WO2024126797A1 - Article de génération d'aérosol amélioré avec trous de surface - Google Patents

Article de génération d'aérosol amélioré avec trous de surface Download PDF

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Publication number
WO2024126797A1
WO2024126797A1 PCT/EP2023/086084 EP2023086084W WO2024126797A1 WO 2024126797 A1 WO2024126797 A1 WO 2024126797A1 EP 2023086084 W EP2023086084 W EP 2023086084W WO 2024126797 A1 WO2024126797 A1 WO 2024126797A1
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WO
WIPO (PCT)
Prior art keywords
aerosol
substrate
heater
forming substrate
base
Prior art date
Application number
PCT/EP2023/086084
Other languages
English (en)
Inventor
Rui Nuno Rodrigues Alves BATISTA
Valerio OLIANA
Original Assignee
Philip Morris Products S.A.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Philip Morris Products S.A. filed Critical Philip Morris Products S.A.
Publication of WO2024126797A1 publication Critical patent/WO2024126797A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D1/00—Cigars; Cigarettes
    • A24D1/20—Cigarettes specially adapted for simulated smoking devices
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/42—Cartridges or containers for inhalable precursors
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B3/00—Preparing tobacco in the factory
    • A24B3/14—Forming reconstituted tobacco products, e.g. wrapper materials, sheets, imitation leaves, rods, cakes; Forms of such products
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/20—Devices using solid inhalable precursors

Definitions

  • the present disclosure relates to an aerosol-generating article.
  • the present disclosure also relates to an aerosol-generating device and an aerosol-generating system.
  • a typical aerosol-generating system may comprise an aerosol-generating device and an aerosol-generating article.
  • the aerosol-generating device may comprise a heating element and the aerosol-generating article may comprise an aerosol-forming substrate.
  • the heating element of the aerosol-generating device may heat the aerosol-forming substrate of the aerosolgenerating article so as to release an aerosol from the aerosol-forming substrate.
  • a user may inhale that aerosol.
  • a typical aerosol-generating article may appear similar to a conventional cigarette.
  • such an aerosol-generating article may be s substantially cylindrical article comprising an aerosol-forming substrate and other components such as mouthpiece filter element, all wrapped in a cigarette paper.
  • Dimensions of typical aerosol-generating articles are often similar to the dimensions of conventional cigarettes.
  • an aerosol-generating article for use with an aerosol-generating device to form an inhalable aerosol.
  • the aerosol-generating article may comprise an aerosol-forming substrate.
  • the aerosol-forming substrate may have a base.
  • the base may be defined by an x dimension and a y dimension.
  • the aerosol-forming substrate may have a height.
  • the height may be defined by a z dimension.
  • an aerosolgenerating article for use with an aerosol-generating device to form an inhalable aerosol.
  • the aerosol-generating article comprises an aerosol-forming substrate having a base defined by an x dimension and a y dimension.
  • the aerosol-forming substrate has a height defined by a z dimension.
  • the x, y, and z dimensions may extend in x, y, and z directions respectively.
  • the x, y and z directions may all be mutually perpendicular.
  • a planar lower surface of the aerosol-forming substrate is defined by the base and a planar upper surface of the aerosolforming substrate being parallel to the planar lower surface.
  • an aerosol-generating article for use with an aerosol-generating device to form an inhalable aerosol may comprise an aerosol-forming substrate having a base defined by an x dimension and a y dimension and a height defined by a z dimension, a planar lower surface of the aerosol-forming substrate being defined by the base, and a planar upper surface of the aerosol-forming substrate being parallel to the planar lower surface, in which the aerosolgenerating article further comprises a plurality of holes or notches defined in an upper surface of the aerosol-forming substrate.
  • the aerosol-forming substrate may be, or be described as, a planar substrate, or a flat substrate.
  • a planar or flat substrate may be a volume of substrate having two predominantly planar sides that are of greater area than the remaining sides making up the volume of the substrate. That is, the x and y dimensions of the flat or planar substrate are preferably greater in magnitude than the z dimension of the substrate.
  • the base forms a lower surface of the aerosol-forming substrate, an upper surface of the aerosol-forming substrate being substantially parallel to the lower surface and spaced from the lower surface by the z dimension.
  • a plurality of holes or notches are defined in an upper surface of the aerosol-forming substrate.
  • Aerosol-generating devices use various heating systems, for example resistance heating elements or inductive heating elements. Heating elements may be arranged to be in physical contact with an aerosol-forming substrate.
  • a rod-shaped aerosol-forming substrate may be heated externally, by a heating element arranged around the rod, or internally, by a heating element arranged to penetrate the rod.
  • a significant portion of the substrate may not be heated sufficiently to aerosolize volatile components of the aerosol-forming substrate, and therefore a portion of the substrate may be wasted.
  • An advantageous solution to wasted aerosol-forming substrate may be to use a substantially planar substrate as defined herein as a consumable.
  • a system in which a planar consumable is arranged in relation with a planar heater of an aerosol-generating device may allow substantially all of an aerosol-forming substrate to be heated to sufficient temperature to form an aerosol, thereby reducing or eliminating wastage. This is achieved due to the high surface to volume ratio of a planar substrate, which when heated through one or both planar surfaces enables the entire substrate to reach appropriate aerosol forming temperature.
  • aerosol- is generated by gases and vapours released at the opposite planar surface. Gases and vapours may also be released between the heated planar surface and the heater. Gases released between the aerosol-forming substrate and the heater may form bubbles which reduce the efficiency of thermal transfer between the heater and the substrate and may distort the shape of the aerosol-forming substrate.
  • a plurality of holes or notches defined in an upper surface of the aerosol-forming substrate may advantageously facilitate release of volatilised components of the aerosol-forming substrate into an air stream passing over a surface of the aerosol-forming substrate.
  • such holes or notches may provide a low resistance path for gasses and vapours formed by heating the aerosol-forming substrate to escape from the volume of the substrate to the upper surface of the substrate.
  • aerosol deliveries may be improved and substrate utilisation efficiency may be improved.
  • At least a portion of the plurality of holes are blind holes that do not extend through the thickness of the aerosol-forming substrate.
  • At least a portion of the plurality of holes are through-holes that extend through the thickness of the aerosol-forming substrate between the upper surface and the base.
  • Through holes may advantageously provide a path for gasses and vapours generated on a lower side of the aerosol-forming substrate to pass through to the upper surface of the substrate.
  • Such gasses and vapours may therefore be prevented from forming bubbles between the aerosol-forming substrate and a heater element. In this way, heating efficiency may be maintained and distortions of the aerosol-forming substrate during heating may be minimised.
  • the gasses and vapours may be entrained in an air-flow over the upper surface of the substrate and form part of the deliverable aerosol, thereby increasing efficiency of utilisation of aerosol forming constituents of the substrate.
  • some, or each, of the plurality of holes has an opening defined in the upper surface of the aerosol-forming substrate and a bore extending into the aerosol-forming substrate, in which a maximum dimension of a hole at its opening is greater than a maximum dimension of the same hole at a position midway between the upper and lower surface.
  • each of the plurality of holes may have an opening defined in the upper surface of the aerosol-forming substrate and at least some of the holes may have a funnel shape in which the maximum diameter of the hole is at its opening.
  • Such structures may improve the ability for various gaseous elements generated within the aerosol-forming substrate on heating to escape from the substrate, while maintaining structural integrity of the substrate.
  • the plurality of holes may be formed by a docker during manufacture of the aerosol-generating article.
  • a docker hole is a small hole made in a biscuit during manufacture to prevent the biscuit expanding or blistering during baking, and a docker is a tool that forms the holes in biscuit dough.
  • holes formed in an aerosol-forming substrate described herein have a similar appearance to holes in a biscuit, they may be conveniently referred to as docker holes.
  • the holes may be formed in the aerosol-forming substrate by means of a docker tool.
  • a docker has a plurality of protrusions, which may be arranged in a pattern, which may be pressed into a surface of the aerosol-forming substrate to create the holes or notches.
  • each of the plurality of holes may have a maximum diameter in the range of 0.01 mm to 2.5 mm, for example in which the diameter at the opening of each of the plurality of holes is within the range 0.01 mm to 2.5 mm.
  • the diameter at the opening of each of the plurality of holes may be within the range 0.02 mm to 2.3 mm, for example 0.03 mm to 1.5 mm, for example 0.04 mm to 1 mm, for example 0.10 mm to 0.80 mm, for example between 0.15 mm and 0.77 mm.
  • the density of holes defined in the upper surface may be between 3 and 100 per cm 2 , for example between 4 and 75 per cm 2 , for example between 5 and 50 per cm 2 , or between 10 and 40 per cm 2 , for example between 12 and 35 per cm 2 .
  • the aerosol-forming substrate comprises both through holes and blind holes.
  • the through holes have a larger opening diameter than the blind holes.
  • the aerosol-forming substrate may have a different density of blind holes compared to through holes.
  • the density of through holes may be between 2 and 6 per cm 2 , for example between 3 and 5 per cm 2 .
  • the density of blind holes may be between 15 and 50 per cm 2 , for example between 20 and 30 per cm 2 .
  • the magnitude of the x dimension may be between 80% and 120%, or between 90% and 110%, of the magnitude of the y dimension.
  • the x dimension is approximately the same magnitude as the y dimension.
  • the base of the aerosol-forming substrate is substantially planar.
  • the base may define, or be referred to as, a lower surface of the substrate.
  • the base may define a substantially planar lower surface of the aerosol-forming substrate.
  • a planar base or planar lower surface may allow better thermal contact with a planar heater of an aerosol-generating device.
  • one or both of the aerosol-forming substrate and the aerosol-generating article is in the form of a 3-dimensional shape that may be described as tablet-shaped, coin-shaped, disc-shaped, or cylindrical, for example a right cylindrical or right circular cylindrical.
  • one or both of the x dimension and the y dimension have a magnitude equal to or greater than 3 times the z dimension.
  • one or both of the x dimension and the y dimension have a magnitude equal to or greater than 3.5 times the z dimension.
  • one or both of the x dimension and the y dimension have a magnitude equal to or greater than 4 times the z dimension.
  • one or both of the x dimension and the y dimension may have a magnitude equal to or greater than 4.5 times the z dimension, or 5 times the z dimension, or 5.5 times the z dimension, or 6 times the z dimension.
  • a larger base area may provide greater surface area for heating by a planar heater of an aerosol-generating device.
  • a smaller height may allow a smaller temperature gradient or difference across the height of the substrate during heating.
  • the base of the substrate 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.
  • this may allow heating of a greater proportion of the substrate 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 substrate sufficiently to release an aerosol.
  • the aerosol-forming substrate is in the form of a cylinder, such as a right cylinder or right circular cylinder, defined by the base and the height.
  • the base is circular or substantially circular.
  • the symmetry of a circular base may allow the substrate to be inserted into a corresponding, circular cavity of a device in any orientation. This may make inserting the substrate into the device less fiddly for a user. This may be particularly important for substrates with relatively small heights, for example with heights less than 20, 10, or 8 mm.
  • orientation may be used to refer to a rotational orientation of the substrate about the z direction.
  • the base may have a diameter.
  • the diameter may be equal to the x dimension and the y dimension.
  • the diameter may have a magnitude equal to or greater than 3 times the z dimension, or height.
  • the diameter may have a magnitude equal to or greater than 3.5 times the z dimension, or height.
  • the diameter may have a magnitude equal to or greater than 4 times the z dimension, or height, for example greater than 5, or greater than 5.5, or greater than 6 times the z dimension, or height.
  • the substrate is a right circular cylinder in shape
  • the area of the base is equal to the area of the curved surface when the magnitude of the diameter is equal to 4 times the height, or z dimension, of the substrate.
  • the area of the base is greater than the area of the curved surface, and so it may be more efficient to heat the base, for example using a planar heater, than to attempt to heat the curved surface.
  • the base is defined by a base 2-dimensional shape.
  • This 2-dimensional shape may form a lower surface of the aerosol-forming substrate.
  • the aerosol-forming substrate comprises an upper surface.
  • the upper surface of the aerosol-forming substrate is defined by defined by an upper surface 2-dimensional shape, which may be identical in shape to the base 2-dimensional shape.
  • the upper surface may be spaced from the base by the height.
  • the upper surface may face an opposite direction to the base.
  • Both the base, which may also be referred to as the lower surface, and the upper surface may be planar surfaces, optionally located on parallel planes spaced by the height.
  • the aerosol-forming substrate has one or both of a substantially circular lower surface and a substantially circular upper surface.
  • the base or lower surface is defined by a first 2-dimensional shape having a base perimeter.
  • the upper surface is defined by a second 2-dimensional shape having an upper surface perimeter.
  • One or more peripheral surfaces may extend, optionally perpendicularly, between the lower surface and the upper surface.
  • One or more peripheral surfaces may be defined between the perimeter of the first 2-dimensional shape and the perimeter of the second 2-dimensional shape, optionally in which the perimeter of the first shape is identical to the perimeter of the second shape.
  • the aerosol-forming substrate has a substantially planar lower surface.
  • the aerosol-forming substrate has a substantially planar upper surface.
  • planar surfaces may allow better thermal contact with planar heaters.
  • a ratio of the largest of the x dimension and the y dimension to the z dimension is between 3: 1 and 25: 1 , for example between 4:1 and 20: 1 , for example between 4.2:1 and 10:1 , for example between 4.5:1 and 8:1.
  • a ratio of a diameter of the base (for example as defined by the x dimension or the y dimension) to the z dimension is between 4:1 and 20:1 , for example between 4.2:1 and 10:1 , for example between 4.5:1 and 8:1.
  • a ratio of a radius of the base (for example as defined by half the x dimension or half the y dimension) to the z dimension is between 2: 1 and 10: 1 , for example between 2.1 :1 and 5:1 , for example between 2.25:1 and 4:1.
  • these ratios above may provide a compromise between at least the following four factors: a base surface area for heating, which may increase with the x and y dimensions, a temperature difference across the height of the substrate when heated at one or both of the base and the upper surface, which may increase with the z dimension, a structural rigidity of the substrate or article, which, for substrates having x and y dimensions greater than 4 times the z dimension, may decrease with the x and y dimensions for a given z dimension, and increase with the z dimension for given x and y dimensions, and a capability of the substrate to generate a sufficient quantity of aerosol to satisfy a user, which may increase with the x, y and z dimensions.
  • the aerosol-forming substrate has an upper surface and a lower surface, as set out above, and one or both of the upper surface and the lower surface is in the form of a circle or an oval or a polygonal 2-dimensional shape, for example a polygon selected from the list consisting of triangle, square, rectangle, pentagon, hexagon, heptagon, octagon, nonagon, and decagon.
  • one or both of the x dimension and the y dimension is between 10 mm and 50 mm, for example between 12 mm and 30 mm, for example between 14 mm and 26 mm, for example between 16 mm and 24 mm, for example between 18 mm and 22 mm, for example about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.
  • the aerosol-forming substrate is in the form of a cylinder defined by a circular base and a height, and in which a diameter of the base is between 10 mm and 50 mm, for example between 12 mm and 30 mm, for example between 14 mm and 26 mm, for example between 16 mm and 24 mm, for example between 18 mm and 22 mm, for example about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.
  • the z dimension is between 1 mm and 5 mm, for example between 1.2 mm and 4.5 mm, for example between 1.4 mm and 4 mm, for example between 1 .6 mm and 3.5 mm, for example between 1.7 mm and 3 mm, for example about 1 .7 mm, or about 1 .8 mm, or about 1 .9 mm, or about 2 mm, or about 2.1 mm.
  • the z dimension is less than 20 mm, for example less than 10 mm, for example less than 8 mm.
  • the aerosol-forming substrate is in the form of a cylinder defined by a base and a height, and in which the height is between 1 mm and 5 mm, for example between 1.2 mm and 4.5 mm, for example between 1 .4 mm and 4 mm, for example between 1 .6 mm and 3.5 mm, for example between 1.7 mm and 3 mm, for example about 1 .7 mm, or about 1 .8 mm, or about 1 .9 mm, or about 2 mm, or about 2.1 mm.
  • the aerosol-forming substrate is in the form of a cylinder, for example a right circular cylinder, defined by a base and a height, in which a diameter of the base is between 10 mm and 50 mm, preferably between 14 mm and 50 mm, and in which the height is between 1 mm and 5, preferably between 1 mm and 4 mm.
  • the dimensions discussed in the above paragraphs may provide a compromise between the four factors discussed above with relation to the ratios between the x, y, and z dimensions.
  • the article consists entirely of the aerosol-forming substrate.
  • this may provide one or more of the following benefits: a reduction in the cost to manufacture the article, a reduction in the weight and therefore cost to transport the article, and a reduction in waste from manufacturing or using the article.
  • the aerosol-generating article may comprise a porous layer.
  • the aerosol-generating article consists of the aerosol-forming substrate and the porous layer.
  • the porous layer may cover at least one surface of the aerosol-forming substrate.
  • the porous layer completely encapsulates the aerosol-forming substrate.
  • the porous layer is a porous paper or a porous mesh.
  • porous is used to mean sufficiently porous so as to allow aerosol formed by the aerosol-forming substrate to escape through the porous layer in use.
  • the porous layer may have a total outer surface area. At least 20, 50, 80, or 90 percent of the total outer surface area may be open, for example open so as to expose the substrate to the external environment, or to allow aerosol from the substrate to pass therethrough, or both.
  • the porous layer may be or comprise a mesh.
  • the porous layer may be or comprise teabag material.
  • the porous layer may protect the aerosol-forming substrate from one or both of physical damage and chemical contamination.
  • the porous layer may also help to prevent transfer of aerosol-forming material from the aerosol-forming substrate onto a user handling the aerosol-forming substrate.
  • the aerosol-generating article may comprise a protective layer.
  • a protective layer for example, one or both of the upper surface and lower surface may be covered by a protective layer.
  • the planar lower surface may be covered by a protective layer, for example a water impervious layer such as a metallic foil, for example an aluminium foil.
  • the aerosol-forming substrate may comprise an aerosol-forming material.
  • the aerosol-forming substrate consists entirely of aerosol-forming material.
  • the aerosolforming substrate comprises one or both of nicotine and tobacco.
  • the aerosol-forming substrate may be substantially homogenous.
  • the aerosol-forming substrate comprises or consists of tobacco material, for example homogenised tobacco material.
  • the aerosolforming substrate comprises or consists of a solid aerosol-forming material.
  • the aerosol-forming substrate comprises or consists of a liquid aerosol-forming material retained within a porous matrix.
  • the aerosol-forming substrate comprises or consists of a gel aerosol-forming material.
  • a first portion of the aerosol-forming substrate comprises a first aerosol-forming material.
  • a second portion of the aerosol-forming substrate comprises a second aerosol-forming material.
  • the second aerosol-forming material may be different to the first aerosol-forming material.
  • substrates with two different aerosol-forming materials may allow combinations of aerosol-forming materials which may not otherwise be available. This could allow, for example, combinations of flavours which enhance the user experience.
  • one or both of the first aerosol-forming material and the second aerosol-forming material comprises one or both of tobacco and nicotine.
  • one or both of the first aerosolforming material and the second aerosol-forming material is substantially homogenous.
  • one or both of the first aerosol-forming material and the second aerosol-forming material comprises or consists of a solid aerosol-forming material.
  • one or both of the first aerosol-forming material and the second aerosol-forming material comprises or consists of a liquid aerosol-forming material retained within a porous matrix.
  • one or both of the first aerosol-forming material and the second aerosol-forming material comprises or consists of a gel aerosol-forming material.
  • one or both of the first aerosol-forming material and the second aerosol-forming material extend through the height or z dimension of the aerosol-forming substrate, for example through an entirety of the height or z dimension of the aerosol-forming substrate.
  • one or both of the first aerosol-forming material and the second aerosol-forming material extend through an entirety of the height or z dimension of the aerosol-forming substrate, from the base of the substrate to the upper surface of the substrate.
  • the first portion, or first aerosol-forming material occupies an inner portion of the base or substrate.
  • the second portion, or second aerosol-forming material occupies a peripheral portion of the base or substrate.
  • the peripheral portion at least partially surrounds the inner portion.
  • the inner portion may or may not comprise a radially central portion of the base.
  • the first aerosol-forming material may be shaped as a circular based cylinder, for example a right circular cylinder, located at a radially central portion of the base or an annular cylinder, for example right annular cylinder, located around a radially central portion of the base, and the second aerosol-forming material may be shaped as an annular cylinder, for example right annular cylinder, at least partially surrounding the first aerosol-forming material.
  • the first portion, or first aerosol-forming material occupies a radially inner or central portion of the base.
  • the second portion, or second aerosol-forming material occupies a radially peripheral portion of the base at least partially surrounding the inner or central portion.
  • the first aerosol-forming material is shaped as a circular based cylinder located at a radially central portion of the base or an annular cylinder located around a radially central portion of the base, and the second aerosol-forming material is shaped as an annular cylinder at least partially surrounding the first aerosol-forming material.
  • the arrangements discussed in the above two paragraphs may mean that an orientation of the substrate is unimportant when placing the base of the substrate in thermal contact with a planar heater similarly having an inner or central heating portion and an outer heating portion. Regardless of the orientation, the first aerosol-forming material would be in thermal contact with the inner or central heating portion and the second aerosol-forming material would be in thermal contact with the outer heating portion. This would not be the case with, for example, a cylindrical substrate where the first aerosol-forming material occupies a left half of the substrate and the second aerosol-forming material occupies a right half of the substrate.
  • orientation may be used to refer to a rotational orientation of the substrate about the z direction.
  • an aerosol-generating article for use with an aerosol-generating device to form an inhalable aerosol.
  • the aerosol-generating article comprises an aerosol-forming substrate, the aerosol-forming substrate having a base defined by an x dimension and a y dimension and a height defined by a z dimension.
  • a first portion of the aerosol-forming substrate comprises a first aerosol-forming material
  • a second portion of the aerosol-forming substrate comprises a second aerosol-forming material different to the first aerosol-forming material.
  • the first aerosol-forming material occupies an inner portion of the base
  • the second aerosolforming material occupies a peripheral portion of the base at least partially surrounding the inner portion.
  • a plurality of holes or notches are preferably defined in an upper surface of the aerosolforming substrate.
  • the holes or notches may be located in the first material, the second material, or both the first material and the second material.
  • the first portion of the substrate may occupy a volume which is between 25 and 400, 25 and 200, 25 and 100, or 25 and 50, percent of a volume of the second portion of the substrate.
  • All of the first aerosol-forming material of the substrate may occupy a volume which is between 25 and 400, 25 and 200, 25 and 100, or 25 and 50, percent of a volume of all of the second aerosol-forming material of the substrate.
  • any one, two or all of the aerosol-forming material, the first aerosol-forming material and the second aerosol-forming material may comprise one or more organic materials such as tobacco. Any one, two or all of the aerosol-forming material, the first aerosol-forming material and the second aerosol-forming material may comprise one or more of herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenised tobacco, extruded tobacco and expanded tobacco.
  • any one, two or all of the aerosol-forming material, the first aerosol-forming material and the second aerosol-forming material may comprise one or more aerosol-formers.
  • Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosolformers 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.
  • 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
  • the aerosolformer may be or comprise glycerine. Any one, two or all of the aerosol-forming material, the first aerosol-forming material and the second aerosol-forming material may comprise at least 1 , 2, 5, 10, or 15 weight percent aerosol-former.
  • any one, two or all of the aerosol-forming material, the first aerosol-forming material and the second aerosol-forming material may comprise nicotine.
  • Any one, two or all of the aerosolforming material, the first aerosol-forming material and the second aerosol-forming material may comprise one or more cannabinoid compounds such as one or more of: tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannabivarin (CBV), cannabidivarin (CBDV), tetrahydrocannabivarin (THCV), cannabichromene (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin
  • any one, two or all of the aerosol-forming material, the first aerosol-forming material and the second aerosol-forming material 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 comprises a centrally located hole or aperture.
  • the centrally located aperture may be located at a substantially central, for example radially central, portion of the substrate.
  • the centrally located aperture may be referred to as a radially central through-hole.
  • this aperture may help to accommodate thermal expansion of the substrate during use. This may minimise deformation of the substrate, which can lead to worse thermal contact with a planar heater if the substrate deforms so as to bend or shrink away from the planar heater.
  • the aperture could form an air flow path through the substrate. This could aid aerosol generation or aerosol entrainment into an air flow through or past the substrate.
  • the aperture may have a largest cross-sectional dimension, for example largest dimension in the x or y direction, of at least 1 , 2, 3, 5, or 10 mm.
  • the aperture may have a largest cross- sectional dimension, for example largest dimension in the x or y direction, of no more than 20 or 10 mm.
  • the aperture may have a smallest cross-sectional dimension, for example smallest dimension in the x or y direction, of at least 1 , 2, 3, 5, or 10 mm.
  • the aperture may have a smallest cross-sectional dimension, for example smallest dimension in the x or y direction, of no more than 20 or 10 mm.
  • these sizes may provide a compromise between sufficiently accommodating thermal expansion of, and air flow through, the substrate, and the substrate still containing enough aerosol-forming material to be able to form enough aerosol to satisfy a user.
  • the first aerosol-forming material is a first homogenised tobacco material.
  • the second aerosol-forming material is a second homogenised tobacco material having a different composition to the first homogenised tobacco material.
  • the first homogenised tobacco material differs from the second tobacco composition by virtue of having at least one difference selected from the list consisting of: different aerosol-former content, different tobacco content, different flavourant content, different water content, and different nicotine content.
  • a plurality of holes or notches are defined in an upper surface of the aerosol-forming substrate.
  • a plurality of holes or notches may be defined in the base or lower surface of the aerosol-forming substrate.
  • at least a portion of the plurality of holes are blind holes that do not extend through an entirety of the height, or through an entirety of the z dimension, of the aerosol-forming substrate.
  • at least a portion of the plurality of holes are through-holes that extend through the height, or through an entirety of the z dimension, of the aerosol-forming substrate, for example from the upper surface to the base.
  • the aerosol-generating article is substantially symmetrical about a plane extending in the x and y dimensions through a location halfway between the base and the upper surface.
  • the base and the upper surface of the aerosol-generating article are substantially indistinguishable.
  • the base and the upper surface of the aerosolgenerating article are interchangeable, for example in the sense that a substantially identical aerosol is released from heating the base of the substrate, and from flipping the article upsidedown and heating the upper surface (which may now be considered the new base) of the substrate.
  • the base and the upper surface of the aerosol-generating article are both equally suitable for heating by a heater, for example planar heater.
  • this may allow a user to insert the article into a cavity of an aerosol-generating device without needing to worry about the article being upside down.
  • the aerosol-forming substrate may be manufactured by any suitable process.
  • a slurry may be formed comprising the constituents of an aerosol-forming material and additional water.
  • the slurry may be cast and dried to form a sheet of the aerosol-forming material, which may then be cut to shape.
  • a multiple-material aerosol-forming substrate may be formed in similar manner. For example, a first slurry may be formed comprising the constituents of the first aerosol-forming material and additional water. A second slurry may be formed comprising the constituents of the second aerosol-forming material and additional water. These first and second slurries may be cast and dried to form sheets of the first aerosol-forming material and the second aerosol-forming material.
  • the sheet of first aerosol-forming material may then be cut and shaped into a long right circular cylinder.
  • the sheet of second aerosol-forming material may then be wrapped around the long right cylinder of first aerosol-forming material to form a long, right circular cylinder with a central portion of the first aerosol-forming material and an outer portion of the second aerosolforming material.
  • This long cylinder may then be cut in several places through its curved surface. This may result in forming a plurality of aerosol-forming substrates which are short right circular cylinders in shape, and have an inner, central portion of the first aerosol-forming material and an outer, peripheral portion of the second aerosol-forming material surrounding the first aerosolforming material.
  • Holes or notches may be formed in a surface of the aerosol-forming substrate by pressing a suitable tool, for example a stamp or a docker tool, into the surface.
  • the stamp or docker tool may comprise a plurality of protrusions to form corresponding holes or notches when pressed into the surface of the aerosol-forming substrate.
  • short right circular cylinders may be stamped out of the sheet of the first aerosol-forming material.
  • Short right annular cylinders may be stamped out of the sheet of the second aerosol-forming material.
  • the short right circular cylinders of the first aerosol-forming material may then be placed into the central holes in the short right annular cylinders of the second aerosol-forming material. This may result in the formation of an aerosol-forming substrate which is right circular cylinder in shape, has a height equal to the thickness of the sheets of the first and second aerosol-forming materials, and has an inner, central portion of the first aerosol-forming material and an outer, peripheral portion of the second aerosol-forming material surrounding the first aerosol-forming material.
  • an aerosol-forming substrate could be made using known extrusion processes.
  • a stiff slurry of aerosol-forming material may be put in an extruder, and extruded through an extrusion head to form an elongated extrusion.
  • This elongated extrusion is then preferably dried, for example by passing through a continuous drying oven, and sliced to form individual aerosol-forming substrates.
  • a two-material aerosol-forming substrate may be formed in a similar manner using two extruders and a single dual extrusion head.
  • Such systems are well known for the production of multi-material extrusions.
  • the first aerosolforming material may be placed in a first extruder and fed through a first die of a dual extruder head.
  • the second aerosol-forming material may be placed in a second extruder and fed through a second die of the dual extruder head.
  • the resulting extrusion may be in the form of a continuous cylinder having an inner portion of the first aerosol-forming material and an outer portion of the second aerosol-forming material.
  • This continuous cylinder may then be dried and cut in multiple positions. Portions of the cut cylinder may then be laid flat and textured with a docking roller, or similar means, to form a desired pattern of surface holes and notches to form aerosol-forming substrates according to the present disclosure, for example the aerosol-forming substrate according to the preferred embodiment of the first aspect.
  • an aerosol-generating device for heating an aerosol-generating article to form an aerosol.
  • the aerosol-generating device may comprise a cavity for receiving at least a portion, for example an entirety, of the aerosol-generating article.
  • the aerosol-generating device may comprise a heater for heating the aerosol-forming article, for example an aerosol-forming substrate of the aerosol-generating article.
  • the heater may be arranged to provide heat to a base of the cavity.
  • the base of the cavity may be dimensioned to receive a base of an aerosol-generating article as described above, for example an aerosol-generating article according to the first aspect.
  • an aerosolgenerating device for heating an aerosol-generating article to form an aerosol.
  • the aerosolgenerating device comprises a cavity for receiving at least a portion, for example an entirety, of the aerosol-generating article, and a heater for heating the aerosol-generating article.
  • the heater is preferably arranged to provide heat to a base of the cavity.
  • the base of the cavity is preferably dimensioned to receive a base of an aerosol-generating article according to the first aspect.
  • the heater is preferably arranged to provide heat to a base of the cavity and the cavity is preferably dimensioned to receive a base of an aerosol-generating article according to the first aspect.
  • this may be a particularly efficient heating arrangement.
  • the heater is a planar heater.
  • the base of the cavity is substantially planar.
  • a planar heater or base may provide good thermal contact with a planar surface of an aerosol-forming substrate.
  • the heater may be arranged at the base of the cavity or beneath the base of the cavity.
  • the heater comprises a first portion configured to heat a first portion of the base of the cavity and a second portion configured to heat a second portion of the base of the cavity.
  • the first portion of the heater is configured to heat an inner portion of the base of the cavity.
  • the second portion of the heater may be configured to heat a peripheral portion of the base of the cavity.
  • the peripheral portion may at least partially surround the inner portion of the base of the cavity.
  • the inner portion may be or comprise a central portion of the base of the cavity.
  • the inner portion may be substantially circular in cross-section or shape, or substantially annular in cross-section or shape.
  • the peripheral portion may be substantially annular in cross-section or shape.
  • the first portion of the heater is configured to heat a radially central portion of the base of the cavity.
  • the second portion of the heater is configured to heat a radially peripheral portion of the base of the cavity at least partially surrounding the radially central portion of the base of the cavity, for example in which the first portion of the heater is configured to heat a radially central circular portion of the base of the cavity and the second portion of the heater is configured to heat an annular portion of the base of the cavity surrounding the central portion of the base of the cavity.
  • the arrangements of the first and second portions of the heater discussed above may mean that the first and second portions of the heater contact the same portions of an aerosol-forming substrate in use regardless of the orientation of the aerosol-forming substrate when inserted into the cavity of the device.
  • orientation may be used to refer to a rotational orientation of the substrate about the z direction.
  • the first heater portion and the second heater portion are configured to operate independently of one another, for example to independently heat respective portions of the base of the cavity.
  • this may allow the first and second heater portions to heat first and second portions of the aerosol-forming substrate to different temperatures, or at different times, or to different temperatures and at different times.
  • the first heater portion and the second heater portion are configured to operate simultaneously to heat respective portions of the base of the cavity.
  • this may allow the first and second heater portions to heat first and second portions of the aerosol-forming substrate simultaneously.
  • the first heater portion and the second heater portion are configured to heat respective portions, for example the first and second portions, of the base of the cavity to different temperatures.
  • this may allow the first and second heater portions to heat first and second portions of the aerosol-forming substrate to temperatures which are optimised specifically for the first and second portions of the aerosol-forming substrate.
  • the first portion of the aerosol-forming substrate may release an optimised aerosol at a first temperature
  • the second portion of the aerosol-forming substrate may be different to the first aerosol-forming substrate and so may release an optimised aerosol at a second temperature, different to the first temperature.
  • the first heater portion and the second heater portion being configured to heat first and second portions of the base of the cavity to different temperatures may allow release of optimised aerosols from both of the first and second portions of the aerosol-forming substrate.
  • the heater is or comprises a resistance heater.
  • one or both of the first heater portion and the second heater portion is or comprises a resistance heater.
  • the heater is or comprises an inductive heater.
  • one or both of the first heater portion and the second heater portion is or comprises an inductive heater.
  • the inductive heater may comprise one or both of a susceptor and an inductor.
  • the aerosol-generating device may comprise a device body.
  • the device body may comprise the heater.
  • the aerosol-generating device may comprise a mouthpiece element.
  • the device body may comprise a device body housing.
  • the device body housing may define the cavity for receiving at least a portion of the aerosol-generating article.
  • the device body and the mouthpiece element may be releasably connectable.
  • the mouthpiece element may be releasably connectable with the device body, for example the device body housing.
  • the mouthpiece element may be releasably connectable with the device body, for example the device body housing, between a connected position and a disconnected position.
  • the cavity In the connected position, the cavity may be at least partially covered, for example by the mouthpiece element.
  • the disconnected position the cavity may be at least partially exposed, for example so as to allow insertion of the article into the cavity.
  • the mouthpiece element may be moveable, for example pivotable about a hinge, relative to the device body, for example between a first position and a second position. In the first position, the cavity may be at least partially covered, for example by the mouthpiece element. In the second position, the cavity may be at least partially exposed, for example so as to allow insertion of the article into the cavity.
  • covering the cavity, or the article in the cavity may ensure most aerosol from the article travels along the desired flow path to the user, rather than escaping to the external environment.
  • the device for example the device body, may comprise a power source such as a battery.
  • the power source may provide power to the heater.
  • the device for example the device body, may comprise a controller. The controller may be configured to control power from the power supply to the heater.
  • the device body may comprise a distal end and a proximal end.
  • the cavity may be defined at the proximal end of the device body.
  • the mouthpiece element may comprise a distal end and a proximal end. The distal end of the mouthpiece element may be configured to releasably connect to the proximal end of the device body.
  • the mouthpiece element may be configured to be inserted into a mouth of a user.
  • the proximal end of the mouthpiece element may be configured to be inserted into a mouth of a user.
  • the aerosol-generating device may comprise a second heater.
  • the device body may comprise the second heater.
  • the mouthpiece element may comprise the second heater.
  • the power source may be configured to provide power to the second heater.
  • the controller may control power from the power source to the second heater.
  • the mouthpiece element may be moveable relative to, or connectable to, the device body so as to electrically connect the power source of the device body to the second heater.
  • the device body may comprise device body electrical contacts connected to the power source
  • the mouthpiece element may comprise mouthpiece element electrical contacts connected to the second heater.
  • the device body electrical contacts may contact the mouthpiece element electrical contacts so as to electrically connect the power source to the second heater.
  • the second heater may be configured to contact, or provide heat to, or both contact and provide heat to, one or both of an upper surface and a side surface of the aerosol-generating article or aerosol-forming substrate in use.
  • the device for example a mouthpiece element or device body of the device, may comprise a second surface.
  • the second surface may be a second heating surface.
  • the second heater may comprise, or be configured to provide heat to, the second surface.
  • the second surface may be configured to contact, or provide heat to, or both contact and provide heat to, one or both of an upper surface and a side surface of the aerosol-generating article or aerosol-forming substrate in use.
  • the device may be configured to provide heat to both the base of the cavity and to the second surface.
  • this may allow heating of both a base and an upper or side surface of the aerosol-generating article or aerosol-forming substrate.
  • This may allow heating of a greater proportion of the substrate to a temperature at which an aerosol is released whilst minimising the risk of burning the hottest portions of the substrate closest to the heater or second heater. Alternatively, or in addition, this may reduce a time required to heat the substrate sufficiently to release an aerosol.
  • the second surface may be configured to push the aerosol-generating article towards the base of the cavity in use.
  • the aerosol-generating system may be configured such that, when the article is received at least partially, for example entirely, in the cavity of the device, the second surface of the device pushes or urges the article towards the base of the cavity of the device. Movement of the device from a second or disconnected position to a first or connected position may result in the second surface contacting, and optionally pushing against, the article or substrate, for example contacting or pushing against the upper surface of the article or substrate.
  • this pushing may help to ensure good thermal contact between the base of the aerosol-forming substrate and the base of the cavity of the device.
  • the second surface may provide a ceiling of the cavity.
  • the second surface may be configured to provide the ceiling of the cavity when the mouthpiece is connected to the device body.
  • the second surface may not provide the ceiling of the cavity when the mouthpiece is not connected to the device body.
  • the second heater or the second surface, may be located adjacent to or at least partially within a portion of the device body housing, optionally thereby providing the ceiling of the cavity, for example when the mouthpiece element is connected to the device body.
  • the mouthpiece element comprises the second surface, or the second heater
  • the mouthpiece element may be connectable to the device body so as to locate the second surface, or second heater, adjacent to or at least partially within a portion of the device body housing, optionally thereby providing the ceiling of the cavity.
  • One or both of the second surface and the second heater may be planar.
  • a planar second heater or planar second surface may provide good thermal contact with a planar surface of a substrate to be heated.
  • the second surface may oppose the base of the cavity, for example when the mouthpiece element is connected to the device body.
  • the second heater may oppose the heater, for example when the mouthpiece element is connected to the device body.
  • a planar surface of the second heater may oppose a planar surface of the heater.
  • the cavity may be located between the heater and the second heater, for example between a planar surface of the heater and a planar surface of the second heater.
  • a spacing between the base and the second surface may be sufficient to accommodate the height, or z dimension, of the aerosol-generating article.
  • This spacing may be present when the mouthpiece element is connected to the device body. This spacing may be present when the device is in a first or connected position of the device, for example as opposed to a second or disconnected position of the device. This spacing may be at least 50, 60, 70, 80, or 90 percent of the z dimension of the aerosol-generating article prior to being received in the cavity. This spacing may be no more than 200, 150, 120, or 110 percent of the z dimension of the aerosol-generating article prior to being received in the cavity.
  • This spacing may be between 50% and 200%, preferably between 50% and 150%, more preferably between 80% and 120%, of the z dimension of the aerosol-generating article prior to being received in the cavity.
  • the z dimension of the article may be reduced when received in the cavity if compressed, for example between the base and the second surface.
  • the heater may heat a base of the article and the second heater may heat an upper surface of the article.
  • this may allow heating of a greater proportion of the substrate to a temperature at which an aerosol is released whilst minimising the risk of burning the hottest portions of the substrate closest to the heater or second heater.
  • features described in relation to the heater may be applicable to the second heater.
  • features described in relation to first and second heater portions of the heater may be applicable to first and second heater portions of the second heater.
  • the second heater is a planar heater.
  • a planar heater may provide good thermal contact with a planar surface of an aerosol-forming substrate.
  • the second heater may be arranged at or adjacent to the second surface or beneath the second surface.
  • the second heater comprises a first portion configured to heat a first portion of the second surface and a second portion configured to heat a second portion of the second surface.
  • the first portion of the second heater is configured to heat an inner portion of the second surface.
  • the second portion of the second heater may be configured to heat a peripheral portion of the second surface.
  • the peripheral portion may at least partially surround the inner portion.
  • the inner portion may be or comprise a central portion of the second surface.
  • the inner portion may be substantially circular in cross-section or shape, or substantially annular in cross-section or shape.
  • the peripheral portion may be substantially annular in cross-section or shape.
  • the first portion of the second heater is configured to heat a radially central portion of the second surface.
  • the second portion of the heater is configured to heat a radially peripheral portion of the second surface at least partially surrounding the radially central portion of the second surface, for example in which the first portion of the second heater is configured to heat a radially central circular portion of the second heating surface and the second portion of the second heater is configured to heat an annular portion of the second surface surrounding the central portion of the second surface.
  • the arrangements of the first and second portions of the second heater discussed above may mean that the first and second portions of the second heater heat the same portions of an upper surface of an aerosol-forming substrate in use regardless of the orientation of the aerosol-forming substrate when inserted into the cavity of the device.
  • orientation may be used to refer to a rotational orientation of the substrate about the z direction.
  • the first heater portion and the second heater portion of the second heater are configured to operate independently of one another, for example to independently heat respective portions of the base of the cavity.
  • this may allow the first and second heater portions of the second heater to heat first and second portions of the aerosol-forming substrate to different temperatures, or at different times, or to different temperatures and at different times.
  • the first heater portion and the second heater portion of the second heater are configured to operate simultaneously to heat respective portions of the second surface.
  • this may allow the first and second heater portions of the second heater to heat first and second portions of the aerosol-forming substrate simultaneously.
  • the first heater portion and the second heater portion of the second heater are configured to heat respective portions, for example the first and second portions, of the second surface to different temperatures.
  • this may allow the first and second heater portions of the second heater to heat first and second portions of the aerosol-forming substrate to temperatures which are optimised specifically for the first and second portions of the aerosolforming substrate.
  • the first portion of the aerosol-forming substrate may release an optimised aerosol at a first temperature
  • the second portion of the aerosol-forming substrate may be different to the first aerosol-forming substrate and so may release an optimised aerosol at a second temperature, different to the first temperature.
  • the first heater portion and the second heater portion of the second heater being configured to heat first and second portions of the second surface to different temperatures may allow release of optimised aerosols from both of the first and second portions of the aerosol-forming substrate.
  • the second heater is or comprises a resistance heater.
  • one or both of the first heater portion and the second heater portion of the second heater is or comprises a resistance heater.
  • the second heater is or comprises an inductive heater.
  • one or both of the first heater portion and the second heater portion of the second heater is or comprises an inductive heater.
  • the inductive heater may comprise one or both of a susceptor and an inductor.
  • the device for example the device body, may comprise one or more peripheral walls around the cavity. These one or more peripheral walls may extend from the base. These one or more peripheral walls may extend from the base at least partway to second surface, for example when the mouthpiece element is connected to the device body.
  • the device may comprise a third heater.
  • the device body may comprise the third heater.
  • the mouthpiece element may comprise the third heater.
  • the third heater may comprise, or be configured to provide heat to, the one or more peripheral walls around the cavity.
  • the third heater may allow heating of the side surface between the base and the upper surface of the aerosol-generating article.
  • the third heater is or comprises a resistance heater.
  • the third heater is or comprises an inductive heater.
  • the inductive heater may comprise one or both of a susceptor and an inductor.
  • the second heater, or the second surface may be located adjacent to or at least partially within the one or more peripheral walls around the cavity, optionally thereby providing the ceiling of the cavity, for example when the mouthpiece element is connected to the device body.
  • the mouthpiece element comprises the second surface, or the second heater
  • the mouthpiece element may be connectable to the device body so as to locate the second surface, or second heater, adjacent to or at least partially within the one or more peripheral walls around the cavity, optionally thereby providing the ceiling of the cavity.
  • the device for example one or both of the device body and the mouthpiece element, may comprise an air inlet.
  • the device for example the mouthpiece element, may comprise an air outlet.
  • the device may comprise an air flow path fluidly connecting the air inlet to the air outlet.
  • the air flow path may extend one or both of through and past the cavity.
  • the device may be configured such that, when a negative pressure is applied to the air outlet, for example by a user drawing on the air outlet, air is drawn in through the air inlet, then past an aerosol-generating article received in the cavity, thereby entraining aerosol released from the aerosol-forming substrate of the article, then out through the air outlet.
  • an aerosol-generating system may comprise an aerosol-generating article, for example an aerosol-generating article as described above, such as the aerosol-generating article according to the first aspect.
  • the system may comprise an aerosol-generating device, for example an aerosol-generating device as described above, such as the aerosol-generating device according to the second aspect.
  • an aerosolgenerating system comprising an aerosol-generating article according to the first aspect and an aerosol-generating device according to the second aspect.
  • the aerosol-generating device may comprise a device body and a mouthpiece element, and the device body and the mouthpiece element may be moveable relative to one another, for example releasably connectable.
  • the device body and the mouthpiece element may have a first or connected position and a second or disconnected position.
  • aerosol-generating article may refer to an article able to generate, or release, an aerosol.
  • an 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.
  • 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.
  • 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.
  • An aerosol-generating article for use with an aerosol-generating device to form an inhalable aerosol, the aerosol-generating article comprising an aerosol-forming substrate having a base defined by an x dimension and a y dimension and a height defined by a z dimension, preferably a planar lower surface of the aerosol-forming substrate being defined by the base and a planar upper surface of the aerosol-forming substrate being parallel to the planar lower surface, in which the aerosol-generating article further comprises a plurality of holes or notches, for example a plurality of holes, defined in an upper surface of the aerosol-forming substrate.
  • Ex2 An aerosol-generating article according to any preceding example in which the base forms a lower surface of the aerosol-forming substrate, an upper surface of the aerosolforming substrate being substantially parallel to the lower surface and spaced from the lower surface by the z dimension, in which a plurality of holes or notches, for example a plurality of holes, are defined in an upper surface of the aerosol-forming substrate.
  • An aerosol-generating article in which at least a portion of the plurality of holes, for example each of the plurality of holes, has an opening defined in the upper surface of the aerosol-forming substrate and a bore extending into the aerosolforming substrate, in which a maximum dimension of a hole at its opening is greater than a maximum dimension of the same hole at a position midway between the upper and lower surface.
  • each of the plurality of holes has an opening defined in the upper surface of the aerosol-forming substrate and at least some of the holes have a funnel shape in which the maximum diameter of the hole is at its opening.
  • An aerosol-generating article according to any preceding example in which the diameter at the opening of each of the plurality of holes is within the range 0.02 mm to 2.3 mm, for example 0.03 mm to 1.5 mm, for example 0.04 mm to 1 mm, for example 0.10 mm to 0.80 mm, for example between 0.15 mm and 0.77 mm.
  • Ex13 An aerosol-generating article according to example Ex11 or Ex12 in which the density of through holes is between 2 and 6 per cm2, for example between 3 and 5 per cm2.
  • an aerosol-generating article for use with an aerosol-generating device to form an inhalable aerosol
  • the aerosol-generating article comprising: an aerosol-forming substrate comprising an aerosol-forming material, the aerosol-forming substrate being in the form of a 3-dimensional shape having a base defined by an x dimension and a y dimension and a height defined by a z dimension, in which the largest of the x dimension and the y dimension has a magnitude equal to or greater than 4 times the z dimension.
  • an aerosol-generating article in which the base of the aerosol-forming substrate forms the lower surface defined by a first 2-dimensional shape having a perimeter, the aerosol-forming substrate further comprising the upper surface defined by a second 2-dimensional shape having a perimeter, and one or more peripheral surface extending perpendicularly between the first surface and the second surface, for example one or more peripheral surface defined between the perimeter of the first shape and the perimeter of the second shape.
  • an aerosol-generating article in the form of a cylinder, for example a right cylinder, defined by a substantially circular base and a height, for example in which the x dimension and the y dimension equal a diameter of the circular base of the cylinder and in which the z dimension equals the height of the cylinder.
  • An aerosol-generating article according to any of examples Ex1 to Ex11 in which the aerosol-forming substrate has an upper surface and/or a lower surface in the form of a polygonal 2-dimensional shape, for example a polygon selected from the list consisting of triangle, square, rectangle, pentagon, hexagon, heptagon, octagon, nonagon, and decagon.
  • An aerosol-generating article according to any preceding example in which the x dimension and/or the y dimension is between 10 mm and 50 mm, for example between 12 mm and 30 mm, for example between 14 mm and 26 mm, for example between 16 mm and 24 mm, for example between 18 mm and 22 mm, for example about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.
  • an aerosol-generating article in which the aerosol-forming substrate is in the form of a cylinder defined by a circular base and a height, and in which a diameter of the base is between 10 mm and 50 mm, for example between 12 mm and 30 mm, for example between 14 mm and 26 mm, for example between 16 mm and 24 mm, for example between 18 mm and 22 mm, for example about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.
  • an aerosol-generating article in which the aerosol-forming substrate is in the form of a cylinder defined by a circular base and a height, and in which a radius of the base is between 5 mm and 25 mm, for example between 6 mm and 15 mm, for example between 7 mm and 13 mm, for example between 8 mm and 12 mm, for example between 9 mm and 11 mm, for example about 9 mm, or about 10 mm, or about 11 mm.
  • An aerosol-generating article according to any preceding example in which the z dimension is between 1 mm and 5 mm, for example between 1.2 mm and 4.5 mm, for example between 1.4 mm and 4 mm, for example between 1.6 mm and 3.5 mm, for example between 1.7 mm and 3 mm, for example about 1.7 mm, or about 1 .8 mm, or about 1 .9 mm, or about 2 mm, or about 2.1 mm.
  • an aerosol-generating article in which the aerosol-forming substrate is in the form of a cylinder defined by a base and a height, and in which the height is between 1 mm and 5 mm, for example between 1.2 mm and 4.5 mm, for example between 1.4 mm and 4 mm, for example between 1 .6 mm and 3.5 mm, for example between 1 .7 mm and 3 mm, for example about 1.7 mm, or about 1 .8 mm, or about 1 .9 mm, or about 2 mm, or about 2.1 mm.
  • Ex49 An aerosol-generating article according to any preceding example in which a first portion of the aerosol-forming substrate comprises a first aerosol-forming material, and a second portion of the aerosol-forming substrate comprises a second aerosol-forming material different to the first aerosol-forming material.
  • Ex49A An aerosol-forming material according to example Ex49 in which the first aerosolforming material and the second aerosol-forming material extend through a width of the aerosolforming substrate, for example through the x direction of the aerosol-forming substrate and/or the y direction of the aerosol-forming substrate.
  • Ex49B An aerosol-forming substrate according to example Ex49 or Ex49A in which the first aerosol-forming material forms an upper portion of the aerosol-forming substrate and the second aerosol-forming material forms a lower portion of the aerosol-forming substrate.
  • Ex52 An aerosol-generating article according to example Ex50 or Ex51 in which the first aerosol-forming material occupies a radially central portion of the base and the second aerosolforming material occupies a radially peripheral portion of the base surrounding the central portion, for example in which the first aerosol-forming material is shaped as a circular based cylinder located at a radially central portion of the base and the second aerosol-forming material is shaped as an annular cylinder surrounding the first aerosol-forming material.
  • Ex54 An aerosol-forming article according to example Ex53 in which the first homogenised tobacco material differs from the second tobacco composition by virtue of having at least one difference selected from the list consisting of; different aerosol-former content, different tobacco content, different flavourant content, different water content, and different nicotine content.
  • An aerosol-generating article comprising a printed indicia, for example an identification marking or an orientation marking printed on a portion of the aerosol-forming substrate or on a protective layer applied to a surface of the aerosolforming substrate, for example on a porous protective layer.
  • a printed indicia for example an identification marking or an orientation marking printed on a portion of the aerosol-forming substrate or on a protective layer applied to a surface of the aerosolforming substrate, for example on a porous protective layer.
  • thermochromatic indicator configured to show whether the aerosol-generating article has been heated above a predetermined temperature
  • a thermal indicator or thermochromatic indicator located on a portion of the aerosol-forming substrate or on a protective layer applied to a surface of the aerosol-forming substrate, for example on a porous protective layer.
  • thermochromatic indicator comprises or consists citric acid.
  • An aerosol-generating article comprising an embossed layer, for example an embossed layer of a protective layer applied to a surface of the aerosol-forming substrate, for example on a porous protective layer, the embossed layer providing a texture of between 10 and 50 microns above or below the plane of the layer.
  • An aerosol-generating device for heating an aerosol generating article to form an aerosol, the aerosol-generating device comprising; a cavity for receiving the aerosol-generating article, and a heater for heating the aerosol-forming article, the heater being arranged to provide heat to a base of the cavity, in which the base of the cavity is dimensioned to receive a base of an aerosolgenerating article according to any preceding example.
  • Ex60 An aerosol-generating device according to example Ex59 in which the heater is a planar heater arranged at the base of the cavity or beneath the base of the cavity.
  • Ex61 An aerosol-generating device according to example Ex59 or Ex60 in which the heater comprises a first portion configured to heat a first portion of the base of the cavity and a second portion configured to heat a second portion of the base of the cavity.
  • Ex62 An aerosol-generating device according to example Ex61 in which the first portion of the heater is configured to heat a central portion of the base of the cavity and the second portion of the heater is configured to heat a peripheral portion of the base of the cavity surrounding the central portion of the base of the cavity.
  • Ex65 An aerosol-generating device according to any of examples Ex61 to Ex64 in which the first heater portion and the second heater portion are configured to operate simultaneously to heat respective portions of the base of the cavity.
  • Ex66 An aerosol-generating device according to any of examples Ex61 to Ex65 in which the first heater portion and the second heater portion are configured to heat respective portions of the base of the cavity to different temperatures.
  • Ex68 An aerosol-generating device according to any of examples Ex59 to Ex66 in which the heater is an inductive heater, for example in which the heater comprises a susceptor and an inductor.
  • Figure 1 shows an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device for use with the aerosol-generating article;
  • Figure 2 shows the aerosol-generating system of Figure 1 in a loaded, connected position
  • Figure 3 is a schematic illustration of a portion of an aerosol-generating device showing a planar aerosol-forming substrate being heated by a planar heater;
  • Figure 4 is a schematic illustration of a portion of an aerosol-generating device showing a planar aerosol-forming substrate comprising conical-shaped holes being heated by a planar heater;
  • Figure 5 is a schematic illustration of a portion of an aerosol-generating device showing a planar aerosol-forming substrate comprising cylindrical-shaped holes being heated by a planar heater;
  • Figure 6 is a schematic illustration of the upper surface of an aerosol-forming substrate
  • Figure 7 is a cross-sectional view of the aerosol-forming substrate of figure 6;
  • Figure 8 is a schematic illustration of the upper surface of an aerosol-forming substrate
  • Figure 9 is a cross-sectional view of the aerosol-forming substrate of figure 8.
  • Figure 10 is a cross-sectional view of a further example of an aerosol-forming substrate
  • Figure 11 is a schematic illustration of the upper surface of an aerosol-forming substrate
  • Figure 12 is a cross-sectional view of the aerosol-forming substrate of figure 11 ;
  • Figure 13 is a schematic illustration of the lower surface of the aerosol-forming substrate of figure 11 .
  • Figure 1 shows an aerosol-generating system 100 comprising an aerosol-generating article 200 and an aerosol-generating device 300 for use with the aerosol-generating article 200.
  • Figure 2 shows the same system 100 in a loaded, connected position.
  • the aerosol-generating article 200 is for use with the aerosol-generating device 300 to form an inhalable aerosol.
  • the aerosol-generating article 200 consists entirely of an aerosol-forming substrate 210 and is a circular right cylinder in shape.
  • the substrate 210 has a planar, circular base 212 and a planar, circular upper surface 213, each with a diameter, which may be referred to as an x or y dimension of the substrate 210, of around 20 mm.
  • the substrate 210 has a height, which may be referred to as a z dimension of the substrate 210, of around 3 mm extending from the base 212 to the upper surface 213.
  • the aerosol-forming substrate 210 consists of a first portion 214 of a first aerosol-forming material and a second portion 216 of a second aerosol-forming material different to the first aerosol-forming material.
  • the first aerosol-forming material is a first homogenised tobacco material and the second aerosol-forming material is a second homogenised tobacco material having a different composition to the first homogenised tobacco material.
  • the first homogenised tobacco material differs from the second tobacco composition by virtue of having a different flavourant content. Specifically, the first homogenised tobacco material a menthol flavourant homogeneously distributed throughout whereas the second homogenised tobacco material does not.
  • the first homogenised tobacco material could differ from the second tobacco composition in a number of ways, for example by virtue of having at least one difference selected from: different aerosol-former content, different tobacco content, different flavourant content, different water content, and different nicotine content.
  • a composition of a suitable aerosol-forming material which may be a second aerosol-forming material of the specific embodiment described above, may be as follows. Percentages are given in weight percent with respect to the product in its final state.
  • the second aerosol-forming material may be a second homogenised tobacco material with a moisture of about 5 to 25%, preferably of about 7 to 15%, at final product state. Such a material may be used, for example, as the second portion 216 of the aerosol-forming substrate 210 described above.
  • the second aerosol-forming material may further comprise the following:
  • Tobacco leaf for example about 15 to 45%, preferably of about 20 to 35% of a blend of tobacco leaf, incorporating at least one of the following tobacco types: bright tobacco; dark tobacco; aromatic tobacco.
  • Tobacco material is ground and graded to a particle size of about 100 to 380 mesh, preferably of about 170 to 320 mesh.
  • Cellulose fibres for example about 1 to 15%, preferably of about 3 to 7%, of cellulose fibres, of a length of about 10 to 250 pm, preferably of about 10 to 120 pm.
  • Tobacco fibres for example about 5 to 20%, preferably of about 7 to 15% of tobacco fibres, as filler, of any tobacco type or a blend of tobacco types.
  • Tobacco fibres are preferably derived from stems and/or or stalks, graded to fibres of a length of about 10 to 350 pm, preferably of about 10 to 180 pm.
  • Binder for example 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, ethylhydroxymethyl and carboxym ethyl, celluloses; dextran; and xanthan gum.
  • the preferable binder is guar.
  • Aerosol-former for example about 5 to 35%, preferably of about 10 to 25%, of an aerosol former.
  • Suitable aerosol-formers known in the art include: glycerine; monohydric alcohols like menthol, polyhydric alcohols, such as triethylene glycol; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyls of those.
  • tobacco type means one of the different varieties of tobacco, for example based on the distinct curing process that the tobacco undergoes before it is further processed in a tobacco product.
  • 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 Africa.
  • 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.
  • a composition of a further aerosol-forming material which may be suitable as a first aerosol-forming material in the specific embodiment described above, may be as follows. Percentages are given in weight percent with respect to the product in its final state.
  • the first aerosol-forming material may be primarily used for flavouring purposes, and may be suitable as the first portion 214 of the aerosol-forming substrate 210 described above.
  • the first aerosol-forming material may comprise:
  • An aerosol-former such as Glycerin; for example about 10 to 40 %, preferably of about 20 to 30 %.
  • Organic fibres for example about 10 to 30 %, preferably of about 15 to 25%, of any botanical variety suitable and with purity to comply with applicable FDA F&B grade requirements, as commonly available in the market.
  • organic fibres may derive from cellulose, cotton, wood, tea botanical varieties as sub-products, and subprocessed waste, of F&B tea industry.
  • Organic fibres are preferably of a length of about 10 to 400 pm, preferably of about 10 to 200 pm.
  • Organic botanical glycerite 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, and compounds of those. 4.
  • Organic botanical extracts for example about 1 to 15 %, preferably of about 2 to 7 %, of any of the previously referred botanicals, as well as menthol (dl-Menthol, C10H20O, 2- lsopropyl-5-methylcyclohexanol) such as obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related botanic varieties, as well as P-menthan-3-ol, as any secondary alcohol as diastereoisomers of 5-methyl-2-(propan-2-yl)cyclohexan-1- ol.
  • menthol dl-Menthol, C10H20O, 2- lsopropyl-5-methylcyclohexanol
  • such aerosol-forming material may also contain botanical essential oils of about 0.5 to 5 %, preferably of about 1 to 3 %, such as of palm, coconut, and wooden-based essential oils.
  • the aerosol-forming substrate may be formed from the first aerosol-forming material and the second aerosol-forming material using a known co-axial extrusion process.
  • the first aerosol-forming material may be placed in a first extruder and fed through a first, central, die of a dual extruder head.
  • the second aerosol-forming material may be placed in a second extruder and fed through a second, outer, die of the dual extruder head.
  • the resulting extrusion may be in the form of a continuous cylinder having an inner portion of the first aerosolforming material and an outer portion of the second aerosol-forming material.
  • This continuous cylinder may then be dried, for example by passing through a continuous IR drying oven, and cut in multiple positions to form multiple slices of aerosol-forming material having a central first portion 214 of the first aerosol-forming material and a radially external second portion 216 of the second aerosol-forming material. These slices may then be laid flat and textured, for example by use of a docking roller, to form a desired pattern of holes and/or notches in an upper surface of each slice, thereby forming a plurality of aerosol-forming substrates.
  • the first portion 214 and second portion 216 extend through the entire height of the substrate 210.
  • the first portion 214 is a right circular cylinder in shape and occupies a radially central portion of the substrate 210.
  • the second portion 216 is an annular cylinder in shape and occupies a radially peripheral portion of the substrate 210 surrounding the central portion.
  • the outer diameter of the second portion 216 is approximately twice the outer diameter of the first portion 214.
  • the aerosol-forming substrate 210 comprises a plurality of notches (not visible in Figure 1) in its upper surface 213 which do not extend through an entirety of the height of the substrate 210.
  • the aerosol-forming substrate 210 also comprises a plurality of through-holes (not visible in Figure 1) from upper surface 213, through an entirety of the height of the substrate 210, to the base 212 of the substrate 210.
  • the aerosol-generating device 300 comprises a mouthpiece element 310 and a device body 320 which are releasably connectable to one another.
  • this releasable connection may be facilitated by any suitable means, such as a magnetic connection, a snap-fit connection, or a threaded connection.
  • the device body 320 comprises a device body housing 322 defining a substantially right circular cylindrical cavity 324 for receiving the aerosol-generating article 200.
  • the device body 320 further comprises a power source 326 and a controller 328.
  • the device body 320 further comprises a heater 330 configured to provide heat to a substantially circular, planar base 332 of the cavity 324.
  • the heater 330 is a planar heater arranged beneath the base 332 of the cavity 324.
  • the heater 330 has a substantially circular cross-section and comprises a first heater portion and a second heater portion.
  • the first heater portion is a circular, radially central portion of the heater 330 and the second heater portion is an annular, radially peripheral portion of the heater 330 surrounding the first heater portion.
  • the first heater portion is configured to heat a circular, radially central portion of the base 332 of the cavity 324 and the second heater portion configured to heat an annular, radially peripheral portion of the base 332 of the cavity 324 surrounding the circular, radially central portion of the base 332 of the cavity 324.
  • the first heater portion and the second heater portion are configured to operate independently of one another. That is, the controller 328 is able to control a supply of power to the first heater portion and the second heater portion independently. This allows independent heating of the first and second portions of the base 332 of the cavity 324. If desired, the first heater portion and the second heater portion can be operated simultaneously to heat the first and second portions of the base 332 of the cavity 324 simultaneously.
  • the first heater portion and the second heater portion are configured to heat respective portions of the base 332 of the cavity 324 to different temperatures to heat the first and second portions 214, 216 of the aerosol-forming substrate 210 to different temperatures.
  • the first heater portion is configured to heat the first portion of the base 332 of the cavity 324 to around 180 degrees Celsius and the second heater portion is configured to heat the second portion of the base 332 of the cavity 324 to around 140 degrees Celsius.
  • the heater 330 is a resistance heater. That is, the heater 330 is an electrically resistive heater.
  • the first heater portion comprises an electrically resistive track deposited on a circular substrate.
  • the second heater portion comprises an electrically resistive track deposited on an annular substrate surrounding the circular substrate.
  • the heater could equally be an inductive heater, for example a heater comprising a susceptor and an inductor.
  • the mouthpiece element 310 comprises an air inlet 312 and an air outlet 314. The air inlet 312 and the air outlet 314 are fluidly connected by an air flow path within the mouthpiece element 310.
  • the aerosol-generating article 200 is received in the cavity 324 of the device body 320.
  • the mouthpiece element 310 is connected to the device body 320. This is considered a loaded, connected position of the aerosol-generating system 100.
  • a second surface 316 of the mouthpiece element 310 contacts and presses against the upper surface 213 of the substrate 210. This pressing urges the substrate 210 towards the base 332 of the cavity 324, thus ensuring good thermal contact between the base 212 of the substrate 210 and the base 332 of the cavity 324.
  • FIG 2 shows the aerosol-generating system 100 of Figure 1 in the loaded, connected position. The system 100 is ready for use in this position.
  • a user may insert a proximal end of the mouthpiece element 310, including the air outlet 314, into their mouth. The user may then press and hold depressed a button (not shown) on the device body 320 and draw on the air outlet 314.
  • the controller 328 supplies power from the power source 326 to the heater 330. Specifically, the controller 328 supplies power from the power source 326 to the first heater portion and then, after a short delay, also to the second heater portion. This delay allows the first and second heater portions to reach their optimal temperatures of 180 and 140 degrees Celsius at roughly the same time.
  • the device body 320 further comprises a temperature sensor (not shown) for monitoring the temperatures of the first and second heater portions of the heater 330 whilst the button is depressed. Once the first and second heater portions of the heater 330 are at their optimal temperatures, the controller 328, based on feedback from the temperature sensor, controls the supply of power to the heater 330 so as to maintain the heater portions at or close to their optimal temperatures.
  • the supply of power to the first and second heater portion causes the first and second heater portions to heat the first and second portions of the base 332 of the cavity 324, and thus heat the first and second portions 214, 216 of the substrate 210 so as to release first and second aerosols. Aerosol is released, via the holes and notches, to the air flowing over an upper surface of the aerosol-forming substrate 210.
  • the user may repeat the drawing, or puffing, process until satisfied or until they decide that the article 200 is spent.
  • the user may then disconnect the mouthpiece element 310 from the device body 320 and discard the article 200.
  • the device may then be re-used with another aerosol-generating article.
  • Figure 3 is a schematic illustration of a portion of an aerosol-generating device in which a planar aerosol-generating article 390 consisting of an aerosol-forming substrate is being heated by a planar heater 3100.
  • a lower surface 301 of the article/substrate 390 rests on an upper surface of the heater.
  • volatile components of the substrate for example glycerine, water, nicotine
  • the device is configured such that air drawn into the device by a user follows an airflow path 3300 that passes over the upper surface 302 of the substrate 390.
  • Volatile components 3200 released from the substrate are entrained in this airflow and condense to form an aerosol which can be inhaled by a user 350.
  • FIG 4 is a schematic illustration of a portion of an aerosol-generating device in which a planar aerosol-forming substrate 400 is being heated by a planar heater 3100.
  • the planar substrate 400 of figure 4 is similar to the planar substrate 390 of figure 3, with the difference that the planar substrate 400 of figure 4 has a plurality of holes 440 defined in it, these holes 440 being defined through the thickness of the planar substrate 400 and opening at an upper surface 302 of the substrate 400. The diameter of each hole at its opening is 2 mm.
  • the planar substrate 400 is a parallelepiped shaped substrate having an x dimension of 12 mm, a y dimension of 12 mm, and a z dimension of 3 mm.
  • the plurality of holes 440 are formed in the substrate during manufacture by passing the aerosol-forming substrate (which may be a sheet of homogenised tobacco) through a docker roller.
  • the docker roller has a cylinder the surface of which comprises conical shaped protrusions. These protrusions press into the surface of the aerosol-forming substrate and form a plurality of conical shaped holes 440 through the substrate.
  • the holes 440 provide travelling paths for gaseous components, evolved from the aerosol-forming substrate on heating, to pass through the solid substrate.
  • the holes 440 also provide thermal paths to allow more even heating of the substrate.
  • the “docker” holes 440 of figure 4 also increase the effective area of the upper surface 402 of the substrate 400, thereby increasing the efficiency of aerosolization.
  • FIG. 5 is a schematic illustration of a portion of an aerosol-generating device in which a planar aerosol-forming substrate 500 is being heated by a planar heater 3100.
  • the substrate 500 of figure 5 is circular cylindrical and has a diameter of 20 mm and a thickness of 3 mm.
  • the substrate may be formed from, or comprise, any suitable aerosol-forming material, for example homogenised tobacco.
  • a plurality of straight sided through-holes 540 are defined through the thickness of the substrate.
  • the planar substrate 500 of figure 5 may be formed by a process in which an aerosol-forming material having desired properties and composition is formed, for example according to known processes for forming homogenised tobacco materials.
  • the aerosolforming material may be cut to the desired external diameter and then the through holes formed in the otherwise finished substrate.
  • the through holes may be formed in a sheet of material prior to cutting to the shape of the substrate. It is desirable that the through holes are formed in ready-to-use aerosol-forming material. It is possible to form holes in aerosol-forming material at an earlier stage, for example before final drying, but account should then be made of possible shrinkage of the aerosol-forming material and holes.
  • FIG 6 is a schematic illustration of the upper surface of an aerosol-forming substrate 600.
  • the aerosol-forming substrate is substantially the same as the substrate 500 of figure 5, with a different pattern of holes.
  • the upper surface of the substrate 600 comprises a plurality of conical shaped holes 640 (docker holes) arranged in a pattern.
  • the diameter of the substrate is 20 mm and there are 28 holes 640 at a density of 9 holes per cm 2 .
  • Figure 7 illustrates a cross-sectional view of the substrate of figure 6, showing the substantially conical shape of the holes 640.
  • FIG 8 is a schematic illustration of the upper surface of an aerosol-forming substrate 800.
  • the aerosol-forming substrate may be substantially the same dimensions as the substrate 500 of figure 5, with a different pattern of holes.
  • the upper surface of the substrate 800 comprises a plurality of circular holes 840 arranged in a pattern. Each hole has a diameter of 3 mm.
  • the diameter of the substrate is 20 mm and there are 7 holes 840 at a density of ⁇ 3 holes per cm 2 .
  • Figure 9 illustrates a cross-sectional view of the substrate of figure 8, showing the substantially straight sided cross-sectional shape of the holes 840.
  • the substrate 800 may be any suitable substrate, for example a non-tobacco nicotine containing product (NCP).
  • NCP non-tobacco nicotine containing product
  • Such a NCP may contain nicotine and an aerosol-former such as glycerine, as well as a flavourant such as menthol.
  • Figure 10 illustrates a cross-sectional view of another substrate 8001 having the same upper profile as the substrate 800 of figure 8.
  • the through holes 1040 include a step 1043.
  • the step 1043 results in an upper opening 1041 of the through holes 1040 having a lower diameter than a lower opening 1042 of the through holes 1040.
  • the stepped design of the holes may result in an improved air-flow for a particular aerosol-forming substrate.
  • FIGS 11 , 12, and 13 illustrate a further embodiment of an aerosol-forming article 1100.
  • the aerosol-forming article 1100 is formed from an aerosol forming substrate comprising a first aerosol-forming material 1101 , and a second aerosol-forming material different to the first aerosol-forming material 1102.
  • the first aerosol-forming material 1101 may be a non-tobacco aerosol-forming material
  • the second aerosol-forming material 1102 may be a homogenised tobacco material.
  • the first aerosol-forming material 1101 forms an upper portion of the aerosol-forming article 1100, and an upper surface of the aerosol-forming article (as illustrated in figure 11) and comprises a first pattern of holes.
  • the second aerosol-forming material 1102 forms a lower portion of the aerosol-forming article 1100, and a lower surface of the aerosol-forming article (as illustrated in figure 13) and comprises a second pattern of holes.
  • Figure 12 illustrates a cross-sectional view of the article 1100 showing the upper portion formed from the first aerosol-forming material 1101 and the lower portion formed from the second aerosolforming material. Hole patterns and dimensions in the upper and lower portions may be tailored to provide optimal airflow for each different aerosol-forming material.
  • the first aerosol-forming material may be configured to form an aerosol at a lower temperature than the second aerosolforming material, the second aerosol-forming material being in closer proximity to a heater.

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  • Containers And Packaging Bodies Having A Special Means To Remove Contents (AREA)

Abstract

L'invention concerne un article de génération d'aérosol (200, 390, 400, 500, 600, 800, 1100) destiné à être utilisé avec un dispositif de génération d'aérosol (300) pour former un aérosol inhalable. L'article de génération d'aérosol comprend un substrat de formation d'aérosol (210, 510), le substrat de formation d'aérosol ayant une base définie par une dimension x et une dimension y et une hauteur définie par une dimension z. Une pluralité de trous ou d'encoches sont définis dans une surface supérieure du substrat de formation d'aérosol, ce qui contribue à faciliter une égalisation thermique et une distribution d'aérosol optimale.
PCT/EP2023/086084 2022-12-15 2023-12-15 Article de génération d'aérosol amélioré avec trous de surface WO2024126797A1 (fr)

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EP22213973.5 2022-12-15

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102014106589A1 (de) * 2014-05-09 2015-11-12 Aie Investments S.A. Elektrische Zigarette
CN107411172A (zh) * 2017-04-20 2017-12-01 深圳市泰康瑞科技有限公司 一种蜂窝式发热体
US20200163377A1 (en) * 2017-07-18 2020-05-28 British American Tobacco (Investments) Limited Tobacco constituent releasing components
US20210204600A1 (en) * 2018-05-31 2021-07-08 Philip Morris Products S.A. Heater assembly with pierced transport material
WO2022013433A1 (fr) * 2020-07-17 2022-01-20 Jt International Sa Dispositif de génération d'aérosol et produit consommable
US20220211101A1 (en) * 2019-05-29 2022-07-07 Jt International S.A. Cartridge for an Aerosol Generating Device
WO2022223707A1 (fr) * 2021-04-23 2022-10-27 Jt International Sa Article de génération d'aérosol et son procédé de fabrication, et système de génération d'aérosol

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102014106589A1 (de) * 2014-05-09 2015-11-12 Aie Investments S.A. Elektrische Zigarette
CN107411172A (zh) * 2017-04-20 2017-12-01 深圳市泰康瑞科技有限公司 一种蜂窝式发热体
US20200163377A1 (en) * 2017-07-18 2020-05-28 British American Tobacco (Investments) Limited Tobacco constituent releasing components
US20210204600A1 (en) * 2018-05-31 2021-07-08 Philip Morris Products S.A. Heater assembly with pierced transport material
US20220211101A1 (en) * 2019-05-29 2022-07-07 Jt International S.A. Cartridge for an Aerosol Generating Device
WO2022013433A1 (fr) * 2020-07-17 2022-01-20 Jt International Sa Dispositif de génération d'aérosol et produit consommable
WO2022223707A1 (fr) * 2021-04-23 2022-10-27 Jt International Sa Article de génération d'aérosol et son procédé de fabrication, et système de génération d'aérosol

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