol.

[0045] 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.

[0046] As used herein, the term “granule” refers to a discrete, solid particle formed of the aerosolforming substrate as defined above. The granule may have a regular or irregular shape.

[0047] As used herein, the term “bead” refers to a discrete, solid particle formed of the aerosolforming substrate as defined above and which has a rounded, typically spherical, form.

[0048] As used herein, the term “aerosol-generating device” may refer to a device for use with an aerosol-generating article to enable the generation, or release, of an aerosol.

[0049] 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. As used herein with reference to the invention, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.

[0050] 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.

[0051] 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 by-products 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.

[0052] 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.

[0053] 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.

[0054] The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0055] Example Ex1 :An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article having a length extending in an x direction, a width extending in a y direction and a height extending in a z direction, the height being less than each of the length and the width, the aerosol-generating article comprising: first and second cavities= an aerosol-forming substrate disposed in each of the first and second cavities; and a third cavity positioned between the first and second cavities.

[0056] Example Ex2: An aerosol-generating article according to Ex1 , wherein each of the first and second cavities comprises a respective air inlet and air outlet.

[0057] Example Ex3: An aerosol-generating article according to either one of Ex1 or Ex2, wherein the third cavity is hermetically isolated from outside of the aerosol-generating article.

[0058] Example Ex3a: An aerosol-generating article according to any one of Ex1 to Ex3, wherein the third cavity is hermetically isolated from each of the first and second cavities.

[0059] Example Ex4: An aerosol-generating article according to any one of Ex1 to Ex3a, wherein the third cavity is free of aerosol-forming substrate.

[0060] Example Ex5: An aerosol-generating article according to any one of Ex1 to Ex4, wherein the third cavity defines an empty void.

[0061] Example Ex6: An aerosol-generating article according to any one of Ex1 to Ex5, wherein the first and second cavities are arranged relative to each other in opposing halves of the aerosolgenerating article.

[0062] Example Ex7: An aerosol-generating article according to Ex6, wherein the first and second cavities are arranged relative to each other in opposing halves of the length of the aerosolgenerating article.

[0063] Example Ex8: An aerosol-generating article according to Ex7, wherein the first and second cavities are symmetrically arranged relative to each other in the opposing halves of the length of the aerosol-generating article.

[0064] Example Ex9: An aerosol-generating article according to either one of Ex7 or Ex8, wherein the third cavity extends through at least 75%, for example at least 85%, for example at least 95% of a width of the aerosol-generating article.

[0065] Example Ex10: An aerosol-generating article according to any one of Ex7 to Ex9, wherein each of the first and second cavities comprises a respective air inlet and air outlet, wherein for each of the first and second cavities the respective air inlet and air outlet are arranged on opposite sides of the width of the aerosol-generating article.

[0066] Example Ex11 : An aerosol-generating article according to Ex6, wherein the first and second cavities are arranged relative to each other in opposing halves of the width of the aerosolgenerating article.

[0067] Example Ex12: An aerosol-generating article according to Ex1 1 , wherein the first and second cavities are symmetrically arranged relative to each other in the opposing halves of the width of the aerosol-generating article.

[0068] Example Ex13: An aerosol-generating article according to either one of Ex11 or Ex12, wherein the third cavity extends through at least 75%, for example at least 85%, for example at least 95% of a length of the aerosol-generating article.

[0069] Example Ex14: An aerosol-generating article according to any one of Ex11 to Ex13, wherein each of the first and second cavities comprises a respective air inlet and air outlet, wherein for each of the first and second cavities the respective air inlet and air outlet are arranged on opposite ends of the length of the aerosol-generating article.

[0070] Example Ex15: An aerosol-generating article according to any one of Ex1 to Ex14, wherein the aerosol-generating article is symmetric along any one or more of the length, width and height of the aerosol-generating article.

[0071] Example Ex16: An aerosol-generating article according to Ex15, wherein the aerosolgenerating article is symmetric along each of the length, width and height of the aerosolgenerating article.

[0072] Example Ex17: An aerosol-generating article according to any one of Ex1 to Ex16, wherein substantially the entirety of each of the first and second cavities is filled with aerosol-forming substrate.

[0073] Example Ex18: An aerosol-generating article according to any one of Ex1 to Ex17, wherein the composition of the aerosol-forming substrate in the first cavity is different to the composition of the aerosol-forming substrate in the second cavity.

[0074] Example Ex19: An aerosol-generating article according to any one of Ex1 to Ex18, wherein the ratio of the volume of the third cavity to the volume of each of the first and second cavities is less than 0.5:1 , for example less than 0.25:1 , for example less than 0.1 :1 .

[0075] Example Ex20: An aerosol-generating article according to any one of Ex1 to Ex19, wherein the ratio of the volume of the first cavity to the volume of the second cavity is between 0.9 and 1 .11 , for example between 0.95 and 1 .05.

[0076] Example Ex21 : An aerosol-generating article according to any one of Ex1 to Ex20, wherein the ratio of the mass of aerosol-forming substrate in the first cavity to the mass of aerosol-forming substrate in the second cavity is between 0.9 and 1 .11 , for example between 0.95 and 1 .05.

[0077] Example Ex22: An aerosol-generating article according to any one of Ex1 to Ex21 , wherein the aerosol-forming substrate comprises a free-flowing aerosol-forming substrate.

[0078] Example Ex23: An aerosol-generating article according to Ex22, wherein the free-flowing aerosol-forming substrate comprises or consists of a plurality of beads.

[0079] Example Ex24: An aerosol-generating article according to any one of Ex1 to Ex23, wherein the aerosol-generating article comprises opposed planar upper and lower external surfaces, the opposed planar upper and lower external surfaces spaced apart from each other in the z direction.

[0080] Example Ex25: An aerosol-generating article according to Ex24, wherein the planar upper external surface and the planar lower external surface are parallel to each other.

[0081] Example Ex26: An aerosol-generating article according to any one of Ex1 to Ex23, wherein the aerosol-generating article comprises opposed outwardly-convex upper and lower external surfaces, the opposed outwardly-convex upper and lower external surfaces spaced apart from each other in the z direction. Example Ex27: An aerosol-generating article according to any one of Ex1 to Ex26, wherein the aerosol-generating article comprises a frame, the frame at least partially defining each of the first, second and third cavities.

[0082] Example Ex28: An aerosol-generating article according to Ex27, wherein each of the first and second cavities extends through a full height of the frame to define opposed upper and lower openings through corresponding upper and lower surfaces of the frame.

[0083] Example Ex29: An aerosol-generating article according to Ex28, further comprising upper and lower sheets coupled to the respective upper and lower surfaces of the frame to cover the opposed upper and lower openings of the first and second cavities.

[0084] Example Ex30: An aerosol-generating article according to Ex29, wherein the upper and lower sheets are substantially impermeable, for example being water impermeable.

[0085] Example Ex31 : An aerosol-generating article according to Ex30, wherein the upper and lower sheets have a permeability of between 1 and 5 Coresta units.

[0086] Example Ex32: An aerosol-generating article according to Ex29, wherein one or both of the upper and lower sheets are porous to permit passage of airflow into and / or out of the first and second cavities.

[0087] Example Ex33: An aerosol-generating article according to any one of Ex27 to Ex32, wherein the third cavity extends through a full height of the frame.

[0088] Example Ex34: An aerosol-generating article according to any one of Ex27 to Ex32, wherein the third cavity extends through only part of the height of the frame.

[0089] Example Ex35: An aerosol-generating article according to Ex34, wherein the third cavity extends through between 50% and 95% of the height of the frame.

[0090] Example Ex36: An aerosol-generating article according to any one of Ex27 to Ex35, wherein the frame comprises a plurality of layers successively arranged over each other.

[0091] Example Ex37: An aerosol-generating article according to Ex36, wherein each of the plurality of layers extends over the length of the aerosol-generating article.

[0092] Example Ex38: An aerosol-generating article for use with an aerosol-generating device to generate an aerosol (for example, an aerosol-generating article according to any one of Ex1 to Ex37), the aerosol-generating article having a length extending in an x direction, a width extending in a y direction and a height extending in a z direction, the height being less than each of the length and the width, the aerosol-generating article comprising an aerosol-forming substrate and a cavity, wherein the cavity is free of aerosol-forming substrate and hermetically isolated from outside of the aerosol-generating article.

[0093] Example Ex39: An aerosol-generating article according to Ex38, further comprising at least one additional cavity, wherein aerosol-forming substrate is disposed in the additional cavity.

[0094] Example Ex40: An aerosol-generating article according to Ex39, wherein the additional cavity is distinct from and hermetically isolated from the cavity free of aerosol-forming substrate.

[0095] Examples will now be further described with reference to the figures in which: Figure 1 is a perspective exploded view of the components of an aerosol-generating article according to a first embodiment of the present disclosure;

[0096] Figure 2 is a plan view of a frame of the aerosol-generating article of figure 1 ;

[0097] Figure 3 is a perspective view of the aerosol-generating article of figure 1 when partially assembled;

[0098] Figure 4 is a perspective view of the aerosol-generating article of figure 1 when fully assembled;

[0099] Figure 5 is a perspective exploded view of the components of an aerosol-generating article according to a second embodiment of the present disclosure;

[0100] Figure 6 is a perspective view of the aerosol-generating article of figure 5 when fully assembled;

[0101] Figure 7 is a perspective exploded view of the components of an aerosol-generating article according to a third embodiment of the present disclosure;

[0102] Figure 8 is a perspective view of the aerosol-generating article of figure 7 when fully assembled;

[0103] Figure 9 is a perspective exploded view of a multi-layered frame for use as part of the aerosol-generating article of figures 1 to 4;

[0104] 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 aerosolgenerating article;

[0105] Figure 1 1 shows a schematic end view of the aerosol-generating device of figure 10;

[0106] Figure 12 is a schematic view showing an aerosol-generating article in engagement with the aerosol-generating device of figure 11 ;

[0107] Figure 1 is a perspective exploded view of the components of an aerosol-generating article 100 according to a first embodiment of the present disclosure. The components of the article 100 are shown alongside the x, y, z axes of a cartesian coordinate system. The article 100 has a frame 101 positioned between lower and upper sheets 102, 103. The frame 101 has two cavities 104, 105 symmetrically positioned in opposite halves of the length of the frame. A third cavity 106 is centrally positioned along the length of the frame between the first and second cavities 104, 105. The third cavity 106 extends in the y direction through about 75% of the width of the frame 101 (see figure 2). The third cavity 106 extends in the y direction for a distance corresponding to and aligned with the width of the first and second cavities 104, 105. For this first embodiment, the first and second cavities 104, 105 are of substantially the same volume, with the third cavity 106 having a volume of about one sixth of the volume of each of the first and second cavities. A first air inlet 107 and first air outlet 108 are defined in opposing side walls of the frame 101. The first air inlet 107 and first air outlet 108 are in fluid communication with the first cavity 104. An air flow path 109 is defined through the first cavity 104 between the first air inlet 107 and first air outlet 108. A second air inlet 110 and second air outlet 1 11 are defined in opposing side walls of the frame 101 . The second air inlet 110 and second air outlet 1 11 are in fluid communication with the second cavity 105. An air flow path 1 12 is defined through the second cavity 105 between the second air inlet 110 and second air outlet 1 11. The first and second cavities 104, 105 are not in fluid communication with each other or with the third cavity 106. The first and second cavities 104, 105 extend through the full height of the frame 101 in the z direction to define apertures or openings through lower and upper surfaces 113, 1 14 of the frame.

[0108] First and second portions 115, 116 of aerosol-forming substrate are provided for the respective first and second cavities 104, 105. For the embodiment illustrated in figure 1 , the aerosol-forming substrate is in the form of a plurality of beads of aerosol-generating material. The aerosol-generating material may contain nicotine. The aerosol-generating material may contain tobacco. The aerosol-generating material may contain an aerosol-former such as glycerin or any other suitable aerosol former. It will be appreciated that in other embodiments, other forms of aerosol-forming substrate may be used in place of a plurality of beads, such as cut filler, or shreds, strips or sheets of homogenised tobacco.

[0109] The frame 101 is formed of cardboard. The frame 101 has a length (extending in the x direction) of about 30 mm, a width (extending in the y direction) of about 12 mm and a height (extending in the z direction) of about 3 mm. The first and second cavities 104, 105 each have a length (extending in the x direction) of about 12 mm and a width (extending in the y direction) of about 7 mm. The third cavity has a length (extending in the y direction) of about 7 mm and a width (extending in the x direction) of about 2 mm.

[0110] The lower and upper sheets 102, 103 are formed of a lamination of a layer of paper and a layer of metallic foil. The lower and upper sheets 102, 103 are essentially impermeable to water. The lower and upper sheets 102, 103 each have a thickness of about 45 micrometres. The length and width of the lower and upper sheets 102, 103 correspond to that of the frame 101.

[0111] The aerosol-generating article 100 has a length (extending in the x direction) of about 30 mm, a width (extending in the y direction) of about 12 mm and a height (extending in the z direction) of about 3.1 mm.

[0112] During assembly of the components of the aerosol-generating article 100, the lower sheet 102 is bonded to the lower surface 113 of the frame 101 . The first and second cavities 104, 105 are then filled with the respective portions 115, 1 16 of the beads of aerosol-forming substrate until the beads are approximately level with the upper surface 114 of the frame 101. The third cavity 106 is left empty other than for the presence of air. The upper sheet 103 is then bonded to the upper surface 1 14 of the frame 101 to cover and close the first, second and third cavities 104, 105, 106 (see figure 3).

[0113] The assembled aerosol-generating article 100 is illustrated in figure 4. The aerosolgenerating article 100 of figure 4 is adapted for use in two distinct usage sessions. In a first usage session, heat would be applied to deplete the aerosol-forming substrate in one of the first and second cavities 104, 105. In a second usage session, heat would be applied to deplete the aerosol-forming substrate in the other of the first and second cavities 104, 105. More specifically, in use over a usage session, heat would be imparted to about one half of the length of the aerosolgenerating article 100 to heat the portion 1 15, 1 16 of aerosol-forming substrate contained in the respective cavity 104 or 105 for that half of the article. On application of sufficient heat, the aerosol-forming substrate in the heated cavity 104 or 105 would begin to vaporise. The application of suction at the air outlet 108 or 1 11 of the heated cavity 104 or 105 would, in turn, induce an inflow of air through the air inlet 107 or 1 10 of the heated cavity into and through the heated cavity. The vaporised aerosol-forming substrate would become entrained with the incoming air flow entering the heated cavity 104 or 105, with the entrained flow cooling and condensing to form an aerosol on flowing towards the air outlet 108 or 11 1 of the heated cavity to exit the aerosolgenerating article 100. The third cavity 106 would help to thermally isolate the first and second cavities 104, 105 from each other. The thermal isolating capability of the third cavity 106 is assisted by the cavity only containing air, with air being a good thermal insulator. So, where heat is applied to the half of the article 100 containing the first cavity 104, the empty third cavity 106 would act as a thermal insulation barrier limiting undesired heat flow from the aerosol-forming substrate 115 in the first cavity to the aerosol-forming substrate 116 in the second cavity 105. In this manner, the third cavity 106 would reduce the likelihood of any undesired premature depletion of the aerosol-forming substate 116 in the second cavity 105 arising from the application of heat to the aerosol-forming substrate 115 in the first cavity 104. The same principles apply where heat is instead applied to the half of the article 100 containing the second cavity 105, with the third cavity 106 then reducing the likelihood of any undesired premature depletion of the aerosolforming substrate 115 in the first cavity 104 arising from the application to heat to aerosol-forming substrate 1 16 in the second cavity 105.

[0114] Figures 5 and 6 relate to a second embodiment of aerosol-generating article 200. The aerosol-generating article 200 differs from article 100 in the frame 200 lacking any holes or cutouts defining an air inlet or air outlet. Rather, the aerosol-generating article 200 of figures 5 and 6 employs a porous construction for the lower and upper sheets 202, 203. Pores extend through the thickness of the lower and upper sheets 202, 203, as schematically indicated in the representation of the lower and upper sheets in figure 5. In common with the first embodiment, the frame 201 has first and second cavities 204, 205 in opposing halves of the length of the article 200, with a third cavity 206 positioned between the first and second cavities. First and second portions 215, 216 of aerosol-forming substrate are provided to substantially fill the respective cavities 204, 205. Lower and upper sheets 202, 203 are bonded to respective lower and upper surfaces 213, 214 of the frame 201 to cover and close each of cavities 204, 205, 206.

[0115] The assembled aerosol-generating article 200 is illustrated in figure 6. In common with aerosol-generating article 100, aerosol-generating article 200 is adapted for use in two distinct usage sessions. In a first usage session, heat would be applied to deplete the aerosol-forming substrate in one of the first and second cavities 204, 205. In a second usage session, heat would be applied to deplete the aerosol-forming substrate in the other of the first and second cavities 204, 205. More specifically, in use over a usage session, heat would be imparted to about one half of the length of the aerosol-generating article 200 to heat the portion 215, 216 of aerosolforming substrate contained in the respective cavity 204 or 205 for that half of the article. On application of sufficient heat, the aerosol-forming substrate in the heated cavity 204 or 205 would begin to vaporise. The application of suction across that part of the porous upper sheet 203 overlying the heated cavity 204 or 205 would, in turn, induce an inflow of air through that part of the porous lower sheet 202 overlying the heated cavity into and through the cavity. The vaporised aerosol-forming substrate would become entrained with the incoming air flow entering the heated cavity 204 or 205, with the entrained flow cooling and condensing to form an aerosol on flowing towards the porous upper sheet 203 to exit the aerosol-generating article 200. In the same manner described for the aerosol-generating article 100, the third cavity 206 would help to thermally isolate the first and second cavities 204, 205 from each other and also help to avoid premature depletion of aerosol-forming substrate in the non-heated one of cavities 204, 205.

[0116] Figures 7 and 8 relate to a third embodiment of aerosol-generating article 300. The aerosolgenerating article 300 differs from article 100 in that the first and second cavities 304, 305 are provided in opposing halves of the width of the frame 300. The first and second cavities 304, 305 are intended to be filled with portions 315, 316 of aerosol-forming substrate. Third cavity 306 is provided between the first and second cavities 304, 305. As can be see in figures 7 and 8, the third cavity 306 extends in the x direction for a distance corresponding to and aligned with the length of the first and second cavities 304, 305. A first air inlet 307 and first air outlet 308 are defined in opposing end walls of the frame 301 . The first air inlet 307 and first air outlet 308 are in fluid communication with the first cavity 304. An air flow path 309 is defined within the first cavity 304 between the first air inlet 307 and first air outlet 308. A second air inlet 310 and second air outlet 31 1 are also defined in opposing end walls of the frame 301 . The second air inlet 310 and second air outlet 311 are in fluid communication with the second cavity 305. An air flow path 312 is defined within the second cavity 305 between the second air inlet 310 and second air outlet 31 1. In common with the aerosol-generating articles 100, 200, the first and second cavities 304, 305 are not in fluid communication with each other or with the third cavity 306. The first and second cavities 304, 305 extend through the full height of the frame 301 in the z direction to define openings or apertures through lower and upper surfaces 313, 314 of the frame.

[0117] During assembly of the components of the aerosol-generating article 300, the lower sheet 302 is bonded to the lower surface 313 of the frame 301 . The first and second cavities 304, 305 are then filled with respective portions 315, 316 of beads of aerosol-forming substrate until the beads are approximately level with the upper surface 314 of the frame 301. The third cavity 306 remains empty other than for the presence of air. The upper sheet 303 is then bonded to the upper surface 314 of the frame 301 to cover and close the first, second and third cavities 304, 305, 306 (see figure 8).

[0118] The assembled aerosol-generating article 300 is illustrated in figure 8. The aerosolgenerating article 300 of figure 8 is adapted for use in two distinct usage sessions. In a first usage session, heat would be applied to deplete the aerosol-forming substrate in one of the first and second cavities 304, 305. In a second usage session, heat would be applied to deplete the aerosol-forming substrate in the other of the first and second cavities 304, 305. More specifically, in use over a usage session, heat would be imparted to one half of the width of the aerosolgenerating article 300 to heat the portion 315, 316 of aerosol-forming substrate contained in the respective cavity 304 or 305 located in that half of the article. On application of sufficient heat, the aerosol-forming substrate in the heated cavity 304 or 305 would begin to vaporise. The application of suction at the air outlet 308 or 311 of the heated cavity 304 or 305 would, in turn, induce an inflow of air through the air inlet 307 or 310 of the heated cavity and into and through the heated cavity. The vaporised aerosol-forming substrate would become entrained with the incoming air flow, with the entrained flow cooling and condensing to form an aerosol on flowing towards the air outlet 308 or 31 1 of the heated cavity to exit the aerosol-generating article 300. The third cavity 306 would helps to thermally isolate the first and second cavities 304, 305 from each other.

[0119] For the aerosol-generating articles 100, 200, 300, the frame 101 , 201 , 301 is illustrated as a homogenous element. However, in other embodiments the frame 101 , 201 , 301 may instead be formed of a plurality of layers successively overlaid over each other, for example in the z direction. Figure 9 illustrates an exploded view of a frame 401 formed of three layers 401 1 , 4012, 4013. The middle layer 4012 of the three layers is provided with various cut-outs. When the three layers 401 1 , 4012, 4013 are bonded to each other to form the frame 401 , the cut-outs in the middle layer define openings for the flow of air into and / or out of first and second cavities 404, 405 defined by the frame 401. As can be seen, each of the layers 4011 , 4012, 4013 defines a portion of the height of first, second and third cavities 404, 405, 406. Where the multilayered frame construction of figure 9 is applied to the frame 101 of aerosol-generating article 100 illustrated in figure 1 , the cut-outs in the middle layer 4012 may define the air inlets 107, 1 10 and air outlets 108, 11 1.

[0120] Figures 10 and 1 1 illustrate an aerosol-generating device 5000 configured for use with an aerosol-generating article 500.

[0121] The aerosol-generating article 500 generally corresponds in configuration to aerosolgenerating article 100, having portions 515, 516 of aerosol-forming substrate located in first and second cavities 504, 505 located in opposing halves of the length of the aerosol-generating article 500. An empty third cavity 506 is located between the first and second cavities 504, 505.

[0122] The device 5000 is an elongate aerosol-generating device extending between a proximal end 5001 and a distal end 5002. The device 5000 comprises a battery 5010, a controller 5020 and a heater 5030 located within a housing 5040. The controller 5020 controls supply of power from the battery 5010 to the heater 5030. A cavity 5050 is defined in the device 5000, the cavity having an opening 5051 defined in the proximal end 5001 of the device. The opening 5051 is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosol-generating article 500. The cavity 5050 comprises an upper planar surface 5052 and a lower planar surface 5053. The heater 5030 is located in the lower planar surface 5053 to heat a lower surface of one half of the length of the aerosol-generating article 500 when inserted into the cavity 5050. An incoming air-flow path (not shown) is configured to allow air to flow into the cavity 5050 from outside the device 5000.

[0123] Figure 12 illustrates the device 5000 of figure 10 in engagement with the aerosol-generating article 500 ready to commence a first usage session. The half of the aerosol-generating article 500 containing first cavity 504 and its respective portion 515 of aerosol-forming substrate is inserted into the opening 5051 of the cavity 5050. When the aerosol-generating article 500 is received in the cavity 5050, the heater 5030 is positioned adjacent a lower surface of the aerosolgenerating article and extends over the first cavity 504. A user can then activate the aerosolgenerating device 5000 for the first usage session. The heater 5030 heats a lower surface of the aerosol-generating article 500, and as a result the portion 515 of aerosol-forming substrate in the first cavity 504 of the aerosol-generating article 500 is heated. Volatile components of the portion 515 of aerosol-forming substrate are evaporated due to the heating action of heater 5030. The user draws on the proximal end 5001 of the aerosol-generating device 500, thereby inducing an air flow through the interior of the device 5000 into and through the first cavity 504 via an air inlet and an air outlet of the cavity. The vaporised volatile compounds from the portion 515 of aerosol-forming substrate become entrained with the air flow through the cavity 504, cooling and condensing to form an aerosol as they flow towards the air outlet of the cavity 504. The aerosol then flows within an outgoing air flow path (not shown) defined within the aerosol-generating device 5000 to be inhaled by the user. On completion of the first usage session, the portion 515 of aerosol-generating substrate in the first cavity 504 of the aerosol-generating article 500 will have been depleted of volatile components. The aerosol-generating article 500 is then removed and reinserted into the cavity 5050 of the device 5000 so that the half of the article containing the second cavity 505 is positioned adjacent to the heater 5030 for commencing a second usage session. The aerosol-generating device 5000 is then activated to commence the second usage session to deplete the second portion 516 of aerosol-forming substrate in the same manner as described for the first usage session.

[0124] 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 having a length extending in an x direction, a width extending in a y direction and a height extending in a z direction, the height being less than each of the length and the width, the aerosol-generating article comprising: first and second cavities; an aerosol-forming substrate disposed in each of the first and second cavities; and a third cavity positioned between the first and second cavities.

2. An aerosol-generating article according to claim 1 , wherein each of the first and second cavities comprises a respective air inlet and air outlet.

3. An aerosol-generating article according to either one of claim 1 or claim 2, wherein the third cavity is hermetically isolated from outside of the aerosol-generating article.

4. An aerosol-generating article according to any one of claims 1 to 3, wherein the third cavity defines an empty void.

5. An aerosol-generating article according to any one of claims 1 to 4, wherein the first and second cavities are arranged relative to each other in opposing halves of the length of the aerosolgenerating article.

6. An aerosol-generating article according to claim 5, wherein the third cavity extends through at least 75%, for example at least 85%, for example at least 95% of a width of the aerosolgenerating article.

7. An aerosol-generating article according to any one of claims 1 to 4, wherein the first and second cavities are arranged relative to each other in opposing halves of the width of the aerosolgenerating article.

8. An aerosol-generating article according to any one of claims 1 to 7, wherein the aerosolgenerating article is symmetric along any one or more of the length, width and height of the aerosol-generating article.

9. An aerosol-generating article according to any one of claims 1 to 8, wherein the ratio of the volume of the third cavity to the volume of each of the first and second cavities is less than 0.5:1 , for example less than 0.25:1 , for example less than 0.1 :1 .

10. An aerosol-generating article according to any one of claims 1 to 9, wherein the aerosolforming substrate comprises a free-flowing aerosol-forming substrate.

11. An aerosol-generating article according to any one of claims 1 to 10, wherein the aerosolgenerating article comprises opposed planar upper and lower external surfaces, the opposed planar upper and lower external surfaces spaced apart from each other in the z direction.

12. An aerosol-generating article according to any one of claims 1 to 10, wherein the aerosolgenerating article comprises opposed outwardly-convex upper and lower external surfaces, the opposed outwardly-convex upper and lower external surfaces spaced apart from each other in the z direction.

13. An aerosol-generating article according to any one of claims 1 to 12, wherein the aerosolgenerating article comprises a frame, the frame at least partially defining each of the first, second and third cavities.

14. An aerosol-generating article according to claim 13, wherein each of the first and second cavities extends through a full height of the frame to define opposed upper and lower openings through corresponding upper and lower surfaces of the frame.15 An aerosol-generating article according to claim 14, further comprising upper and lower sheets coupled to the respective upper and lower surfaces of the frame to cover the opposed upper and lower openings of the first and second cavities, optionally wherein the upper and lower sheets are substantially impermeable, for example being water impermeable., or wherein one or both of the upper and lower sheets are porous to permit passage of airflow into and / or out of the first and second cavities.

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