WO2025132653A1

WO2025132653A1 - Aerosol-generating article with aerosol-forming beads

Info

Publication number: WO2025132653A1
Application number: PCT/EP2024/087219
Authority: WO
Inventors: Matteo Bologna; Laurent Serge LAVANANT; Jean-Yves VOLLMER
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2023-12-21
Filing date: 2024-12-18
Publication date: 2025-06-26
Anticipated expiration: 2026-06-21

Abstract

There is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article is defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness. The aerosol-generating article comprises a first external surface and a second external surface facing in substantially the opposite direction to the first external surface, a cavity located within the aerosol-generating article between the first external surface and the second external surface, and an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity. An aerosol-forming substrate is located within the cavity, the aerosol-forming substrate being in the form of a plurality of discrete beads having an average particle diameter of between 0.1 mm and 4 mm.

Description

AEROSOL-GENERATING ARTICLE WITH AEROSOL-FORMING BEADS

The present disclosure relates to an aerosol-generating article comprising an aerosol-forming substrate.

A typical aerosol-generating article may appear similar to a conventional cigarette. For example, such an aerosol-generating article may be a substantially cylindrical article comprising an aerosolforming 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.

Research has shown that, in such a typical aerosol-generating article comprising a plug of aerosol-forming substrate, a significant portion of the plug of aerosol-forming substrate may not be sufficiently heated to form an aerosol during use. This is undesirable since this portion of the plug of aerosol-forming substrate contributes to the cost of manufacture and transport of the aerosolgenerating article but does not contribute to the aerosol delivered to an end user. This may be the case regardless of the way in which the aerosol-forming substrate is heated, for example regardless of whether a resistive or inductive heater is used and regardless of whether the plug of aerosol-forming substrate is heated from the inside or the outside.

It is an aim of the present disclosure to provide an aerosol-generating article, in which a greater portion of an aerosol-forming substrate of the aerosol-generating article is sufficiently heated to form an aerosol during use.

According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article is defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness. The aerosol-generating article may comprise a first external surface and an opposing second external surface. A cavity may be located within the aerosol-generating article between the first external surface and the second external surface. An airflow passage may be defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage preferably extending through the cavity. An aerosol-forming substrate is located within the cavity. The aerosol-forming substrate may be in the form of a plurality of beads. The aerosol-forming substrate may be in the form of a plurality of discrete beads. The aerosol-forming substrate may be in the form of a plurality of free-flowing beads. The plurality of beads may have an average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm. Preferable average particle diameters may be between about 1 mm and 1 .7 mm.

In preferred examples there may be provided, an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: a first external surface and a second external surface facing in substantially the opposite direction to the first external surface; a cavity located within the aerosol-generating article between the first external surface and the second external surface; and an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity, wherein an aerosol-forming substrate is located within the cavity, the aerosol-forming substrate being in the form of a plurality of discrete beads having an average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm. Preferably, the plurality of discrete beads forms a free-flowing mass of beads.

The first external surface and the second external surface may be described as being opposing external surfaces.

The term “bead” refers to a discrete, solid particle formed of the aerosol-generating substrate. A bead may have a rounded, typically spherical, form. Rounded or spherical beads have a low contact area with other beads and a plurality of such beads may have good flowability. This means that a mass or volume of such beads may be capably of flowing freely. The ability of a plurality of beads to flow, or be poured, may be highly advantageous in providing a consistent dose of substrate during manufacture. Other terms may be used to define the substrate such as, for example, “granule”.

The aerosol-forming substrate is in the form of a plurality of beads, preferably a plurality of beads having the specific average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm. This provides so advantages. Beads can be easily handled compared to other aerosol-forming substrates such as fine powders or cut filler. The beads flow easily, and so can reliably and consistently fill the cavity of the aerosol-generating article during manufacture. Cut filler in particular cannot be reliably and repeatably poured into the cavity of an article. This may allow a consistent and reproducible amount of aerosol-forming substrate to be loaded into each article during manufacture. Beads may also be cleaner to handle than powders and cut fillers, which may cause dust in factories, and may leak from aerosol-generating articles in transit or in use. By selecting beads with appropriate bead sizes and appropriate particle size distributions, air flow through the cavity of the aerosol-generating article may be controlled more reproducibly than would be the case for, say, a cut filler substrate. It is noted that the plurality of beads referred to herein are a plurality of discrete beads, that is the beads are not bound to each other with a binder or matrix phase.

Where a particle is not perfectly spherical, but a diameter of the particle is referred to, the term “diameter” may refer to a largest dimension of the particle. Alternatively, the term “diameter” may refer to the diameter of a perfectly spherical particle having the same volume as the not perfectly spherical particle.

The term “average particle diameter”, as used herein, may refer to a number average particle diameter. Other methods of determining average particle diameter are known. Thus, the average particle diameter may be, for example, a volume average particle diameter.

Unless otherwise mentioned, values given for average particle diameters in this specification refer to a “number average particle diameter”. Specifically, a “number average particle diameter” is calculated as a sum of the diameters of the particles in a group divided by the number of particles in the group. Mathematically, this can be expressed as: Number average particle diameter =

N

In the above equation, N is the total number of particles, and D_n is the diameter of the n^th particle.

Each of the plurality of beads may be defined in terms of a maximum dimension (d_max) and a minimum dimension (d_min). Preferably, the plurality of beads has an average d_max of less than 4 mm, for example less than 3 mm. Preferably, the plurality of beads has an average d_min of greater than 0.5 mm, for example greater than 0.75 mm. The bead dimensions are selected such that the beads flow easily and such that the volume of the beads is not so great that volatile components cannot be substantially completely liberated from each bead on heating for a short duration of time. The beads may be substantially spherical. The beads may be non-spherical, but in this case, they are preferably of low aspect ratio, for example ovoid, such that the beads still flow easily.

The plurality of beads may have an average diameter of between of between 0.75 mm and 2.5 mm, for example between 1 mm and 2 mm, for example about 1 .5 mm or about 1 .7 mm, or about 2 mm.

The plurality of beads may have a particle size distribution defined by a D10 diameter and a D90 diameter. The D10 diameter may be greater than 0.5 mm, for example greater than 0.75 mm. The D90 diameter may be less than 4 mm, for example less than 3 mm. The size distribution may be a relatively narrow size distribution. This may facilitate the provision of a consistent amount of aerosol-forming substrate in each article by helping to prevent settling and clumping within the plurality of beads. Thus, the plurality of beads may have a particle size distribution defined by a D10 diameter and a D90 diameter, in which the D10 diameter is within 25 % of the value of the D90 diameter.

Optionally, the plurality of beads has a d_max value, the d_max being the distance of the longest axis of the bead, of between of between 0.5 mm and 3 mm, for example between 0.75 mm and 2.5 mm, for example between 1 mm and 2 mm, for example about 1 .5 mm or about 1 .7 mm, or about 2 mm.

Optionally, the plurality of beads has a dmin value, the d_min being the distance of the shortest axis of the particle, of between of between 0.5 mm and 3 mm, for example between 0.75 mm and 2.5 mm, for example between 1 mm and 2 mm, for example about 1 .5 mm or about 1 .7 mm, or about 2 mm.

The plurality of beads may be substantially spherical beads. Alternatively, non-spherical shapes of beads may be used, such as ovoid or ellipsoid beads. The plurality of beads may have a bimodal size distribution. For example, the plurality of beads comprises a first phase of beads having a first average diameter and a second phase having a second average diameter different to the first phase. The first phase and the second phase are distinct phases within the plurality of beads. The first phase may have a different size distribution to the second phase. Such a bimodal distribution may allow beads of the phase with the smaller average particle size to settle within interstices formed by the phase having the larger average particle size. The use of a bimodal distribution may preserve benefits associated with an aerosolforming substrate in the form of beads, for example easy handling and free flowing, while allowing a greater packing density of the aerosol-forming substrate within the cavity than would otherwise be possible with a narrow unimodal distribution of bead sizes.

Optionally, the first phase of beads may have an average d_max of less than 3 mm and an average d_min of greater than 1 .75 mm, and the second phase of beads has an average d_max of less than 1 .25 mm and an average d_min of greater than 0.5 mm.

The plurality of beads preferably comprises plant material, for example tobacco. The plant material may be in the form of plant particles, that is small fragments of plant material, such as powdered plant material. The plurality of beads preferably comprises a binder, for example one or more hydrocolloid binders. Discrete beads forming the plurality of beads preferably comprise a binder, for example one or more hydrocolloid binders. For example, the total amount of hydrocolloid binder in the beads forming the aerosol-generating substrate may be between 0.5 percent and 5 percent by weight, or between 0.5 percent and 4 percent by weight, or between 0.5 percent and 3 percent by weight, or between 0.5 percent and 2 percent by weight, on a dry weight basis.

The plurality of beads preferably comprises an aerosol-former, for example an aerosol former selected from the list consisting of glycerine and propylene glycol. The beads may have an aerosol-former content of at least 10 wt % on a dry weight basis, for example an aerosol-former content of greater than 20 wt % on a dry weight basis, for example greater than 25 wt %, or greater than 30 wt %, for example greater than 35 wt %. The plurality of beads may comprise one or more flavour compounds.

Preferably, beads of the plurality of beads are at least partially coated with a powder. For examples, the plurality of beads may be at least partially coated with tobacco powder. Alternatively or in addition, the plurality of beads may be at least partially coated with a cellulosic material, for example microcrystalline cellulose (MCC).

The provision of a powder coating may advantageously prevent the adhesion of the beads or granules to each other, which may facilitate the handling of the aerosol-generating substrate, for example, during production of aerosol-generating articles incorporating the aerosol-generating substrate. In addition, the powder coating may provide a moisture barrier to protect the aerosolgenerating substrate from environmental moisture. The plurality of beads may be formed by a process comprising steps of powder spherodising particles of aerosol-forming material, for example spherodising particles of tobacco, preferably in combination with a binder. Spherodising processes are highly controllable and may produce beads that are substantially spherical and of controlled and consistent particle dimensions.

The plurality of beads may be formed by a process in which a dough of aerosol-forming material is formed and extruded and cut to for individual particles. These particles may then be spheronized and dried to for substantially spherical beads suitable for used in articles according to the invention.

The plurality of beads may comprise at least 60 percent by weight of plant particles, for example at least 65 percent by weight of the plant particles, for example at least 70 percent by weight of the plant particles, for example at least 75 percent by weight of the plant particles, on a dry weight basis. The plurality of beads may comprise less than or equal to 95 percent by weight of the plant particles, for example less than or equal to 90 percent by weight of the plant particles, for example less than or equal to 85 percent by weight of the plant particles, on a dry weight basis.

The cavity may have a length of at least 10 millimetres, or at least 12 millimetres. The cavity may have a length of less than or equal to 20 millimetres, or less than or equal to 15 millimetres. For example, the cavity may have a length of between 10 millimetres and 20 millimetres, or between 12 millimetres and 15 millimetres.

The cavity may have a width of at least 5 millimetres, or at least 6 millimetres. The cavity may have a width of less than or equal to 10 millimetre, or less than or equal to 8 millimetres. For example, the cavity may have a width of between 5 millimetres and 10 millimetres, or between 6 millimetres and 8 millimetres.

The cavity may have a depth of at least 2 millimetres, or at least 3 millimetres. The cavity may have a depth of less than or equal to 5 millimetres, or less than or equal to 4 millimetres. For example, the cavity may have a depth of between 2 millimetres and 5 millimetres, or between 3 millimetres and 4 millimetres.

The cavity may have a volume of at least 200 square millimetres, or at least 250 square millimetres. The cavity may have a volume of less than or equal to 400 square millimetres, or less than or equal to 350 square millimetres. For example, the cavity may have a volume of between 200 square millimetres and 400 square millimetres, or between 250 square millimetres and 350 square millimetres.

Preferably, the cavity comprises between 50 mg and 300 mg of the plurality of beads, for example between 100 mg and 200 mg, for example between 125 mg and 175 mg, for example between 140 mg and 160 mg, for example about 140 mg, or about 150 mg or about 160 mg. By selecting beads of appropriate particle size and distribution, utilisation of aerosol-forming compounds within the beads may be optimised, allowing a relatively low mass of the beads in each aerosolforming article.

Preferably, the cavity contains between 50% and 85% of the plurality of beads by volume. The cavity may contain the plurality of beads and between 15% and 50% free space. The cavity may contain a further component such as a corrugated element in addition to the plurality of beads.

The aerosol-generating article may be a planar aerosol-generating article having a base defined by a length extending in an x direction, a width extending in a y direction, and a height extending in a z direction.

According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device. By way of example, the aerosol-generating article may be as described in any of the preceding paragraphs. The aerosol-generating article may comprise a substantially planar upper surface and a substantially planar lower surface. The upper surface and the lower surface may be vertically spaced from each other by a height defined in a z direction. The aerosol-generating article may further comprise one or more susceptor materials. The one or more susceptor materials may be arranged in thermal communication with the aerosol-forming substrate.

The substantially planar upper surface may be defined by a length extending in an x direction and a width extending in a y direction.

The substantially planar lower surface may be defined by a length extending in an x direction and a width extending in a y direction.

The one or more susceptor materials, if present, may serve as a heater for imparting heat to the aerosol-generating article. Heating of the one or more susceptor materials may occur when the aerosol-generating article is placed within a changing magnetic field, with the changing magnetic field resulting in heating of the susceptor material(s) by one or both of eddy current heating and magnetic hysteresis. Such a changing magnetic field may result from an alternating current being supplied to an inductor coil. Preferably, the inductor coil forms a component part of an aerosol-generating device to which the aerosol-generating article may be coupled.

The aerosol-generating article of the present disclosure is generally flat and thin. The provision of a generally flat and thin aerosol-generating article provides for rapid and efficient heating of the aerosol-forming substrate and improved uniformity in through-thickness heating. The primary source of aerosol-forming substrate is in the form of beads and preferably porous and/or of low density. Preferably, the aerosol-generating article is free of any single-use plastics, thereby providing an aerosol-generating article with improved sustainability.

The upper surface and the lower surface may be parallel to each other.

The aerosol-generating article may extend over its length between a distal end and a proximal end. The proximal end may be a mouth end of the aerosol-generating article.

Aerosol-generating articles according to the present disclosure may preferably be substantially flat articles or substantially planar articles. Such articles have a large base area relative to the volume of the article. Advantageously, a larger base area may provide greater surface area for heating by a planar heater of an aerosol-generating device. Advantageously, a smaller height may allow a smaller temperature gradient or difference across the height of the aerosol-generating article during heating. For example, where the base of the aerosol-generating article is in contact with, and heated by, a planar heater, there may be a smaller temperature difference between the base and an upper surface opposing the base if the spacing, or height, between the base and the upper surface is smaller. Advantageously, this may allow heating of a greater proportion of the aerosol-forming substrate of the aerosol-generating article to a temperature at which an aerosol is released, whilst minimising the risk of burning the hottest portion of the substrate closest to the heater. Alternatively, or in addition, this may reduce a time required to heat the aerosol-forming substrate beads located within the cavity sufficiently to release an aerosol.

The aerosol-generating article according to any of the aspects disclosed herein may have an air flow path extending through the aerosol-generating article. The aerosol-generating article may have an air-flow path defined through the aerosol-generating article in an x/y plane from one side of the aerosol-generating article to the other side of the aerosol-generating article. The aerosolgenerating article preferably has a resistance to draw (RTD) of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in the direction of the airflow path. Preferably, the aerosolgenerating article has a RTD of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in at least one direction in an x/y plane of the aerosol-generating article. An aerosol-generating article with a low resistance air-flow path may allow for superior air-flow management and allow aerosol to be extracted more efficiently from the aerosol-generating article and guided to a user.

Unless otherwise specified, the resistance to draw (RTD) is measured in accordance with ISO 6565-2015. The RTD refers to the pressure required to force air through the full length of a component, such as the aerosol-generating article. The terms “pressure drop” or “draw resistance” of a component or article may also refer to the “resistance to draw”. Such terms generally refer to the measurements made in accordance with ISO 6565-2015 and are normally carried out at under test at a volumetric flow rate of about 17.5 millilitres per second at the output or downstream end of the measured component at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr) and a relative humidity of about 60%.

The aerosol-generating article according to any of the aspects disclosed herein may comprise substantially planar upper and lower surfaces. A vertical separation between the substantially planar upper and lower surfaces may define a height (for example, a z dimension) of the aerosol-generating article. An air flow channel may be defined between the substantially planar upper and lower surfaces. The height of the aerosol-generating article may be less than 5 millimetres, for example between 1.5 millimetres and 5 millimetres, for example between 1.5 millimetres and 4 millimetres, for example between 1.5 millimetres and 3 millimetres, for example between 1.5 millimetres and 2 millimetres. Although the beads are the primary source of aerosol-forming substrate, one or both of the substantially planar upper and lower surfaces may comprise an additional aerosol-forming substrate. The aerosol-generating article may comprise upper and lower layers, at least one of the upper and lower layers comprising or consisting of additional aerosol-forming substrate, the upper layer forming the substantially planar upper surface and the lower layer forming the substantially planar lower surface.

The aerosol-generating article may further comprise an intermediate layer arranged between an upper layer and a lower layer. The upper surface may define an external surface of the upper layer and the lower surface may define an external surface of the lower layer. An air-flow path may be defined through the aerosol-generating article in an x/y plane between a distal end and a proximal end of the aerosol-generating article. The intermediate layer may be located within the cavity. The intermediate layer may help define the cavity.

A resistance to draw (RTD) of the aerosol-generating article, along the air-flow path, may be less than 20 millimetres H2O.

One or both of the upper layer and the lower layer may comprise a sub-layer of aerosolforming substrate laminated with a sub-layer of one or more susceptor materials. The sub-layer of aerosol-forming substrate may define an inward-facing surface of the respective upper or lower layer.

The intermediate layer may comprise or consist of a paper-based substrate.

The intermediate layer may be free of aerosol-forming substrate.

The intermediate layer may comprise or consist of aerosol-forming substrate. The intermediate layer may further comprise one or more susceptor materials.

A plurality of longitudinally extending channels may be defined by corrugations between the upper layer and the intermediate layer and between the intermediate layer and the lower layer. The longitudinally extending channels may extend along in an x/y plane between the distal end and the proximal end. The corrugations may be located within the cavity and the beads may be disposed in one or more of the corrugations.

The intermediate layer may be fixed relative to at least one of the upper layer and lower layer by an adhesive. For example, the adhesive may comprise guar gum. The adhesive may comprise an aerosol-forming material such as homogenised tobacco slurry.

The intermediate layer may comprise a corrugated element.

The intermediate layer may comprise a plurality of corrugated elements. Two or more of the plurality of corrugated elements may be arranged in vertical relationship to each other between the upper layer and the lower layer. One or more of the plurality of corrugated elements may comprise one or more susceptor materials and other one or ones of the plurality of corrugated elements may comprise aerosol-forming substrate. The intermediate layer may further comprise a planar element positioned between two of the plurality of corrugated elements. The planar element may comprise or consist of one or more susceptor materials.

According to the present disclosure, there may be provided an aerosol-generating article comprising a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer. The beads may be located within one or more channels of the corrugated layer. The use of a corrugated structure in the aerosol-generating article may advantageously allow the production of an aerosol-generating article that has extremely low RTD while still being sufficiently rigid to for a user to handle. Further, use of a corrugated structure may allow a low density, low RTD, aerosol-generating article to be produced using high speed production methods similar to those used for production of corrugated cardboard.

The aerosol-generating article may further comprise a planar frame positioned between an upper layer and a lower layer. The upper surface may define an external surface of the upper layer and the lower surface may define an external surface of the lower layer. The planar frame may define the cavity. An air flow path may be defined through the aerosol-generating article in an x/y plane, the air-flow path extending through the cavity.

The upper layer and the lower layer may be coupled to opposing surfaces of the frame to overlie opposing ends of the cavity.

One or both of the upper layer and the lower layer may comprise or consist of one or more susceptor materials.

A corrugated element may be disposed within the cavity between the upper and lower layers. A plurality of longitudinally extending channels are defined by corrugations between the upper layer and the corrugated element and between the corrugated element and the lower layer. The longitudinally extending channels may extend along in an x/y plane between opposing ends of the frame.

The air-flow path may be at least partially defined by the frame. The frame may comprise an inlet air-flow channel and an outlet air-flow channel, the inlet air-flow channel configured to permit a flow of air into the cavity and the outlet air-flow channel configured to permit a flow of air to exit the cavity. The inlet air-flow channel and the outlet air-flow channel may be defined on opposing ends of the frame. The inlet air-flow channel may be defined in a first width edge of the frame and the outlet air-flow channel defined in a second width edge of the frame.

According to the present disclosure, there may be provided an aerosol-generating article, the aerosol-generating article comprising: a first planar external surface, a second planar external surface, a cavity, a frame positioned between the first planar external surface and the second planar external surface, the frame at least partially defining the cavity, the beads of aerosol-forming substrate positioned in the cavity between the first planar external surface and the second planar external surface, and an air inlet and an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity. The aerosol-generating article may further comprise one or more susceptor materials arranged in thermal communication with the aerosol-forming substrate.

The frame may comprise a peripheral wall at least partially circumscribing or encircling the cavity. The frame may comprise a peripheral wall wholly circumscribing or encircling the cavity.

The aerosol-generating article may comprise a first planar external layer and a second planar external layer, in which the first planar external layer forms the first planar external surface, and the second planar external layer forms the second planar external surface. Optionally, at least one of the first planar external layer, the second planar external layer, and the frame may comprise or consist of additional aerosol-forming substrate. A corrugated layer may be positioned within the cavity.

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

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

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

The aerosol-generating article of any of the aspects of the present disclosure when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), oval, or circle, ora combination thereof. Where the aerosol-generating article comprises substantially planar upper and lower surfaces, one or both of the upper and lower surfaces when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof. A perimeter of the aerosol-generating article when viewed in plan may be formed of a plurality of straight sides, a plurality of curved sides, or a combination of straight and curved sides. Where the aerosol-generating article comprises substantially planar upper and lower surfaces, a perimeter of one or both of the upper and lower surfaces when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof.

The aerosol-forming substrate may comprise nicotine. Nicotine may be present in the form of a tobacco material or may be in the form of a nicotine extract.

References to aerosol-forming substrate below may relate to either the aerosol-forming substrate of the beads or any additional aerosol-forming substrate present in the article. The aerosolforming substrate 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 aerosol-formers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosol-former to be or comprise glycerine.

The aerosol-forming substrate may comprise at least 1 , 2, 5, 10, or 15 weight percent aerosolformer. The aerosol-forming substrate may comprise greater than 15 weight percent aerosol-former, for example greater than 20 weight percent, or greater than 25 weight percent, or greater than 30 weight percent, or greater than 40 weight percent, or greater than 50 weight percent aerosol-former.

The aerosol-forming substrate may comprise less than or equal to 30 percent by weight of aerosol former, less than or equal to 25 percent by weight of aerosol former, or less than or equal to 20 percent by weight of aerosol former. That is, the aerosol-forming substrate may have an aerosol former content of less than or equal to 30 percent by weight, less than or equal to 25 percent by weight, or less than or equal to 20 percent by weight.

The aerosol-forming substrate may comprise between 1 percent and 30 percent by weight of aerosol former, between 1 percent and 25 percent by weight of aerosol former, or between 1 percent and 20 percent by weight of aerosol former.

The aerosol-forming substrate may comprise between 5 percent and 30 percent by weight of aerosol former, between 5 percent and 25 percent by weight of aerosol former, or between 5 percent and 20 percent by weight of aerosol former.

The aerosol-forming substrate may comprise between 10 percent and 30 percent by weight of aerosol former, between 10 percent and 25 percent by weight of aerosol former, or between 10 percent and 20 percent by weight of aerosol former.

The aerosol-forming substrate may comprise between 15 percent and 30 percent by weight of aerosol former, between 15 percent and 25 percent by weight of aerosol former, or between 15 percent and 20 percent by weight of aerosol former.

The aerosol-forming substrate may comprise at least 50 percent by weight of aerosol former, at least 60 percent by weight of aerosol former, or at least 70 percent by weight of aerosol former.

The aerosol-forming substrate may comprise less than or equal to 85 percent by weight of aerosol former, less than or equal to 80 percent by weight of aerosol former, or less than or equal to 75 percent by weight of aerosol former.

The aerosol-forming substrate may comprise between 50 percent and 85 percent by weight of aerosol former, between 50 percent and 80 percent by weight of aerosol former, or between 50 percent and 75 percent by weight of aerosol former.

The aerosol-forming substrate may comprise between 60 percent and 85 percent by weight of aerosol former, between 60 percent and 80 percent by weight of aerosol former, or between 60 percent and 75 percent by weight of aerosol former.

The aerosol-forming substrate may comprise between 70 percent and 85 percent by weight of aerosol former, between 70 percent and 80 percent by weight of aerosol former, or between 70 percent and 75 percent by weight of aerosol former.

The aerosol-forming substrate may comprise nicotine. The aerosol-forming material may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

The aerosol-forming substrate may comprise at least 0.5 percent by weight of nicotine, at least 1 percent by weight of nicotine, at least 1.5 percent by weight of nicotine, or at least 2 percent by weight of nicotine. That is, the aerosol-forming substrate may have a nicotine content of at least 0.5 percent by weight, at least 1 percent by weight, at least 1 .5 percent by weight, or at least 2 percent by weight.

The aerosol-forming substrate 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 (CBE), cannabicitran (CBT). It may be preferable that the cannabinoid compound is CBD or THC. It may be particularly preferable that the cannabinoid compound is CBD.

The aerosol-forming substrate may comprise one or more flavourants. The one or more flavourants may comprise one or more of: one or more essential oils such as eugenol, peppermint oil and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and a herbaceous material. Suitable herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, coffee, thyme, and caraway. The one or more flavourants may comprise a tobacco material.

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

The aerosol-generating substrate may have a carboxylic acid content of at least 0.5 percent by weight, preferably at least 1 percent by weight, more preferably at least 2 percent by weight, on a dry weight basis.

The aerosol-generating substrate may have a carboxylic acid content of less than or equal to 10 percent by weight, preferably less than or equal to 8 percent by weight, more preferably less than or equal to 8 precent by weight, on a dry weight basis.

For example, the aerosol-generating substrate may comprise between about 0.5 percent by weight and about 10 percent by weight of the acid, or between about 1 percent by weight and about 8 percent by weight of the acid, or between about 2 percent by weight and about 6 percent by weight of the acid.

The aerosol-forming substrate may have a moisture content of about 5 to 25%, preferably of about 7 to 15%, at final product state. For example, the aerosol-forming substrate may be a homogenised tobacco material with a moisture of about 5 to 25%, preferably of about 7 to 15%, at final product state.

The aerosol-forming substrate may comprise 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 such as tobacco leaf is preferably ground and graded to a particle size of about 100 to 380 mesh, preferably of about 170 to 320 mesh. This tobacco material may, for example, be used to form the beads of aerosol-forming substrate.

“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 Tanzania.

Examples of aromatic tobaccos are Oriental Turkey, Greek Oriental, semi-oriental tobacco but also Fire Cured, US Burley, such as Perique, and Rustica.

Examples of dark tobacco are Dark Cured Brazil Galpao, Burley Malawi or other African Burley, Sun Cured or Air Cured Indonesian Kasturi.

The aerosol-forming substrate may comprise Cellulose fibres. For example, the aerosol-forming substrate may comprise about 1 to 15% of cellulose fibres, preferably of about 3 to 7% of cellulose fibres. Preferably, cellulose fibres may have a length of about 10 to 250 pm, preferably of about 10 to 120 pm.

The aerosol-forming substrate may comprise organic fibres such as non-tobacco fibres, or tobacco fibres. For example, the aerosol-forming substrate may comprise about 5 to 20%, preferably about 7 to 15% of tobacco fibres. 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. The aerosolforming substrate may comprise about 10 to 30 %, preferably of about 15 to 25%, of a non-tobacco organic fibre. For example, organic fibres may derive from cellulose, cotton, wood, tea botanical varieties as sub-products, and sub-processed waste, the tea industry. Organic fibres are preferably of a length of about 10 to 400 pm, preferably of about 10 to 200 pm.

The aerosol-forming substrate may comprise a binder. For example, the aerosol-forming substrate may comprise about 1 to 10%, preferably of about 1 to 5%, of a binder such as any of common gums or pectins used in food and beverage (F&B) industries. Preferred binders may be natural pectins, such as fruit, for example citrus, or tobacco pectins; guar gums, land locust bean gums, such as hydroxyethyl and/or hydroxypropyl of those; starches, such as modified or derivatized starches; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl, celluloses; dextran; and xanthan gum. A preferable binder is guar.

The aerosol-forming substrate may comprise an organic botanical glycerite. For example, the aerosol-forming substrate may comprise 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.

The aerosol-forming substrate may comprise organic botanical extracts. For example, the aerosol-forming substrate may comprise 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. The aerosol-forming substrate may comprise botanical essential oils, for example about 0.5 to 5 %, preferably of about 1 to 3 %, of a botanical essential oil, for example a botanical essential oil such as of palm, coconut, and wooden-based essential oils.

The aerosol-forming substrate preferably comprises an 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.

As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol.

As used herein, the term “aerosol-forming substrate” may refer to a substrate capable of releasing an aerosol or volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. An aerosol-forming substrate may comprise an aerosol-forming material. An aerosol-forming substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. An aerosol-forming substrate may conveniently be part of an aerosol-generating article or smoking article.

As used herein, the term “aerosol-generating device” may refer to a device for use with an aerosol-generating article to enable the generation, or release, of an aerosol.

As used herein, the term “aerosol generating system” refers to a combination of an aerosolgenerating device and one or more aerosol-forming articles for use with the device. An aerosolgenerating system may include additional components, such as a charging unit for recharging an onboard electric power supply in an electrically operated or electric aerosol-generating device.

As used herein, the term “aerosol former” may refer to any suitable known compound or mixture of compounds that, in use, facilitates formation of an aerosol. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-forming substrate or aerosol-generating article.

As used herein with reference to the invention, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.

As used herein with reference to the invention, the terms “proximal”, “distal”, “upstream” and “downstream” are used to describe the relative positions of components, or portions of components, of the aerosol-generating article.

As used herein, the term “longitudinal” refers to the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. During use, air may be drawn through the aerosolgenerating article in the longitudinal direction.

As used herein, the term “sheet” denotes a laminar element having a width and length substantially greater than the thickness thereof. The width of a sheet may be greater than 10 mm, preferably greater than 20 mm or 30 mm. In certain embodiments, sheets of material for use in forming aerosol-forming substrates as described herein may have a thickness of between 10 pm and about 1000 pm, for example between 10 pm and about 300 pm. As used herein, the term “homogenised tobacco material” encompasses any tobacco material formed by the agglomeration of particles of tobacco material. Sheets or webs of homogenised tobacco material are formed by agglomerating particulate tobacco obtained by grinding or otherwise powdering of one or both of tobacco leaf lamina and tobacco leaf stems. In addition, homogenised tobacco material may comprise a minor quantity of one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during the treating, handling and shipping of tobacco. The sheets of homogenised tobacco material may be produced by casting, extrusion, paper making processes or other any other suitable processes known in the art.

The term “cast leaf’ is used herein to refer to a product made by a casting process that is based on casting a slurry comprising plant particles (for example, clove particles or tobacco particles and clove particles in a mixture) and a binder (for example, guar gum) onto a supportive surface, such as a belt conveyor, drying the slurry and removing the dried sheet from the supportive surface. An example of the casting or cast leaf process is described in, for example, US-A-5,724,998 for making cast leaf tobacco. In a cast leaf process, particulate plant materials are produced by pulverizing, grinding, or comminuting parts of the plant. The particles produced from one or more plants are mixed with a liquid component, typically water, to form a slurry. Other components in the slurry may include fibres, a binder and an aerosol former. The particulate plant materials may be agglomerated in the presence of the binder. The slurry is cast onto a supportive surface and dried into a sheet of homogenized plant material. Preferably, homogenized plant material used in articles according to the present invention may be produced by casting. Such homogenized plant material may comprise agglomerated particulate plant material.

As used herein, resistance to draw is expressed with the units of pressure “mm H2O” or “mm WG” or “mm of water gauge” and may be measured in accordance with ISO 6565:2002.

The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

Exi. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article length being greater or equal to the article width, the article width being greater than the article thickness, the aerosol-generating article comprising: a cavity located within the aerosol-generating article; and an aerosol-forming substrate located within the cavity, the aerosol-forming substrate being in the form of a plurality of discrete and/or free-flowing beads.

ExiA. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, for example an aerosol-generating article according to Exi, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article length being greater or equal to the article width, the article width being greater than the article thickness, the aerosolgenerating article comprising: a cavity located within the aerosol-generating article; and an aerosol-forming substrate located within the cavity, the aerosol-forming substrate being in the form of a plurality of discrete beads having an average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm.

ExiB. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, for example an aerosol-generating article according to any preceding example, the aerosolgenerating article comprising: a first planar external surface; and a second planar external surface, a cavity located within the aerosol-generating article between the first planar external surface; and the second planar external surface; and an aerosol-forming substrate located within the cavity, the aerosol-forming substrate being in the form of a plurality of discrete and/or free-flowing beads.

ExiC. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, for example an aerosol-generating article according to any preceding example, the aerosolgenerating article comprising: a first planar external surface; and a second planar external surface, a cavity located within the aerosol-generating article between the first planar external surface; and the second planar external surface; and an aerosol-forming substrate located within the cavity, the aerosol-forming substrate being in the form of a plurality of discrete beads having an average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm.

ExiD. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article, for example an aerosol-generating article according to any preceding example, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosolgenerating article comprising: a first external surface and a second external surface facing in substantially the opposite direction to the first external surface, for example a first external surface and an opposing second external surface; a cavity located within the aerosol-generating article between the first external surface and the second external surface; wherein. an aerosol-forming substrate is located within the cavity, the aerosol-forming substrate being in the form of a plurality of discrete beads having an average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm.

ExiE. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article, for example an aerosol-generating article according to any preceding example, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: a first external surface and a second external surface facing in substantially the opposite direction to the first external surface, for example a first external surface and an opposing second external surface; a cavity located within the aerosol-generating article between the first external surface and the second external surface; wherein. an aerosol-forming substrate is located within the cavity, the aerosol-forming substrate being in the form of a plurality of discrete and/or free-flowing beads.

Ex1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article, for example an aerosol-generating article according to any preceding example, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: a first external surface and a second external surface facing in substantially the opposite direction to the first external surface, for example a first external surface and an opposing second external surface; a cavity located within the aerosol-generating article between the first external surface and the second external surface; and an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity, wherein. an aerosol-forming substrate is located within the cavity, the aerosol-forming substrate being in the form of a plurality of beads having an average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm.

Ex2. An aerosol-generating article according to any preceding example in which each of the plurality of beads has a maximum dimension (d_max) and a minimum dimension (d_min), in which the plurality of beads has an average d_max of less than 4 mm, for example less than 3 mm, and an average d_min of greater than 0.5 mm, for example greater than 0.75 mm.

Ex3. An aerosol-generating article according to any preceding example in which the plurality of beads has a particle size distribution defined by a D10 diameter and a D90 diameter, in which the D10 diameter is greater than 0.1 mm, for example greater than 0.5 mm, for example greater than 0.75 mm, and the D90 diameter is less than 4 mm, for example less than 3 mm.

Ex4. An aerosol-generating article according to any preceding example in which the plurality of beads has a particle size distribution defined by a D10 diameter and a D90 diameter, in which the D10 diameter is within 25 % of the value of the D90 diameter. Ex5. An aerosol-generating article according to any preceding example in which the plurality of beads has a bimodal size distribution, for example in which the plurality of beads comprises a first phase and a second phase, the first phase having a different size distribution to the second phase.

Ex6. An aerosol-generating article according to Ex5 in which the first phase of beads has an average dmax of less than 3 mm and an average d_min of greater than 1 .75 mm, and the second phase of beads has an average d_max of less than 1 .25 mm and an average d_min of greater than 0.1 mm.

Ex7. An aerosol-generating article according to any preceding example in which the plurality of beads comprises plant material, for example tobacco, and a binder, for example one or more hydrocolloid binders, for example in which the plant material is in the form of plant particles.

Ex8. An aerosol-generating article according to any preceding example in which the plurality of beads comprise an aerosol-former, for example an aerosol former selected from the list consisting of glycerine and propylene glycol, for example in which the aerosol-forming particles have an aerosolformer content of greater than 20 wt % on a dry weight basis, for example greater than 25 wt %, or greater than 30 wt %, for example greater than 35 wt %.

Ex9. An aerosol-generating article according to any preceding example in which the plurality of beads comprises one or more flavour compounds.

Ex10. An aerosol-generating article according to any proceeding example in which the plurality of beads is formed by a process comprising steps of powder spherodising particles of aerosol-forming material, for example powder spherodising particles of tobacco, preferably in combination with a binder, or in which the plurality of beads is formed by a spheronization process, for example spheronization of a dough formed from aerosol-forming material.

Ex11 . An aerosol-generating article according to any proceeding example in which the plurality of beads comprises at least 60 percent by weight of plant particles, for example at least 65 percent by weight of the plant particles, for example at least 70 percent by weight of the plant particles, for example at least 75 percent by weight of the plant particles, on a dry weight basis.

Ex12. An aerosol-generating article according to any proceeding example in which the plurality of beads comprises less than or equal to 95 percent by weight of the plant particles, for example less than or equal to 90 percent by weight of the plant particles, for example less than or equal to 85 percent by weight of the plant particles, on a dry weight basis.

Ex13. An aerosol-generating article according to any preceding example in which the cavity comprises between 50 mg and 300 mg of the plurality of beads, for example between 100 mg and 200 mg, for example between 125 mg and 175 mg, for example between 140 mg and 160 mg, for example about 140 mg, or about 150 mg or about 160 mg. Ex14. An aerosol-generating article according to any preceding example in which the plurality of beads has an average diameter of between of between 0.75 mm and 2.5 mm, for example between 1 mm and 2 mm, for example about 1 .5 mm or about 1 .7 mm, or about 2 mm.

Ex15. An aerosol-generating article according to any preceding example in which the plurality of beads has a d_max value, the d_max being the distance of the longest axis of the bead, of between of between 0.5 mm and 3 mm, for example between 0.75 mm and 2.5 mm, for example between 1 mm and 2 mm, for example about 1 .5 mm or about 1 .7 mm, or about 2 mm.

Ex16. An aerosol-generating article according to any preceding example in which the plurality of beads has a d_min value, the d_min being the distance of the shortest axis of the particle, of between of between 0.5 mm and 3 mm, for example between 0.75 mm and 2.5 mm, for example between 1 mm and 2 mm, for example about 1 .5 mm or about 1 .7 mm, or about 2 mm.

Ex17. An aerosol-generating article according to any preceding example in which the plurality of beads are low aspect ratio beads, for example spheroid beads, for example substantially spherical beads.

Ex17A. An aerosol-generating article according to any preceding example in which the plurality of beads are a plurality of free-flowing beads.

Ex17B. An aerosol-generating article according to any preceding example in which the plurality of beads are shaped to be poured into the aerosol-generating article during manufacture.

Ex18. An aerosol-generating article according to any preceding example in which the cavity contains between 50% and 85% of the plurality of beads by volume.

Ex19. An aerosol-generating article according to any preceding example in which the cavity contains the plurality of beads and between 15% and 50% free space.

Ex20. An aerosol-generating article according to any preceding example comprising a frame positioned between the first external surface and the second external surface, the frame at least partially defining the cavity, for example in which side walls of the cavity are at least partially defined by the frame.

Ex21. An aerosol-generating article according to any preceding example in which at least one of the first external surface and second external surface is a substantially planar surface, for example in which the first external surface is a substantially planar surface, for example in which both the first external surface and the second external surface is a substantially planar surface.

Ex22. An aerosol-generating article according to any preceding example, wherein the cavity has a width between 30 percent and 95 percent of the width of the aerosol-generating article. Ex23. An aerosol-generating article according to any preceding example, wherein the cavity has a length between 30 percent and 95 percent of the length of the aerosol-generating article.

Ex24. An aerosol-generating article according to any preceding example, wherein the cavity has a thickness between 30 percent and 95 percent of the thickness of the aerosol-generating article.

Ex25. An aerosol-generating article according to any preceding example, wherein the cavity has a length between 14 millimetres and 40 millimetres, a width between 4.5 millimetres and 13 millimetres, and a thickness between 0.5 millimetres and 4.5 millimetres.

Ex26. An aerosol-generating article according to any preceding example, wherein the cavity has a length between 20 millimetres and 30 millimetres, a width between 7 millimetres and 10 millimetres, and a thickness between 2.5 millimetres and 4 millimetres.

Ex27. An aerosol-generating article according to any preceding example, wherein a thickness of the aerosol-generating article is less than 50 percent of both a length and a width of the aerosolgenerating article.

Ex28. An aerosol-generating article according to any preceding example, wherein the frame comprises a peripheral wall circumscribing or encircling the cavity.

Ex29. An aerosol-generating article according to Ex28, wherein the peripheral wall is formed by a frame inner surface and a frame outer surface, and wherein the frame inner surface defines a cavity outer wall, and the frame outer surface at least partially defines one or more external walls of the aerosol-generating article.

Ex30. An aerosol-generating article according to Ex28 or Ex29, wherein the peripheral wall has a radial thickness between 1 millimetre and 3 millimetres.

Ex31 . An aerosol-generating article according to any of Ex20 to Ex30, wherein the frame has a thickness greater than or equal to 80 percent of the thickness of the aerosol-generating article.

Ex32. An aerosol-generating article according to any of Ex20 to Ex31 , wherein the frame has a thickness between 80 percent and 95 percent of the thickness of the aerosol-generating article.

Ex33. An aerosol-generating article according to any of Ex20 to Ex32, wherein the frame has a thickness between 1 millimetre and 5.5 millimetres.

Ex34. An aerosol-generating article according to any of Ex20 to Ex33, wherein the frame comprises a cellulosic material.

Ex35. An aerosol-generating article according to Ex34, wherein the cellulosic material has a grammage between 300 grams per square metre and 900 grams per square metre. Ex36. An aerosol-generating article according to Ex34 or Ex35, wherein the cellulosic material is paper, paperboard, or cardboard.

Ex37. An aerosol-generating article according to any of Ex20 to Ex36, wherein the frame is a unitary component.

Ex38. An aerosol-generating article according to any of Ex20 to Ex37, wherein the frame comprises a first frame layer and a second frame layer.

Ex39. An aerosol-generating article according to Ex21 , wherein the first frame layer is bonded to the second frame layer with an adhesive.

Ex40. An aerosol-generating article according to Ex21 or Ex22, wherein the frame comprises a third frame layer.

Ex42. An aerosol-generating article according to Ex40, wherein the second frame layer is positioned between the first frame layer and the third frame layer.

Ex43. An aerosol-generating article according to Ex40 or Ex41 , wherein the second frame layer is bonded to the third frame layer with an adhesive.

Ex44. An aerosol-generating article according to any of Ex20 to Ex43, wherein the one or more aerosol-generating substrates comprise a first aerosol-generating substrate layer positioned between the first planar external surface and the frame, and a second aerosol-generating substrate layer positioned between the second planar external surface and the frame.

Ex45. An aerosol-generating article according to Ex44, wherein one or both the first aerosolgenerating substrate layer and the second aerosol-generating substrate layer comprises an aerosolgenerating material in the form of a sheet of aerosol-generating material.

Ex46. An aerosol-generating article according to Ex45, wherein the sheet of aerosol-generating material is a sheet of homogenised tobacco material.

Ex47. An aerosol-generating article according to Ex44 or Ex45, wherein the sheet of aerosolgenerating material comprises one or more aerosol-formers, such as one or both of glycerine and propylene glycol.

Ex48. An aerosol-generating article according to any one of Ex45 to Ex47, wherein the first aerosolgenerating substrate layer and the second aerosol-generating substrate layer define opposing end walls of the cavity.

Ex49. An aerosol-generating article according to any one of Ex45 to Ex48, wherein one or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer has a thickness between 100 micrometres and 600 micrometres. Ex50. An aerosol-generating article according to any one of Ex45 to Ex49, wherein one or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer has a length substantially the same as the length of the aerosol-generating article.

Ex51 . An aerosol-generating article according to any one of Ex45 to Ex50, wherein one or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer has a width substantially the same as the width of the aerosol-generating article.

Ex52. An aerosol-generating article according to any preceding example comprising an outer wrapper defining the first planar external surface and the second planar external surface.

Ex53. An aerosol-generating article according to any preceding example comprising a first planar external layer and a second planar external layer, wherein the first planar external layer defines the first planar external surface, and the second planar external layer defines the second planar external surface.

Ex54. An aerosol-generating article according to Ex53, wherein the first planar external layer and the second planar external layer overlie opposing ends of the cavity.

Ex55. An aerosol-generating article according to Ex53 or Ex54, wherein one or both of the first planar external layer and the second planar external layer comprise a cellulosic material.

Ex56. An aerosol-generating article according to Ex55, wherein the cellulosic material is paper or cardboard.

Ex57. An aerosol-generating article according to any one of Ex27 to Ex30, wherein one or both of the first planar external layer and the second planar external layer has a length substantially the same as the length of the aerosol-generating article.

Ex58. An aerosol-generating article according to any one of Ex27 to Ex31 , wherein one or both of the first planar external layer and the second planar external layer has a width substantially the same as the width of the aerosol-generating article.

Ex59. An aerosol-generating article according to any one of Ex20 to Ex58, wherein the air inlet is defined by the frame.

Ex60. An aerosol-generating article according to any preceding example, wherein the air inlet has an equivalent diameter between 0.1 millimetres and 3 millimetres.

Ex61 . An aerosol-generating article according to any preceding example, wherein the air inlet has a width of between 0.3 millimetres and 3 millimetres.

Ex62. An aerosol-generating article according to any preceding example, wherein the air inlet has a thickness of between 0.3 millimetres and 3 millimetres. Ex63. An aerosol-generating article according to any one of Ex20 to Ex62, wherein the air outlet is defined by the frame.

Ex64. An aerosol-generating article according to any preceding example, wherein the air outlet has an equivalent diameter between 0.1 millimetres and 3 millimetres.

Ex65. An aerosol-generating article according to any preceding example, wherein the air outlet has a width of between 0.3 millimetres and 3 millimetres.

Ex66. An aerosol-generating article according to any preceding example, wherein the air outlet has a thickness of between 0.3 millimetres and 3 millimetres.

Ex67. An aerosol-generating article according to any preceding example, wherein a ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article is between 2:1 and 15:1.

Ex68. An aerosol-generating article according to any preceding example, wherein a ratio between the length and the width of the aerosol-generating article is between 1 :1 and 10:1.

Ex69. An aerosol-generating article according to any preceding example, wherein the aerosolgenerating article has a length between 15 millimetres and 45 millimetres, for example between 25 millimetres and 30 millimetres.

Ex70. An aerosol-generating article according to any preceding example, wherein the aerosolgenerating article has a width between 3 millimetres and 17 millimetres, for example between 9 millimetres and 11 millimetres.

Ex71. An aerosol-generating article according to any preceding example, wherein the aerosolgenerating article has a thickness between 1 millimetre and 5.5 millimetres, for example between 3 millimetres and 3.5 millimetres.

Ex72. An aerosol-generating article according to any preceding example, wherein the aerosolgenerating article has resistance to draw between 0 millimetres H2O and 9.9 millimetres H2O.

Ex73. An aerosol-generating article according to any preceding example, wherein each of the plurality of beads has a density of less than or equal to 2 grams per cubic centimetre, for example less than or equal to 1 .9 grams per cubic centimetre, for example less than or equal to 1 .8 grams per cubic centimetre.

Ex74. An aerosol-generating article according to any preceding example, wherein the total weight of the plurality of beads is at least 50 mg, for example at least 100 mg, for example at least 125 mg, for example at least 150 mg.

Ex75. An aerosol-generating article according to any preceding example, wherein the total weight of the plurality of beads of granules is less than or equal to 350 mg, for example less than or equal to 300 mg, for example less than or equal to 250 mg. Ex76. An aerosol-generating article according to any preceding example, wherein the bulk density of the plurality of beads is at least 200 mg per cubic centimetre, for example at least 225 mg per cubic centimetre, for example at least 250 mg per cubic centimetre.

Ex77. An aerosol-generating article according to any preceding example, wherein the bulk density of the plurality of beads is less than or equal to 500 mg per cubic centimetre, for example less than or equal to 475 mg per cubic centimetre, for example less than or equal to 450 mg per cubic centimetre. Ex78. An aerosol-generating article according to any preceding example, wherein the mean surface area of the plurality of beads is at least 3 millimetres squared, for example at least 10 millimetres squared, for example at least 20 millimetres squared.

Ex79. An aerosol-generating article according to any preceding example, wherein the mean surface area of the plurality of beads is less than or equal to 80 millimetres squared, for example less than or equal to 60 millimetres squared, for example less than or equal to 40 millimetres squared.

Ex80. An aerosol-generating article according to any preceding example, wherein the total surface area of the plurality of beads is at least 120 millimetres squared, for example at least 240 millimetres squared.

Ex81 . An aerosol-generating article according to any preceding example, wherein the total surface area of the plurality of beads is less than or equal to 650 millimetres squared, for example less than or equal to 500 millimetres squared.

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

Figure 1 is a perspective side view of an aerosol-generating article according to a first embodiment of the present disclosure;

Figure 2 is a perspective side view of an aerosol-generating article according to a second embodiment of the present disclosure;

Figure 3 is a schematic end view of an aerosol-generating article according to a third embodiment of the present disclosure;

Figure 4 is a schematic side view of the aerosol-generating article of figure 3;

Figure 5 is a schematic plan view of the aerosol-generating article of figure 3;

Figure 6 shows a schematic illustration of a corrugated element as used in the aerosolgenerating article of figure 3;

Figure 7 shows a perspective view of an aerosol-generating article according to a sixth embodiment of the present disclosure;

Figure 8 shows an exploded perspective view of the aerosol-generating article of Figure 7;

Figure 9 shows a further exploded perspective view of the aerosol-generating article of Figure 7;

Figure 10 shows a schematic transverse cross-sectional view of the aerosol-generating article of Figure 7; and

Figure 11 shows a schematic longitudinal cross-sectional view of the aerosol-generating article of Figure 7. Figure 1 illustrates a perspective side view of an aerosol-generating article 100 according to a first embodiment of the present disclosure. The aerosol-generating article 100 has upper and lower surfaces 110, 120 which are flat or planar.

The aerosol-generating article 100 comprises an internal cavity containing beads of aerosolforming substrate (not shown). In one embodiment, the aerosol-generating article 100 may consist substantially of aerosol-forming substrate in the form of the beads and other components. In another embodiment, the aerosol-forming substrate may be a subset of a plurality of component parts of the aerosol-generating article 100 (for example, only the beads). The aerosol-forming substrate is enclosed within an interior of the aerosol-generating article 100. Aerosol-forming substrate may at least partially define an exterior of the aerosol-generating article 100; for example, one or both of the upper and lower surfaces 110, 120 may comprise or consist of aerosol-forming substrate. One or more susceptor materials may be enclosed within an interior of the aerosol-generating article 100.

The aerosol-generating article 100 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (which may also be referred to as a thickness), extending in a z dimension, of 3.6 millimetres.

Figure 2 illustrates a perspective side view of an aerosol-generating article 200 according to a second embodiment of the present disclosure, being a variant of aerosol-generating article 100. Features in common with aerosol-generating article 100 are referred to with like reference signs. An air flow path 230 is defined through the aerosol-generating article 200 between the upper and lower surfaces 110, 120. The air flow path 230 extends between opposed first and second ends 201 , 202 of the aerosol-generating article 200, and passes through a cavity 231 containing a plurality of beads of aerosol-forming substrate 290. The first end 201 may define a distal end of the aerosol-generating article 200, and the second end 202 may define a proximal end of the aerosol-generating article. The air flow path 230 may be directed towards a mouth of a user to allow a user to inhale aerosol generated in consequence of heating of aerosol-forming substrate of the aerosol-generating article 200. Parameters such as the total weight of aerosol-forming substrate 290 within the cavity 230, density of aerosol-forming material within the cavity, and total porosity within the cavity, may be controlled by controlling the bead size and bead size distribution for the plurality of beads 290.

In this specific embodiment, the beads of aerosol-generating substrate 290 are substantially spherical beads. The beads 290 have a mean diameter of 1 .5 millimetres and a density of 1 .3 grams per cubic centimetre. The total weight of beads 290 in the substrate cavity 231 is approximately 150 mg. The beads 290 are formed of an aerosol-generating substrate comprising plant particles, aerosol former and a hydrocolloid binder. An example of a suitable composition of the aerosol-generating substrate forming the beads is provided below.

Examples

Suitable compositions for forming beads of aerosol-generating substrate according to the invention are set out in Table 1 below:

All amounts are shown as percentages by weight, on a dry weight basis, based on the total weight of the aerosol-generating element.

In order to make the beads, the tobacco particles are first mixed with glycerin. The HPMC or CMC binder is dispersed in glycerin and then water is added to form an aqueous binder solution. The binder solution is added to the mixture of tobacco particles and glycerin and all of the components are mixed to form a dough. The dough is extruded to form a plurality of discrete elements and the discrete elements are then spheronized at low speed to form spherical beads having an average diameter of 1 .5 millimetres. The beads are dried in an oven to a desired moisture content. The dried beads can then be incorporated into a variety of different aerosol-generating articles, as described above.

When such beads were incorporated into an aerosol-generating article as described herein and heated, an aerosol was generated containing nicotine and glycerin from the aerosol-generating substrate. The ratio of nicotine to glycerin in each puff of aerosol was found to remain consistent over the duration of the heating. This is in contrast to the aerosol generated from an article having a similar construction but in which the aerosol-generating substrate is in the form of tobacco cast leaf. With the tobacco cast leaf substrate, the aerosol generated under the same conditions was found to have a much more variable ratio of nicotine to glycerin per puff. The provision of an aerosol with a more consistent ratio of nicotine to glycerin across puffs provides an optimal sensory experience to the consumer over the duration of the heating.

For exemplary purposes applicable to any of the embodiments described herein, a composition of aerosol-forming material that may be used to form the plurality of aerosol-forming beads may be as follows. Percentages are given in weight percent with respect to the product in its final state. The aerosol-forming substrate may have a moisture of about 5 to 25%, preferably of about 7 to 15%, at final product state. The aerosol-forming substrate may further comprise the following:

1 . 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.

2. 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.

3. 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.

4. 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 carboxymethyl, celluloses; dextran; and xanthan gum. The preferable binder is guar.

5. 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.

For exemplary purposes, a composition of a further aerosol-forming substrate, which may also be suitable for use as the aerosol-forming substrate in any of the embodiments described above is described below. Percentages are given in weight percent with respect to the product in its final state. The aerosol-forming substrate may comprise:

1 . An aerosol-former such as Glycerin; for example, about 10 to 40 %, preferably of about 20 to 30 %.

2. 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. For example, organic fibres may derive from cellulose, cotton, wood, tea botanical varieties as sub-products, and sub-processed 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.

3. 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.

Alternatively, such aerosol-forming substrate 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.

A dough formed from any such aerosol-forming material may be extruded to form a plurality of discrete elements, and the discrete elements may then be spheronized at low speed to form substantially spherical beads having an average diameter of between 0.5 millimetres and 4 millimetres. The beads are dried in an oven to a desired moisture content. The dried beads can then be incorporated into a variety of different aerosol-generating articles, as described above.

Figures 3, 4, and 5 illustrate respectively an end view, a side view, and a plan view of an aerosolgenerating article 300 according to a third embodiment of the present disclosure. The aerosol- generating article 300 comprises a planar upper layer 310, a planar lower layer 320, and an intermediate or separation layer 340 arranged between the upper layer 310 and lower layer 320.

The planar upper layer 310 is formed from a sheet of paper having a thickness of 100 microns. The planar lower layer 320 is formed from a sheet of paper having a thickness of 100 microns. The intermediate layer 340 is a corrugated element formed from a corrugated sheet of paper 345. A suitable aerosol-forming substrate may be beads of tobacco material 390 located within longitudinal cavities 361 , 362 formed by the corrugated sheet. The beads of tobacco material 390 may be as described above in relation to figure 1 .

Figure 6 illustrates the corrugated sheet of paper 345. The corrugations have an amplitude 346 of 3 millimetres and a wavelength 347 of 3 millimetres. The corrugated sheet of paper 345 forming the intermediate layer 340 has a thickness of 150 microns.

Points of intersection 351 , 352 between the upper layer 310 and the intermediate layer 340 and between the lower layer 320 and the intermediate layer 340 comprise an adhesive that joins the respective layers.

The aerosol-generating article 300 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (or thickness), extending in a z dimension, of 3.6 millimetres.

Corrugations of the intermediate layer 340 form a first set of longitudinally extending cavities or channels 361 that are bounded by the upper layer 310 and the intermediate layer 340, and a second set of longitudinally extending cavities or channels 362 bounded by the lower layer 320 and the intermediate layer 340. The first and second sets of longitudinally extending channels 361 , 362 extend through the length of the corrugated sheet between a proximal end 371 of the sheet 345 and a distal end 372 of the sheet 345. The longitudinally extending channels 361 , 362 contain beads of aerosolforming substrate 390 and also define an air-flow path through the sheet 345. The air-flow path, therefore, passes over of the beads of aerosol-forming substrate.

The corrugated sheet 345 may be a material other than paper, for example the corrugated sheet may be a sheet of any suitable aerosol-forming substrate.

Figure 7 shows an aerosol-generating article 600 according to a sixth embodiment of the present disclosure. The aerosol-generating article 600 comprises a first planar external layer 624 forming a first planar external surface 621 , a second planar external layer 625 forming a second planar external surface 622, and a frame 650 positioned between the first planar external layer 624 and the second planar external layer 625. The second planar external surface 622 is positioned parallel to the first planar external surface 621 .

Figures 8 and 9 show exploded views of the aerosol-generating article 600 of Figure 7. The frame 650 circumscribes and at least partially defines a cavity 630. Figure 8 shows the cavity 630 in an empty state. Figure 9 shows the cavity 630 filled with beads of aerosol-forming substrate 640. Figures 10 and 11 show respective transverse and longitudinal cross-sectional views of the aerosolgenerating article 600 when the cavity 630 is filled with a plurality of beads of aerosol-forming substrate 640. The plurality of beads 640 may be the same substantially spherical beads having a mean diameter of 1 .5 mm as described above in relation to figure 1 .

The first planar external layer 624 and the second planar external layer 625 are made from sheets of paper, and are in physical contact, with and bonded to, the frame 650. The first planar external layer 624 overlies a first end of the cavity 630 and forms a first cavity end wall 631. The second planar external layer 625 overlies a second end of the cavity 630 and forms a second cavity end wall 632, the second cavity end wall 632 being opposite to the first cavity end wall 631 . That is, the frame 650, the first planar external layer 624 and the second planar external layer 625 collectively define the cavity 630.

The frame 650 has a hollow cuboid shape and is made from cardboard. The frame 650 defines an aperture extending through the height (also referred to as the thickness) of the frame 650 and the aperture at least partially forms the cavity 630 of the aerosol-generating article 600. The frame 650 comprises a peripheral wall 651 that circumscribes the cavity 630. The peripheral wall 651 includes a front wall 613 and a back wall 614. In more detail, the peripheral wall 651 is defined by an inner transverse surface 652 of the frame 450 and an outer transverse surface 653 of the frame 650. The inner transverse surface 652 of the peripheral wall 651 at least partially defines a perimeter of the cavity 630. The outer transverse surface 653 of the peripheral wall 651 at least partially defines a perimeter of the aerosol-generating article 600. The peripheral wall 651 has a radial thickness measured between the inner transverse surface 652 of the frame 650 and the outer transverse surface 653 of the frame 650 of about 5 millimetres.

An air inlet 611 and an air outlet 612 are defined by, and extend through, the peripheral wall 651 of the frame 650. More specifically, the air inlet 611 extends through the front wall 613 and the air outlet 612 extends through the back wall 614. The air inlet 611 and the air outlet 612 have an equivalent diameter of 5 millimetres. An airflow passage extends between the air inlet 611 and the air outlet 612 through the cavity 630. As shown in Figures 11 to 13, an aerosol-forming substrate 640 is positioned within the cavity 630. The beads of aerosol-forming substrate 640 comprise tobacco. As shown, the beads of aerosol-forming substrate 640 fill the entire volume of the cavity 630, and airflow through the cavity is provided by interstices between adjacent beads.

The aerosol-generating article 600 has a cuboid shape and has a height (or thickness) extending in a z dimension, as measured between the first planar external surface 621 and the second planar external surface 622, of 8 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The frame 650 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The cavity 630 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 39.93 millimetres and a length extending in an x dimension of 52 millimetres.

An alternative exemplary aerosol-generating article of the same structure as illustrated in figures 7 to 11 may have smaller dimensions. For example, in preferred embodiments a height extending in the z dimension, as measured between the first planar external surface 621 and the second planar external surface 622, may be between 2.8 and 3.6 mm, for example about 3.3 mm. A width extending in a y dimension may be between 10 mm and 12 mm, for example about 11 mm. A length extending in an x dimension may be between 25 mm and 35 mm, for example about 30 mm. The cavity may have a height (or thickness) extending in a z dimension of between 2.8 and 3.6 mm, for example about 3.3 mm, a width extending in a y dimension of between 5 mm and 8 mm, for example 6 mm or 7 mm, and a length extending in an x dimension of between 10 mm and 15 mm, for example 12 mm.

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

Claims

1. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: a first external surface and a second external surface facing in substantially the opposite direction to the first external surface; a cavity located within the aerosol-generating article between the first external surface and the second external surface; and an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity, wherein. an aerosol-forming substrate is located within the cavity, the aerosol-forming substrate being in the form of a plurality of discrete beads having an average particle diameter of between 0.1 mm and 4 mm.

2. An aerosol-generating article according to claim 1 in which each of the plurality of beads has a maximum dimension (d_max) and a minimum dimension (d_min), in which the plurality of beads has an average d_max of less than 4 mm, for example less than 3 mm, and an average d_min of greater than 0.1 mm, for example greater than 0.5 mm, for example greater than 0.75 mm.

3. An aerosol-generating article according to any preceding claim in which the plurality of beads has a particle size distribution defined by a D10 diameter and a D90 diameter, in which the D10 diameter is greater than 0.5 mm, for example greater than 0.75 mm, and the D90 diameter is less than 4 mm, for example less than 3 mm.

4. An aerosol-generating article according to any preceding claim in which the plurality of beads has a particle size distribution defined by a D10 diameter and a D90 diameter, in which the D10 diameter is within 25 % of the value of the D90 diameter.

5. An aerosol-generating article according to any preceding claim in which the plurality of beads has a bimodal size distribution, for example in which the plurality of beads comprises a first phase and a second phase, the first phase having a different size distribution to the second phase.

6. An aerosol-generating article according to claim 5 in which the first phase of beads has an average d_max of less than 3 mm and an average dmin of greater than 1 .75 mm, and the second phase of beads has an average d_max of less than 1 .25 mm and an average d_min of greater than 0.1 mm.

7. An aerosol-generating article according to any preceding claim in which individual beads forming the plurality of beads comprise tobacco and a binder.

8. An aerosol-generating article according to any preceding claim in which the cavity comprises between 50 mg and 300 mg of the plurality of beads, for example between 100 mg and 200 mg, for example between 125 mg and 175 mg, for example between 140 mg and 160 mg, for example about 140 mg, or about 150 mg or about 160 mg.

9. An aerosol-generating article according to any preceding claim in which the plurality of beads are substantially spherical beads.

10. An aerosol-generating article according to any preceding claim in which the cavity contains between 50% and 85% of the plurality of beads by volume.

11. An aerosol-generating article according to any preceding claim in which the cavity contains the plurality of beads and between 15% and 50% free space.

12. An aerosol-generating article according to any preceding claim in which at least one of the first external surface and second external surface is a substantially planar surface, for example in which the first external surface is a substantially planar surface, for example in which both the first external surface and the second external surface is a substantially planar surface.

13. An aerosol-generating article according to any preceding example, wherein the cavity has a length between 14 millimetres and 40 millimetres, a width between 4.5 millimetres and 13 millimetres, and a thickness between 0.5 millimetres and 4.5 millimetres.

14. An aerosol-generating article according to any preceding claim, wherein both the air inlet and the air outlet has a width of between 0.3 millimetres and 3 millimetres and a thickness of between 0.3 millimetres and 3 millimetres.

15. An aerosol-generating article according to any preceding example, wherein the aerosolgenerating article has a length of between 15 millimetres and 45 millimetres, a width of between 4.5 millimetres and 17 millimetres, and a thickness of between 1 millimetres and 5.5 millimetres.