AEROSOL-GENERATING ARTICLE WITH SUBSTRATE CONFORMING SURFACE
The present disclosure relates to an aerosol-generating article comprising an aerosol-forming substrate.
A typical aerosol-generating article may appear similar to a conventional cigarette. For example, such an aerosol-generating article may be substantially cylindrical and comprise an aerosol-forming substrate and other components such as a mouthpiece filter element and a cooling element, all arranged together in the form of a rod and wrapped in a cigarette paper. Dimensions of typical aerosol-generating articles are often similar to the dimensions of conventional cigarettes.
However, a significant portion of the aerosol-forming substrate in these cylindrical aerosolgenerating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-forming substrate 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. This may be the case regardless of the way in which the aerosol-forming substrate is heated, for example regardless of whether a resistive or inductive heater is used and regardless of whether the aerosol-forming substrate 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.
It is an aim of the present disclosure to provide an aerosol-generating article, in which a greater portion of an aerosol-forming substrate of the aerosol-generating article is sufficiently heated to form an aerosol during use. It is also an aim of the present disclosure to provide an aerosol-generating article that can be manufactured relatively efficiently and cheaply.
According to the present disclosure, there is provided an aerosol-generating article. The aerosol-generating article may be for use with an aerosol-generating device to generate an aerosol. The aerosol generating article may comprise a cavity. The cavity may be defined between an upper surface, a lower surface, and at least one side surface. The aerosol-generating article may comprise an aerosol-forming substrate. The aerosol-forming substrate may be arranged in the cavity. The aerosol-generating article may be defined by a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction. The upper and lower surfaces may be separated from each other in the z direction. The thickness of the aerosolgenerating article may be less than each of the width and the length of the aerosol-generating article. At least one of the upper surface, the lower surface, and the at least one side surface may be a contact surface. At least a portion of the contact surface may be configured to contact the aerosol-forming substrate. At least a portion of the contact surface may be configured to conform to a shape of the aerosol-forming substrate where the surface is in contact with the aerosol-forming substrate.
According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol generating article comprises a cavity defined between an upper surface, a lower surface, and at least one side surface. The aerosol-generating article comprises an aerosol-forming substrate arranged in the cavity. The aerosol-generating article is defined by a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction. The upper and lower surfaces are separated from each other in the z direction. The thickness of the aerosol-generating article is less than each of the width and the length of the aerosol-generating article. At least one of the upper surface, the lower surface, and the at least one side surface is a contact surface. At least a portion of the contact surface is configured to contact the aerosol-forming substrate and to conform to a shape of the aerosol-forming substrate where the surface is in contact with the aerosol-forming substrate.
Configuring at least a portion of at least one of the upper surface, the lower surface, and the at least one side surface as a contact surface, that is configured to contact the aerosol-forming substrate and to conform to a shape of the aerosol-forming substrate where the surface is in contact with the aerosol-forming substrate may advantageously reduce the presence of air gaps or spaces between the aerosol-forming substrate and a surface of the cavity. Advantageously, reducing the presence of air gaps or spaces between the aerosol-forming substrate and surfaces of the cavity may promote the majority of the airflow through the aerosol-generating article to pass through the aerosol-forming substrate. Advantageously, reducing the presence of air gaps or spaces between the aerosol-forming substrate and surfaces of the cavity may increase airflow through the aerosol-forming substrate, rather than around the periphery of the aerosol-forming substrate. Ensuring that as much of the airflow through the aerosol-generating article as possible passes through the aerosol-forming substrate may improve the entrainment of vapour released from the heated aerosol-forming substrate, and increase the delivery of aerosol from the aerosolgenerating article.
At least one of the upper surface, the lower surface, and the at least one side surface is a contact surface. In some embodiments, the upper surface is a contact surface. In some embodiments, the lower surface is a contact surface. In some embodiments, the at least one side surface is a contact surface. In some embodiments, two or more of the upper surface, the lower surface, and the at least one side surface are contact surfaces. The upper surface and the lower surface may be contact surfaces. The upper surface and the at least one side surface may be contact surfaces. The lower surface and the at least one side surface may be contact surfaces. The upper surface, the lower surface, and the at least one side surface may be a contact surface.
The at least one side surface may comprise a first side surface and a second side surface. The first side surface and the second side surface may be separated from each other in the y- direction. The first side surface may be a contact surface. The second side surface may be a contact surface. The first side surface, and the second side surface may be contact surfaces.
At least a portion of the contact surface is configured to contact the aerosol-forming substrate. At least a portion of the contact surface may be in contact with the aerosol-forming substrate.
At least a portion of the contact surface is configured to conform to a shape of the aerosolforming substrate where the surface is in contact with the aerosol-forming substrate. The contact surface may be configured to conform to a shape of the aerosol-forming substrate where the contact surface is in contact with the aerosol-forming substrate.
In some preferred embodiments, at least a portion of the contact surface is non-planar where the contact surface is in contact with the aerosol-forming substrate. In some of these preferred embodiments, the contact surface is substantially planar except where the contact surface is in contact with the aerosol-forming substrate.
As used herein, “conform” refers to the contact surface having a similar form or shape as the outer form or external shape as the aerosol-forming substrate, or assuming a similar form or shape as the outer form or external shape as the aerosol-forming substrate during use. In one example, the contact surface may be deformable, such that the contact surface conforms to an external shape of the aerosol-forming substrate where the contact surface is in contact with the aerosolforming substrate. In another example, the aerosol-forming substrate may have a predefined external shape, and the contact surface may have a predefined external shape that conforms to at least a portion of the predefined external shape of the aerosol-forming substrate where the contact surface is in contact with the aerosol-forming substrate.
In some preferred embodiments, the contact surface is deformable. The contact surface may be deformable such that the contact surface conforms to a shape of the aerosol-forming substrate where the contact surface is in contact with the aerosol-forming substrate. In other words, the contact surface may assume the shape of the aerosol-forming substrate where the contact surface is in contact with the aerosol-forming substrate. In some embodiments, the contact surface is flexible. Advantageously, providing a contact surface that is deformable such that it assumes the external shape of the aerosol-forming substrate where the contact surface is in contact with the aerosol-forming substrate may enable close contact between the external surface of the aerosol- forming substrate and the contact surface. This may minimise the air gaps between the external surface of the aerosol-forming substrate and the contact surface.
The deformable contact surface may be formed from any suitable deformable material. The contact surface may be formed from a deformable or flexible material, such as paper or cardboard.
According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol generating article comprises a cavity defined between an upper surface, a lower surface, and at least one side surface. The aerosol-generating article comprises an aerosol-forming substrate arranged in the cavity. The aerosol-generating article is defined by a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction. The upper and lower surfaces are separated from each other in the z direction. The thickness of the aerosol-generating article is less than each of the width and the length of the aerosol-generating article. At least one of the upper surface, the lower surface, and the at least one side surface is a deformable contact surface. The contact surface is deformable such that the contact surface conforms to a shape of the aerosol-forming substrate where the contact surface is in contact with the aerosol-forming substrate.
In some preferred embodiments, at least a portion of the aerosol-forming substrate has a predefined external shape. In some of these preferred embodiments, at least a portion of the contact surface has a predefined shape. At least a portion of the predefined shape of the contact surface may be the same as at least a portion of the predefined external shape of the aerosolforming substrate. The predefined shape of the contact surface may be the same as the predefined external shape of the aerosol-forming substrate. The predefined shape of the contact surface may conform to the predefined external shape of the aerosol-forming substrate where the contact surface is in contact with the aerosol-forming substrate. Advantageously, providing a contact surface with a predefined shape that is the same as, or conforms to, the predefined external shape of the aerosol-forming substrate where the contact surface is in contact with the aerosol-forming substrate may enable close contact between the external surface of the aerosolforming substrate and the contact surface. This may minimise the air gaps between the external surface of the aerosol-forming substrate and the contact surface.
According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol generating article comprises a cavity defined between an upper surface, a lower surface, and at least one side surface. The aerosol-generating article comprises an aerosol-forming substrate arranged in the cavity. The aerosol-generating article is defined by a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction. The upper and lower surfaces are separated from each other in the z direction. The thickness of the aerosol-generating article is less than each of the width and the length of the aerosol-generating article. At least one of the upper surface, the lower surface, and the at least one side surface is a contact surface having a predefined shape. At least a portion of the aerosol-forming substrate has a predefined external shape, and at least a portion of the predefined shape of the contact surface conforms to at least a portion of the predefined external shape of the aerosol-forming substrate where the contact surface is in contact with the aerosol-forming substrate.
In some preferred embodiments, the aerosol-generating article comprises a frame. The frame may define the at least one side surface. The frame may define at least one external side surface of the aerosol-generating article.
In some particularly preferred embodiments, the aerosol-generating article comprises an upper layer and a lower layer. The upper layer may define the upper surface. The lower layer may define the lower surface. The upper layer may define an upper external surface of the aerosolgenerating article. The lower layer may define a lower external surface of the aerosol-generating article. In some particularly preferred embodiments, the aerosol-generating article comprises an upper layer and a lower layer, the upper layer defining the upper surface, and the lower layer defining the lower surface, and aerosol-generating article comprises a frame arranged between the upper layer and the lower layer, the frame defining the at least one side surface.
In some of these particularly preferred embodiments, at least one of the upper layer and the lower layer may be a contact surface. At least one of the upper layer and the lower layer may be a deformable contact surface. At least one of the upper layer and the lower layer may be a deformable contact surface that assumes the external shape of the aerosol-forming substrate where the contact surface is in contact with the aerosol-forming substrate. In some of these particularly preferred embodiments, the frame has a height in the z-direction, the aerosol-forming substrate has a height in the z-direction, and the height of at least a portion of the frame is less than the height of the aerosol-forming substrate.
The aerosol-forming substrate may have a length extending in the x-direction. A crosssection of the aerosol-forming substrate at a point along the length of the aerosol-forming substrate may have a perimeter. The at least one contact surface may be in contact with the aerosol-forming substrate around substantially the entire perimeter of the cross-section of the aerosol-forming substrate at a point along the length of the aerosol-forming substrate. Advantageously, providing contact between at least one contact surface around the entire perimeter of a cross-section of the aerosol-forming substrate at a point along the length of the aerosol-forming substrate may reduce the presence of air gaps or spaces between the aerosol-forming substrate and a surface of the cavity. Advantageously, reducing the presence of air gaps or spaces between the aerosol-forming substrate and surfaces of the cavity may promote the majority of the airflow through the aerosolgenerating article to pass through the aerosol-forming substrate.
In some embodiments, the cavity of the aerosol-generating article is filled with aerosolforming substrate. In some embodiments, the cavity of the aerosol-generating article is filled with aerosol-forming substrate such that the upper surface, the lower surface, and the at least one side surface defining the cavity are all in contact with the aerosol-forming substrate.
In some embodiments, the cavity of the aerosol-generating article is not filled with aerosolforming substrate. In some embodiments, at least one of the at least one contact surface is not in contact with the aerosol-forming substrate when the aerosol-generating article is not received in a cavity of an aerosol-generating device. In some of these embodiments, the at least one of the at least one contact surface is deformable. Preferably, when the aerosol-generating article is received in the cavity of an aerosol-generating device, the aerosol-generating device and the aerosolgenerating article are configured to engage to deform the at least one of the at least one contact surface to bring the at least one of the at least one contact surface into contact with an external surface of the aerosol-forming substrate.
In some embodiments, the aerosol-generating article comprises a first end portion and a second end portion. The first end portion and the second end portion may be separated from each other in the x-direction.
In some preferred embodiments, the aerosol-generating article comprises a narrow portion arranged between the first end portion and the second end portion.
The narrow portion may have a minimum width in the y-direction that is less than a maximum width of the first end portion and less than a maximum width of the second end portion. The narrow portion may have a minimum height in the z-direction that is less than a maximum height of the first end portion and less than a maximum height of the second end portion. The narrow portion may comprise a notch, or a recess, or a channel, or a groove in an external surface of the aerosolgenerating article. The narrow portion may comprise a pair of opposing notches, or a pair of opposing recesses, or a pair of opposing channels, or a pair of opposing grooves in opposing external surfaces of the aerosol-generating article.
Providing a narrow portion of the aerosol-generating article, between the first end portion and the second end portion, may provide several different advantages. For example, a narrow portion may provide a user holding the aerosol-generating article with improved grip on the aerosolgenerating article, enabling a user to remove the aerosol-generating article from a cavity of an aerosol-generating device more easily. For example, a narrow portion may enable the aerosolgenerating article to be held by an aerosol-generating device, within a cavity of the aerosolgenerating device, to prevent the aerosol-generating article from falling out of the cavity, such as under the influence of gravity. For example, a narrow portion of the aerosol-generating article may increase the amount of contact between the aerosol-forming substrate and surfaces of the cavity, reducing air gaps between the aerosol-forming substrate and the surface of the cavity, and increasing airflow through the aerosol-forming substrate, rather than around the periphery of the aerosol-forming substrate.
The aerosol-generating article comprises a cavity. The cavity may be disposed between the upper external surface and the lower external surface. In some preferred embodiments, the aerosolforming substrate is arranged in the cavity. In some of these embodiments, the narrow portion is spaced from the aerosol-forming substrate in the x-direction. In some of these embodiments, the narrow portion is arranged at the aerosol-forming substrate in the cavity.
Arranging the narrow portion at the aerosol-forming substrate may reduce the presence of air gaps or spaces between the aerosol-forming substrate and the surfaces of the cavity.
Advantageously, reducing the presence of air gaps or spaces between the aerosol-forming substrate and the surfaces of the cavity may promote the majority of the airflow through the aerosol-generating article to pass through the aerosol-forming substrate. Ensuring that as much of the airflow through the aerosol-generating article as possible passes through the aerosol-forming substrate may improve the entrainment of vapour released from the heated aerosol-forming substrate, and increase the delivery of aerosol from the aerosol-generating article.
In some preferred embodiments, the aerosol-generating article comprises a frame. The frame may be disposed between the upper external surface and the lower external surface. Preferably, the frame comprises at least one side wall.
In some of these preferred embodiments in which the aerosol-generating article comprises a frame comprising at least one side wall, the at least one side wall may have a minimum height in the z-direction at the narrow portion. The minimum height of the at least one side wall at the narrow portion may be less than a maximum height of the at least one side wall at the first end portion. The minimum height of the at least one side wall at the narrow portion may be less than a maximum height of the at least one side wall at the second end portion. Where an aerosol-forming substrate is arranged in the cavity, and the narrow portion is arranged at the aerosol-forming substrate, the aerosol-forming substrate may have a maximum height that is greater than the minimum height of the at least one side wall at the narrow portion.
In some particularly preferred embodiments, the frame comprises a first side wall and a second side wall, wherein the first side wall and the second side wall are separated in the y- direction. The first side wall may have a minimum height in the z-direction at the narrow portion. The minimum height of the first side wall at the narrow portion may be less than a maximum height of the first side wall at the first end portion. The minimum height of the first side wall at the narrow portion may be less than a maximum height of the first side wall at the second end portion. The second side wall may have a minimum height in the z-direction at the narrow portion. The minimum height of the second side wall at the narrow portion may be less than a maximum height of the second side wall at the first end portion. The minimum height of the second side wall at the narrow portion may be less than a maximum height of the second side wall at the second end portion.
Where the aerosol-generating article comprises a cavity, the frame may at least partially define the cavity. Where the aerosol-generating article has a frame with at least one side wall, the frame at least partially defines a cavity, and the aerosol-forming substrate is arranged in the cavity, the at least one side wall of the frame may have a minimum height at the narrow portion that is less than the maximum height of the aerosol-forming substrate at the narrow portion. In some of these embodiments, the height of the aerosol-forming substrate at the narrow portion is greater than the minimum height of the at least one side wall of the frame at the narrow portion.
The narrow portion may have any suitable form. The narrow portion may comprises a notch in an external surface of the aerosol-generating article. The narrow portion may comprise a recess in an external surface of the aerosol-generating article. The narrow portion may comprise a channel in an external surface of the aerosol-generating article. The narrow portion may comprise a groove in an external surface of the aerosol-generating article.
The notch, recess, channel, or groove may extend across a portion of the width of the aerosol-generating article. The notch, recess, channel, or groove may extend across the width of the aerosol-generating article. The notch, recess, channel, or groove may extend across the entire width of the aerosol-generating article.
The notch, recess, channel, or groove may extend across a portion of the height of the aerosol-generating article. The notch, recess, channel, or groove may extend across the height of the aerosol-generating article. The notch, recess, channel, or groove may extend across the entire height of the aerosol-generating article.
The notch, recess, channel, or groove may circumscribe the aerosol-generating article.
The narrow portion may comprise a pair of opposing notches in opposing external surfaces of the aerosol-generating article. The narrow portion may comprise a pair of opposing recesses in opposing external surfaces of the aerosol-generating article. The narrow portion may comprise a pair of opposing channels in opposing external surfaces of the aerosol-generating article. The narrow portion may comprise a pair of opposing grooves in opposing external surfaces of the aerosol-generating article.
The aerosol-generating article may have any suitable length. The aerosol-generating article may have a length greater than or equal to 15 millimetres, or greater than or equal to 20 millimetres, or greater than or equal to 25 millimetres, or greater than or equal to 30 millimetres, or greater than or equal to 35 millimetres, or greater than or equal to 40 millimetres.
The aerosol-generating article may have a length less than or equal to 45 millimetres, or less than or equal to 40 millimetres, or less than or equal to 35 millimetres, or less than or equal to 30 millimetres.
The aerosol-generating article may have a length of between 10 millimetres and 100 millimetres, or between 10 millimetres and 50 millimetres, or between 10 millimetres and 40 millimetres, or between 12 millimetres and 30 millimetres, or between 14 millimetres and 26 millimetres, or between 16 millimetres and 24 millimetres, or between 18 millimetres and 22 millimetres, or between 15 millimetres and 45 millimetres, or between 20 millimetres and 40 millimetres, or between 20 millimetres and 35 millimetres, or between 25 millimetres and 30 millimetres.
The aerosol-generating article may have a length of about 18 millimetres, or about 19 millimetres, or about 20 millimetres, or about 21 millimetres, or about 22 millimetres.
The separation between the upper external surface and the lower external surface may define the height of the aerosol-generating article.
The aerosol-generating article may have any suitable height.
The aerosol-generating article may have a height greater or equal to 0.3 millimetres, or greater than or equal to 0.4 millimetres, or greater than or equal to 0.5 millimetres, or greater than or equal to 0.7 millimetres, or greater than or equal to 0.8 millimetres, or greater than or equal to 0.9 millimetres, greater than or equal to 1 millimetre, or greater than or equal to 1 .5 millimetres, or greater than or equal to 2 millimetres, or greater than or equal to 2.5 millimetres, or greater than or equal to 3 millimetres, or greater than or equal to 3.5 millimetres, or greater than or equal to 4 millimetres, or greater than or equal to 4.5 millimetres, or greater than or equal to 5 millimetres, or greater than or equal to 6 millimetres, or greater than or equal to 7 millimetres, or greater than or equal to 8 millimetres, or greater than or equal to 9 millimetres, or greater than or equal to 10 millimetres, or greater than or equal to 12 millimetres, or greater than or equal to 14 millimetres, or greater than or equal to 16 millimetres, or greater than or equal to 18 millimetres, or greater than or equal to 20 millimetres, or greater than or equal to 22 millimetres.
The aerosol-generating article may have a height less than or equal to 25 millimetres, or less than or equal to 23 millimetres, or less than or equal to 21 millimetres, or less than or equal to 19 millimetres, or less than or equal to 17 millimetres, or less than or equal to 15 millimetres, or less than or equal to 13 millimetres, or less than or equal to 11 millimetres, or less than or equal to 10 millimetres, or less than or equal to 9 millimetres, or less than or equal to 8 millimetres, or less than or equal to 7 millimetres, or less than or equal to 6 millimetres, or less than or equal to 5.5 millimetres, or less than or equal to 5 millimetres, or less than or equal to 4.5 millimetres, or less than or equal to 4 millimetres, or less than or equal to 3.5 millimetres, or less than or equal to 3 millimetres, or less than or equal to 2.5 millimetres, or less than or equal to 2 millimetres, or less than or equal to 1 millimetre, or less than or equal to 0.9 millimetres, or less than or equal to 0.8 millimetres, or less than or equal to 0.7 millimetres, or less than or equal to 0.6 millimetres, or less than or equal to 0.5 millimetres.
The aerosol-generating article may have a height of between 0.3 millimetres and 25 millimetres, or between 0.4 millimetres and 23 millimetres, or between 0.5 millimetres and 21 millimetres, or between 0.6 millimetres and 19 millimetres, or between 0.7 millimetres and 17 millimetres, or between 0.8 millimetres and 15 millimetres, or between 0.9 millimetres and 13 millimetres, or between 1 millimetres and 10 millimetres, or between 1 millimetres and 5 millimetres, or between 1.2 millimetres and 8 millimetres, or between 1 .4 millimetres and 7 millimetres, or between 1 .5 millimetres and 5 millimetres, or between 1.5 millimetres and 4 millimetres, or between 1.5 millimetres and 3 millimetres, or between 1.5 millimetres and 2 millimetres, or between 1.6 millimetres and 6 millimetres, or between 1.7 millimetres and 5 millimetres, or between 2 millimetres and 4.5 millimetres, or between 2.5 millimetres and 4 millimetres, or between 3 millimetres and 3.5 millimetres.
The aerosol-generating article may have a height of about 1.7 millimetres, or about 4.5 millimetres, or about 2 millimetres, or about 3 millimetres, or about 4 millimetres.
As used above, the “height” of the aerosol-generating article is the maximum height of the aerosol-generating article. The aerosol-generating article has a maximum height and a minimum height. Where the maximum height and the minimum height are equal, the aerosol-generating article has an entirely consistent height along its length and width, and the ratio of the minimum height of the aerosol-generating article to the maximum height of the aerosol-generating article is 1 .
The ratio of the minimum height of the aerosol-generating article to the maximum height of the aerosol-generating article may be greater than or equal to 0.5, or greater than or equal to 0.55, or greater than or equal to 0.6, or greater than or equal to 0.65, or greater than or equal to 0.7, or greater than or equal to 0.75, or greater than or equal to 0.8, or greater than or equal to 0.85, or greater than or equal to 0.9, or greater than or equal to 0.95, or about 1 .
The ratio of the minimum height of the aerosol-generating article to the maximum height of the aerosol-generating article may be less than or equal to 1 , or less than or equal to 0.95, or less than or equal to 0.9, or less than or equal to 0.85, or less than or equal to 0.8, or less than or equal to 0.75, or less than or equal to 0.7. The ratio of the minimum height of the aerosol-generating article to the maximum height of the aerosol-generating article may be between 0.5 and 1 , or between 0.55 and 1 , or between 0.6 and 1 , or between 0.65 and 1 , or between 0.7 and 1 , or between 0.75 and 1 , or between 0.8 and 1 , or between 0.85 and 1 , or between 0.9 and 1 , or between 0.95 and 1 , or about 1 .
The aerosol-generating article may have any suitable width.
The aerosol-generating article may have a width equal to greater than 3 millimetres, or greater than 5 millimetres, or greater than 7.5 millimetres, or greater than 9 millimetres, or greater than 11 millimetres, or greater than 13 millimetres.
The aerosol-generating article may have a width less than or equal to 17 millimetres, or less than or equal to 15 millimetres, or less than or equal to 12.5 millimetres, or less than or equal to 11 millimetres, or less than or equal to 9 millimetres.
The aerosol-generating article may have a width of between 3 millimetres and 20 millimetres, or between 3 millimetres and 17 millimetres, or between 5 millimetres and 20 millimetres, or between 5 millimetres and 15 millimetres, or between 7.5 millimetres and 12.5 millimetres, or between 8 millimetres and 18 millimetres, or between 9 millimetres and 11 millimetres, or between 10 millimetres and 16 millimetres, or between 11 millimetres and 15 millimetres, or between 12 millimetres and 14 millimetres.
The aerosol-generating article may have a width of about 10 millimetres, or about 11 millimetres, or about 12 millimetres, or about 13 millimetres, or about 14 millimetres, or about 15 millimetres, or about 16 millimetres.
As used above, the “width” of the aerosol-generating article is the maximum width of the aerosol-generating article. The aerosol-generating article has a maximum width and a minimum width. Where the maximum width and the minimum width are equal, the aerosol-generating article has an entirely consistent width along its length and height, and the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article is 1 .
The ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article may be greater than or equal to 0.5, or greater than or equal to 0.55, or greater than or equal to 0.6, or greater than or equal to 0.65, or greater than or equal to 0.7, or greater than or equal to 0.75, or greater than or equal to 0.8, or greater than or equal to 0.85, or greater than or equal to 0.9, or greater than or equal to 0.95, or about 1 .
The ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article may be less than or equal to 1 , or less than or equal to 0.95, or less than or equal to 0.9, or less than or equal to 0.85, or less than or equal to 0.8, or less than or equal to 0.75, or less than or equal to 0.7. The ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article may be between 0.5 and 1 , or between 0.55 and 1 , or between 0.6 and 1 , or between 0.65 and 1 , or between 0.7 and 1 , or between 0.75 and 1 , or between 0.8 and 1 , or between 0.85 and 1 , or between 0.9 and 1 , or between 0.95 and 1 , or about 1 .
A ratio between the length and the height of the aerosol-generating article, and between the width and the height of the aerosol-generating article may be greater than 2:1 , greater than 5:1 , greater than 10:1 , greater than 12:1 , or greater than 15:1 .
A ratio between the length and the height of the aerosol-generating article, and between the width and the height of the aerosol-generating article may be less than 15:1 , less than 12:1 , less than 10:1 , less than 5:1 , or less than 2.5:1 .
A ratio between the length and the height of the aerosol-generating article, and between the width and the height of the aerosol-generating article may be between 2:1 and 15:1 , between 2:1 and 12:1 , between 2:1 and 10:1 , or between 5:1 and 10:1.
A ratio between the length and the width of the aerosol-generating article may be greater than 1 :1 , greater than 2:1 , greater than 3:1 , greater than 4:1 , or greater than 5:1 .
A ratio between the length and the width of the aerosol-generating article may be less than 10:1 , less than 8:1 , less than 5:1 , less than 4:1 , less than 3:1 , or less than 2:1 .
A ratio between the length and the width of the aerosol-generating article may be between 1 :1 and 10:1 , between 1 :1 and 5:1 , between 1 :1 and 4:1 , between 1 :1 and 3:1 , between 2:1 and 4:1 , or between 2:1 and 3:1 .
In some embodiments, the at least one of the at least one contact surface is deformable, and when the aerosol-generating article is received in the cavity of an aerosol-generating device, the aerosol-generating device and the aerosol-generating article are configured to engage to deform the at least one of the at least one contact surface to bring the at least one of the at least one contact surface into contact with an external surface of the aerosol-forming substrate.
Where one or both of the upper surface and the lower surface is a contact surface, and the contact surface is deformable, deformation of the contact surface by the aerosol-generating device may reduce the minimum height of the aerosol-generating article, resulting in an aerosol-generating article that has a lower ratio of the minimum height of the aerosol-generating article to the maximum height of the aerosol-generating article than before deformation.
Where one or both of the upper surface and the lower surface is a contact surface, and the contact surface is deformable, before deformation of the contact surface by an aerosol-generating device, the ratio of the minimum height of the aerosol-generating article to the maximum height of the aerosol-generating article may be greater than or equal to 0.5, or greater than or equal to 0.55, or greater than or equal to 0.6, or greater than or equal to 0.65, or greater than or equal to 0.7, or greater than or equal to 0.75, or greater than or equal to 0.8, or greater than or equal to 0.85, or greater than or equal to 0.9, or greater than or equal to 0.95, or about 1 .
Where one or both of the upper surface and the lower surface is a contact surface, and the contact surface is deformable, before deformation of the contact surface by an aerosol-generating device, the ratio of the minimum height of the aerosol-generating article to the maximum height of the aerosol-generating article may be less than or equal to 1 , or less than or equal to 0.95, or less than or equal to 0.9, or less than or equal to 0.85, or less than or equal to 0.8, or less than or equal to 0.75, or less than or equal to 0.7.
Where one or both of the upper surface and the lower surface is a contact surface, and the contact surface is deformable, before deformation of the contact surface by an aerosol-generating device, the ratio of the minimum height of the aerosol-generating article to the maximum height of the aerosol-generating article may be between 0.5 and 1 , or between 0.55 and 1 , or between 0.6 and 1 , or between 0.65 and 1 , or between 0.7 and 1 , or between 0.75 and 1 , or between 0.8 and 1 , or between 0.85 and 1 , or between 0.9 and 1 , or between 0.95 and 1 , or about 1 .
Where one or both of the upper surface and the lower surface is a contact surface, and the contact surface is deformable, when the contact surface is deformed by an aerosol-generating device, the ratio of the minimum height of the aerosol-generating article to the maximum height of the aerosol-generating article may be greater than or equal to 0.3, or greater than or equal to 0.35, or greater than or equal to 0.4, or greater than or equal to 0.45, or greater than or equal to 0.5, or greater than or equal to 0.55, or greater than or equal to 0.6, or greater than or equal to 0.65, or greater than or equal to 0.7, or greater than or equal to 0.75, or greater than or equal to 0.8, or greater than or equal to 0.85, or greater than or equal to 0.9.
Where one or both of the upper surface and the lower surface is a contact surface, and the contact surface is deformable, when the contact surface is deformed by an aerosol-generating device, the ratio of the minimum height of the aerosol-generating article to the maximum height of the aerosol-generating article may be less than or equal to 1 , or less than or equal to 0.95, or less than or equal to 0.9, or less than or equal to 0.85, or less than or equal to 0.8, or less than or equal to 0.75, or less than or equal to 0.7, or less than or equal to 0.65, or less than or equal to 0.6, or less than or equal to 0.55, or less than or equal to 0.5, or less than or equal to 0.45, or less than or equal to 0.4.
Where one or both of the upper surface and the lower surface is a contact surface, and the contact surface is deformable, when the contact surface is deformed by an aerosol-generating device, the ratio of the minimum height of the aerosol-generating article to the maximum height of the aerosol-generating article may be between 0.3 and 1 , or between 0.3 and 0.95, or between 0.4 and 0.95, or between 0.45 and 0.9, or between 0.5 and 0.9, or between 0.55 and 0.85, or between 0.6 and 0.85.
Where one or both of the upper surface and the lower surface is a contact surface, and the contact surface is deformable, the ratio between the ratio of the minimum height of the aerosolgenerating article to the maximum height of the aerosol-generating article when the contact surface is deformed by an aerosol-generating device and the ratio of the minimum height of the aerosolgenerating article to the maximum height of the aerosol-generating article before deformation of the contact surface by an aerosol-generating device is less than 1 .
Where one or both of the upper surface and the lower surface is a contact surface, and the contact surface is deformable, the ratio between the ratio of the minimum height of the aerosolgenerating article to the maximum height of the aerosol-generating article when the contact surface is deformed by an aerosol-generating device and the ratio of the minimum height of the aerosolgenerating article to the maximum height of the aerosol-generating article before deformation of the contact surface by an aerosol-generating device may be greater than or equal to 0.3, or greater than or equal to 0.35, or greater than or equal to 0.4, or greater than or equal to 0.45, or greater than or equal to 0.5, or greater than or equal to 0.55, or greater than or equal to 0.6, or greater than or equal to 0.65, or greater than or equal to 0.7, or greater than or equal to 0.75, or greater than or equal to 0.8, or greater than or equal to 0.85, or greater than or equal to 0.9
Where one or both of the upper surface and the lower surface is a contact surface, and the contact surface is deformable, the ratio between the ratio of the minimum height of the aerosolgenerating article to the maximum height of the aerosol-generating article when the contact surface is deformed by an aerosol-generating device and the ratio of the minimum height of the aerosolgenerating article to the maximum height of the aerosol-generating article before deformation of the contact surface by an aerosol-generating device may be less than or equal to 1 , or less than or equal to 0.95, or less than or equal to 0.9, or less than or equal to 0.85, or less than or equal to 0.8, or less than or equal to 0.75, or less than or equal to 0.7, or less than or equal to 0.65, or less than or equal to 0.6, or less than or equal to 0.55, or less than or equal to 0.5, or less than or equal to 0.45, or less than or equal to 0.4
Where one or both of the upper surface and the lower surface is a contact surface, and the contact surface is deformable, the ratio between the ratio of the minimum height of the aerosolgenerating article to the maximum height of the aerosol-generating article when the contact surface is deformed by an aerosol-generating device and the ratio of the minimum height of the aerosolgenerating article to the maximum height of the aerosol-generating article before deformation of the contact surface by an aerosol-generating device may be between 0.3 and 0.95, or between 0.4 and 0.95, or between 0.45 and 0.9, or between 0.5 and 0.9, or between 0.55 and 0.85, or between 0.6 and 0.85.
Where the at least one side surface is a contact surface, and the contact surface is deformable, deformation of the contact surface by the aerosol-generating device may reduce the minimum width of the aerosol-generating article, resulting in an aerosol-generating article that has a lower ratio of the minimum width of aerosol-generating article to the maximum width of the aerosol-generating article than before deformation.
Where the at least one side surface is a contact surface, and the contact surface is deformable, before deformation of the contact surface by an aerosol-generating device, the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article may be greater than or equal to 0.5, or greater than or equal to 0.55, or greater than or equal to 0.6, or greater than or equal to 0.65, or greater than or equal to 0.7, or greater than or equal to 0.75, or greater than or equal to 0.8, or greater than or equal to 0.85, or greater than or equal to 0.9, or greater than or equal to 0.95, or about 1 .
Where the at least one side surface is a contact surface, and the contact surface is deformable, before deformation of the contact surface by an aerosol-generating device, the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article may be less than or equal to 1 , or less than or equal to 0.95, or less than or equal to 0.9, or less than or equal to 0.85, or less than or equal to 0.8, or less than or equal to 0.75, or less than or equal to 0.7.
Where the at least one side surface is a contact surface, and the contact surface is deformable, before deformation of the contact surface by an aerosol-generating device, the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article may be between 0.5 and 1 , or between 0.55 and 1 , or between 0.6 and 1 , or between 0.65 and 1 , or between 0.7 and 1 , or between 0.75 and 1 , or between 0.8 and 1 , or between 0.85 and 1 , or between 0.9 and 1 , or between 0.95 and 1 , or about 1 .
Where the at least one side surface is a contact surface, and the contact surface is deformable, when the contact surface is deformed by an aerosol-generating device, the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article may be greater than or equal to 0.3, or greater than or equal to 0.35, or greater than or equal to 0.4, or greater than or equal to 0.45, or greater than or equal to 0.5, or greater than or equal to 0.55, or greater than or equal to 0.6, or greater than or equal to 0.65, or greater than or equal to 0.7, or greater than or equal to 0.75, or greater than or equal to 0.8, or greater than or equal to 0.85, or greater than or equal to 0.9.
Where the at least one side surface is a contact surface, and the contact surface is deformable, when the contact surface is deformed by an aerosol-generating device, the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article may be less than or equal to 1 , or less than or equal to 0.95, or less than or equal to 0.9, or less than or equal to 0.85, or less than or equal to 0.8, or less than or equal to 0.75, or less than or equal to 0.7, or less than or equal to 0.65, or less than or equal to 0.6, or less than or equal to 0.55, or less than or equal to 0.5, or less than or equal to 0.45, or less than or equal to 0.4.
Where the at least one side surface is a contact surface, and the contact surface is deformable, when the contact surface is deformed by an aerosol-generating device, the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article may be between 0.3 and 1 , or between 0.3 and 0.95, or between 0.4 and 0.95, or between 0.45 and 0.9, or between 0.5 and 0.9, or between 0.55 and 0.85, or between 0.6 and 0.85.
Where the at least one side surface is a contact surface, and the contact surface is deformable, the ratio between the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article when the contact surface is deformed by an aerosol-generating device and the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article before deformation of the contact surface by an aerosol-generating device is less than 1.
Where the at least one side surface is a contact surface, and the contact surface is deformable, the ratio between the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article when the contact surface is deformed by an aerosol-generating device and the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article before deformation of the contact surface by an aerosol-generating device may be greater than or equal to 0.3, or greater than or equal to 0.35, or greater than or equal to 0.4, or greater than or equal to 0.45, or greater than or equal to 0.5, or greater than or equal to 0.55, or greater than or equal to 0.6, or greater than or equal to 0.65, or greater than or equal to 0.7, or greater than or equal to 0.75, or greater than or equal to 0.8, or greater than or equal to 0.85, or greater than or equal to 0.9
Where the at least one side surface is a contact surface, and the contact surface is deformable, the ratio between the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article when the contact surface is deformed by an aerosol-generating device and the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article before deformation of the contact surface by an aerosol-generating device may be less than or equal to 1 , or less than or equal to 0.95, or less than or equal to 0.9, or less than or equal to 0.85, or less than or equal to 0.8, or less than or equal to 0.75, or less than or equal to 0.7, or less than or equal to 0.65, or less than or equal to 0.6, or less than or equal to 0.55, or less than or equal to 0.5, or less than or equal to 0.45, or less than or equal to 0.4 Where the at least one side surface is a contact surface, and the contact surface is deformable, the ratio between the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article when the contact surface is deformed by an aerosol-generating device and the ratio of the minimum width of the aerosol-generating article to the maximum width of the aerosol-generating article before deformation of the contact surface by an aerosol-generating device may be between 0.3 and 0.95, or between 0.4 and 0.95, or between 0.45 and 0.9, or between 0.5 and 0.9, or between 0.55 and 0.85, or between 0.6 and 0.85.
An air flow channel may be defined between the upper external surface and the lower external surface.
In some preferred embodiments, the upper external surface is substantially planar and the lower external surface is substantially planar. In some particularly preferred embodiments, the planar upper external surface and the planar lower external surface extend substantially in parallel planes. The aerosol-generating article may have a constant height along the length of the aerosolgenerating article. The aerosol-generating article may have a constant height along the width of the aerosol-generating article.
Where the aerosol-generating article has a narrow portion having a minimum height in the z-direction that is less than a maximum height of the first end portion and less than a maximum height of the second end portion, the planar upper external surface and the planar lower external surface may be non-planar at the narrow portion. Where the aerosol-generating article has a narrow portion having a minimum height in the z-direction that is less than a maximum height of the first end portion and less than a maximum height of the second end portion, the aerosol-generating article may have a constant height along the length of the aerosol-generating article except for at the narrow portion. Where the aerosol-generating article has a narrow portion having a minimum height in the z-direction that is less than a maximum height of the first end portion and less than a maximum height of the second end portion, the aerosol-generating article may have a constant height along the width of the aerosol-generating article except for at the narrow portion.
In some preferred embodiments, the aerosol-generating article comprises a first external side surface, and a second external side surface, the second external side surface being spaced from the first external side surface in the y-direction. In some particularly preferred embodiments, the first external side surface is substantially planar, and the second external side surface is substantially planar. The planar first external side surface and the planar second external side surface may extend in parallel planes. The aerosol-generating article may have a constant width along the length of the aerosol-generating article. The aerosol-generating article may have a constant width along the height of the aerosol-generating article. Where the aerosol-generating article has a narrow portion having a minimum width in the y-direction that is less than a maximum width of the first end portion and less than a maximum width of the second end portion, the planar first external side surface, and the planar second external side surface may be non-planar at the narrow portion. Where the aerosol-generating article has a narrow portion having a minimum width in the y-direction that is less than a maximum width of the first end portion and less than a maximum width of the second end portion, the aerosol-generating article may have a constant width along the length of the aerosol-generating article except for at the narrow portion. Where the aerosol-generating article has a narrow portion having a minimum width in the y-direction that is less than a maximum width of the first end portion and less than a maximum width of the second end portion, the aerosol-generating article may have a constant width along the height of the aerosol-generating article except for at the narrow portion.
According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising an aerosol-forming substrate for producing an aerosol, the aerosol-generating article being a planar aerosol-generating article having a base defined by a length extending in an x direction, a width extending in a y direction, and a height extending in a z direction.
The height of the aerosol-generating article is less than both of the length and width of the aerosol-generating article. For the purpose of the present disclosure, the “height” of the aerosolgenerating article may also be referred to as the “thickness” of the aerosol-generating article.
According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising an aerosol-forming substrate for producing an aerosol, the aerosol-generating article comprising a substantially planar upper surface defined by a length extending in an x direction and a width extending in a y direction, and a substantially planar lower surface defined by a length extending in an x direction and a width extending in a y direction. The substantially planar upper surface and the substantially planar lower surface may be vertically spaced from each other by a height defined in a z direction.
Aerosol-generating articles according to the present disclosure may preferably be substantially flat articles or substantially planar articles. Such articles have a large base area relative to the volume of the article. In particular, the height of the aerosol-generating article may be less than 50 percent of both the length and width of the aerosol-generating article. Advantageously, a larger base area may provide greater surface area for heating by a planar heater of an aerosol-generating device. Advantageously, a smaller height may allow a smaller temperature gradient or difference across the height of the aerosol-generating article during heating. For example, where the base of the aerosolgenerating article is in contact with, and heated by, a planar heater, there may be a smaller temperature difference between the base and an upper surface opposing the base if the spacing, or height, between the base and the upper surface is smaller. Advantageously, this may allow heating of a greater proportion of the aerosol-forming substrate of the aerosol-generating article to a temperature at which an aerosol is released, whilst minimising the risk of burning the hottest portion of the substrate closest to the heater. Alternatively, or in addition, this may reduce a time required to heat the aerosol-forming substrate sufficiently to release an aerosol.
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 aerosolgenerating 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 aerosolgenerating 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.
Unless otherwise specified, the resistance to draw (RTD) is measured in accordance with ISO 6565-2015. The RTD refers to the pressure required to force air through the full length of a component, such as the aerosol-generating article. The terms “pressure drop” or “draw resistance” of a component or article may also refer to the “resistance to draw”. Such terms generally refer to the measurements made in accordance with ISO 6565-2015 and are normally carried out at under test at a volumetric flow rate of about 17.5 millilitres per second at the output or downstream end of the measured component at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr) and a relative humidity of about 60%.
The aerosol-generating article according to any of the aspects disclosed herein may comprise substantially planar upper and lower surfaces. A vertical separation between the substantially planar upper and lower surfaces may define a height (for example, a z dimension) of the aerosol-generating article. An air flow channel may be defined between the substantially planar upper and lower 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. One or both of the substantially planar upper and lower surfaces may comprise an aerosol-forming substrate. The aerosol-generating article may comprise upper and lower layers, the upper layer forming the substantially planar upper surface and the lower layer forming the substantially planar lower surface. At least one of the upper and lower layers may comprise or consist of aerosol-forming substrate. According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer. At least one of the first planar layer, the second planar layer and the corrugated layer may comprise or consist of an aerosol-forming substrate.
The use of a corrugated structure in the aerosol-generating article may advantageously allow the production of an aerosol-generating article that has extremely low RTD while still being sufficiently rigid to for a user to handle. Further, use of a corrugated structure may allow a low density, low RTD, aerosol-generating article to be produced using high speed production methods similar to those used for production of corrugated cardboard.
According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article may comprise a first planar external surface, a second planar external surface, a cavity and a frame. The frame is positioned between the first planar external surface and the second planar external surface. The frame at least partially defines the cavity. The aerosol-generating article comprises an aerosolforming substrate. The aerosol-generating article may comprise an air inlet and an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity.
Preferably, an aerosol-forming substrate is positioned between the first planar external surface and the second planar external 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.
The aerosol-generating article may comprise a first planar external layer and a second planar external layer, in which the first planar external layer forms the first planar external surface and the second planar external layer forms the second planar external surface. Optionally, at least one of the first planar external layer, the second planar external layer, and the frame may comprise or consist of aerosol-forming substrate.
The cavity may be substantially empty.
Aerosol-forming substrate may be positioned within the cavity.
A corrugated layer may be positioned within the cavity.
The frame may be a planar frame.
The frame may have a height between 50 percent and 95 percent of the height of the aerosolgenerating 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 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 be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.
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.
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.
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 aerosol-generating 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 upper and lower 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 may consist entirely of aerosol-forming substrate. Alternatively, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-generating article.
The aerosol-forming substrate may comprise nicotine. Nicotine may be present in the form of a tobacco material or may be in the form of a nicotine extract.
The aerosol-forming substrate may comprise one or more organic materials such as tobacco, mint, tea and cloves. The aerosol-forming substrate may comprise one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenised tobacco such as cast leaf, extruded tobacco, expanded tobacco, aerosol-generating films and gel compositions. The aerosol-forming substrate may comprise or consist of homogenised tobacco material, for example a reconstituted tobacco material or a cast leaf tobacco material.
The aerosol-forming substrate may be in the form of shredded aerosol-generating material. The shredded aerosol-generating material may comprise one or more of: strips and strands of aerosol-generating material, such as strips and strands of tobacco or homogenised tobacco material. The shredded aerosol-generating material may be in the form of a shredded sheet of homogenised tobacco material.
The aerosol-forming substrate may be cut filler. The aerosol-forming substrate may be tobacco cut filler. The cut filler may comprise one or more of bright tobacco, dark tobacco, aromatic tobacco and filler tobacco. Examples of bright tobaccos are 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 are Oriental Turkey, Greek Oriental, semi-oriental tobacco but also Fire Cured, US Burley, such as Perique, and Rustica. Examples of dark tobacco are Dark Cured Brazil Galpao, Burley Malawi or other African Burley, Sun Cured or Air Cured Indonesian Kasturi. As used herein, the term “cut filler” is used to describe a blend of shredded plant material, such as tobacco plant material, including, in particular, one or more of leaf lamina, processed stems and ribs, homogenised plant material.
The aerosol-forming substrate may be in the form of a sheet of aerosol-generating material. As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenised tobacco material, such as a cast leaf sheet.
The aerosol-forming substrate may comprise a bound collection of strips, strands or particles of tobacco material. The aerosol-forming substrate may be in the form of a compressed plug of tobacco material; for example, in which a plug having a substantially circular cross-section in an initial state of the plug is compressed into a flatter cross-sectional profile in a subsequent state of the plug. The tobacco material may be enclosed by a wrapper. The aerosol-forming substrate may be in the form of strips, strands or particles of tobacco material bound together in a binder matrix.
The aerosol-forming substrate may comprise one or more aerosol-formers. Suitable aerosolformers are well known in the art and include, but are not limited to, one or more aerosol-formers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosol-former to be or comprise one or both of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.
The aerosol-forming substrate may have an aerosol-former content greater than or equal to 1 , 2, 5, 10, or 15 percent by weight on a dry weight basis. The aerosol-forming substrate may have an aerosol-former content greater than or equal to 15 percent by weight on a dry weight basis, for example greater than 20 by weight on a dry weight basis, or greater than 25 by weight on a dry weight basis, or greater than 30 by weight on a dry weight basis, or greater than 40 by weight on a dry weight basis, or greater than 50 by weight on a dry weight basis.
The aerosol-forming substrate may have an aerosol-former content less than or equal to 30 percent by weight on a dry weight basis, less than or equal to 25 percent by weight on a dry weight basis, or less than or equal to 20 percent by weight on a dry weight basis. That is, the aerosolforming substrate may have an aerosol-former content less than or equal to 30 by weight on a dry weight basis, less than or equal to 25 by weight on a dry weight basis, or less than or equal to 20 by weight on a dry weight basis.
The aerosol-forming substrate may have an aerosol-former content between 1 percent and 30 percent by weight on a dry weight basis, between 1 percent and 25 percent by weight on a dry weight basis, or between 1 percent and 20 percent by weight on a dry weight basis.
The aerosol-forming substrate may comprise at least 50 percent by weight of aerosol former, at least 60 percent by weight of aerosol former, or at least 70 percent by weight of aerosol former.
The aerosol-forming substrate may comprise less than or equal to 85 percent by weight of aerosol former, less than or equal to 80 percent by weight of aerosol former, or less than or equal to 75 percent by weight of aerosol former.
The aerosol-forming substrate may comprise between 50 percent and 85 percent by weight of aerosol former, between 50 percent and 80 percent by weight of aerosol former, or between 50 percent and 75 percent by weight of aerosol former.
The aerosol-forming substrate may comprise nicotine. The aerosol-forming substrate may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.
The aerosol-forming substrate may comprise at least 0.5 percent by weight of nicotine, at least 1 percent by weight of nicotine, at least 1 .5 percent by weight of nicotine, or at least 2 percent by weight of nicotine.
The aerosol-forming substrate may comprise one or more flavourants. The one or more flavourants may comprise one or more of: one or more essential oils such as eugenol, peppermint oil and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and a herbaceous material. Suitable herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavourants may comprise a tobacco material.
The aerosol-forming substrate may comprise one or more botanicals. For example, the aerosol-forming substrate may comprise about 1 to 90 %, for example about 15 to 55 %, preferably of about 20 to 35 %, of botanicals such as Clove, Echinacea sp., Fennel, Ginger, Hawthorn berry, Elderberry, Monarda, Mullein leaves, Nettle, Plantain, Turmeric, Yarrow, Rooibos, Star Anise, Thyme, Anethum, Chamomile and compounds of those.
The aerosol-forming substrate may have a moisture content of about 5 to 25%, preferably of about 7 to 15%, at final product state. For example, the aerosol-forming substrate may be a homogenised tobacco material with a moisture of about 5 to 25%, preferably of about 7 to 15%, at final product state.
The aerosol-forming substrate may comprise a binder. For example, the aerosol-forming substrate may comprise about 1 to 10%, preferably of about 1 to 5%, of a binder such as any of common gums or pectins used in food and beverage (F&B) industries. Preferred binders may be natural pectins, such as fruit, for example citrus, or tobacco pectins; guar gums, land locust bean gums, such as hydroxyethyl and/or hydroxypropyl of those; starches, such as modified or derivatized starches; alginate; methyl, ethyl, ethyl hydroxymethyl and carboxymethyl, celluloses; dextran; and xanthan gum. A preferable binder is guar.
The aerosol-forming substrate may comprise, or consist of, a solid aerosol-forming material. The aerosol-forming substrate may comprise a liquid aerosol-forming material, for example a liquid aerosol-forming material retained within a porous matrix. The aerosol-forming substrate may comprise a gel aerosol-forming material.
The aerosol-forming substrate may be in the form of a plurality of beads. The plurality of beads may have an average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm.
The term “bead” refers to a discrete, solid particle formed of the aerosol-forming substrate. A bead may have a rounded, typically spherical, form. Other terms may be used to define the substrate such as, for example, “granule”.
Providing the aerosol-forming substrate as a plurality of beads may provide certain advantages. Beads can be easily handled compared to other aerosol-forming substrates such as fine powders or cut filler. The beads flow easily, and so can reliably and consistently fill the cavity of the aerosol-generating article during manufacture. This may allow a consistent and reproducible amount of aerosol-forming substrate to be loaded into each article during manufacture. Beads may also be cleaner to handle than powders and cut fillers, which may cause dust in factories, and may leak from aerosol-generating articles in transit or in use. By selecting beads with appropriate bead sizes and appropriate particle size distributions, air flow through the cavity of the aerosol-generating article may be controlled more reproducibly than would be the case for, say, a cut filler substrate. Where a particle is not perfectly spherical, but a diameter of the particle is referred to, the term “diameter” may refer to a largest dimension of the particle. Alternatively, the term “diameter” may refer to the diameter of a perfectly spherical particle having the same volume as the not perfectly spherical particle.
The term “average particle diameter”, as used herein, may refer to a number average particle diameter. Other methods of determining average particle diameter are known. Thus, the average particle diameter may be, for example, a volume average particle diameter.
The aerosol-forming substrate may be in form of a wrapped body of aerosol-forming substrate, the wrapped body comprising a wrapper at least partially enclosing aerosol-forming substrate.
The wrapped body of aerosol-forming substrate may occupy between 15% and 100% of the interior volume of the cavity. The wrapped body of aerosol-forming substrate may occupy between 30% and 100% of the interior volume of the cavity. The wrapped body of aerosol-forming substrate may occupy between 50% and 100% of the interior volume of the cavity. The wrapped body of aerosol-forming substrate may occupy between 50% and 80% of the interior volume of the cavity. The wrapped body of aerosol-forming substrate may occupy between 50% and 70% of the interior volume of the cavity.
According to the present disclosure, there is provided an aerosol-generating system. The aerosol-generating system may comprise an aerosol-generating article as described above, and an aerosol-generating device. The aerosol-generating device is configured to be used with the aerosol-generating article to generate an aerosol.
The aerosol-generating device may be configured to receive the aerosol-generating article. The aerosol-generating device may be configured to receive a portion of the aerosol-generating article. The aerosol-generating device may be configured to receive a portion of the aerosolgenerating article, such that a portion of the aerosol-generating article is arranged outside of the aerosol-generating device when the aerosol-generating article is received in the aerosol-generating device. The aerosol-generating device may be configured to receive the entirety of the aerosolgenerating article, such that the aerosol-generating article is wholly enclosed within the aerosolgenerating device. The aerosol-generating device may be configured to receive the entirety of the aerosol-generating article.
The aerosol-generating device may comprise a cavity configured to receive the aerosolgenerating article. The cavity may be dimensioned to receive the aerosol-generating article. The cavity may be configured to receive at least a portion of the aerosol-generating article. The cavity may be configured to receive a portion of the aerosol-generating article. The cavity may be configured to receive the entire aerosol-generating article.
In some preferred embodiments, the aerosol-generating device comprises a cavity configured to receive at least a portion of the aerosol-generating article. In some particularly preferred embodiments, where a contact surface of the aerosol-generating article is deformable, the aerosolgenerating device is configured to deform at least a portion of the deformable contact surface of the aerosol-generating article when the aerosol-generating article is received in the cavity to urge the contact surface to contact the aerosol-forming substrate.
The aerosol-generating device may be configured to deform at least a portion of the deformable contact surface in any suitable way. Preferably, the cavity of the aerosol-generating device is shaped to deform at least a portion of the deformable contact surface of the aerosolgenerating article when the aerosol-generating article is received in the cavity of the aerosolgenerating device. The aerosol-generating device may comprise at least one protrusion into the cavity, the protrusion being configured to deform at least a portion of the deformable contact surface of the aerosol-generating article when the aerosol-generating article is received in the cavity of the aerosol-generating device.
In some particularly preferred embodiments, the at least one protrusion of the aerosolgenerating device is a heating element of the aerosol-generating device. The heating element may be configured to heat the aerosol-forming substrate of the aerosol-generating article when the aerosol-generating article is received in the cavity of the aerosol-generating device.
Advantageously, configuring the at least one protrusion as a heating element may bring the heating element into close proximity to the aerosol-forming substrate when the aerosol-generating article is received in the cavity of the aerosol-generating device, improving heat transfer between the heating element and the aerosol-forming substrate.
In some embodiments, the aerosol-generating device may comprise two opposing protrusions, each protrusion extending into the cavity of the aerosol-generating device. The two opposing protrusions may extend towards each other into the cavity of the aerosol-generating device. In some embodiments, one of the two opposing protrusions is a heating element of the aerosol-generating device. In some embodiments, both of the two opposing protrusions are heating elements of the aerosol-generating device.
The aerosol-generating system comprises an aerosol-generating device.
The aerosol-generating device may comprise a cavity configured to receive at least a portion of the aerosol-generating article described above. The aerosol-generating device may comprise a heater or heating means. The aerosol-generating device may comprise a power source for supplying power to the heater or heating means. The aerosol-generating device may comprise a controller to control supply of power to the heater or heating means. Preferably, the aerosol-generating device is configured to heat an aerosol-forming substrate, for example an aerosol-forming substrate that is a component part of an aerosol-generating article, to form an aerosol, for example an inhalable aerosol.
The cavity may comprise an opening into which a distal end of the aerosol-generating article can be inserted. The cavity may have any suitable cross-sectional shape. For example, the cavity may have a rectangular transverse cross-section, for example a rectangular cross-section having opposing top and bottom sides that are greater in length than left and right sides.
Preferably, at least one internal surface of the cavity is a heating surface configured to heat an aerosol-generating article. The heating surface may comprise a heater, for example a resistance heater, or an infra-red heater, or a susceptor configured to be heated by engagement with an inductor. The heating surface may comprise an inductor, for example the surface may comprise a coil arranged to generate a fluctuating electromagnetic field within a space of the cavity. The heating surface may be a surface that is permeable to a fluctuating electromagnetic field, such that an inductor arranged outside the cavity can project a fluctuating electromagnetic field through the heating surface to engage with a susceptor arranged within the cavity.
According to the present disclosure, an aerosol-generating device for receiving an aerosolgenerating article as disclosed herein, or an aerosol-forming substrate as disclosed herein, may comprise a cavity dimensioned to receive at least a portion of the aerosol-generating article or aerosol-forming substrate, a heater or heating means, a power source for supplying power to the heater or heating means, and a controller to control supply of power to the heater or heating means. The aerosol-generating device is configured to heat an aerosol-forming substrate, for example an aerosol-forming substrate that is a component part of an aerosol-generating article, to form an aerosol, for example an inhalable aerosol.
As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol.
As used herein, the term “aerosol-forming substrate” may refer to a substrate capable of releasing an aerosol or volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. An aerosol-forming substrate may comprise an aerosol-forming material. An aerosol-forming substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. An aerosol-forming substrate may conveniently be part of an aerosol-generating article or smoking article.
As used herein, the term “aerosol-generating device” may refer to a device for use with an aerosol-generating article to enable the generation, or release, of an aerosol. As used herein, the term “aerosol generating system” refers to a combination of an aerosolgenerating device and one or more aerosol-forming articles for use with the device. An aerosolgenerating system may include additional components, such as a charging unit for recharging an onboard electric power supply in an electrically operated or electric aerosol-generating device.
As used herein, the term “aerosol former” may refer to any suitable known compound or mixture of compounds that, in use, facilitates formation of an aerosol. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-forming substrate or aerosol-generating article.
As used herein with reference to the invention, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.
As used herein, the term “transverse” refers to a direction extending between the upper external surface and the lower external surface. The transverse direction may also be referred to as the “z-direction”.
As used herein, the term “longitudinal” refers to a direction that is perpendicular to the transverse direction. For example, a direction between a front wall and a back wall of the aerosolgenerating article. The lateral direction may also be referred to as the “x-direction”.
As used herein, the term “lateral” refers to a direction that is perpendicular to the transverse direction and the longitudinal direction. For example, a direction from a first side wall to a second side wall of the aerosol-generating article. The lateral direction may also be referred to as the “y- direction”.
As used herein, the term “height” refers to a dimension of the aerosol-generating article or a component of the aerosol-generating article in the transverse direction. The term “height” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the transverse direction, unless otherwise specified.
As used herein, the term “length” refers to a dimension of the aerosol-generating article or a component of the aerosol-generating article in the longitudinal direction. The term “length” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the longitudinal direction, unless otherwise specified.
As used herein, the term “width” refers to a dimension of the aerosol-generating article or a component of the aerosol-generating article in the lateral direction. The term “width” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the lateral direction, unless otherwise specified.
As used herein with reference to the invention, the terms “proximal”, “distal”, “upstream” and “downstream” are used to describe the relative positions of components, or portions of components, of the aerosol-generating article. As used herein, the term “longitudinal” refers to the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. During use, air may be drawn through the aerosol-generating article in the longitudinal direction.
As used herein, the term “sheet” denotes a laminar element having a width and length substantially greater than the thickness thereof. The width of a sheet may be greater than 10 mm, preferably greater than 20 mm or 30 mm. In certain embodiments, sheets of material for use in forming aerosol-forming substrates as described herein may have a thickness of between 10 pm and about 1000 pm, for example between 10 pm and about 300 pm.
As used herein, the term “homogenised tobacco material” encompasses any tobacco material formed by the agglomeration of particles of tobacco material. Sheets or webs of homogenised tobacco material are formed by agglomerating particulate tobacco obtained by grinding or otherwise powdering of one or both of tobacco leaf lamina and tobacco leaf stems. In addition, homogenised tobacco material may comprise a minor quantity of one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during the treating, handling and shipping of tobacco. The sheets of homogenised tobacco material may be produced by casting, extrusion, paper making processes or other any other suitable processes known in the art.
The term “cast leaf” is used herein to refer to a product made by a casting process that is based on casting a slurry comprising plant particles (for example, clove particles or tobacco particles and clove particles in a mixture) and a binder (for example, guar gum) onto a supportive surface, such as a belt conveyor, drying the slurry and removing the dried sheet from the supportive surface. An example of the casting or cast leaf process is described in, for example, US-A-5,724,998 for making cast leaf tobacco. In a cast leaf process, particulate plant materials are produced by pulverizing, grinding, or comminuting parts of the plant. The particles produced from one or more plants are mixed with a liquid component, typically water, to form a slurry. Other components in the slurry may include fibres, a binder and an aerosol former. The particulate plant materials may be agglomerated in the presence of the binder. The slurry is cast onto a supportive surface and dried into a sheet of homogenized plant material. Preferably, homogenized plant material used in articles according to the present invention may be produced by casting. Such homogenized plant material may comprise agglomerated particulate plant material.
As used herein, resistance to draw is expressed with the units of pressure “mm H2O” or “mm WG” or “mm of water gauge” and may be measured in accordance with ISO 6565:2002.
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. EX1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol generating article comprising: a cavity defined between an upper surface, a lower surface, and at least one side surface; and an aerosol-forming substrate arranged in the cavity, wherein the aerosol-generating article is defined by a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction; wherein the upper and lower surfaces are separated from each other in the z direction; wherein the thickness of the aerosol-generating article is less than each of the width and the length of the aerosol-generating article; and wherein at least one of the upper surface, the lower surface, and the at least one side surface is a contact surface.
EX2. An aerosol-generating article according to example EX1 , wherein at least a portion of the contact surface is configured to contact the aerosol-forming substrate and to conform to a shape of the aerosol-forming substrate where the surface is in contact with the aerosol-forming substrate.
EX3. An aerosol-generating article according to example EX1 or EX2, wherein at least a portion of the contact surface is non-planar where the contact surface is in contact with the aerosolforming substrate.
EX4. An aerosol-generating article according to any one of examples EX1 to EX3, wherein the contact surface is substantially planar except where the contact surface is in contact with the aerosol-forming substrate.
EX5. An aerosol-generating article according to any one of examples EX1 to EX4, wherein the contact surface is deformable, such that the contact surface conforms to a shape of the aerosol-forming substrate where the contact surface is in contact with the aerosol-forming substrate.
EX6. An aerosol-generating article according to any one or examples EX1 to EX4, wherein at least a portion of the aerosol-forming substrate has a predefined external shape, and wherein at least a portion of the contact surface has a predefined shape that conforms to at least a portion of the predefined external shape of the aerosol-forming substrate where the contact surface is in contact with the aerosol-forming substrate.
EX7. An aerosol-generating article according to any one of examples EX1 to EX6, wherein two or more of the upper surface, the lower surface, and the at least one side surface are contact surfaces. EX8. An aerosol-generating article according to example EX7, wherein the upper surface is a contact surface and the lower surface is a contact surface, and optionally wherein the at least one side surface is a contact surface.
EX9. An aerosol-generating article according to example EX7, wherein the at least one side surface comprises a first side surface and a second side surface, wherein the first side surface and the second side surface are separated from each other in the y-direction, and wherein at least one of the first side surface is a contact surface and the second side surface is a contact surface.
EX10. An aerosol-generating article according to example EX9, wherein the first side surface is a contact surface and the second side surface is a contact surface.
EX11 . An aerosol-generating article according to any one of examples EX1 to EX9, wherein the aerosol-generating article comprises a frame, the frame defining the at least one side surface, and optionally wherein the frame defines at least one external side surface of the aerosolgenerating article.
EX12. An aerosol-generating article according to any one of examples EX1 to EX11 , wherein the aerosol-generating article comprises an upper layer and a lower layer, the upper layer defining the upper surface, and the lower layer defining the lower surface, optionally wherein the upper layer defines an upper external surface of the aerosol-generating article, and optionally wherein the lower layer defines a lower external surface of the aerosol-generating article.
EX13. An aerosol-generating article according to any one of examples EX1 to EX12, wherein: the aerosol-generating article comprises an upper layer and a lower layer, the upper layer defining the upper surface, and the lower layer defining the lower surface; and the aerosol-generating article comprises a frame arranged between the upper layer and the lower layer, the frame defining the at least one side surface.
EX14. An aerosol-generating article according to any one of examples EX1 to EX13, wherein the aerosol-forming substrate has a length extending in the x-direction, wherein a crosssection of the aerosol-forming substrate at a point along the length of the aerosol-forming substrate has a perimeter, and wherein the at least one contact surface is in contact with the aerosol-forming substrate around substantially the entire perimeter of the cross-section of the aerosol-forming substrate at a point along the length of the aerosol-forming substrate.
EX15. An aerosol-generating system comprising: an aerosol-generating article according to any one of examples EX1 to EX14; and an aerosol-generating device configured to be used with the aerosol-generating article to generate an aerosol. EX16. An aerosol-generating system comprising an aerosol-generating article according to example EX5, and an aerosol-generating device configured to be used with the aerosol-generating article to generate an aerosol, wherein the aerosol-generating device comprises a cavity configured to receive at least a portion of the aerosol-generating article; and wherein the aerosol-generating device is configured to deform at least a portion of the deformable contact surface of the aerosolgenerating article when the aerosol-generating article is received in the cavity to urge the contact surface to contact the aerosol-forming substrate.
EX17. An aerosol-generating system according to example EX16, wherein the aerosolgenerating device comprises at least one protrusion extending into the cavity of the aerosolgenerating device, the at least one protrusion being configured to deform at least a portion of the deformable contact surface of the aerosol-generating article when the aerosol-generating article is received in the cavity to urge the contact surface to contact the aerosol-forming substrate.
EX18. An aerosol-generating system according to example EX17, wherein the at least one protrusion of the aerosol-generating device is a heating element of the aerosol-generating device.
Examples will now be further described with reference to the figures in which:
Figure 1 shows a perspective side view of an aerosol-generating article;
Figure 2 shows a perspective side view of an aerosol-generating article;
Figure 3 shows a schematic end view of an aerosol-generating article;
Figure 4 shows a schematic side view of the aerosol-generating article of Figure 3;
Figure 5 shows a schematic plan view of the aerosol-generating article of Figure 3;
Figure 6 shows a schematic illustration of a corrugated element as used in the aerosolgenerating article of Figure 3;
Figure 7 shows a perspective view of an aerosol-generating article;
Figure 8 shows an exploded perspective view of the aerosol-generating article of Figure 7;
Figure 9 shows a further exploded perspective view of the aerosol-generating article of Figure 7;
Figure 10 shows a schematic transverse cross-sectional view of the aerosol-generating article of Figure 7;
Figure 11 shows a schematic longitudinal cross-sectional view of the aerosol-generating article of Figure 7;
Figure 12 shows an exploded perspective view of an aerosol-generating article;
Figure 13 shows a schematic transverse cross-sectional view of the aerosol-generating article of Figure 12;
Figure 14 shows a schematic lateral cross-sectional view of the aerosol-generating article of Figure 12; Figure 15 shows an exploded perspective view of an aerosol-generating article according to an embodiment of the disclosure;
Figure 16 shows a schematic perspective side view of the aerosol-generating article of Figure 15;
Figure 17 shows an exploded perspective view of an aerosol-generating article according to an embodiment of the disclosure;
Figure 18 shows a schematic perspective side view of the aerosol-generating article of Figure 17;
Figure 19 shows a schematic plan view of an aerosol-generating article according to an embodiment of the disclosure;
Figure 20 shows a schematic transverse cross-sectional view of the aerosol-generating article of Figure 19;
Figure 21 shows a schematic transverse cross-section of the aerosol-generating article of Figures 19 and 20, and heating elements of an aerosol-generating device configured for use with the aerosol-generating article of Figures 19 and 20;
Figure 22 shows a schematic transverse cross-section of the aerosol-generating article of Figures 19 and 20 in use with the heating elements of Figure 21 ;
Figure 23 shows a schematic view of an aerosol-generating device comprising the heating elements of Figures 21 and 22, the device being configured to engage with the aerosol-generating article of Figures 19 and 20;
Figure 24 shows a schematic end view of the aerosol-generating device of Figure 23;
Figure 25 shows a schematic view of the aerosol-generating article of Figures 19 and 20 in engagement with the aerosol-generating device of Figures 23 and 24; and
Figure 26 shows a schematic view of an alternative embodiment to that of Figures 23 to 25, showing an aerosol-generating article in engagement with an aerosol-generating device.
Figure 1 illustrates a perspective side view of an aerosol-generating article 100. The aerosolgenerating article 100 has upper and lower surfaces 110, 120 which are flat or planar.
The aerosol-generating article 100 comprises an aerosol-forming substrate (not shown). In one embodiment, the aerosol-generating article 100 may consist substantially of aerosol-forming substrate. In another embodiment, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-generating article 100. The aerosol-forming substrate may be enclosed within an interior of the aerosol-generating article 100. The aerosol-forming substrate may at least partially define an exterior of the aerosol-generating article 100; for example, one or both of the upper and lower surfaces 110, 120 may comprise or consist of aerosol-forming substrate.
A suitable aerosol-forming substrate may be homogenised tobacco. The aerosol-generating article 100 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (which may also be referred to as a thickness), extending in a z dimension, of 3.6 millimetres.
Figure 2 illustrates a perspective side view of an aerosol-generating article 200, the aerosolgenerating article 200 of Figure 2 being a variant of aerosol-generating article 100 of Figure 1. Features in common with aerosol-generating article 100 are referred to with like reference signs but commencing with numeral 2 instead of numeral 1 . An air flow path 230 is defined through the aerosolgenerating article 200 between the upper and lower surfaces 210, 220. The air flow path 230 extends between opposed first and second ends 201 , 202 of the aerosol-generating article 200. The first end 201 may define a distal end of the aerosol-generating article 200, and the second end 202 may define a proximal or mouth end of the aerosol-generating article. The air flow path 230 may be directed towards a mouth of a user to allow a user to inhale aerosol generated in consequence of heating of aerosol-forming substrate of the aerosol-generating article 200.
Figures 3, 4, and 5 illustrate respectively an end view, a side view, and a plan view of an aerosol-generating article 300. The aerosol-generating article 300 comprises a planar upper layer 310, a planar lower layer 320, and an intermediate or separation layer 340 arranged between the upper layer 310 and lower layer 320.
The planar upper layer 310 is formed from a sheet of paper having a thickness of 300 microns. The planar lower layer 320 is formed from a sheet of paper having a thickness of 300 microns. The intermediate layer 340 is a corrugated element formed from a corrugated sheet of aerosol-forming substrate 345. A suitable aerosol-forming substrate may be homogenised tobacco. Thus, the intermediate layer 340 may be formed from a corrugated sheet of homogenised tobacco material 345.
Figure 6 illustrates the corrugated sheet of aerosol-forming substrate 345. The corrugations have an amplitude 346 of 3 millimetres and a wavelength 347 of 3 millimetres. The sheet of aerosolforming substrate 345 forming the intermediate layer 340 has a thickness of 150 microns.
Points of intersection 351 , 352 between the upper layer 310 and the intermediate layer 340 and between the lower layer 320 and the intermediate layer 340 comprise an adhesive that joins the respective layers.
The aerosol-generating article 300 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (or thickness), extending in a z dimension, of 3.6 millimetres.
Corrugations of the intermediate layer 340 form a first set of longitudinally extending channels 361 that are bounded by the upper layer 310 and the intermediate layer 340, and a second set of longitudinally extending channels 362 bounded by the lower layer 320 and the intermediate layer 340. The first and second sets of longitudinally extending channels 361 , 362 extend through the length of the aerosol-forming substrate between a proximal end 371 of the substrate 345 and a distal end 372 of the substrate 345. The longitudinally extending channels 361 , 362 define an air-flow path through the substrate 345. The air-flow path, therefore, passes over both sides of the sheet of aerosol-forming substrate 345. The porosity of the aerosol-generating article along the air-flow path is in the region of 90 %. This provides a very low resistance to draw (RTD) of less than 5 mm H2O. In fact, the RTD is close to zero.
The aerosol-forming substrate 345 may be a sheet of any suitable aerosol-forming substrate.
During use of the aerosol-generating article 300, the aerosol-forming substrate 345 is heated up to cause the aerosol-forming substrate 345 to release volatile compounds, which are then entrained in air drawn into the channels 361 , 362 via the distal end 372. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the channels 361 , 362 of the aerosol-generating article 300 via the proximal end 371 .
Figure 7 shows an aerosol-generating article 400. The aerosol-generating article 400 comprises a first planar external layer 424 forming a first planar external surface 421 , a second planar external layer 425 forming a second planar external surface 422, and a frame 450 positioned between the first planar external layer 424 and the second planar external layer 425. The second planar external surface 422 is positioned parallel to the first planar external surface 421 .
Figures 8 and 9 show exploded views of the aerosol-generating article 400 of Figure 7. The frame 450 circumscribes and at least partially defines a cavity 430. Figure 8 shows the cavity 430 in an empty state. Figure 9 shows the cavity 430 filled with aerosol-forming substrate 440. Figures 10 and 11 show respective transverse and longitudinal cross-sectional views of the aerosol-generating article 400 when the cavity 430 is filled with aerosol-forming substrate 440.
The first planar external layer 424 and the second planar external layer 425 are made from cigarette paper having a thickness of 35 micrometres and are in physical contact, with and bonded to, the frame 450. The first planar external layer 424 overlies a first end of the cavity 430 and forms a first cavity end wall 431 . The second planar external layer 425 overlies a second end of the cavity 430 and forms a second cavity end wall 432, the second cavity end wall 432 being opposite to the first cavity end wall 431 . That is, the frame 450, the first planar external layer 424 and the second planar external layer 425 collectively define the cavity 430.
The frame 450 has a hollow cuboid shape and is made from cardboard. The frame 450 defines an aperture extending through the height (also referred to as the thickness) of the frame 450 and the aperture at least partially forms the cavity 430 of the aerosol-generating article 400. The frame 450 comprises a peripheral wall 451 that circumscribes the cavity 430. The peripheral wall 451 includes a front wall 413 and a back wall 414. In more detail, the peripheral wall 451 is defined by an inner transverse surface 452 of the frame 450 and an outer transverse surface 453 of the frame 450. The inner transverse surface 452 of the peripheral wall 451 at least partially defines a perimeter of the cavity 430. The outer transverse surface 453 of the peripheral wall 451 at least partially defines a perimeter of the aerosol-generating article 400. The peripheral wall 451 has a radial thickness measured between the inner transverse surface 452 of the frame 450 and the outer transverse surface 453 of the frame 450 of about 5 millimetres.
An air inlet 411 and an air outlet 412 are defined by, and extend through, the peripheral wall 451 of the frame 450. More specifically, the air inlet 411 extends through the front wall 413 and the air outlet 412 extends through the back wall 414. The air inlet 411 and the air outlet 412 have an equivalent diameter of 5 millimetres. An airflow passage extends between the air inlet 411 and the air outlet 412 through the cavity 430. As shown in Figures 9-11 , an aerosol-forming substrate 440 is positioned within the cavity 430. The aerosol-forming substrate 440 comprises an aerosol-forming substrate in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. As shown, the aerosol-forming substrate 440 fills the entire volume of the cavity 430.
The aerosol-generating article 400 has a cuboid shape and has a height (or thickness) extending in a z dimension, as measured between the first planar external surface 421 and the second planar external surface 422, of 8 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The frame 450 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The cavity 430 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 30 millimetres and a length extending in an x dimension of 50 millimetres.
Figure 12 shows an aerosol-generating article 500. Features in common with aerosolgenerating article 400 are referred to with like reference signs but commencing with numeral 5 instead of numeral 4. Aerosol-generating article 500 differs from aerosol-generating article 400 in that the aerosol-forming substrate is in the form of a sheet of aerosol-forming substrate 540, in particular a corrugated sheet of homogenised tobacco material. Figures 13 and 14 show respective transverse and lateral cross-section views of the aerosol-generating article 500 of Figure 12.
As with the aerosol-generating article 400, the aerosol-generating article 500 comprises a first planar external layer 524 forming a first planar external surface 521 , a second planar external layer 525 forming a second planar external surface 522, and a frame 550 positioned between the first planar external layer 524 and the second planar external layer 525. The second planar external surface 522 is positioned parallel to the first planar external surface 521 . An air inlet 511 and an air outlet 512 are defined by, and extend through, a peripheral wall 551 of the frame 550. The frame 550 circumscribes and at least partially defines a cavity 530. The cavity 530 contains the aerosolforming substrate 540, in the form of a corrugated sheet of homogenised tobacco material.
The corrugated sheet of homogenised tobacco material 540 comprises a plurality of parallel corrugations having a plurality of substantially parallel peaks 543 and troughs 544. The plurality of parallel corrugations are defined by a corrugation profile which, as seen in Figure 13, is sinusoidal. The plurality of parallel corrugations have a corrugation wavelength of about 4.6 millimetres. The corrugation amplitude is approximately the same as the height (or thickness) of the cavity 530, as shown by the peaks 543 and troughs 544 coinciding with a first cavity end wall 531 and a second cavity end wall 532, respectively.
The plurality of parallel corrugations form a plurality of channels 545 between the sheet of aerosol-forming substrate 540 and the first cavity end wall 531 , and a plurality of channels 546 between the sheet of aerosol-forming substrate 540 and the second cavity end wall 532. The plurality of channels 545, 546 extend in a longitudinal direction of the aerosol-generating article 500 and form at least a portion of the airflow passage extending between the air inlet 511 and the air outlet 512.
During use of each of the aerosol-generating articles 400, 500, the aerosol-forming substrate 440, 540 is heated up to cause the aerosol-forming substrate 440, 540 to release volatile compounds, which are then entrained in air drawn through the air inlet 411 , 511 into the cavity 430, 530. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the aerosol-generating article 400, 500 through the air outlet 412, 512.
Figures 15 and 16 show an aerosol-generating article 600 according to an embodiment of the disclosure. Figure 15 illustrates an exploded view of the aerosol-generating article 600, and Figure 16 illustrates a perspective side view of the aerosol-generating article 600, the aerosol-generating article 600 being a variant of the aerosol-generating article 400 of Figures 7 to 11. Features in common with aerosol-generating article 400 are referred to with like reference signs but commencing with numeral 6 instead of numeral 4.
The aerosol-generating article 600 comprises a first planar external layer 624 forming a first planar external surface 621 , a second planar external layer 625 forming a second planar external surface 622, and a frame 650 positioned between the first planar external layer 624 and the second planar external layer 625. The second planar external surface 622 is positioned parallel to the first planar external surface 621 .
The frame 650 circumscribes and at least partially defines a cavity 630. An aerosol-forming substrate 640 is arranged in the cavity 630, as described in more detail below.
The first planar external layer 624 and the second planar external layer 625 are made from cigarette paper having a thickness of 35 micrometres and are in physical contact, with and bonded to, the frame 650. The first planar external layer 624 overlies a first end of the cavity 630 and forms a first cavity end wall. The second planar external layer 625 overlies a second end of the cavity 630 and forms a second cavity end wall, the second cavity end wall being opposite to the first cavity end wall. That is, the frame 650, the first planar external layer 624, and the second planar external layer 625 collectively define the cavity 630.
The frame 650 has a hollow cuboid shape and is made from cardboard. The frame 650 defines an aperture extending through the height (also referred to as the thickness) of the frame 650, and the aperture at least partially forms the cavity 630 of the aerosol-generating article 600. The frame 650 comprises a peripheral wall that circumscribes the cavity 630.
An air inlet 611 and an air outlet 612 are defined by, and extend through, the peripheral wall of the frame 650. More specifically, the air inlet 611 extends through the front wall and the air outlet 612 extends through the back wall. The air inlet 611 and the air outlet 612 have an equivalent diameter of 5 millimetres. An airflow passage extends between the air inlet 611 and the air outlet 612 through the cavity 630.
The aerosol-generating article 600 has a generally cuboid shape and has a height (or thickness) extending in a z dimension, as measured between the first planar external surface 621 and the second planar external surface 622, of 8 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The frame 650 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The cavity 630 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 30 millimetres and a length extending in an x dimension of 50 millimetres.
An aerosol-forming substrate 640 is positioned within the cavity 630. The aerosol-forming substrate 640 comprises an aerosol-forming substrate in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis.
In this embodiment, the aerosol-forming substrate does not fill the entire volume of the cavity 630. Instead, the aerosol-forming substrate 640 occupies a central region of the cavity 630, with the entire perimeter of the aerosol-forming substrate 640 in contact with a surface of the cavity 630. In other words, an inner surface of the frame 650 contacts the aerosol-forming substrate 640, and inner surfaces of the first external layer 624, and the second external layer 625 contact the aerosol-forming substrate 640.
In this embodiment, the aerosol-forming substrate 640 has a height in the z dimension of 9.93 millimetres, which means that the aerosol-forming substrate 640 has a height that is 2 millimetres greater than the height of the cavity 630, which is defined by the height of the frame 650. As a result, when the first external layer 624 is bonded to the frame 650, an upper portion of the aerosol-forming substrate 640 extends above the frame 650, and deforms the first external layer 624. Since the first external layer 624 is formed from paper, it deforms, and conforms to the external shape of the upper portion of the aerosol-forming substrate 640. Similarly, when the second external layer 625 is bonded to the frame 650, a lower portion of the aerosol-forming substrate 640 extends below the frame 650, and deforms the second external layer 625. Since the second external layer 625 is formed from paper, it deforms, and conforms to the external shape of the lower portion of the aerosol-forming substrate 640. The deformation of the first external layer 624 and the second external layer 625, such that the layers 624 and 625 conform to the external shape of the aerosol-forming substrate 640 ensures close contact between the aerosol-forming substrate 640 and the layers 624 and 625. This reduces the formation of air channels between the aerosol-forming substrate 640 and the layers 624 and 625, promoting airflow through the aerosol-generating article 600 to flow through the aerosolforming substrate 640.
Figures 17 and 18 show an aerosol-generating article 700 according to an embodiment of the disclosure. Figure 17 illustrates an exploded view of the aerosol-generating article 700, and Figure 18 illustrates a perspective side view of the aerosol-generating article 700, the aerosol-generating article 700 being a variant of the aerosol-generating article 600 of Figures 15 and 16. Features in common with aerosol-generating article 600 are referred to with like reference signs but commencing with numeral 7 instead of numeral 6.
Aerosol-generating article 700 of Figures 17 and 18 differs from aerosol-generating article 600 of Figures 15 and 16 in that the aerosol-forming substrate 740 has a height in the z dimension of 7.93 millimetres, which is equal to the height of the frame 750, rather than being greater than the frame, as in the aerosol-generating article 600 of Figures 15 and 16. However, in this embodiment, the frame 750 has a narrow portion 703, arranged at the aerosol-forming substrate. The narrow portion 703 comprises a channel, with a depth of about 1 millimetre, which extends around the circumference of the aerosol-generating article 700, reducing the width and height of the frame 750. Accordingly, the height of the frame 750 at the narrow portion 703 is 5.93 millimetres, which is lower than the height of the aerosol-forming substrate 740. As a result, when the first external layer 724 is bonded to the frame 750, and deforms into the channel of the narrow portion 703, the first external layer 724 deforms around an upper portion of the aerosol-forming substrate 740, conforming to an external shape of the aerosol-forming substrate 740. Similarly, when the second external layer 724 is bonded to the frame 750, and deforms into the channel of the narrow portion 703, the second external layer 724 deforms around an upper portion of the aerosol-forming substrate 740, conforming to an external shape of the aerosol-forming substrate 740.
Figures 19 and 20 show an aerosol-generating article 800 according to an embodiment of the disclosure. Figure 19 illustrates a schematic plan view of the aerosol-generating article 800, and Figure 20 illustrates a schematic side view of the aerosol-generating article 800, the aerosol- generating article 800 being a variant of the aerosol-generating article 600 of Figures 15 and 16. Features in common with aerosol-generating article 600 are referred to with like reference signs but commencing with numeral 8 instead of numeral 6.
Aerosol-generating article 800 of Figures 19 and 20 differs from aerosol-generating article 600 of Figures 15 and 16 in that the aerosol-forming substrate 940 has a height, Hs, in the z dimension of 5.93 millimetres, which is less than the height, HA, of the frame 750, rather than being greater than the frame, as in the aerosol-generating article 600 of Figures 15 and 16. As a result, when the first external layer 824 is bonded to the frame 850, the first external layer 824 does not contact the aerosol-forming substrate 840. Similarly, when the second external layer 825 is bonded to the frame 850, the second external layer 825 does not contact the aerosol-forming substrate 840.
Figure 21 shows a schematic transverse cross-section of heating elements 6030 of an aerosolgenerating device 6000, described in more detail below, which are configured for use with the aerosol-generating article 800 of Figures 19 and 20, and Figure 22 shows the aerosol-generating article 800 of Figures 19 and 20 in use with the heating elements 6030 of Figure 21 .
The heating elements 6030 are substantially identical, and each comprise protrusions that are sized and shaped to fit in the gap between the first external layer 824 and the aerosol-forming substrate 840, and the gap between the second external layer 825 and the aerosol-forming substrate 840. The heating elements 6030 are arranged opposite each other, with the protrusions spaced in the z-direction with a gap of 5.93 millimetres, which is the thickness of the aerosol-forming substrate 840. The space between the heating elements 6030 forms a portion of the cavity of the aerosolgenerating device, as described in more detail below. When the aerosol-generating article 800 is inserted into the cavity, the protrusions of the heating elements 6030 are pushed into the gap between the first external layer 824 and the aerosol-forming substrate 840, and the gap between the second external layer 825 and the aerosol-forming substrate 840. One heating element 6030 urges the first external layer 824 into contact with the aerosol-forming substrate 840, such that the first external layer 824 conforms to the external shape of the aerosol-forming substrate 840. other heating element 6030 urges the second external layer 825 into contact with the aerosol-forming substrate 840, such that the second external layer 825 conforms to the external shape of the aerosol-forming substrate 840. In this arrangement, the heating elements 6030 are arranged in close proximity to the aerosolforming substrate 840, and no air gaps are provided between the heating elements 6030, the layers 824, and 825, and the aerosol-forming substrate 840.
Figures 21 and 22 illustrate an aerosol-generating device 6000 configured for use with the aerosol-generating article 800. 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 pair of heaters 6030, as described above. The controller 6020 controls supply of power from the battery 6010 to the heaters 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 800. The cavity 6050 comprises an upper planar surface 6052 and a lower planar surface 6053. One of the heaters 6030 extends through the lower planar surface 6053 to heat a lower surface of the aerosol-generating article 800 inserted into the cavity 6050, and the other one of the heaters 6030 extends through the upper planar surface 6052 to heat an upper surface of the aerosol-generating article 800 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.
Figure 25 illustrates the device 6000 of Figure 23 in engagement with the aerosol-generating article 800. There is little tolerance between outer surfaces of the aerosol-generating article 800 and the internal surfaces of the cavity 6050. Thus, there is a snug fit between the aerosol-generating article 800 and the device 6000. As the RTD of the aerosol-generating article 800 is negligible, the RTD of the system formed by the combination of aerosol-generating article 800 and aerosolgenerating device 6000 is controlled by the air-flow path defined within the device. When a user has inserted the aerosol-generating article 800 into the cavity 6050, the device 6000 can be operated. The heaters 6030 heat lower and upper surfaces of the aerosol-generating article 800, and as a result the aerosol-forming substrate 840 of the aerosol-generating article 800 is heated. Volatile components of the aerosol-forming substrate 840 are evaporated and condense in longitudinal airflow channels defined within the aerosol-generating article 800 to form an aerosol. The user inhales the aerosol by drawing on the proximal end of the aerosol-generating article 800. Once the aerosolforming substrate 840 of the aerosol-generating article 800 has been depleted of volatile components, the aerosol-generating article 800 is removed from the cavity 6050 of the device 6000 and disposed of.
Although Figure 25 shows part of the aerosol-generating article 800 extending outside of the aerosol-generating device 6000, in other embodiments the entirety of an aerosol-generating article may be wholly enclosed within an aerosol-generating device. By way of example, Figure 26 illustrates an alternative embodiment to that of Figure 25, with like features referred to by the same reference numbers but with the addition of a prime symbol ’.
As with the aerosol-generating article 800, the aerosol-generating article 800’ comprises an aerosol-forming substrate 840’. As with the aerosol-generating device 6000, the aerosol-generating device 6000’ is an elongate aerosol-generating device extending between a proximal end 600T and a distal end 6002’. The aerosol-generating device 6000’ comprises a battery 601 O’, a controller 6020’ and a heater 6030’ located within a housing 6040’. A cavity 6050’ is defined in the device 6000’, the cavity 6050’ 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 800’. The cavity 6050’ comprises an upper planar surface 6052’ and a lower planar surface 6053’. An air-flow path is configured to allow air to flow into the cavity 6050’ from outside the device 6000’.
For the alternative embodiment of Figure 26, the entirety of aerosol-generating article 800’ is enclosed within the interior of aerosol-generating device 6000’. Also, the aerosol-generating device 6000’ comprises a single heating element extending into the cavity 6050’ through the lower planar surface 6053’. In this embodiment, the protrusion of the heating element 6030’ is large enough to urge the aerosol-forming substrate 840’ against both the layers 824’ and 825’ when the aerosolgenerating article 800 is received in the cavity 6050’.
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.