Article for an aerosol-generating system

Abstract

There is provided an article (100, 900) for an aerosol-generating system, the article comprising: an aerosol-generating substrate (102); and a paper or paper-based wrapper (104) containing the aerosol- generating substrate, wherein at least a first end portion (108) of the wrapper is sealed. An article pack, aerosol-generating system, and related methods are also provided.

Description

[0001] FTR3967 / PCT (P / 90833. W001)

[0002] 1

[0003] ARTICLE FOR AN AEROSOL-GENERATING SYSTEM

[0004] The present disclosure relates to an article for an aerosol-generating system. The present disclosure also relates to systems and methods associated with the article.

[0005] A typical aerosol-generating system may comprise an aerosol-generating device and an aerosol-generating article. The aerosol-generating article may comprise an aerosol-generating substrate and the aerosol-generating device may comprise a heater. In use, the heater of the aerosolgenerating device may heat the aerosol-generating substrate of the aerosol-generating article so as to release an aerosol from the aerosol-generating substrate. A user may inhale that aerosol.

[0006] A typical aerosol-generating article may appear similar to a conventional cigarette. For example, such an aerosol-generating article may be substantially cylindrical and comprise an aerosolgenerating substrate and other components such as a mouthpiece filter element and a cooling element, all arranged together in the form of a rod and wrapped in a cigarette paper. Dimensions of typical aerosol-generating articles are often similar to the dimensions of conventional cigarettes.

[0007] However, the components of these cylindrical aerosol-generating articles normally need to have the same or very similar outer diameters so that they can be brought together, accurately positioned in co-axial alignment and wrapped in a cigarette paper to hold them together. This can lead to increased cost and complexity of manufacture. The presence of multiple components in the articles may also have an environmental impact.

[0008] It is an object of the present disclosure to provide an article for an aerosol-generating system which may be manufactured relatively efficiently and cheaply. It is also an object of the present disclosure to provide an article for an aerosol-generating system with a reduced environmental impact.

[0009] According to the present disclosure, there is provided an article for an aerosol-generating system. The article may comprise an aerosol-generating substrate. The article may comprise a wrapper. The wrapper may be a paper or paper-based wrapper. The wrapper may contain the aerosolgenerating substrate. At least a first end portion of the wrapper may be sealed.

[0010] Thus, according to a first aspect of the present disclosure, there is provided an article for an aerosol-generating system. The article comprises an aerosol-generating substrate and a wrapper, preferably a paper or paper-based wrapper, containing the aerosol-generating substrate. At least a first end portion of the wrapper is sealed.

[0011] Advantageously, such an article may provide an alternative to conventional aerosol-generating articles currently available. The article provided may advantageously be manufactured relatively efficiently and cheaply because it may have fewer components than conventional aerosol-generating articles, and it may not require components to be accurately positioned in co-axial alignment and wrapped in a cigarette paper to hold them together. The provided article may also advantageously have a reduced environmental impact because it may have fewer components than conventional aerosol-generating articles.

[0012] Optionally, the wrapper comprises a second end portion. Optionally, the article comprises a mouthpiece. Optionally the mouthpiece is located at the second end portion of the wrapper. Optionally, the mouthpiece is in contact with the wrapper, for example with the second end portion of the wrapper. The second end portion of the wrapper may be located at an opposite end portion of the wrapper to the first end portion of the wrapper. The first end portion of the wrapper may be an upstream end portion of the wrapper. The second end portion of the wrapper may be a downstream end portion of the wrapper. The wrapper, for example the second end portion of the wrapper, may circumscribe at least a portion of the mouthpiece. The wrapper, for example the second end portion of the wrapper, may be attached to the mouthpiece. Advantageously, the mouthpiece may allow a user to puff or draw directly on the article. Advantageously, the mouthpiece may provide a consistent and satisfying puffing experience for users.

[0013] The mouthpiece may comprise a filter. The mouthpiece may comprise filter material. The filter or filter material may be porous. The filter or filter material may be air-permeable. The mouthpiece may comprise any one or more of: cellulose acetate, paper, and cotton. Advantageously, the mouthpiece, particularly any filter or filter material of the mouthpiece, if present, may prevent loose aerosolgenerating substrate or other debris or unwanted particles from entering a mouth of a user when user inhales or draws on the article.

[0014] When drawing on the mouthpiece of the article, the article may have a resistance to draw of at least 40 or 50 millimetres of Water Column (mmWC). When drawing on the mouthpiece of the article, the article may have a resistance to draw of no more than 90 or 60 mmWC. When drawing on the mouthpiece of the article, the article may have a resistance to draw of between 40 and 90 mmWC, preferably between 50 and 60 mmWC. Advantageously, the mouthpiece may give the article a desired resistance to draw.

[0015] Optionally, the mouthpiece has a density of at least 0.1 , preferably at least 0.15, more preferably at least 0.175 grams per centimetre cubed. Optionally, the mouthpiece has a density of no more than 0.3, preferably no more than 0.25, more preferably no more than 0.225, grams per centimetre cubed. Optionally, the mouthpiece has a density of between 0.1 and 0.3, preferably between 0.15 and 0.25, more preferably between 0.175 and 0.225, grams per centimetre cubed. Advantageously, such densities may give the mouthpiece a desired resistance to draw.

[0016] Optionally, the aerosol-generating substrate is contained in a cavity. Optionally, at least 90 or 95 percent, or an entirety, of a bounding area defining the cavity is defined by only the wrapper and the mouthpiece. Optionally, the cavity is defined partially, mostly or entirely by only the wrapper and the mouthpiece. Advantageously, by not requiring minimal, if any, further components to define the cavity for the substrate, the article may be straightforward and inexpensive to manufacture. The article may also advantageously have a reduced environmental impact. This contrasts to conventional aerosol-generating articles which may have front plugs or cooling tubes holding the substrate in position.

[0017] As the skilled person would understand from this disclosure, the paper or paper-based wrapper may contain all of the aerosol-generating substrate of the article. The paper or paper-based wrapper may contain an entirety of the aerosol-generating substrate of the article. All of the aerosol-generating substrate of the article may be contained within the cavity. An entirety of the aerosol-generating substrate of the article may be contained within the cavity. Outside of the cavity, the aerosol-generating article may be free of aerosol-generating substrate. Outside of the cavity, the aerosol-generating article may be aerosol-generating substrate-free.

[0018] Optionally, the second end portion of the article has a second end portion cross-section. The second end portion cross-section may be defined by a second end portion width and a second end portion depth. The second end portion width may be no more than 3 or 2 or 1.5 or 1 .2 times the second end portion depth. The second end portion width may be between 0.9 and 1.1 times the second end portion depth. The second end portion width may be substantially equal to the second end portion depth. The second end portion cross-section may be substantially circular. Advantageously, such a cross-section may be comfortable for insertion into a mouth of a user and for a user to draw on. Where the second end portion cross-section varies along a length of the second end portion, the second end portion cross-section may refer to a cross-section at a mid-point along the length of the second end portion.

[0019] Optionally, the second end portion of the wrapper is sealed. Optionally, the second end portion of the wrapper is sealed to provide a second end portion seal. This may be as an alternative to a mouthpiece being located at the second end portion of the wrapper. Advantageously, the second end portion of the wrapper being sealed may prevent the aerosol-generating substrate from falling out of the second end of wrapper.

[0020] Optionally, the second end portion is sealed by an air-tight seal. Forming the second end portion seal may comprise any one or more of: folding the wrapper, applying pressure to the wrapper, applying heat to the wrapper, and applying adhesive to the wrapper. Optionally, the second end portion of the wrapper is sealed by adhering or otherwise attaching a first part of the second end portion of the wrapper to a second part of the second end portion of the wrapper. Optionally, the second end portion is crimp-sealed.

[0021] Optionally, the article, for example the second end portion, may be configured to be opened or unsealed. Optionally, the article, for example the second end portion, may be configured to be opened or unsealed by tearing some or all of the second end portion. Optionally, the article, for example the second end portion, may be configured to be opened or unsealed by tearing some or all of the second end portion off the article. Advantageously, this opening or unsealing may allow air to flow, or more air to flow, into the article. Advantageously, this opening or unsealing may allow a user to pour the aerosol-generating substrate from the article, for example into a holder or into a device cavity, as explained in more detail later.

[0022] Optionally, the article comprises one or more of: at least one notch, at least one perforation, and at least one line of weakness, for example in or proximate to the second end portion. The at least one notch, at least one perforation, or at least one line of weakness may extend in a width direction of the article. Advantageously, the at least one notch, perforation, or line of weakness may facilitate tearing of the wrapper, for example tearing the second end portion of the wrapper off. Optionally, the aerosol-generating substrate is contained in a cavity, as set out above. Optionally, at least 90 or 95 percent, or an entirety, of a bounding area defining the cavity is defined by only the wrapper. Optionally, the cavity is defined partially, mostly or entirely by only the wrapper. Advantageously, by not requiring minimal, if any, further components to define the cavity for the substrate, the article may be relatively straightforward and inexpensive to manufacture. The article may also advantageously have a reduced environmental impact. This contrasts to conventional aerosol-generating articles which may have front plugs or cooling tubes holding the substrate in position.

[0023] The first end portion of the wrapper is sealed. Optionally, the first end portion of the wrapper is sealed to provide a first end portion seal. Advantageously, the first end portion of the wrapper being sealed may prevent the aerosol-generating substrate from falling out of the first end of the wrapper.

[0024] Optionally, the first end portion is sealed by an air-tight seal. Forming the first end portion seal may comprise any one or more of: folding the wrapper, applying pressure to the wrapper, applying heat to the wrapper, and applying adhesive to the wrapper. Optionally, the first end portion of the wrapper is sealed by adhering or otherwise attaching a first part of the first end portion of the wrapper to a second part of the first end portion of the wrapper. Optionally, the first end portion is crimp-sealed.

[0025] Optionally, the article, for example the first end portion, may be configured to be opened or unsealed. Optionally, the article, for example the first end portion, may be configured to be opened or unsealed by tearing some or all of the first end portion. Optionally, the article, for example the first end portion, may be configured to be opened or unsealed by tearing some or all of the first end portion off the article. Advantageously, this opening or unsealing may allow air to flow, or more air to flow, into the article. Advantageously, this opening or unsealing may allow a user to pour the aerosol-generating substrate from the article, for example into a holder or into a device cavity, as explained in more detail later.

[0026] Optionally, the article comprises one or more of: at least one notch, at least one perforation, and at least one line of weakness, for example in or proximate to the first end portion. The at least one notch, at least one perforation, or at least one line of weakness may extend in a width direction of the article. Advantageously, the at least one notch, perforation, or line of weakness may facilitate tearing of the wrapper, for example tearing the first end portion of the wrapper off.

[0027] Optionally, the first end portion of the article has a first end portion cross-section. The first end portion cross-section may be defined by a first end portion width and a first end portion depth. The first end portion width may be at least 2, 3 or 5 times the first end portion depth. Advantageously, this may be a result of a straightforward way of sealing the first end portion. Advantageously, this cross-section may facilitate easy tearing of the wrapper proximate or in the first end portion. Where the first end portion cross-section varies along a length of the first end portion, the first end portion cross-section may refer to a cross-section at a mid-point along the length of the first end portion.

[0028] The aerosol-generating substrate may have a mass of at least 50, 100, or 200 milligrams. The aerosol-generating substrate may have a mass of no more than 1 ,000, 600 or 500 milligrams. The aerosol-generating substrate may have a mass of between 50 and 1 ,000, or between 100 and 600, or between 200 and 500, milligrams.

[0029] The aerosol-generating substrate may comprise plant particles. The aerosol-generating substrate may comprise at least 50, 60, or 75 percent by weight of plant particles, on a dry weight basis. The aerosol-generating substrate may comprise no more than 95, 90, or 85 percent by weight of plant particles, on a dry weight basis. The aerosol-generating substrate may comprise between 50 and 95, between 60 and 90, or between 75 and 85, percent by weight of plant particles on a dry weight basis.

[0030] The plant particles may comprise or consist of tobacco particles. The term “tobacco” may describe any plant member of the genus Nicotiana. The tobacco particles may include tobacco material from one or more of Bright tobacco, dark tobacco, aromatic tobacco, and filler tobacco.

[0031] Alternatively, or in addition to tobacco particles, the plant particles may comprise non-tobacco particles. For example, the plant particles may comprise one or more of: tea, coffee, star anise, lavender, clove, peppermint, chamomile, rosemary, eucalyptus, ginger, dill seed, thyme, oregano, and cumin.

[0032] In alternative embodiments, the plant particles may be substantially free from tobacco material such that the aerosol-generating substrate is tobacco free.

[0033] The aerosol-generating substrate may comprise one or more aerosol formers. Suitable aerosolformers are well known in the art and include, but are not limited to, one or more aerosol-formers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosol former to be or comprise one or more of glycerin and propylene glycol. The aerosol former may consist of glycerin or propylene glycol or of a combination of glycerin and propylene glycol. A particularly preferred aerosol former may be glycerin.

[0034] The aerosol-generating substrate may comprise at least 5, 10, 15, 20, 25, 30 or 40 percent by weight of aerosol former, on a dry weight basis. The aerosol-generating substrate may comprise no more than 70, 60 or 55 percent by weight of aerosol former, on a dry weight basis. The aerosolgenerating substrate may comprise between 5 and 70, 15 and 60, or 25 and 55, percent by weight of aerosol former, on a dry weight basis. The aerosol-generating substrate may comprise between 10 and 40, 15 and 35, or 20 and 30, percent by weight of aerosol former, on a dry weight basis.

[0035] The aerosol-generating substrate may comprise at least 5, 10, 15, 20, 25, 30 or 40 percent by weight of glycerin, on a dry weight basis. The aerosol-generating substrate may comprise no more than 70, 60 or 55 percent by weight of glycerin. The aerosol-generating substrate may comprise between 5 and 70, 15 and 60, or 25 and 55, percent by weight of glycerin, on a dry weight basis. The aerosol-generating substrate may comprise between 10 and 40, 15 and 35, or 20 and 30, percent by weight glycerin, on a dry weight basis. The percentages by weight for aerosol former may be the case where the aerosol former is glycerin.

[0036] It may be preferable for a weight ratio of plant particles to aerosol former in the aerosolgenerating substrate to be at least 2, 2.5, or 3.

[0037] The aerosol-generating substrate may comprise a binder. Advantageously, the binder may improve the binding of the plant particles in the aerosol-generating substrate. Advantageously, the binder may improve the structural integrity of the aerosol-generating substrate.

[0038] The aerosol-generating substrate may comprise no more than 5, 4, 3 or 2 percent by weight of the binder on a dry weight basis. The aerosol-generating substrate may comprise at least 0.5, 0.6, 0.7 or 0.8 percent of the binder by weight on a dry weight basis. The aerosol-generating substrate may comprise between 0.5 and 5, or between 0.6 and 4, or between 0.7 and 3, or between 0.8 and 2, percent by weight of the binder on a dry weight basis.

[0039] Suitable binders may be or comprise any of common gums or pectins used in food and beverage industries. Preferred binders may be natural pectins, such as fruit, for example citrus, or tobacco pectins; guar gums, land locust bean gums, such as hydroxyethyl and / or hydroxypropyl of those; starches, such as modified or derivatized starches; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl, celluloses; dextran; and xanthan gum. A preferable binder is guar.

[0040] It may be particularly preferable if the binder is or comprises one or more hydrocolloid binders. Suitable hydrocolloid binders would be known to the skilled person. Preferably, the one or more hydrocolloid binders are selected from the group consisting of: starch, modified starch, dextrin, alginate, pectin, cellulose, cellulose derivatives (such as carboxymethyl cellulose), agar, carrageenan, gelatin, natural gums (such as tragancanth gum, konjac gum, guar gum or xanthan gum) and combinations thereof. More preferably, the one or more hydrocolloid binders are selected from the group consisting of: carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), guar gum or alginate. Even more preferably, the one or more hydrocolloid binders comprises a cellulosic binder. Even more preferably still, the one or more hydrocolloid binders comprises a cellulose derivative. Most preferably, the hydrocolloid binder comprises hydroxypropyl methyl cellulose (HPMC). The aerosol-generating substrate may comprise at least 0.5 percent by weight of HPMC, on a dry weight basis. The aerosol-generating substrate may comprise no more than 2 or 1 .5 percent by weight of HPMC, on a dry weight basis. The aerosol-generating substrate may comprise between 0.5 and 2 percent by weight of HPMC, preferably between 0.5 and 1 .5 percent by weight of HPMC, on a dry weight basis.

[0041] The aerosol-generating substrate may further comprise one or more active agents. For example, the aerosol-generating substrate may comprise exogenous nicotine. The term “exogenous” refers to nicotine that is added to the aerosol-generating substrate as a distinct component from any nicotine that is intrinsically present in the plant particles, for example, where the plant particles comprise tobacco particles. The term “nicotine” encompasses nicotine, a nicotine base, or a nicotine salt. In embodiments in which the aerosol-generating substrate comprise 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.

[0042] The aerosol-generating substrate may comprise nicotine. The aerosol-generating substrate may comprise natural nicotine or synthetic nicotine.

[0043] The total nicotine content of the aerosol-substrate may be at least 0.5, 1 , 1.5 or 2 percent by weight on a dry weight basis. The total nicotine content of the aerosol-substrate may be no more than 5, 3 or 2 percent by weight on a dry weight basis. The total nicotine content of the aerosol-substrate may be between 1 and 5, preferably between 1 and 3, percent by weight, on a dry weight basis. The total nicotine content corresponds to the total combined amount of intrinsic nicotine which may be present in tobacco material and any exogenous nicotine that is added instead of, or in addition to, tobacco particles.

[0044] The aerosol-generating substrate may comprise one or more cannabinoid compounds selected from the group consisting of: tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannabivarin (CBV), cannabidivarin (CBDV), tetrahydrocannabivarin (THCV), cannabichromene (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), cannabicitran (CBT) and combinations thereof. Preferably, the one or more cannabinoid compounds are selected from CBD, THC, and a combination thereof. Particularly preferably, the one or more cannabinoid compounds includes CBD.

[0045] The aerosol-generating substrate may comprise one or more flavourants. Suitable flavourants would be known to the skilled person. The one or more flavourants may comprise one or more of: one or more essential oils such as eugenol, peppermint oil and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool.

[0046] The aerosol-generating substrate may further comprise one or more acids, preferably one or more carboxylic acids. Advantageously, where the active agent comprises nicotine, including one or more acids in the aerosol-generating substrate may create a nicotine salt. The one or more acids may comprise one or more of lactic acid, levulinic acid, benzoic acid, fumaric acid or acetic acid. Preferably, the one or more acids comprises at least one of lactic acid or levulinic acid.

[0047] The aerosol-generating substrate may have an acid content of at least 0.5, 1 or 2 percent by weight, on a dry weight basis. The aerosol-generating substrate may have an acid content of no more than 10, 8, or 6 percent by weight, on a dry weight basis. The aerosol-generating substrate may have an acid content of between 0.5 and 10, 1 and 8, or 2 and 6, percent by weight, on a dry weight basis.

[0048] The aerosol-generating substrate may comprise water. The aerosol-generating substrate may comprise a total water content of less than or equal to 50, 30, 20 or 15 percent by weight. The aerosolgenerating substrate may comprise a total water content of at least 1 , 2 or 5 percent by weight. The aerosol-generating substrate may comprise a total water content of between 1 and 50, 1 and 30, 2 and 20, or 5 and 15, percent by weight. The aerosol-generating substrate may comprise a relatively high level of water, for example as mentioned. Advantageously, the article described herein may be better suited to handling aerosol-generating substrates with relatively high levels of water, compared with other articles where the wrapper does not have a sealed first end portion, for example where the article relies includes a front plug.

[0049] It may be particularly preferable for the aerosol-generating substrate to comprise plant particles such as tobacco particles, aerosol former such as glycerin, and a hydrocolloid binder such as hydroxypropyl methyl cellulose (HPMC). Thus, it may be particularly preferable for the aerosolgenerating substrate to comprise tobacco particles, glycerin, and hydroxypropyl methyl cellulose (HPMC). It may be particularly preferable for the substrate to comprise at least 50 percent by weight of plant particles, on a dry weight basis. It may be particularly preferable for the substrate to comprise at least 10 percent by weight of aerosol former, on a dry weight basis. It may be particularly preferable for the substrate to comprise one or more hydrocolloid binders, wherein the total amount of hydrocolloid binder is less than or equal to 5 percent by weight of the aerosol-generating substrate, on a dry weight basis. It may be particularly preferable for a weight ratio of plant particles to aerosol former in the aerosol-generating substrate to be at least 2.5.

[0050] Advantageously, when incorporated into an article and heated to a temperature of between 200 and 240 degrees Celsius whilst a user puffed on the article, an aerosol was generated containing nicotine and glycerin from the aerosol-generating substrate. The ratio of nicotine to glycerin in each puff of aerosol was found to remain consistent over the duration of the heating. This is in contrast to the aerosol generated from an article having a similar construction but in which the aerosol-generating substrate is in the form of tobacco cast leaf. With the tobacco cast leaf substrate, the aerosol generated under the same conditions was found to have a much more variable ratio of nicotine to glycerin per puff. The provision of an aerosol with a more consistent ratio of nicotine to glycerin across puffs may provide an optimal sensory experience to the consumer over the duration of the heating.

[0051] Optionally, the aerosol-generating substrate comprises, or is in the form of, a plurality of particles. The particles may be discrete, solid particles. Optionally, the aerosol-generating substrate comprises, or is in the form of, a powder. Optionally, the powder comprises, or is, the plurality of particles. Optionally, the aerosol-generating substrate comprises, or is in the form of, a plurality of beads. Optionally, the aerosol-generating substrate comprises, or is in the form of, a plurality of granules. The terms “bead” and “granule” may refer to a discrete, solid particle.

[0052] The terms “particle”, “bead” and “granule” may be used interchangeably herein. In particular, where the term “particle” is used below, this may refer to a particle, bead, or granule.

[0053] Each of the plurality of particles may have any suitable shape. For example, some or all of the plurality of particles may be substantially rounded, or substantially spherical, in shape.

[0054] The plurality of particles may comprise at least 5, 10, 20, 50, 100, or 200 particles.

[0055] Some, for example at least 50 or 80 percent, or all, of the plurality of particles may comprise aerosol-forming material.

[0056] Optionally, the plurality of particles has a volume particle size distribution defined by a volume D10 particle size, a D50 particle size and a volume D90 particle size. The volume D10 particle size is defined such that 10% of the sum of the volumes of all of the particles is accounted for by the sum of the volumes of the particles having a particle size less than or equal to the volume D10 particle size. Similarly, the volume D50 particle size is defined such that 50% of the sum of the volumes of all of the particles is accounted for by the sum of the volumes of the particles having a particle size less than or equal to the volume D50 particle size. And the volume D90 particle size is defined such that 90% of the sum of the volumes of all of the particles is accounted for by the sum of the volumes of the particles having a particle size less than or equal to the volume D90 particle size.

[0057] Optionally, the volume D10 particle size is at least 50, 100, or 150 microns. Optionally, the volume D10 particle size is no more than 500, 350, or 250 microns. Optionally, the volume D10 particle size is between 50 and 500, preferably between 100 and 350, more preferably between 150 and 250 microns.

[0058] Optionally, the volume D50 particle size is at least 100 or 200 microns. Optionally, the volume D50 particle size is no more than 600, or 400 microns. Optionally, the volume D50 particle size is between 100 and 600 microns, preferably between 200 and 400 microns.

[0059] Optionally, the volume D90 particle size is at least 100, 200 or 300 microns. Optionally, the volume D90 particle size is no more than 750, 600, or 500 microns. Optionally, the volume D90 particle size is between 100 and 750, preferably between 200 and 600, more preferably between 300 and 500 microns.

[0060] Advantageously, the particle sizes above may provide an optimal compromise between ease of particle handling during manufacture, aerosol formation when heated, and mass of particles that may be contained in the article.

[0061] Optionally, the volume D90 particle size is no more than 15, 10 or 5 times the volume D10 particle size. Advantageously, a tighter particle size distribution may provide more consistent aerosol delivery during use.

[0062] The bulk density of the plurality of particles is preferably at least 100, 200, or 250 milligrams per cubic centimetre. Preferably, the bulk density of the plurality of particles is less than or equal to 600, 500 or 450 milligrams per cubic centimetre. Preferably, the bulk density of the plurality of particles is between 100 and 600, or 200 and 500, or 250 and 450 milligrams per cubic centimetre. The bulk density of the plurality of particles may be defined as the total weight of the plurality of particles, divided by the volume of the space occupied by the plurality of particles.

[0063] The plurality of particles may be formed by a method comprising grinding or milling particles. This may provide substantially spherical particles. This may provide particles of an appropriate size.

[0064] The aerosol-generating substrate may be or comprise a liquid, for example an aerosolgenerating liquid. The liquid may be liquid at 20 degrees Celsius and atmospheric pressure. The aerosol-generating liquid may comprise one or more aerosol formers. The aerosol-generating liquid may comprise one or both of propylene glycol and glycerin. The aerosol-generating liquid may comprise nicotine. Features set out above, such as the aerosol former content of the aerosolgenerating substrate, may apply to the aerosol-generating liquid.

[0065] The aerosol-generating substrate may be or comprise a gel composition, for example an aerosol-generating gel composition. The gel composition may be gel at 20 degrees Celsius and atmospheric pressure. Suitable gel compositions are described in WO-A-2021 / 170642.

[0066] The gel composition may comprise at least one gelling agent and aerosol former. The gel composition may comprise nicotine. Optionally, the gel composition comprises less than 5 weight percent tobacco on a dry weight basis. Optionally, the gel composition is tobacco-free.

[0067] Optionally, the gel composition comprises between 0.5 percent and 10 percent by weight of nicotine, or between 1 percent and 8 percent by weight of nicotine, or between 2 percent and 6 percent by weight of nicotine, on a dry weight basis.

[0068] Optionally, the gel composition comprises at least 50, 60, or 70 percent by weight of aerosol former, on a dry weight basis. Optionally, the gel composition may comprise no more than 80 percent by weight of aerosol former on a dry weight basis. Optionally, the gel composition comprises between 50 and 80, 60 and 80, or 70 and 80 percent by weight of aerosol former, on a dry weight basis. Preferably, the aerosol former in the gel composition is or comprises glycerin or glycerol or both.

[0069] The aerosol-generating substrate may be or comprise a film, for example an aerosol-generating film. Suitable aerosol-generating films are described in WO-A-2020 / 207733 and WO-A-2022 / 074157.

[0070] The aerosol-generating film may comprise a cellulosic based film-forming agent and aerosol former. Optionally, the aerosol-generating film comprises nicotine. Optionally, the aerosol-generating film comprises a cellulose based strengthening agent. Optionally, the aerosol-generating film comprises water, preferably 30 percent by weight or less of water.

[0071] Optionally, the cellulose based film-forming agent is selected from the group consisting of hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethyl methyl cellulose (HEMO), hydroxyethyl cellulose (HEC), hydroxypropyl cellulose (HPC), and combinations thereof. Preferably, the cellulose based film-forming agent is HPMC.

[0072] Optionally, the aerosol former content of the aerosol-generating film is at least 40 or 50 weight percent on a dry weight basis. Optionally, the aerosol former content of the aerosol-generating film is no more than 80 or 70 weight percent on a dry weight basis. Optionally, the aerosol former content of the aerosol-generating film is between 40 and 80, or 50 and 70, weight percent on a dry weight basis.

[0073] Optionally, the aerosol-generating film comprises between 0.5 percent and 10 percent by weight of nicotine, or between 1 percent and 8 percent by weight of nicotine, or between 2 percent and 6 percent by weight of nicotine, on a dry weight basis.

[0074] Optionally, the aerosol-generating film comprises less than 5 weight percent tobacco on a dry weight basis. Optionally, the aerosol-generating film is tobacco-free.

[0075] Advantageously, the article described herein may be better suited to handling liquid or gel aerosol-generating substrates, compared with other articles where the wrapper does not have a sealed first end portion, for example where the article relies includes a front plug. The article may comprise a membrane. The membrane may contain the aerosol-generating substrate. The membrane may be located in the cavity of the article. The wrapper may contain the membrane. The membrane may be made from tea bag material, or a similar material. Advantageously, the membrane may hold the aerosol-generating substrate together. Advantageously, the membrane may reduce a likelihood of bits of the aerosol-generating substrate falling out of the wrapper if an end of the wrapper is opened or unsealed. The membrane may be particularly advantageous if solid aerosol-generating substrate is used.

[0076] The membrane may be porous. The membrane may be air-permeable. Advantageously, in this way, the membrane may not significantly affect the resistance to draw of the article.

[0077] At least a portion of the wrapper may be liquid-impermeable. At least a portion of the wrapper may be treated to be resistant to leakage, for example liquid leakage. At least a portion of the wrapper may comprise, or be treated with, such as co-laminated with, a substantially waterproof material. At least a portion of the wrapper may comprise, or be treated with, such as co-laminated with, one or more of: metal, metallic material, or plastic. At least a portion of the wrapper may be plasticised. Advantageously, this may allow the wrapper to better resist leakage. This may be particularly beneficial if the aerosol-generating substrate is or comprises a gel or a liquid.

[0078] Optionally, the wrapper has a grammage of at least 50, 60 or 78 grams per square metre. Optionally, the wrapper has a grammage of no more than 200, 150 or 110 grams per square metre. Optionally, the wrapper has a grammage of between 50 and 200, preferably between 60 and 150, more preferably between 78 and 110 grams per square metre.

[0079] Optionally, the wrapper has a thickness of at least 50, 75 or 100 and 140 microns. Optionally, the wrapper has a thickness of 300, 200 or 140 microns. Optionally, the wrapper has a thickness of between 50 and 300, preferably between 75 and 300, more preferably between 100 and 140 microns.

[0080] These grammages and thicknesses of the wrapper may be unusually low compared with that of wrappers of conventional aerosol-generating articles. However, with the article according to the first aspect, these grammages and thicknesses of the wrapper may advantageously be sufficiently small to allow one or both of: easy tearing of the wrapper and the easy formation of air holes or perforations by lasers. These holes may allow air to flow into the wrapper in use without significantly compromising the structural integrity of the article. If the wrapper were much thicker, using a laser to provide air holes in the wrapper could burn or scorch nearby wrapper material or substrate and this could result in an unpleasant appearance, or an unpleasant taste during use. In addition, greater thicknesses and grammages may be desirable in conventional articles to maintain a cigarette-like appearance, or to align multiple components longitudinally in the article. But advantageously, this may not be required or desirable in the article according to the first aspect, or may be achievable with lower wrapper thickness or grammage because there are fewer components to be supported in the article according to the first aspect.

[0081] Optionally, the wrapper is air-permeable. Optionally, the wrapper comprises a plurality of air holes. Optionally, the wrapper comprises a plurality of air holes for air flow. The plurality of air holes may comprise at least 5, 10, 20 or 50 air holes. Each of the plurality of air holes may be sufficiently large to allow air to flow therethrough. Each of the plurality of air holes may be sufficiently small to prevent aerosol-generating substrate from passing therethrough. As set out above, the aerosolgenerating substrate may comprise a plurality of particles having a particle size distribution having a D10 particle size. In this case, each air hole of the plurality of air holes may have a dimension less than the D10 particle size. The dimension in the previous sentence may be a smallest dimension of the respective air hole, or may be a smallest dimension passing through a centre or centroid of the respective air hole, or may be an equivalent diameter of the respective air hole. The equivalent diameter of an air hole is equal to a diameter of a circle having an area equal to a cross-sectional area of the air hole. If the cross-sectional area of the air hole varies, the minimum cross-sectional area of the air hole is used to calculate the equivalent diameter.

[0082] Each air hole of the plurality of air holes may have a dimension less than 1 ,000, 500, 200, 100, 50, 20, or 10 microns. Each air hole of the plurality of air holes may have a dimension of at least 5, 10, 20, 50, 100, 200, or 500 microns.

[0083] Optionally, the wrapper comprises one or more barrier layers. Optionally, the one or more barrier layers comprises a barrier layer located on an internal surface of the wrapper. Optionally, the one or more barrier layers comprises a barrier layer located on an external surface of the wrapper. Optionally, one or more barrier layers are coated onto the wrapper, for example onto one or both of the internal and external surfaces of the wrapper.

[0084] The one or more barrier layers may comprise or consist of any one or more of: a polymeric, wax, or metallic material. The one or more barrier layers may comprise or consist of any one or more of: Polyethylene (PE), Polypropylene (PP), Polyethylene Terephthalate (PET), Aluminium Foil, Wax Coatings, Biodegradable Polymers (e.g., PLA - Polylactic Acid), Silicon Oxide (SiOx) and Aluminium Oxide (AIOx), PVDC (Polyvinylidene Chloride), Chitosan, and Gelatin and Other Protein-Based Coatings.

[0085] Optionally, at least a portion of an external surface of the wrapper forms at least a portion of an external surface of the article. Optionally, an external surface of the wrapper forms at least a portion of an external surface of the article. Optionally, at least a portion of an external surface of a barrier layer located on an external surface of the wrapper forms at least a portion of an external surface of the article. Optionally, an external surface of a barrier layer located on an external surface of the wrapper forms at least a portion of an external surface of the article.

[0086] Optionally, the article is defined by a length of at least 20, 30 or 35 millimetres. Optionally, the article is defined by a length of no more than 100, 70 or 55 millimetres. Optionally, the article is defined by a length of between 20 and 100, preferably between 30 and 70, more preferably between 35 and 55 millimetres.

[0087] Optionally, the article is defined by a width of at least 1 , 3 or 4 millimetres. Optionally, the article is defined by a width of no more than 6, 5.5 or 5 millimetres. Optionally, the article is defined by a width of between 1 and 6, preferably between 3 and 5.5, more preferably between 4 and 5 millimetres. Optionally, the article is defined by a depth of at least 1 , 3 or 4 millimetres. Optionally, the article is defined by a depth of no more than 6, 5.5 or 5 millimetres. Optionally, the article is defined by a depth of between 1 and 6, preferably between 3 and 5.5, more preferably between 4 and 5 millimetres.

[0088] Advantageously, the dimensions above may make handling of the article easy for a user. Advantageously, the dimensions above may allow the article to contain the right amount of aerosolgenerating substrate for a single usage session of an aerosol-generating system incorporating the article. That is, the dimensions above may allow the article to contain enough aerosol-generating substrate for a user to have somewhere between 6 and 25, ideally between 8 and 20, high quality puffs during use of an aerosol-generating system incorporating the article.

[0089] Where the article comprises a mouthpiece, the mouthpiece may have a width or a depth or both a width and a depth of at least 1 , 3 or 4 millimetres. The mouthpiece may have a width or a depth or both a width and a depth of no more than 6, 5.5 or 5 millimetres. The mouthpiece may have a width or a depth or both a width and a depth of between 1 and 6, preferably between 3 and 5.5, more preferably between 4 and 5 millimetres. The mouthpiece may have a substantially circular crosssection such that the width of the mouthpiece is equal to the depth of the mouthpiece.

[0090] Where the article comprises a mouthpiece, the mouthpiece may protrude past an end of the wrapper by at least 2, 5 or 7 millimetres. The mouthpiece may protrude past an end of the wrapper by no more than 15, 11 or 9 millimetres. The mouthpiece may protrude past an end of the wrapper by between 2 and 15, preferably between 5 and 11 , more preferably between 7 and 9, millimetres.

[0091] The wrapper may have a length. The length may extend from a first end of the wrapper to a second end of the wrapper. The first end may be part of the first end portion. The second end may be part of the second end portion. The length of the wrapper may be at least 10, 20 or 25 millimetres. The length of the wrapper may be no more than 90, 60 or 45 millimetres. The length of the wrapper may be between 10 and 90, preferably between 20 and 60, more preferably between 25 and 45, millimetres.

[0092] According to the present disclosure, there is provided an article pack comprising a first article and a second article. The first article may be attached to the second article. The first article may be an article an article according to the first aspect. The second article may be an article according to the first aspect.

[0093] Thus, according to a second aspect of the present disclosure, there is provided an article pack comprising a first article and a second article. The first article is attached to the second article. The first article is an article according to the first aspect. The second article is an article according to the first aspect.

[0094] Optionally, the first article is attached to the second article along a line of weakness. The line of weakness may comprise one or more of: a fold and one or more perforations such as a line of perforations. Advantageously, this may facilitate separation of the first and second articles by a user.

[0095] Optionally, the wrapper of the first article is attached to the wrapper of the second article, for example along the line of weakness. Optionally, the first article comprises a second wrapper around the wrapper of the first article, and the second article comprises a second wrapper around the wrapper of the second article. Optionally, the second wrapper of the first article is attached to the second wrapper of the second article, for example along the line of weakness.

[0096] The article pack may comprise at least 5 articles. Each of the articles may be an article according to the first aspect. Each of the articles may be attached to at least one other adjacent article of the articles, for example along a line of weakness.

[0097] Each article of the article pack may be defined by a length. Optionally, this length is at least 15, 25 or 30 millimetres. Optionally, this length is no more than 95, 65 or 50 millimetres. Optionally, this length is between 15 and 95, preferably between 25 and 65, more preferably between 30 and 50 millimetres. The line of weakness may extend along this length.

[0098] Each article of the article pack may be defined by a width. Optionally, this width is at least 2, 3, or 6 millimetres. Optionally, this width is no more than 10, 8 or 7 millimetres. Optionally, this width is of between 2 and 10, preferably between 4 and 8, more preferably between 6 and 7 millimetres.

[0099] According to the present disclosure, there is provided an aerosol-generating system comprising an article and an aerosol-generating device. The article may be an article according to the first aspect.

[0100] Thus, according to a third aspect of the present disclosure, there is provided an aerosolgenerating system comprising an article and an aerosol-generating device. The article is an article according to the first aspect.

[0101] The aerosol-generating device may be for engaging with the article. The device may comprise a device cavity. The device, for example the device cavity, may be configured to receive at least a portion, for example at least the first end portion, of the article. The device, for example the device cavity, may be configured to receive at least the aerosol-generating substrate of the article.

[0102] The device cavity may comprise an opening. The device cavity may comprise an opening into which at least a portion, for example a distal end, for example the first end, of the article can be inserted. The first end portion of the wrapper may comprise the first or distal end of the article. When the article is fully inserted into the device cavity, a mouthpiece of the article, where present, may be at least partially located outside of the device cavity. This may allow a user to puff directly on the mouthpiece of the article.

[0103] Alternatively, the device, for example the device cavity, may be configured to receive an entirety of the article. The device, for example the device cavity, may be configured to receive an entirety of the article so as to wholly enclose the article. In this context, the term “wholly enclose” may be used to mean surround on all sides. This may mean that, when the article is received, it is not possible to draw a straight line from the article to the external environment that does not pass through the device.

[0104] Alternatively, the device, for example the device cavity, may be configured to receive the aerosol-generating substrate of the article. The device, for example the device cavity, may be configured to receive only the aerosol-generating substrate of the article. That is, the device, for example the device cavity, may be configured to receive the aerosol-generating substrate of the article and no other component of the article. For example, in use, a user may pour the aerosol-generating substrate into the device or device cavity. Or, in use, a user may pour the aerosol-generating substrate into a holder and then insert the holder with the aerosol-generating substrate into the device or device cavity. The device may have an open state in which the aerosol-generating substrate can be poured or otherwise moved into or out of the device cavity. The device may have a closed state in which the aerosol-generating substrate cannot be poured or otherwise moved into or out of the device cavity. The device may comprise a mouthpiece. The mouthpiece of the device may be moveable relative to the device cavity. The mouthpiece of the device may be moveable to transition the device between the open and closed states of the device. The mouthpiece of the device may close the opening of the device cavity when the device is in the closed state. The mouthpiece may not close the opening of the device cavity when the device is in the open state. These options are explained in more detail later.

[0105] The device cavity may have a circular or oval transverse cross-section. This may be particularly preferable if at least a portion of the article has a circular or oval transverse cross-section. This may also be particularly preferable if the article comprises a mouthpiece.

[0106] The device cavity may have a rectangular transverse cross-section. This may be particularly preferable if the device, for example the device cavity, is configured to receive an entirety of the article, for example so as to wholly enclose the article. This may be particularly preferable if the second end portion of the wrapper is sealed, as discussed above.

[0107] The device may comprise a housing. The housing may define the device cavity. The device may be a handheld device. The device may be a smoking device. The device may be for recreational use.

[0108] The device may comprise a heater. The heater may be or comprise a resistive heater. The heater may be or comprise an inductor, such as an inductor coil, configured to inductively heat a susceptor or susceptor material. The susceptor or susceptor material may be part of the device or the article. The heater may comprise the susceptor or susceptor material. The heater may be or comprise an infra-red heater. The heater may be configured to heat the aerosol-generating substrate of the article in use.

[0109] The device may comprise a power source. The power source may be configured to supply power to the heater. The device may comprise a controller. The controller may be configured to control a supply of power from the power source to the heater.

[0110] At least part of the heater may be located adjacent to, or form at least part of, the device cavity. At least part of the heater may spiral around the device cavity.

[0111] Optionally, at least one internal surface of the device cavity is a heating surface configured to heat aerosol-generating substrate of an article. The heater may comprise the heating surface. The heating surface may comprise a resistance heater, or an infra-red heater, or a susceptor configured to be heated by engagement with an inductor, for example an inductor of the device. The heating surface may be a flat or planar heating surface.

[0112] Where the device comprises an inductor, such as an inductor coil, the inductor may be arranged to generate a fluctuating electromagnetic field within a space of the device cavity when the inductor coil is supplied with an alternating current. The heating surface may be a surface that is permeable to a fluctuating electromagnetic field, such that an inductor arranged outside the cavity can project a fluctuating electromagnetic field through the heating surface to engage with a susceptor or susceptor material arranged within the cavity.

[0113] Optionally, the system comprises a holder. The holder may be distinct from the article. The holder may be distinct from the aerosol-generating device. The holder may be suitable for holding the aerosol-generating substrate. Optionally, the holder comprises an open end for receiving the aerosolgenerating substrate of the article. Optionally, the open end is an upstream and of the holder during use. Optionally, during use, air flows into the holder through the open end. Optionally, the holder comprises a mouthpiece. Optionally, the aerosol-generating device comprises a device cavity for receiving at least a portion of the holder, for example for receiving at least a first end of the holder. The first end of the holder may oppose an end of the holder at which the mouthpiece is located, if the mouthpiece is present. Optionally, the mouthpiece is located at a downstream end of the holder.

[0114] Optionally, the holder is defined by a length of at least 15, 25 or 30 millimetres. Optionally, the holder is defined by a length of no more than 95, 65 or 50 millimetres. Optionally, the holder is defined by a length of between 15 and 95, preferably between 25 and 65, more preferably between 30 and 50 millimetres.

[0115] Optionally, the holder has a first end and a second end opposing the second end. Optionally, the first end of the holder is defined by a width or a depth or both a width and a depth of at least of at least 1 , 3 or 4 millimetres. Optionally, the first end of the holder is defined by a width or a depth or both a width and a depth of no more than 6, 5.5 or 5 millimetres. Optionally, the first end of the holder is defined by a width or a depth or both a width and a depth of between 1 and 6, preferably between 3 and 5.5, more preferably between 4 and 5 millimetres. Optionally, the second end of the holder is defined by a width or a depth or both a width and a depth of at least of at least 2, 4 or 6 millimetres. Optionally, the second end of the holder is defined by a width or a depth or both a width and a depth of no more than 10, 8 or 7 millimetres. Optionally, the second end of the holder is defined by a width or a depth or both a width and a depth of between 2 and 10, preferably between 4 and 8, more preferably between 6 and 7 millimetres. Optionally, the first end of the holder has a substantially circular cross-section such that the depth and width of the first end of the holder are equal. Optionally, the second end of the holder has a substantially circular cross-section such that the depth and width of the second end of the holder are equal.

[0116] Four preferred examples of aerosol-generating systems according to the third aspect are set out below.

[0117] In a first preferred example of an aerosol-generating system according to the present disclosure, the system comprises an article according to the first aspect and an aerosol-generating device. The article comprises a mouthpiece. The aerosol-generating device comprises a device cavity configured to receive at least the first end portion of the article. The aerosol-generating device comprises a heater for heating the aerosol-generating substrate of the received article. Other features described above in relation to the article and device may apply. In use, at least the first end portion of the article may be received in the device cavity. Optionally, prior to at least the first end portion of the article being received in the device cavity, the article may be opened or unsealed. For example, the first end portion may be opened or unsealed. When at least the first end portion of the article is received in the device cavity, at least a portion of the mouthpiece of the article may protrude out of the device cavity. When at least the first end portion of the article is received in the device cavity, heater may heat the aerosolgenerating substrate of the article. This may generate an aerosol. A user may inhale the aerosol by puffing on the mouthpiece of the article.

[0118] In a second preferred example of an aerosol-generating system according to the present disclosure, the system comprises an article according to the first aspect, a holder, and an aerosolgenerating device. The second end portion of the article is sealed. The holder is configured to receive and hold aerosol-generating substrate from the article. The aerosol-generating device comprises a device cavity configured to receive at least an end of the holder whilst the holder is holding aerosolgenerating substrate from the article. The aerosol-generating device comprises a heater for heating aerosol-generating substrate being held in the holder. Other features described above in relation to the article, holder and device may apply. In use, the article may be opened or unsealed. For example, the first end portion may be opened or unsealed. The aerosol-generating substrate may then be poured from the article into the holder, for example via an open end of the holder. At least a portion of the holder may then be received in the device cavity. For example, one or both of the aerosolgenerating substrate held in the holder, and the open end of the holder, may then be received in the device cavity. When at least a portion of the holder is received in the device cavity, the heater may heat the aerosol-generating substrate held in the holder. This may generate an aerosol. A user may inhale the aerosol by puffing on a mouthpiece of the device.

[0119] In a third preferred example of an aerosol-generating system according to the present disclosure, the system comprises an article according to the first aspect and an aerosol-generating device. The second end portion of the article is sealed. The aerosol-generating device comprises a device cavity configured to receive aerosol-generating substrate from the article. The device may have an open state in which the aerosol-generating substrate can be poured or otherwise moved into or out of the device cavity. The device may have a closed state in which the aerosol-generating substrate cannot be poured or otherwise moved into or out of the device cavity. The aerosol-generating device comprises a heater for heating the aerosol-generating substrate. Other features described above in relation to the article and device may apply. In use, the article may be opened or unsealed. For example, the first end portion may be opened or unsealed. The aerosol-generating substrate may then be poured or otherwise moved from the article, for example from the unsealed first end portion, into the device cavity. The device may be in the open state during this pouring. The device may then may moved into the closed state. When the aerosol-generating substrate is in the device cavity, and optionally where the device is in the closed state, if the closed state is a feature of the device, the heater may heat the aerosol-generating substrate in the device cavity. This may generate an aerosol. A user may inhale the aerosol by puffing on a mouthpiece of the device. The aerosol-generating substrate may then be poured or otherwise moved from the device cavity, for example to be discarded.

[0120] In a fourth preferred example of an aerosol-generating system according to the present disclosure, the system comprises an article according to the first aspect and an aerosol-generating device. The second end portion of the article is sealed. The aerosol-generating device comprises a device cavity configured to receive at least the first end portion of the article, preferably an entirety of the article. The aerosol-generating device comprises a heater, preferably a planar heater, for heating the aerosol-generating substrate of the received article. Other features described above in relation to the article and device may apply. In use, at least the first end portion of the article, preferably an entirety of the article, may be received in the device cavity. Optionally, prior to the article being received in the device cavity, the article may be opened or unsealed. For example, one or both of the first end portion and the second end portion may be opened or unsealed. When at least the first end portion of the article is received in the device cavity, the heater may heat the aerosol-generating substrate of the article. This may generate an aerosol. A user may inhale the aerosol by puffing on a mouthpiece of the device.

[0121] According to the present disclosure, there is provided a method of using an aerosol-generating system. The system may be a system according to the third aspect. The method of use may comprise the aerosol-generating device of the system receiving at least the aerosol-generating substrate of the article of the system. The method of use may comprise the aerosol-generating device heating the aerosol-generating substrate of the article.

[0122] Thus, according to a fourth aspect of the present disclosure, there is provided a method of using an aerosol-generating system. The system is a system according to the third aspect. The method of use comprises the aerosol-generating device receiving at least the aerosol-generating substrate of the article. The method of use comprises the aerosol-generating device heating the aerosol-generating substrate of the article.

[0123] The method of use may comprise opening or unsealing the article. The method may comprise opening or unsealing the article by tearing some or all of the first end portion of the article. The method may comprise opening or unsealing the article by tearing some or all of the second end portion of the article. The method may comprise opening or unsealing the article by one or both of: tearing the first end portion of the article off the article; and tearing the second end portion of the article off the article.

[0124] The method of use may comprise tamping the aerosol-generating substrate, for example tamping the aerosol-generating substrate in the wrapper. The method of use may comprise tamping the aerosol-generating substrate towards the mouthpiece, if present, or towards the second end portion of the wrapper. This may occur after the optional step of opening or unsealing the article, as set out in the previous paragraph. Advantageously, tamping the substrate may reduce a likelihood of aerosol-generating substrate falling from the wrapper if turned such that the opened or unsealed end faces downwards. The method of use may comprise the device, for example the device cavity, receiving the first end portion, or all, of the article. This may occur after the optional step of opening or unsealing the article, as set out above, or may occur after the optional step of tamping the substrate, as set out in the previous paragraph.

[0125] The method of use may comprise moving the device from the open state to the closed state. The open and closed states of the device are described above in relation to the device. Any pouring of the aerosol-generating substrate into the device cavity may occur whilst the device is in the open state. Movement of the device from the open state to the closed state may occur after any pouring of the aerosol-generating substrate into the device cavity. Movement of the device from the open state to the closed state may occur before any heating of the aerosol-generating substrate. Any heating of the aerosol-generating substrate may occur after movement of the device from the open state to the closed state. Any heating of the aerosol-generating substrate may occur whilst the device is in the closed state.

[0126] The method of use comprises the aerosol-generating device heating the aerosol-generating substrate of the article. This may occur after the step of the device, for example the device cavity, receiving at least the aerosol-generating substrate, or receiving at least the first end portion, or receiving all, of the article. The method of use comprises the aerosol-generating device heating the aerosol-generating substrate of the article to cause the aerosol-generating substrate to release volatile compounds, or to generate an aerosol.

[0127] The method of use may comprise a user puffing on a mouthpiece of the article or a mouthpiece of the device. This may occur after the step of the device receiving at least part of the article, as set out in the previous paragraph.

[0128] Puffing on the mouthpiece of the article or the mouthpiece of the device may cause air to flow into the article through the first end portion. Puffing on the mouthpiece of the article or the mouthpiece of the device may cause air to flow into the article through any air holes present in the wrapper, as described earlier. Puffing on the mouthpiece of the article or the mouthpiece of the device may cause air to flow through or past the aerosol-generating substrate, for example after flowing into the article as described in the previous two sentences. The air flow through or past the aerosol-generating substrate may entrain volatile compounds released by the aerosol-generating substrate or aerosol generated by the aerosol-generating substrate. Entrained volatile compounds may cool to form an aerosol. Aerosol may ultimately be delivered to the user through the mouthpiece.

[0129] Four preferred examples of methods of use according to the fourth aspect are set out below.

[0130] The first preferred example of use is a method of using an aerosol-generating system according to the first preferred example of an aerosol-generating system according to the third aspect, described above. The method of use comprises at least the first end portion of the article being received in the device cavity. Optionally, prior to at least the first end portion of the article being received in the device cavity, the method of use comprises the article being opened or unsealed. For example, the first end portion may be opened or unsealed. The method of use comprises the heaterthen heating the aerosol- generating substrate of the received article. This may generate an aerosol. A user may inhale the aerosol by puffing on the mouthpiece of the article. Other features set out above may apply to this method of use.

[0131] The second preferred example of use is a method of using an aerosol-generating system according to the second preferred example of an aerosol-generating system according to the third aspect, described above. The method of use comprises the article being opened or unsealed. Specifically, the first end portion is opened or unsealed. The aerosol-generating substrate is then poured or otherwise moved from the article, for example via the unsealed first end portion, into the holder. At least a portion of the holder is then received in the device cavity. The heater then heats the aerosol-generating substrate held in the holder. This may generate an aerosol. A user may inhale the aerosol by puffing on a mouthpiece of the device. Other features set out above may apply to this method of use.

[0132] The third preferred example of use is a method of using an aerosol-generating system according to the third preferred example of an aerosol-generating system according to the third aspect, described above. The method of use comprises the article being opened or unsealed. Specifically, the first end portion is opened or unsealed. The aerosol-generating substrate is then poured or otherwise moved from the article, for example via the unsealed first end portion, into the device cavity. The heater then heats the aerosol-generating substrate in the device cavity. This may generate an aerosol. A user may inhale the aerosol by puffing on a mouthpiece of the device. Other features set out above may apply to this method of use. For example, where the device comprises the open and closed states discussed above, the method of use may comprise moving the device from the open state to the closed state. The pouring or otherwise moving of the aerosol-generating substrate from the article into the device cavity may occur while the device is in the open state. Movement of the device from the open state to the closed state may occur after the pouring or otherwise moving of the aerosol-generating substrate from the article into the device cavity. Movement of the device from the open state to the closed state may occur before the heating of the aerosol-generating substrate in the device cavity. The heating of the aerosol-generating substrate in the device cavity may occur while the device is in the closed state. Movement of the device from the open state to the closed state may be effected by moving a mouthpiece of the device, for example moving a mouthpiece of the device so as to cover an opening of the device cavity.

[0133] The fourth preferred example of use is a method of using an aerosol-generating system according to the fourth preferred example of an aerosol-generating system according to the third aspect, described above. The method of use comprises at least the first end portion of the article, preferably an entirety of the article, being received in the device cavity. Optionally, prior to the article being received in the device cavity, the article may be opened or unsealed. For example, one or both of the first end portion and the second end portion may be opened or unsealed. The method of use comprises the heater then heating the aerosol-generating substrate in the device cavity. This may generate an aerosol. A user may inhale the aerosol by puffing on a mouthpiece of the device. Other features set out above may apply to this method of use.

[0134] According to the present disclosure, there is provided a method of manufacturing an article. The article may be an article according to the first aspect. The method may comprise feeding the aerosol-generating substrate into the wrapper, for example through an open end of the wrapper. The method may comprise sealing the open end of the wrapper, for example to form the first end portion of the wrapper.

[0135] Thus, according to a fifth aspect of the present disclosure, there is provided a method of manufacturing an article. The article is an article according to the first aspect. The method comprises feeding the aerosol-generating substrate into the wrapper through an open end of the wrapper. The method comprises sealing the open end of the wrapper to form the first end portion of the wrapper.

[0136] The method of manufacture may comprise attaching the mouthpiece, if present, to the second end portion of the wrapper. This may occur before feeding the substrate into the wrapper. The method of manufacture may comprise sealing the second end portion of the wrapper. This may occur before feeding the substrate into the wrapper. During the step of feeding the aerosolgenerating substrate into the wrapper, the mouthpiece may be attached to the second end portion of the wrapper, or the second end portion of the wrapper may be sealed. The mouthpiece or sealed second end portion may function as a stop to prevent aerosol-generating substrate from falling out of the wrapper during the step of feeding the substrate into the wrapper. Advantageously, this may simplify the method of manufacture.

[0137] During the step of feeding the aerosol-generating substrate into the wrapper, the wrapper may be oriented such that the second end portion is lower than the first end portion, or lower than a portion of the wrapper which is to become the first end portion after sealing. Advantageously, this may allow the substrate to be fed into the wrapper under gravity.

[0138] During the step of feeding the aerosol-generating substrate into the wrapper, the wrapper may be moved or vibrated. Advantageously, this may reduce a likelihood of air pockets forming in the substrate in the wrapper.

[0139] The step of feeding the aerosol-generating substrate into the wrapper may be or comprise a step of feeding the aerosol-generating substrate from a hopper into the wrapper.

[0140] Optionally, during the step of feeding the aerosol-generating substrate into the wrapper, at least 0.05, 0.1 or 0.2 grams of substrate is fed into the wrapper. Optionally, during the step of feeding the aerosol-generating substrate into the wrapper, no more than 1 , 0.6 or 0.5 grams of substrate is fed into the wrapper. Optionally, during the step of feeding the aerosol-generating substrate into the wrapper, between 0.05 and 1 , preferably between 0.1 and 0.6, more preferably between 0.2 and 0.6, grams of substrate is fed into the wrapper.

[0141] After feeding the aerosol-generating substrate into the wrapper through the open end of the wrapper, the method may comprise cutting the wrapper. After feeding the aerosol-generating substrate into the wrapper through the open end of the wrapper, the method may comprise folding or crimping the wrapper.

[0142] After feeding the aerosol-generating substrate into the wrapper through the open end of the wrapper, the method may comprise the step of sealing the open end of the wrapper to form the first end portion of the wrapper. The sealing of the open end of the wrapper may comprise any one or more of: folding the wrapper, applying pressure to the wrapper, applying heat to the wrapper, and applying adhesive to the wrapper. Optionally, the sealing is achieved by adhering or otherwise attaching a first part of wrapper, for example a first part of the first end portion of the wrapper, to a second part of the wrapper, for example a second part of the first end portion of the wrapper. Optionally, the sealing is crimp-sealing. The sealing may form the sealed first end portion of the wrapper of the article according to the first aspect. The sealing may form the article according to the first aspect.

[0143] The article according to the first aspect may be made using a vertical form, fill and seal machine (a VFFS machine), in an analogous manner to how sugar packets are made. This may be the case if both the first and second end portions of the wrapper are sealed.

[0144] As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol. The article according to the first aspect may be an aerosol-generating article.

[0145] As used herein, the term “aerosol-generating 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-generating substrate. An aerosol-generating substrate may comprise an aerosol-forming material. An aerosol-generating substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. An aerosol-generating substrate may conveniently be part of an aerosol-generating article or smoking article.

[0146] 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.

[0147] As used herein, the term “aerosol-generating system” refers 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.

[0148] 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-generating substrate or aerosol-generating article.

[0149] As used herein, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.

[0150] As used herein, 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, for example during use.

[0151] As used herein, resistance to draw may be measured in accordance with ISO 6565:2002. As used herein, the term “particle size” may refer to a single dimension and may be used to characterise the size of a particle. The dimension may be the diameter of a spherical particle occupying the same volume as the given particle at the same density as the particle. All particle sizes and particle size distributions herein can be obtained using a standard laser diffraction technique. Particle sizes and particle size distributions as stated herein may be obtained using a commercially available sensor or analyser, for example a Sympatec HELOS laser diffraction sensor or a Malvern Mastersizer 3000 laser diffraction particle size analyser.

[0152] As used herein, where not otherwise specified, the term “density” may be used to refer to true density. Thus, where not otherwise specified, the density of a plurality of particles may refer to the true density of the plurality of particles (rather than a bulk density of the plurality of particles, which can vary greatly depending on how the plurality of particles are handled). The measurement of true density can be done using a number of standard methods, these methods often being based on Archimedes’ principle. The most widely used method, when used to measure the true density of a plurality of particles, entails the plurality of particles being placed inside a container (a pycnometer) of known volume, and weighed. The pycnometer is then filled with a fluid of known density, in which the plurality of particles is not soluble. The volume of the plurality of particles is determined by the difference between the volume as shown by the pycnometer, and the volume of liquid added.

[0153] 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.

[0154] Example Ex1 . An article for an aerosol-generating system, the article comprising: an aerosol-generating substrate; and a paper or paper-based wrapper containing the aerosol-generating substrate, wherein at least a first end portion of the wrapper is sealed.

[0155] Example Ex2. An article according to example Ex1 , wherein the article comprises a mouthpiece, optionally wherein the mouthpiece is located at a second end portion of the wrapper.

[0156] Example Ex3. An article according to example Ex2, wherein the aerosol-generating substrate is contained in a cavity, and at least 90 percent or an entirety of a bounding area defining the cavity is defined by only the wrapper and the mouthpiece.

[0157] Example Ex4. An article according to example Ex2 or Ex3, wherein the second end portion of the article has a second end portion cross-section defined by a second end portion width and a second end portion depth, the second end portion width being no more than 2 times the second end portion depth, preferably wherein the second end portion width is between 0.9 and 1.1 times the second end portion depth, more preferably wherein the second end portion width is substantially equal to the second end portion depth, for example wherein the second end portion cross-section is substantially circular. Example Ex5. An article according to example Ex2 or Ex3 or Ex4, wherein the mouthpiece has a density of between 0.1 and 0.3, preferably between 0.15 and 0.25, more preferably between 0.175 and 0.225, grams per centimetre cubed.

[0158] Example Ex6. An article according to example Ex1 , wherein a second end portion of the paper wrapper is sealed.

[0159] Example Ex7. An article according to example Ex6, wherein the second end portion is sealed by an air-tight seal, for example wherein the second end portion is crimp-sealed.

[0160] Example Ex8. An article according to example Ex6 or Ex7, wherein the aerosol-generating substrate is contained in a cavity, and at least 90 percent or an entirety of a bounding area defining the cavity is defined by only the wrapper.

[0161] Example Ex9. An article according to example Ex6, Ex7, or Ex8, wherein the article comprises at least one notch, perforation, or line of weakness in or proximate to the second end portion.

[0162] Example Ex10. An article according to any preceding example, wherein one or both of: the first end portion is sealed by an air-tight seal and the first end portion is crimp-sealed.

[0163] Example Ex11 .An article according to any preceding example, wherein the first end portion is sealed by attaching a first part of the first end portion of the wrapper to a second part of the first end portion of the wrapper.

[0164] Example Ex12. An article according to any preceding example, wherein the article comprises one or more of: at least one notch, at least one perforation, and at least one line of weakness, preferably wherein the one or more of the at least one notch, the at least one perforation, and the at least one line of weakness is in or proximate to the first end portion.

[0165] Example Ex13. An article according to any preceding example, wherein the first end portion of the article has a first end portion cross-section defined by a first end portion width and a first end portion depth, the first end portion width being at least 2 times the first end portion depth.

[0166] Example Ex14. An article according to any preceding example, wherein the aerosol-generating substrate comprises one or more of: tobacco; nicotine; and one or more aerosol formers.

[0167] Example Ex15. An article according to example Ex15, wherein the plurality of particles comprises one or more of: a plurality of particles; a plurality of granules; and a plurality of beads.

[0168] Example Ex16. An article according to example Ex15 or Ex16, wherein the plurality of particles has a volume particle size distribution defined by a volume D10 particle size and a volume D90 particle size.

[0169] Example Ex17.An article according to example Ex17, wherein the volume D10 particle size is at least 50, 100, or 150 microns.

[0170] Example Ex18.An article according to example Ex17, wherein the volume D10 particle size is no more than 500, 350, or 250 microns.

[0171] Example Ex19.An article according to example Ex17, wherein the volume D10 particle size is between 50 and 500, preferably between 100 and 350, more preferably between 150 and 250 microns. Example Ex20. An article according to example Ex17 or Ex18, wherein the volume D90 particle size is at least 100, 200 or 300 microns.

[0172] Example Ex21 . An article according to example Ex17 or Ex18, wherein the volume D90 particle size is no more than 750, 600, or 500 microns.

[0173] Example Ex22. An article according to example Ex17 or Ex18, wherein the volume D90 particle size is between 100 and 750, preferably between 200 and 600, more preferably between 300 and 500 microns.

[0174] Example Ex23. An article according to example Ex17, or Ex18, or Ex19, wherein the volume D90 particle size is no more than 15, 10 or 5 times the volume D10 particle size.

[0175] Example Ex24. An article according to any preceding example, wherein the wrapper has a grammage of between 50 and 200, preferably between 60 and 150, more preferably between 78 and 110 grams per square metre.

[0176] Example Ex25. An article according to any preceding example, wherein the wrapper has a thickness of no more than 300, 200 or 140 microns.

[0177] Example Ex26. An article according to any preceding example, wherein the wrapper has a thickness of between 50 and 300, preferably between 75 and 200, more preferably between 100 and 140 microns.

[0178] Example Ex27. An article according to any preceding example, wherein one or both of: the wrapper is air-permeable and the wrapper comprises a plurality of air holes for air flow.

[0179] Example Ex28. An article according to any preceding example, wherein the wrapper comprises at least one barrier layer, for example wherein the at least one barrier layer comprises one or both of: a barrier layer located on an internal surface of the wrapper; and a barrier layer located on an external surface of the wrapper.

[0180] Example Ex29. An article according to any preceding example, wherein the article is defined by a length of at least 20, 30 or 35 millimetres.

[0181] Example Ex30. An article according to any preceding example, wherein the article is defined by a length of no more than 100, 70 or 55 millimetres.

[0182] Example Ex31 . An article according to any preceding example, wherein the article is defined by a length of between 20 and 100, preferably between 30 and 70, more preferably between 35 and 55 millimetres.

[0183] Example Ex32. An article according to any preceding example, wherein the article is defined by a width of at least 1 , 3 or 4 millimetres.

[0184] Example Ex33. An article according to any preceding example, wherein the article is defined by a width of no more than 6, 5.5 or 5 millimetres.

[0185] Example Ex34. An article according to any preceding example, wherein the article is defined by a width of between 1 and 6, preferably between 3 and 5.5, more preferably between 4 and 5 millimetres. Example Ex35. An article according to any preceding example, wherein the article is defined by a depth of at least 1 , 3 or 4 millimetres.

[0186] Example Ex36. An article according to any preceding example, wherein the article is defined by a depth of no more than 6, 5.5 or 5 millimetres.

[0187] Example Ex37. An article according to any preceding example, wherein the article is defined by a depth of between 1 and 6, preferably between 3 and 5.5, more preferably between 4 and 5 millimetres.

[0188] Example Ex38.An article according to any preceding example, wherein at least a portion of an external surface of the wrapper of the article, or an external surface of a barrier layer, if present, on the external surface of the wrapper of the article, comprises at least a portion of an external surface of the article.

[0189] Example Ex39. An article according to any preceding example, wherein the article comprises a membrane and the membrane contains the aerosol-generating substrate, preferably wherein one or both of: the membrane is air-permeable and the wrapper contains the membrane.

[0190] Example Ex40. An article pack comprising a first article according to any preceding example and a second article according to any preceding example, wherein the first article is attached to the second article.

[0191] Example Ex41 . An article pack according to example Ex40, wherein the first article is attached to the second article along a line of weakness.

[0192] Example Ex42.An aerosol-generating system comprising: an article according to any of examples 1 to 39; an aerosol-generating device configured to receive at least the aerosol-generating substrate of the article, wherein the aerosol-generating device is configured to heat the aerosol-generating substrate of the article.

[0193] Example Ex43. An aerosol-generating system according to example Ex42, wherein the aerosolgenerating device comprises a device cavity for receiving at least a portion of the article, for example at least the first end portion of the article.

[0194] Example Ex44. An aerosol-generating system according to example Ex42, wherein the system comprises a holder distinct from the article and the aerosol-generating device, the holder being suitable for holding the aerosol-generating substrate.

[0195] Example Ex45. An aerosol-generating system according to example Ex44, wherein the holder comprises an open end for receiving the aerosol-generating substrate of the article.

[0196] Example Ex46. An aerosol-generating system according to example Ex44 or Ex45, wherein the holder comprises a mouthpiece.

[0197] Example Ex47. An aerosol-generating system according to example Ex44, Ex45 or Ex46, wherein the aerosol-generating device comprises a device cavity for receiving at least a portion of the holder. Example Ex48. An aerosol-generating system according to example Ex42, wherein the aerosolgenerating device comprises a device cavity for pouring the aerosol-generating substrate into.

[0198] Example Ex49. An aerosol-generating system according to example Ex42 or Ex43, wherein the aerosol-generating device comprises a mouthpiece.

[0199] Example Ex50. An aerosol-generating system according to example Ex43, wherein the aerosolgenerating device comprises a planar heater for heating the aerosol-generating substrate of the article.

[0200] Example Ex51 . A method of using an aerosol-generating system according to any of examples Ex40 to Ex50, wherein the method comprises: the aerosol-generating device receiving at least the aerosol-generating substrate of the article; and the aerosol-generating device heating the aerosol-generating substrate of the article.

[0201] Example Ex52. A method of making an article according to any of examples 1 to 39, wherein the method comprises: feeding the aerosol-generating substrate into the wrapper through an open end of the wrapper; and sealing the open end of the wrapper to form the first end portion of the wrapper.

[0202] Examples will now be further described with reference to the figures in which:

[0203] Figure 1 is a perspective view of a first article;

[0204] Figure 2 is a side cross-sectional view of the first article;

[0205] Figure 3 is a top cross-section view of the first article;

[0206] Figure 4 is a view of machinery involved in a method of manufacturing the first article;

[0207] Figure 5 is a cross-sectional view of a first aerosol-generating system;

[0208] Figure 6 is a series of cross-sectional views of the first article during a method of use;

[0209] Figure 7 is a cross-sectional view of a second aerosol-generating system;

[0210] Figure 8 is a cross-sectional view of an article pack;

[0211] Figure 9 is a cross-sectional view of a second article;

[0212] Figure 10 is a view of the second article and a holder;

[0213] Figure 11 is a cross-sectional view of a third aerosol-generating system;

[0214] Figure 12 is a perspective view of a fourth aerosol-generating system; and

[0215] Figure 13 is a side cross-sectional view of the fourth aerosol-generating system.

[0216] Figures 1 , 2 and 3 are a perspective view, a side cross-sectional view, and a top cross-sectional view, respectively, of a first article 100 for an aerosol-generating system.

[0217] The article 100 comprises an aerosol-generating substrate 102, a paper or paper-based wrapper 104, and a mouthpiece 106.

[0218] There is 300 milligrams of aerosol-generating substrate 102. The aerosol-generating substrate 102 is in the form of a plurality of substantially spherical beads. The beads are formed of plant particles, aerosol former and a hydrocolloid binder. An example of a suitable composition of the aerosolgenerating substrate for forming the beads is set out in Table 1 below.

[0219] Table 1

[0220] All weight percents are on a dry weight basis based on the total weight of the aerosol-generating substrate.

[0221] In orderto make the beads, the tobacco particles are first mixed with glycerin. The hydroxypropyl methyl cellulose (HPMC) binder is dispersed in glycerin and then water is added to form an aqueous binder solution. The binder solution is added to the mixture of tobacco particles and glycerin and all of the components are mixed to form a dough. The dough is extruded to form a plurality of discrete elements, and the discrete elements are then spheronised at low speed to form spherical beads having volume D10 particle size of 200 microns, a volume D50 particle size of 300 microns, and a volume D90 particle size of 400 microns. The beads are then dried in an oven to a desired moisture content. In other embodiments, the aerosol-generating substrate could include, or instead be, an aerosolgenerating liquid, gel or film.

[0222] The wrapper 104 contains the aerosol-generating substrate 102. In particular, the aerosolgenerating substrate is contained within a cavity defined by only the wrapper 104 and the mouthpiece 106. The wrapper 104 comprises a first end portion 108 which is sealed. The wrapper 104 comprises a second end portion 110 opposing the first end portion 108. The second end portion 110 is attached to the mouthpiece 106. In particular, the second end portion 1 10 circumscribes a portion of the mouthpiece 106, and an inner surface of the second end portion 110 is adhered to an outer surface of the mouthpiece 106. The wrapper 104 also comprises a plurality of air holes 112. The air holes 112 are formed by a laser prior to feeding the substrate 102 into the wrapper 104. The air holes 112 are circular and are sized to allow air to flow into the article 100 but not allow the beads of the substrate 102 to fall out through the air holes 112. The wrapper 104 has a thickness of 120 microns and a grammage of 90 grams per square metre. The wrapper 104 comprises a notch 114 leading to a line of weakness formed of perforations across a width of the article 100 in order to facilitate tearing the first end portion 108 off the article 100.

[0223] The mouthpiece 106 is substantially right circular cylindrical in shape, with a length of 9 millimetres, of which 7 millimetres protrudes from a second end of the wrapper 104, and a diameter of 4 millimetres. The mouthpiece 106 has a density of 0.2 grams per centimetre cubed and is formed from a cotton-based material.

[0224] The article 100 has a length of around 50 millimetres, measured from a downstream end of the article 100, being the downstream end of the mouthpiece 106, to an upstream end of the article 100, being an upstream end of the first end portion 108 of the wrapper 104. The first end portion 108 of the wrapper 104 has a substantially rectangular cross-section as a result of it being sealed. The crosssection having a width of around 6 millimetres and a depth which slowly reduces towards the first end. The depth at a mid-point of the first end portion 108 is around 0.4 millimetres. The second end portion 110 of the wrapper 104 has a circular cross-section as a result of the mouthpiece 106, the crosssection having a diameter of around 4 millimetres.

[0225] Figure 4 is a view of machinery involved in a method of manufacturing the first article 100. The machinery 400 comprises a hopper 402 and a crimper and blade component 404.

[0226] To make the first article 100 of Figures 1 to 3, a wrapper is obtained, and air holes are made using a laser. The wrapper 104 is then attached to a mouthpiece 106 to form a pre-article 406, as shown in Figure 4. This pre-article 406 is held beneath the hopper 402. The pre-article 406 comprises the wrapper 104 attached to the mouthpiece 106 of the first article 100, but the end of the wrapper 104 opposing the end with the mouthpiece 106 is open and has not yet been sealed. In this position, aerosol-generating substrate in the form of the beads as described before is fed from the hopper 402 into an open end of the wrapper 104. During this feeding, the pre-article 406 is vibrated or shook to reduce a risk of air pockets forming. Once 300 milligrams of substrate has been fed into the wrapper 104, the crimper and blade component 404 is used to cut the wrapper 104 if required, and to seal the wrapper 104 to form the sealed first end portion of the wrapper 104. Optionally, sealing the wrapper 104 may involve the use of one or more of heat, pressure, folding the wrapper, and an adhesive. Once the first end portion is sealed, the notch and line of weakness, as described in relation to the first article 100, are made, and the first article 100 is thereby formed.

[0227] Figure 5 is a cross-sectional view of a first aerosol-generating system 500 comprising the first article 100 and a first aerosol-generating device 550.

[0228] The device 550 comprises a battery 552, a controller 554 and a heater 556. The battery 552 is connected to, and configured to supply power to, the heater 556. The controller 554 is connected to the battery 552 and configured to control the supply of power from the batter 552 to the heater 556.

[0229] The device 550 also comprises a device cavity 558 for receiving a portion of the article 100, as shown in Figure 5. When received, the mouthpiece 106 of the article 100 extends out of the device cavity 558, enabling a user to place their mouth on the mouthpiece 106.

[0230] The heater 552 in this embodiment is a resistive heater spiralling around the device cavity 558 configured to heat the aerosol-generating substrate 102. However, in other embodiments, the heater could be an inductor coil spiralling around the device cavity 558, and the aerosol-generating substrate or walls of the device cavity could comprise susceptor material. Then, in use, supplying an alternating current to the inductor could induce an alternating electromagnetic field which would inductively heat the susceptor material and thus the aerosol-generating substrate.

[0231] In the embodiment shown in Figure 5, the first end portion of the article 100 has not been torn off. Sufficient air flow is able to enter the article 100 through the air holes in the wrapper of the article 100 shown in Figure 1 . In use, after inserting the article 100 into the device cavity 558, via an opening at the top end of the device cavity 558, to reach the position shown in Figure 5, a user may press a button (not shown) on the device 500 to activate the heater 556. Then the user may begin puffing on the mouthpiece 106 of the article 100, which protrudes out of the device cavity 558.

[0232] The heater 556 then heats the aerosol-generating substrate 102 to around 200 degrees Celsius, causing the substrate to release volatile compounds. The user puffing on the mouthpiece 106 draws air into the device cavity 558. This air may enter the device cavity 558 through the opening at the top end of the device cavity 558 or via another air passage into the device cavity 558 or both. The air in the device cavity 558 then flows through the air holes in the wrapper of the article 100. This air flow then entrains the released volatile compounds and travels towards the mouthpiece 106. During this travel, the volatile compounds cool and condense to form an aerosol in the article 100. This aerosol is then delivered to the user through the mouthpiece 106. When the user is finished with the article 100, the article 100 may be removed from the device cavity 558 and disposed of.

[0233] Figure 6 is a series of four cross-sectional views of the first article 100 during a method of use. The method of use is an alternative to the use described in relation to Figure 5.

[0234] The first, left-most cross-sectional view shows the first article 100 of Figures 1 , 2 and 3. The adjacent, second cross-sectional view shows the first article 100 after the first end portion 108 has been torn off the article 100, using the notch 114. The adjacent, third cross-sectional view shows the first article 100 when a user is gently pressing sides of the wrapper 104 towards each other to open the end of the wrapper 104 slightly. The adjacent, further cross-sectional view shows the first article 100 after a user has tamped the aerosol-generating substrate 102. This pushes the substrate 102 further down the article 100, towards the mouthpiece 106, and stops substrate 102 falling out of the open end when the article 100 is turned upside down.

[0235] Figure 7 is a cross-sectional view of a second aerosol-generating system 700. The system 700 comprises the device 550 of Figure 5 and the first article 100 after the method steps described in relation to Figure 6.

[0236] Operation of the system 700 is identical to operation of the system 500 of Figure 5. However, because of the open, rather than sealed, end of the article 100, greater air flow may enter the article 100 when a user puffs on the mouthpiece 106 because air can enter the article 100 through the air holes and through the opened first end.

[0237] Figure 8 is a cross-sectional view of an article pack 800. The article pack 800 comprises a first pack article 810, a second pack article 820, a third pack article 830, and a fourth pack article 840. The pack articles 810, 820, 830, 840 each comprise an aerosol-generating substrate 102 identical to the substrate 102 of the first article 100. Each of the pack articles 810, 820, 830, 840 comprises a wrapper 814, 824, 834, 844 containing the substrate 102, each wrapper having a sealed first end portion 818, 828, 838, 848 and a sealed second end portion 819, 829, 839, 849.

[0238] The wrappers 814, 824, 834, 844 of the pack articles 810, 820, 830, 840 are flattened on either side, along their lengths, and are attached, along a line ofweaking comprising a series of perforations, to wrappers of adjacent pack articles 810, 820, 830, 840 along their length. This is shown in Figure 8. To separate a pack article from the rest of the article pack 800, a user simply tears along the line of weakness. This is shown in Figure 8 with the fourth pack article 840 being separated from the third pack article 830, along the line of weakness between those pack articles 830, 840.

[0239] In alternative embodiments, it may be a component of each pack article other than the wrapper, such as an outer wrapper located around the wrapper, which is attached to the corresponding component of adjacent pack articles.

[0240] Figure 9 is a cross-sectional view of a second article 900.

[0241] The second article 900 is identical to first article 100 of Figures 1 to 3, including the aerosolgenerating substrate 102, except for the following. Instead of the mouthpiece 106 at the second end portion of the wrapper of the first article 100, the wrapper of the second article 900 has a second end portion 910 which is sealed, similarly to the first end portion 108. In addition, there is no notch or line of weakness to facilitate tearing. Though in other embodiments there could be.

[0242] The second article 900 may be made in a similar way to the first article 100 as explained with reference to Figure 4 but, instead of attaching the mouthpiece to form the pre-article 406, the second end portion is sealed to form a sealed second end portion 910 in the pre-article. This sealing may comprise any one or more of: folding, applying heat to, applying pressure to, and applying adhesive to, the wrapper, for example the second end portion of the wrapper. Flattened edges along the sides of the article as shown in Figure 8, if desired, may be formed using one or more of folding the wrapper, applying heat, and applying pressure to the sides of the wrapper. But such flattened edges are not present in the embodiment of Figure 8.

[0243] Figure 10 shows the second article 900 after the first end portion 108 has been torn off the article 900 and the second article 900 has then been tipped to pour the aerosol-generating substrate 102 into a holder 1010.

[0244] The holder 1010 comprises a circular open end 1012 for receiving the aerosol-forming 102. The holder 1010 also comprises a substantially circular right cylindrical mouthpiece 1014 at an opposite end to the open end 1012.

[0245] The holder 1010 has a length of around 45 millimetres. The open end 1012 has a diameter of around 6.5 millimetres and the mouthpiece has a diameter of around 4.5 millimetres. This taper may be advantageous to provide a larger open end for receiving the substrate 102.

[0246] After pouring the substrate 102 into the holder 1010, a user may tamp the substrate 102 down, towards the mouthpiece 1014 to prevent substrate 102 falling out when the holder 1010 is turned upside down. A user may then insert the holder 1010 into a device, for example into a device cavity of the device 550 shown in Figure 5. A user may then use the device with the holder 1010 in a similar way as the device is used with the first article 100, as described with reference to Figure 5. So the device 550 may heat the substrate 102 held in the holder 1010 and a user may puff on the mouthpiece 1014 of the holder 1010. When finished, a user may empty the holder 1010, optionally clean the holder 1010, and the holder 1010 may be re-filled by another article 900 and used again. In other embodiments, the open end of the holder may be closeable, for example with a lid such as an air-permeable lid. This may prevent substrate falling out in use. In such embodiments, tamping the substrate may not be done.

[0247] Figure 11 is a cross-sectional view of a third aerosol-generating system 1100. The system 1100 comprises the article 900 of Figure 9 and an aerosol-generating device 1150. The device 1150 is identical to the device 550 of Figure 5, except that the device 1150 comprises a mouthpiece 1152 and an air passage 1154.

[0248] In use, a user tears of the first end portion 108 of the article 900, then pours the aerosolgenerating substrate 102 into the device cavity 558. This is shown in Figure 11. Once all of the substrate 102 has been poured into the device cavity 558, the rest of the article 900 can be discarded. The user may then slide the mouthpiece 1152 from the open position shown in Figure 11 across to a closed position in which it sits above the device cavity 558. This movement may be considered moving the device 1150 from a closed state to an open state. Once slid across, if the device 1100 were turned upside down, the substrate 102 would not be able to fall out of the device cavity 558 because the mouthpiece 1152 would be in the way. Operation of the device 1100 is then similar to operation of the device 550 of Figure 5. A user activates the heater 556 with a button (not shown) and puffs on the mouthpiece 1152. Air is able to enter the device cavity 558 through the air passage 1154. The air passage 1154 is too small for the beads of the substrate 102 to enter but sufficiently large to allow a sufficient air flow. The aerosol-generating substrate 102 is heated to release volatile compounds. Air flows through the air passage, into the device cavity 558, and through and past the aerosol-generating substrate 102, entraining released volatile compounds as it travels. During this travel, the released volatile compounds cool and condense to form an aerosol. This aerosol is delivered to the user through the mouthpiece 1152. When the user is finished puffing, the user may slide the mouthpiece 1152 back to the open position shown in Figure 11 , then empty the substrate 102 from the device cavity 558, and optionally clean the device cavity 558, ready for use with other aerosol-generating substrate 102 from another article 900.

[0249] Figures 12 and 13 are a perspective view and a side cross-sectional view, respectively, of a fourth aerosol-generating system 1200. The system 1200 comprises the article 900 of Figure 9 and an aerosol-generating device 1250.

[0250] The aerosol-generating device 1250 comprises a battery 1252, a controller 1254 and a heater 1256. The battery 1252 is connected to, and configured to supply power to, the heater 1256. The controller 1254 is connected to the battery 1252 and configured to control the supply of power from the batter 1252 to the heater 1256.

[0251] The device 1250 also comprises a device cavity 1258 for the article 900, the device cavity 1258 being formed in a cuboid box hingedly coupled to a housing of the device 1250. In this embodiment, the article 900, excluding the first and second end portions 108, 910, is received after the first and second end portions 108, 910 have been torn off and discarded, as shown in Figure 12. In other embodiments, the first and second end portions are not torn off and air enters the article through the air holes in the wrapper of the article.

[0252] The heater 1256 in this embodiment is a planar resistive heater adjacent to the device cavity 558 and configured to heat the aerosol-generating substrate 102. However, in other embodiments, the heater could be an inductor coil spiralling around the device cavity, and the aerosol-generating substrate or walls of the device cavity could comprise susceptor material. Then, in use, supplying an alternating current to the inductor would induce an alternating electromagnetic field which would inductively heat the susceptor material and thus the aerosol-generating substrate.

[0253] In use, after tearing the first and second end portions 108, 910 off the article 900, the article 900 is inserted into the device cavity 1258, as indicated by the arrow in Figure 12. The box defining the device cavity 1258 is then pivoted about a hinge to rest within the outer perimeter of the device shape, as shown in Figure 13. The box may comprise a handle (not shown) to facilitate movement of the box between its open position, ready to receive part of an article, as shown in Figure 12, and its closed position, ready to heat the received part of the article, as shown in Figure 13.

[0254] Once in the position shown in Figure 13, a user may press a button (not shown) on the device 1250. This may activate the planar heater 1256. Then the user may begin puffing on a mouthpiece 1260 of the device 1250.

[0255] The heater 1256 heats the aerosol-generating substrate 102 to around 200 degrees Celsius, causing the substrate to release volatile compounds. And the user puffing on the mouthpiece 1260 draws air through an air inlet 1262 of the device 1250, into the device cavity 1258, and into the article 900 through the air holes in the wrapper of the article 900 and through the open, upstream end of the portion of the article 900 in the device cavity 1258. This air flow then entrains the released volatile compounds and travels towards the mouthpiece 1260. During this travel, the volatile compounds cool and condense to form an aerosol in the article 900. This aerosol ultimately exits the article 900 through the open downstream end of the portion of the article 900 in the device cavity 1258, and is then delivered to the user through the mouthpiece 1260 of the device 1250. When the user is finished with the article 900, the user moves the box back to the position shown in Figure 12, and then tips the article 900 out of the box to discard the article 900.

[0256] 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.

Claims

1. 35CLAIMS1 . An article for an aerosol-generating system, the article comprising: an aerosol-generating substrate; and a paper or paper-based wrapper containing the aerosol-generating substrate, wherein at least a first end portion of the wrapper is sealed, and wherein either: the article comprises a mouthpiece located at a second end portion of the wrapper; or a second end portion of the paper wrapper is sealed, the first end portion being located at an opposite end of the wrapper to the second end portion.

2. An article according to claim 1 , wherein the article comprises the mouthpiece located at the second end portion of the wrapper.

3. An article according to claim 1 , wherein the second end portion of the paper wrapper is sealed, the first end portion being located at the opposite end of the wrapper to the second end portion.

4. An article according to claim 3, wherein the second end portion of the wrapper is sealed by adhering or otherwise fixing a first part of the second end portion of the wrapper to a second part of the second end portion of the wrapper.

5. An article according to any preceding claim, wherein the first end portion of the wrapper is sealed by adhering or otherwise fixing a first part of the first end portion of the wrapper to a second part of the first end portion of the wrapper.

6. An article according to any preceding claim, wherein the wrapper has a thickness of no more than 300 microns.

7. An article according to any preceding claim, wherein the wrapper has a thickness of no more than 140 microns.

8. An article according to any preceding claim, wherein the wrapper comprises a plurality of air holes for air flow.

9. An article according to any preceding claim, wherein, in or proximate to the first end portion, the wrapper comprises one or more of: at least one notch, at least one perforation, and at least one line of weakness.

10. An article according to any preceding claim, wherein the article is defined by a length of between 20 and 100 millimetres, a width of between 1 and 6 millimetres, and a depth of between 1 and 6 millimetres.

11. An article according to any preceding claim, wherein the aerosol-generating substrate comprises or consists of a plurality of discrete, solid particles.

12. An article pack comprising a first article according to any preceding claim and a second article according to any preceding claim, wherein the first article is attached to the second article.

13. An aerosol-generating system comprising: an article according to any of claims 1 to 11 ; an aerosol-generating device configured to receive at least the aerosol-generating substrate of the article, wherein the aerosol-generating device is configured to heat the aerosol-generating substrate to generate an aerosol.

14. A method of using an aerosol-generating system according to claim 13, the method comprising: the aerosol-generating device receiving at least the aerosol-generating substrate of the article; and the aerosol-generating device heating the aerosol-generating substrate to generate an aerosol.

15. A method of making an article according to any of claims 1 to 11 , the method comprising: feeding the aerosol-generating substrate into the wrapper through an open end of the wrapper; and sealing the open end of the wrapper to form the first end portion of the wrapper.

Images