Aerosol-generating article

Abstract

There is provided an aerosol-generating article (100) for an aerosol-generating device (400). The aerosol-generating article (100) comprises a container (101). The container (101) comprises a first wall (102); a second wall (103) opposing the first wall (102); a peripheral wall (104) extending between the first wall (102) and the second wall (103); a substrate compartment (105) between the first wall (102) and the second wall (103), and at least partially circumscribed by the peripheral wall (104). The container (101) comprises an air inlet (106) in the peripheral wall (104) and an air outlet (107) in the peripheral wall (104). An aerosol-generating substrate is located in the substrate compartment (105). The aerosol-generating substrate comprises a plurality of aerosol-generating elements (108). One or more air-permeable barriers (109) are received in the substrate compartment (105). The one or more air-permeable barriers (105) are arranged to cover the air inlet (106) and the air outlet (107) to prevent the plurality of aerosol- generating elements (108) from entering each of the air inlet (106) and the air outlet (107). There is also provided an aerosol-generating system (1000) comprising the aerosol-generating article (100) and an aerosol-generating device (400) configured to heat the aerosol-generating article (100).

Description

[0001] P / 90792.W001

[0002] - 1 -

[0003] AEROSOL-GENERATING ARTICLE

[0004] The present disclosure relates to an aerosol-generating article for use with an aerosolgenerating device. The present disclosure also relates to an aerosol-generating system comprising the aerosol-generating article and an aerosol-generating device.

[0005] Aerosol-generating articles in which an aerosol-generating substrate, such as a tobacco containing substrate, is heated rather than combusted are known in the art. In heated aerosolgenerating articles, the aerosol is generated by heating the aerosol-generating substrate.

[0006] One type of aerosol-generating system is an electrically operated smoking system. Known handheld electrically operated smoking systems typically comprise an aerosol-generating device comprising a rechargeable battery, control electronics and an electric heater for heating an aerosol-generating article designed specifically for use with the aerosol-generating device. In some examples, the aerosol-generating article comprises an aerosol-forming substrate, such as a tobacco rod or a tobacco plug, and the heater contained within the aerosol-generating device is inserted into or located around the aerosol-forming substrate when the aerosol-generating article is inserted into the aerosol-generating device.

[0007] A heating element may be provided in an aerosol-generating device for generating an inhalable vapor. Such a device may heat the aerosol-generating substrate contained in the aerosol-generating article without burning the aerosol-generating substrate. In doing so, the aerosol-generating substrate may generate an aerosol which may be delivered to a user.

[0008] Such aerosol-generating articles may take the form of a conventional cigarette. Where this is the case, the aerosol-generating substrate may be wrapped in cigarette paper. This approach may be appropriate where the aerosol-generating substrate comprises strands or spaghettis of material, for example strands of cast leaf tobacco or strands of shredded tobacco.

[0009] However, this approach may not effectively retain other forms of aerosol-generating substrate, such as granules of aerosol-generating substrate, beads of aerosol-generating substrate or powdered aerosol-generating substrate. Such aerosol-generating articles may be prone to loss of the aerosol-generating substrate during storage, handling and use thereof. Loss of aerosol-generating substrate may disadvantageously reduce the lifespan of the aerosolgenerating article comprising the aerosol-generating substrate. Loss of aerosol-generating substrates may negatively impact the overall performance of the aerosol-generating article. For example, loss of aerosol-generating substrates may negatively impact the consistency of the inhalable aerosol generated by an aerosol-generating system comprising the aerosol-generating article. Loss of aerosol-generating substrates may cause damage to other components of aerosol-generating systems comprising the aerosol-generating article.

[0010] Furthermore, as referred to above, such aerosol-generating articles may appear similar and have similar dimensions to a conventional cigarette. For example, such an aerosol- generating article may be substantially cylindrical and comprise an aerosol-generating substrate in addition to other components such as mouthpiece filter element and a cooling element, which are arranged in the form of a rod and wrapped in a cigarette paper.

[0011] However, a significant portion of the aerosol-generating substrate in these cylindrical aerosol-generating articles may not be sufficiently heated to form an aerosol during use. This may be undesirable since the insufficiently heated portion of the aerosol-generating substrate contributes to the cost of manufacture and transport of the aerosol-generating article but does not contribute to the aerosol delivered to the consumer. Moreover, the components of these cylindrical aerosol-generating articles typically need to have the same or very similar outer diameters to each other so that they can be brought together, accurately positioned in axial alignment and then wrapped in a cigarette paper. This can lead to increased cost and complexity of manufacture.

[0012] There is a need to provide an aerosol-generating article that is able to retain different forms of aerosol-generating substrate, such as granules of aerosol-generating substrate, beads of aerosol-generating substrate or powdered aerosol-generating substrate.

[0013] There is also a need to provide an aerosol-generating article in which loss of the aerosolgenerating substrate is reduced or prevented.

[0014] There is also a need to provide an aerosol-generating article in which a greater proportion of the aerosol-generating substrate is sufficiently heated to form an aerosol during use, compared to known articles.

[0015] There is also a need to provide an aerosol-generating article in which the quality and consistency of aerosol delivered to a user is improved, compared to known articles.

[0016] There is also a need to provide an aerosol-generating article that can be manufactured relatively efficiently and cheaply.

[0017] According to a first aspect of the present disclosure there is provided an aerosolgenerating article for an aerosol-generating device. The aerosol-generating article may comprise a container. The container may comprise a first wall. The container may comprise a second wall opposing the first wall. The container may comprise a peripheral wall extending between the first wall and the second wall. The container may comprise a substrate compartment between the first wall and the second wall. The substrate compartment may be at least partially circumscribed by the peripheral wall. The container may comprise an air inlet in the peripheral wall. The container may comprise an air outlet in the peripheral wall. The aerosol-generating article may comprise an aerosol-generating substrate located in the substrate compartment. The aerosol-generating substrate may comprise a plurality of aerosol-generating elements. The aerosol-generating article may comprise one or more air-permeable barriers. The one or more air-permeable barriers may be received in the substrate compartment. The one or more air-permeable barriers may be arranged to cover the air inlet and the air outlet to prevent the plurality of aerosol-generating elements from entering each of the air inlet and the air outlet.

[0018] According to a first aspect of the present invention there is provided an aerosol-generating article for an aerosol-generating device. The aerosol-generating article comprises a container. The container comprises a first wall. The container comprises a second wall opposing the first wall. The container comprises a peripheral wall extending between the first wall and the second wall. The container comprises a substrate compartment between the first wall and the second wall. The substrate compartment is at least partially circumscribed by the peripheral wall. The container comprises an air inlet in the peripheral wall. The container comprised an air outlet in the peripheral wall. The aerosol-generating article comprises an aerosol-generating substrate located in the substrate compartment. The aerosol-generating substrate comprises a plurality of aerosolgenerating elements. The aerosol-generating article comprises one or more air-permeable barriers. The one or more air-permeable barriers are received in the substrate compartment. The one or more air-permeable barriers are arranged to cover the air inlet and the air outlet to prevent the plurality of aerosol-generating elements from entering each of the air inlet and the air outlet.

[0019] Advantageously, providing an aerosol-generating article comprising one or more air-permeable barriers received in the substrate compartment and arranged to cover the air inlet and the air outlet to prevent the plurality of aerosol-generating elements from entering each of the air inlet and the air outlet may allow the aerosol-generating article to retain different forms of aerosolgenerating substrate, such as granules of aerosol-generating substrate, beads of aerosolgenerating substrate or powdered aerosol-generating substrate.

[0020] Advantageously, providing an aerosol-generating article comprising one or more air-permeable barriers received in the substrate compartment and arranged to cover the air inlet and the air outlet to prevent the plurality of aerosol-generating elements from entering each of the air inlet and the air outlet may prevent clogging of the air inlet and the air outlet with the plurality of aerosol-generating elements.

[0021] Advantageously, providing an aerosol-generating article comprising one or more air-permeable barriers received in the substrate compartment and arranged to cover the air inlet and the air outlet to prevent the plurality of aerosol-generating elements from entering each of the air inlet and the air outlet may prevent the plurality of aerosol-generating elements from passing through the air inlet and the air outlet.

[0022] Advantageously, providing an aerosol-generating article comprising one or more air-permeable barriers received in the substrate compartment and arranged to cover the air inlet and the air outlet to prevent the plurality of aerosol-generating elements from entering each of the air inlet and the air outlet may provide an aerosol-generating article in which loss of the aerosolgenerating substrate is reduced or prevented. Advantageously, reducing or preventing loss of the aerosol-generating substrate may improve the consistency of the inhalable aerosol generated by the aerosol-generating article, compared to known articles.

[0023] Advantageously, reducing or preventing loss of the aerosol-generating substrate may improve the lifespan of the aerosol-generating article comprising the aerosol-generating substrate, compared to known articles.

[0024] Advantageously, reducing or preventing loss of the aerosol-generating substrate may improve the overall performance of the aerosol-generating article and the user experience, compared to known articles.

[0025] Advantageously, reducing or preventing loss of the aerosol-generating substrate may prevent damage to other components of aerosol-generating systems comprising the aerosolgenerating article.

[0026] Advantageously, providing an aerosol-generating article comprising one or more air-permeable barriers received in the substrate compartment and arranged to cover the air inlet and the air outlet to prevent the plurality of aerosol-generating elements from entering each of the air inlet and the air outlet may reduce or avoid the need for filtration elements provided downstream or upstream of the container which may reduce the amount of cellulosic material and non-tobacco materials that is needed in the aerosol-generating article, compared to known articles.

[0027] Advantageously, providing the one or more air-permeable barriers received in the substrate compartment may reduce or avoid the need for filtration elements provided downstream of the container which may reduce unwanted condensation of aerosol downstream of the container, compared to known articles.

[0028] Advantageously, providing a substrate compartment between the first wall and the second wall wherein the second wall opposes the first wall may advantageously provide a large surface area for heating of the aerosol-generating substrate, thereby leading to effective heating of the aerosol-generating substrate and effective generation of aerosol for delivery to a user.

[0029] Advantageously, providing an aerosol-generating article comprising a first wall and the second wall wherein the second wall opposes the first wall, and a peripheral wall extending between the first wall and the second wall, and a substrate compartment between the first wall and the second wall, and at least partially circumscribed by the peripheral wall may help to minimise the number of components or walls needed to form the container. This may simplify manufacturing of the aerosol-generating article, for example, due to the need to align and bond fewer components to form the container. Furthermore, minimising the number of components needed to form the container may minimise the number of interfaces from which separation of the components may occur. This may improve sealing of the aerosol-generating substrate to improve the quality and consistency of aerosol delivered to a user during use of the aerosol-generating article. Minimising the number of interfaces may help to improve the consistency in the resistance to draw of the aerosol-generating article from one aerosol-generating article to another aerosolgenerating article.

[0030] As used herein, the term “aerosol-generating substrate” denotes a substrate capable of releasing volatile compounds upon heating, which can condense to form an aerosol.

[0031] As used herein, the term “aerosol” denotes a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. The aerosol may be visible or invisible. The aerosol may include vapours of substances that are ordinarily liquid or solid at room temperature as well as solid particles, or liquid droplets, or a combination of solid particles and liquid droplets.

[0032] As used herein, the term “aerosol-generating article” denotes an article comprising an aerosol-generating substrate that is capable of releasing volatile compounds that can form an aerosol.

[0033] As used herein, the term “aerosol-generating device” denotes a device that interacts with an aerosol-generating substrate to generate an aerosol. In some examples, the aerosolgenerating device heats the aerosol-generating substrate to facilitate release of volatile compounds from the substrate.

[0034] As used herein, the term “aerosol-generating system” refers to the combination of an aerosol-generating device and an aerosol-generating article.

[0035] As used herein, the term “air permeable” refers to the ability of a material, in particular of the one or more air-permeable barriers, to allow air to pass bidirectionally through the material.

[0036] As used herein, the term “longitudinal” is used to describe the direction between the downstream end or proximal end and the opposed upstream end or distal end of aerosolgenerating articles, aerosol-generating devices and aerosol-generating systems according to the disclosure. The longitudinal direction of the aerosol-generating article may be aligned with the longitudinal direction of the aerosol-generating system when the aerosol-generating article is used with an aerosol-generating device.

[0037] As used herein, the term “length” is used to describe the maximum dimension of elements, or portions of elements, of aerosol-generating articles, aerosol-generating devices and aerosolgenerating systems according to the disclosure. The length may be defined in the longitudinal direction or along a longitudinal axis.

[0038] As used herein, the term “transverse” is used to describe the direction perpendicular to the longitudinal direction or the length.

[0039] As used herein, the term “width” is used to describe the maximum transverse dimension of elements, or portions of elements, of aerosol-generating articles, aerosol-generating devices and aerosol-generating systems according to the disclosure. Unless otherwise stated, references to the “cross-section” of the aerosol-generating article or a component of the aerosol-generating article refer to the transverse cross-section, perpendicular to the longitudinal direction or axis, or the length.

[0040] As used herein, the term “thickness” is used to describe the smallest dimension of elements, or portions of elements, of aerosol-generating articles, aerosol-generating devices and aerosol-generating systems according to the disclosure. The thickness may be measured perpendicular to the length and width of elements, or portions of elements, of aerosol-generating articles, aerosol-generating devices and aerosol-generating systems according to the disclosure.

[0041] Preferably, the one or more air-permeable barriers are one or more air-permeable sheets. As used herein, the term ‘sheet’ denotes a laminar element having a width and length substantially greater than the thickness thereof.

[0042] Advantageously, providing one or more air-permeable barriers that are one or more air-permeable sheets may reduce the resistance to draw (RTD) provided by the one or more air-permeable barriers.

[0043] Preferably, the one or more air-permeable barriers comprise a cellulosic material.

[0044] As used herein, the term “cellulosic material” refers to a material which is made from or is a derivative of cellulose.

[0045] Preferably, the one or more air-permeable barriers comprise a non-woven fabric. Preferably, the non-woven fabric is Lyocell or Viscose.

[0046] As used herein, the term “non-woven” refers to a manufactured sheet, web or batt of directionally or randomly orientated fibres, bonded by one or more of friction, cohesion and adhesion, excluding products which are woven, knitted, tufted, stitch-bonded incorporating binding yarns or filaments, or felted by wet-milling, whether or not additionally needled. The fibres may be of natural or man-made origin. The non-woven fabric may be a non-woven material as defined by ISO standard 9092:2019. The non-woven fabric may be a non-woven material as defined by CEN EN 29092:1992.

[0047] Advantageously, providing the one or more air-permeable barriers comprising non-woven fabric may reduce or prevent emission of the plurality of aerosol-generating elements, in particular when provided in the form of a powder, through the one or more air-permeable barriers.

[0048] Preferably, the one or more air-permeable barriers are configured to sorb water, such as absorb or adsorb water. The one or more air-permeable barriers may comprise a hygroscopic material, such a hygroscopic non-woven fabric.

[0049] Advantageously, providing the one or more air-permeable barriers configured to sorb water may reduce moisture build-up in the substrate compartment.

[0050] The one or more air-permeable barriers may be a single air-permeable barrier. A single air-permeable barrier may be arranged to cover the air inlet and the air outlet to prevent the plurality of aerosol-generating elements from entering each of the air inlet and the air outlet. The one or more air-permeable barriers may comprise pores. The pores may extend through each of the one or more air-permeable barriers.

[0051] The one or more air-permeable barriers may comprise pores having a pore size of less than or equal to 500 micrometres, less than or equal to 250 micrometres, less than or equal to 100 micrometres, less than or equal to 50 micrometres, less than or equal to 30 micrometres, less than or equal to 20 micrometres, less than or equal to 10 micrometres, or less than or equal to 5 micrometres.

[0052] The one or more air-permeable barriers may comprise pores having a pore size of greater than or equal to 1 micrometres, greater than or equal to 5 micrometres, or greater than or equal to 10 micrometres.

[0053] For example, the one or more air-permeable barriers may comprise pores having a pore size of between 5 micrometres and 500 micrometres, or between 10 micrometres and 100 micrometres.

[0054] As used herein, the term “pore size” refers to the maximum cross-sectional dimension of the pores.

[0055] Preferably, a diameter of one or both of the air inlet and the air outlet is greater than the pore size of the one or more air-permeable barriers.

[0056] For the avoidance of doubt, as used herein, the term “diameter” is used to describe the maximum dimension of elements, or portions of elements, of aerosol-generating articles, aerosolgenerating devices and aerosol-generating systems according to the disclosure. For elements having a substantially circular cross-section or a substantially spherical shape, the term diameter refers to the diameter of the circular cross-section or the diameter of the sphere respectively. However, where an element is not substantially spherical or does not have a substantially circular cross-section, the term ‘diameter’ may be used to refer to the maximum dimension of the element or a maximum cross-sectional dimension of the element respectively. In other words, the term ‘diameter’ and ‘width’ may be used interchangeably. For example, where one or both of the air inlet and the air outlet have a non-circular cross-section, the diameter refers to the maximum dimension of the non-circular cross-sectional shape.

[0057] The one or more air-permeable barriers may comprise pores having a maximum pore size of less than or equal to 500 micrometres, less than or equal to 250 micrometres, less than or equal to 100 micrometres, less than or equal to 50 micrometres, less than or equal to 30 micrometres, less than or equal to 20 micrometres, less than or equal to 10 micrometres, or less than or equal to 5 micrometres.

[0058] The one or more air-permeable barriers may comprise pores having a maximum pore size of greater than or equal to 1 micrometres, greater than or equal to 5 micrometres, or greater than or equal to 10 micrometres. For example, the one or more air-permeable barriers may comprise pores having a maximum pore size of between 5 micrometres and 500 micrometres, or between 10 micrometres and 100 micrometres.

[0059] Advantageously, providing one or more air-permeable barriers having a pore size disclosed herein may improve retention of granules of aerosol-generating substrate, beads of aerosol-generating substrate or powdered aerosol-generating substrate in the aerosol-generating article.

[0060] Preferably, a diameter of one or both of the air inlet and the air outlet is greater than the maximum pore size of the one or more air-permeable barriers.

[0061] The one or more air-permeable barriers may each have a thickness of less than or equal to 1000 micrometres, less than or equal to 750 micrometres, less than or equal to 500 micrometres, less than or equal to 400 micrometres, less than or equal to 300 micrometres, less than or equal to 200 micrometres, or less than or equal to 100 micrometres.

[0062] The one or more air-permeable barriers may each have a thickness of greater than or equal to 50 micrometres, greater than or equal to 150 micrometres, greater than or equal to 250 micrometres, greater than or equal to 350 micrometres, or greater than or equal to 450 micrometres.

[0063] Advantageously, providing one or more air-permeable barriers each having a thickness disclosed herein may reduce the resistance to draw (RTD) provided by the one or more air-permeable barriers.

[0064] The one or more air-permeable barriers may be flexible.

[0065] As used herein, the term “flexible” is used to describe the ability of a material to bend easily without breaking.

[0066] The one or more air-permeable barriers may comprise a material which is heat resistant up to at least 200 degrees Celsius, up to at least 220 degrees Celsius, up to at least 240 degrees Celsius, up to at least 260 degrees Celsius, or up to at least 280 degrees Celsius.

[0067] As used herein, the term “heat resistant” denotes a material that will not substantially thermally degrade or decompose when exposed to a given temperature range.

[0068] The one or more air-permeable barriers may have a substantially planar shape when received in the substrate compartment. The one or more air-permeable barriers may define a volume with one or more open sides.

[0069] At least part of the one or more air-permeable barriers may be positioned between the peripheral wall and the first wall or between the peripheral wall and the second wall.

[0070] The one or more air-permeable barriers may be attached to one or more of the first wall, the peripheral wall and the second wall, for example using an adhesive.

[0071] The one or more air-permeable barriers may comprise a first air-permeable barrier and a second air-permeable barrier. The first air-permeable barrier may be in the form of an air-permeable sheet. The first air-permeable barrier may be formed from a non-woven fabric. The first air-permeable barrier may be received in the substrate compartment. The first air-permeable barrier may be arranged to cover the air inlet. The first air-permeable barrier may cover the air inlet to prevent the plurality of aerosol-generating elements from entering the air inlet. The first air-permeable barrier may overlie part of the peripheral wall. The first air-permeable barrier may be attached to the peripheral wall by an attaching means, for example by an adhesive. Preferably, the adhesive of the first air-permeable barrier is positioned proximate to two opposing edges of the first air-permeable barrier. In other words, the first air permeable barrier may comprise at least two adhesive elements, and at least one adhesive element may be provided on each opposing side of the peripheral wall that defines the air inlet. Preferably, the air inlet is located between the at least two adhesive elements of the first air-permeable barrier. Preferably, the adhesive of the first air-permeable barrier is not located on a region of the first air-permeable barrier which covers the air inlet. Preferably, the adhesive of the first air-permeable barrier is applied on the same face of the first air-permeable barrier. Preferably, the adhesive of the first air-permeable barrier is spaced apart from the air inlet. In other words, preferably the adhesive of the first air-permeable barrier is spaced apart from an edge of the peripheral wall that defines the air inlet.

[0072] The second air-permeable barrier may be in the form of an air-permeable sheet. The second air-permeable barrier may be formed from a non-woven fabric. The second air-permeable barrier may be received in the substrate compartment. The second air-permeable barrier may be arranged to cover the air outlet. The second air-permeable barrier may cover the air outlet to prevent the plurality of aerosol-generating elements from entering the air outlet. The second air-permeable barrier may overlie part of the peripheral wall. The second air-permeable barrier may be attached to the peripheral wall by an attaching means, for example by an adhesive. Preferably, the adhesive of the second air-permeable barrier is positioned proximate to two opposing edges of the second air-permeable barrier. In other words, the second air permeable barrier may comprise at least two adhesive elements, and at least one adhesive element may be provided on each opposing side of the peripheral wall that defines the air outlet. Preferably, the air outlet is located between the at least two adhesive elements of the second air-permeable barrier. Preferably, the adhesive of the second air-permeable barrier is not located on a region of the second air-permeable barrier which covers the air outlet. Preferably, the adhesive of the second air-permeable barrier is applied on the same face of the second air-permeable barrier. Preferably, the adhesive of the second air-permeable barrier is spaced apart from the air outlet. In other words, preferably the adhesive of the second air-permeable barrier is spaced apart from an edge of the peripheral wall that defines the air outlet.

[0073] Each of the first air-permeable barrier and the second air-permeable barrier may comprise pores extending through each of the first air-permeable barrier and the second air-permeable barrier respectively. Preferably, a diameter of the air inlet is greater than a maximum pore size of the first air-permeable barrier. Preferably, a diameter of the air outlet is greater than a maximum pore size of the second air-permeable barrier.

[0074] The container may comprise a layered structure. For example, the container may comprise a first layer comprising the first wall, a second layer comprising the peripheral wall, and a third layer comprising the second wall. At least part of the one or more air-permeable barriers may be positioned between the first layer and the second layer. Alternatively or in addition, at least part of the one or more air-permeable barriers may be positioned between the second layer and the third layer.

[0075] Advantageously, providing the one or more air-permeable barriers between the peripheral wall and the first wall or between the peripheral wall and the second wall may help to hold the one or more air-permeable barriers in position. Advantageously, providing the one or more air-permeable barriers between the peripheral wall and the first wall or between the peripheral wall and the second wall may hold the one or more air-permeable barriers in position such that adhesives are not required or a reduced amount of adhesive may be used.

[0076] At least part of the one or more air-permeable barriers may extend into one or both of the air inlet and the air outlet.

[0077] The one or more air-permeable barriers may overlie at least part of the peripheral wall. The one or more air-permeable barriers may contact the peripheral wall. The one or more air-permeable barriers may contact one or both of the first wall and the second wall.

[0078] The one or more air-permeable barriers may at least partially define one or more pouches, the one or more pouches containing the plurality of aerosol-generating elements. The one or more pouches may be received in the substrate compartment.

[0079] For example, each of the one or more air-permeable barriers may define a pouch. The one or more pouches may conform to the shape of the substrate compartment. The one or more pouches may be attached to one or more of the first wall, the peripheral wall and the second wall, for example using an adhesive.

[0080] Advantageously, providing one or more pouches that conform to the shape of the substrate compartment may help to retain the one or more pouches in the substrate compartment.

[0081] The one or more pouches may be a single pouch. The single pouch may cover both the air inlet and the air outlet.

[0082] The one or more pouches may be a plurality of pouches.

[0083] The plurality of pouches may comprise a first pouch and a second pouch. The one or more air-permeable barriers may comprise a first air-permeable barrier defining the first pouch and a second air-permeable barrier defining the second pouch. The second pouch may be located downstream of the first pouch. For example, the first pouch may cover the air inlet and the second pouch may cover the air outlet. The second pouch may abut the first pouch.

[0084] Advantageously, providing the one or more air-permeable barriers at least partially defining one or more pouches may simplify an assembly process for the aerosol-generating article. For example, providing the one or more air-permeable barriers at least partially defining one or more pouches may allow the pouch to be filled with the plurality of aerosol-generating elements and the pouch to be inserted into the substrate compartment in an assembly process to be performed in at least two separate steps which may simplify the assembly process.

[0085] As used herein, the terms ’’upstream”, “downstream”, “proximal” and “distal” are used to describe the relative positions of elements, or portions of elements, of aerosol-generating articles, aerosol-generating devices and aerosol-generating systems according to the disclosure.

[0086] Aerosol-generating systems as described herein may comprise a proximal end through which, in use, an aerosol exits the aerosol-generating system. The proximal end may also be referred to as the mouth end. In use, a user may draw on the proximal end or mouth end of an aerosol-generating system in order to inhale an aerosol generated by the aerosol-generating article. The aerosol-generating system may comprise a distal end opposite the proximal end or mouth end. The proximal end or mouth end of the aerosol-generating system may also be referred to as the downstream end. The distal end of the aerosol-generating system may also be referred to as the upstream end. Components, or portions of components, of the aerosol-generating system may be described as being upstream or downstream of one another based on their relative positions between the proximal or downstream end and the distal or upstream end of the aerosol-generating system.

[0087] The plurality of aerosol-generating elements may comprise a plurality of first aerosolgenerating elements and a plurality of second aerosol-generating elements. The first pouch may comprise the plurality of first aerosol-generating elements and the second pouch may comprise the plurality of second aerosol-generating elements.

[0088] The plurality of second aerosol-generating elements may have a different composition to the plurality of first aerosol-generating elements.

[0089] As used herein, the term “different composition” refers to comprising one or more of a different chemical components, a different chemical structure, a different materials structure, or a different ratio of chemical components.

[0090] Advantageously, providing the plurality of second aerosol-generating elements having a different composition to the plurality of first aerosol-generating elements may improve the customisability of the aerosol-generating article. One or both of the first wall and the second wall may comprise at least one opening to the substrate compartment. The at least one opening to the substrate compartment may be larger than one or both of the air inlet and the air outlet.

[0091] Advantageously, providing at least one opening to the substrate compartment in one or both of the first wall and the second wall may improve access to the substrate compartment. Advantageously, providing at least one opening to the substrate compartment in one or both of the first wall and the second wall may improve the transfer of heat from a heater in an aerosolgenerating device to the aerosol-generating substrate in the substrate compartment of the aerosol-generating article.

[0092] The at least one opening may be covered by the one or more air-permeable barriers to prevent the plurality of aerosol-generating elements from entering the opening. In other words, the one or more air-permeable barriers may cover the air inlet, the air outlet and the at least one opening.

[0093] The at least one opening may comprise a first opening in the first wall and a second opening in the second wall. One of the first opening and the second opening may be covered by the one or more air-permeable barriers. Alternatively, both of the first opening and the second opening may be covered by the one or more air-permeable barriers.

[0094] The aerosol-generating article may comprise an air flow path extending from the air inlet through the substrate compartment of the container to the air outlet.

[0095] The one or more air-permeable barriers may be arranged between the air inlet and the air outlet.

[0096] The air inlet may be on an opposing side to the air outlet. The air inlet may be at an upstream end of the container. The air outlet may be at a downstream end of the container.

[0097] The peripheral wall may comprise one or more walls.

[0098] The peripheral wall may comprise an upstream wall and a downstream wall. The upstream wall may oppose the downstream wall. The air inlet may be provided in the upstream wall of the peripheral wall of the container. The air outlet may be provided in the downstream wall of the peripheral wall of the container.

[0099] The air inlet and the air outlet may be aligned along a longitudinal axis of the container. The air inlet may comprise one or more air inlets.

[0100] The one or more air inlets may comprise a single air inlet. In other words, the aerosolgenerating article may comprise a single air inlet.

[0101] The one or more air inlets may comprise a plurality of air inlets. In other words, the aerosolgenerating article may comprise a plurality of air inlets.

[0102] The air outlet may comprise one or more air outlets.

[0103] The one or more air outlets may comprise a single air outlet. In other words, the aerosolgenerating article may comprise a single air outlet. The one or more air outlets may comprise a plurality of air outlets. In other words, the aerosol-generating article may comprise a plurality of air outlets.

[0104] Each of the one or more air inlets may have a cross-sectional area of less than 1 square millimetre, less than 0.5 square millimetres, less than 0.45 square millimetres, less than 0.4 square millimetres, less than 0.35 square millimetres, less than 0.3 square millimetres, less than 0.25 square millimetres, or less than 0.2 square millimetres.

[0105] Each of the one or more air inlets may have a cross-sectional area of greater than or equal to 0.01 square millimetres, greater than or equal to 0.05 square millimetres, greater than or equal to 0.1 square millimetres, greater than or equal to 0.15 square millimetres, or greater than or equal to 0.2 square millimetres.

[0106] Each of the one or more air outlets may have a cross-sectional area of less than 1 square millimetre, less than 0.5 square millimetres, less than 0.45 square millimetres, less than 0.4 square millimetres, less than 0.35 square millimetres, less than 0.3 square millimetres, less than 0.25 square millimetres, or less than 0.2 square millimetres.

[0107] Each of the one or more air outlets may have a cross-sectional area of greater than or equal to 0.01 square millimetres, greater than or equal to 0.05 square millimetres, greater than or equal to 0.1 square millimetres, greater than or equal to 0.15 square millimetres, or greater than or equal to 0.2 square millimetres.

[0108] A separation between the first wall and the second wall may define a thickness of the container. The thickness of the container may be less than or equal to 10 millimetres, less than or equal to 8 millimetres, less than or equal to 6 millimetres, less than or equal to 5 millimetres, or less than or equal to 4 millimetres. The thickness of the container may be greater than or equal to 0.5 millimetres, greater than or equal to 1 millimetre, greater than or equal to 2 millimetres, or greater than or equal to 3 millimetres.

[0109] The container may be made from or comprise a cellulosic material. The first wall, the second wall and the peripheral wall may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may comprise cellulose fibres. The cellulosic material may be paper, paperboard, or cardboard.

[0110] The container may be made from or comprise a polymer. The first wall, the second wall and the peripheral wall may be made from or comprise a polymer.

[0111] The plurality of aerosol-generating elements may comprise one or more of a powder, a plurality of beads or a plurality of granules.

[0112] As used herein, the term “granule” refers to a discrete, solid particle. The granule may have a regular or irregular shape.

[0113] As used herein, the term “bead” refers to a discrete, solid particle which has a rounded, typically spherical, form. As used herein, the term “powder” refers to a solid substance in the form of loose fine particles.

[0114] Preferably, the plurality of aerosol-generating elements comprise a powder.

[0115] The plurality of aerosol-generating elements may comprise greater than or equal to 5 aerosol-generating elements, greater than or equal to 10 aerosol-generating elements, greater than or equal to 100 aerosol-generating elements, greater than or equal to 1000 aerosolgenerating elements, or greater than or equal to 10000 aerosol-generating elements.

[0116] The plurality of aerosol-generating elements may each have any suitable shape. For example, the plurality of aerosol-generating elements may each have a substantially ellipsoid shape, a substantially ovoid shape or a substantially spherical shape.

[0117] A median (D50) diameter of the plurality of aerosol-generating elements may be less than or equal to 1 millimetre, less than or equal to 500 micrometres, less than or equal to 250 micrometres, less than or equal to 150 micrometres, less than or equal to 100 micrometres, less than or equal to 50 micrometres, less than or equal to 30 micrometres, less than or equal to 20 micrometres, less than or equal to 10 micrometres, or less than or equal to 5 micrometres.

[0118] A median (D50) diameter of the plurality of aerosol-generating elements may be greater than or equal to 1 micrometre, greater than or equal to 5 micrometres, greater than or equal to 10 micrometres, greater than or equal to 30 micrometres, greater than or equal to 50 micrometres, greater than or equal to 0.1 millimetres, greater than or equal to 0.5 millimetres, or greater than or equal to 0.6 millimetres.

[0119] For example, a median (D50) diameter of the plurality of aerosol-generating elements may be between 5 micrometres and 1 millimetre, or between 0.6 millimetres and 1 millimetre.

[0120] As used herein, the term “median diameter of the plurality of aerosol-generating elements” refers to the “D50 size the plurality of aerosol-generating elements”. The D50 size is the diameter of an aerosol-generating element which splits the distribution of diameters of the plurality of aerosol-generating elements in half, where half of the plurality of aerosol-generating elements are larger than the D50 size and half of the plurality of aerosol-generating elements are smaller than the D50 size. The distribution of diameters of the plurality of aerosol-generating elements may be determined by laser diffraction. For example, the particle size distribution may be determined by laser diffraction using a Malvern Mastersizer 3000 laser diffraction particle size analyser in accordance with the manufacturer’s instructions

[0121] A maximum diameter of the plurality of aerosol-generating elements may be less than or equal to 1 millimetre, less than or equal to 500 micrometres, less than or equal to 250 micrometres, less than or equal to 150 micrometres, less than or equal to 100 micrometres, less than or equal to 50 micrometres, less than or equal to 30 micrometres, less than or equal to 20 micrometres, less than or equal to 10 micrometres, or less than or equal to 5 micrometres. A maximum diameter of the plurality of aerosol-generating elements may be greater than or equal to 1 micrometres, greater than or equal to 5 micrometres, greater than or equal to 10 micrometres, greater than or equal to 30 micrometres, greater than or equal to 50 micrometres, greater than or equal to 0.1 millimetres, greater than or equal to 0.5 millimetres, or greater than or equal to 0.6 millimetres.

[0122] For example, a maximum diameter of the plurality of aerosol-generating elements may be between 5 micrometres and 1 millimetre, or between 0.6 millimetres and 1 millimetre.

[0123] Preferably, a diameter of one or both of the air inlet and the air outlet is greater than the maximum diameter of the plurality of aerosol-generating elements.

[0124] As used herein, the term “maximum diameter of the plurality of aerosol-generating elements” refers to the largest diameter of the plurality of aerosol-generating elements. In other words, none of the plurality of aerosol-generating elements may have a diameter which is greater than the maximum diameter of the plurality of aerosol-generating elements.

[0125] Preferably, where the one or more air-permeable barriers comprise a plurality of pores, a maximum pore size may be less than a minimum diameter of the plurality of aerosol-generating elements. In other words, none of the plurality of aerosol-generating elements may have a diameter which is less than a pore size of the one or more air-permeable barriers. Advantageously, this may prevent any of the plurality of aerosol-generating elements from entering any of the pores of the one or more air-permeable barriers.

[0126] As used herein, the term “minimum diameter of the plurality of aerosol-generating elements” refers to the smallest diameter of the plurality of aerosol-generating elements. In other words, none of the plurality of aerosol-generating elements may have a diameter which is less than the minimum diameter of the plurality of aerosol-generating elements.

[0127] The total mass of the plurality of aerosol-generating elements is at least 50 milligrams, at least 100 milligrams, at least 125 milligrams, or at least 150 milligrams.

[0128] Preferably, the total mass of the plurality of aerosol-generating elements is less than or equal to 350 milligrams, less than or equal to 300 milligrams, less than or equal to 250 milligrams, or less than or equal to 200 milligrams.

[0129] For example, the total mass of the plurality of aerosol-generating elements may be between 50 milligrams and 350 milligrams, between 100 milligrams and 300 milligrams, between 125 milligrams and 250 milligrams, or between 150 milligrams and 200 milligrams.

[0130] As used herein, the term “total mass of the plurality of aerosol-generating elements” is defined as the sum of the mass of each of the plurality of aerosol-generating elements.

[0131] The plurality of aerosol-generating elements may comprise an encapsulated liquid or gel. As used herein, the term “gel” is used to describe a substantially dilute cross-linked material, which exhibits no flow in the steady state. The plurality of aerosol-generating elements may comprise a flavourant. The plurality of aerosol-generating elements may comprise encapsulated flavourants.

[0132] Suitable flavourants include, but are not limited to: menthol, mint such as peppermint or spearmint, cocoa, liquorice, fruit (such as citrus), gamma octalactone, vanillin, spices (such as cinnamon), methyl salicylate, linalool, eugenol, eucalyptol, bergamot oil, eugenol oil, geranium oil, lemon oil, ginger oil, and tobacco flavour.

[0133] The plurality of aerosol-generating elements may comprise nicotine.

[0134] As used herein, the term “nicotine” is used to describe nicotine, a nicotine base or a nicotine salt. In embodiments in which the aerosol-generating substrate comprises a nicotine base or a nicotine salt, the amounts of nicotine recited herein are the amount of free base nicotine or amount of protonated nicotine, respectively.

[0135] The plurality of aerosol-generating elements may comprise natural nicotine or synthetic nicotine.

[0136] The plurality of aerosol-generating elements may comprise tobacco.

[0137] The plurality of aerosol-generating elements may comprise homogenised tobacco material. The plurality of aerosol-generating elements may comprise a plurality of shreds of tobacco material, such as tobacco cut filler or shreds of homogenised tobacco material. Shreds of homogenised tobacco material may be formed from a sheet of homogenised tobacco material, for example, by cutting or shredding. Shreds of homogenised tobacco material may be formed by other methods, for example, by extrusion.

[0138] The plurality of aerosol-generating elements may comprise a carrier medium and a liquid or gel sorbed in the carrier medium. The carrier medium may comprise a solid continuous matrix structure and a solid porous substrate dispersed within the solid continuous matrix structure.

[0139] As used herein, the term “sorbed in” refers to the process by which the carrier medium retains a liquid or gel. The sorption may include one or more of adsorption and absorption. For example, the sorption may comprise drawing the liquid or gel into any pores of the carrier medium by capillary action. It will be appreciated that “sorbed in” may also refer to the liquid or gel being adsorbed on the carrier medium.

[0140] The plurality of aerosol-generating elements may comprise an aerosol-former.

[0141] The plurality of aerosol-generating elements may comprise a polyhydric alcohol. Polyhydric alcohols suitable for use in the plurality of aerosol-generating elements include, but are not limited to, propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin. Preferably, the polyhydric alcohol is selected from the group consisting of glycerin, propylene glycol, and combinations thereof.

[0142] The plurality of aerosol-generating elements may comprise an acid. The plurality of aerosol-generating elements may comprise a carboxylic acid. Suitable carboxylic acids include, but are not limited to: 2- Ethylbutyric acid, acetic acid, adipic acid, benzoic acid, butyric acid, cinnamic acid, cycloheptanecarboxylic acid, fumaric acid, glycolic acid, hexanoic acid, lactic acid, levulinic acid, malic acid, myristic acid, octanoic acid, oxalic acid, propanoic acid, pyruvic acid, succinic acid, and undecanoic acid.

[0143] The plurality of aerosol-generating elements may comprise a cellulose based filler.

[0144] The plurality of aerosol-generating elements may comprise one or more hydrocolloid binders.

[0145] The plurality of aerosol-generating elements may be at least partially coated.

[0146] For example, the plurality of aerosol-generating elements may be at least partially coated with a powder. For example, the plurality of aerosol-generating elements may be at least partially coated with tobacco powder. The plurality of aerosol-generating elements may be at least partially coated with a cellulosic material, for example microcrystalline cellulose (MCC).

[0147] According to a second aspect of the present disclosure there is provided an aerosolgenerating system. The aerosol-generating system may comprise an aerosol-generating article according to the first aspect of the present disclosure. The aerosol-generating system may comprise an aerosol-generating device configured to heat the aerosol-generating article.

[0148] According to a second aspect of the present invention there is provided an aerosolgenerating system. The aerosol-generating system comprises an aerosol-generating article according to the first aspect of the present invention. The aerosol-generating system comprises an aerosol-generating device configured to heat the aerosol-generating article.

[0149] 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.

[0150] The aerosol-generating device may comprise a housing defining a device cavity for receiving the aerosol-generating article. The device cavity of the aerosol-generating device may have a shape substantially the same as the shape of the aerosol-generating article.

[0151] The aerosol-generating device may comprise one or more heaters. The aerosolgenerating device may comprise a power supply. The power supply may be a battery. The aerosol-generating device may comprise a controller configured to control a supply of power from the power supply to the one or more heaters.

[0152] The one or more heaters of the aerosol-generating device may comprise an external heater. The one or more heaters may not contact the one or more air-permeable barriers of the aerosol-generating article.

[0153] The one or more heaters of the aerosol-generating device may comprise at least one of a resistive heating element and an inductive heating element.

[0154] The inductive heating element may comprise a susceptor element. Where a susceptor element is provided, the aerosol-generating device may comprise an inductor coil arranged to inductively heat the susceptor element. The aerosol-generating device may comprise an inductor coil.

[0155] The aerosol-generating device may comprise a mouthpiece element. The mouthpiece element may be configured to be inserted into a mouth of a user.

[0156] 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.

[0157] The aerosol-generating system may comprise an air flow path connecting the air inlet of the aerosol-generating device to the air inlet of the container, the air inlet of the container to the air outlet of the container, and the air outlet of the container to the air outlet of the aerosolgenerating device.

[0158] 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.

[0159] Example EX1 : An aerosol-generating article for an aerosol-generating device, the aerosolgenerating article comprising:

[0160] a container, the container comprising:

[0161] a first wall;

[0162] a second wall opposing the first wall;

[0163] a peripheral wall extending between the first wall and the second wall; a substrate compartment between the first wall and the second wall, and at least partially circumscribed by the peripheral wall; and

[0164] an air inlet in the peripheral wall and an air outlet in the peripheral wall; an aerosol-generating substrate located in the substrate compartment, wherein the aerosol-generating substrate comprises a plurality of aerosol-generating elements; and

[0165] one or more air-permeable barriers received in the substrate compartment, the one or more air-permeable barriers arranged to cover the air inlet and the air outlet to prevent the plurality of aerosol-generating elements from entering each of the air inlet and the air outlet.

[0166] Example EX2: An aerosol-generating article according to example EX1, wherein the one or more air-permeable barriers are one or more air-permeable sheets.

[0167] Example EX3: An aerosol-generating article according to example EX1 or EX2, wherein the one or more air-permeable barriers comprise a cellulosic material.

[0168] Example EX4: An aerosol-generating article according to any one of examples EX1 to EX3, wherein the one or more air-permeable barriers comprise a non-woven fabric.

[0169] Example EX5: An aerosol-generating article according to any preceding example, wherein the non-woven fabric is Lyocell or Viscose. Example EX6: An aerosol-generating article according to any preceding example, wherein the one or more air-permeable barriers is a single air-permeable barrier.

[0170] Example EX7: An aerosol-generating article according to any preceding example, wherein the one or more air-permeable barriers comprise pores having a maximum pore size of less than or equal to 500 micrometres, optionally less than or equal to 250 micrometres, optionally less than or equal to 100 micrometres, optionally less than or equal to 50 micrometres, optionally less than or equal to 30 micrometres, optionally less than or equal to 20 micrometres, optionally less than or equal to 10 micrometres, or optionally less than or equal to 5 micrometres.

[0171] Example EX8: An aerosol-generating article according to any preceding example, wherein the one or more air-permeable barriers comprise pores having a maximum pore size of greater than or equal to 1 micrometres, optionally greater than or equal to 5 micrometres, or optionally greater than or equal to 10 micrometres.

[0172] Example EX9: An aerosol-generating article according to any preceding example, wherein the one or more air-permeable barriers each have a thickness of less than or equal to 1000 micrometres, optionally less than or equal to 750 micrometres, optionally less than or equal to 500 micrometres, optionally less than or equal to 400 micrometres, optionally less than or equal to 300 micrometres, optionally less than or equal to 200 micrometres, or optionally less than or equal to 100 micrometres.

[0173] Example EX10: An aerosol-generating article according to any preceding example, wherein at least part of the one or more air-permeable barriers is positioned between the peripheral wall and the first wall or between the peripheral wall and the second wall.

[0174] Example EX11: An aerosol-generating article according to any preceding example, wherein at least part of the one or more air-permeable barriers extends into one or both of the air inlet and the air outlet.

[0175] Example EX12: An aerosol-generating article according to any preceding example, wherein the one or more air-permeable barriers overlie at least part of the peripheral wall.

[0176] Example EX13: An aerosol-generating article according to any preceding example, wherein the one or more air-permeable barriers at least partially define one or more pouches, the one or more pouches containing the plurality of aerosol-generating elements.

[0177] Example EX14: An aerosol-generating article according to example EX13, wherein the one or more pouches are a single pouch.

[0178] Example EX15: An aerosol-generating article according to example EX13, wherein the one or more pouches are a plurality of pouches.

[0179] Example EX16: An aerosol-generating article according to example EX15, wherein the plurality of pouches comprise a first pouch and a second pouch, optionally wherein the second pouch is located downstream of the first pouch. Example EX17: An aerosol-generating article according to any preceding example, wherein one or both of the first wall and the second wall comprise at least one opening to the substrate compartment.

[0180] Example EX18: An aerosol-generating article according to example EX17, wherein the at least one opening is covered by the one or more air-permeable barriers to prevent the plurality of aerosol-generating elements from entering the at least one opening.

[0181] Example EX19: An aerosol-generating article according to any preceding example, wherein the plurality of aerosol-generating elements comprise one or more of a powder, a plurality of beads or a plurality of granules.

[0182] Example EX20: An aerosol-generating article according to any preceding example, wherein the plurality of aerosol-generating elements comprise encapsulated flavourants.

[0183] Example EX21: An aerosol-generating article according to any preceding example, wherein the plurality of aerosol-generating elements comprise tobacco.

[0184] Example EX22: An aerosol-generating article according to any preceding example, wherein the plurality of aerosol-generating elements comprise nicotine.

[0185] Example EX23: An aerosol-generating article according to any preceding example, wherein a median (D50) diameter of the plurality of aerosol-generating elements is less than or equal to 1 millimetre, optionally less than or equal to 500 micrometres, optionally less than or equal to 250 micrometres, optionally less than or equal to 150 micrometres, optionally less than or equal to 100 micrometres, optionally less than or equal to 50 micrometres, optionally less than or equal to 30 micrometres, optionally less than or equal to 20 micrometres, optionally less than or equal to 10 micrometres, or optionally less than or equal to 5 micrometres

[0186] Example EX24: An aerosol-generating article according to any preceding example, wherein a median (D50) diameter of the plurality of aerosol-generating elements is greater than or equal to 1 micrometre, optionally greater than or equal to 5 micrometres, optionally greater than or equal to 10 micrometres, optionally greater than or equal to 30 micrometres, optionally greater than or equal to 50 micrometres, optionally greater than or equal to 0.1 millimetres, optionally greater than or equal to 0.5 millimetres, or optionally greater than or equal to 0.6 millimetres.

[0187] Example EX25: An aerosol-generating article according to any preceding example, wherein the air inlet and the air outlet are aligned along a longitudinal axis of the container.

[0188] Example EX26: An aerosol-generating system comprising:

[0189] an aerosol-generating article according to any preceding example; and

[0190] an aerosol-generating device configured to heat the aerosol-generating article.

[0191] Example EX27: An aerosol-generating system according to example EX26, wherein the aerosol-generating device comprises an external heater. Example EX28: An aerosol-generating system according to example EX26 or EX27, wherein the aerosol-generating device comprises at least one of a resistive heating element and an inductive heating element.

[0192] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:

[0193] Figure 1 is a cross-sectional view of an aerosol-generating article according to a first embodiment of the disclosure.

[0194] Figure 2 is an exploded perspective view of the aerosol-generating article according to Figure 1.

[0195] Figure 3 is a cross-sectional view of an aerosol-generating article according to a second embodiment of the disclosure.

[0196] Figure 4 is a cross-sectional view of an aerosol-generating article according to a third embodiment of the disclosure.

[0197] Figure 5 is a cross-sectional view of a portion of an aerosol-generating system comprising the aerosol-generating article of Figure 1 and a portion of an aerosol-generating device.

[0198] Figure 6 is an exploded perspective view of an aerosol-generating article according to a fourth embodiment of the disclosure.

[0199] Figure 7 is a cross-sectional view of an aerosol-generating article according to Figure 6. Figure 1 shows a schematic cross-sectional view of an aerosol-generating article 100 and Figure 2 shows an exploded perspective view of the aerosol-generating article 100. The aerosolgenerating article 100 comprises a container 101. The container 101 comprises a first wall 102 and a second wall 103 opposing the first wall 102. The container also comprises a peripheral wall 104 extending between the first wall 102 and the second wall 103. A substrate compartment 105 is provided between the first wall 102 and the second wall 103. The substrate compartment 105 is at least partially circumscribed by the peripheral wall 104.

[0200] An air inlet 106 is provided in the peripheral wall 104. An air outlet 107 is provided in the peripheral wall 104.

[0201] An aerosol-generating substrate is located in the substrate compartment 105. The aerosol-generating substrate comprises a plurality of aerosol-generating elements 108. A diameter of each of the air inlet 106 and the air outlet 107 is greater than a maximum diameter of the plurality of aerosol-generating elements 108.

[0202] A single air-permeable barrier 109 in the form of an air-permeable sheet is provided. The air-permeable barrier 109 is formed from a non-woven fabric. The air-permeable barrier 109 is received in the substrate compartment 105. A part of the air-permeable barrier 109 is positioned between the peripheral wall 104 and the first wall 102. The air-permeable barrier 109 is arranged to cover the air inlet 106 and the air outlet 107 to prevent the plurality of aerosol-generating elements 108 from entering each of the air inlet 106 and the air outlet 107. The air-permeable barrier 109 overlies part of the peripheral wall 104.

[0203] The air-permeable barrier 109 comprises pores extending through the air-permeable barrier 109. A diameter of each of the air inlet 106 and the air outlet 107 is greater than a maximum pore size of the air-permeable barrier 109.

[0204] The first wall 102 comprises a first opening 110 to the substrate compartment 105. The first opening 110 is larger than each of the air inlet 106 and the air outlet 107.

[0205] The second wall 103 comprises a second opening 111 to the substrate compartment 105. The second opening 111 is larger than each of the air inlet 106 and the air outlet 107.

[0206] The second opening 111 is covered by the air-permeable barrier 109 to prevent the plurality of aerosol-generating elements 108 from entering the second opening 111.

[0207] Figure 3 shows a schematic cross-sectional view of an aerosol-generating article 200. The aerosol-generating article 200 comprises a container 201. The container 201 is substantially the same as the container 101.

[0208] The container 201 comprises a first wall 202 and a second wall 203 opposing the first wall 202. The container also comprises a peripheral wall 204 extending between the first wall 202 and the second wall 203. A substrate compartment 205 is provided between the first wall 202 and the second wall 203. The substrate compartment 205 is at least partially circumscribed by the peripheral wall 204.

[0209] An air inlet 206 is provided in the peripheral wall 204. An air outlet 207 is provided in the peripheral wall 204.

[0210] An aerosol-generating substrate is located in the substrate compartment 205. The aerosol-generating substrate comprises a plurality of aerosol-generating elements 208. A diameter of each of the air inlet 206 and the air outlet 207 is greater than a maximum diameter of the plurality of aerosol-generating elements 208.

[0211] The air-permeable barrier 209 defines a single pouch. The pouch is received in the substrate compartment 205. The pouch conforms to the shape of the substrate compartment 205 to retain the pouch in the substrate compartment 205. The pouch contains the plurality of aerosolgenerating elements 208. The air-permeable barrier 209 is formed from a non-woven fabric.

[0212] The air-permeable barrier 209 of the pouch is arranged to cover the air inlet 206 and the air outlet 207 to prevent the plurality of aerosol-generating elements 208 from entering each of the air inlet 206 and the air outlet 207.

[0213] The air-permeable barrier 209 comprises pores extending through the air-permeable barrier 209. A diameter of each of the air inlet 206 and the air outlet 207 is greater than a maximum pore size of the air-permeable barrier 209. The first wall 202 comprises a first opening 210 to the substrate compartment 205. The first opening 210 is larger than each of the air inlet 206 and the air outlet 207.

[0214] The second wall 203 comprises a second opening 211 to the substrate compartment 205. The second opening 211 is larger than each of the air inlet 206 and the air outlet 207.

[0215] Both the first opening 210 and the second opening 211 are covered by the air-permeable barrier 209.

[0216] Figure 4 shows a schematic cross-sectional view of an aerosol-generating article 300. The aerosol-generating article 300 comprises a container 301. The container 301 is substantially the same as the container 101.

[0217] The container 301 comprises a first wall 302 and a second wall 303 opposing the first wall 302. The container also comprises a peripheral wall 304 extending between the first wall 302 and the second wall 303. A substrate compartment 305 is provided between the first wall 302 and the second wall 303. The substrate compartment 305 is at least partially circumscribed by the peripheral wall 304.

[0218] An air inlet 306 is provided in the peripheral wall 304. An air outlet 307 is provided in the peripheral wall 304.

[0219] An aerosol-generating substrate is located in the substrate compartment 305.

[0220] The aerosol-generating substrate comprises a plurality of aerosol-generating elements. The plurality of aerosol-generating elements comprise a plurality of first aerosol-generating elements 308 and a plurality of second aerosol-generating elements 312.

[0221] The plurality of second aerosol-generating elements 312 have a different composition to the plurality of first aerosol-generating elements 308.

[0222] A diameter of each of the air inlet 306 and the air outlet 307 is greater than a maximum diameter of each of the plurality of first aerosol-generating elements 308 and the plurality of second aerosol-generating elements 312.

[0223] A first air-permeable barrier 309 defines a first pouch. A second air-permeable barrier 313 defines a second pouch.

[0224] The first pouch and the second pouch are received in the substrate compartment 305. The second pouch is located downstream of the first pouch. The second pouch abuts the first pouch. The first pouch and the second pouch conform to the shape of the substrate compartment 305 to retain the pouches in the substrate compartment 305.

[0225] The first pouch comprises the plurality of first aerosol-generating elements 308 and the second pouch comprises the plurality of second aerosol-generating elements 312.

[0226] Each of the first air-permeable barrier 309 and the second air-permeable barrier 313 are formed from a non-woven fabric.

[0227] The first air-permeable barrier 309 of the first pouch is arranged to cover the air inlet 306 and the second air-permeable barrier 313 of the second pouch is arranged to cover the air outlet 307 to prevent the plurality of aerosol-generating elements from entering each of the air inlet 306 and the air outlet 307.

[0228] The first air-permeable barrier 309 comprises pores extending through the first air-permeable barrier 309. The second air-permeable barrier 313 comprises pores extending through the second air-permeable barrier 313.

[0229] A diameter of each of the air inlet 306 and the air outlet 307 is greater than a maximum pore size of the first air-permeable barrier 309. A diameter of each of the air inlet 306 and the air outlet 307 is greater than a maximum pore size of the second air-permeable barrier 313.

[0230] The first wall 302 comprises a first opening 310 to the substrate compartment 305. The first opening 310 is larger than each of the air inlet 306 and the air outlet 307.

[0231] The second wall 303 comprises a second opening 311 to the substrate compartment 305. The second opening 311 is larger than each of the air inlet 306 and the air outlet 307.

[0232] Both the first opening 310 and the second opening 311 are covered by the first air-permeable barrier 309 and the second air-permeable barrier 313.

[0233] Figure 5 shows a schematic cross-sectional view of a portion of an aerosol-generating system 1000 comprising the aerosol-generating article 100 of Figures 1 and 2, and a portion of an aerosol-generating device 400.

[0234] The aerosol-generating device 400 comprises a heating element in the form of an external heating element 401. The external heating element 401 is located on an inner surface of a device cavity 402. The external heating element 401 is a resistive heating element. The external heating element 401 has a substantially flat planar shape.

[0235] In use, the user inserts the aerosol-generating article 100 into the device cavity 402 of the aerosol-generating device 400, such that the external heating element 401 is proximate the aerosol-generating article 100 when the aerosol-generating article 100 is received in the device cavity 402.

[0236] The aerosol-generating device 400 further comprises a power supply (not shown) and a controller (not shown) that allow the external heating element 401 to be actuated to heat the plurality of aerosol-generating elements 108 of the aerosol-generating article 100 when the aerosol-generating article 100 is received in the device cavity 402. An aerosol is generated upon heating of the plurality of aerosol-generating elements 108 of the aerosol-generating article 100. Such actuation may be manually operated or may occur automatically in response to a user drawing on a downstream end of the aerosol-generating device 400 when the aerosol-generating article 100 is inserted into the device cavity 402.

[0237] The aerosol-generating system 1000 comprises an air flow path connecting an air inlet 403 of the aerosol-generating device 400 to the air inlet 106 of the container 101, the air inlet 106 of the container 101 to the air outlet 107 of the container 101, and the air outlet 107 of the container 101 to an air outlet 404 of the aerosol-generating device 400. In particular, during use, the external heating element 401 heats the plurality of aerosolgenerating elements 108 of the aerosol-generating article 100 received in the device cavity 402 to generate an aerosol. Upon the user drawing on a downstream end of the aerosol-generating device 400, air is drawn through the air inlet 403 of the aerosol-generating device 400 into the air inlet 106 of the container 101. Air drawn into the air inlet 106 of the container 101 then enters the substrate compartment 105 and mixes with aerosol generated from the heating of the plurality of aerosol-generating elements 108 of the aerosol-generating article 100 by the external heating element 401. Aerosol is then drawn through the air outlet 404 of the aerosol-generating device 400. The aerosol is then drawn into the mouth of the user.

[0238] Figure 6 shows an exploded perspective view of an aerosol-generating article 500 and Figure 7 shows a schematic cross-sectional view of the aerosol-generating article 500.

[0239] The aerosol-generating article 500 comprises a container 501. The container 501 comprises a first wall 502 and a second wall 503 opposing the first wall 502. The container also comprises a peripheral wall 504 extending between the first wall 502 and the second wall 503. A substrate compartment 505 is provided between the first wall 502 and the second wall 503. The substrate compartment 505 is at least partially circumscribed by the peripheral wall 504.

[0240] An air inlet 506 is provided in the peripheral wall 504. An air outlet 507 is provided in the peripheral wall 504.

[0241] An aerosol-generating substrate is located in the substrate compartment 505. The aerosol-generating substrate comprises a plurality of aerosol-generating elements 508. A diameter of each of the air inlet 506 and the air outlet 507 is greater than a maximum diameter of the plurality of aerosol-generating elements 508.

[0242] A first air-permeable barrier 509 in the form of an air-permeable sheet is provided. The first air-permeable barrier 509 is formed from a non-woven fabric. The first air-permeable barrier 509 is received in the substrate compartment 505. The first air-permeable barrier 509 is arranged to cover the air inlet 506 to prevent the plurality of aerosol-generating elements 508 from entering the air inlet 506. The first air-permeable barrier 509 overlies part of the peripheral wall 504. The first air-permeable barrier 509 is attached to the peripheral wall by an adhesive 522 positioned proximate to two opposing edges of the firstair-permeable barrier 509. In other words, the air inlet 506 is located between two elements of adhesive 522.

[0243] A second air-permeable barrier 519 in the form of an air-permeable sheet is provided. The second air-permeable barrier 519 is formed from a non-woven fabric. The second air-permeable barrier 519 is received in the substrate compartment 505. The second air-permeable barrier 519 is arranged to cover the air outlet 507. The second air-permeable barrier 519 is arranged to cover the air outlet 507 to prevent the plurality of aerosol-generating elements 508 from entering the air outlet 507. The second air-permeable barrier 519 overlies part of the peripheral wall 504. The second air-permeable barrier 519 is attached to the peripheral wall by an adhesive 524 positioned proximate to two opposing edges of the second air-permeable barrier 519. In other words, the air outlet 507 is located between two elements of adhesive 524.

[0244] Each of the first air-permeable barrier 509 and the second air-permeable barrier 519 comprise pores extending through each of the first air-permeable barrier 509 and the second air-permeable barrier 519 respectively. A diameter of each of the air inlet 506 and the air outlet 507 is greater than a maximum pore size of each of the first air-permeable barrier 509 and the second air-permeable barrier 519.

[0245] It will be appreciated that the aerosol-generating article 500 may be used in the aerosolgenerating system 1000 comprising the aerosol-generating device 400.

[0246] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". In this context, therefore, a number A is understood as A ± 10 percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

- 27 -Claims1. An aerosol-generating article for an aerosol-generating device, the aerosol-generating article comprising:a container, the container comprising:a first wall;a second wall opposing the first wall;a peripheral wall extending between the first wall and the second wall;a substrate compartment between the first wall and the second wall, and at least partially circumscribed by the peripheral wall; andan air inlet in the peripheral wall and an air outlet in the peripheral wall;an aerosol-generating substrate located in the substrate compartment, wherein the aerosol-generating substrate comprises a plurality of aerosol-generating elements; andone or more air-permeable barriers received in the substrate compartment, the one or more air-permeable barriers arranged to cover the air inlet and the air outlet to prevent the plurality of aerosol-generating elements from entering each of the air inlet and the air outlet.

2. An aerosol-generating article according to claim 1 , wherein the one or more air-permeable barriers are one or more air-permeable sheets.

3. An aerosol-generating article according to claim 1 or 2, wherein the one or more air-permeable barriers comprise a non-woven fabric.

4. An aerosol-generating article according to claim 3, wherein the non-woven fabric is Lyocell or Viscose.

5. An aerosol-generating article according to any preceding claim, wherein the one or more air-permeable barriers each have a thickness of less than or equal to 500 micrometres.

6. An aerosol-generating article according to any preceding claim, wherein the one or more air-permeable barriers overlie at least part of the peripheral wall.

7. An aerosol-generating article according to any preceding claim, wherein at least part of the one or more air-permeable barriers is positioned between the peripheral wall and the first wall or between the peripheral wall and the second wall.

8. An aerosol-generating article according to any one of claims 1 to 6, wherein the one or more air-permeable barriers at least partially define one or more pouches, the one or more pouches containing the plurality of aerosol-generating elements.

9. An aerosol-generating article according to claim 8, wherein the one or more pouches are a plurality of pouches, the plurality of pouches comprising a first pouch and a second pouch.

10. An aerosol-generating article according to any preceding claim, wherein one or both of the first wall and the second wall comprise at least one opening to the substrate compartment.

11. An aerosol-generating article according to claim 10, wherein the at least one opening is covered by the one or more air-permeable barriers to prevent the plurality of aerosol-generating elements from entering the at least one opening.

12. An aerosol-generating article according to any preceding claim, wherein the plurality of aerosol-generating elements comprise one or more of a powder, a plurality of beads or a plurality of granules.

13. An aerosol-generating article according to any preceding claim, wherein the air inlet and the air outlet are aligned along a longitudinal axis of the container.

14. An aerosol-generating article according to any preceding claim, wherein a median (D50) diameter of the plurality of aerosol-generating elements is less than or equal to 1 millimetre.

15. An aerosol-generating system comprising:an aerosol-generating article according to any preceding claim; and an aerosol-generating device configured to heat the aerosol-generating article.

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