Aerosol-generating article with aerosol-generating agglomerate

Abstract

An aerosol-generating article (100) for use with an aerosol-generating device (6000) to generate an aerosol. The aerosol-generating article (100) is defined by an article length, an article width, and an article thickness. The article width is greater than the article thickness. The aerosol-generating article (100) comprises a first external surface (110) and a second external surface (120) facing in substantially the opposite direction to the first external surface (110). The aerosol- generating article (100) comprises a cavity (130) between the first external surface and the second external surface. An airflow path is defined through the aerosol-generating article between an air inlet (151) and an air outlet (152). The airflow path extends through the cavity (130). An aerosol-generating agglomerate (150) is located in the cavity (130). The aerosol-generating agglomerate (150) comprises a plurality of connected aerosol-generating elements (161). Each element of the plurality of aerosol-generating elements (161) comprises a core (362) comprising an aerosol-generating material, and an outer coating (363) configured to facilitate connection to adjacent aerosol-generating elements (161).

Description

[0001] P / 91601.W001

[0002] - 1 - AEROSOL-GENERATING ARTICLE WITH AEROSOL-GENERATING AGGLOMERATE

[0003] The present disclosure relates to an aerosol-generating article comprising an aerosolgenerating agglomerate. Specifically, the present disclosure relates to an aerosol-generating article comprising an aerosol-generating agglomerate, the aerosol-generating agglomerate comprising a plurality of connected aerosol-generating elements.

[0004] 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 aerosol-generating material 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.

[0005] However, a significant portion of the aerosol-generating material in these cylindrical aerosol-generating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-generating material contributes to the cost of manufacture and transport of the aerosol-generating article, but does not contribute to the aerosol delivered to an end user.

[0006] Moreover, even if a portion of the aerosol-generating material is sufficiently heated to form an aerosol during use, this can take time due to the thermal inertia. As a result, there can be a significant delay between beginning heating and aerosol generation. In addition, the initial inhalations from the aerosol-generating article may have a low concentration of aerosol compared to the later inhalations. More broadly, typical aerosol-generating materials of the prior art may not produce sufficient aerosol without a very high density of aerosol-generating material. However, where the density of aerosol-generating material increases, this is typically accompanied by a corresponding increase in resistance to draw which can make the aerosol-generating article difficult to use. This may be the case regardless of the way in which the aerosol-generating material is heated, for example regardless of whether a resistive or inductive heater is used and regardless of whether the aerosol-generating material is heated from the inside or the outside. Moreover, the components of these cylindrical aerosol-generating articles normally need to have the same or very similar outer diameters so that they can be brought together, accurately positioned in co-axial alignment and wrapped in a cigarette paper. This can lead to increased cost and complexity of manufacture.

[0007] Furthermore, many aerosol-generating articles of the prior art comprise a particulate aerosol-generating material. However, it has been found that adding the particulate aerosolgenerating material to the body of the article at high speed during manufacturing may lead to particles of aerosol-generating material flying out of the article. In addition, depending on theirsize, the particulate aerosol-generating material may escape the article through one or more air inlets and air outlets during manufacture, storage, transport, or use. This may disadvantageously reduce the volume of aerosol-generating material in the aerosol-generating article, block the one or more air inlets and air outlets, and create mess. Moreover, aerosol-generating articles of the prior art comprising particulates of aerosol-generating material require filtration elements, which can lead to increased costs and complexity of manufacture.

[0008] It is an aim of the present disclosure to provide an aerosol-generating article, in which a greater portion of the aerosol-generating material is sufficiently heated to form an aerosol during use. It is also an objective of the present disclosure to provide an aerosol-generating article that can be manufactured relatively efficiently and cheaply. It is also an objective of the present disclosure to provide an aerosol-generating article that does not require filtration elements to prevent particulates of aerosol-generating material from escaping, and therefore reducing the complexity and costs of manufacturing. It is also an objective of the present disclose to provide an aerosol-generating article which is easier to manufacture and transport without damage. It is also an objective of the present disclosure to provide an aerosol-generating article in which the delay between heating and aerosol delivery is reduced, and which produces a consistent aerosol over the full duration of the experience. In addition, it would be desirable to provide an increase in aerosol delivery without increasing the resistance to draw of the aerosol-generating article to an unacceptably high level. It would be even more desirable to provide an aerosol-generating article with a uniform density distribution across the aerosol-generating material, therefore produce a consistent delivery of aerosol over the full duration of the experience.

[0009] According to a first aspect of the present disclosure there is provided an aerosolgenerating article. The aerosol-generating article may be for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article may be defined by an article length, an article width, and an article height. The article width may be greater than the article height. The aerosol-generating article may comprise a first external surface. The aerosol-generating article may comprise a second external surface. The second external surface may face in substantially the opposite direction to the first external surface. The aerosol-generating article may comprise a cavity between the first external surface and the second external surface. The aerosol-generating article may comprise an airflow path defined through the aerosol-generating article between an air inlet and an air outlet. The airflow path may extend through the cavity. The aerosol-generating article may comprise an aerosol-generating agglomerate located in the cavity. The aerosolgenerating agglomerate may comprise a plurality of connected aerosol-generating elements. Each element of the plurality of aerosol-generating elements may comprise a core comprising an aerosol-generating material. Each element of the plurality of aerosol-generating elements may comprise an outer coating configured to facilitate connection to adjacent aerosol-generating elements.According to a first aspect of the present invention, there is provided an aerosol-generating article. The aerosol-generating article is for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article is defined by an article length, an article width, and an article height, the article width being greater than the article height. The aerosol-generating article comprises a first external surface. The aerosol-generating article comprises a second external surface facing in substantially the opposite direction to the first external surface. The aerosolgenerating article comprises a cavity between the first external surface and the second external surface. The aerosol-generating article comprises an airflow path defined through the aerosolgenerating article between an air inlet and an air outlet. The airflow path extends through the cavity. The aerosol-generating article comprises an aerosol-generating agglomerate located in the cavity. The aerosol-generating agglomerate comprises a plurality of connected aerosolgenerating elements. Wherein each element of the plurality of aerosol-generating elements comprises a core comprising an aerosol-generating material, and an outer coating configured to facilitate connection to adjacent aerosol-generating elements.

[0010] The provision of an aerosol-generating agglomerate comprising a plurality of connected aerosol-generating elements ensures that the aerosol-generating article does not comprise a plurality of loose particulates of aerosol-generating material. As a result, the provision of an aerosol-generating agglomerate may advantageously allow for simple handling of the aerosolgenerating article during assembly and manufacture of the aerosol-generating article. Furthermore, the provision of an aerosol-generating agglomerate comprising a plurality of connected aerosol-generating elements may advantageously allow the aerosol-generating agglomerate to be added to the cavity at high speed with reduced risk that some or all of the aerosol-generating material may leave the cavity during manufacture. This may be a particular problem where the aerosol-generating material comprises loose particulate aerosol-generating material. Moreover, the provision of an aerosol-generating agglomerate may advantageously remove the requirement of a filtration element in the aerosol-generating article, therefore reducing the complexity and costs of manufacture. By contrast, aerosol-generating articles of the prior art which comprise loose particulate aerosol-generating material typically include a filtration element to prevent particulates escaping. In addition, an aerosol-generating article including an aerosolgenerating agglomerate comprising a plurality of connected aerosol-generating elements may be stronger and more resilient to handling than an aerosol-generating article including loose particulate aerosol-generating material. The provision of an aerosol-generating agglomerate comprising a plurality of connected aerosol-generating elements may advantageously also prevent aerosol-generating material from leaving the aerosol-generating article through one or more of the air inlet or air outlet.

[0011] The provision of an aerosol-generating agglomerate comprising a plurality of connected aerosol-generating elements may mean that the density of aerosol-generating material issubstantially consistent across the aerosol-generating agglomerate. As a result, the thermal inertia of the aerosol-generating material is consistent across the aerosol-generating agglomerate. This may advantageously ensure that aerosol generation is more consistent over the full duration of the experience. In addition, the provision of an aerosol-generating agglomerate having a substantially consistent density may mean that the orientation in which the agglomerate is inserted into the cavity has minimal impact on the aerosol generation and delivery. This may advantageously improve the consistency between different aerosol-generating articles and simplify manufacture.

[0012] Moreover, the provision of an aerosol-generating agglomerate comprising a plurality of connected aerosol-generating elements may make it easier to control the parameters of the aerosol-generating material including the resistance to draw, the porosity, density, and the heat conductivity of the aerosol-generating material compared to, for example, loose particulate aerosol-generating material. The provision of a plurality of connected aerosol-generating elements may allow for an aerosol-generating agglomerate having a higher density of aerosolgenerating material compared to traditional gathered and wrapped arrangements. This may advantageously improve the aerosol delivery of the aerosol-generating article during use. Typically, a high density aerosol-generating article may result in an unacceptably high resistance to draw. However, where aerosol-generating articles comprise an agglomerate, small spaces between the connected aerosol-generating elements may provide air passages which keep the resistance to draw of the aerosol-generating element at an acceptable level.

[0013] In addition, aerosol-generating elements of the prior art may comprise tobacco cut filler or tobacco cast leaf gathered and wrapped into a plug. Where this is the case, the tobacco may become detached from the aerosol-generating element if it is not handled with care. In addition, the arrangement of the prior art requires a separate paper wrapper to keep the tobacco substrate together. This adds a further material to the aerosol-generating element which does not contribute to aerosol-generation. This adds cost and may prevent or reduce heat conduction to the tobacco aerosol-generating substrate. By contrast, the provision of an agglomerate of the present invention may advantageously keep the aerosol-generating material together without the need for a separate paper wrapper. This may advantageously help to simplify manufacture while also making the aerosol-generating article more robust for assembly and transport. In addition, the removal of the paper wrapper may advantageously improve heat conduction from the aerosolgenerating device to the aerosol-generating material of the aerosol-generating element. This may in turn improve aerosol generation.

[0014] The removal of the need for a paper wrapper may also advantageously remove the need for a glue or adhesive which is typically used to stick the wrapper together. This may make the aerosol-generating article more sustainable and potentially even biodegradable. In addition, the absence of a paper wrapper may visually distinguish the aerosol-generating article of the presentinvention from conventional cigarettes. This may advantageously remind users that the aerosolgenerating article of the present invention must be used differently to conventional cigarettes.

[0015] As used herein, the term “aerosol-generating article” refers to an article for producing an aerosol comprising an aerosol-generating substrate that is intended to be heated rather than combusted in order to release volatile compounds that can form an aerosol.

[0016] As used herein, the term “agglomerate” refers to a plurality of aerosol-generating elements connected to form a singular structure.

[0017] As used herein, the term “aerosol-generating element” refers to an element capable of releasing an aerosol or volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-generating material. An aerosol-generating element may comprise an aerosol-generating material. An aerosol-generating element may conveniently be part of an aerosol-generating article or smoking article.

[0018] As used herein, the term “aerosol-generating material” refers to a material capable of releasing an aerosol or volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-generating material.

[0019] As used herein, the term “aerosol” denotes a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. The aerosol may be visible or invisible. The aerosol may include vapours of substances that are ordinarily liquid or solid at room temperature as well as solid particles, or liquid droplets, or a combination of solid particles and liquid droplets.

[0020] The aerosol-generating agglomerate may comprise a plurality of connected discrete aerosol-generating elements. Each discrete element of the plurality discrete of aerosol-generating elements comprises a core comprising an aerosol-generating material, and an outer coating configured to facilitate connection to adjacent discrete aerosol-generating elements. Where the plurality of connected aerosol-generating elements are discrete, each individual aerosolgenerating element includes both a core and an outer coating.

[0021] The outer coating may form a distinct layer on or around the core of the aerosol-generating elements. Each element of the plurality of aerosol-generating elements may comprises a core comprising an aerosol-generating material, and an outer coating provided as a discrete layer on or around each core.

[0022] The aerosol-generating agglomerate may have a generally parallelepiped shape. As used herein, the term “parallelepiped” refers to three-dimensional shape, wherein each face of said three-dimensional shape is substantially parallelogrammatic. The aerosol-generating agglomerate may have a generally cuboidal shape.

[0023] The aerosol-generating agglomerate may be defined by an agglomerate length, an agglomerate width, and an agglomerate height, the agglomerate width being greater than theagglomerate height. The aerosol-generating agglomerate may have any length, any width, and any height.

[0024] The aerosol-generating agglomerate may have a length of at least 50 millimetres, at least 65 millimetres, or preferably at least 80 millimetres.

[0025] The aerosol-generating agglomerate may have a length of no more than 120 millimetres, no more than 110 millimetres, or preferably no more than 100 millimetres.

[0026] For example, the aerosol-generating agglomerate may have a length of between about 50 millimetres and about 120 millimetres, between about 65 millimetres and about 110 millimetres, or preferably between about 80 millimetres and about 100 millimetres. The aerosol-generating agglomerate may have a length of about 90 millimetres.

[0027] The aerosol-generating agglomerate may have a width of at least 20 millimetres, at least 25 millimetres, or preferably at least 30 millimetres.

[0028] The aerosol-generating agglomerate may have a width of no more than 50 millimetres, no more than 45 millimetres, or preferably no more than 40 millimetres.

[0029] For example, the aerosol-generating agglomerate may have a width of between about 20 millimetres and about 50 millimetres, between about 25 millimetres and about 45 millimetres, or preferably between about 30 millimetres and about 40 millimetres. The aerosol-generating agglomerate may have a width of about 35 millimetres.

[0030] The aerosol-generating agglomerate may have a height of at least 5 millimetres, at least 6 millimetres, or preferably at least 7 millimetres.

[0031] The aerosol-generating agglomerate may have a height of no more than 20 millimetres, no more than 18 millimetres, or preferably no more than 15 millimetres.

[0032] For example, the aerosol-generating agglomerate may have a height of between about 5 millimetres and about 20 millimetres, between about 6 millimetres and about 18 millimetres, or preferably between about 7 millimetres and about 15 millimetres. The aerosol-generating agglomerate may have a height of about 11 millimetres.

[0033] The range of dimensions disclosed for the length, height, and width of the aerosolgenerating agglomerate have been identified by the inventors as the most optimally sized aerosolgenerating agglomerate. The inventors have identified that the optimally sized aerosol-generating agglomerate increases the amount of the aerosol-generating material present in each aerosolgenerating article, whilst also ensuring the agglomerate can easily and quickly be placed into the cavity of the aerosol-generating article during manufacture.

[0034] The plurality of aerosol-generating elements may be defined by a median external diameter. The plurality of aerosol-generating elements may have any median external diameter.

[0035] As used herein, the term “diameter” refers to the distance between the two furthest points on an external surface of a singular element. To be clear, the use of the term “diameter” does not imply that the element is of a substantially spherical nature. The plurality of aerosol-generatingelements may have any shape. For example, the plurality of aerosol-generating elements may be substantially spherical.

[0036] As used herein, the term “median” refers to the average D50 external diameter of the plurality of aerosol-generating elements. The average D50 external diameter of the plurality of aerosol-generating elements is the aerosol-generating elements diameter which splits the distribution in half, where half of the aerosol-generating elements are larger than the D50 diameter and half of the aerosol-generating elements are smaller than the D50 diameter. The aerosolgenerating elements diameter distribution may be determined by laser diffraction. For example, the aerosol-generating elements diameter distribution may be determined by laser diffraction using a Malvern Mastersizer 3000 laser diffraction particle size analyser in accordance with the manufacturer’s instructions.

[0037] The plurality of aerosol-generating elements may have a median external diameter of at least 0.4 millimetres, at least 0.6 millimetres, or preferably at least 0.75 millimetres.

[0038] The plurality of aerosol-generating elements may have a median external diameter of no more than 3.5 millimetres, no more than 3.0 millimetres, or preferably no more than 2.5 millimetres.

[0039] For example, the plurality of aerosol-generating elements may have a median external diameter range of between about 0.4 millimetres and about 3.5 millimetres, between about 0.6 millimetres and about 3.0 millimetres, or preferably between about 0.75 millimetres and about 2.5 millimetres. The plurality of aerosol-generating elements may have a median external diameter of about 1.6 millimetres.

[0040] The provision of aerosol-generating elements of median external diameters within these disclosed ranges may advantageously improve the density of the aerosol-generating material within the aerosol-generating agglomerate, leading to an improved user experience.

[0041] Preferably, the external diameters of the aerosol-generating elements may follow a defined statistical dispersion. A standard deviation of the aerosol-generating elements within the aerosol-generating agglomerate may help define the statistical dispersion. The statistical dispersion may be a statistical dispersion wherein a specified percentage of the aerosolgenerating elements have an external diameter that fall outside of one standard deviation of the mean external diameter of the plurality of aerosol-generating elements.

[0042] As used herein, the term “mean” refers to the arithmetic mean external diameter of the aerosol-generating elements and is determined by dividing the sum of all the external diameters of the aerosol-generating elements in the distribution by the total number of aerosol-generating elements in the distribution.

[0043] As used herein, the term “standard deviation” refers to a measure of how far values in a distribution are from the mean value. In this case, the standard deviation is calculated by determining the square of the sum of the difference between each external diameter and themean external diameter. This value is then divided by the number of aerosol-generating elements in the distribution and the square root of the result is taken.

[0044] The percentage of the aerosol-generating elements that have an external diameter outside of one standard deviation of the mean external diameter may be any percentage. The percentage of the aerosol-generating elements that have an external diameter outside of one standard deviation of the mean external diameter may be at least 5 percent, at least 10 percent, at least 20 percent, at least 30 percent, at least 50 percent, at least 60 percent, or at least 70 percent.

[0045] The percentage of the aerosol-generating elements that have an external diameter outside of one standard deviation of the mean external diameter may be no more than 95 percent, no more than 90 percent, or no more than 85 percent.

[0046] For example, the percentage of the aerosol-generating elements that have an external diameter outside of one standard deviation of the mean external diameter may be between about 5 percent and about 95 percent, between about 20 percent and 90 percent, between about 5 percent and 20 percent, or between 70 percent and 85 percent.

[0047] The provision of aerosol-generating elements with a distribution of external diameters within an aerosol-generating agglomerate may advantageously further improve the density of the aerosol-generating agglomerate. For example, the aerosol-generating elements that have an external diameter which is substantially smaller than the mean external diameter may occupy the interstitial spaces between the aerosol-generating elements that have an external diameter substantially greater than the median external diameter.

[0048] Moreover, the inventors have identified that the provision of a statistical dispersion wherein a percentage of the aerosol-generating elements have an external diameter that fall outside of one standard deviation of the mean external diameter may be optimised. The inventors have further identified that the disclosed ranges for the percentages of aerosol-generating elements outside of one standard deviation of the mean external diameter are optimised such that the density of the aerosol-generating agglomerate may be increased without significantly increasing the resistance to draw to an unacceptable level.

[0049] The cores of the plurality of aerosol-generating elements may be substantially spherical. The outer coating of the plurality of aerosol-generating elements may have any thickness. The outer coating of the plurality of aerosol-generating elements may have a median thickness of at least 0.02 millimetres, at least 0.025 millimetres, or preferably at least 0.03 millimetres.

[0050] This minimum median thickness for the outer coating of the aerosol-generating elements has been identified by the inventors as the minimum thickness required to facilitate a strong enough connection between the aerosol-generating elements within the aerosol-generating agglomerate.The outer coating of the plurality of aerosol-generating elements may have a median thickness of no more than 0.2 millimetres, no more than 0.18 millimetres, or preferably no more than 0.15 millimetres.

[0051] The inventors have identified that any thickness larger than this specified maximum median thickness for the outer coating of the aerosol-generating element would not result in a stronger connection between the aerosol-generating elements within the aerosol-generating agglomerate, and hence would result in a waste of material.

[0052] For example, the outer coating of the plurality of aerosol-generating elements may have median thickness of between about 0.02 millimetres and about 0.2 millimetres, between about 0.025 millimetres and about 0.18 millimetres, or preferably between about 0.03 millimetres and about 0.15 millimetres. The outer coating of the plurality of aerosol-generating elements may have a median thickness of about 0.09 millimetres.

[0053] The aerosol-generating material may comprise a tobacco leaf blend. The tobacco leaf blend may comprise one or more of: bright tobacco, dark tobacco, and aromatic tobacco. The tobacco may be ground to any particle size. The tobacco may be ground to a particle size of at least 100 mesh, at least 140 mesh, or preferably at least 170 mesh.

[0054] The tobacco may be ground to a particle size of no more than 380 mesh, no more than 350 mesh, or preferably no more than 320 mesh.

[0055] For example, the tobacco may be ground to a particle size of between about 100 and about 380 mesh, between about 140 and about 350 mesh, or preferably between about 170 and about 320 mesh.

[0056] The aerosol-generating material may comprise any weight of the tobacco leaf blends on a dry weight basis. The aerosol-generating material may comprise at least 15 percent by weight, at least 18 percent by weight, or preferably at least 20 percent by weight of the tobacco leaf blends on a dry weight basis.

[0057] The aerosol-generating material may comprise no more than 45 percent by weight, no more than 40 percent by weight, or preferably no more than 35 percent by weight of the tobacco leaf blends on a dry weight basis.

[0058] For example, the aerosol-generating material may comprise between about 15 percent by weight and about 45 percent by weight, between about 18 percent by weight and about 40 percent by weight, or preferably between about 20 percent by weight and about 35 percent by weight of the tobacco leaf blends on a dry weight basis. The aerosol-generating material may comprise about 27 percent of the tobacco leaf blends on a dry weight basis.

[0059] As used herein, a content of a component on a “dry weight basis” refers to the weight of a particular non-water component relative to the sum of the weights of all non-water components in a mixture, expressed as a percentage. A mass ratio of two or more components on a “dry weightbasis” refers to a ratio of the weight of a particular non-water component relative to another particular non-water component.

[0060] The aerosol-generating material may further comprise cellulose fibres. The cellulose fibres may have any median length. The cellulose fibres may have a median length of at least 5 micrometers, at least 7 micrometers, or preferably at least 10 micrometers.

[0061] The cellulose fibres may have a median length of no more than 250 micrometers, no more than 200 micrometers, or preferably no more than 120 micrometers.

[0062] For example, cellulose fibres may have a median length of between about 5 micrometers and about 250 micrometers, between about 7 micrometers and about 200 micrometers, or preferably between about 10 micrometers and about 120 micrometers. The cellulose fibres may have a median length of about 65 micrometers.

[0063] The aerosol-generating material may comprise any weight of the cellulose fibres on a dry weight basis. The aerosol-generating material may comprise at least 1 percent by weight, at least 2 percent by weight, or preferably at least 3 percent by weight of the cellulose fibres on a dry weight basis.

[0064] The aerosol-generating material may comprise no more than 15 percent by weight, no more than 10 percent by weight, or preferably no more than 7 percent by weight of the cellulose fibres on a dry weight basis.

[0065] For example, the aerosol-generating material may comprise between about 1 percent by weight and about 15 percent by weight, between about 2 percent by weight and about 10 percent by weight, or preferably between about 3 percent by weight and about 7 percent by weight of the cellulose fibres on a dry weight basis. The aerosol-generating material may comprise about 5 percent by weight of the cellulose fibres on a dry weight basis.

[0066] The cellulose fibres may comprise fibres of cellulose acetate.

[0067] The aerosol-generating material may further comprise tobacco fibres. The tobacco fibres may be any tobacco type or blend of tobacco types. As used herein, the term “tobacco type” may refer to any one of the following varieties of tobacco: bright tobacco, aromatic tobacco, or dark tobacco. Each type of tobacco may be further distinguished by namely basing the tobacco on the distinct curing process that the tobacco undergoes before the tobacco is further processed in a tobacco product. Examples of bright tobaccos may be any one of the following: Flue-Cured Brazil, Indian Flue-Cured, Chinese Flue-Cured, US Flue-Cured such as Virginia tobacco, and Flue-Cured from Tanzania. Examples of aromatic tobaccos may be any one of the following: Oriental Turkey, Greek Oriental, semi-oriental tobacco but also Fire Cured, US Burley, such as Perique, and Rustica. Examples of dark tobacco may be any one of the following: Dark Cured Brazil Galpao, Burley Malawi or other African Burley, Sun Cured or Air Cured Indonesian Kasturi.

[0068] The tobacco fibres may be used as a filler. Furthermore, the tobacco fibres may be may be derived from stem, or alternatively from stems and stalks. The tobacco fibres may be groundto fibres of any length. The tobacco fibres may have a median length of at least 5 micrometers, at least 7 micrometers, or preferably at least 10 micrometers.

[0069] The tobacco fibres may have a median length of no more than 250 micrometers, no more than 200 micrometers, or preferably no more than 120 micrometers.

[0070] For example, tobacco fibres may have a median length of between about 5 micrometers and about 250 micrometers, between about 7 micrometers and about 200 micrometers, or preferably between about 10 micrometers and about 120 micrometers. The tobacco fibres may have a median length of about 65 micrometers.

[0071] The aerosol-generating material may comprise any weight of the tobacco fibres on a dry weight basis. The aerosol-generating material may comprise at least 5 percent by weight, at least 6 percent by weight, or preferably at least 7 percent by weight of the tobacco fibres on a dry weight basis.

[0072] The aerosol-generating material may comprise no more than 20 percent by weight, no more than 18 percent by weight, or preferably no more than 15 percent by weight of the tobacco fibres on a dry weight basis.

[0073] For example, the aerosol-generating material may comprise between about 5 percent by weight and about 20 percent by weight, between about 6 percent by weight and about 18 percent by weight, or preferably between about 7 percent by weight and about 15 percent by weight of the tobacco fibres on a dry weight basis. The aerosol-generating material may comprise about 11 percent by weight of the tobacco fibres on a dry weight basis.

[0074] The aerosol-generating material may further comprise a binder. The binder may be any type of gum or pectin commonly used in the Food and Beverage (F&B) industry. Preferably, the binder may comprise any one or more of the following: natural pectins, such as a citrus pectin or a tobacco pectin, guar gum, locust bean gum, hydroxyethyl derivatives, hydroxypropyl derivatives, hydroxyethyl and hydroxypropyl derivatives, modified or derivatized starches, alginate, methyl, ethyl, ethylhydroxymethyl, carboxymethyl celluloses, dextran, and xanthan gum. Even more preferably, the binder may be a guar. Alternatively, the binder may comprise carboxymethyl cellulose (CMC) compounds. The inventors have identified that CMC compounds may advantageously reduce the water content in the binder and hence facilitate a faster drying of the binder.

[0075] The aerosol-generating material may comprise any weight of the binder on a dry weight basis. The aerosol-generating material may comprise at least 0.2 percent by weight, at least 0.5 percent by weight, or preferably at least 1 percent by weight of the binder on a dry weight basis.

[0076] The aerosol-generating material may comprise no more than 10 percent by weight, no more than 7 percent by weight, or preferably no more than 5 percent by weight of the binder on a dry weight basis.For example, the aerosol-generating material may comprise between about 0.2 percent by weight and about 10 percent by weight, between about 0.5 percent by weight and about 7 percent by weight, preferably between about 1 percent by weight and about 10 percent by weight, or more preferably between about 1 percent by weight and about 5 percent by weight of the binder on a dry weight basis. The aerosol-generating material may comprise about 3 percent by weight of the binder on a dry weight basis.

[0077] The aerosol-generating material may further comprise an aerosol former. The aerosol former may comprise glycerin. The aerosol former may comprise monohydric alcohols, such as menthol. The aerosol former may comprise polyhydric alcohols, such as triethylene glycol. The aerosol former may comprise esters of polyhydric alcohols, such as glycerol monoacetate, glycerol diacetate, and glycerol triacetate. The aerosol former may comprise aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids, such as dimethyl esters.

[0078] The aerosol-generating material may comprise any weight of the aerosol former on a dry weight basis. The aerosol-generating material may comprise at least 5 percent by weight, at least 7 percent by weight, or preferably at least 10 percent by weight of the aerosol former on a dry weight basis.

[0079] The aerosol-generating material may comprise no more than 35 percent by weight, no more than 30 percent by weight, or preferably no more than 25 percent by weight of the aerosol former on a dry weight basis.

[0080] For example, the aerosol-generating material may comprise between about 5 percent by weight and about 35 percent by weight, between about 7 percent by weight and about 30 percent by weight, or preferably between about 10 percent by weight and about 25 percent by weight of the aerosol former on a dry weight basis. The aerosol-generating material may comprise about 18 percent by weight of the aerosol former on a dry weight basis.

[0081] The core of aerosol-generating material may further comprise a flavouring agent. The flavouring agent may be a compound material. The inventors have identified that the provision of a flavouring agent may advantageously enhance the sensory experience of the user.

[0082] The flavouring agent may comprise glycerin. The flavouring agent may comprise any weight of glycerin on a dry weight basis. The flavouring agent may comprise at least 10 percent by weight, at least 15 percent by weight, or preferably at least 20 percent by weight of glycerin on a dry weight basis.

[0083] The flavouring agent may comprise no more than 40 percent by weight, no more than 35 percent by weight, or preferably no more than 30 percent by weight of glycerin on a dry weight basis.

[0084] For example, the flavouring agent may comprise between about 10 percent by weight and about 40 percent by weight, between about 15 percent by weight and about 35 percent by weight, or preferably between about 20 percent by weight and about 30 percent by weight of glycerin ona dry weight basis. The flavouring agent may comprise about 25 percent by weight of glycerin on a dry weight basis.

[0085] The flavouring agent may further comprise organic fibres. The organic fibres may be of any botanical variety suitable for and compliant with applicable Food and Drug Administration (FDA) F&B grade requirements. The organic fibres may be any one the following: cellulose, cotton, wood, tea botanical varieties as sub-products, and sub-processed waste from the F&B tea industry. The organic fibres may have any median length. The organic fibres may have a median length of at least 5 micrometers, at least 7 micrometers, or preferably at least 10 micrometers.

[0086] The organic fibres may have a median length of no more than 400 micrometers, no more than 300 micrometers, or preferably no more than 200 micrometers.

[0087] For example, the organic fibres may have a median length of between about 5 micrometers and about 400 micrometers, between about 7 micrometers and about 300 micrometers, or preferably between about 10 micrometers and about 200 micrometers. The organic fibres may have a median length of about 105 micrometers.

[0088] The flavouring agent may comprise any weight of the organic fibres on a dry weight basis. The flavouring agent may comprise at least 10 percent by weight, at least 12 percent by weight, or preferably at least 15 percent by weight of the organic fibres on a dry weight basis.

[0089] The flavouring agent may comprise no more than 30 percent by weight, no more than 27 percent by weight, or preferably no more than 25 percent by weight of the organic fibres on a dry weight basis.

[0090] For example, the flavouring agent may comprise between about 10 percent by weight and about 30 percent by weight, between about 12 percent by weight and about 27 percent by weight, or preferably between about 15 percent by weight and about 25 percent by weight of the organic fibres on a dry weight basis. The flavouring agent may comprise about 20 percent by weight of the organic fibres on a dry weight basis.

[0091] The flavouring agent may further comprise organic botanical glycerite. The organic botanical glycerite may be comprise at least one of the following botanicals: clove, Echinacea purpurea, fennel, ginger, hawthorn berry, elderberry, Monarda, mullein leaves, nettle, plantain, turmeric, yarrow, and their compounds.

[0092] The flavouring agent may comprise any weight of the organic botanical glycerite on a dry weight basis. The flavouring agent may comprise at least 15 percent by weight, at least 17 percent by weight, or preferably at least 20 percent by weight of the organic botanical glycerite on a dry weight basis.

[0093] The flavouring agent may comprise no more than 55 percent by weight, no more than 45 percent by weight, or preferably no more than 35 percent by weight of the organic botanical glycerite on a dry weight basis.For example, the flavouring agent may comprise between about 15 percent by weight and about 55 percent by weight, between about 17 percent by weight and about 45 percent by weight, or preferably between about 20 percent by weight and about 35 percent by weight of the organic botanical glycerite on a dry weight basis. The flavouring agent may comprise about 27 percent by weight of the organic botanical glycerite on a dry weight basis.

[0094] The flavouring agent may further comprise organic botanical extracts. The organic botanical extracts may be comprise at least one extract from any one of the aforementioned botanicals. The organic botanical extracts may further comprise menthol. For example, the menthol may be DL-Menthol. Optionally, the menthol may be 2-lsopropyl-5-methylcyclohexanol which may be obtained from any one of the following: Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related botanical varieties. The organic botanical extracts may further comprise P-menthan-3-ol, a secondary alcohol and diastereoisomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.

[0095] The flavouring agent may comprise any weight of the organic botanical extracts on a dry weight basis. The flavouring agent may comprise at least 1 percent by weight, at least 1.5 percent by weight, or preferably at least 2 percent by weight of the organic botanical extracts on a dry weight basis.

[0096] The flavouring agent may comprise no more than 15 percent by weight, no more than 11 percent by weight, or preferably no more than 7 percent by weight of the organic botanical extracts on a dry weight basis.

[0097] For example, the flavouring agent may comprise between about 1 percent by weight and about 15 percent by weight, between about 1.5 percent by weight and about 11 percent by weight, or preferably between about 2 percent by weight and about 7 percent by weight of the organic botanical extracts on a dry weight basis. The flavouring agent may comprise about 5 percent by weight of the organic botanical extracts on a dry weight basis.

[0098] The flavouring agent may further comprise botanical essential oils. The botanical essential oils may be palm-based, coconut- based, or wood-based essential oils.

[0099] The flavouring agent may comprise any weight of the botanical essential oils on a dry weight basis. The flavouring agent may comprise at least 0.5 percent by weight, at least 0.75 percent by weight, or preferably at least 1 percent by weight of the botanical essential oils on a dry weight basis.

[0100] The flavouring agent may comprise no more than 5 percent by weight, no more than 4 percent by weight, or preferably no more than 3 percent by weight of the botanical essential oils on a dry weight basis.

[0101] For example, the flavouring agent may comprise between about 0.5 percent by weight and about 5 percent by weight, between about 0.75 percent by weight and about 4 percent by weight, or preferably between about 1 percent by weight and about 3 percent by weight of the botanicalessential oils on a dry weight basis. The flavouring agent may comprise about 2 percent by weight of the botanical essential oils on a dry weight basis.

[0102] The outer coating of the aerosol-generating elements may partially encapsulate the core of the aerosol-generating element. Alternatively, the outer coating of the aerosol-generating elements may fully encapsulate the core of the aerosol-generating element.

[0103] The outer coating may comprise any alginate-based formulation. The alginate-based formulation may be commonly used in the F&B industry and compliant with applicable FDA F&B grade requirements. The outer coating may comprise at least one or more of the following: alginate, alginate-maltodextrin, alginate-galbanum gum, and starch-alginate. The alginate-based formulation may be cross-linked with a cross-linking agent. The cross-linking agent may comprise calcium. More specifically, the cross-linking agent may comprise at least one or more of the following: calcium chloride, calcium chloride-carboxymethylcellulose, calcium gluconate, calcium lactate, and tapioca starch.

[0104] The outer coating may comprise at least one of carboxymethylated starch and hydroxypropylated starch, (such as Solvitose®), cellulose nano-fibres (CNF), dextrin or chitosan. When the binder is Solvitose®, the binder may be a 5% solution of Solvitose® in water.

[0105] The provision of such an outer coating may advantageously help the accurate dosing of aerosol-generating material. The provision of such an outer coating may also advantageously prevent small particles of aerosol-generating material from escaping the aerosol-generating article.

[0106] The outer coating may further comprise an anti-microbial substance. Preferably, the antimicrobial substance may be compliant with any applicable FDA requirements. The anti-microbial substance may be heat resistant up to about 150 degrees Celsius, up to about 200 degrees Celsius, or preferably up to 250 degrees Celsius. Such an anti-microbial substance that is heat resistant up to the disclosed temperatures may advantageously prevent the anti-microbial substance from decaying when heated in use, ensuring the article meets the requirements for use with an oral cavity of a user. The anti-microbial substance may be a natural substance. The anti-microbial substance may comprise at least one or more of the following: vanillin, thyme oil, lemongrass extract, carvacrol, methyl cinnamate, nisin, acetic acid, lactic acid, potassium sorbate, Ziziphora persica essential oil and extracts, sodium lactate, sodium diacetate, and pomegranate peel extract.

[0107] The aerosol-generating elements may further comprise an outer substrate disposed between the core of aerosol-generating material and the outer coating. The outer substrate may be a hydrogel composition. The hydrogel composition may comprise sodium alginate. Sodium alginate is a natural polysaccharide and may be derived from brown seaweed. The inventors have identified that sodium alginate may advantageously enhance the gel-like formation of the hydrogel composition when cross-linked with divalent cations.The hydrogel composition may comprise any weight of sodium alginate on a dry weight basis. The hydrogel composition may comprise at least 1.7 percent by weight, at least 1.8 percent by weight, or preferably at least 2 percent by weight of sodium alginate on a dry weight basis.

[0108] The hydrogel composition may comprise no more than 2.8 percent by weight, no more than 2.7 percent by weight, or preferably no more than 2.5 percent by weight of sodium alginate on a dry weight basis.

[0109] For example, hydrogel composition may comprise between about 1.7 percent by weight and about 2.8 percent by weight, between about 1.8 percent by weight and about 2.7 percent by weight, or preferably between about 2 percent by weight and about 2.5 percent by weight of sodium alginate on a dry weight basis. The hydrogel composition may comprise about 2.3 percent by weight of sodium alginate on a dry weight basis.

[0110] The hydrogel composition may further comprise N-isopropylacrylamide. The inventors have identified that the provision of N-isopropylacrylamide may advantageously enhance the formation of the hydrogel such that the hydrogel is sensitive to changes in temperatures.

[0111] The hydrogel composition may comprise any weight of N-isopropylacrylamide on a dry weight basis. The hydrogel composition may comprise at least 30 percent by weight, at least 35 percent by weight, or preferably at least 40 percent by weight of N-isopropylacrylamide on a dry weight basis.

[0112] The hydrogel composition may comprise no more than 60 percent by weight, no more than 55 percent by weight, or preferably no more than 50 percent by weight of N-isopropylacrylamide on a dry weight basis.

[0113] For example, hydrogel composition may comprise between about 30 percent by weight and about 60 percent by weight, between about 35 percent by weight and about 55 percent by weight, or preferably between about 40 percent by weight and about 50 percent by weight of N-isopropylacrylamide on a dry weight basis. The hydrogel composition may comprise about 45 percent by weight of N-isopropylacrylamide on a dry weight basis.

[0114] The hydrogel composition may further comprise a copolymer of N-isopropylacrylamide and vinyl sulfonic acid. The inventors have identified that the provision of the copolymer may advantageously enhance the mechanical properties and responsiveness of the hydrogel composition.

[0115] The hydrogel composition may comprise any weight of the copolymer on a dry weight basis. The hydrogel composition may comprise at least 7.5 percent by weight, at least 8 percent by weight, or preferably at least 10 percent by weight of the copolymer on a dry weight basis.

[0116] The hydrogel composition may comprise no more than 20 percent by weight, no more than 18 percent by weight, or preferably no more than 15 percent by weight of the copolymer on a dry weight basis.For example, hydrogel composition may comprise between about 7.5 percent by weight and about 20 percent by weight, between about 8 percent by weight and about 18 percent by weight, or preferably between about 10 percent by weight and about 15 percent by weight of the copolymer on a dry weight basis. The hydrogel composition may comprise about 13 percent by weight of the copolymer on a dry weight basis.

[0117] The hydrogel composition may further comprise vinyl sulfonic acid. The inventors have identified that the provision of vinyl sulfonic acid may advantageously enhance the swelling behavior and mechanical strength of the hydrogel composition.

[0118] The hydrogel composition may comprise any weight of vinyl sulfonic acid on a dry weight basis. The hydrogel composition may comprise at least 7 percent by weight, at least 8 percent by weight, or preferably at least 10 percent by weight of vinyl sulfonic acid on a dry weight basis.

[0119] The hydrogel composition may comprise no more than 18 percent by weight, no more than 17 percent by weight, or preferably no more than 15 percent by weight of vinyl sulfonic acid on a dry weight basis.

[0120] For example, hydrogel composition may comprise between about 7 percent by weight and about 18 percent by weight, between about 8 percent by weight and about 17 percent by weight, or preferably between about 10 percent by weight and about 15 percent by weight of vinyl sulfonic acid on a dry weight basis. The hydrogel composition may comprise about 13 percent by weight of vinyl sulfonic acid on a dry weight basis.

[0121] The hydrogel composition may further comprise a crosslinker. The crosslinker may be N,N’-methylenebisacrylamide. The inventors have identified that the provision of the crosslinker may advantageously form stable hydrogel networks within the hydrogel composition.

[0122] The hydrogel composition may comprise any weight of the crosslinker on a dry weight basis. The hydrogel composition may comprise at least 0.05 percent by weight, at least 0.075 percent by weight, or preferably at least 0.1 percent by weight of the crosslinker on a dry weight basis.

[0123] The hydrogel composition may comprise no more than 0.25 percent by weight, no more than 0.225 percent by weight, or preferably no more than 0.2 percent by weight of the crosslinker on a dry weight basis.

[0124] For example, hydrogel composition may comprise between about 0.05 percent by weight and about 0.25 percent by weight, between about 0.075 percent by weight and about 0.225 percent by weight, or preferably between about 0.1 percent by weight and about 0.2 percent by weight of the crosslinker on a dry weight basis. The hydrogel composition may comprise about O.15 percent by weight of the crosslinker on a dry weight basis.

[0125] The hydrogel composition may further comprise an initiator. The initiator may be ammonium persulfate. The provision of the initiator may be used to start the polymerisation process of hydrogel composition.The hydrogel composition may comprise any weight of the initiator on a dry weight basis. The hydrogel composition may comprise at least 0.5 percent by weight, at least 0.75 percent by weight, or preferably at least 1 percent by weight of the initiator on a dry weight basis.

[0126] The hydrogel composition may comprise no more than 2.5 percent by weight, no more than 2.25 percent by weight, or preferably no more than 2 percent by weight of the initiator on a dry weight basis.

[0127] For example, hydrogel composition may comprise between about 0.5 percent by weight and about 2.5 percent by weight, between about 0.75 percent by weight and about 2.25 percent by weight, or preferably between about 1 percent by weight and about 2 percent by weight of the initiator on a dry weight basis. The hydrogel composition may comprise about 1.5 percent by weight of the initiator on a dry weight basis.

[0128] The hydrogel composition may further comprise a catalyst. The catalyst may be N,N,N’,N’-tetramethylethylenediamine. The provision of the catalyst may advantageously accelerate the polymerisation process of the hydrogel composition.

[0129] The hydrogel composition may comprise any weight of the catalyst on a dry weight basis. The hydrogel composition may comprise at least 8 percent by weight, at least 9 percent by weight, or preferably at least 10 percent by weight of the catalyst on a dry weight basis.

[0130] The hydrogel composition may comprise no more than 16 percent by weight, no more than 15 percent by weight, or preferably no more than 14 percent by weight of the catalyst on a dry weight basis.

[0131] For example, hydrogel composition may comprise between about 8 percent by weight and about 16 percent by weight, between about 9 percent by weight and about 15 percent by weight, or preferably between about 10 percent by weight and about 14 percent by weight of the catalyst on a dry weight basis. The hydrogel composition may comprise about 12 percent by weight of the catalyst on a dry weight basis.

[0132] Where the plurality of aerosol-generating elements comprise an outer substrate disposed between the core of aerosol-generating material and the outer coating, the outer coating of the aerosol-generating elements may partially encapsulate the outer substrate of the aerosolgenerating element. Alternatively, the outer coating of the aerosol-generating elements may fully encapsulate the outer substrate of the aerosol-generating element.

[0133] The outer substrate of the plurality of aerosol-generating elements may have any may have any median external diameter.

[0134] The outer substrate of the plurality of aerosol-generating elements may have a median external diameter of at least 0.1 millimetres, at least 0.5 millimetres, or preferably at least 1 millimetre.The outer substrate of the plurality of aerosol-generating elements may have a median external diameter of no more than 3.5 millimetres, no more than 3.0 millimetres, or preferably no more than 2.5 millimetres.

[0135] For example, the outer substrate of the plurality of aerosol-generating elements may have a median external diameter range of between about 0.1 millimetres and about 3.5 millimetres, between about 0.5 millimetres and about 3.0 millimetres, or preferably between about 1 millimetre and about 2.5 millimetres. The outer substrate of the plurality of aerosol-generating elements may have a median external diameter of about 1.7 millimetres

[0136] The provision of outer substrate of the aerosol-generating elements of median external diameters within these disclosed ranges may advantageously improve the density of the aerosolgenerating material within the aerosol-generating agglomerate, leading to an improved user experience.

[0137] Where the plurality of aerosol-generating elements comprise an outer substrate, the cores of the plurality of aerosol-generating elements may have a median external diameter of at least 0.25 millimetres, at least 0.4 millimetres, or preferably at least 0.5 millimetres.

[0138] The cores of the plurality of aerosol-generating elements may have a median external diameter of no more than 2.5 millimetres, no more than 2.3 millimetres, or preferably no more than 2.0 millimetres.

[0139] For example, the cores of the plurality of aerosol-generating elements may have a median external diameter of between about 0.25 millimetres and about 2.5 millimetres, between about 0.4 millimetres and about 2.3 millimetres, or preferably between about 0.5 millimetres and about 2.0 millimetres. The cores of the plurality of aerosol-generating elements may have a median external diameter of about 1.3 millimetres.

[0140] The aerosol-generating article according to any of the aspects disclosed herein may comprise substantially planar first and second external surfaces. A vertical separation between the substantially planar first and second external surfaces may define a height of the aerosolgenerating article. An air flow channel may be defined between the substantially planar first and second external surfaces. The height of the aerosol-generating article may be less than 5 millimetres, for example between 1.5 millimetres and 5 millimetres, for example between 1.5 millimetres and 4 millimetres, for example between 1.5 millimetres and 3 millimetres, for example between 1.5 millimetres and 2 millimetres. The height of the aerosol-generating article may be about 1.8 millimetres.

[0141] According to the present disclosure, the aerosol-generating article may comprise a frame positioned between the planar first and second external surfaces. The frame may at least partially defines the cavity.

[0142] The first external surface may be a planar surface. The second external surface may be a planar surface.The frame may comprise a peripheral wall at least partially circumscribing or encircling the cavity. The frame may comprise a peripheral wall wholly circumscribing or encircling the cavity. Advantageously, the frame may allow the aerosol-generating article to be relatively thin whilst maintaining structural rigidity.

[0143] The frame may have a height between 50 percent and 95 percent of the height of the aerosol-generating article. The frame may have a height between 60 percent and 95 percent of the height of the aerosol-generating article. The frame may have a height between 70 percent and 95 percent of the height of the aerosol-generating article. The frame may have a height between 80 percent and 95 percent of the height of the aerosol-generating article. The frame may have a height of about 87 percent of the height of the aerosol-generating article.

[0144] The frame may have a height between 1 millimetre and 5.5 millimetres. The frame may have a height between 1 millimetre and 5 millimetres. Preferably, the frame may have a height between 1.5 millimetres and 5 millimetres. The frame may have a height of about 3.3 millimetres.

[0145] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0146] The frame may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may comprise cellulose fibres. The cellulosic material may be paper, paperboard, or cardboard. The frame may be made from or comprise a plant material, such as tobacco. The frame may be made entirely from a cellulosic material.

[0147] The frame may be a unitary component. Alternatively, the frame may comprise two or more layers. That is, the frame may have a laminated structure.

[0148] The aerosol-generating article of any of the aspects of the present disclosure may have a length of between 10 millimetres and 100 millimetres, or between 10 millimetres and 50 millimetres, for example between 10 millimetres and 40 millimetres, for example between 12 millimetres and 30 millimetres, for example between 14 millimetres and 26 millimetres, for example between 16 millimetres and 24 millimetres, for example between 18 millimetres and 22 millimetres, for example about 18 millimetres, or about 19 millimetres, or about 20 millimetres, or about 21 millimetres, or about 22 millimetres.

[0149] The aerosol-generating article may have a width of between 5 millimetres and 20 millimetres, for example between 8 millimetres and 18 millimetres, for example between 10 millimetres and 16 millimetres, for example between 11 millimetres and 15 millimetres, for example between 12 millimetres and 14 millimetres, for example about 13 millimetres.

[0150] The aerosol-generating article may have a height of between 1 millimetres and 10 millimetres, for example between 1.2 millimetres and 8 millimetres, for example between 1.4 millimetres and 7 millimetres, for example between 1.6 millimetres and 6 millimetres, for examplebetween 1.7 millimetres and 5 millimetres, for example about 1.7 millimetres, or about 4.5 millimetres, or about 2 millimetres, or about 3 millimetres, or about 4 millimetres.

[0151] The aerosol-generating article may have a length of at least 55 millimetres, at least 70 millimetres, or preferably at least 85 millimetres.

[0152] The aerosol-generating article may have a length of no more than 125 millimetres, no more than 115 millimetres, or preferably no more than 105 millimetres.

[0153] For example, the aerosol-generating article may have a length of between about 55 millimetres and about 125 millimetres, between about 70 millimetres and about 115 millimetres, or preferably between about 85 millimetres and about 105 millimetres. The aerosol-generating article may have a length of about 95 millimetres.

[0154] The aerosol-generating article may have a width of at least 22 millimetres, at least 27 millimetres, or preferably at least 32 millimetres.

[0155] The aerosol-generating article may have a width of no more than 52 millimetres, no more than 47 millimetres, or preferably no more than 42 millimetres.

[0156] For example, the aerosol-generating article may have a width of between about 22 millimetres and about 52 millimetres, between about 27 millimetres and about 47 millimetres, or preferably between about 32 millimetres and about 42 millimetres. The aerosol-generating article may have a width of about 37 millimetres.

[0157] The aerosol-generating article may have a height of at least 7 millimetres, at least 8 millimetres, or preferably at least 9 millimetres.

[0158] The aerosol-generating article may have a height of no more than 22 millimetres, no more than 20 millimetres, or preferably no more than 17 millimetres.

[0159] For example, the aerosol-generating article may have a height of between about 7 millimetres and about 22 millimetres, between about 8 millimetres and about 20 millimetres, or preferably between about 9 millimetres and about 17 millimetres. The aerosol-generating article may have a height of about 13 millimetres.

[0160] The aerosol-generating article of any of the aspects of the present disclosure when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof. Where the aerosol-generating article comprises substantially planar upper and lower surfaces, one or both of the upper and lower surfaces when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof. A perimeter of the aerosolgenerating article when viewed in plan may be formed of a plurality of straight sides, a plurality of curved sides, or a combination of straight and curved sides. Where the aerosol-generating article comprises substantially planar first and second surfaces, a perimeter of one or both of the upper and lower surfaces when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof.The aerosol-generating article according to any of the aspects disclosed herein may have an air flow path extending through the aerosol-generating article. The aerosol-generating article may have an air-flow path defined through the aerosol-generating article in an x / y plane from one side of the aerosol-generating article to the other side of the aerosol-generating article. The aerosol-generating article preferably has a resistance to draw (RTD) of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in the direction of the airflow path. Preferably, the aerosol-generating article has a RTD of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in at least one direction in an x / y plane of the aerosol-generating article. An aerosol-generating article with a low resistance air-flow path may allow for superior air-flow management and allow aerosol to be extracted more efficiently from the aerosol-generating article and guided to a user. The resistance to draw of the aerosol-generating article between the air inlet and air outlet is at least 5 millimetre H2O.

[0161] The air inlet may have any diameter. The air inlet may have a diameter of at least 4 millimetres, at least 5 millimetres, at least 6 millimetres, or at least 8 millimetres.

[0162] The air outlet may have any diameter. The air outlet may have a diameter of at least 4 millimetres, at least 5 millimetres, at least 6 millimetres, or at least 8 millimetres.

[0163] As used herein, the “diameter” of the air inlet and air outlet refers to the longest dimension of the air inlet and air outlet.

[0164] The provision of at least one of the air inlet and air outlet having a relatively large diameter may advantageously improve the airflow through the cavity. This may reduce the overall resistance to draw of the aerosol-generating article. Moreover, the provision of an aerosolgenerating agglomerate may work particularly well with an enlarged air inlet and air outlet since the aerosol-generating material is not free to move around the cavity but is bound in the agglomerate. As a result, the risk that aerosol-generating substrate may escape the article through one or more air inlets and air outlets is reduced, even where the air inlets and air outlets have large diameters.

[0165] The air inlet and air outlet may have the same diameter.

[0166] The air inlet and air outlet may be formed in the frame of the aerosol-generating article. According to a second aspect of the present disclosure there is provided an aerosolgenerating system for generating an aerosol. The aerosol-generating system may comprise an aerosol-generating device comprising an electrical power source and a recess for receiving an aerosol-generating article. The aerosol-generating system may further comprise an aerosolgenerating article according to the first aspect of the present disclosure.

[0167] According to a second aspect of the present disclosure there is provided an aerosolgenerating system for generating an aerosol. The aerosol-generating system comprises an aerosol-generating device comprising an electrical power source and a recess for receiving anaerosol-generating article. The aerosol-generating system further comprises an aerosolgenerating article according to the first aspect of the present disclosure.

[0168] As used herein, the term “aerosol-generating system” refers to the combination of an aerosol-generating device and an aerosol-generating article.

[0169] 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.

[0170] 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.

[0171] Example 1: An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: a first external surface and a second external surface facing in substantially the opposite direction to the first external surface; a cavity between the first external surface and the second external surface; an airflow path defined through the aerosolgenerating article between an air inlet and an air outlet, the airflow path extending through the cavity, and an aerosol-generating agglomerate located in the cavity, the aerosol-generating agglomerate comprising a plurality of connected aerosol-generating elements, wherein each element of the plurality of aerosol-generating elements comprises a core comprising an aerosolgenerating material, and an outer coating configured to facilitate connection to adjacent aerosolgenerating elements.

[0172] Example 2: An aerosol-generating article according to Example 1, wherein the aerosolgenerating agglomerate generally has a parallelepiped shape.

[0173] Example 3: An aerosol-generating article according to Example 1 or Example 2, wherein the aerosol-generating agglomerate has a length of at least 50 millimetres, preferably at least 80 millimetres.

[0174] Example 4: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating agglomerate has a length of no more than 120 millimetres, preferably no more than 100 millimetres.

[0175] Example 5: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating agglomerate has a height of at least 5 millimetres, preferably at least 7 millimetres.

[0176] Example 6: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating agglomerate has a height of no more than 20 millimetres, preferably no more than 15 millimetres.Example 7: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating agglomerate has a width of at least 20 millimetres, preferably at least 30 millimetres.

[0177] Example 8: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating agglomerate has a width of no more than 50 millimetres, preferably no more than 40 millimetres.

[0178] Example 9: An aerosol-generating article according to any preceding Example, wherein at least 5 percent of the plurality of aerosol-generating elements have an external diameter outside of one standard deviation of the mean external diameter of the plurality of aerosol-generating elements.

[0179] Example 10: An aerosol-generating article according to any preceding Example, wherein the plurality of aerosol-generating elements have a median (D50) external diameter of at least 0.4 millimetres, preferably at least 0.75 millimetres.

[0180] Example 11: An aerosol-generating article according to any preceding Example, wherein the plurality of aerosol-generating elements have a median (D50) external diameter of no more than 3.5 millimetres, preferably no more than 2.5 millimetres.

[0181] Example 12: An aerosol-generating article according to any preceding Example, wherein the cores of the plurality of aerosol-generating elements have a median (D50) external diameter of at least 0.25 millimetres, preferably at least 0.5 millimetres.

[0182] Example 13: An aerosol-generating article according to any preceding Example, wherein the cores of the plurality of aerosol-generating elements have a median (D50) external diameter of no more than 2.5 millimetres, preferably no more than 2 millimetres.

[0183] Example 14: An aerosol-generating article according to any preceding Example, wherein the outer coating of the plurality of aerosol-generating elements has a median (D50) thickness of at least 0.02 millimetres, preferably at least 0.03 millimetres.

[0184] Example 15: An aerosol-generating article according to any preceding Example, wherein the outer coating of the plurality of aerosol-generating elements has a median (D50) thickness of no more than 0.2 millimetres, preferably no more than 0.15 millimetres.

[0185] Example 16: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating material comprises tobacco leaf blends.

[0186] Example 17: An aerosol-generating article according to Example 16, wherein the aerosolgenerating material comprises between 15 percent and 45 percent by weight of the tobacco leaf blends on a dry weight basis.

[0187] Example 18: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating material further comprises cellulose fibres.Example 19: An aerosol-generating article according to Example 18, wherein the aerosolgenerating material comprises between 1 percent and 15 percent by weight of the cellulose fibres on a dry weight basis.

[0188] Example 20: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating material further comprises tobacco fibres.

[0189] Example 21 : An aerosol-generating article according to Example 20, wherein the aerosolgenerating material comprises between 5 percent and 20 percent by weight of the tobacco fibres on a dry weight basis.

[0190] Example 22: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating material further comprises binders.

[0191] Example 23: An aerosol-generating article according to Example 22, wherein the aerosolgenerating material comprises between 1 percent and 10 percent by weight of the binders on a dry weight basis.

[0192] Example 24: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating material further comprises aerosol formers.

[0193] Example 25: An aerosol-generating article according to Example 24, wherein the aerosolgenerating material comprises between 5 percent and 35 percent by weight of the aerosol formers on a dry weight basis.

[0194] Example 26: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating material further comprises a flavouring agent.

[0195] Example 27: An aerosol-generating article according to Example 26, wherein the flavouring agent comprises glycerine.

[0196] Example 28: An aerosol-generating article according to Example 27, wherein the flavouring agent comprises between 10 percent and 40 percent by weight of the glycerine on a dry weight basis.

[0197] Example 29: An aerosol-generating article according to Example 26, wherein the flavouring agent further comprises organic fibres.

[0198] Example 30: An aerosol-generating article according to Example 29, wherein the flavouring agent comprises between 10 percent and 30 percent by weight of the organic fibres on a dry weight basis.

[0199] Example 31: An aerosol-generating article according to Example 26, wherein the flavouring agent further comprises organic botanical glycerite.

[0200] Example 32: An aerosol-generating article according to Example 31, wherein the flavouring agent comprises between 15 percent and 55 percent by weight of the organic botanical glycerite on a dry weight basis.

[0201] Example 33: An aerosol-generating article according to Example 26, wherein the flavouring agent further comprises organic botanical extracts.Example 34: An aerosol-generating article according to Example 33, wherein the flavouring agent comprises between 1 percent and 15 percent by weight of the organic botanical extracts on a dry weight basis.

[0202] Example 35: An aerosol-generating article according to Example 26, wherein the flavouring agent further comprises botanical essential oils.

[0203] Example 36: An aerosol-generating article according to Example 35, wherein the flavouring agent comprises between 0.5 percent and 5 percent by weight of the botanical essential oils on a dry weight basis.

[0204] Example 37: An aerosol-generating article according to any preceding Example, wherein the outer coating fully encapsulates the core of the aerosol-generating element.

[0205] Example 38: An aerosol-generating article according to any preceding Example, wherein the outer coating comprises an alginate-based formulation.

[0206] Example 39: An aerosol-generating article according to any preceding Example, wherein the outer coating comprises one or more of alginate, alginate-maltodextrin, alginate-galbanum gum, and starch-alginate.

[0207] Example 39.5: An aerosol-generating article according to any preceding Example, wherein the outer coating comprises at least one of carboxymethylated starch and hydroxypropylated starch, (such as Solvitose®), cellulose nano-fibres (CNF), dextrin or chitosan.

[0208] Example 40: An aerosol-generating article according to any preceding Example, wherein the outer coating comprises an anti-microbial substance.

[0209] Example 41: An aerosol-generating article according to Example 40, wherein the antimicrobial substance is heat resistant up to about 250 degrees Celsius.

[0210] Example 42: An aerosol-generating article according to Example 40 or Example 41, wherein the anti-microbial substance is a natural substance.

[0211] Example 43: An aerosol-generating article according to any of Example 40, Example 41, and Example 42, wherein the anti-microbial substance comprises one or more of vanillin, thyme oil, lemongrass extract, carvacrol, methyl cinnamate, nisin, acetic acid, lactic acid, potassium sorbate, Ziziphora persica essential oil and extracts, sodium lactate, sodium diacetate, and pomegranate peel extract.

[0212] Example 44: An aerosol-generating article according to Example 38 or Example 39, wherein the alginate-based formulation is cross-linked with a cross-linking agent.

[0213] Example 45: An aerosol-generating article according to Example 44, wherein the crosslinking agent comprises calcium.

[0214] Example 46: An aerosol-generating article according to Example 44 or Example 45, wherein the cross-linking agent comprises one or more of calcium chloride, calcium chloridecarboxymethylcellulose, calcium gluconate, calcium lactate, and tapioca starch.Example 47: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating elements further comprise an outer substrate disposed between the core substrate and the outer coating.

[0215] Example 48: An aerosol-generating article according to Example 47, wherein the outer substrate is a hydrogel composition.

[0216] Example 49: An aerosol-generating article according to Example 48, wherein the hydrogel composition comprises sodium alginate.

[0217] Example 50: An aerosol-generating article according to Example 49, wherein the hydrogel composition comprises between 1.7 percent and 2.8 percent by weight of the sodium alginate on a dry weight basis.

[0218] Example 51: An aerosol-generating article according to any of Example 48, Example 49, and Example 50, wherein the hydrogel composition further comprises N-isopropylacrylamide.

[0219] Example 52: An aerosol-generating article according to Example 51 , wherein the hydrogel composition comprises between 30 percent and 60 percent by weight of the N-isopropylacrylamide on a dry weight basis.

[0220] Example 53: An aerosol-generating article according to any of Examples 48 to 52, wherein the hydrogel composition further comprises a copolymer of N-isopropylacrylamide and vinyl sulfonic acid.

[0221] Example 54: An aerosol-generating article according to Example 53, wherein the hydrogel composition comprises between 7.5 percent and 20 percent by weight of the copolymer on a dry weight basis.

[0222] Example 55: An aerosol-generating article according to any of Examples 48 to 54, wherein the hydrogel composition further comprises vinyl sulfonic acid.

[0223] Example 56: An aerosol-generating article according to Example 55, wherein the hydrogel composition comprises between 7 percent and 18 percent by weight of the vinyl sulfonic acid on a dry weight basis.

[0224] Example 57: An aerosol-generating article according to any of Examples 48 to 56, wherein the hydrogel composition further comprises a crosslinker.

[0225] Example 58: An aerosol-generating article according to Example 57, wherein the hydrogel composition comprises between 0.05 percent and 0.25 percent by weight of the crosslinker on a dry weight basis.

[0226] Example 59: An aerosol-generating article according to any of Examples 48 to 58, wherein the hydrogel composition further comprises an initiator.

[0227] Example 60: An aerosol-generating article according to Example 59, wherein the hydrogel composition comprises between 0.5 percent and 2.5 percent by weight of the initiator on a dry weight basis.Example 61 : An aerosol-generating article according to any of Examples 48 to 60, wherein the hydrogel composition further comprises a catalyst.

[0228] Example 62: An aerosol-generating article according to Example 61 , wherein the hydrogel composition comprises between 8 percent and 16 percent by weight of the catalyst on a dry weight basis.

[0229] Example 63: An aerosol-generating system for generating an aerosol, the aerosolgenerating system comprising; an aerosol-generating device comprising an electrical power source and a recess for receiving an aerosol-generating article, and an aerosol-generating article according to any preceding Example.

[0230] In the following non-limiting examples, the invention will be further described with reference to the drawings of the accompanying Figures, in which:

[0231] Figure 1 shows an aerosol-generating article according to the present disclosure, Figure 2 shows an aerosol-generating agglomerate according to the present disclosure, Figure 3 shows a schematic representation of the cross sectional structure of an aerosolgenerating element according to a first embodiment of the present disclosure,

[0232] Figure 4 shows a schematic representation of the cross sectional structure of an aerosolgenerating element according to a second embodiment of the present disclosure,

[0233] Figure 5 shows a schematic view of an aerosol-generating device according to an embodiment of the present disclosure, the device configured to engage with an aerosolgenerating article, for example the aerosol-generating article of Figure 1,

[0234] Figure 6 shows a schematic end view of the aerosol-generating device of Figure 5, Figure 7 is a schematic view showing an aerosol-generating article (for example, the aerosol-generating article of Figure 1) in engagement with the aerosol-generating device of Figure 5, and

[0235] Figure 8 is a schematic view of an alternative embodiment to that of Figures 5 to 7, showing an aerosol-generating article in engagement with an aerosol-generating device.

[0236] Figure 1 illustrates a perspective side view of an aerosol-generating article 100 according to the present disclosure. The aerosol-generating article 100 when viewed in plan has a substantially rectangular shape. The aerosol-generating article 100 comprises a substantially planar first external surface 110. The aerosol-generating article comprises a substantially planar second external surface 120 facing in substantially the opposite direction to the first external surface 110. The height of the aerosol-generating article 100, as measured vertically between the first external surface 110 and the second external surface 120, is between 9 millimetres and 17 millimetres. The width of the aerosol-generating article 100, as measured orthogonally from the height dimension, is between 32 millimetres and 42 millimetres. The length of the aerosolgenerating article 100, as measured orthogonally from the height dimension and the width dimension, is between 85 millimetres and 105 millimetres.The aerosol-generating article 100 further comprises a cavity 130 between the first external surface 110 and the second external surface 120. The aerosol-generating article comprises a frame 140 positioned between the first and second external surfaces, wherein the frame 140 partially defines the cavity 130. The frame comprises a periphery wall 141 that circumscribes the cavity 130. The frame 140 is made from paperboard and has a laminated structure. The aerosol-generating article 100 comprises an airflow path defined through the aerosol-generating article 100 between an air inlet 151 and an air outlet 152. The airflow path extends through the cavity 130. The aerosol-generating article 100 has a RTD of less than 20 millimetre H2O. The air inlet 151 and air outlet 152 have the same diameter of at least 8 millimetres. The aerosol-generating article 100 further comprises an aerosol-generating agglomerate 160 located in the cavity 130.

[0237] Figure 2 illustrates a perspective side view of the aerosol-generating agglomerate 160. The aerosol-generating agglomerate 160 comprises a plurality of connected aerosol-generating elements 161. The aerosol-generating agglomerate 150 has a generally cuboidal shape. The aerosol-generating agglomerate 150 has a length (L) of between about 80 millimetres and about 100 millimetres, a width (W) of between about 30 millimetres and about 40 millimetres, and a height (H) of between about 7 millimetres and about 15 millimetres. The plurality of aerosolgenerating elements 161 are substantially spherical and have a mean external diameter. The external diameters of the aerosol-generating elements 361 within the aerosol-generating agglomerate 160 follow a defined statistical dispersion. The statistical dispersion is a statistical dispersion wherein about 20 percent of the aerosol-generating elements have an external diameter that fall outside of one standard deviation of the mean external diameter of the plurality of aerosol-generating elements.

[0238] Figure 3 illustrates a schematic representation of the cross sectional structure of an aerosol-generating element 361 according to a first embodiment of the present disclosure. The aerosol-generating element 361 comprises a core 362 comprising an aerosol-generating material, and an outer coating 363 configured to facilitate connection to adjacent aerosol-generating elements 361. The aerosol-generating element 361 has a median external diameter 370 of between about 0.75 millimetres and about 2.5 millimetres. The outer coating 363 of the aerosolgenerating element has a median thickness 380 of between about 0.03 millimetres and about 0.15 millimetres.

[0239] The aerosol-generating material comprises between about 20 percent and 35 percent by weight of a tobacco leaf blend. The tobacco leaf blend is a blend of bright tobacco, dark tobacco, and aromatic tobacco. The tobacco leaf blend is ground to a particle size of between about170 mesh and 320 mesh.The aerosol-generating material further comprises between about 3 percent by weight and about 7 percent by weight of cellulose fibres on a dry weight basis. The cellulose fibres have a median length of between about 10 micrometers and about 120 micrometers.

[0240] The aerosol-generating material comprises between about 7 percent by weight and about 15 percent by weight of tobacco fibres on a dry weight basis. The tobacco fibres are a blend of tobacco types, specifically a blend of bright tobacco, aromatic tobacco, and dark tobacco. Even more specifically, the tobacco fibres are a blend of Flue-Cured Brazil tobacco, Oriental Turkey tobacco, and Burley Malawi tobacco. The tobacco fibres are derived from stems and ground to a length such that the median length of the tobacco fibres is between about 10 micrometers and about 120 micrometers.

[0241] The aerosol-generating material further comprises between about 1 percent by weight and about 5 percent by weight of a binder on a dry weight basis. The binder comprises CMC compounds such that the water content in the binder is reduced to facilitate a faster drying time of the binder.

[0242] The aerosol-generating material comprises between about 10 percent by weight and about 25 percent by weight of an aerosol former on a dry weight basis. The aerosol former comprises glycerin, menthol, glycerol monoacetate, and dimethyl esters.

[0243] The aerosol-generating material optionally comprises a flavouring agent. The optional flavouring agent is a compound material comprising between about 20 percent by weight and about 30 percent by weight of glycerin on a dry weight basis. The optional flavouring agent further comprises between about 15 percent by weight and about 25 percent by weight of organic fibres on a dry weight basis. The organic fibres are of a botanical variety suitable for and compliant with F&B grade requirement, more specifically the organic fibres are cellulose cotton. The organic fibres have a median length of between about 10 micrometers and about 200 micrometers. The optional flavouring agent further comprises between about 20 percent by weight and about 35 percent by weight of an organic botanical glycerite on a dry weight basis. The organic botanical glycerite comprises botanical cloves, more specifically the botanical glycerite comprises fennel, ginger, and hawthorn berry. The optional flavouring agent comprises between about 2 percent by weight and about 7 percent by weight of organic botanical extracts on a dry weight basis. The organic botanical extracts comprise botanical cloves, more specifically the botanical extracts comprise fennel, ginger, and hawthorn berry. Furthermore, the botanical extracts comprise menthol, more specifically 2-lsopropyl-5-methylcyclohexanol obtained from Chaerophyllum Macrospermum. The optional flavouring agent even further comprises between about 1 percent by weight and about 3 percent by weight of botanical essential oils on a dry weight basis. The botanical essential oils are coconut-based.

[0244] The outer coating 363 partially encapsulates the core 362 of the aerosol-generating element 361. The outer coating 363 is an alginate based formulation compliant with applicableF&B FDA requirements, more specifically the outer coating 363 comprises alginate-maltodextrin. Alternatively, the outer coating comprises a solution of 5% (by weight) Solvitose® in water. The outer coating 363 is cross-linked with calcium chloride, a typical cross-linking agent. The outer coating 363 further comprises an anti-microbial substance compliant with any applicable FDA requirements. More specifically, the anti-microbial substance is a natural substance comprising vanillin, thyme, and potassium sorbate. The anti-microbial substance is heat resistant up to 250 degrees Celsius.

[0245] Figure 4 illustrates a schematic representation of the cross sectional structure of an aerosol-generating element 461 according to a second embodiment of the present disclosure. The aerosol-generating element 461 comprises a core 462 comprising an aerosol-generating material, an outer coating 363 configured to facilitate connection to adjacent aerosol-generating elements 461, and further an outer substrate 464 for flavour immobilisation. The aerosolgenerating material of the core 462 of the second embodiment of the aerosol-generating element 461 is the same aerosol-generating material of the core 362 of the first embodiment of the aerosolgenerating element 361. Furthermore, the outer coating 363 of the second embodiment of the aerosol-generating element 461 is the same as the outer coating 363 of the first embodiment of the aerosol-generating element 361. The core 462 has a median external diameter 480 of between about 0.5 millimetres and about 2.0 millimetres. The outer substrate 464 has a median external diameter 490 of between about 1 millimetre and about 2.5 millimetres.

[0246] The outer substrate 464 of the aerosol-generating element 461 is disposed between the core 462 and the outer coating 363.

[0247] The outer substrate 464 is a hydrogel composition comprising between about 2 percent by weight and about 2.5 percent by weight of sodium alginate on a dry weight basis. The sodium alginate is a natural polysaccharide derived from brown seaweed. The hydrogel composition further comprises between about 40 percent by weight and about 50 percent by weight of N-isopropylacrylamide on a dry weight basis to enhance the formation of the hydrogel composition and increase the sensitivity to changes in temperatures.

[0248] The hydrogel composition comprises a copolymer of N-isopropylacrylamide and vinyl sulfonic acid to enhance the mechanical properties and responsiveness of the hydrogel composition. More specifically, the hydrogel composition between about 10 percent by weight and about 15 percent by weight of the copolymer on a dry weight basis.

[0249] The hydrogel composition further comprises between about 10 percent by weight and about 15 percent by weight of vinyl sulfonic acid on a dry weight basis to enhance the swelling behavior and mechanical strength of the hydrogel composition.

[0250] The hydrogel composition even further comprises between about 0.1 percent by weight and about 0.2 percent by weight of a crosslinker on a dry weight basis to form stable hydrogelnetworks within the hydrogel composition. More specifically, the crosslinker is N,N’-methylenebisacrylamide.

[0251] The hydrogel composition comprises between about 1 percent by weight and about 2 percent by weight of an initiator on a dry weight basis to start the polymerisation process of the hydrogel composition. More specifically, the initiator is ammonium persulfate.

[0252] The hydrogel composition comprises between about 10 percent by weight and about 14 percent by weight of a catalyst on a dry weight basis to accelerate the polymerisation process of the hydrogel composition. The catalyst is N,N,N’,N’-tetramethylethylenediamine.

[0253] Figures 5 and 6 illustrate an aerosol-generating device 6000 configured for use with an aerosol-generating article 100 comprising an aerosol-generating agglomerate 160. The device 6000 is an elongate aerosol-generating device extending between a proximal end 6001 and a distal end 6002. The device 6000 comprises a battery 6010, a controller 6020 and a heater 6030 located within a housing 6040. The controller 6020 controls supply of power from the battery 6010 to the heater 6030. A cavity 6050 is defined in the device 6000, the cavity having an opening 6051 defined in the proximal end 6001 of the device. The opening 6051 is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosol-generating article 100. The cavity 6050 comprises an upper planar surface 6052 and a lower planar surface 6053. The heater 6030 is located in the lower planar surface 6053 to heat a lower surface of the aerosolgenerating article 100 inserted into the cavity 6050. An air-flow path is configured to allow air to flow into the cavity 6050 from outside the device 6000.

[0254] Figure 7 illustrates the device 6000 of Figure 5 in engagement with the aerosol-generating article 100. There is little tolerance between outer surfaces of the aerosol-generating article 100 and the internal surfaces of the cavity 6050. Thus, there is a snug fit between the aerosolgenerating article 600 and the device 6000. As the RTD of the aerosol-generating article 100 is negligible, the RTD of the system formed by the combination of aerosol-generating article 100 and aerosol-generating device 6000 is controlled by the air-flow path defined within the device. When a user has inserted the aerosol-generating article 100 into the cavity 6050, the device 6000 can be operated. The heater 6030 heats a lower surface of the aerosol-generating article 100, and as a result the aerosol-generating agglomerate 160 of the aerosol-generating article 100 is heated. Volatile components of the aerosol-generating agglomerate 160 are evaporated and condense in longitudinal air-flow channels defined within the aerosol-generating article 100 to form an aerosol. The user inhales the aerosol by drawing on the proximal end 101 of the aerosolgenerating article 100. Once the aerosol-generating agglomerate 160 of the aerosol-generating article 100 has been depleted of volatile components, the aerosol-generating article 100 is removed from the cavity 6050 of the device 6000 and disposed of.

[0255] Although Figure 7 shows part of the aerosol-generating article 100 extending outside of the aerosol-generating device 6000, in other embodiments the entirety of an aerosol-generatingarticle 100 may be wholly enclosed within an aerosol-generating device. By way of example, Figure 8 illustrates an alternative embodiment to that of Figure 8, with like features referred to by the same reference numbers but with the addition of a prime symbol For the alternative embodiment of Figure 8, the entirety of aerosol-generating article 100’ is enclosed within the interior of aerosol-generating device 6000’.

[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. The terms “in which” and “wherein” are used synonymously through this specification.

Claims

- 34 - Claims:

1. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising:a first external surface and a second external surface facing in substantially the opposite direction to the first external surface;a cavity between the first external surface and the second external surface;an airflow path defined through the aerosol-generating article between an air inlet and an air outlet, the airflow path extending through the cavity, andan aerosol-generating agglomerate located in the cavity, the aerosol-generating agglomerate comprising a plurality of connected aerosol-generating elements,wherein each element of the plurality of aerosol-generating elements comprises a core comprising an aerosol-generating material, and an outer coating configured to facilitate connection to adjacent aerosol-generating elements.

2. A aerosol-generating article according to claim 1, wherein the aerosol-generating agglomerate has a length of at least 50 millimetres, preferably at least 80 millimetres.

3. A aerosol-generating article according to claim 1 or claim 2, wherein the aerosolgenerating agglomerate has a length of no more than 120 millimetres, preferably no more than 100 millimetres.

4. A aerosol-generating article according to any preceding claim, wherein the aerosolgenerating agglomerate has a height of at least 5 millimetres, preferably at least 7 millimetres.

5. A aerosol-generating article according to any preceding claim, wherein the aerosolgenerating agglomerate has a height of no more than 20 millimetres, preferably no more than 15 millimetres.

6. A aerosol-generating article according to any preceding claim, wherein the aerosolgenerating agglomerate has a width of at least 20 millimetres, preferably at least 30 millimetres.

7. A aerosol-generating article according to any preceding claim, wherein the aerosolgenerating agglomerate has a width of no more than 50 millimetres, preferably no more than 40 millimetres.- 35 -8. A aerosol-generating article according to any preceding claim, wherein the plurality of aerosol-generating elements have a median (D50) external diameter of at least 0.4 millimetres, preferably at least 0.75 millimetres.

9. A aerosol-generating article according to any preceding claim, wherein the plurality of aerosol-generating elements have a median (D50) external diameter of no more than 3.5 millimetres, preferably no more than 2.5 millimetres.

10. A aerosol-generating article according to any preceding claim, wherein the cores of the plurality of aerosol-generating elements have a median (D50) external diameter of at least 0.25 millimetres, preferably at least 0.5 millimetres.

11. An aerosol-generating article according to any preceding claim, wherein the outer coating fully encapsulates the core of the aerosol-generating element.

12. An aerosol-generating article according to claim 11 , wherein the outer coating comprises an alginate-based formulation.

13. An aerosol-generating article according to any preceding claim, wherein the aerosolgenerating elements further comprise an outer substrate disposed between the core substrate and the outer coating.

14. An aerosol-generating article according to claim 13, wherein the outer substrate is a hydrogel composition.

15. An aerosol-generating system for generating an aerosol, the aerosol-generating system comprising;an aerosol-generating device comprising an electrical power source and a recess for receiving an aerosol-generating article, andan aerosol-generating article according to any preceding claim.

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