Aerosol-generating article

Abstract

The present disclosure relates to an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. There is provided an aerosol-generating article (100) for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article (100) comprises a plurality of micro-cavities (113). Sensorial media is disposed within at least some of the plurality of micro-cavities (113).

Description

[0001] FTR4265 / PCT - P / 92591.WO01

[0002] 1 / 23

[0003] AEROSOL-GENERATING ARTICLE

[0004] The present disclosure relates to an aerosol-generating article for use with an aerosolgenerating device to generate an aerosol.

[0005] A typical aerosol-generating article contains a plug or body of sensorial media. For example, a conventional cigarette contains a cylindrical body of tobacco. Similarly, aerosol-generating articles adapted to generate aerosol through heating rather than burning of an aerosol-forming substrate are known containing a plug of aerosol-forming substrate, for example a plug of homogenised tobacco. Such known articles also contain a wrapper surrounding and enclosing the sensorial media, with the wrapper and sensorial media being separate and distinct from each other. Where the sensorial media is in the form of a liquid or gel, it is known for the sensorial media to be provided in a capsule or cartridge enclosed by a wrapping or housing of the article.

[0006] The present disclosure provides an aerosol-generating article in which sensorial media may be stored with enhanced volumetric efficiency and which may be particularly suitable for the efficient storing of liquid- or gel-based sensorial media.

[0007] According to a first aspect of the present disclosure, there may be provided an aerosolgenerating article for use with an aerosol-generating device to generate an aerosol. The aerosolgenerating article may comprise a plurality of micro-cavities. Sensorial media may be disposed within at least some of the plurality of micro-cavities.

[0008] By having sensorial media disposed within at least some of the plurality of micro-cavities, different ones of the micro-cavities are able to facilitate storage and containment of the sensorial media.

[0009] The micro-cavities of the article may be particularly beneficial in containing sensorial media in the form of a gel, a slurry or a liquid. These forms of sensorial media are inherently “wet”. The use of “wet” sensorial media may assist the sensorial media to adhere to surfaces of the micro-cavities, for example through surface tension.

[0010] Preferably, each of the plurality of micro-cavities may define a volume of no more than 5 mm3, for example no more than 2.5 mm3, for example no more than 1 mm3. These exemplary values may define an upper bound value for the volume of each of the plurality of micro-cavities.

[0011] Preferably, each of the plurality of micro-cavities may define of volume of no less than 0.01 mm3, for example no less than 0.05 mm3, for example no less than 0.1 mm3. These exemplary values may define a lower bound value for the volume of each of the plurality of micro-cavities.

[0012] Each of the plurality of micro-cavities may define a volume within a range defined by a lower bound value and a lower bound value according to the values recited in the preceding paragraphs.

[0013] Preferably, the plurality of micro-cavities may have an open cell structure. The use of an open cell structure may facilitate vapours evolved from sensorial media held in different ones of the microcavities (for example, in response to the application of heat) being able to mix and combine with each other and / or with air flowing adjacent to the micro-cavities.

[0014] Heat may be applied to the aerosol-generating article by a heating element of an aerosolgenerating device. By way of example and without limitation, the aerosol-generating device may have a cavity configured to receive the aerosol-generating article. A heating element may be arranged within the aerosol-generating device (for example within the cavity of the device) to overlie the aerosolgenerating article received in the cavity of the device. The heating element may be a resistive heating element. Conveniently, the heating element may be planar in form, with the aerosol-generating article also being generally planar.

[0015] Preferably, an airflow path may be defined within the aerosol-generating article between an inlet end and an outlet end of the aerosol-generating article. The outlet end may define a mouth end of the aerosol-generating article for a user to inhale vapours and aerosol therefrom. The inlet end and the outlet end may be separated from each other along a length direction of the article. Alternatively, the inlet end and the outlet end may be separated from each other along a width direction of the article.

[0016] Advantageously, the airflow path may be arranged over and in fluid communication with the plurality of micro-cavities. In this manner, volatile compounds evolved from the sensorial media disposed in the micro-cavities (for example, in response to heating of the article) may become entrained in air flowing along the airflow path.

[0017] The airflow path may be wholly or at least partly defined by a subset of the plurality of microcavities. Having the airflow path defined by a subset of the plurality of micro-cavities may facilitate providing a more compact structure for the aerosol-generating article compared to having an airflow path which is separate from and passes over the micro-cavities. By way of example, a first subset of the plurality of micro-cavities may be free of sensorial media and wholly or at least partly define the airflow path, and a second subset of the plurality of micro-cavities contain sensorial media. The airflow path defined by the first subset of micro-cavities may extend along a path through or adjacent to the second subset of the micro-cavities. Where the plurality of micro-cavities have an open cell structure, volatile compounds evolved from heating of the sensorial media contained in the second subset of the plurality of micro-cavities may be able to flow into the airflow path defined by the first subset of the plurality of micro-cavities.

[0018] Preferably, at least some of the plurality of micro-cavities may be defined in a wall or layer of the aerosol-generating article. An or the airflow path may extend over the wall or layer. Advantageously, at least some of the plurality of micro-cavities may open onto a surface of the wall or layer. In this manner, volatile compounds evolved from the sensorial media may be able to easily disperse outside of the structure of the wall or layer, for example into an airflow path passing over the wall or layer. The wall or layer may be a porous wall or layer. Advantageously, pores of the porous wall or layer may define different ones of the micro-cavities.

[0019] Having the sensorial media contained within micro-cavities defined in a wall or layer of the article provides the aerosol-generating article with the ability to store sensorial media with greater volumetric efficiency.

[0020] An or the airflow path may extend through the porous wall or layer. For example, pores of the porous wall or layer may define at least part of the airflow path. As described above, the pores may define different ones of the micro-cavities.

[0021] Preferably, the aerosol-generating article may further comprise an embossed or corrugated layer arranged over and in surface contact with the wall or layer to thereby define one or more airflow passages adjacent the micro-cavities. Advantageously, the use of such an embossed or corrugated layer may enhance flexural stiffness of the aerosol-generating article whilst also defining a structure through which air can flow over the micro-cavities. The use of an embossed or corrugated layer may also serve to enhance aerosol generation during use of the aerosol-generating article, whilst keeping the thickness and mass of the article low. During use of the aerosol-generating article, vapours evolved from heating of sensorial media contained in different ones of the micro-cavities may diffuse into the one or more airflow passages to become entrained with air flowing through and along the one or more airflow passages.

[0022] The embossed or corrugated layer may be formed from a combination of foil and paper, for example, a laminate of foil and paper. The embossed or corrugated layer may have a thickness in a range of between about 0.005 to 0.1 mm. The height defined by the distance between the upper and lower extremities of the embossed or corrugated layer (for example, between upper and lower extremities of corrugations of the layer) may be in a range of between about 0.75 to 1 .5 mm.

[0023] The embossed or corrugated layer may be sandwiched between opposed interior-facing upper and lower surfaces of the aerosol-generating article. A plurality of micro-cavities may be disposed in or on each of opposed interior-facing upper and lower surfaces of the aerosol-generating article, with the embossed or corrugated layer arranged between the opposed interior-facing upper and lower surfaces to define one or more upper airflow passages between the upper surface and the embossed or corrugated layer and one or more lower airflow passages between the lower surface and the embossed or corrugated layer. Sensorial media may be disposed within at least some of the plurality of micro-cavities of the upper surface and within at least some of the plurality of micro-cavities of the lower surface. Advantageously, the embossed or corrugated layer provides separation of airflows between lower and upper halves of the aerosol-generating article. The separation of airflows between lower and upper halves of the aerosol-generating article may allow aerosol generated from sensorial media held in micro-cavities defined in the lower surface to be isolated from aerosol generated from sensorial media held in micro-cavities defined in the upper surface. Where the sensorial media held in the micro-cavities of the lower surface is of a different composition to the sensorial media held in the micro-cavities of the upper surface, the isolation of airflows and aerosols provided by the embossed or corrugated layer may facilitate avoiding cross-contamination or mixing / blending between the different aerosols generated from the different sensorial media.

[0024] The embossed or corrugated layer may define a plurality of linearly extending channels. The plurality of linearly extending channels may define distinct airflow passages. The plurality of linear channels may preferably extend along a length of the aerosol-generating article. Advantageously, the provision of linear channels defined by the embossed or corrugated layer may provide for generally laminar flow along the channels, and tend to reduce the likelihood of turbulent flow occurring within the channels.

[0025] In another example, the embossed or corrugated layer may define an exterior layer of the aerosol-generating article, with the embossed or corrugated layer arranged to cover and / or seal the micro-cavities. The embossed or corrugated layer may have similar dimensions to the plurality of micro-cavities. For example, the embossed or corrugated layer may define a plurality of channels, wherein a width of each of the plurality of channels differs from a major diameter of each of the micro-cavities by no more than 20%, or no more than 15%, or no more than 10%, or no more than 5%.

[0026] Advantageously, a plurality of micro-cavities may be disposed in or on each of opposed interiorfacing upper and lower surfaces of the aerosol-generating article. Sensorial media may be disposed within at least some of the plurality of micro-cavities disposed in or on the upper surface and within at least some of the plurality of micro-cavities disposed in or on the lower surface.

[0027] Preferably, the opposed interior-facing upper and lower surfaces may be separated from each other by a gap, an or the airflow path extending through gap over the opposed interior-facing upper and lower surfaces. As described above, an airflow path may be defined within the aerosol-generating article between an inlet end and an outlet end of the aerosol-generating article. Where sensorial media contained in micro-cavities of both the upper and lower interior-facing surfaces is intended to be vaporised and consumed in the same usage session, air flowing through the gap between the surfaces may easily mix and become entrained with volatile compounds evolved from sensorial media stored in the micro-cavities of both surfaces.

[0028] Preferably, the opposed interior-facing upper and lower surfaces form part of respective opposed upper and lower sheets. Preferably, the micro-cavities of the opposed interior-facing upper and lower surfaces may form an integral part of the respective opposed upper and lower sheets. So, advantageously the micro-cavities may be an integral part of the structure of the upper and lower sheets.

[0029] The micro-cavities of at least one of the opposed upper and lower sheets may extend from the respective interior-facing surface part-way through the thickness of the respective sheet. Avoiding the micro-cavities extending through to exterior-facing surfaces of the sheets may facilitate minimising or preventing unwanted escape of sensorial media from the article.

[0030] Although the sensorial media in the micro-cavities of the upper and lower surfaces may be identical in composition, in an alternative example micro-cavities of the upper surface may contain sensorial media having a first composition and micro-cavities of the lower surface contain sensorial media having a second composition, the first composition being different to the second composition. Where sensorial media in micro-cavities of both the upper and lower surfaces is consumed simultaneously in a given usage session, vapours evolved from the first composition of sensorial media held in micro-cavities of the upper surface may combine with vapours evolved from the second composition of sensorial media held in micro-cavities of the lower surface, with the user able to inhale an aerosol formed of constituents of both compositions of sensorial media. The combination of vapours from the sensorial media of the upper and lower surfaces may be aided by having an airflow path defined in a gap separating the opposed interior-facing surfaces from each other. Alternatively, where heat is applied to different ones of the upper and lower sheets in different usage sessions, a user may receive vapours of different compositions in different usage sessions according to which one of the sheets is heated. The upper and lower sheets may each have a length extending in an x direction, a width extending in a y direction and a thickness extending in a z direction, wherein the thickness is less than each of the length and the width. The x, y and z directions are preferably aligned perpendicular to each other.

[0031] Each of the upper and lower sheets may comprise a first layer formed of a paper-based material and a second layer, wherein the second layer of the upper sheet is bonded to the second layer of the lower sheet, for example by use of an adhesive. The second layer may be formed of a bio-polymeric compound. Using such materials facilitates enhancing recyclability of the aerosol-generating article, thereby enhancing the sustainability of the article. The second layer may be selected to be impermeable, for example to be water impermeable. Impermeability of the second layer may facilitate avoiding moisture content from the sensorial media from seeping into the paper-based first layer and reducing the flexural stiffness of the article; this may be especially advantageous where the sensorial media is liquid or gel-based. The respective micro-cavities of the upper and lower sheets may be formed within the material of the second layer, or in a third layer overlying the second layer and separated from the first layer by the second layer.

[0032] The first layer may be paper-based and have a thickness of about 1 .1 to about 4.5 microns, a basis weight of about 45 to about 140 g / m, preferably of about 50 to 110 g / m, and a permeability of about 1 to 5 Coresta Units. The second layer may be in the form of an impermeable coating or impermeable layer having a thickness of about 0.75 to about 1 .5 microns. The composition of the second impermeable coating or layer is preferably selected to be compliant with FDA Reg. 21 CFR; for example, the impermeable coating or layer may comprise dispersions based on copolymers consisting of acrylic ester and styrene, or based on styrene-butadiene copolymers, applied during paper processing as aqueous dispersions of copolymers of styrene-butadiene with a solids content of approximately 50 %.

[0033] Preferably, the upper and lower sheets may be aligned parallel to each other. Parallel alignment of the upper and lower sheets may facilitate providing the article with a uniform thickness or height.

[0034] At least 95% - preferably all - of the plurality of micro-cavities of the lower sheet may be defined in a first intruded area of the lower sheet, the first intruded area surrounded by a peripheral region of the lower sheet. Similarly, at least 95% - preferably all - of the plurality of micro-cavities of the upper sheet may be defined in a first intruded area of the upper sheet, the first intruded area surrounded by a peripheral region of the upper sheet.

[0035] The intruded areas may be formed by deforming an initially planar sheet by use of a stamping, extruding or similar mechanical deformation process. In this manner, the initially planar sheet may be deformed into a sheet having a tray-shaped profile defined by a peripheral rim surrounding an intruded area. When viewing the deformed sheet from above, the intruded area would appear sunk or depressed relative to the peripheral rim. When viewing the deformed sheet from below, the part of the deformed sheet in which the intruded area is formed would appear raised relative to the peripheral rim. Where a stamp or extruding tool is used to form the intruded area, a working surface of the stamp or extruding tool may be formed with a plurality of micro-protrusions so as to define complementary micro-cavities in a surface of the sheet when the tool is applied thereto. In this manner, the microcavities may form an integral part of the structure of the sheet.

[0036] Preferably, the peripheral region of the upper sheet may be bonded to the peripheral region of the lower sheet. Bonding corresponding peripheral regions of the upper and lower sheets to each other may help in sealing or containing the sensorial media within the confines of the aerosolgenerating article. Preferably, the seal between corresponding peripheral regions of the upper and lower sheets defines a hermetic seal therebetween. The sealing between the corresponding peripheral regions of the upper and lower sheets may be performed by use of an adhesive.

[0037] Advantageously, the peripheral regions of the upper and lower sheets may be free of microcavities. Having the corresponding peripheral regions of the upper and lower sheets free of microcavities may make it easier to provide a dependable seal between the peripheral surfaces.

[0038] Preferably, at least one of the upper and lower sheets may be formed with a second intruded area proximate a or the inlet end of the article and a third intruded area proximate a or the outlet end of the article. The second and third intruded areas may preferably be disposed at opposed ends of and be shallower in depth than the first intruded area of the respective sheet. Preferably, the second and third minor intruded areas may be free of micro-cavities. Having the second and third intruded areas being shallower in depth than the first intruded area may avoid sensorial media held within micro-cavities of the first intruded area from migrating into the second and third intruded areas. In this way, the shallower second and third intruded areas may remain free for the unimpeded passage of airflow.

[0039] The aerosol-generating article may be manufactured with an inlet and an outlet at respective inlet and outlet ends of the article. Alternatively, the inlet and outlet may be formed during handling or use of the article, as may be understood from the paragraphs below.

[0040] Preferably, one or both of the upper and lower sheets may comprise a first pre-rupture region proximate an or the inlet end, the first pre-rupture region configured to be breached to define an air inlet in fluid communication with an or the airflow path of the aerosol-generating article on said breaching. One or both of the upper and lower sheets may also comprise a second pre-rupture region proximate an or the outlet end, the second pre-rupture region configured to be breached to define an air outlet in fluid communication with the airflow path of the aerosol-generating article on said breaching. The first and second pre-rupture regions may be manually breached by a user; for example, by use of the user’s fingers or by a user applying a suitably shaped tool to the pre-rupture regions. Alternatively, the pre-rupture regions may instead be breached in consequence of a user coupling the article with an aerosol-generating device. For example, an aerosol-generating device may be provided with one or cutting surfaces adapted to breach the pre-rupture regions on coupling of the article with the device.

[0041] Preferably, one or both of the upper and lower sheets may comprise one or more first lines of weakening between a first detachable portion of the aerosol-generating article and a remainder of the aerosol-generating article. The first detachable portion may be severable from the article along the one or more first lines of weakening to define an air inlet in fluid communication with an or the airflow path of the aerosol-generating article on said severing. In a similar manner, one or both of the upper and lower sheets may comprise one or more second lines of weakening between a second detachable portion of the aerosol-generating article and a remainder of the aerosol-generating article. The second detachable portion may be severable from the article along the one or more second lines of weakening to define an air outlet in fluid communication with an or the airflow path of the aerosol-generating article on said severing. The lines of weakening may be in form of score lines defined in the upper and / or lower sheets.

[0042] Although the sensorial media in the micro-cavities of the upper and lower sheets may be identical in composition to each other, in other examples micro-cavities of the upper sheet may contain sensorial media having a first composition and micro-cavities of the lower sheet contain sensorial media having a second composition, with the first composition differing from the second composition. Where the sensorial media in both upper and lower sheets is consumed simultaneously in a given usage session, vapours evolved from the first composition of sensorial media of the upper sheet may combine with vapours evolved from the second composition of sensorial media of the lower sheet, with the user able to inhale an aerosol formed of constituents of both compositions of sensorial media. The combination of vapours from the sensorial media of the upper and lower sheet may be aided by having an airflow path defined in a gap separating opposed interior-facing surfaces of the sheets from each other.

[0043] The opposed interior-facing upper and lower surfaces and their respective micro-cavities may form part of respective upper and lower porous inserts. The upper and lower porous inserts may be disposed on corresponding interior-facing surfaces of respective opposed upper and lower sheets of the aerosol-generating article, with the upper and lower porous inserts being structurally distinct from the upper and lower sheets. The upper and lower porous inserts may be held in place on the respective upper and lower sheets by bonding, for example by use of an adhesive.

[0044] The upper and lower porous inserts may be disposed within corresponding upper and lower intruded areas defined in the respective upper and lower sheets.

[0045] The upper porous insert may contain sensorial media having a first composition and the lower porous insert contain sensorial media having a second composition, the first composition differing from the second composition. Where the sensorial media in both upper and lower porous inserts is consumed simultaneously in a given usage session, vapours evolved from the first composition of sensorial media of the upper porous insert disposed on the upper sheet may combine with vapours evolved from the second composition of sensorial media of the lower porous insert disposed on the lower sheet, with the user able to inhale an aerosol formed of constituents of both compositions of sensorial media. The combination of vapours from the sensorial media of the upper and lower porous inserts may be aided by having an airflow path defined in a gap separating opposed interior-facing surfaces of the porous inserts from each other.

[0046] The article preferably has a length extending in an x direction, a width extending in a y direction and a thickness extending in a z direction, wherein the thickness is less than each of the length and the width. In this manner, the article is provided with a profile which is flat and compact in thickness (relative to the length and width). As described above, the x, y and z directions are preferably aligned perpendicular to each other. Preferably, at least 50%, for example at least 75%, for example at least 90%, for example the entirety of the mass of sensorial media of the aerosol-generating article is disposed within the plurality of micro-cavities.

[0047] The mass of the sensorial media of the aerosol-generating article may be between 30 and 80 mg, for example between 30 and 60 mg, for example between about 30 to 50 mg, for example about 40 mg.

[0048] As discussed above, preferably the sensorial media is a gel, a slurry or a liquid. These forms of sensorial media are inherently “wet”. The use of “wet” sensorial media may assist the sensorial media to adhere to surfaces of the micro-cavities, for example through surface tension.

[0049] The sensorial media may comprise or be an aerosol-forming substrate or a flavouring agent. The sensorial media may comprise nicotine. It is preferred that the sensorial media is physically and chemically stable over a broad range of environmental conditions. In this manner, the sensorial media may be better capable of retaining freshness during storage and transportation. Where the sensorial media is in the form of a gel composition comprising nicotine, it is preferred that on the application of heat to the sensorial media, the sensorial media vaporises nicotine, but does not release or absorb liquid phase matter (for example, water). It is preferred that the sensorial media does not release or absorb water over a range of humidity levels, for example from about 5% to about 70% relative humidity.

[0050] The sensorial media preferably may have a composition adapted to facilitate the generation of an aerosol upon application of a heating profile to the sensorial media. The heating profile may be adapted to cause volatile compounds to be vaporise from the sensorial media through heating rather than burning of the sensorial media. Heat may be imparted to the sensorial media by a heating element of an aerosol-generating device; for example, the aerosol-generating device may be configured to receive the aerosol-generating article and apply the heating profile to the sensorial media of the aerosol-generating article. The vaporised volatile compounds may become entrained with an airflow flowing over the sensorial media (for example, an airflow flowing along an airflow path through the aerosol-generating device and over or through the aerosol-generating article), with the entrained airflow progressively cooling to form an aerosol for subsequent inhalation by a user.

[0051] The sensorial media may be a gel composition incorporating a gelling agent forming a solid medium, with glycerol dispersed in the solid medium, and nicotine dispersed in the glycerol. The sensorial media may be formed of about 80% to about 90% wt. glycerol, with a water content of less than about 20% wt., with a total combined weight of water and glycerol in a range from of about 85 to 95% wt. The gelling agent may be incorporated in the gel composition in a range from about 2% to about 7% by weight. Suitable gelling agents include xanthan gum, as well as low acyl gellan, and agar, or a mix of those in approximately equal amounts.

[0052] Advantageously, the sensorial media may remain stable when exposed to a relative humidity in a range from about 10% to about 60% at 24 degrees Celsius and one atmosphere. Preferably, the sensorial media may keep its volumetric and geometrical shape (not changing by more than about 2%), and the overall mass of the sensorial media not changing by more than about 1 %, under such environmental conditions. The sensorial media may be a gel composition containing nicotine, in which the content of nicotine in the sensorial media may vary within a range of about 1 to about 3% wt. of nicotine. The gel composition may incorporate about 85% to about 95% wt. glycerol; about 1 % to about 5% wt. agar, xanthan gum and low acyl gellan ; levulinic acid. The gel composition may be substantially free of water content.

[0053] Reference to “nicotine content” refers to nicotine and nicotine derivatives, including free-base nicotine, and nicotine salts.

[0054] Alternatively or in addition, the sensorial media may have a composition containing flavouring agents, preferably natural flavouring agents. The flavouring agent may be of a single type, or a blend of flavouring agents may be used. The sensorial media may be formed of about 1% to about 4% wt. flavouring agent, preferably of about 1% to about 2% wt. Such flavouring agents may be obtained by a physical process such as roasting, heating, or chemical processes such as extraction, distillation, enzymatic, or microbiological processes from plant parts, including from tobacco stems. The flavouring agents may be in the form of essential oil, oleoresin, and essences, as alcoholic or hydroalcoholic solutions of volatile substances, or extractive, distillate, or any product of roasting, heating, or enzymolysis. Examples of flavouring agents that may be successfully used in the composition of sensorial media are complex volatile oil I anise oil, aldehyde I vanillin, ginger oil, peppermint oil, lemongrass oil, tobacco extract oil, and menthol oil.

[0055] As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol. For example, an aerosol-generating article may be an article comprising an aerosol-forming substrate that is capable of releasing volatile compounds that can form an aerosol. The aerosol-generating article may be disposable.

[0056] As used herein, the term “sensorial media” relates to a substrate capable of releasing one or more volatile compounds that can form an aerosol or a vapor or that can be brought into the gaseous phase. The sensorial media may serve as one or more of a nicotine provider, a flavour enhancer, and a volume enhancer. The sensorial media may be an aerosol-forming substrate. The aerosol-forming substrate may include an aerosol former.

[0057] As used herein, the term “aerosol-forming substrate” may refer to a substrate capable of releasing an aerosol or volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. An aerosol-forming substrate may comprise an aerosol-forming material. An aerosol-forming substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. An aerosol-forming substrate may conveniently be part of an aerosol-generating article or smoking article.

[0058] As used herein, the term “aerosol former” may refer to any suitable known compound or mixture of compounds that, in use, facilitates formation of an aerosol. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-forming substrate or aerosol-generating article.

[0059] As used herein, the term “aerosol-generating device” may refer to a device for use with an aerosol-generating article to enable the generation, or release, of an aerosol. As used herein, the term “aerosol generating system” may refer to a combination of an aerosolgenerating device and one or more aerosol-forming articles for use with the device. An aerosolgenerating system may include additional components, such as a charging unit for recharging an onboard electric power supply in an electrically operated or electric aerosol-generating device.

[0060] As used herein with reference to the invention, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.

[0061] As used herein with reference to the invention, the terms “proximal”, “distal”, “upstream” and “downstream” are used to describe the relative positions of components, or portions of components, of the aerosol-generating article.

[0062] 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.

[0063] Example Ex1 : An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising a plurality of micro-cavities, wherein sensorial media is disposed within at least some of the plurality of micro-cavities.

[0064] Example Ex2: An aerosol-generating article according to Ex1 , wherein each of the plurality of micro-cavities defines a volume of no more than 5 mm3, for example no more than 2.5 mm3, for example no more than 1 mm3.

[0065] Example Ex3: An aerosol-generating article according to either one of Ex1 or Ex2, wherein each of the plurality of micro-cavities defines a volume of no less than 0.01 mm3, for example no less than 0.05 mm3, for example no less than 0.1 mm3.

[0066] Example Ex4: An aerosol-generating article according to any one of Ex1 to Ex3, wherein the plurality of micro-cavities have an open cell structure.

[0067] Example Ex5: An aerosol-generating article according to any one of Ex1 to Ex4, further comprising an airflow path defined within the aerosol-generating article between an inlet end and an outlet end of the aerosol-generating article.

[0068] Example Ex6: An aerosol-generating article according to Ex5, wherein the inlet end and the outlet end are separated from each other along a length direction of the article.

[0069] Example Ex7: An aerosol-generating article according to Ex5, wherein the inlet end and the outlet end are separated from each other along a width direction of the article.

[0070] Example Ex8: An aerosol-generating article according to any one of Ex5 to Ex7, wherein the airflow path is arranged over and in fluid communication with the plurality of micro-cavities.

[0071] Example Ex9: An aerosol-generating article according to any one of Ex5 to Ex8, wherein the airflow path is at least partly defined by a subset of the plurality of micro-cavities.

[0072] Example Ex10: An aerosol-generating article according to Ex9, wherein a first subset of the plurality of micro-cavities is free of sensorial media and wholly or at least partly defines the airflow path, and a second subset of the plurality of micro-cavities contains sensorial media, wherein the airflow path defined by the first subset of micro-cavities extends along a path through or adjacent to the second subset of micro-cavities. Example Ex11 : An aerosol-generating article according to any one of Ex1 to Ex10, wherein at least some of the plurality of micro-cavities are defined in a wall or layer of the aerosol-generating article.

[0073] Example Ex12: An aerosol-generating article according to Ex11 , wherein an or the airflow path extends over the wall or layer.

[0074] Example Ex13: An aerosol-generating article according to either one of Ex11 or Ex12, wherein at least some of the plurality of micro-cavities open onto a surface of the wall or layer.

[0075] Example 13a: An aerosol-generating article according to any one of Ex11 to Ex13, wherein the wall or layer is a porous wall or layer.

[0076] Example Ex14: An aerosol-generating article according to Ex13a, wherein an or the airflow path extends through the porous wall or layer.

[0077] Example Ex14a: An aerosol-generating article according to any one of Ex11 to Ex14, further comprising an embossed or corrugated layer arranged over and in surface contact with the wall or layer to thereby define one or more airflow passages adjacent the micro-cavities.

[0078] Example Ex14b: An aerosol-generating article according to Ex14a, wherein a plurality of microcavities are disposed in or on each of opposed interior-facing upper and lower surfaces of the aerosolgenerating article, wherein the embossed or corrugated layer is arranged between the opposed interior-facing upper and lower surfaces to define one or more upper airflow passages between the upper surface and the embossed or corrugated layer and one or more lower airflow passages between the lower surface and the embossed or corrugated layer.

[0079] Example Ex14c: An aerosol-generating article according to Ex14b, wherein sensorial media is disposed within at least some of the plurality of micro-cavities of the upper surface and within at least some of the plurality of micro-cavities of the lower surface.

[0080] Example Ex14d: An aerosol-generating article according to Ex14a, wherein the embossed or corrugated layer defines an exterior layer of the aerosol-generating article, with the embossed or corrugated layer arranged to cover and / or seal the micro-cavities.

[0081] Example Ex14e: An aerosol-generating article according to any one of Ex14a to Ex14d, wherein the embossed or corrugated layer defines a plurality of channels, wherein a width of each of the plurality of channels differs from a major diameter of each of the micro-cavities by no more than 20%, or no more than 15%, or no more than 10%, or no more than 5%.

[0082] Example Ex15: An aerosol-generating article according to any one of Ex1 to Ex14e, wherein a plurality of micro-cavities are disposed in or on each of opposed interior-facing upper and lower surfaces of the aerosol-generating article, wherein sensorial media is disposed within at least some of the plurality of micro-cavities disposed in or on the upper surface and within at least some of the plurality of micro-cavities disposed in or on of the lower surface.

[0083] Example Ex16: An aerosol-generating article according to Ex15, wherein the opposed interiorfacing upper and lower surfaces are separated from each other by a gap, an or the airflow path extending through the gap over the opposed interior-facing upper and lower surfaces. Example Ex17: An aerosol-generating article according to either one of Ex15 or Ex16, wherein the opposed interior-facing upper and lower surfaces form part of respective opposed upper and lower sheets.

[0084] Example Ex17a: An aerosol-generating article according to Ex17, wherein the micro-cavities of the opposed interior-facing upper and lower surfaces form an integral part of the respective opposed upper and lower sheets.

[0085] Example Ex18: An aerosol-generating article according to Ex17a, wherein the micro-cavities of at least one of the opposed upper and lower sheets extend from the respective interior-facing surface part-way through the thickness of the respective sheet.

[0086] Example Ex19: An aerosol-generating article according to any one of Ex15 to Ex18, wherein the micro-cavities of the upper surface contain sensorial media having a first composition and the microcavities of the lower surface contain sensorial media having a second composition, the first composition differing from the second composition.

[0087] Example Ex20: An aerosol-generating article according to any one of Ex17 to Ex19, wherein the upper and lower sheets each have a length extending in an x direction, a width extending in a y direction and a thickness extending in a z direction, wherein the thickness is less than each of the length and the width.

[0088] Example Ex21 : An aerosol-generating article according to any one of Ex17 to Ex20, wherein each of the upper and lower sheets comprise a first layer formed of a paper-based material and a second layer formed of a bio-polymeric compound, wherein the second layer of the upper sheet is bonded to the second layer of the lower sheet, for example by use of an adhesive.

[0089] Example Ex22: An aerosol-generating article according to any one of Ex17 to Ex21 , wherein the upper and lower sheets are aligned parallel to each other.

[0090] Example Ex23: An aerosol-generating article according to any one of Ex17 to Ex22, wherein at least 95% of the plurality of micro-cavities of the lower sheet are defined in a first intruded area of the lower sheet, the first intruded area of the lower sheet surrounded by a peripheral region of the lower sheet.

[0091] Example Ex24: An aerosol-generating article according to Ex23, wherein at least 95% of the plurality of micro-cavities of the upper sheet are defined in a first intruded area of the upper sheet, the first intruded area of the upper sheet surrounded by a peripheral region of the upper sheet.

[0092] Example Ex25: An aerosol-generating article according to Ex24, wherein the peripheral region of the upper sheet is bonded to the peripheral region of the lower sheet.

[0093] Example Ex26: An aerosol-generating article according to either one of Ex24 or Ex25, wherein the peripheral regions of the upper and lower sheets are free of micro-cavities.

[0094] Example Ex27:An aerosol-generating article according to any one of Ex23 to Ex26, wherein at least one of the upper and lower sheets is formed with a second intruded area proximate a or the inlet end of the article and a third intruded area proximate a or the outlet end of the article, the second and third intruded areas disposed at opposite ends of and being shallower in depth than the first intruded area of the respective sheet. Example Ex28: An aerosol-generating article according to Ex27, wherein the second and third intruded areas are free of micro-cavities.

[0095] Example Ex29: An aerosol-generating article according to any one of Ex17 to Ex28, wherein one or both of the upper and lower sheets comprise a first pre-rupture region proximate an or the inlet end, the first pre-rupture region configured to be breached to define an air inlet in fluid communication with an or the airflow path of the aerosol-generating article on said breaching.

[0096] Example Ex29: An aerosol-generating article according to Ex28, wherein one or both of the upper and lower sheets comprise a second pre-rupture region proximate an or the outlet end, the second pre-rupture region configured to be breached to define an air outlet in fluid communication with the airflow path of the aerosol-generating article on said breaching.

[0097] Example Ex30: An aerosol-generating article according to any one of Ex17 to Ex29, wherein one or both of the upper and lower sheets comprise one or more first lines of weakening between a first detachable portion of the aerosol-generating article and a remainder of the aerosol-generating article, wherein the first detachable portion is severable from the article along the one or more first lines of weakening to define an air inlet in fluid communication with an or the airflow path of the aerosolgenerating article on said severing.

[0098] Example Ex31 : An aerosol-generating article according to Ex30, wherein one or both of the upper and lower sheets comprise one or more second lines of weakening between a second detachable portion of the aerosol-generating article and a remainder of the aerosol-generating article, wherein the second detachable portion is severable from the article along the one or more second lines of weakening to define an air outlet in fluid communication with the airflow path of the aerosolgenerating article on said severing.

[0099] Example Ex32: An aerosol-generating article according to any one of Ex15 to Ex31 , wherein the opposed interior-facing upper and lower surfaces and their respective micro-cavities form part of respective upper and lower porous inserts, the upper and lower porous inserts disposed on corresponding interior-facing surfaces of respective opposed upper and lower sheets of the aerosolgenerating article, the upper and lower porous inserts structurally distinct from the upper and lower sheets.

[0100] Example Ex33: An aerosol-generating article according to Ex32, wherein the upper and lower porous inserts are disposed within respective upper and lower intruded areas defined in the respective upper and lower sheets.

[0101] Example Ex34: An aerosol-generating article according to either one of Ex32 or Ex33, wherein the upper porous insert contains sensorial media having a first composition and the lower porous insert contains sensorial media having a second composition, the first composition differing from the second composition.

[0102] Example Ex35: An aerosol-generating article according to any one of Ex1 to Ex34, wherein the article has a length extending in an x direction, a width extending in a y direction and a thickness extending in a z direction, wherein the thickness is less than each of the length and the width. Example Ex36: An aerosol-generating article according to any one of Ex1 to Ex35, wherein at least 50%, for example at least 75%, for example at least 90%, for example the entirety of the mass of sensorial media of the aerosol-generating article is disposed within the plurality of micro-cavities.

[0103] Example Ex37: An aerosol-generating article according to any one of Ex1 to Ex36, wherein the mass of the sensorial media of the aerosol-generating article is between 30 and 80 mg, for example between 30 and 60 mg, for example between about 30 to 50 mg, for example about 40 mg.

[0104] Example Ex38: An aerosol-generating article according to any one of Ex1 to Ex37, wherein the sensorial media is a gel, a slurry or a liquid.

[0105] Example Ex39: An aerosol-generating article according to any one of Ex1 to Ex38, wherein the sensorial media comprises an aerosol-forming substrate or a flavouring agent.

[0106] Examples will now be further described with reference to the figures in which:

[0107] Figure 1 is a schematic perspective view of an intruded sheet of an aerosol-generating article according to a first embodiment of the present disclosure;

[0108] Figure 2 is a schematic perspective view of an intruded sheet of an aerosol-generating article according to a second embodiment of the present disclosure;

[0109] Figure 3 is a schematic perspective view of an intruded sheet of an aerosol-generating article according to a third embodiment of the present disclosure;

[0110] Figure 4 includes a schematic perspective view and schematic side elevation views of component parts of an aerosol-generating article, including the intruded sheet of figure 3;

[0111] Figure 5 is a schematic plan view of the aerosol-generating article of figure 4 in a storage state and a usage state;

[0112] Figure 6 is a schematic cross-sectional view along section A-A of the aerosol-generating article of figure 5 in the usage state;

[0113] Figure 7 is a schematic perspective view of component parts of an aerosol-generating article according to a fourth embodiment of the present disclosure;

[0114] Figure 8 is a schematic side elevation view of the aerosol-generating article of figure 7 after assembly and in a storage state.

[0115] Figure 9 is a schematic cross-sectional view of the aerosol-generating article of figure 7 in a usage state;

[0116] Figure 10 is a schematic view of the aerosol-generating article of figure 8 being placed into a cavity of an aerosol-generating device so as to form an inlet and outlet opening in the article;

[0117] Figure 11 is a schematic perspective view of component parts of an aerosol-generating article according to a fifth embodiment of the present disclosure;

[0118] Figure 12 is a further schematic view of the component parts of the aerosol-generating article of figure 11 ;

[0119] Figure 13 includes schematic side elevation and cross-sectional views of the aerosol-generating article of figures 11 and 12 prior to and after assembly;

[0120] Figure 14 is a schematic perspective view illustrating various dimensions applicable to the lower and / or upper sheets illustrated and described in relation to figures 1 to 13. Figure 1 shows a sheet 110 of an aerosol-generating article 100 relative to the x, y and z axes of a cartesian coordinate system. The sheet 110 has a length extending along the x axis, a width extending along the y axis and a depth extending along the z axis. The sheet 110 is generally rectangular when viewed in plan along the z axis. The sheet 110 has a peripheral region 111 and a primary intruded region 112. The peripheral region 111 surrounds the primary intruded region 112. The peripheral region 111 and primary intruded region 112 are each generally planar in form. The primary intruded region 112 is sunk or recessed relative to the peripheral region 111 , thereby giving the sheet a profile resembling that of a tray. The primary intruded region 112 is formed with a plurality of micro-cavities 113. The microcavities 113 are an integral part of the structure of the sheet 110. Each of the micro-cavities 113 have a volume of less than 1 mm3. The micro-cavities 1121 have an open cell structure. Secondary intruded regions 114, 115 are defined at opposite first and second ends 116, 117 of the sheet 110. The secondary intruded regions 114, 115 are shallower in depth than the primary intruded region 112. A nicotine-containing liquid or gel-based aerosol-forming substrate is disposed within the micro-cavities 113.

[0121] The sheet 110 is formed of two layers - a first layer of a paper-based material and a second layer of a bio-polymeric compound. The second layer forms the upper surface of the sheet 110 that is visible in figure 1 .

[0122] The sheet 110 may itself define an aerosol-generating article 100. For example, an airflow 118 may be provided over the upper surface of the sheet 110, passing over the exposed micro-cavities 113 in the primary intruded region 112. The airflow 118 may be induced by the inhalation action of a user. In use, heat may be applied to the sheet 110 to cause volatile compounds of the aerosol-forming substrate in the micro-cavities 113 of the primary intruded region 112 to be vaporised. The vapours evolved from the aerosol-forming substrate may, in turn, become entrained in the airflow 118 passing over the upper surface of the sheet 110. As the entrained airflow 118 cools, an aerosol is formed, which may be inhaled by a user. However, as described in subsequent paragraphs, in other embodiments the sheet 110 may be coupled to another similar or identical sheet positioned to overlie sheet 110, with the combination of the two sheets defining the aerosol-generating article.

[0123] Figure 2 illustrates a second embodiment of a sheet 210 of an aerosol-generating article 200. Features in common with the sheet 110 of Figure 1 are referred to with like reference signs but commencing with numeral ‘2’ instead of numeral ‘1 ’. The sheet 210 differs from the sheet 110 of figure 1 in that the structure of the sheet in the primary intruded region 212 does not include microcavities. Rather, for the embodiment of Figure 2, a porous sheet 219 is provided that is dimensioned to form a snug fit inside a cavity defined by the primary intruded region 212 of the sheet 210. Pores 220 of the porous sheet 219 define a plurality of micro-cavities. The porous sheet 219 is soaked in liquid or gel-based aerosol-forming substrate such that the pores 220 of the porous sheet contain aerosol-forming substrate. The porous sheet 219 has a thickness less than the depth of the cavity defined by the primary intruded region 212 of the sheet 210 so that when the porous sheet is installed in the primary intruded region, the peripheral region 211 of the sheet 210 is elevated relative to an exposed face of the porous sheet. Figure 2(a) shows the porous sheet 219 before being placed within the primary intruded region 212 of the sheet 210. Figure 2(b) shows the porous sheet 219 after being located within the primary intruded region 212 of the sheet 210. The porous sheet 219 may also be referred to as a porous insert. In a similar manner to the embodiment of figure 1 , an airflow 218 may be provided over the upper surface of the porous sheet 219, passing over the exposed micro-cavities 220 of the porous sheet.

[0124] Figure 3 illustrates a third embodiment of a sheet 310 of an aerosol-generating article 300. Features in common with the sheet 110 of figure 1 are referred to with like reference signs but commencing with numeral ‘3’ instead of numeral ‘1 ’. The sheet 310 incorporates all of the features of the sheet 110 of figure 1 , but additionally has first and second score lines 321 , 322 provided at the respective first and second ends 316, 317 of the sheet. Score line 321 extends from the first end 316 of the sheet 310 for a short distance in the x direction, then laterally in the y direction through the secondary intruded portion 314 of the sheet, and then extends back along the x direction to terminate at the first end 316 of the sheet. In a similar manner, score line 322 extends from the second end 317 of the sheet 310 for a short distance in the x direction, then laterally in the y direction through the secondary intruded portion 315 of the sheet, and then extends back along the x direction to terminate at the second end 317 of the sheet. The score lines 321 , 322 may be formed as a continuous line, or as a series of discontinuous scored segments separated from each other by non-thinned regions of the sheet 310. The score lines 321 , 322 define first and second detachable portions 323, 324 in the sheet 310. A user may pull on the detachable portions 323, 324 to separate them from the sheet 310. This is described in more detail in relation to figure 5.

[0125] Figure 4 is a schematic view illustrating the component parts and steps of assembly of an aerosol-generating article 300 incorporating two of the intruded sheets of figure 3. The article 300 is formed of a lower sheet 310 and an upper sheet 310’. The lower and upper sheets 310, 310’ are identical in structure to each other, with features of the upper sheet 310’ referred to with like reference signs to the lower sheet 310 but with the addition of a prime symbol ’. The aerosol-generating article 300 is formed by combining the lower and upper sheets 310, 310’ together, as indicated in figures 4(b) and (c). More specifically, the peripheral regions 311 , 311 ’ of the lower and upper sheets 310, 310’ are bonded to each other by use of an adhesive or other means. The bonding of the corresponding peripheral regions 311 , 311 ’ of the lower and upper sheets 310, 310’ provides a hermetic seal between the two sheets. The aerosol-forming substrate is held within micro-cavities 313, 313’ of the lower and upper sheets 310, 310’. The bonding together of the corresponding peripheral regions 311 , 311 ’ of the lower and upper sheets 310, 310’ thereby serves to hermetically seal the aerosol-forming substrate within an interior of the aerosol-generating article - specifically, within the micro-cavities 313, 313’. Figure 4(c) shows how the assembled aerosol-generating article 300 is generally flat, having a thickness considerably less than the length (and width) of the aerosolgenerating article. The aerosol-generating article 300 has a thickness defined by the separation distance between planar outward-facing surfaces 325, 325’ of the lower sheet 310 and the upper sheet 310’ corresponding to the locations of the primary intruded regions 312, 312’. As can be seen in figures 4(b) and (c), the lower and upper sheets 310, 310’ of the article 300 are aligned parallel to each other.

[0126] Figure 5 shows plan views of the assembled aerosol-generating article 300 of figure 4 in a storage state (shown in figure 5(a)) and a usage state (shown in figure 5(b)). Figure 5 shows the outline of the primary intruded regions 312, 312’ and the secondary intruded regions 314, 314’, 315, 315’ of the lower and upper sheets 310, 310’ of the article 300. The storage state is the state of the aerosol-generating article 300 as shown in figures 4(c) and 5(a), in which the aerosol-generating substrate is hermetically sealed within the interior of the aerosol-generating article 300 within the micro-cavities 313, 313’ of the primary intruded regions 312, 312’ of the lower and upper sheets 310, 31 O’. In the storage state of figure 5(a), no inlet or outlet aperture is defined in the aerosol-generating article 300, with the score lines 321 , 321 ’, 322, 322’ intact. The aerosol-generating article 300 is converted to the usage state of figure 5(b) by detaching the detachable portions 323, 323’, 324, 324’. Removal of the detachable portions 323, 323’, 324, 324’ from the article 300 is performed by a user engaging their thumb and finger(s) with the detachable portions and pulling in the directions shown by arrows in figure 5(b) to cause the score lines 321 , 321 ’, 322, 322’ to be severed. Detachment of the detachable portions 323, 323’, 324, 324’ results in first and second openings 326, 327 being defined in the respective first and second ends 316, 317 of the aerosol-generating article 300. In use, one of the first and second openings 326, 327 may serve as an air inlet of the article and the other of the first and second openings serve as an air outlet of the article.

[0127] Figure 6 shows detail cross-section views through section A-A of figure 5(b), localised on the first end 316 and the second end 317 of the article 300. A clearance ‘d’ is provided between opposed interior-facing surfaces of the lower and upper sheets 310, 310’ in the location of the primary intruded regions 312, 312’ containing the micro-cavities 313, 313’. The clearance ‘d’ extends along the length of the article 300 from the first opening 326 at first end 316 to the second opening 327 at second end 317. The clearance ‘d’ serves to define an airflow passage 318 within the article 300 between the first and second openings 326, 327. In use of the aerosol-generating article 300, heat may be applied to one or both of the lower and upper sheets 310, 310’ proximate the primary intruded regions 312, 312’. The application of heat acts to cause volatile compounds of the aerosol-forming substrate contained in the micro-cavities 313, 313’ of the primary intruded regions 312, 312’ to be vaporised. The open cell structure of the micro-cavities 313, 313’ assists in allowing the vaporised volatile compounds to disperse within the airflow passage 318 defined by the clearance ‘d’ between opposed interior-facing surfaces of the primary intruded regions 312, 312’. Suction applied at the second opening 327 causes air to be drawn into the aerosol-generating article 300 through the first opening 326 and to flow downstream along the airflow passage 318 towards the second opening 327. The vaporised volatile compounds become entrained with the airflow, with the entrained airflow flowing downstream along the airflow path 318 towards the second opening 327. The entrained airflow cools on flowing downstream, condensing to form an aerosol which flows out from the second opening 327. The aerosol flowing out from the second opening 327 may be inhaled by a user of the article 300. For the example described, the first opening 326 defines an air inlet and the second opening 327 defines an air outlet. The second end 317 may itself define a mouth end of the article, with the user engaging their mouth directly with the second end to inhale aerosol from the second opening or air outlet 327. Alternatively, a user may engage their mouth with a mouthpiece of an aerosol-generating device, with the device configured to be coupled with the aerosol-generating article 300 such that the mouthpiece is in fluid communication with the second opening or air outlet 327. In other embodiments, the flow through the article 300 may the reverse of that shown in figure 6, with the second opening 327 defining an air inlet and the first opening 326 defining an air outlet.

[0128] In an alternative embodiment to that of figures 4 to 6, score lines may be formed in only one of the lower and upper sheets 310, 310’ so that detachable portions are defined in only one of the two sheets. For example, the lower sheet 310 may include the first and second score lines 321 , 322 to define the detachable portions 323, 324 at respective first and second ends 316, 317 of the sheet, with the upper sheet 310’ being free of any such score lines.

[0129] Figure 7 is a schematic perspective view illustrating the component parts of a further embodiment of aerosol-generating article 400. Features in common with the components of the aerosol-generating article 300 of figures 4 to 6 are referred to with like reference signs, but commencing with numeral ‘4’ instead of numeral ‘3’. The lower sheet 410 of aerosol-generating article 400 differs from the lower sheet 310 of aerosol-generating article 300 in that the score lines 421 , 422 do not extend to a free edge of the lower sheet, but instead define a continuous path confined to within the secondary intruded regions 414, 415 at opposite ends of the lower sheet. The upper sheet 410’ is a mirror image of the lower sheet 410, but differs in lacking any score lines corresponding to those provided in the lower sheet. The lower and upper sheets 410, 410’ are bonded to each other in the same manner the sheets 310, 310’ of figure 4, via use of adhesive to couple the peripheral regions 411 , 411 ’ of the lower and upper sheets to each other.

[0130] Figure 8 shows a schematic side elevation view of the resulting aerosol-generating article 400 of figure 7. The article 400 is in a storage state, in which the score lines are intact to thereby ensure that aerosol-forming substrate held within micro-cavities 413, 413’ of the primary intruded regions 412, 412’ is hermetically sealed within the interior of the article.

[0131] Figure 9 shows detail schematic longitudinal cross-sectional views of the article, localised to the first end 416 and the second end 417 of the article 400 after the score lines 421 , 422 in the lower sheet 410 have been breached to define a first opening 426 and a second opening 427 through the lower sheet. Figure 9 represents the article 400 in a usage state. The first opening 426 defines an air inlet for the article and the second opening 427 defines an air outlet for the article. In common with article 300, clearance ‘d’ is provided between opposed interior-facing surfaces of the lower and upper sheets 410, 410’ in the location of the primary intruded regions 412, 412’ containing the micro-cavities 4131 , 413’. The clearance ‘d’ extends along the length of the article 400 from the first opening 426 to the second opening 427. The clearance ‘d’ defines an airflow passage 418 within the article 400 between the first and second openings 426, 427. The airflow in, through and out of the article 400 is as described for the article 300.

[0132] The score lines 421 , 422 may be breached by a user manually applying a tool to the lower sheet 410 around the score lines 421 , 422 to breach the lower sheet. However, in another embodiment, the score lines 421 , 422 may instead be breached by a cutting surface of an aerosol-generating device as a consequence of the article being coupled with the aerosol-generating device. An example of such a device is illustrated in figure 10.

[0133] Figure 10 shows a portion of an aerosol-generating device 4000. The device 4000 has a lower portion 4100 and an upper portion 4200 which are separable from each other. A recess 4101 is defined in a surface of the lower portion 4100 of the device 4000. The recess 4101 is dimensioned to receive the aerosol-generating article 400 of figure 8 in its intact storage state. The recess 4101 is complementary in shape to that part of the lower sheet 410 containing the primary intruded region 412. Cutting surfaces 4102, 4103 extend upwardly from the surface of the lower portion 4100 of the device 4000 just outside of the recess 4101 . The cutting surfaces 4102, 4103 are positioned to engage with the lower sheet 410 of the article 400 at the location of the score lines 421 , 422 when the article is placed within the recess 4101 . A recess 4201 is also defined in a surface of the upper portion 4200 of the device 4000. The recess 4201 is complementary in shape to that part of the upper sheet 410’ containing the primary intruded region 412’. The article 400 is placed into the recess 4101 of the lower portion 4100 of the device 4000, with the cutting surfaces 4102, 4103 engaging with the lower sheet 410 adjacent to the score lines 421 , 422. The upper portion 4200 of the device 4000 is then moved down towards the lower portion 4100 of the device to press down on the upper sheet 410’ of the article 400. The downward motion of the upper portion 4200 urges the article 400 against the cutting surfaces 4102, 4103, causing the cutting surfaces to breach the score lines 421 , 422, thereby creating the first and second openings 426, 427 in or through the article 400. In some embodiments, the cutting surfaces 4102, 4103 may be retractable.

[0134] Figures 11 to 13 are schematic perspective views illustrating the component parts of a further embodiment of aerosol-generating article 500. Features in common with the components of the aerosol-generating article 300 of figures 4 to 6 are referred to with like reference signs, but commencing with numeral ‘5’ instead of numeral ‘3’. A corrugated layer 530 is disposed between lower and upper sheets 510, 510’. The corrugated layer 530 is formed of a laminate of foil and paper, with the laminate having a thickness of about 0.025 mm. The lower sheet 510 has first and second primary intruded regions 512, 5121 disposed in opposite halves of the length of the sheet 510. Similarly, the upper sheet 510’ has first and second primary intruded regions 512’, 5121 ’ disposed in opposite halves of the length of the sheet 510’. The first and second primary intruded regions 512, 5121 of the lower sheet 510 are formed with a plurality of micro-cavities 513. Similarly, the first and second primary intruded regions 512’, 5121 ’ of the upper sheet 510’ are also formed with a plurality of micro-cavities 513’. The microcavities 513, 513’ are an integral part of the structure of the sheets 510, 51 O’. Aerosolforming substrate is held within the micro-cavities 513, 513’. The corrugated layer 530 extends laterally in the y direction to have planar or flat portions 531 , 532 disposed on opposite ends of the width of the layer 530. The corrugated layer 530 is positioned over the lower sheet 510 so that the planar portions 531 , 532 sit on laterally opposed parts of the peripheral region 511 of the lower sheet 510. The upper sheet 510’ is then positioned over the corrugated layer 530. Adhesive is used to define a bond between the lower sheet 510, the corrugated layer 530 and the upper sheet 510’ around the path defined by the peripheral regions 511 , 511 ’ of the lower and upper sheets 510, 510’. The corrugated layer 530 defines a plurality of linear flow channels 533 in the lower half of the article 500 (between the microcavities 513 of the primary intruded regions 512, 5121 of the lower sheet 510 and the corrugated layer 530) and a plurality of linear flow channels 533’ in the upper half of the article 500 (between the microcavities 513’ of the primary intruded regions 512’, 5121 ’ of the upper sheet 510’ and the corrugated layer 530). The linear flow channels 533, 533’ extend lengthwise along the x direction. The corrugated layer 530 has a height defined by the distance between the upper and lower extremities of the corrugated layer 530 of about 1 mm. Figure 13(c) shows lateral cross-section views along section Z- Z’ of figure 13(b).

[0135] The corrugated layer 530 separates and isolates the primary intruded regions of the lower and upper sheets 510, 510’ from each other. Where the aerosol-forming substrate held in micro-cavities 513 of the lower sheet 510 is of a different composition to the aerosol-forming substrate held in microcavities 513’ of the upper sheet 510’, the corrugated layer 530 may help to isolate and prevent mixing and cross-contamination between aerosol generated from the substrate held in micro-cavities 513 and aerosol generated from the substrate held in micro-cavities 513’.

[0136] Figure 14 is a schematic perspective view of the sheet 110 of figure 1 , but is also applicable to the lower sheet 210 of figure 2 and the lower and upper sheets 310, 410, 510, 310’, 410’, 510’ of figures 3 to 13. In figure 14, different reference signs have been assigned to the different dimensions of the sheet. Table 1 below shows some exemplary ranges for the various dimensions of the sheet 110. Dimensions G, H and I are applicable to the size of the primary intruded region 112 of sheet 110, or to the size of the porous sheet 218 of figure 2.

[0137] Table 1

[0138] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term “about”. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number “A” is understood as “A” ± 10% of “A”. Within this context, a number “A” may be considered to include numerical values that are within general standard error for the measurement of the property that the number “A” modifies. The number “A”, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which “A” deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. The terms “in which” and “wherein” are used synonymously through this specification.

Claims

22 / 24CLAIMS1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising a plurality of micro-cavities, wherein sensorial media is disposed within at least some of the plurality of micro-cavities.

2. An aerosol-generating article according to claim 1 , wherein each of the plurality of microcavities defines a volume of no more than 5 mm3, for example no more than 2.5 mm3, for example no more than 1 mm3.

3. An aerosol-generating article according to either one of claim 1 or claim 2, further comprising an airflow path defined within the aerosol-generating article between an inlet end and an outlet end of the aerosol-generating article, preferably wherein the airflow path is arranged over and in fluid communication with the plurality of micro-cavities.

4. An aerosol-generating article according to any one of claims 1 to 3, wherein at least some of the plurality of micro-cavities are defined in a wall or layer of the aerosol-generating article.

5. An aerosol-generating article according to claim 4, wherein at least some of the plurality of micro-cavities open onto a surface of the wall or layer.

6. An aerosol-generating article according to either one of claim 4 or claim 5, further comprising an embossed or corrugated layer arranged over and in surface contact with the wall or layer to thereby define one or more airflow passages adjacent the micro-cavities.

7. An aerosol-generating article according to claim 6, wherein a plurality of micro-cavities are disposed in or on each of opposed interior-facing upper and lower surfaces of the aerosol-generating article, wherein the embossed or corrugated layer is arranged between the opposed interior-facing upper and lower surfaces to define one or more upper airflow passages between the upper surface and the embossed or corrugated layer and one or more lower airflow passages between the lower surface and the embossed or corrugated layer.

8. An aerosol-generating article according to any one of claims 1 to 7, wherein a plurality of microcavities are disposed in or on each of opposed interior-facing upper and lower surfaces of the aerosolgenerating article, wherein sensorial media is disposed within at least some of the plurality of microcavities disposed in or on the upper surface and within at least some of the plurality of micro-cavities disposed in or on of the lower surface.

9. An aerosol-generating article according to claim 8, wherein the opposed interior-facing upper and lower surfaces are separated from each other by a gap, an or the airflow path extending through the gap over the opposed interior-facing upper and lower surfaces.

10. An aerosol-generating article according to either one of claim 8 or claim 9, wherein the opposed interior-facing upper and lower surfaces form part of respective opposed upper and lower sheets, preferably wherein the micro-cavities of the opposed interior-facing upper and lower surfaces form an integral part of the respective opposed upper and lower sheets.

11. An aerosol-generating article according to claim 10, wherein at least 95% of the plurality of micro-cavities of the lower sheet are defined in a first intruded area of the lower sheet, the first intruded area of the lower sheet surrounded by a peripheral region of the lower sheet, preferably wherein at least 95% of the plurality of micro-cavities of the upper sheet are defined in a first intruded area of theupper sheet, the first intruded area of the upper sheet surrounded by a peripheral region of the upper sheet.

12. An aerosol-generating article according to claims 11 , wherein at least one of the upper and lower sheets is formed with a second intruded area proximate a or the inlet end of the article and a third intruded area proximate a or the outlet end of the article, the second and third intruded areas disposed at opposite ends of and being shallower in depth than the first intruded area of the respective sheet.

13. An aerosol-generating article according to any one of claims 10 to 12, wherein one or both of the upper and lower sheets comprise a first pre-rupture region proximate an or the inlet end, the first pre-rupture region configured to be breached to define an air inlet in fluid communication with an or the airflow path of the aerosol-generating article on said breaching, preferably wherein one or both of the upper and lower sheets comprise a second pre-rupture region proximate an or the outlet end, the second pre-rupture region configured to be breached to define an air outlet in fluid communication with the airflow path of the aerosol-generating article on said breaching.

14. An aerosol-generating article according to any one of claims 10 to 13, wherein one or both of the upper and lower sheets comprise one or more first lines of weakening between a first detachable portion of the aerosol-generating article and a remainder of the aerosol-generating article, wherein the first detachable portion is severable from the article along the one or more first lines of weakening to define an air inlet in fluid communication with an or the airflow path of the aerosol-generating article on said severing, preferably wherein one or both of the upper and lower sheets comprise one or more second lines of weakening between a second detachable portion of the aerosol-generating article and a remainder of the aerosol-generating article, wherein the second detachable portion is severable from the article along the one or more second lines of weakening to define an air outlet in fluid communication with the airflow path of the aerosol-generating article on said severing.

15. An aerosol-generating article according to any one of claims 8 to 14, wherein the opposed interior-facing upper and lower surfaces and their respective micro-cavities form part of respective upper and lower porous inserts, the upper and lower porous inserts disposed on corresponding interior-facing surfaces of respective opposed upper and lower sheets of the aerosol-generating article, the upper and lower porous inserts structurally distinct from the upper and lower sheets.

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