Aerosol generating article with conductive wire in the form of inductive stitches

Abstract

The invention provides an aerosol-generating system (1000) comprising an aerosol-generating article (1, 10, 100, 200, 400, 500, 600, 700, 800), and an aerosol-generating device 80, wherein the aerosol-generating article (1, 10, 100, 200, 400, 500, 600, 700, 800) comprises a sheet material (13), and a conductive wire (3, 30, 300), wherein the conductive wire (3, 30, 300) pierces through the sheet material (13). The invention further provides a method for producing an aerosol-generating article (1, 10, 100, 200, 400, 500, 600, 700, 800) for use with an aerosol-generating device (80), wherein the aerosol-generating article comprises at least one sheet material (13) and at least one conductive wire (3, 30, 300), wherein the conductive wire pierces through the sheet material (13). The invention further provides a use of a seam to provide a conductive wire (3, 30, 300) on an aerosol-generating article (1, 10, 100, 200, 400, 500, 600, 700, 800), wherein the conductive wire (3, 30, 300) is a susceptor adapted to be heated by induction, wherein the aerosol-generating device (80) is configured to heat the conductive wire (3, 30, 300) for heating the sheet material (13) to generate an inhalable aerosol.

Description

[0001] Aerosol generating article with conductive wire in the form of inductive stitches

[0002] The present invention relates to an aerosol-generating article for use with an aerosolgenerating device, an aerosol-generating system, a method for producing an aerosol-generating article and / or a use of a seam to provide a conductive wire on an aerosol-generating article.

[0003] A typical aerosol-generating system comprises an aerosol-generating device and an aerosol-generating article comprising an aerosol-generating material. In use, the aerosolgenerating device is arranged to heat a heating element that is positioned near, or in contact with, the aerosol-generating material, which causes the aerosol-generating material 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 have similar dimensions to a conventional cigarette. For example, such an aerosol-generating article may be substantially cylindrical and comprise an aerosol-generating material, typically in the form of a tobacco plug, as well as a susceptor strip extending along a central axis of the tobacco plug.

[0005] However, due to the central positioning of the susceptor strip within the aerosol-generating material, a significant portion of the aerosol-generating material in these aerosol-generating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since insufficiently heated portions of the aerosol-generating substrate contribute to the cost of manufacture and transport of the aerosol-generating article but do not contribute to the aerosol delivered to the consumer.

[0006] Moreover, achieving uniform heating depends on the susceptor strip being precisely centered within the tobacco plug, a challenging requirement to maintain consistently during production. The sensitivity of this process results in a significant number of defective aerosolgenerating article, as even minor misalignments can cause uneven heating.

[0007] It may be desirable to provide an aerosol-generating article in which a greater portion of the aerosol-generating material is sufficiently heated to form an aerosol during use. It may be desirable to provide an aerosol-generating article, whose heating profiles is customized to specific heating requirements. It may be desirable to provide a simple method for precise placement of the susceptor strip in the aerosol-generating article.

[0008] According to a first aspect of the present invention, there is provided an aerosol-generating article for use with an aerosol-generating device. The aerosol-generating article comprises a sheet material, and a conductive wire. The conductive wire pierces through the sheet material.

[0009] This may ensure precise placement and integration of the conductive wire on or within the sheet material. By piercing the conductive wire through the sheet material or through the container or both, the conductive wire may be securely fixed. Relative movement of the conductive wire to the sheet material may be reduced or prevented. It may be ensured that the assembly of the aerosol-generating article remains unchanged during use. This may positively contribute to a consistent user experience.

[0010] The sheet material may be an aerosol-generating material.

[0011] It is beneficial that the sheet material may be heated from the inside and that the conductive wire may be in closer or direct contact with the sheet material. This may further improve heating of the sheet material, heat distribution within the aerosol-generating article and thus the release of volatile compounds forming the aerosol during use.

[0012] The aerosol-generating article may further comprise a container, wherein the sheet material may be a wall of the container, in particular wherein the container may at least partially surround aerosol-generating material. The aerosol-generating material, e.g. homogenised tobacco material, within the container may be of powdered, shredded or granular form.

[0013] The container may be a pouch or a wrapper. The container, in particular in the form of a pouch, may fully surround the aerosol-generating material. The container, in particular in the form of a wrapper, may only partially surround the aerosol-generating material. The wrapper may be predominantly wrapped around one axis, and may be open at the respective ends of the axis. The wrapper may be in a round or elliptical cylindrical form. The container may be a pouch with several closed pouch volumes, wherein at least one or all pouch volumes are filled with sheet material.

[0014] In particular, the sheet material may denote a material capable of releasing volatile compounds upon heating, which can condense to form an aerosol.

[0015] In particular, the aerosol is 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.

[0016] In particular, the aerosol-generating article comprises a sheet material that is capable of releasing volatile compounds that can form an aerosol. The aerosol-generating article may be disposable.

[0017] The aerosol-generating article of the present invention may be for an aerosol-generating device. That is, the aerosol-generating article may be configured to be used with an aerosolgenerating device.

[0018] The conductive wire may heat the sheet material to a temperature at which the sheet material may generate an aerosol. The aerosol may be delivered via the aerosol-generating device to a user.

[0019] The conductive wire may be of a material, which is non-resistively, e.g. inductively, or resistively heatable. For example, the conductive wire may be of iron, copper, brass, aluminum, silver, gold or stainless steel. The conductive wire may be of one or more ferromagnetic material, e.g. titanium, zirconium, tantalum, and / or metals from the platinum group. The conductive wire may be of a metal alloy comprising stainless steel, nickel-, cobalt-, chromium-, aluminumtitanium- zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese-, gold-, iron-containing alloys, super-alloys based on nickel, iron, cobalt, stainless steel, Timetai® and / or iron-manganese-aluminum based alloys. The conductive wire may be of a composite material comprising doped or undoped ceramics, e.g. doped silicon carbides. The conductive wire may be of a carbon based material, e.g. graphite, metals, metal alloys, composite materials made of a ceramic material and / or a metallic material.

[0020] The conductive wire may be a susceptor adapted to be heated by induction. This may advantageously increase the heating of the sheet material. This may allow a simple and energyefficient heating of the sheet material. The conductive wire may have a round, a flat or a rectangular cross-section. The flat shaped heating element may have a height perpendicular to its respective width and depth, wherein the height is less than 20% of the width and depth.

[0021] The sheet material may comprise leaf tobacco, in particular one or more of tobacco, a botanical material and a plurality of aerosol-generating elements. The sheet material may comprise homogenised tobacco material. Optionally, the sheet material may comprise other nontobacco materials and / or additives such as aerosol formers, humectants, plasticizers, flavorings, fillers, and aqueous and non-aqueous solvents.

[0022] The sheet material may have a flat, a rectangular or a round cross-section. The flat shaped sheet material may have a height perpendicular to its respective width and depth, wherein the height is less than 20% of the width and depth.

[0023] The sheet material may be a flat sheet material.

[0024] The flat shaped sheet material may have a height perpendicular to its respective width and depth, wherein the height is less than 20% of the width and depth.

[0025] The container may surround the sheet material by covering between 5 and 90 percent, in particular between 10 and 80 percent, in particular between 20 and 70 percent, of an outer surface of the aggregated sheet material. The container may completely surround the sheet material, e.g. cover approximately 100 percent of the surface of the sheet material. The container may surround a circumferential surface and / or front surfaces of a sheet-like aerosol-generating material.

[0026] In particular, the conductive wire at least partially passes through the sheet material and / or through the container. Thus, the conductive wire may be in closer or direct contact with the sheet material. This may further improve heat distribution within the aerosol-generating article and thus the release of volatile compounds forming the aerosol during use. A length of the conductive wire, in particular in an unpierced state, may be between 200 and 2000 percent, in particular between 400 and 1500 percent, in particular between 600 percent and 1000 percent, of a thickness of the conductive wire.

[0027] The length of the conductive wire may be between 5 and 50 millimeters, in particular between 10 and 40 millimeters, in particular between 20 and 30 millimeters.

[0028] The conductive wire may have a thickness between 30 and 100 micrometres, in particular between 40 and 90 micrometres, in particular between 50 and 80 micrometres. The thickness may be a diameter or a width of the conductive wire.

[0029] Using one or more thin, long conductive wire instead of the prior art susceptor strip, the surface area of the conductive wire for heating by an external inductor of an aerosol-generating device may be increased. This may allow the sheet material to be quickly heated to a temperature sufficient for generating an aerosol. In particular, the conductive wire may be heated to its predetermined aerosol-generating temperature in less than 5 seconds, preferably less than 1 second. In particular when distributing the conductive wires throughout the sheet material, the sheet material may be more uniformly heated. Thus, there is a lower risk of uneven heating of the sheet material, in particular of not heating a part of the sheet material at all, compared to a prior art susceptor strip, where even minor misalignments can cause uneven heating.

[0030] The conductive wire may have a mass between 0.1 milligrams and 10.0 milligrams, in particular between 01.5 milligrams and 8.0 milligrams, in particular between 3.0 milligrams and 5 milligram.

[0031] The conductive wire may be ferromagnetic when heated up to at most 250 degrees Celsius, in particular up to at most 300 degrees Celsius, in particular up to at most 350 degrees Celsius, in particular up to at most 400 degrees Celsius.

[0032] The conductive wire may pierce through the sheet material on a plurality of entry points of the sheet material.

[0033] By piercing the conductive wire on a plurality of entry points through the sheet material and / or through the container, the fixation of the conductive wire may be further secured. The conductive wire may enter the sheet material by passing through a first entry point and may exit the sheet material by passing through a second entry point. The entry points may be located on the same side of the sheet material or on different sides thereof. The conductive wire may, in particular from a side view, pass through the whole cross section of the sheet material or at least part of it.

[0034] The plurality of entry points may be at least two entry points, or more in particular between 2 and 40, between 5 and 30, or between 10 and 20, entry points in the sheet material. The number of entry points may depend on the dimension, in particular a surface, of the sheet material. It may be desirable to use more entry points to improve the heating of the sheet material. The conductive wire may serve as a structural component to maintain the integrity and structure of the aerosol-generating material. The conductive wire may be prevented from slipping on the sheet material. It may be ensured that the assembly of the aerosol-generating article and thus the user experience remains unchanged during use. It is beneficial that several parts of the conductive wire may be in closer or direct contact with the sheet material. This may further improve heat distribution within the aerosol-generating article and thus the release of volatile compounds forming the aerosol during use.

[0035] Another advantage of a conductive wire is that, instead of a single susceptor strip being placed in the centre of a tobacco plug, the heat distributing surface of the pierced conductive wire is larger than that of the single susceptor strip. Thus, approximately the same level of heating can be reached at lower temperatures. Prior art susceptor strips are heated to approximately 380 degrees Celsius.

[0036] In contrast, the inventive conductive wire may be heated to an aerosol-generating temperature between 200 degrees Celsius and 400 degrees Celsius, in particular to between 200 degrees Celsius and 380 degrees Celsius, in particular to between 220 degrees Celsius and 300 degrees Celsius, in particular to between 220 degrees Celsius and 280 degrees Celsius, in particular to between 240 degrees Celsius and 300 degrees Celsius, in particular to between 240 degrees Celsius and 280 degrees Celsius, in order sufficiently heat the sheet material for release of volatile compounds forming the aerosol during use. A more consistent temperature distribution may be obtained.

[0037] The conductive wire may be distributed throughout the sheet material. Beneficially, several parts of the conductive wire are in closer or direct contact with the sheet material. E.g. compared to prior art susceptor strips being placed in the centre of the sheet material, which heats the sheet material only from the centre, several regions of the sheet material may be heated simultaneously. This may contribute to a more uniform heating and thus a better release of volatile compounds forming the aerosol during use. The distribution of the conductive wire throughout the sheet material may scale with the number of entry points. The more entry points, the better the sheet material may be heated, in particular because the conductive wire may pass several times through the sheet material, e.g. the aerosol-generating material, and thus, the heat distributing surface of the conductive wire, which is in contact with the sheet material, may be increased.

[0038] The conductive wire may form a net or three dimensional grid. This may further improve the heating of the sheet material as well as the heat distribution within the aerosol-generating article.

[0039] The conductive wire may be arranged in the net or three dimensional grid on or within the sheet material in in such a way that it follows a non-linear way, in particular when viewed from a perspective view respectively. In particular, the conductive wire may extend in all three directions. In particular, the conductive wire may follow a zig-zag, circular, spiral or serpentine line. Parts of the conductive wire forming the net or grid may be distanced from one another, regionally contact each other, cross each other and / or be regionally parallel with one another.

[0040] The conductive wire may regionally extend along an outer surface of the sheet material. This may improve the fixation of the conductive wire on or within the sheet material. The conductive wire may be avoided from slipping on the sheet material. It may be ensured that the assembly of the aerosol-generating article and thus the user experience remains unchanged during use. Beneficially, in addition to heating the sheet material from the inside, it may be heated from the outside. This may further improve the heating of the sheet material.

[0041] The conductive wire may regionally extend on a cylindrical outer surface of the sheet material. The conductive wire may regionally extend on a longitudinal end surface of the sheet material or of the container.

[0042] The conductive wire may regionally extend along the outer surface of the sheet material in a continuous line. In particular, at least on the outer surface of the sheet material, the parts of the conductive wire may be arranged directly adjacent to one another. A continuous line may be formed by at least two, in particular at least five, in particular at least ten parts of the conductive wire arranged one after the other in a line. Parts of the conductive wire may contact one another on their end portions. This may be achieved by guiding parts of the conductive wire through the same entry point. In other words, there may be no gap between the parts of the conductive wire or the entry points through which the conductive wire is guided.

[0043] The conductive wire may regionally extend along the outer surface of the sheet material in an interrupted line. In particular, at least on the outer surface of the sheet material, the parts of the conductive wire are arranged distanced from one another. Parts of the conductive wire may not contact one another on their end portions. This may be achieved by guiding parts of the conductive wire through different entry points. In other words, there may be a gap between the parts of the conductive wire or the entry points through which the conductive wire is guided.

[0044] The distribution of the conductive wire along the outer surface of the sheet material may scale with the number of entry points. Between 1 and 40 per centimeter, in particular between 5 and 30 per centimeter, in particular 10 and 20 per centimeter, parts of the conductive wire may extend along the outer surface.

[0045] The conductive wire may regionally extend along the outer surface of the sheet material in a linear line. In particular, the conductive wire extends in at most one direction or that the individual parts of the conductive wire extending on the outer surface are arranged in alignment with each other in at most one direction.

[0046] The conductive wire may regionally extend along the outer surface of the sheet material in a circular line. In particular, the conductive wire or the parts of the conductive wire form a circle. If a plurality of conductive wires are provided, they may form individual circles of different radii. The conductive wire may regionally extend along the outer surface of the sheet material in a cross pattern. In particular, the individual parts of the conductive wire extending on the outer surface contact each other in a middle part thereof, in particular cross each other.

[0047] The conductive wire may regionally extend along the outer surface of the sheet material in a spiral pattern. In particular, the conductive wire or the individual parts of the conductive wire extending on the outer surface may be arranged on a single line whose radius decreases towards a circle center point.

[0048] The above-mentioned arrangements of the conductive wire can coexist and / or be combined with each other.

[0049] The aerosol-generating article may comprise a plurality of conductive wires. This may further improve the heating of the sheet material, heat distribution within the aerosol-generating article and thus the release of volatile compounds forming the aerosol during use. The number of conductive wires may scale with the generation of heat in the aerosol-generating article.

[0050] For the plurality of conductive wires may be at least two conductive wires. The aerosolgenerating article may comprise between 2 and 20 conductive wires, in particular between 5 and 15 conductive wires, in particular between 7 and 10 conductive wires. The more conductive wires are provided, the larger the surface area of the conductive wires for heating by an external inductor of an aerosol-generating device may be. This may allow the sheet material to be quickly heated to a temperature sufficient for generating an aerosol. In particular when distributing the conductive wires throughout the sheet material, the sheet material may be more uniformly heated.

[0051] For example, when between 15 and 20 conductive wires are provided, a ratio of the mass of the conductive wires compared to a mass of the sheet material may be about 3 to 4 milligrams of the conductive wires per about 250 to 350 milligrams of the sheet material.

[0052] The conductive wires may be distanced from one another. This may further improve heat distribution within the aerosol-generating article and thus the release of volatile compounds forming the aerosol during use. The sheet material may be positioned between the individual conductive wires. Thus, the sheet material may be heated not only from one direction, but from a plurality of directions. Positioning the conductive wires at a distance to each other may also increase their durability by preventing excessive heating due to conductive wires contacting each other.

[0053] The conductive wires may regionally contact each other. The conductive wires may cross each other. This may lead to a higher local heat release.

[0054] The aerosol-generating article may further comprise a mounting thread, wherein the mounting thread may be electrically non-conductive, and wherein the mounting thread may pierce through the sheet material. By piercing the mounting thread through the sheet material comprising the conductive wire, the fixation of the conductive wire may be improved. The conductive wire may be avoided from slipping on the sheet material. It may be ensured that the assembly of the aerosol-generating article and thus the user experience remains unchanged during use.

[0055] The mounting thread may pierce through the sheet material on a plurality of access points of the sheet material. By piercing the mounting thread on a plurality of access points through the sheet material and / or through the container, the fixation of the mounting thread and thus of the conductive wire may be further secured.

[0056] In particular, the mounting thread pierces through the sheet material on at least two access points. There may be between 2 and 40, in particular between 5 and 30, in particular between 10 and 20, access points. The number of access points may depend on the dimension of the sheet material and / or of the conductive wire, e.g. the number of entry points. The number access points of the mounting thread may be the same or be different from the number of entry points of the conductive wire. It may be desirable to use more access points, to improve the fixation of the conductive wire.

[0057] The mounting thread may be of a non-woven material. The mounting thread may comprise high temperature stable fibers, in particular comprising cellulosic-based material.

[0058] The mounting thread may comprise additives, preferably a flavoring adapted to be released upon heating. This may positively affect the release of aerosol and the user experience. The additives may comprise aerosol-generating substances, such as one or more of glycerin, glycerol, and propylene glycol. The flavouring may be a menthol, spearmint, peppermint, eucalyptus, vanilla, cocoa, chocolate, coffee, tea, spices (such as cinnamon, clove, and ginger) and / or fruit flavoring. The additive may comprise nicotine. The additive may be pure menthol. The additive may comprise liquid menthol, in particular molten menthol.

[0059] The mounting thread and the conductive wire may be wound around one another. This may improve the fixation of the conductive wire on or within the sheet material. The conductive wire may be avoided from slipping on the sheet material. It may be ensured that the assembly of the aerosol-generating article and thus the user experience remains unchanged during use.

[0060] The mounting thread and the conductive wire may have different mechanical properties. The mounting thread may be more elastic than the conductive wire. The mounting thread may apply tension on the conductive wire, in particular to influence the placement of the conductive wire in or on the sheet material.

[0061] The mounting thread and the conductive wire may be fastened with a knot. I.e. the mounting thread and the conductive wire together may form a knot or one of the mounting thread and the conductive wire forms a knot around the other one. The knot may be positioned within the sheet material or between two sheets of sheet material. Since the knot may be a weak point of the conductive wire, this internal placement may protect the knot from external influences. The conductive wire, and optionally the mounting thread, may be fixed to the sheet material, at least regionally, in a sewing pattern, in particular a lockstitch-pattern. This may allow to flexibly vary the arrangement of the conductive wire and optionally of the mounting thread in or on the sheet material, in particular depending on the design of the sheet material. The sewing pattern may affect the distribution of the conductive wire throughout the sheet material and thus, may scale with the amount of heat generation in the aerosol-generating article. Depending on the sewing pattern, the conductive wire may be distributed closer or wider within the sheet material. Thus, it is possible to create customized heating profiles.

[0062] The sewing pattern may be, at least regionally, a zig-zag-stitch pattern. The sewing pattern may be, at least regionally, an overlock-stitch pattern. The sewing pattern may be, at least regionally, a blind-stitch pattern. The conductive wire or the mounting thread may, at least regionally, not intermesh. The conductive wire or the mounting thread may, at least regionally, form meshes.

[0063] The above-mentioned sewing patterns can coexist and / or be combined with each other.

[0064] The aerosol-generating article may comprise a plurality of sheet materials, wherein the sheet materials may be fixed to one another by means of the conductive wire, and optionally the mounting thread. This may increase the amount of released volatile compounds and thus intensify the customer’s experience. By fixing the sheet materials by means of the conductive wire, and optionally the mounting thread, no further fixation element, e.g. glue or envelope, may be required. This may simplify the construction and reduce the cost and mass of the aerosol-generating article. The plurality of sheet materials comprises at least two sheet materials. The sheet material may comprise between 2 and 10 stacked sheet materials, in particular between 3 and 8 stacked sheet materials, in particular between 4 and 6 stacked sheet materials. The sheet materials may be in the form of a sheet. The sheets may be stacked.

[0065] A cover sheet may be provided on an outer surface of the sheet material, in particular of the stack of sheet materials. The cover sheet may protect the sheet material from being damaged during handling, e.g. when transported during production or put in the aerosol-generating article. The sheet materials may be avoided from shifting but remain stacked. It may be ensured that the assembly of the aerosol-generating article and thus the user experience remains unchanged during use. Optionally two or more cover sheets may be provided. A cover sheet may be provided on each outer surface of the sheet material.

[0066] The cover sheet may cover the sheet material or the stack at least partially. The cover sheet may cover between 5 and 90 percent, in particular between 10 and 80 percent, in particular between 20 and 70 percent, of a surface of the sheet material or the stack respectively. The cover sheet may completely surround the sheet material or the stack respectively, e.g. approximately 100 percent thereof. The cover sheet may be formed of paper-based material. The cover sheet may for example be a wrapper. The conductive wire, and optionally the mounting thread, may pierce through the stack of sheet materials and the cover sheet. This may allow for a simple and tight fixation of the cover sheet on the (stack of) sheet material(s), in particular without any further fixation element.

[0067] The container may comprise a first wall and a second wall. The first wall and second wall may together define a first aerosol-generating material compartment of the container. The sheet material may be provided in the first aerosol-generating material compartment. Providing a first aerosol-generating material compartment defined by the first wall and second wall of the container may advantageously allow the aerosol-generating article to accommodate a greater variety of aerosol-generating material, for example granulated or powdered aerosol-generating material.

[0068] The first wall and the second wall may be identical or differ from one another, e.g. regarding material and shape. The first wall and the second wall may comprise a non-woven material, e.g. non-woven carbon fiber fabric, cellulosic non woven such as lyocell, viscose, cotton or other related natural based fibers.

[0069] The first wall and the second wall may comprise edges. A glue may be placed on the edges to fix the first wall to the second wall. The glue may comprise , in particular hot melt, polyvinyl alcohol (PVA) and / or ethylene vinyl acetate (EVA) copolymer, in particular comprising wax and starch.

[0070] The conductive wire, and optionally the mounting thread, may pierce through the first or second wall or both through the first wall and the second wall. This may allow for a simple and safe fixation of the conductive wire, and optionally the mounting thread, on the container. By placing the conductive wire, and optionally the mounting thread, on the first wall and / or the second wall, in particular when distributing it throughout the first and / or second wall, the conductive wire may be in close contact with the sheet material within the container and efficiently heat the sheet material. This may improve heating of the sheet material, heat distribution within the aerosolgenerating article and thus the release of volatile compounds forming the aerosol during use. Additionally, the conductive wire, and optionally the mounting thread, may pierce through the sheet material within the container. This may further improve heating of the sheet material as presented above.

[0071] The aerosol-generating article may comprise a third wall. The third wall and the second wall together may define a second aerosol-generating material compartment of the container. The sheet material may be provided in the second aerosol-generating material compartment. As a result, a larger amount of sheet material may be contained in the aerosol-generating article. The first aerosol-generating material compartment and the second aerosol-generating material compartment may be identical or different, e.g. in terms of volume. The second wall may contact the first aerosol-generating material compartment and the second aerosol-generating material compartment, in particular separate them from another.

[0072] The third wall may be identical to or different from the first wall and / or the second wall. Edges of the second wall and third wall may be glued together by a glue. The glue may comprise, in particular hot melt, polyvinyl alcohol (PVA) and / or ethylene vinyl acetate (EVA) copolymer, in particular comprising wax and starch.

[0073] The conductive wire, and optionally the mounting thread, may pierce through the third wall. This may allow for a simple and safe fixation of the conductive wire, and optionally the mounting thread, on the container. By placing the conductive wire, and optionally the mounting thread, on the third, and optionally the first wall and / or second wall, the conductive wire may be in close contact with the aerosol-generating material within the container and efficiently heat the aerosolgenerating material. This may improve heat distribution within the aerosol-generating article and thus the release of volatile compounds forming the aerosol during use. For example, the aerosolgenerating material in the first aerosol-generating material compartment and in the second aerosol-generating material compartment may be heated by a conductive wire pierced through the second wall. This provides a simple and cost-effective solution for easily attaching the conductive wire to the container and efficiently heating the adjacent aerosol-generating material.

[0074] According to a second aspect of the present invention, there is provided an aerosolgenerating system comprising: an aerosol-generating article, and an aerosol-generating device, wherein the aerosol-generating device is configured to heat the conductive wire for heating the sheet material to generate an inhalable aerosol.

[0075] In particular, the aerosol-generating system is a combination of an aerosol-generating device and a distinct aerosol-generating article.

[0076] Since the aerosol-generating system of this disclosure comprises an aerosol-generating article described herein, the advantages specified above for the aerosol-generating article also apply to the aerosol-generating system itself.

[0077] In particular, the aerosol-generating device interacts with a sheet material to generate an aerosol. The aerosol-generating device may heat the sheet material to facilitate release of volatile compounds from the material.

[0078] The aerosol-generating device may comprise a housing defining a cavity for partially or fully 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.

[0079] The aerosol-generating device may comprise an inductor for heating the conductive wire. The inductor may be an induction coil. Alternatively, the aerosol-generating device may comprise a pair of electrodes, which may be electrically connectable to the ends of the conductive wire for being resistively heated. The aerosol-generating device may comprise one or more inductors. For example, the aerosol-generating device may comprise two inductors. The one or more inductors may be substantially planar. In particular the planar inductor may be generally formed in a single 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 plane. A shape of the inductor may be adapted to a shape of the housing of the aerosol-generating device, in particular its cavity. E.g., the inductor may have a cylindrical shape.

[0080] The inductor may be configured to heat the sheet material of the aerosol-generating article to a temperature at which the sheet material may generate an aerosol. This aerosol may be delivered from the aerosol-generating device to a user.

[0081] The inductor may be adapted for heating the conductive wire to between 200 degrees Celsius and 400 degrees Celsius, in particular to between 220 degrees Celsius and 380 degrees Celsius, in particular to between 240 degrees Celsius and 350 degrees Celsius. The aerosolgenerating device may comprise a power source for supplying power to the one or more inductors. The power source may be a battery.

[0082] The aerosol-generating device may comprise a controller configured to control a supply of power to the one or more inductors.

[0083] The aerosol-generating device may comprise a mouthpiece element. The mouthpiece element may be configured to be inserted into a mouth of a user.

[0084] 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. The aerosol-generating device may comprise an airflow path connecting the air inlet to the air outlet. The airflow path may extend through the cavity of the aerosol-generating device. The airflow path may extend past or through the sheet material or the aerosol-generating material compartment(s) of the container of the aerosol-generating article. As such, in use, the aerosolgenerating 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 aerosol-generating substrate of the aerosolgenerating article.

[0085] According to a third aspect of the present invention, there is provided a method for producing an aerosol-generating article for use with an aerosol-generating device, wherein the aerosol-generating article comprises at least one sheet material and at least one conductive wire. The conductive wire is pierced through the sheet material. The piercing of the conductive wire through the sheet material may allow for a simple production of the aerosol-generating article. Since the conductive wire may be fixed by itself to the sheet material, no further fixation element for the conductive wire, e.g. glue or envelope, may be required. This may simplify the construction and reduce the mass of the aerosol-generating article.

[0086] For producing the sheet material, an endless web of homogenised tobacco material may be pressed to a web comprising a desired thickness. The pressed web may be cut into a sheet of desired length and width or into granular form, in particular shreds, for filling into the container. Shreds of homogenised tobacco material may be formed from the 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.

[0087] Multiple sheet materials may be stacked. This may increase the amount of released volatile compounds and thus intensify the customer’s experience. The sheet materials may have a sheetform.

[0088] A non-conductive mounting thread may be pierced through the sheet material. The mounting thread may be added simultaneous to or after the fixation of the conductive wire. By piercing the mounting thread through the sheet material, the fixation of the conductive wire may be improved.

[0089] The conductive wire, and optionally the mounting thread, may be pierced through the stack of sheet materials. By fixing the sheet materials by means of the conductive wire, and optionally the mounting thread, no further fixation element, e.g. glue or envelope, may be required. This may simplify the construction and reduce the mass of the aerosol-generating article.

[0090] A cover sheet, in particular comprising a paper-based material, may be provided on an outer surface of the sheet material, in particular of the stack of sheet materials. The cover sheet may protect the sheet material from being damaged during handling, e.g. when transported during production or put in the aerosol-generating article. The conductive wire, and optionally the mounting thread, may be pierced through the stack of sheet materials and / or the cover sheet. This may allow for a simple and tight fixation of the cover sheet on the stack of sheet materials, in particular without any further fixation element for the cover sheet.

[0091] For forming a container, the first wall may be formed, e.g. by means of a press, in particular a die, to create a first aerosol-generating material compartment. Before or after forming the first wall, a conductive wire may be fixed to the first wall. Optionally, the first wall may not comprise a conductive wire. The first aerosol-generating material compartment may be filled with shredded aerosol-generating material. The second wall may be placed on the first wall to cover the filled first aerosol-generating material compartment. Before positioning the second wall to the first wall, the second wall may be formed, e.g. by means of a press, in particular a die. Optionally, the second wall may not be formed, but has an approximately planar shape. Before or after positioning the second wall to the first wall, a conductive wire may be fixed to the second wall. Optionally, the second wall may not comprise a conductive wire. Before positioning the first wall on the second wall, a glue, in particular based on hot melt polyvinyl alcohol (PVA) and ethylene vinyl acetate (EVA) copolymer comprising wax and starch, may be applied along edges of the first wall and / or the second wall to create a glued joint when pressing the first wall and the second wall.

[0092] A third wall may be formed, e.g. by means of a press, in particular a die, to create the second aerosol-generating material compartment. Before or after forming the third wall, a conductive wire may be fixed to the third wall. Optionally, the third wall may not comprise a conductive wire. The second aerosol-generating material compartment may be filled with shredded sheet material. The second wall may be placed on the third wall to cover the filled second aerosol-generating material compartment. Before positioning the second wall on the third wall, a glue, in particular based on hot melt polyvinyl alcohol (PVA) and ethylene vinyl acetate (EVA) copolymer comprising wax and starch, may be applied along edges of the second wall and / or the third wall to create a glued joint when pressing the third wall and the second wall.

[0093] A non-conductive mounting thread may be pierced through the sheet material. The mounting thread may be added simultaneous to or after the fixation of the conductive wire. By piercing the mounting thread through the sheet material comprising the conductive wire, the fixation of the conductive wire may be improved.

[0094] The piercing of the conductive wire and / or of the mounting thread may be performed by means of a needle. The piercing may be performed manually or automatically, e.g. by means of a sewing machine. It offers enhanced customization due to the various stitching patterns available, which contrast with the more limited geometries of current susceptors. This flexibility could potentially lead to optimized performance in specific applications, such as potentially increasing aerosol generating efficiency from a customized heating profile.

[0095] According to a fourth aspect of the present invention, there is provided a use of a seam to provide a conductive wire on an aerosol-generating article. The advantages specified for the method for producing an aerosol-generating article also apply to the use of the seam to provide a conductive wire on a sheet material and / or on the container itself.

[0096] The article according to the first aspect may be part of the system according to the second aspect, may be produced by a method according to the third aspect or may be used according to the fourth aspect.

[0097] The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein. Example Ex 1 : An aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article comprising: a sheet material, and a conductive wire, wherein the conductive wire pierces through the sheet material.

[0098] Example Ex 2: An aerosol-generating article according to Ex 1 , wherein the sheet material is an aerosol-generating material.

[0099] Example Ex 3: An aerosol-generating article according to Ex 1 , further comprising a container, wherein the sheet material is a wall of the container, in particular wherein the container is at least partially surrounding aerosol-generating material.

[0100] Example Ex 4: An aerosol-generating article according Ex 3, wherein the container is a pouch or a wrapper.

[0101] Example Ex 5: An aerosol-generating article according to any Ex 1 to Ex 4, wherein the conductive wire is a susceptor adapted to be heated by induction.

[0102] Example Ex 6: An aerosol-generating article according to any Ex 1 to Ex 5, wherein the conductive wire has a round, a flat or a rectangular cross-section.

[0103] Example Ex 7: An aerosol-generating article according to any Ex 1 to Ex 6, wherein the sheet material has a flat, a rectangular or a round cross-section.

[0104] Example Ex 8: An aerosol-generating article according to any Ex 1 to Ex 7, wherein the sheet material is a flat sheet material.

[0105] Example Ex 9: An aerosol-generating article according to Ex 3, wherein the aerosol- generating material within the container may be of powdered, shredded or granular form.

[0106] Example Ex 10: An aerosol-generating article according to any Ex 1 to Ex 9, wherein a length of the conductive wire, in particular in an unpierced state, is between 200 and 2000 percent, in particular between 400 and 1500 percent, in particular between 600 percent and 1000 percent, of a thickness of the conductive wire.

[0107] Example Ex 11 : An aerosol-generating article according to Ex 10, wherein the length of the conductive wire is between 5 and 50 mm, in particular between 10 and 40 mm, in particular between 20 and 30 mm.

[0108] Example Ex 12: An aerosol-generating article according to any Ex 1 to Ex 11 , wherein the conductive wire has a thickness between 30 and 100 micrometres, in particular between 40 and 90 micrometres, in particular between 50 and 80 micrometres.

[0109] Example Ex 13: An aerosol-generating article according to any Ex 1 to Ex 12, wherein the conductive wire has a mass between 0.1 milligrams and 10 milligrams, in particular between 1.5 milligrams and 8 milligrams, in particular between 3 milligrams and 5 milligrams.

[0110] Example Ex 14: An aerosol-generating article according to any Ex 1 to Ex 13, wherein the conductive wire is ferromagnetic when heated up to at most 250 degrees Celsius, in particular up to at most 300 degrees Celsius, in particular up to at most 350 degrees Celsius, in particular up to at most 400 degrees Celsius.

[0111] Example Ex 15: An aerosol-generating article according to any Ex 1 to Ex 14, wherein the conductive wire pierces through the sheet material on a plurality of entry points of the sheet material.

[0112] Example Ex 16: An aerosol-generating article according to any Ex 1 to Ex 15, wherein the conductive wire is distributed throughout the sheet material.

[0113] Example Ex 17: An aerosol-generating article according to any Ex 1 to Ex 16, wherein the conductive wire forms a net or three dimensional grid.

[0114] Example Ex 18: An aerosol-generating article according to any Ex 1 to Ex 17, wherein the conductive wire regionally extends along an outer surface of the sheet material.

[0115] Example Ex 19: An aerosol-generating article according to any Ex 1 to Ex 18, wherein the conductive wire regionally extends on a cylindrical outer surface of the sheet material.

[0116] Example Ex 20: An aerosol-generating article according to any Ex 1 to Ex 19, wherein the conductive wire regionally extends on a longitudinal end surface of the sheet material.

[0117] Example Ex 21 : An aerosol-generating article according to any Ex 1 to Ex 20, wherein the conductive wire regionally extends along the outer surface of the sheet material in a continuous line.

[0118] Example Ex 22: An aerosol-generating article according to any Ex 1 to Ex 21 , wherein the conductive wire regionally extends along the outer surface of the sheet material in an interrupted line.

[0119] Example Ex 23: An aerosol-generating article according to any Ex 1 to Ex 22, wherein the conductive wire regionally extends along the outer surface of the sheet material in a linear line.

[0120] Example Ex 24: An aerosol-generating article according to any Ex 1 to Ex 23, wherein the conductive wire regionally extends along the outer surface of the sheet material in a circular line.

[0121] Example Ex 25: An aerosol-generating article according to any Ex 1 to Ex 24, wherein the conductive wire regionally extends along the outer surface of the sheet material in a cross pattern.

[0122] Example Ex 26: An aerosol-generating article according to any Ex 1 to Ex 25, wherein the conductive wire regionally extends along the outer surface of the sheet material in a spiral pattern.

[0123] Example Ex 27: An aerosol-generating article according to any Ex 1 to Ex 26, further comprising a plurality of conductive wires.

[0124] Example Ex 28: An aerosol-generating article according to Ex 27, wherein the aerosolgenerating article comprises between 2 and 15 conductive wires, in particular between 5 and 12 conductive wires, in particular between 7 and 10 conductive wires.

[0125] Example Ex 29: An aerosol-generating article according to Ex 27 or Ex 28, wherein the conductive wires are distanced from one another. Example Ex 30: An aerosol-generating article according to any Ex 27 to Ex 29, wherein the conductive wires regionally contact each other.

[0126] Example Ex 31 : An aerosol-generating article according to any Ex 27 to Ex 30, wherein the conductive wires cross each other.

[0127] Example Ex 32: An aerosol-generating article according to any Ex 1 to Ex 31 , further comprising a mounting thread, wherein the mounting thread is electrically non-conductive, and wherein the mounting thread pierces through the sheet material.

[0128] Example Ex 33: An aerosol-generating article according to Ex 32, wherein the mounting thread comprises additives, preferably flavoring adapted to be released upon heating.

[0129] Example Ex 34: An aerosol-generating article according to Ex 32 or Ex 33, wherein the mounting thread and the conductive wire are wound around one another.

[0130] Example Ex 35: An aerosol-generating article according to any Ex 32 to Ex 34, wherein the mounting thread and the conductive wire are fastened with a knot.

[0131] Example Ex 36: An aerosol-generating article according to any Ex 1 to Ex 35, wherein the conductive wire, and optionally the mounting thread, is fixed to the sheet material, at least regionally, in a sewing pattern, in particular a lockstitch-pattern.

[0132] Example Ex 37: An aerosol-generating article according to Ex 36, wherein the sewing pattern is, at least regionally, a zig-zag-stitch pattern.

[0133] Example Ex 38: An aerosol-generating article according to Ex 36 or Ex 37, wherein the sewing pattern is, at least regionally, an overlock-stitch pattern.

[0134] Example Ex 39: An aerosol-generating article according to any Ex 36 to Ex 38, wherein the sewing pattern is, at least regionally, a blind-stitch pattern.

[0135] Example Ex 40: An aerosol-generating article according to any Ex 36 to Ex 39, wherein the conductive wire or the mounting thread does, at least regionally, not intermesh.

[0136] Example Ex 41 : An aerosol-generating article according to any Ex 36 to Ex 40, wherein the conductive wire or the mounting thread, at least regionally, forms meshes.

[0137] Example Ex 42: An aerosol-generating article according to any Ex 1 to Ex 41 , further comprising a plurality of sheet materials, wherein the sheet materials are fixed to one another by means of the conductive wire, and optionally the mounting thread.

[0138] Example Ex 43: An aerosol-generating article according to Ex 42, wherein the aerosolgenerating article comprises between 2 and 10 stacked sheet material sheets, in particular between 3 and 8 stacked aerosol-generating sheets, in particular between 4 and 6 stacked aerosol-generating sheets.

[0139] Example Ex 44: An aerosol-generating article according to any Ex 1 to Ex 43, wherein a cover sheet is provided on an outer surface of the sheet material, in particular of the stack of sheet materials. Example Ex 45: An aerosol-generating article according to Ex 44, wherein the cover sheet is formed of paper-based material.

[0140] Example Ex 46: An aerosol-generating article according to Ex 44 or Ex 45, wherein the cover sheet is a wrapper.

[0141] Example Ex 47: An aerosol-generating article according to Ex 44 to Ex 46, wherein the conductive wire, and optionally the mounting thread, pierces through the sheet material and the cover sheet.

[0142] Example Ex 48: An aerosol-generating article according to Ex 3, wherein the container comprises a first wall and a second wall.

[0143] Example Ex 49: An aerosol-generating article according to Ex 48, wherein the first wall and the second wall together define a first aerosol-generating material compartment of the container.

[0144] Example Ex 50: An aerosol-generating article according to Ex 48 or Ex 49, wherein the conductive wire, and optionally the mounting thread, pierces through the first wall or second wall or both through the first wall and the second wall.

[0145] Example Ex 51 : An aerosol-generating article according to any Ex 48 to Ex 50, wherein the aerosol-generating article comprises a third wall, wherein the third wall and the second wall together define a second aerosol-generating material compartment of the container.

[0146] Example Ex 52: An aerosol-generating article according to Ex 51 , wherein the conductive wire, and optionally the mounting thread, pierces through the third wall.

[0147] Example Ex 53: An aerosol-generating system comprising: an aerosol-generating article according to any Ex. 1 to Ex. 52, and an aerosol-generating device, wherein the aerosolgenerating device is configured to heat the conductive wire for heating the sheet material to generate an inhalable aerosol.

[0148] Example Ex 54: An aerosol-generating system according to Ex 53, wherein the aerosolgenerating device has a housing defining a cavity for partially or fully receiving the aerosolgenerating article.

[0149] Example Ex 55: An aerosol-generating system according to Ex 53 or Ex 54, wherein the aerosol-generating device comprises an inductor for heating the conductive wire.

[0150] Example Ex 56: An aerosol-generating system according to Ex 55, wherein the inductor is adapted for heating the conductive wire to between 200 degrees Celsius and 400 degrees Celsius, in particular to between 220 degrees Celsius and 380 degrees Celsius, in particular to between 240 degrees Celsius and 350 degrees Celsius.

[0151] Example Ex 57: Method for producing an aerosol-generating article for use with an aerosolgenerating device, wherein the aerosol-generating article comprises at least one sheet material and at least one conductive wire, and wherein the conductive wire pierces through the sheet material. Example Ex 58: Method according to Ex 57, wherein a non-conductive mounting thread pierces through the sheet material.

[0152] Example Ex 59: Method according to Ex 57 or Ex 58, wherein multiple sheet materials are stacked.

[0153] Example Ex 60: Method according to Ex 59, wherein the conductive wire pierces at least partially through the stack of sheet materials.

[0154] Example Ex 61 : Method according to any Ex 57 to Ex 60, wherein a cover sheet, in particular comprising a paper-based material, is placed on an outer surface of the sheet material, in particular of the stack of sheet materials.

[0155] Example Ex 62: Method according to Ex 61 , wherein the conductive wire, and optionally the mounting thread, pierces through the sheet material and the cover sheet.

[0156] Example Ex 63: Use of a seam to provide a conductive wire on an aerosol-generating article.

[0157] Examples will now be further described with reference to the figures in which:

[0158] Figure 1 shows a perspective view of an aerosol-generating article according to a first embodiment;

[0159] Figure 2 shows a side view of the aerosol-generating article according to the first embodiment;

[0160] Figure 4 shows a top view of an aerosol-generating article according to a second embodiment comprising two conductive wires;

[0161] Figure 5 shows a side view of an aerosol-generating article according to a third embodiment;

[0162] Figure 6 shows a side view of an aerosol-generating article according to a fourth embodiment;

[0163] Figures 7 and 8 show a top view and a base view of an aerosol-generating article according to the fifth embodiment;

[0164] Figures 3 and 9 to 11 show different stitching patterns;

[0165] Figure 12 shows a side view of an aerosol-generating article according to a fifth embodiment in the form of a container; and

[0166] Figure 13 shows a side view of an aerosol-generating system.

[0167] Figure 1 shows a perspective view of a rod shaped aerosol-generating article 1 according to a first embodiment for use with an aerosol-generating device 80 (cf. Figure 13). The aerosolgenerating article 1 comprises a sheet material 13 in the form of a sheet-like aerosol-generating material 2, and a conductive wire 3.

[0168] The aerosol-generating material 2 comprises a homogenised tobacco material as well as aerosol formers, humectants, plasticizers, flavorings, fillers, and aqueous and non-aqueous solvents. The aerosol-generating material 2 has a flat rectangular cross-section. It has a height 91 of 1 millimetre, which is smaller than a width 92 of the aerosol-generating material 2 of three millimetres. A length 90 of the aerosol-generating material 2 is 20 millimeters.

[0169] The conductive wire 3 is a conductive copper wire with a round cross section, which is inductively heatable by an external inductor (cf. Figure 13). The conductive wire 3 pierces through the aerosol-generating material 2. The piercing is performed automatically by means of a sewing machine (not shown). The piercing ensures precise placement and integration of the conductive wire 3 on and within the aerosol-generating material 2. By piercing the conductive wire 3 through the aerosol-generating material 2, the fixation of the conductive wire 3 is secured. The conductive wire 3 is avoided from slipping on the aerosol-generating material 2. It is ensured that the assembly of the aerosol-generating article 1 and thus the user experience remains unchanged during use.

[0170] The length of the conductive wire 3, in particular in an unpierced state, is 30 millimetres. A diameter (not shown) of the conductive wire 3 is 50 micrometres. The present conductive wire 3 has a mass of 0.3 milligrams.

[0171] Compared to a commonly known susceptor strip having a length of approximately 12 millimetres, a width of approximately 4 millimeters, and a thickness of approximately 60 micrometers, the present conductive wire 3 is 250 percent longer and at least 10 percent thinner. The mass of the present conductive wire 3 is 85 percent lower than that of a prior art susceptor strip of two milligrams. This reduces the total mass of the aerosol-generating article 1 without negatively affecting the heat distribution. The mass is further reduced by the fact that the conductive wire 3 is fixed to the aerosol-generating material 2 by itself, i.e. without additional fixation element, e.g. glue. This also simplifies the construction of the aerosol-generating article

[0172] 1.

[0173] As Figures 1 and 2 further demonstrate, the conductive wire 3 is distributed throughout the length 90 of the aerosol-generating material 2. Thus, several parts of the conductive wire 3 are in closer or direct contact with the aerosol-generating material 2. This contributes to a more uniform heating of the aerosol-generating material 2 and release of volatile compounds forming the aerosol during use.

[0174] The conductive wire 3 pierces through the aerosol-generating material 2 entering and exiting the aerosol-generating material 2 on a plurality of, in the present embodiment 24, entry points 4. By piercing the conductive wire on a plurality of entry points through the aerosolgenerating material 2, the conductive wire 3 forms a net within the aerosol-generating material 2 in the form of a serpentine line, in particular when viewed from the side view of Figure 2. This arrangement further secures fixation of the conductive wire 3 on the aerosol-generating material

[0175] 2. Another advantage is that, instead of a single conductive wire being placed in the centre of the aerosol-generating material 2, a heat distributing surface of the pierced conductive wire 3 is larger than that of the single conductive wire. Thus, approximately the same level of heating is reached at lower temperatures, approximately at 280 degrees Celsius, in order sufficiently heat the aerosol-generating material 2 for release of volatile compounds forming the aerosol during use.

[0176] As can be seen in Figures 1 and 2, due to the piercing fixation, the conductive wire 3 regionally extend along an outer surface 12 of the aerosol-generating material 2, in particular a top side 5 and a bottom side 6 of the aerosol-generating material 2, improving the fixation of the conductive wire 3 on the aerosol-generating material 2. When viewed from the top, six outer conductive wire parts 11 of the conductive wire 3 regionally extend along the top side 5 and a bottom side 6 of the aerosol-generating material 2 in a linear interrupted line. This means that, at least on the top side 5 and the bottom side 6 of the aerosol-generating material 2, outer conductive wire parts 11 are distanced from one another. This is achieved by guiding parts of the conductive wire 3 through different entry points 4. In other words, there is a gap 7 between the outer conductive wire parts 11 on the top side 5 and bottom side 6 respectively.

[0177] Further arrangements of the conductive wire 3 are shown in Figures 3 and 9 to 13.

[0178] Figure 3 shows an aerosol-generating article 10 comprising a conductive wire 3 being pierced through the outer surface 12, in particular the front surface 8 and the end surface 9 of the aerosol-generating material 2, i.e. an area spanned by the width 92 and height 91. On the front surface 8 and the end surface 9 of the aerosol-generating material 2, the conductive wire 3 extends in an interrupted linear line.

[0179] Figure 9 shows an aerosol-generating article 100 comprising a conductive wire 3 extending along the top side 5 of the aerosol-generating material 2 in a spiral pattern in form of an interrupted line.

[0180] Figure 10 shows an aerosol-generating article 200 comprising a conductive wire 3 extending along the top side 5 of the aerosol-generating material 2 in a cross pattern in form of an interrupted line.

[0181] Figure 11 shows an aerosol-generating article 400 comprising a conductive wire 3 extending along the top side 5 of the aerosol-generating material 2 in a circular line in form of a continuous line. Thus, at least on the top side 5 of the aerosol-generating material 2, parts of the conductive wire 3 are arranged directly adjacent to one another, forming a closed circle. This is achieved by guiding parts of the conductive wire 3 through the same entry point 4. In other words, there is no gap between the entry points 4.

[0182] Figure 4 shows a top view of an aerosol-generating article 500 according to a second embodiment comprising three conductive wires, in particular a first conductive wire 3, a second conductive wire 30 and a third conductive wire 300. These are fixed to the aerosol-generating material 2 as already described and shown in Figures 1 and 2. The first conductive wire 3, the second conductive wire 30 and the third conductive wire 300 are arranged parallel to each other, extending along the length 90 of the aerosol-generating material 2. By adding the second conductive wire 30 and the third conductive wire 300, the heating of the aerosol-generating material 2 and thus heat distribution within the aerosol-generating article 500 is further increased. The surface area of the conductive wires 3, 30, 300 for heating by an external inductor is increased compared to a single conductive wire 3. This allows the aerosol-generating material 2 to be quickly heated. Moreover, by positioning the conductive wires 3, 30, 300 distanced to another by a distance 94 of 0.5 millimetres, the aerosol-generating material 2 is more uniformly heated.

[0183] Figure 5 shows a side view of an aerosol-generating article 600 according to a third embodiment. The aerosol-generating article 600 comprises an aerosol-generating material 2 and a conductive wire 3 as previously described. Additionally, the aerosol-generating article 600 comprises two paper-based cover sheets 20, 21 , which are placed on the top side 5 and the bottom side 6 of the aerosol-generating material 2. The cover sheets 20, 21 protect the aerosolgenerating material 2 from being damaged during handling, e.g. when transported during production or put in the aerosol-generating article 600. The cover sheets 20, 21 are each fixed to the aerosol-generating material 2 by means of the conductive wire 3, which pierces through the cover sheets 20, 21 and the aerosol-generating material 2. This allows for a simple and tight fixation of the cover sheets 20, 21 on the aerosol-generating material 2, in particular without any further fixation element for the cover sheets 20, 21.

[0184] Figure 6 shows a side view of an aerosol-generating article 700 according to a fourth embodiment. The aerosol-generating article 700 comprises three sheet-like aerosol-generating materials 2, 22, 222, which are stacked onto each other. By using three aerosol-generating materials 2, 22, 222, the amount of releasable volatile compounds is increased, thus intensifying the customer’s experience.

[0185] The aerosol-generating materials 2, 22, 222 are bond together by means of a conductive wire 3 and a mounting thread 40. The conductive wire 3 pierces through the aerosol-generating materials 2, 22. The mounting thread 40 pierces through the third aerosol-generating material 222. The mounting thread 40 is an electrically non-conductive wire made of a non-woven material comprising high temperature stable cellulosic-based fibers.

[0186] It serves for improving the positioning and fixation of the conductive wire 3 on the aerosolgenerating material stack. By fixing the aerosol-generating materials 2, 22, 222 by means of the conductive wire 3 and the mounting thread 40, no further fixation element, e.g. glue or envelope, is required. This simplifies the construction and reduces the mass of the aerosol-generating article 700. As Figure 6 illustrates the mounting thread 40 pierces through the aerosol-generating material 222 on a plurality of, in particular 16, access points 41 of the aerosol-generating material 222. This improves the fixation of the mounting thread 40 and of the conductive wire 3.

[0187] Moreover, the mounting thread 40 and the conductive wire 3 are wound around one another forming four knots 50. By forming knots 50, the mounting thread 40 and the conductive wire 3 are fixed together and to the aerosol-generating materials 2, 22, 222 in a sewing pattern, in particular a lockstitch-pattern. By pulling the mounting thread 40, wound around the conductive wire 3, the conductive wire 3 is shifted downwards to the third aerosol-generating material 222 and tightened. The knot 50 is thus shifted and positioned between the second aerosol-generating materials 22 and the third aerosol-generating material 222. This placement protects the knot 50 from outer influences, e.g. when handling the aerosol-generating article 700. Thus, the tightened mounting thread 40 serves for adjusting the position of the conductive wire 3 on the stack of aerosolgenerating materials 2, 22, 222.

[0188] Figures 7 and 8 show the aerosol-generating article 700 from a top view and a bottom view respectively. The conductive wire 3 partially extends on the top side 5. The mounting thread 40 partially extends on the bottom side 6.

[0189] Figure 12 shows a side view of an aerosol-generating article 800 according to a fifth embodiment.

[0190] The aerosol-generating article 800 comprises a container 50 having a first wall 51 , a second wall 52 and a third wall 53, each made of non-woven carbon fiber fabric. The first wall 51 and second wall 52 together define a first aerosol-generating material compartment 61 of the container 50. The third wall 53 and second wall 52 together define a second aerosol-generating material compartment 62 of the container 50. Aerosol-generating material 2 in the form of shreds 23 is provided in the first and second aerosol-generating material compartments 61 , 62. A glue (not shown) based on hot melt polyvinyl alcohol (PVA) and ethylene vinyl acetate (EVA) copolymer comprising wax and starch is provided on edges 71 , 72, 73 of the first, second and third wall 51 , 52, 53 to fix the first, second and third wall 51 , 52, 53 and to provide a sealing for the first and second aerosol-generating material compartments 61 , 62.

[0191] The second wall 52 is configured as sheet material 13 comprising a conductive wire 3, which pierces there through, in particular in the same way as previously described with reference to Figure 1. By placing the conductive wire 3 on the second wall 52, the conductive wire 3 is in close contact with the shreds 23 of aerosol-generating material 2 in the first and second aerosolgenerating material compartments 61 , 62. This allows for a simple and efficient heating of the shreds 23.

[0192] Figure 13 shows a side view of an aerosol-generating system 1000 comprising the aerosolgenerating article 700 as shown in Figures 6 to 8 and an aerosol-generating device 80. The aerosol-generating device 80 comprises a housing 81 defining a cavity 82 for receiving a part of the aerosol-generating article 700. A first inductor 83 and a second inductor 84 are arranged on an inner surface of the cavity 82. The first inductor 83 and the second inductor 84 are configured as induction coils to inductively heat the aerosol-generating materials 2, 22, 222 (cf. Figure 6) of the aerosol-generating article 700 to generate an inhalable aerosol.

[0193] The aerosol-generating device 80 further comprises a battery 85 for supplying power to the first inductor 83 and the second inductor 84.

[0194] The aerosol-generating device 80 further comprises a controller 86 for controlling the supply of power from the battery 84 to the first inductor 83 and the second inductor 84.

[0195] The aerosol-generating device 80 further comprises a mouthpiece element 87, which is configured to be inserted into a mouth of a user for inhaling the generated aerosol.

[0196] Moreover, the aerosol-generating device 80 comprises an air inlet 88 and an air outlet 89, which are fluidly connected by an airflow path.

[0197] When the aerosol-generating article 700 is inserted into the cavity 82 of the aerosolgenerating device 80, and a negative pressure is applied to the air outlet 89, for example by a user drawing on the air outlet 89, air is drawn into the aerosol-generating device 80 through the air inlet 88 of the aerosol-generating device 80, then through the aerosol-generating article 700, thereby entraining aerosol released from the aerosol-generating materials 2, 22, 222, and then through the air outlet 89 at the mouthpiece element 87.

[0198] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 5 % 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 system comprising: an aerosol-generating article, and an aerosol-generating device, wherein the aerosol-generating article comprises: a sheet material, and a conductive wire, wherein the conductive wire pierces through the sheet material, wherein the conductive wire is a susceptor adapted to be heated by induction, wherein the aerosol-generating device is configured to heat the conductive wire for heating the sheet material to generate an inhalable aerosol.

2. An aerosol-generating system according to claim 1 , wherein the sheet material is an aerosolgenerating material.

3. An aerosol-generating system according to claim 1 , further comprising a container, wherein the sheet material is a wall of the container, in particular wherein the container is at least partially surrounding aerosol-generating material.

4. An aerosol-generating system according to one of the preceding claims, wherein the conductive wire pierces through the sheet material on a plurality of entry points of the sheet material.

5. An aerosol-generating system according to one of the preceding claims, wherein the conductive wire is distributed throughout the sheet material.

6. An aerosol-generating system according to one of the preceding claims, wherein the conductive wire regionally extends along an outer surface of the sheet material.

7. An aerosol-generating system according to one of the preceding claims, further comprising a plurality of conductive wires.

8. An aerosol-generating system according to one of the preceding claims, further comprising a mounting thread, wherein the mounting thread is electrically non-conductive, and wherein the mounting thread pierces through the sheet material.

9. An aerosol-generating system according to claim 8, wherein the mounting thread and the conductive wire are wound around one another.

10. An aerosol-generating system according to one of the preceding claims, wherein the conductive wire, and optionally the mounting thread, is fixed to the sheet material, at least regionally, in a sewing pattern, in particular a lockstitch-pattern.

11. An aerosol-generating system according to one of the preceding claims, further comprising a plurality of sheet materials, wherein the sheet materials are fixed to one another by means of the conductive wire, and optionally the mounting thread.

12. Method for using an aerosol-generating article with an aerosol-generating device, wherein the aerosol-generating article comprises: a sheet material, and a conductive wire, wherein the conductive wire pierces through the sheet material, wherein the conductive wire is a susceptor adapted to be heated by induction, wherein the aerosol-generating device heats the conductive wire for heating the sheet material to generate an inhalable aerosol.

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