Aerosol-generating article comprising container

Abstract

There is provided an aerosol-generating article (100) for use with an aerosol-generating device, the aerosol-generating article (100) comprising: a container (110), the container (110) comprising: a first wall (120); a second wall (130) opposing the first wall (120), the first wall (120) and the second wall (130) together defining a substrate compartment of the container (110); an aerosol-generating substrate located in the substrate compartment; an air inlet having a height of at least 0.5 millimetres; and an air outlet having a height of at least 0.5 millimetres, wherein both the first wall (120) and the second wall (130) are non-planar, wherein one or both of the first wall (120) and the second wall (130) comprises a cellulose-based material, and wherein one or both of the first wall and the second wall has a thickness of at least 0.5 millimetres.

Description

[0001] AEROSOL-GENERATING ARTICLE COMPRISING CONTAINER

[0002] The present disclosure relates to an aerosol-generating article comprising a container. In particular, the present invention relates to an aerosol-generating article comprising a container, the container comprising a first and a second wall. The present disclosure also relates to an aerosol-generating system comprising the aerosol-generating article and an aerosol-generating device configured to heat the aerosol-generating article.

[0003] A typical aerosol-generating system comprises an aerosol-generating device and an aerosol-generating article comprising an aerosol-generating substrate. In use, the aerosolgenerating device is arranged to heat a heating element that is positioned near, or in contact with, the aerosol-generating substrate which causes the aerosol-generating substrate to heat up and release volatile compounds. These volatile compounds are then entrained in air that is drawn through the aerosol-generating article. As the volatile compounds cool, they condense to form an aerosol that can be inhaled by a consumer.

[0004] A typical aerosol-generating article may appear similar and have similar dimensions to a conventional cigarette. For example, such an aerosol-generating article may be substantially cylindrical and comprise an aerosol-generating substrate in addition to other components such as mouthpiece filter element and a cooling element, which are arranged in the form of a rod and wrapped in a cigarette paper.

[0005] However, a significant portion of the aerosol-generating 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-generating substrate contributes to the cost of manufacture and transport of the aerosol-generating article but does not contribute to the aerosol delivered to the consumer. 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 axial alignment and wrapped in a cigarette paper. This can lead to increased cost and complexity of manufacture.

[0006] In some other aerosol-generating articles, the aerosol-generating substrate may be contained in a structure involving multiple layers or walls that are combined and bonded together to form a frame. For examples, the layers may be bonded together at their edges to form corners of the frame. The layers may separate at their interfaces due to the shearing forces exerted during cutting of the layers. This may result in exposure of the aerosolgenerating substrate to the external environment degrading the quality of the aerosolgenerating substrate.

[0007] It is an objective of the present disclosure to provide an aerosol-generating article in which a greater portion of the aerosol-generating substrate is sufficiently heated to form an aerosol during use. It is also an objective of the present disclosure to provide an aerosol- generating article in which the quality and consistency of aerosol delivered to a user is improved compared to known articles. It is further an objective of the present disclosure to provide an aerosol-generating article that can be manufactured relatively efficiently and cheaply.

[0008] According to a first aspect of the present disclosure, there is provided an aerosolgenerating article for use with an aerosol-generating device. The aerosol-generating article may comprise a container. The container may comprise a first wall. The container may comprise a second wall. The second wall may oppose the first wall. The first wall and the second wall may together define a substrate compartment of the container. The container may comprise an aerosol-generating substrate. The aerosol-generating substrate may be located in the substrate compartment. The first wall may be planar or non-planar. The second wall may be non-planar. One or both of the first wall and the second wall may comprise a cellulose- based material. The first wall is formed from a first material. The second wall is formed from a second material. Where the first wall is planar, the second material may have a higher stiffness than the first material. Where the first wall is planar, the second material may be more flexible than the first material. Where the first wall is planar, the first material may have a grammage less than a grammage of the second material. Where the first wall is planar, the first wall may have a thickness less than a thickness of the second wall. Where the first wall is planar, the second wall may have a higher stiffness than the first wall.

[0009] According to a first aspect of the present invention, there is provided an aerosolgenerating article for use with an aerosol-generating device, the aerosol-generating article comprising: a container, the container comprising: a first wall; a second wall opposing the first wall, the first wall and the second wall together defining a substrate compartment of the container; and an aerosol-generating substrate located in the substrate compartment, wherein both the first wall and the second wall are non-planar, and wherein one or both of the first wall and the second wall comprises a cellulose-based material.

[0010] There is also provided an aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article comprising: a container, the container comprising: a first wall; a second wall opposing the first wall, the first wall and the second wall together defining a substrate compartment of the container; and an aerosol-generating substrate located in the substrate compartment, wherein the first wall is planar, wherein the second wall is non-planar, wherein one or both of the first wall and the second wall comprises a cellulose-based material, wherein the first wall is formed from a first material, wherein the second wall is formed from a second material, and wherein the second material has one or both of a higher stiffness and a higher grammage than the first material.

[0011] There is also provided an aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article comprising: a container, the container comprising: a first wall; a second wall opposing the first wall, the first wall and the second wall together defining a substrate compartment of the container; and an aerosol-generating substrate located in the substrate compartment, wherein the first wall is planar, wherein the second wall is non-planar, wherein one or both of the first wall and the second wall comprises a cellulose-based material, and wherein the second wall has a thickness greater than a thickness of the first wall.

[0012] Providing a substrate compartment defined by a first wall and a second wall, wherein at least the second wall is non-planar and wherein one or both of the first wall and the second wall comprise a cellulose-based material may advantageously provide a large surface area for heating of the aerosol-generating substrate, thereby leading to effective heating of the aerosol-generating substrate and effective generation of aerosol for delivery to a user.

[0013] By providing a substrate compartment defined by a first wall and an opposing second wall, wherein the first wall is planar or non-planar, and wherein the second wall is non-planar, each of the first wall and the second wall may define a substantial portion of the substrate compartment. This may help to minimise the number of components or walls needed to form the container. This may simplify manufacturing of the aerosol-generating article, for example, due to the need to align and bond fewer components to form the container.

[0014] Minimising the number of components needed to form the container may minimise the number of interfaces from which separation of the components may occur. This may improve sealing of the aerosol-generating substrate to improve the quality and consistency of aerosol delivered to a user during use of the aerosol-generating article. Minimising the number of interfaces may help to improve the consistency in the resistance to draw of the aerosolgenerating article from one aerosol-generating article to another aerosol-generating article.

[0015] A cellulose-based material may be easily shaped into a non-planar wall while avoiding breakage of the wall. Accordingly, providing a wall of the container comprising a cellulose- based material may provide flexibility in design of the container and improve the structural integrity of the container.

[0016] The cellulose-based material may be in the form of a sheet. One or both of the first wall and the second wall may be formed from a sheet of cellulose-based material.

[0017] The first wall may be planar and the second wall may be formed from a material having a higher stiffness or thickness than a material forming the first wall. This may simplify manufacturing of the aerosol-generating article. For example, it may simplify alignment of the first wall and the second wall to form the container. The second wall being formed from a material having a higher stiffness or thickness than the first wall may provide the container with sufficient structural integrity. The first wall being formed from a material having a lower stiffness or lower thickness than the second wall may improve efficient heating of aerosolgenerating substrate in the substrate compartment. This may be the case where the heating element of an aerosol-generating device is configured to heat the aerosol-generating substrate through the first wall of the aerosol-generating article.

[0018] In use, the aerosol-generating article may be inserted into an aerosol-generating device, the aerosol-generating device comprising a heating element. The heating element may heat the aerosol-generating article to a temperature at which the aerosol-generating substrate may generate an aerosol. This aerosol may be delivered from the aerosolgenerating device to a user.

[0019] As used herein, the term “aerosol-generating substrate” denotes a substrate capable of releasing volatile compounds upon heating, which can condense to form an aerosol.

[0020] As used herein, the term “aerosol” denotes a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. The aerosol may be visible or invisible. The aerosol may include vapours of substances that are ordinarily liquid or solid at room temperature as well as solid particles, or liquid droplets, or a combination of solid particles and liquid droplets.

[0021] As used herein, the term “aerosol-generating article” denotes an article comprising an aerosol-generating substrate that is capable of releasing volatile compounds that can form an aerosol. An aerosol-generating article may be disposable.

[0022] The aerosol-generating article of the present invention is for an aerosol-generating device. That is, the aerosol-generating article may be configured to be used with an aerosolgenerating device.

[0023] As used herein, the term “aerosol-generating device” denotes a device that interacts with an aerosol-generating substrate to generate an aerosol. In some examples, the aerosolgenerating device heats the aerosol-generating substrate to facilitate release of volatile compounds from the substrate.

[0024] As used herein, the term “aerosol-generating system” refers to the combination of an aerosol-generating device and an aerosol-generating article.

[0025] As used herein, the term “planar” refers to a feature generally formed in a single Euclidean plane and not wrapped around or otherwise conformed to fit a curved or other non- planar shape. A planar surface may extend in two dimensions in a single Euclidean plane. A planar object may extend in two dimensions in a single Euclidean plane substantially more than in a third dimension perpendicular to the plane. More specifically, a planar object may extend in a first dimension and a second dimension perpendicular to the first dimension at least two, five or ten times further than the object extends in a third dimension perpendicular to the first and second dimensions. The length of the planar object may be measured in the first dimension. The width of the planar object may be measured in the second dimension. The thickness of the planar object may be measured in the third dimension. As used herein, the term “cellulosic material” refers to a material which is made from or is a derivative of cellulose.

[0026] The first wall and the second wall are non-integral and are distinct from one another.

[0027] The first wall and the second wall are assembled together to form the container. As used herein, the term “non-planar” is used to describe the shape of the first wall or the second wall in its assembled form as part of the container.

[0028] One or both of the first wall and the second wall may be formable or shapable. In other words, one or both of the first wall and the second wall may comprise a material which may be formed into a desired shape and may hold this shape once formed. Preferably, both the first wall and the second wall are formable or shapable.

[0029] The first wall may define a first recess. The first wall may be shaped to define a first recess. The second wall may define a second recess. The second wall may be shaped to define a second recess. The first recess and the second recess may together define the substrate compartment. The first recess and the second recess may define substantially the entirety of the substrate compartment.

[0030] The first wall has a first wall external surface and a first wall internal surface opposite the first wall external surface. The first wall external surface may form an external surface of the container. The first wall internal surface may define the substrate compartment.

[0031] The second wall has a second wall external surface and a second wall internal surface opposite the second wall external surface. The second wall external surface may form an external surface of the container. The second wall internal surface may define the substrate compartment.

[0032] One or both of the first wall and the second wall may be embossed to define the first recess and the second recess, respectively. One or both of the first wall and the second wall may be shaped using heat or steam to define the first recess and the second recess, respectively.

[0033] One or both of the first wall and the second wall may be formed by moulded pulp technology to define the respective first recess and the second recess. One or both of the first wall and the second wall may be formed by pulp injection moulding, wet moulding or dry moulding.

[0034] The length of the first recess may be greater than the width of the first recess, which may in turn be greater than the depth of the first recess. The length, width and depth of the first recess are measured in orthogonal directions.

[0035] A ratio of the depth of the first recess to the width of the first recess may be less than or equal to 0.4 or less than or equal to 0.3. A ratio of the depth of the first recess to the width of the first recess may be greater than or equal to 0.1. A ratio of the depth of the first recess to the width of the first recess may be between 0.1 and 0.4, or between 0.1 and 0.3. Increasing the ratio of the depth of the first recess to the width of the first recess may increase tension in the first wall, which may lead to cracking of the first wall. A ratio of the depth of the first recess to the width of the first recess may be selected based on a balance between tension in the first wall and the desired shape of the substrate compartment.

[0036] The material of the first wall may be such that the first wall has no visible cracks when a ratio of the depth of the first recess to the width of the first recess is at least 0.1 .

[0037] The length of the second recess may be greater than the width of the second recess, which may in turn be greater than the second of the first recess. The length, width and depth of the second recess are measured in orthogonal directions.

[0038] A ratio of the depth of the second recess to the width of the second recess may be less than or equal to 0.4 or less than or equal to 0.3. A ratio of the depth of the second recess to the width of the second recess may be greater than or equal to 0.1. A ratio of the depth of the second recess to the width of the second recess may be between 0.1 and 0.4, or between 0.1 and 0.3.

[0039] Increasing the ratio of the depth of the second recess to the width of the second recess may increase tension in the second wall, which may lead to cracking of the second wall. A ratio of the depth of the second recess to the width of the second recess may be selected based on a balance between tension in the second wall and the desired shape of the substrate compartment.

[0040] The material of the second wall may be such that the first wall has no visible cracks when a ratio of the depth of the second recess to the width of the second recess is at least 0.1.

[0041] The depth of the substrate compartment may be equal to the sum of the depth of the first recess and the depth of the second recess. The first recess and the second recess preferably has the same depth. The depth of the substrate compartment may be equal to double the depth of the first recess or double the depth of the second recess.

[0042] The first wall may comprise a first wall planar portion defining a part of the substrate compartment. A first wall planar portion may advantageously increase the surface area to volume ratio of the container. A larger surface area for heating by an external heater of an aerosol-generating device may allow the aerosol-generating substrate to be quickly heated to a temperature sufficient for generating an aerosol. A first wall planar portion may allow for good contact with an external heater, particularly a planar external heater, of an aerosolgenerating device, thereby providing optimum heating of the aerosol-generating substrate.

[0043] The first wall planar portion may form a majority of the first wall.

[0044] The first wall may comprise one or more first wall side portions. The one or more first wall side portions may extend from the first wall planar portion. The one or more first wall side portions may be angled relative to the first wall planar portion. For example, the one or more first wall side portions may depend from the first wall planar portion at an angle. Each of the one or more first wall side portions may depend from the first wall planar portion along a fold line of the first wall. Each of the one or more first wall side portions may be planar.

[0045] The one or more first wall side portions and the first wall planar portion may together define the first recess and thus a part of the substrate compartment.

[0046] Each of the one or more first wall side portions and the first wall planar portion may form an angle of less than or equal to 150 degrees or less than or equal to 130 degrees therebetween. Each of the one or more first wall side portions and the first wall planar portion may form an angle of at least 90 degrees therebetween.

[0047] Increasing the angle of defined between a first wall side portion and the first wall planar portion may reduce tension in the first wall, which may reduce the likelihood of cracking of the first wall. The angle defined between the first wall side portions and the first wall planar portion may be selected based on a balance between tension in the first wall and a desired shape of the substrate compartment.

[0048] The material of the first wall may be such that first wall has no visible cracks when the angle defined between each of the one or more first wall side portions and the first wall planar portion is less than or equal to 150 degrees or less than or equal to 130 degrees. For example, the first wall may have no visible cracks when the angle defined between each of the one or more first wall side portions and the first wall planar portion is less than or equal to 130 degrees and when the ratio of the depth of the first recess to the width of the first recess is at least 0.1 .

[0049] The second wall may comprise a second planar portion defining a part of the substrate compartment. A second wall planar portion may advantageously increase the surface area to volume ratio of the container. A larger surface area for heating by an external heater of an aerosol-generating device may allow the aerosol-generating substrate to be quickly heated to a temperature sufficient for generating an aerosol. A second wall planar portion may allow for good contact with an external heater, particularly a planar external heater, of an aerosolgenerating device, thereby providing optimum heating of the aerosol-generating substrate.

[0050] The second wall planar portion may form a majority of the second wall.

[0051] Where the first wall is planar, the second wall is non-planar and comprises a second wall planar portion, the first wall may be parallel to the second wall planar portion.

[0052] The second wall may comprise one or more second wall side portions. The one or more second wall side portions may extend from the second wall planar portion. The one or more second wall side portions may be angled relative to the second wall planar portion. For example, the one or more second wall side portions may depend from the second wall planar portion at an angle. Each of the one or more second wall side portions may depend from the second wall planar portion along a fold line of the second wall. Each of the one or more second wall side portions may be planar. The one or more second wall side portions and the second wall planar portion may together define the second recess and thus a part of the substrate compartment.

[0053] Each of the one or more second wall side portions and the second wall planar portion may form an angle of less than or equal to 150 degrees or less than or equal to 130 degrees therebetween. Each of the one or more second wall side portions and the second wall planar portion may form an angle of at least 90 degrees therebetween.

[0054] Increasing the angle of defined between a second wall side portion and the second wall planar portion may reduce tension in the second wall, which may reduce the likelihood of cracking of the second wall. The angle defined between the second wall side portions and the second wall planar portion may be selected based on a balance between tension in the second wall and a desired shape of the substrate compartment.

[0055] The material of the second wall may be such that second wall has no visible cracks when the angle defined between each of the one or more second wall side portions and the second wall planar portion is less than or equal to 150 degrees or less than or equal to 130 degrees. For example, the second wall may have no visible cracks when the angle defined between each of the one or more second wall side portions and the second wall planar portion is less than or equal to 130 degrees and when the ratio of the depth of the second recess to the width of the second recess is at least 0.1 .

[0056] The first wall may comprise a first wall planar portion and the second wall may comprise a second wall planar portion. Where this is the case, the first wall planar portion and the second wall planar portion may substantially oppose each other. The first wall planar portion may be considered to form a top surface of the container. Where this is the case, the first wall planar portion may be referred to as the first wall top portion. The second wall planar portion may be considered to form a bottom surface of the container. Where this is the case, the second wall planar portion may be referred to as the second wall bottom portion. The first wall planar portion and the second wall planar portion may be substantially parallel to one another. The one or more first wall side portions may be adjacent to the one or more second wall side portions.

[0057] The first wall and the second wall may have substantially the same shape. This may simplify manufacture of the aerosol-generating article.

[0058] In the assembled state of the container, the second wall may be inverted relative to the first wall.

[0059] The substrate compartment may be substantially symmetrical. The substrate compartment may be substantially symmetrical about a plane connecting the first wall and the second wall.

[0060] The container may be substantially symmetrical. The container may be substantially symmetrical about a plane connecting the first wall and the second wall. The container may not be substantially cylindrical in shape. The substrate compartment may not be substantially cylindrical in shape.

[0061] The substrate compartment may be prismatic in shape.

[0062] The substrate compartment may have cross-sectional shape that is substantially rectangular, pentagonal, or hexagonal.

[0063] As an example, the substrate compartment may be in the shape of a quadrilaterally- faced hexahedron, such as a cube, rectangular cuboid, and parallelepiped.

[0064] As another example, the substrate compartment may be in the shape of a hexagonal prism. Where this is the case, the first wall may comprise a first wall planar portion forming a top portion of the container, two opposing first wall side portions extending from the first wall planar portion at an angle of about 120 degrees, and two opposing first wall side portions (front and back portions) extending from the first wall planar portion at an angle of about 90 degrees; the second wall may comprise a second wall planar portion forming a bottom portion of the container, two opposing second wall side portions extending from the second wall planar portion at an angle of about 120 degrees, and two opposing second wall side portions (front and back portions) extending from the second wall planar portion at an angle of about 90 degrees; the first wall planar portion and the second wall planar portion may be parallel to and oppose each other; and the first wall side portions may be adjacent to the second wall side portions.

[0065] One or both of the first wall and the second wall may comprise a curved portion. Where this is the case, the substrate compartment may have a cross-sectional shape that is substantially circular or elliptical. For example, the substrate compartment may be in the shape of a capsule.

[0066] Preferably, the first wall is thermally stable at the temperatures at which typical aerosolgenerating substrates need to be heated in order to generate an aerosol.

[0067] As used herein, the term “thermally stable” denotes a material that will not substantially thermally degrade or decompose when exposed to a given temperature range. In addition, it is important that the mechanical properties of the first wall are maintained at the temperatures at which typical aerosol-generating substrates need to be heated in order to generate an aerosol.

[0068] Preferably, the first wall is thermally stable up to 230 degrees Celsius, more preferably up to 280 degrees Celsius. This is because typical aerosol-generating substrates need to be heated to between about 100 degrees Celsius and about 280 degrees Celsius in order to generate an aerosol.

[0069] Preferably, the second wall is thermally stable at the temperatures at which typical aerosol-generating substrates need to be heated in order to generate an aerosol. Preferably, the second wall is thermally stable up to 230 degrees Celsius, more preferably up to 280 degrees Celsius. This is because typical aerosol-generating substrates need to be heated to between about 100 degrees Celsius and about 280 degrees Celsius in order to generate an aerosol.

[0070] Ensuring that the first and second walls are thermally stable at these temperatures may advantageously prevent the generation of undesirable thermal decomposition products during heating and may also ensure that the integrity of the container is maintained during use.

[0071] One or both of the first wall and the second wall comprises a cellulose-based material. One or both of the first wall and the second wall may be formed from a cellulose-based material. Suitable cellulose-based materials include paper, paperboard and cardboard.

[0072] Where both the first wall and the second wall are non-planar, the first wall and the second wall may be formed from the same material. This may simplify manufacture of the aerosol-generating article.

[0073] Preferably, both the first wall and the second wall comprise or are formed from paper.

[0074] One or both of the first wall and the second wall may comprise or be formed from: bleached softwood kraft fibers, bleached hardwood kraft fibers, bleached chemithermomechanical pulp (bleached CTMP), fluff pulp, or dissolving pulp. This may particularly be the case where one or both of the first wall and the second wall is formed by moulded pulp technology.

[0075] One or both of the first wall and the second wall may comprise an additive, such as starch and polyethylene glycol (PEG). This may help with the manufacturing process of the first and the second walls, such as moulded pulp technology.

[0076] One or both of the first wall and the second wall may comprise an additive such as starch and microfibri Hated cellulose (MFC). This may improve the strength of the first and second walls.

[0077] One or both of the first wall and the second wall may comprise an additive such as alkyl ketene dimer (AKD), alkyl succinic anhydride (ASA), resin derivatives and waxes. These additives may be used as internal sizing additives.

[0078] One or both of the first wall and the second wall may comprise an additive such as polyvinyl alcohol (PVOH), microfibrillated cellulose (MFC) and biobased polymers (such as polylactic acid (PLA)). These additives may provide the first wall and second wall with an oilgrease barrier and anti-staining properties.

[0079] The cellulose-based material may have a grammage of at least 50 grams per square metre, at least 100 grams per square metre, at least 200 grams per square metre, or at least 300 grams per square metre. This may particularly be the case where the wall comprising the cellulose-based material is non-planar. The cellulose-based material may have a grammage of less than or equal to 900 grams per square metre, less than or equal to 700 grams per square metre, or less than or equal to 500 grams per square metre.

[0080] The cellulose-based material may have a grammage of between 50 grams per square metre and 900 grams per square metre, between 50 grams per square metre and 700 grams per square metre, or between 50 grams per square metre and 500 grams per square metre.

[0081] The cellulose-based material may have a grammage of between 100 grams per square metre and 900 grams per square metre, between 100 grams per square metre and 700 grams per square metre, or between 100 grams per square metre and 500 grams per square metre.

[0082] The cellulose-based material may have a grammage of between 200 grams per square metre and 900 grams per square metre, between 200 grams per square metre and 700 grams per square metre, or between 200 grams per square metre and 500 grams per square metre.

[0083] The cellulose-based material may have a grammage of between 300 grams per square metre and 900 grams per square metre, between 300 grams per square metre and 700 grams per square metre, or between 300 grams per square metre and 500 grams per square metre.

[0084] Where the first wall is planar, the first material forming the first wall may have a grammage less than the grammage of the second material forming the second wall.

[0085] Where the first wall is planar, the first material may have a grammage of at least 10 grams per square metre, or at least 20 grams per square metre. Where the first wall is planar, the first material may have a grammage of less than or equal to 50 grams per square metre, or less than or equal to 40 grams per square metre. Where the first wall is planar, the first material may have a grammage of between 10 grams per square metre and 50 grams per square metre, or between 10 grams per square metre and 40 grams per square metre. Where the first wall is planar, the first material may have a grammage of between 20 grams per square metre and 50 grams per square metre, or between 20 grams per square metre and 40 grams per square metre. The first material may be plug wrap paper.

[0086] The first material may be a cellulose-based material. The second material may be a cellulose based-material.

[0087] One or both of the first wall and the second wall may comprise or be formed from tobacco, such as cast leaf tobacco. Where this is the case, aerosol may be generated from the respective first wall and the second wall. During use of the aerosol-generating article, the heater may be in direct contact with the tobacco to facilitate effective generation of aerosol.

[0088] One or both of the first wall and the second wall may not be formed from a non-woven cellulose material.

[0089] As used herein, the term “non-woven” refers to a manufactured sheet, web or batt of directionally or randomly orientated fibres, bonded by friction, and / or cohesion and / or adhesion, excluding products which are woven, knitted, tufted, stitch-bonded incorporating binding yarns or filaments, or felted by wet-milling, whether or not additionally needled. The fibres may be of natural or man-made origin.

[0090] The non-woven cellulosic material may be a non-woven material as defined by ISO standard 9092. The non-woven cellulosic material may be a non-woven material as defined by CEN EN 29092.

[0091] Preferably, the first wall has a substantially constant thickness. The first wall may have variable thickness.

[0092] The first wall may have a thickness of at least 0.5 millimetres, or at least 1 millimetre. The first wall may have a thickness of less than or equal to 3 millimetres, or less than or equal to 2.5 millimetres. The first wall may have a thickness of between 0.5 millimetres and 3 millimetres, or between 0.5 millimetres and 2.5 millimetres. The first wall may have a thickness of between 1 millimetre and 3 millimetres, or between 1 millimetre and 2.5 millimetres. This may particularly be the case where the first wall is non-planar.

[0093] Where the first wall is planar, the first wall may have a thickness less than a thickness of the second wall. Where the first wall is planar, the first wall may have a thickness of less than or equal to 300 micrometres, less than or equal to 200 micrometres, or less than or equal to 100 micrometres. The first wall may have a thickness of at least 10 micrometres.

[0094] Preferably, the second wall has a substantially constant thickness. The second wall may have variable thickness.

[0095] The second wall may have a thickness of at least 0.5 millimetres, or at least 1 millimetre. The second wall may have a thickness of less than or equal to 3 millimetres, or less than or equal to 2.5 millimetres. The second wall may have a thickness of between 0.5 millimetres and 3 millimetres, or between 0.5 millimetres and 2.5 millimetres. The second wall may have a thickness of between 1 millimetre and 3 millimetres, or between 1 millimetre and 2.5 millimetres.

[0096] The first wall may comprise a first wall sealing portion and the second wall may comprise a second wall sealing portion, wherein the first wall sealing portion overlays the second wall sealing portion to define a sealing region of the container. The first wall sealing portion may be substantially planar. The second wall selaing portion may be substantially planar.

[0097] The sealing region may circumscribe the substrate compartment. The sealing region may extend outwardly from the substrate compartment. A user may handle the aerosolgenerating article by holding the sealing region. This may help to avoid accidental deformation of the substrate compartment.

[0098] The first wall sealing portion may extend outwardly from the substrate compartment. Where the first wall comprises a first wall planar (top) portion and one or more first wall side portions, the first wall sealing portion may extend from the one or more first wall side portions and the first wall sealing portion may be substantially parallel to the first wall planar portion.

[0099] The first wall sealing portion may be ring shaped or annular in shape. As used herein, the term annular is not limited to circular annular, but may also include other shapes such as an elliptical ring.

[0100] The first wall sealing portion may have a width of at least 0.5 millimetres, or at least 1 millimetre. The first wall sealing portion may have a width of less than or equal to 3 millimetres, or less than or equal to 1.5 millimetres. The first wall sealing portion may have a width of between 0.5 millimetres and 3 millimetres, or between 0.5 millimetres and 1.5 millimetres. The first wall sealing portion may have a width of between 1 millimetre and 3 millimetres, or between 1 millimetre and 1.5 millimetres. The width of the first wall sealing portion refers to the dimension of the first wall sealing portion between the radially inner edge of the first wall sealing portion to the radially outer edge of the first wall sealing portion when measured along the same radius.

[0101] The second wall sealing portion may extend outwardly from the substrate compartment. Where the first wall comprises a second wall planar (bottom) portion and one or more second wall side portions, the second wall sealing portion may extend from the one or more second wall side portions and the second wall sealing portion may be substantially parallel to the second wall planar portion.

[0102] The second wall sealing portion may be ring shaped or annular in shape.

[0103] The second wall sealing portion may have a width of at least 0.5 millimetres, or at least 1 millimetre. The second wall sealing portion may have a width of less than or equal to 3 millimetres, or less than or equal to 1.5 millimetres. The second wall sealing portion may have a width of between 0.5 millimetres and 3 millimetres, or between 0.5 millimetres and 1.5 millimetres. The second wall sealing portion may have a width of between 1 millimetre and 3 millimetres, or between 1 millimetre and 1.5 millimetres. The width of the second wall sealing portion refers to the dimension of the second wall sealing portion between the radially inner edge of the second wall sealing portion to the radially outer edge of the second wall sealing portion when measured along the same radius.

[0104] One or both of the first wall sealing portion and the second wall sealing portion may comprise a rounded corner. For example, one or both of the first wall sealing portion and the second wall sealing portion may be in the shape of an elliptical ring.

[0105] Preferably, both the first wall sealing portion and the second wall sealing portion are substantially flat or planar.

[0106] Preferably, the first wall sealing portion and the second wall sealing portion have the same shape. This may ensure alignment of the first wall sealing portion and the second wall sealing portion in the sealing region. The sealing region may comprise an adhesive located between the first wall sealing portion and the second wall sealing portion. The adhesive may join the first wall sealing portion and the second wall sealing portion. This may help to seal the substrate compartment. The adhesive may comprise polyvinyl alcohol. The adhesive may comprise ethylene vinyl acetate. The adhesive may comprise a polyvinyl-alcohol-ethylene vinyl acetate copolymer. Preferably the adhesive is thermally stable at the temperatures required to generate an aerosol from the aerosol-generating substrate. The use of a polyvinyl alcohol based adhesive is advantageous since this adhesive will remain stable at the temperatures required to generate an aerosol from the aerosol-generating substrate.

[0107] The sealing region may comprise between about 1 milligram and about 30 milligrams of adhesive, between about 5 milligrams and about 15 milligrams of adhesive, or between about 8 milligrams and about 12 milligrams of adhesive.

[0108] The adhesive may be provided on only a portion of the sealing region. Preferably, the adhesive is provide on the entire sealing region. This may effectively connect the first wall to the second wall and improve the security of the retention of the aerosol-generating substrate within the substrate compartment.

[0109] The container may be substantially symmetrical about a plane containing the sealing region.

[0110] The container may comprise a ring element circumscribing the substrate compartment.

[0111] The ring element may be located in the sealing region of the container. The ring element may be located adjacent to one or both of the first wall sealing portion and the second wall sealing portion. The ring element may be overlie the first wall sealing portion. The ring element may be located between the first wall sealing portion and the second wall sealing portion. The ring element may be adhered to one or both of the first wall sealing portion and the second wall sealing portion by an adhesive.

[0112] The first wall sealing portion, the second wall sealing portion and the ring element may together form the sealing region of the container.

[0113] The ring element may advantageously act to strengthen the sealing region and to improve the connection between the first wall sealing portion and second wall sealing portion. The ring element may also provide a relatively stiff portion to enable a user to readily hold and manipulate the aerosol-generating article. The ring element may advantageously provide a flat, stiff surface onto which adhesive may be easily applied. The ring element may also provide a flat, stiff surface onto which branding or information may be printed. This may particularly be advantageous where the ring element overlies the first wall sealing portion.

[0114] The ring element may have a higher stiffness than one or both of the first wall and the second wall. The ring element may have a greater grammage than one or both of the first wall and the second wall. The ring element may have a greater thickness than one or both of the first wall and the second wall.

[0115] The ring element may have a width of at least 0.5 millimetres, or at least 1 millimetre. The ring element may have a width of less than or equal to 3 millimetres, or less than or equal to 1.5 millimetres. The ring element may have a width of between 0.5 millimetres and 3 millimetres, or between 0.5 millimetres and 1.5 millimetres. The ring element may have a width of between 1 millimetre and 3 millimetres, or between 1 millimetre and 1.5 millimetres. The width of the ring element refers to the dimension of the ring element between the radially inner edge of the ring element to the radially outer edge of the ring element when measured along the same radius.

[0116] The ring element may be formed from a cellulose-based material, such as paper, paperboard and cardboard. Preferably, the ring element is formed from paper.

[0117] The ring element may have a shape substantially the same as at least one of the first wall sealing portion and the second wall sealing portion.

[0118] The container may comprise one or more perforations provided through one or both of the first wall and the second wall. The perforations are for providing fluid communication between the substrate compartment and an exterior of the aerosol-generating article. This may allow an airflow to pass into the substrate compartment, entrain an aerosol generated by the aerosol-generating substrate, and pass out of the substrate compartment to deliver the aerosol to the user.

[0119] Where one or both of the first wall and the second wall are formed by moulded pulp technology, a perforation step may be included in the moulding process, such as prior to a final forming and cutting step.

[0120] The one or more perforations may be sized to allow air to pass through but to prevent aerosol-generating substrate from passing through. The one or more perforations may each have a diameter of greater than or equal to 100 micrometres, greater than or equal to 250 micrometres, or greater than or equal to 500 micrometres. The one or more perforations may each have a diameter of less than or equal to 1 millimetre.

[0121] Where the first wall comprises a first wall planar portion, the one or more perforations may be provided through the first wall planar portion. Where the first wall comprises one or more first wall side portions, the one or more perforations may be provided through the one or more first wall side portions.

[0122] Where the second wall comprises a second wall planar portion, the one or more perforations may be provide through the second wall planar portion. Where the second wall comprises one or more second wall side portions, the one or more perforations may be provide through the one or more second wall side portions. The container may comprise a plurality of perforations provided through one or both of the first wall and the second wall, such as through one or both of the first wall planar potion and the second wall planar portion.

[0123] The container may comprise an air inlet.

[0124] The air inlet may be located between the first wall and the second wall. One or both of the first wall and the second wall may be shaped to define the air inlet between the first wall and the second wall. One or both of the first wall sealing portion and the second wall sealing portion may be shaped to define the air inlet. One or both of a first wall side portion and a second wall side portion may be shaped to define the air inlet.

[0125] The air inlet may be provided as an opening in a first wall side portion. The air inlet may be provided as an opening in a second wall side portion. The air inlet may not be provided as an opening in the first wall top portion or the second wall bottom portion.

[0126] The air inlet may have a width of at least 3 millimetres. The air inlet may have a width of less than or equal to 5 millimetres. The air inlet may have a width of between 3 millimetres and 5 millimetres. For example, the air inlet may have a width of 4 millimetres. The width of the air inlet is measured in the direction substantially parallel to the plane connecting the first wall and the second wall, such as the plane of a sealing region of the container.

[0127] The air inlet may have a height of at least 0.5 millimetres. The air inlet may have a height of up to 2 millimetres. The air inlet may have a height of between 0.5 millimetres and 2 millimetres. For example, the air inlet may have a height of 1 millimetre. The height of the air inlet is measured in a direction perpendicular to the direction in which the width of the air inlet is measured. The height of the air inlet is measured in the direction extending between the first wall and the second wall. The height of the air inlet is measured in the direction extending between a first wall planar portion and a second wall planar portion.

[0128] The air inlet may have width greater than a length thereof.

[0129] The air inlet may be substantially rectangular, square, circular, elliptical. Preferably, the air inlet is substantially rectangular.

[0130] The container may comprise an air outlet.

[0131] The air outlet may be located between the first wall and the second wall. The first wall and the second wall may be shaped to define the air outlet between the first wall and the second wall. One or both of the first wall sealing portion and the second wall sealing portion may be shaped to define the air outlet. One or both of a first wall side portion and a second wall side portion may be shaped to define the air outlet.

[0132] The air outlet may be provided as an opening in a first wall side portion. The air outlet may be provided as an opening in a second wall side portion. The air outlet may not be provided as an opening in the first wall top portion or the second wall bottom portion. The air outlet may have a width of at least 3 millimetres. The air outlet may have a width of less than or equal to 5 millimetres. The air outlet may have a width of between 3 millimetres and 5 millimetres. For example, the air outlet may have a width of 4 millimetres. The width of the air outlet is measured in the direction substantially parallel to the plane connecting the first wall and the second wall, such as the plane of a sealing region of the container.

[0133] The air outlet may have a height of at least 0.5 millimetres. The air outlet may have a height of up to 2 millimetres. The air outlet may have a height of between 0.5 millimetres and 2 millimetres. For example, the air outlet may have a height of 1 millimetre. The height of the air outlet is measured in a direction perpendicular to the direction in which the width of the air outlet is measured. The height of the air outlet is measured in the direction extending between the first wall and the second wall. The height of the air outlet is measured in the direction extending between a first wall planar portion and a second wall planar portion.

[0134] The air outlet may have a width greater than a width thereof.

[0135] The air outlet may be substantially rectangular, square, circular, elliptical. Preferably, the air outlet is substantially rectangular.

[0136] The container may comprise an airflow passage extending between the air inlet and the air outlet, through the substrate compartment.

[0137] The air outlet preferably substantially opposes the air inlet. Where this is the case, the longitudinal direction of the container may be defined between the air inlet and the air outlet.

[0138] The container may comprise a window provided in the first wall. The container may comprise a window provided in the second wall second wall. The container may comprise a window provided in both the first wall and the second wall. The window may be aligned with a heater of an aerosol-generating device during use of the aerosol-generating article with the aerosol-generating device. The window may help to improve the efficiency of heating of the aerosol-generating substrate in the substrate compartment.

[0139] Where the first wall comprises a first wall planar portion, a window may be provide in the first wall planar portion. Where second wall comprises a second wall planar portion, a window may be provided in the second wall planar portion.

[0140] The window may be a cut-out window.

[0141] The window may have a length of at least 5 millimetres or at least 7 millimetres. The window may have a length of less than or equal to 15 millimetres or less than or equal to 12 millimetres. The window may have a length of between 5 millimetres and 15 millimetres. The window may have a length of between 5 millimetres and 12 millimetres.

[0142] The window may have a width of at least 5 millimetres or at least 6 millimetres. The window may have a width of less than or equal to 10 millimetres or less than or equal to 8 millimetres. The window may have a width of between 5 millimetres and 10 millimetres or between 5 millimetres and 8 millimetres. The window may have a width of between 6 millimetres and 10 millimetres or between 6 millimetres and 8 millimetres.

[0143] The width of the window may be less than the length of the window.

[0144] The window may be substantially rectangular.

[0145] The container may comprise a cover sheet covering the window. The cover sheet may be a sheet of paper or a sheet of substrate material, such as cast leaf tobacco. The cover sheet may be larger than the window.

[0146] The aerosol-generating substrate may be a homogenised aerosol-generating substrate.

[0147] As used herein, the term “homogenised aerosol-generating substrate” refers to an aerosol-generating substrate formed by agglomerating particulate material.

[0148] The aerosol-generating substrate may comprise one or more of tobacco, a botanical material and a plurality of aerosol-generating elements.

[0149] The aerosol-generating substrate may comprise homogenised tobacco material. The aerosol-generating substrate may comprise a plurality of shreds of tobacco material, such as tobacco cut filler or shreds of homogenised tobacco material.

[0150] Shreds of homogenised tobacco material may be formed from a sheet of homogenised tobacco material, for example, by cutting or shredding. Shreds of homogenised tobacco material may be formed by other methods, for example, by extrusion.

[0151] The plurality of aerosol-generating elements may comprise a carrier medium and a liquid or gel sorbed in the carrier medium.

[0152] The carrier medium may comprise a solid continuous matrix structure and a solid porous substrate dispersed within the solid continuous matrix structure.

[0153] The solid continuous matrix structure may be an alginate matrix.

[0154] Alginate is a “matrix-forming polymer”, this term being used herein to denote an encapsulation material in the form of a polymer which is capable of producing a three- dimensional polymer matrix as a result of cross-linking when the matrix-forming polymer is brought into contact with a cross-linking solution of multivalent cations. The resultant polymer matrix is capable of trapping and retaining the aerosol-generating substrate within its crosslinked structure.

[0155] The aerosol-generating element may comprise an aerosol-generating substrate dispersed within the solid continuous matrix structure.

[0156] The plurality of aerosol-generating elements may have any diameter. The plurality of aerosol-generating elements may have a diameter of at least 0.5 millimetres, or at least 1 millimetre. The plurality of aerosol-generating elements may have a diameter of no more than 4 millimetres, or no more than 3 millimetres. The plurality of aerosol-generating elements may have a diameter of between about 1 millimetre and about 3 millimetres. The aerosol-generating substrate may comprise at least one alkaloid.

[0157] As used herein, the term “alkaloid compound” is used to describe any one of a class of naturally occurring organic compounds that contain one or more basic nitrogen atoms. Generally, an alkaloid contains at least one nitrogen atom in an amine-type structure. This or another nitrogen atom in the molecule of the alkaloid compound can be active as a base in acid-base reactions. Most alkaloid compounds have one or more of their nitrogen atoms as part of a cyclic system, such as for example a heterocylic ring. In nature, alkaloid compounds are found primarily in plants, and are especially common in certain families of flowering plants. However, some alkaloid compounds are found in animal species and fungi. In the context of the present invention, the term “alkaloid compounds” is used to describe both naturally derived alkaloid compounds and synthetically manufactured alkaloid compounds. Suitable alkaloid compounds for use in an aerosol-generating element in accordance with the invention include, but are not limited to, nicotine and anatabine.

[0158] In preferred embodiments, the aerosol-generating substrate comprises nicotine or anatabine.

[0159] In particularly preferred embodiments, the aerosol-generating substrate comprises nicotine.

[0160] As used herein, the term “nicotine” is used to describe nicotine, a nicotine base or a nicotine salt. In embodiments in which the aerosol-generating substrate comprises a nicotine base or a nicotine salt, the amounts of nicotine recited herein are the amount of free base nicotine or amount of protonated nicotine, respectively.

[0161] The aerosol-generating substrate may comprise natural nicotine or synthetic nicotine.

[0162] The aerosol-generating substrate may comprise one or more monoprotic nicotine salts.

[0163] As used herein, the term “monoprotic nicotine salt” is used to describe a nicotine salt of a monoprotic acid.

[0164] The aerosol-generating substrate may comprise nicotine.

[0165] The aerosol-generating substrate may comprise an aerosol-former. The aerosolgenerating substrate may contain any amount of aerosol-former. The aerosol-generating substrate may comprise at least 50 weight percent, at least 60 weight percent, or at least 70 weight percent aerosol-former. The aerosol-generating substrate may comprise about 80 weight percent aerosol-former.

[0166] The aerosol-generating substrate may comprise a polyhydric alcohol.

[0167] The polyhydric alcohol acts as the aerosol-former for the aerosol-generating substrate. Polyhydric alcohols suitable for use in the aerosol-generating substrate include, but are not limited to, propylene glycol, triethylene glycol, 1 ,3-butanediol, and glycerin. Preferably, in an aerosol-generating substrate in accordance with the invention the polyhydric alcohol is selected from the group consisting of glycerin, propylene glycol, and combinations thereof. In particularly preferred embodiments the polyhydric alcohol is glycerin.

[0168] The aerosol-generating substrate may comprise granules. The granules may have any diameter. The aerosol-generating substrate may comprise granules with a diameter of greater than or equal to 100 micrometres, greater than or equal to 250 micrometres, or greater than or equal to 500 micrometres.

[0169] The aerosol-generating substrate may comprise granules with a diameter of less than or equal to 5 millimetres, less than or equal to 4 millimetres, or less than or equal to 3 millimetres.

[0170] The aerosol-generating substrate may comprise granules with a diameter of between 500 micrometres and 3 millimetres. The aerosol-generating substrate may comprise granules with a diameter of about 1.5 millimetres.

[0171] The substrate compartment may contain any mass of aerosol-generating substrate. For example, the substrate compartment may contain at least 80 milligrams of aerosolgenerating substrate, at least 85 milligrams of aerosol-generating substrate, or at least 90 milligrams of aerosol-generating substrate.

[0172] The substrate compartment may contain at no more than 300 milligrams of aerosolgenerating substrate, no more than 250 milligrams of aerosol-generating substrate, or no more than 200 milligrams of aerosol-generating substrate.

[0173] The substrate compartment may contain between 80 milligrams and 300 milligrams of aerosol-generating substrate, between 85 milligrams and 250 milligrams of aerosol-generating substrate, and between 100 milligrams and 200 milligrams of aerosol-generating substrate.

[0174] The substrate compartment may have a length of at least 15 millimetres or at least 20 millimetres. The substrate compartment may have a length of less than or equal to 40 millimetres or less than or equal to 30 millimetres. The substrate compartment may have a length of between 15 millimetres and 40 millimetres, or between 15 millimetres and 30 millimetres. The substrate compartment may have a length of between 20 millimetres and 40 millimetres, or between 20 millimetres and 30 millimetres.

[0175] As used herein, the term “length” is used to describe the maximum dimension of elements, or portions of elements, of aerosol-generating articles according to the disclosure. The length may be defined in the longitudinal direction or along a longitudinal axis.

[0176] During use, air may flow along a length of the aerosol-generating article. This may ensure that the airflow passes along the longest dimension of the substrate compartment which may advantageously ensure that the maximum quantity of aerosol is able to be entrained by the air passing through the substrate compartment.

[0177] The substrate compartment may have a width of at least 5 millimetres or at least 7 millimetres. The substrate compartment may have a width of less than or equal to 13 millimetres or less than or equal to 10 millimetres. The substrate compartment may have a width of between 5 millimetres and 13 millimetres, or between 5 millimetres and 10 millimetres. The substrate compartment may have a width of between 7 millimetres and 13 millimetres, or between 7 millimetres and 10 millimetres.

[0178] As used herein, the term “width” is used to describe the second longest orthogonal dimension of elements, or portions of elements, of aerosol-generating articles according to the disclosure, unless otherwise stated. The width of the substrate compartment is perpendicular to the length of the substrate compartment.

[0179] The substrate compartment may have a height of at least 1.5 millimetres or at least 2.5 millimetres. The substrate compartment may have a height of less than or equal to 5 millimetres or less than or equal to 4 millimetres. The substrate compartment may have a height of between 1.5 millimetres and 5 millimetres, or between 1.5 millimetres and 4 millimetres. The substrate compartment may have a height of between 2.5 millimetres and 5 millimetres, or between 2.5 millimetres and 4 millimetres.

[0180] As used herein, the term "height” is used to describe the shortest orthogonal dimension of elements, or portions of elements, of aerosol-generating articles according to the disclosure. The height of elements, or portions of elements, of aerosol-generating article may also be referred to as the depth of the elements, or portions of the elements, of the aerosol-generating article. The height of the substrate compartment is perpendicular to the length and the width of the substrate compartment.

[0181] The container may have a length of at least 15 millimetres or at least 20 millimetres. The container may have a length of less than or equal to 45 millimetres or less than or equal to 30 millimetres. The container may have a length of between 15 millimetres and 45 millimetres, or between 15 millimetres and 30 millimetres. The container may have a length of between 20 millimetres and 45 millimetres, or between 20 millimetres and 30 millimetres.

[0182] The container may have a width of at least 5 millimetres or at least 7.5 millimetres. The container may have a width of less than or equal to 15 millimetres or less than or equal to 12.5 \millimetres. The container may have a width of between 5 millimetres and 15 millimetres, or between 5 millimetres and 12.5 millimetres. The container may have a width of between 7.5 millimetres and 15 millimetres, or between 7.5 millimetres and 12.5 millimetres.

[0183] The container may have a height of at least 1.5 millimetres or at least 2.5 millimetres. The container may have a height of less than or equal to 5 millimetres or less than or equal to 4 millimetres. The container may have a height of between 1.5 millimetres and 5 millimetres, or between 1.5 millimetres and 4 millimetres. The container may have a height of between 2.5 millimetres and 5 millimetres, or between 2.5 millimetres and 4 millimetres.

[0184] The container may extend the entire length of the aerosol-generating article. The aerosol-generating article may have the same length as the container. The aerosol-generating article may have a length of at least 15 millimetres or at least 20 millimetres. The aerosol-generating article may have a length of less than or equal to 45 millimetres or less than or equal to 30 millimetres. The aerosol-generating article may have a length of between 15 millimetres and 45 millimetres, or between 15 millimetres and 30 millimetres. The aerosol-generating article may have a length of between 20 millimetres and 45 millimetres, or between 20 millimetres and 30 millimetres.

[0185] The container may extend the entire width of the aerosol-generating article. The aerosol-generating article may have the same width as the container.

[0186] The aerosol-generating article may have a width of at least 5 millimetres or at least 7.5 millimetres. The aerosol-generating article may have a width of less than or equal to 15 millimetres or less than or equal to 12.5 millimetres. The aerosol-generating article may have a width of between 5 millimetres and 15 millimetres, or between 5 millimetres and 12.5 millimetres. The aerosol-generating article may have a width of between 7.5 millimetres and 15 millimetres, or between 7.5 millimetres and 12.5 millimetres.

[0187] The container may extend the entire height of the aerosol-generating article. The aerosol-generating article may have the same height as the container.

[0188] The aerosol-generating article may have a height of at least 1.5 millimetres or at least 2.5 millimetres. The aerosol-generating article may have a height of less than or equal to 5 millimetres or less than or equal to 4 millimetres. The aerosol-generating article may have a height of between 1.5 millimetres and 5 millimetres, or between 1.5 millimetres and 4 millimetres. The aerosol-generating article may have a height of between 2.5 millimetres and 5 millimetres, or between 2.5 millimetres and 4 millimetres.

[0189] The aerosol-generating article may consist of the container.

[0190] According to a second aspect of the present disclosure, there is provided an aerosolgenerating system. The aerosol-generating system may comprise an aerosol-generating article according to the first aspect of the present disclosure. The aerosol-generating system may comprise an aerosol-generating device configured to heat the aerosol-generating article.

[0191] According to a second aspect of the present invention, there is provided an aerosolgenerating system comprising an aerosol-generating article according to the first aspect of the present invention and an aerosol-generating device configured to heat the aerosol-generating article. The aerosol-generating device is configured to heat the aerosol-generating substrate of the aerosol-generating article to form an aerosol, for example, an inhalable aerosol.

[0192] Since the aerosol-generating system of this disclosure comprises an aerosolgenerating article described herein, the advantages specified above for the aerosol-generating articles also apply to the aerosol-generating system itself. The aerosol-generating device may comprise a housing defining a cavity for receiving the aerosol-generating article. The cavity of the aerosol-generating device may have a shape substantially the same as the shape of the aerosol-generating article.

[0193] The aerosol-generating device may comprise one or more heaters. For example, the aerosol-generating device may comprise two heaters. The one or more heaters may be substantially planar. The aerosol-generating device may comprise a power source for supplying power to the one or more heaters. The power source may be a battery. The aerosolgenerating device may comprise a controller configured to control a supply of power to the one or more heaters.

[0194] The aerosol-generating device may comprise a mouthpiece element. The mouthpiece element may be configured to be inserted into a mouth of a user.

[0195] The aerosol-generating device may comprise an air inlet. The aerosol-generating device, for example the mouthpiece element of the aerosol-generating device, may comprise an air outlet.

[0196] The aerosol-generating device may comprise an air flow path connecting the air inlet of the aerosol-generating device to the air outlet-of the aerosol-generating device. The air flow path may extend one or both of through and past the cavity of the aerosol-generating device. As such, in use, the aerosol-generating system may be configured such that, when a negative pressure is applied to the air outlet of the aerosol-generating device, for example by a user drawing on the air outlet of the aerosol-generating device, air is drawn in through the air inlet of the aerosol-generating device, then past or through the aerosol-generating article received in the aerosol-generating device, thereby entraining aerosol released from the aerosolgenerating substrate of the aerosol-generating article, then

[0197] Where the container of the aerosol-generating article comprises an air inlet and an air outlet, the aerosol-generating system may comprise an air flow path connecting the air inlet of the aerosol-generating device to the air inlet of the container, to the air outlet of the container, and to the air outlet of the aerosol-generating device. The air flow path may extend through the substrate compartment of the container of the aerosol-generating article, out through the air outlet of the aerosol-generating device.

[0198] 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.

[0199] EX1. An aerosol-generating article for use with an aerosol-generating device, the aerosol-generating device comprising: a container, the container comprising a first wall and a second wall.

[0200] EX2. An aerosol-generating article according to EX1 , wherein the first wall opposes the second wall. EX3. An aerosol-generating article according to EX1 or EX2, wherein the first wall and the second wall together define a substrate compartment of the container.

[0201] EX4. An aerosol-generating article according to any of EX1 to EX3 further comprising an aerosol-generating substrate located in the substrate compartment.

[0202] EX5. An aerosol-generating article according to any of EX1 to EX4, wherein the first wall is planar or non-planar.

[0203] EX6. An aerosol-generating article according to any of EX1 to EX5, wherein the second wall is non-planar.

[0204] EX7. An aerosol-generating article according to any of EX1 to EX6, wherein one or both of the first wall and the second wall comprise a cellulose-based material.

[0205] EX8. An aerosol-generating article according to any of EX1 to EX7, wherein one or both of the first wall and the second wall is formed from a sheet of cellulose-based material.

[0206] EX9. An aerosol-generating article according to any one of EX1 to EX8, wherein the first wall defines a first recess and the second wall defines a second recess, the first recess and the second recess together defining the substrate compartment.

[0207] EX10. An aerosol-generating article according to EX9, wherein the first wall is embossed to define the first recess and the second wall is embossed to define the second recess.

[0208] EX11. An aerosol-generating article according to EX9 or EX10, wherein a ratio of the depth of the first recess to the width of the first recess is between 0.1 and 0.4.

[0209] EX12. An aerosol-generating article according to any of EX9 to EX11 , wherein a ratio of the depth of the second recess to the width of the second recess is between 0.1 and 0.4.

[0210] EX13. An aerosol-generating article according to any of EX1 to EX12, wherein the first wall comprises a first wall planar portion defining a part of the substrate compartment.

[0211] EX14. An aerosol-generating article according to EX13, wherein the first wall planar portion forms a majority of the first wall.

[0212] EX15. An aerosol-generating article according to EX13 or EX14, wherein the first wall comprises one or more first wall side portions extending from the first wall planar portion.

[0213] EX16. An aerosol-generating article according to EX15, wherein each of the one or more first wall side portions forms an angle of between 90 degrees and 150 degrees with the first wall planar portion.

[0214] EX17. An aerosol-generating article according to any of EX1 to EX16, wherein the second wall comprises a second wall planar portion defining a part of the substrate compartment.

[0215] EX18. An aerosol-generating article according to EX17 wherein the second wall planar portion is parallel to the first wall planar portion. EX19. An aerosol-generating article according to EX17 or EX18, wherein the second wall planar portion forms a majority of the second wall.

[0216] EX20. An aerosol-generating article according to any of EX17 to EX19, wherein the second wall comprises one or more second wall side portions extending from the second wall planar portion.

[0217] EX21. An aerosol-generating article according to EX20, wherein each of the one or more second wall side portions forms an angle of between 90 degrees and 150 degrees with the second wall planar portion.

[0218] EX22. An aerosol-generating article according to any of EX1 to EX21 , wherein the first wall and the second wall have substantially the same shape.

[0219] EX23. An aerosol-generating article according to any of EX1 to EX22, wherein the container is prismatic in shape.

[0220] EX24. An aerosol-generating article according to any of EX1 to EX23 wherein both the first wall and the second wall is thermally stable up to 230 degrees Celsius.

[0221] EX25. An aerosol-generating article according to any of EX1 to EX24, wherein one or both of the first wall and the second wall is formed from paper, paperboard or cardboard; preferably paper.

[0222] EX26. An aerosol-generating article according to any of EX1 to EX25, wherein the cellulose-based material has a grammage of at least 100 grams per square metre, or at least 200 grams per square metre, or at least 300 grams per square metre.

[0223] EX27. An aerosol-generating article according to any of EX1 to EX26, wherein one or both of the first wall and the second wall has a thickness of between 0.5 millimetres and 3 millimetres.

[0224] EX28. An aerosol-generating article according to any one of EX1 to EX27, wherein the first wall comprises a first wall sealing portion extending outwardly from the substrate compartment, and the second wall comprises a second wall sealing portion extending outwardly from the substrate compartment, and wherein the first wall sealing portion overlays the second wall sealing portion to define a sealing region of the container.

[0225] EX29. An aerosol-generating article according to any of EX1 to EX29 wherein the container further comprises a ring element located in the sealing region of the container.

[0226] EX30. An aerosol-generating article according to EX29 wherein the ring element has a higher stiffness than one or both of the first wall and the second wall.

[0227] EX31. An aerosol-generating article according to any of EX1 to EX30, wherein the container comprises one or more perforations provided through one or both of the first wall and the second wall, and wherein each of the one or more perforations have a diameter of less than or equal to 1 millimetre. EX32. An aerosol-generating article according to any of EX1 to EX31, wherein the container comprises an air inlet having a height of at least 0.5 millimetres, and an air outlet having a height of at least 0.5 millimetres..

[0228] EX33. An aerosol-generating article according to EX32, wherein the air inlet and the air outlet are both located between the first wall and the second wall.

[0229] EX34. An aerosol-generating article according to any of EX1 to EX33, wherein the container comprises a window provided in one or both of the first wall and the second wall, the window having a length of at least 5 millimetres.

[0230] EX35. An aerosol-generating article according to any of EX1 to EX34, wherein the aerosol-generating substrate comprises one or more of tobacco, a botanical material and a plurality of aerosol-generating elements.

[0231] EX36. An aerosol-generating article according to any of EX1 to EX35, wherein the aerosol-generating substrate comprises nicotine.

[0232] EX37. An aerosol-generating article according to any of EX1 to EX36, wherein the substrate compartment has a length of between 15 millimetres and 40 millimetres.

[0233] EX38. An aerosol-generating article according to any of EX1 to EX37, wherein the substrate compartment has a width of between 5 millimetres and 13 millimetres.

[0234] EX39. An aerosol-generating article according to any of EX1 to EX38, wherein the substrate compartment has a height or depth of between 1.5 millimetres and 5 millimetres.

[0235] EX40. An aerosol-generating article according to any of EX1 to EX39, wherein the aerosol-generating article has a length of between 15 millimetres and 45 millimetres.

[0236] EX41. An aerosol-generating article according to any of EX1 to EX40, wherein the aerosol-generating article has a length of less than or equal to 30 millimetres.

[0237] EX42. An aerosol-generating article according to any of EX1 to EX41, wherein the aerosol-generating article has a width of between 5 millimetres and 15 millimetres.

[0238] EX43. An aerosol-generating article according to any of EX1 to EX42, wherein the aerosol-generating article has a height or depth of between 1.5 millimetres and 5 millimetres.

[0239] EX44. An aerosol-generating system comprising an aerosol-generating article according to any of EX1 to EX43 and an aerosol-generating device configured to heat the aerosol-generating article.

[0240] EX45. An aerosol-generating system according to EX44, wherein the aerosolgenerating device comprises a heater configured to heat the aerosol-generating substrate of the aerosol-generating article.

[0241] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:

[0242] Figure 1 shows a schematic perspective view of an aerosol-generating article according to the present disclosure; Figure 2 shows a schematic cross-sectional view of the aerosol-generating article shown in Figure 1 ;

[0243] Figure 3 shows a schematic cross-sectional view of another aerosol-generating article according to the present disclosure;

[0244] Figure 4 shows a schematic plan view of another aerosol-generating article according to the present disclosure;

[0245] Figure 5 shows a schematic perspective view of a further aerosol-generating article according to the present disclosure;

[0246] Figure 6 shows a schematic cross-sectional view of an aerosol-generating device according to the present disclosure; and

[0247] Figure 7 shows a schematic cross-sectional view of an aerosol-generating article according to the present disclosure.

[0248] Figures 1 and 2 show an aerosol-generating article 100 comprising a container 110. The container 110 comprises a first wall 120 and a second wall 130 opposing the first wall 120. The first wall 120 and the second wall 130 together define a substrate compartment 140. An aerosol-generating substrate 145 is provided in the substrate compartment 140.

[0249] The first wall 120 and the second wall 130 have substantially the same shape.

[0250] The first wall 120 is non-planar and comprises a first wall planar portion 121 , four first wall side portions 122, 123, 124 extending from the first wall planar portion 121 along respective fold lines, and a first wall sealing portion 126 extending outwardly from the substrate compartment 140 and circumscribing the substrate compartment 140. The first wall sealing portion 126 is substantially parallel to the first wall planar portion 121.

[0251] The second wall 130 is non-planar and comprise a second wall planar portion 131 opposing and substantially parallel to the first wall planar portion 121 , four second wall side portions 132, 133, 134 extending from the second wall planar portion 131 along respective fold lines, and a second wall sealing portion 136 extending outwardly from the substrate compartment 140 and circumscribing the substrate compartment 140. The second wall sealing portion 136 is substantially parallel to the second wall planar portion 132.

[0252] The substrate compartment 140 has the shape of hexagonal prism.

[0253] The first wall sealing portion 126 overlays the second wall sealing portion 136 to define a sealing region of the container. The first wall sealing portion 126 is adhered directly to the second wall sealing portion 136 by an adhesive. The first wall sealing portion 126 and the second wall sealing portion 236 have substantially the same shape. The aerosol-generating article comprises a plane of symmetry, the plane of symmetry passing through the sealing region.

[0254] The first wall 120 and the second wall 130 are both originally formed from a sheet of shapable paper having a grammage of at least 100 grams per square metre. The sheets of paper were embossed to define a first recess in the first wall 120 and a second recess in the second wall 130. The first recess and the second recess together define the substrate compartment 140.

[0255] The container 110 comprises an air inlet 160 provided as an opening in the first wall side portion 122. The container 120 also comprises an air outlet (not shown) provided as an opening in an first wall side portion. The air inlet 160 and air outlet are substantially aligned and oppose each other. In use, air may be drawn into the substrate compartment 140 through the air inlet 160 and out of the substrate compartment 140 through the air outlet

[0256] The aerosol-generating substrate 145 comprises homogenised tobacco material.

[0257] The container 110 extends the entire length, width and depth of the aerosol-generating article 100.

[0258] The aerosol-generating article 100 has a length of about 30 millimetres.

[0259] Figure 3 shows a cross-sectional view of another aerosol-generating article according to the present disclosure. The aerosol-generating article shown in Figure 3 is generally the same as the aerosol-generating article 100 shown in Figures 1 and 2. However, the aerosolgenerating article shown in Figure 3 differs from the aerosol-generating article shown in Figures 1 and 2 in that the container 110 further comprises a ring element 146 positioned between the first wall sealing portion 126 and the second wall sealing portion 136. The ring element 156 is adhered to both the first wall sealing portion 126 and the second wall sealing portion 136 by an adhesive. The first wall sealing portion 126, the second walls sealing portion 136 and the ring element 156 all have substantially the same shape.

[0260] Figure 4 shows a top plan view of another aerosol-generating article 200. The aerosolgenerating article 200 comprises a container comprising: a first wall 220 and an opposing second wall (not shown) together defining a substrate compartment of the container. The first wall 220 is concavely shaped to define a first recess. In particular, the first wall 220 comprises a first wall curved portion 221. The first wall 210 comprises a first wall sealing portion 226 extending from the first wall curved portion 221 and extending outwardly from the substrate compartment.

[0261] The second wall has substantially the same shape as the first wall 220 and comprises a second wall curved portion and a second wall sealing portion extending from the second wall curved portion and extending outwardly from the substrate compartment. The second wall may be considered to be inverted relative to the first wall in the assembled form as part of the aerosol-generating article.

[0262] The first wall sealing portion 226 and the second wall sealing potion are directly adhered to one another with an adhesive.

[0263] The substrate compartment is capsular in shape. Both the first wall 210 and the second wall comprise a cellulose-based material. For example, both the first wall 210 and the second wall is formed from a sheet of paper.

[0264] The container comprises a plurality of perforations 270 provided through the first wall curved portion 221. During use of the aerosol-generating article 200, air may pass into the substrate compartment through the plurality of perforations 270 and entrain aerosol generated by the aerosol-generating substrate located in the substrate compartment, and pass out of the substrate compartment also through the plurality of perforations 270 to be delivered to a user. Each of the plurality of perforations 270 have a diameter of less than or equal to 1 millimetre. That is, the largest dimension of each of the plurality of perforations 270 is less than or equal to 1 millimetre.

[0265] Figure 5 shows another aerosol-generating article 300. The aerosol-generating article 300 comprises a container comprising: a first wall 320 and an opposing second wall 330. The first wall 320 an the second wall 330 together define a substrate compartment. An aerosolgenerating substrate (not shown) is located in the substrate compartment.

[0266] The first wall 320 and the second wall 330 have substantially the same shape and are invented with respect to one another in the assembled form as part of the container.

[0267] The first wall 320 is non-planar and comprises a first wall planar portion 321 , one or more first wall side portions 322 extending from the first wall planar portion 321 , and a first wall sealing portion 326 extending outwardly from the substrate compartment 340 and circumscribing the substrate compartment 340. The first wall planar portion 321 forms a majority of the first wall 320.

[0268] The second wall is non-planar and comprises a second wall planar portion 331 , one or more second wall side portions extending from the second wall planar portion 331 , and a second wall sealing portion extending outwardly from the substrate compartment 340 and circumscribing the substrate compartment 340. The second wall planar portion 331 forms a majority of the second wall 330.

[0269] The second wall planar portion 331 is substantially parallel to and opposes to the first wall planar portion 321 .

[0270] The substrate compartment 340 is substantially cuboidal.

[0271] The first wall sealing portion 326 is aligned with, overlays and is adhered to the second wall sealing portion.

[0272] The first wall 320 and the second wall are both formed from a cellulosic-based material.

[0273] The first wall sealing portion 326 and the second wall sealing portion are shaped to define an air inlet 372 for providing fluid communication between the substrate compartment 340 and the exterior of the aerosol-generating article 300. The air inlet 370 is located between the first wall sealing portion 326 and the second wall sealing portion. The first wall sealing portion 326 and the second wall sealing portion are shaped to define an air outlet 374 for providing fluid communication between the substrate compartment 340 and the exterior of the aerosol-generating article 300. The air outlet 374 is located between the first wall sealing portion 326 and the second wall sealing portion.

[0274] The air inlet 372 and the air outlet 374 are substantially opposite to each other and define the longitudinal direction of the aerosol-generating article 300. The air inlet 372 and the air outlet 374 have substantially the same shape: substantially rectangular. The air inlet 372 and the air outlet 374 both have a width of 4 millimetres. The air inlet 372 and the air outlet 374 both have a height of 1 millimetre.

[0275] The container comprises a first window 382 provided as a cut out in the first wall planar portion 321. The container also comprises a second window 384 provided as a cut out in the second wall planar portion 331. The first window 382 and the second window 384 have substantially the same shape and are opposed to each other. The first window 382 and the second window 384 both have a length of 10 millimetres. The first window 382 and the second window 384 both have a width of 7 millimetres. The container also comprises a first cover sheet (not shown) covering the first window 382 and a second cover sheet (not shown) covering the second window 384. The first cover sheet and the second cover sheet may formed from cast leaf tobacco.

[0276] The aerosol-generating article 300 has a length (extending in the same direction as the direction extending between the air inlet 160 and the air outlet) of 30 millimetres, a width (the larger dimension of the aerosol-generating article in a direction perpendicular to the longitudinal direction and parallel to the sealing region) of 10 millimetres, and a depth (the smaller dimension of the aerosol-generating article in the other direction perpendicular to the longitudinal direction and parallel to the sealing region) of 3 millimetres.

[0277] Figure 6 shows an aerosol-generating device 400 for an aerosol-generating system. The aerosol-generating device 400 is configured for use with aerosol-generating article 300 shown in Figure 4. The aerosol-generating device comprises a housing defining a cavity 410 for receiving at least a part of the aerosol-generating article 300. The aerosol-generating device 400 comprises a first heater 420 and a second heater 422 both configured to heat the aerosol-generating substrate in the substrate compartment 340 of the aerosol-generating article 300 to generate an inhalable aerosol. The first heater 420 and the second heater 422 are substantially flat. The aerosol-generating device 400 also comprises a battery 430 and a controller 440 for controlling the supply of power from the battery 430 to the first heater 422 and the second heater 424.

[0278] The aerosol-generating device 400 comprises an air inlet 450. When the aerosolgenerating article 300 is inserted into the cavity 410 of the aerosol-generating device, air may be drawn into the aerosol-generating device 400 through the air inlet 450 of the aerosol- generating device 400 and then through the air inlet 472 of the aerosol-generating article 300 and then through the substrate compartment 340 and then through the air outlet 374 of the aerosol-generating article 300.

[0279] Figure 7 shows another aerosol-generating article 500. The second wall 130 of the container of the aerosol-generating article 500 is the same as the second wall 130 of the aerosol-generating article 100 shown in Figures 1 and 2. The first wall 520 of the container of the aerosol-generating article 500 is planar. The first wall 520 opposes the second wall 130. The first wall 520 and the second wall 130 together define a substrate compartment of the container. An aerosol-generating substrate 145 is provided in the substrate compartment.

[0280] The first wall 520 is adhered to the second wall 130 at the second wall sealing portion 136.

[0281] The first wall 520 is formed from a first material, the second wall 130 is formed from a second material, and the second material has a higher stiffness than the first material. The first wall 520 is thinner than the second wall 130.

[0282] The second wall 130 may comprise a plurality of perforations provided through the second wall planar portion 131 and the second wall side portions 134.

[0283] 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". In this context, therefore, a number A is understood as A ± 10 percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

Claims1. An aerosol-generating article for use with an aerosol-generating device, the aerosolgenerating article comprising: a container, the container comprising: a first wall; a second wall opposing the first wall, the first wall and the second wall together defining a substrate compartment of the container; an aerosol-generating substrate located in the substrate compartment; an air inlet having a height of at least 0.5 millimetres; and an air outlet having a height of at least 0.5 millimetres, wherein both the first wall and the second wall are non-planar, wherein one or both of the first wall and the second wall comprises a cellulose- based material, and wherein one or both of the first wall and the second wall has a thickness of at least 0.5 millimetres.

2. An aerosol-generating article according to claim 1 , wherein the first wall is shaped to define a first recess, wherein the second wall is shaped to define a second recess, and wherein the first recess and the second recess together define the substrate compartment.

3. An aerosol-generating article according to claim 2, wherein the first wall is embossed to define the first recess and the second wall is embossed to define the second recess.

4. An aerosol-generating article according to claim 2 or 3, wherein one or both of: i) a ratio of the depth of the first recess to the width of the first recess is between 0.1 and 0.4, and ii) a ratio of the depth of the second recess to the width of the second recess is between 0.1 and 0.4.

5. An aerosol-generating article according to any preceding claim, wherein the first wall comprises a first wall planar portion and the second wall comprises a second wall planar portion, the first wall planar portion being parallel to the second wall planar portion.

6. An aerosol-generating article according to claim 5, wherein the first wall planar portion forms a majority of the first wall, and the second wall planar portion forms a majority of the second wall.

7. An aerosol-generating article according to any preceding claim, wherein one or both of the first wall and the second wall is formed from a sheet of cellulose-based material having a grammage of at least 100 grams per square metre.

8. An aerosol-generating article according to any preceding claim, wherein one or both of the first wall and the second wall has a thickness of at least 1 millimetre.

9. An aerosol-generating article according to any preceding claim, wherein one or both of the first wall and the second wall is formed from paper.

10. An aerosol-generating article according to any preceding claim, wherein the first wall comprises a first wall sealing portion extending outwardly from the substrate compartment, and the second wall comprises a second wall sealing portion extending outwardly from the substrate compartment, and wherein the first wall sealing portion overlays the second wall sealing portion to define a sealing region of the container.

11. An aerosol-generating article according to any preceding claim, wherein the container comprises one or more perforations provided through one or both of the first wall and the second wall, and wherein each of the one or more perforations have a diameter of less than or equal to 1 millimetre.

12. An aerosol-generating article according to any preceding claim, wherein one or both of the air inlet and the air outlet are located between the first wall and the second wall.

13. An aerosol-generating article according to any preceding claim, wherein the container comprises a window provided in one or both of the first wall and the second wall, wherein the window has a length of at least 5 millimetres.

14. An aerosol-generating article according to any preceding claim, wherein the aerosolgenerating substrate comprises tobacco.

15. An aerosol-generating article according to any preceding claim, wherein the aerosolgenerating article has a length of less than or equal to 30 millimetres.

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