WO2025215185A1

WO2025215185A1 - Aerosol-generating article with segmented rod of substrate containing botanical material

Info

Publication number: WO2025215185A1
Application number: PCT/EP2025/059964
Authority: WO
Inventors: Bekele Alemu BEDASSO; CHENG (鄭), Hau Man (巧敏); HAN (韩), Wanjiang (万江); Filip Tack
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2024-04-10
Filing date: 2025-04-10
Publication date: 2025-10-16
Anticipated expiration: 2026-10-10

Abstract

An aerosol-generating article is provided comprising a rod of aerosol-generating substrate. The rod comprises a first segment and a second segment, with the first segment comprising a first substrate, and the first substrate comprises: a first botanical material, wherein the first botanical material comprises at least 40% by weight of a first non-tobacco botanical material, based on the total weight of the first botanical material; and at most 4% by weight of aerosol former, based on the total weight of the first substrate, wherein the first non-tobacco botanical material is a particulate or shredded non-tobacco botanical material. The second substrate comprises a second botanical material and at least 10% by weight of aerosol former, based on the total weight of the second substrate, wherein the second substrate is different to the first substrate.

Description

AEROSOL-GENERATING ARTICLE WITH SEGMENTED ROD OF SUBSTRATE CONTAINING BOTANICAL MATERIAL

The present disclosure relates to an aerosol-generating article comprising a rod of aerosol-generating substrate. The rod comprises a first segment, with the first segment comprising a first substrate comprising a first botanical material. The first botanical material comprises non-tobacco botanical material. The amount of aerosol former present in the first substrate is relatively low, or aerosol former is absent from the first substrate. The first segment is intended to be heated to a maximum temperature of 210 degrees Celsius.

Aerosol-generating articles in which an aerosol-generating substrate, such as a tobacco-containing substrate, is heated rather than combusted, are known in the art. Typically in such articles, an aerosol is generated by the transfer of heat from a heat source to a physically separate aerosol-generating substrate or material, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the substrate by heat transfer from the heat source and are entrained in air drawn through the article. As the released compounds cool, they condense to form an aerosol.

Some aerosol-generating articles comprise a flavourant that is delivered to the consumer during use of the article to provide a different sensory experience to the consumer, for example to enhance the flavour of aerosol. A flavourant can be used to deliver a gustatory sensation (taste), an olfactory sensation (smell), or both a gustatory and an olfactory sensation to the user inhaling the aerosol. It is known to provide heated aerosol-generating articles that include flavourants.

In such articles, the one or more flavourants are typically mixed with the tobacco in the tobacco rod in order to provide additional flavour to the aerosol generated upon heating the tobacco. Such flavourants may be in the form of liquid flavourants, such as essential oils. However, there are a number of potential issues with liquid flavourants, which can have low stability due to the volatilisation of flavour compounds prior to use of the article.

Alternatively, to form solid substrates, non-tobacco botanical material may be subjected to the same slurry or cast-leaf manufacturing process used to manufacture homogenised tobacco material. In use, the homogenised non-tobacco botanical material is typically heated in a device to the same temperatures as homogenised tobacco material, for example 350 degrees Celsius, to form an aerosol.

However, such temperatures may not be optimal for the flavour profile of non-tobacco botanical materials, which are both volatile and heat sensitive. When liquid flavourants are extracted from non-tobacco botanical materials, for example, by distillation, flavour compounds are often extracted as essential oils at temperature of between 60 degrees Celsius to 100 degrees Celsius, with certain flavour compounds extracted at even lower temperatures due to their high volatility and heat sensitivity. Heating non-tobacco botanical materials to temperatures such as 350 degrees Celsius may result in loss of their pleasing flavour, undesirable flavour characteristics and the formation of harmful and potentially harmful compounds (HPHCs).

It is desirable to provide an aerosol-generating article in which the pleasing flavour of non-tobacco botanical materials in the substrate is preserved. It is desirable to provide an aerosol-generating article in which undesirable flavour characteristics arising from non- tobacco botanical materials in the substrate are reduced or eliminated. It is desirable to provide an aerosol-generating article in which the formation of harmful and potentially harmful compounds (HPHCs) arising from non-tobacco botanical materials in the substrate is reduced or eliminated. It is desirable to provide an aerosol-generating article that provides an enhanced, multisensorial consumer experience. It is desirable to provide an aerosolgenerating article that can be manufactured using existing high-speed methods and apparatus.

In a first aspect, the present disclosure relates to an aerosol-generating article comprising a rod of aerosol-generating substrate. The rod may comprise a first segment and a second segment, the first segment may comprise a first substrate and the second segment may comprise a second substrate. The first substrate may comprise a first botanical material, and the first botanical material may comprise at least 40% by weight of a first non-tobacco botanical material, based on the total weight of the first botanical material. The first substrate may further comprise at most 4% by weight of aerosol former, based on the total weight of the first substrate. The first non-tobacco botanical material may be a particulate or shredded non- tobacco botanical material. The second substrate may comprise a second botanical material and at least 10% by weight of aerosol former, based on the total weight of the second substrate. The second substrate may be different to the first substrate.

In a second aspect, the present disclosure relates to an aerosol-generating system comprising an aerosol-generating article according to the first aspect of the disclosure. The aerosol generating system may further comprise an aerosol generating device comprising a heating chamber for receiving the aerosol-generating article. The heating chamber may be configured to heat the first segment of the aerosol-generating article to a maximum temperature of 210 degrees Celsius.

In a first aspect, the present invention relates to an aerosol-generating article comprising a rod of aerosol-generating substrate. The rod comprises a first segment and a second segment, the first segment comprises a first substrate and the second segment may comprise a second substrate. The first substrate comprises a first botanical material, and the first botanical material comprises at least 40% by weight of a first non-tobacco botanical material, based on the total weight of the first botanical material. The first substrate further comprises at most 4% by weight of aerosol former, based on the total weight of the first substrate. The first non-tobacco botanical material is a particulate or shredded non-tobacco botanical material. The second substrate comprises a second botanical material and at least 10% by weight of aerosol former, based on the total weight of the second substrate. The second substrate may be different to the first substrate.

In a second aspect, the present invention relates to an aerosol-generating system comprising an aerosol-generating article according to the first aspect. The aerosol generating system further comprises an aerosol generating device comprising a heating chamber for receiving the aerosol-generating article. The heating chamber is configured to heat the first segment of the aerosol-generating article to a maximum temperature of 210 degrees Celsius.

The invention is defined in accordance with the claims.

As used herein, the term “aerosol-generating article” refers to an article wherein an aerosol-generating substrate is heated to produce and deliver an inhalable aerosol to a consumer.

As used herein, the term “aerosol-generating substrate” refers to a substrate capable of releasing upon heating volatile compounds, which can form an aerosol.

As used herein, the term “aerosol” is used to describe a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets, in a gas.

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 former may be substantially resistant to thermal degradation at the operating temperature of the aerosolgenerating substrate or aerosol-generating article.

As used herein, the term “aerosol-generating device” denotes a device that interacts with an aerosol-generating substrate to generate an aerosol. In particular, the aerosolgenerating device may heat the aerosol-generating article comprising the rod of aerosolgenerating substrate according to the invention.

As used herein, the terms “proximal”, “distal”, “upstream” and “downstream” describe the relative positions of elements, or portions of elements, of an aerosol-generating article in relation to the direction in which the aerosol is transported through the aerosol-generating article during use.

As used herein, the term “longitudinal” refers to a direction extending from an upstream end to a downstream end of the substrate, or to a direction extending from an upstream end to a downstream end of an article or system of which the substrate is part. As used herein, the term “transverse” may refer to a direction perpendicular to the longitudinal direction.

As used herein, the term “length” is used to describe the maximum longitudinal dimension of components, or portions of components, of the aerosol-generating substrate, article or system parallel to the longitudinal axis between the proximal end and the opposed distal end of the aerosol-generating substrate, article or system.

As used herein, the terms “height” and “width” are used to describe the maximum transverse dimensions of components, or portions of components, of the aerosol-generating substrate, article or system perpendicular to the longitudinal axis of the aerosol-generating substrate, article or system. Where the height and width of components, or portions of components, of the substrate, article or system are not the same, the term “width” is used to refer to the larger of the two transverse dimensions perpendicular to the longitudinal axis of the substrate, article or system.

Unless otherwise stated, as used herein, the term “cross-section” refers to the transverse cross-section.

As used herein, the term “rod” refers to a generally cylindrical element of substantially polygonal cross-section and preferably of circular, oval or elliptical cross-section. A rod may have a length greater than or equal to the length of a plug. Typically, a rod has a length that is greater than the length of a plug. A rod may comprise one or more plugs.

The aerosol-generating article according to the invention comprises a rod of aerosolgenerating substrate. The rod comprises a first segment and the first segment comprises a first substrate. The first substrate comprises a first botanical material.

The first botanical material comprises at least 40 percent by weight of a first non-tobacco botanical material, based on the total weight of the first botanical material. The first botanical material may comprise at least about 45 percent, or at least about 50 percent, or at least about 60 percent, or at least about 70 percent, or at least about 75 percent, or at least about 80 percent, or at least about 85 percent, or at least about 90 percent, or at least about 95 percent, or at least about 97.5 percent, or about 100 percent by weight of a first non-tobacco botanical material, based on the total weight of the first botanical material. The first botanical material may comprise at most about 100 percent, or at most about 97.5 percent, or at most about 95 percent, or at most about 90 percent, or at most 85 about percent, or at most 80 percent, or at most about 75 percent, or at most about 70 percent, or at most about 60 percent, or at most about 50 percent of a first non-tobacco botanical material, based on the total weight of the first botanical material. The first botanical material may comprise between about 40 percent and about 100 percent, or between about 45 percent and about 97.5 percent, or between about 50 percent and about 95 percent, or between about 60 percent and about 90 percent, or between about 70 percent and about 85 percent, or between about 75 percent and about 80 percent of a first non-tobacco botanical material, based on the total weight of the first botanical material.

As discussed above, the first botanical material contains relatively volatile components.

Due to the relative volatility of the first botanical material, only a low level of an aerosol former, which may facilitate formation of an aerosol, may be required to be present in the first substrate.

The first substrate comprises at most 4 percent by weight of aerosol former, such as less than 4 percent by weight of aerosol former, based on the total weight of the first substrate. The first substrate may comprise at most about 3 percent, or at most about 2 percent, or at most about 1 percent, or at most about 0.5 percent, or at most about 0.1 percent, or at most about 0.05 percent, or at most about 0.01 percent of an aerosol former, or about 0 percent aerosol former, based on the total weight of the first substrate. The first substrate may comprise between about 0 percent and about 4 percent, or from about 0.01 percent to less than 3.5 percent, or from about 0.05 percent to about 3.4 percent, or from about 0.1 percent to about 3 percent, or from about 0.5 percent to about 3 percent, or from about 1 percent to about 2 percent aerosol former, based on the total weight of the first substrate. Indeed, in some embodiments, the first substrate may be substantially free of aerosol former.

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. The aerosol former may be or comprise glycerine.

The first non-tobacco botanical material may be selected from clove, star anise, eucalyptus, lavender, rosemary, chamomile, common sage, peppermint, verbena, lime, juniper, lemon myrtle, kaffir lime, geranium rosat, passion berry, tolu balsam, timur berry, coriander and tea.

Preferably, the first non-tobacco botanical material is selected from clove, star anise, eucalyptus, lavender, rosemary, common sage and peppermint.

The first non-tobacco botanical material is a particulate non-tobacco botanical material or a shredded non-tobacco botanical material. The first non-tobacco botanical material may be a homogenised non-tobacco botanical material.

As used herein, the term “homogenised plant material” encompasses any plant material formed by the agglomeration of particles of plant. For example, sheets or webs of homogenised non-tobacco botanical material may be formed by agglomerating particles of non-tobacco botanical material obtained by pulverising, grinding or comminuting non-tobacco botanical material. Homogenised plant material may be produced by casting, extrusion, paper making processes or other any other suitable processes known in the art.

Homogenised plant material may be produced by various processes including paper making, casting, dough reconstitution, extrusion or any other suitable process. Some processes such as casting and paper making are more suitable for producing homogenised plant material in sheet form. 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 botanical particles, a binder (for example, guar gum), optionally an aerosol former (for example, glycerol), and optionally reinforcement fibres 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.

The paper-making process for producing sheets of homogenised plant material comprises a first step of mixing a plant material and water to form a dilute suspension comprising mostly separate cellulose fibres. This first step may involve soaking and applying heat. The suspension has a lower viscosity and a higher water content than the slurry produced in the casting process. The suspension may then be separated into an insoluble portion containing solid fibrous components and a liquid or aqueous portion comprising soluble plant substances. The water remaining in the insoluble fibrous portion may be drained through a screen, acting as a sieve, such that a web of randomly interwoven fibres may be laid down. Water may be further removed from this web by pressing with rollers, sometimes aided by suction or vacuum. When most of the moisture has been removed, a generally flat, uniform sheet of plant fibres is achieved. The soluble plant substances that were removed from the sheet may be concentrated, and the concentrated plant substances may be added back to the sheet resulting in a sheet of homogenised plant material. This process, as described in US 3,860,012, has been used with tobacco to make reconstituted tobacco products, also known as tobacco paper.

Other known processes that can be applied to producing homogenised plant materials are dough reconstitution processes of the type described in, for example, US-A-3,894,544; and extrusion processes of the type described in, for example, in GB-A-983,928. Typically, the densities of homogenised plant materials produced by extrusion processes and dough reconstitution processes are greater than the densities of the homogenised plant materials produced by casting processes.

The tensile strength is a measure of force required to stretch a sheet of material until it breaks. Paper-making processes typically yield sheets with relatively higher tensile strengths than those produced by cast-leaf, dough reconstitution or extrusion. In a cast-leaf process, because substantially all the soluble fraction is kept within the plant material, most flavours are advantageously preserved. Additionally, energy-intensive paper-making steps are avoided.

Particle sizes herein are stated as D-values, whereby the D-value refers to the percentage of particles by number with a diameter of less than or equal to the given D-value. For instance, in a D90 particle size distribution, 90 percent of the particles by number are of a diameter less than or equal to the given D90 value, and 10 percent of the particles by number are of a diameter measuring greater than the given D90 value. The particle size distribution may be determined by laser diffraction. For example, the particle size distribution may be determined by laser diffraction using a Malvern Mastersizer 3000 laser diffraction particle size analyser in accordance with the manufacturer’s instructions.

Particles of the first botanical material may have a D90 value of at least 100 microns. Particles of the first botanical material may have a D90 value of at least 100 microns to at most 300 microns. By this is meant that the first botanical material particles may be of a distribution represented by any D90 value within the given range, that is D90 may be equal to 100 microns, or D90 may be equal to 105 microns, et cetera, all the way up to D90 may be equal to 300 microns. Preferably particles of the first botanical material have a D90 value of from greater than or equal to 100 microns to a D90 value of less than or equal to 250 microns, more preferably a D90 value of from greater than or equal to 120 microns to a D90 value of less than or equal to 200 microns. The particle size range of first botanical material enables the non-tobacco botanical material and optional tobacco particles to be combined and used in existing cast leaf processes. Without wishing to be bound by theory, the particle size range of the non-tobacco botanical particles may reduce or prevent loss of volatile flavour essential oils from the non-tobacco botanical particles, as excessive grinding of the particles may cause volatile flavour essential oils to separate from the particles and to evaporate from the relatively large surface area of the relatively small particles.

Optionally, tobacco material may be incorporated into the first substrate.

The first botanical material may comprise less than about 25 percent by weight of tobacco material, based on the total weight of the first botanical material.

The first botanical material may comprise less than about 20 percent by weight, or less than about 15 percent by weight, or less than about 10 percent by weight, or less than about 5 percent by weight, or about 0 percent by weight of tobacco material, on a dry weight basis. The first botanical material may comprise greater than or equal to about 0.5 percent by weight, or greater than or equal to about 1 percent by weight, or greater than or equal to 2.5 percent by weight, or greater than or equal to 5 percent by weight of tobacco material, of the tobacco material, on a dry weight basis. The first botanical material may comprise between about 0.5 percent by weight and about 25 percent by weight, or between about 1 percent by weight and about 20 percent by weight, or between about 2.5 percent by weight and about 15 percent by weight, or between about 5 percent by weight and about 10 percent by weight, or between about 0 percent by weight and about 5 percent by weight, of tobacco material, on a dry weight basis. The tobacco material may be one or more of particulate tobacco material, ground tobacco material, shredded tobacco material, cut filler, homogenised tobacco material or cast leaf.

As used herein, the term “tobacco particles” encompasses ground or powdered tobacco leaf lamina, ground or powdered tobacco leaf stems, tobacco dust, tobacco fines, and other particulate tobacco by-products formed during the treating, handling and shipping of tobacco. By contrast, isolated nicotine and nicotine salts are compounds derived from tobacco but are not considered tobacco for purposes of the invention and are not included in the percentage of tobacco material.

All percentages by weight herein, except where stated otherwise, are on a dry weight basis. As used herein, the term “dry weight” refers to the sum of the weights of all non-water components in a mixture. As used herein, and except with reference to aerosol-generating films, the term “total weight” implies the total dry weight, that is, the total weight of all nonwater components in a mixture. With reference to aerosol-generating films, “total weight” refers to the weight of all components in a mixture. The terms “total weight” and “dry weight” are thus used interchangeably, except with reference to aerosol-generating films.

Preferably the tobacco particles may have a D90 value of from greater than or equal to 30 microns to a D90 value of less than or equal to 275 microns, more preferably a D90 value of from greater than or equal to 100 microns to a D90 value of less than or equal to 250 microns, most preferably a D90 value of from greater than or equal to 120 microns to a D90 value of less than or equal to 200 microns. The tobacco particles may have a D90 value of at least 100 microns. As described above, the particle size range of the tobacco particles enables these tobacco particles to be combined with first non-tobacco plant particles and second nontobacco plant particles in existing cast leaf processes.

In some embodiments, tobacco may be purposely ground to form particulate tobacco material having a defined particle size distribution. This provides the advantage that the size of the tobacco particles can be controlled to provide a desired particle size distribution. The use of purposely ground tobacco therefore advantageously improves the homogeneity of the particulate tobacco material and the consistency of the homogenised tobacco material. This enables aerosol-generating article having a consistent delivery of aerosol to be provided.

Furthermore, specific portions of the tobacco plant may be selected and ground to the desired size. For example, tobacco lamina may be ground to form the particulate tobacco material. This also contributes to an improvement in the consistency of the homogenised plant material, for example, compared to a material formed using waste tobacco.

The tobacco particles may be prepared from one or more varieties of tobacco plants. Any type of tobacco may be used in a blend. Examples of tobacco types that may be used include, but are not limited to, sun-cured tobacco, flue-cured tobacco, Burley tobacco, Maryland tobacco, Oriental tobacco, Virginia tobacco, other speciality tobaccos, blends thereof and the like.

The tobacco material may be in the form of cut filler. The cut width of the cut filler may be between 0.3 and 2, 0.5 and 1 .2, or 0.6 and 0.9 millimetres.

The cut width may affect the distribution of heat in the first substrate, the resistance to draw of the first substrate, and the overall density of the first substrate. The inventors have found that the above cut width ranges may be desirable in terms of heat distribution, resistance to draw, and density.

The tobacco material in the first botanical material may be in the form of cast leaf or homogenised tobacco material. The cast leaf or homogenised tobacco material may be cocast in the same sheets as the non-tobacco botanical material to form the first botanical material, and incorporated into the first substrate. Alternatively, the tobacco material may be cast into separate sheets containing only tobacco material, which may then be gathered along with non-tobacco botanical material sheets to form the first botanical material and first substrate.

The first substrate may comprise the first botanical material, at most 4 percent by weight of an aerosol former, optionally a binder, and optionally reinforcement fibres.

The first substrate may comprise at least about 45 percent by weight, or at least about 50 percent by weight, or at least about 60 percent by weight, or at least about 65 percent by weight, or at least about 70 percent by weight, or at least about 75 percent by weight of the first botanical material, on a dry weight basis. The first substrate may comprise less than or equal to about 80 percent by weight of the first botanical material, on a dry weight basis. The first substrate may comprise between about 45 percent by weight and about 80 percent by weight, or between about 50 percent by weight and about 80 percent by weight, or between about 60 percent by weight and about 80 percent by weight, or between about 65 percent by weight and about 80 percent by weight, or between about 70 percent by weight and about 80 percent by weight, or between about 75 percent by weight and about 80 percent by weight of the first botanical material, on a dry weight basis.

The first botanical material is a particulate non-tobacco botanical material or a shredded non-tobacco botanical material. The first botanical material may be a homogenised plant material. The homogenised plant material may comprise or more binders to help agglomerate the particulate plant material. Alternatively, or in addition, the homogenised plant material may comprise other additives including, but not limited to, lipids, fibres, humectants, plasticisers, flavourants, fillers, aqueous and non-aqueous solvents and combinations thereof.

A binder may be endogenous or exogenous to the particulate plant material. Suitable binders for inclusion in the homogenised plant material as described herein are known in the art and include, but are not limited to: gums such as, for example, guar gum, xanthan gum, arabic gum and locust bean gum; cellulosic binders such as, for example, hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose and ethyl cellulose; polysaccharides such as, for example, starches, organic acids, such as alginic acid, conjugate base salts of organic acids, such as sodium-alginate, agar and pectins; and combinations thereof. Preferably, the binder may comprise guar gum. The binder may be present in an amount of from about 1 percent to about 10 percent by weight, based on the dry weight of the first substrate, preferably in an amount of from about 2 percent to about 5 percent by weight, based on the dry weight of the first substrate.

The homogenised plant material may comprise reinforcement fibres. Suitable reinforcement fibres for inclusion in the homogenised plant material are known in the art and include fibres formed from plant material other than tobacco material, first non-tobacco plant material and second non-tobacco plant material, including but not limited to: cellulose fibres; soft-wood fibres; hard-wood fibres; jute fibres and combinations thereof. Prior to inclusion in the homogenised plant material, fibres may be treated by suitable processes known in the art including, but not limited to: mechanical pulping; refining; chemical pulping; bleaching; sulfate pulping; and combinations thereof. A fibre typically has a length greater than its width. Suitable fibres typically have lengths of greater than 400 pm and less than or equal to 4 mm, preferably within the range of 0.7 mm to 4 mm. The homogenised plant material may be formed of a combination of particulate plant material and reinforcement fibres formed from non-tobacco botanical material or tobacco material. The weight percentages of other fibrous material are not added to the weight of the botanical material in determination of the weight percentages based on total weight of botanical material.

The reinforcement fibres may be present in an amount between about 2 percent to about 15 percent, based on the dry weight of the first substrate, preferably in an amount of from about 3 percent to about 5 percent, based on the dry weight of the first substrate.

Preferably, the homogenised plant material is in the form of one or more sheets of homogenised plant material.

As used herein, the term “sheet” denotes a laminar element having a width and length substantially greater than the thickness thereof. As used herein, the term “thickness” is used to describe the minimum dimension between opposite, substantially parallel surfaces of an aerosol-generating sheet or film.

The one or more sheets as described herein may each individually have a thickness of between 100 microns and 600 microns, preferably between 100 microns and 400 microns, preferably between 150 microns and 300 microns, and most preferably between 200 microns and 280 microns. Individual thickness refers to the thickness of the individual sheet, whereas combined thickness refers to the total thickness of all sheets that make up the aerosolgenerating substrate. For example, if the aerosol-generating substrate is formed from two individual sheets, then the combined thickness is the sum of the thickness of the two individual sheets or the measured thickness of the two sheets where they are stacked in the aerosolgenerating substrate.

The one or more sheets as described herein may each have an average thickness of between 100 microns and 600 microns, preferably between 100 microns and 400 microns, preferably between 150 microns and 300 microns, and most preferably between 200 microns and 280 microns.

The one or more sheets as described herein may each individually have a grammage of between about 100 grams per square metre and about 300 grams per square metre.

The one or more sheets as described herein may each individually have a density of from about 0.3 g/cm3 to about 1.3 g/cm3, and preferably from about 0.7 g/cm3 to about 1.0 g/cm3.

The term “tensile strength” is used throughout the specification to indicate a measure of the force required to stretch a sheet of homogenised plant material until it breaks. More specifically, the tensile strength is the maximum tensile force per unit width that the sheet material will withstand before breaking and is measured in the machine direction or cross direction of the sheet material. It is expressed in units of Newtons per meter of material (N/m). Tests for measuring the tensile strength of a sheet material are well known. A suitable test is described in the 2014 publication of the International Standard ISO 1924-2 entitled “Paper and Board - Determination of Tensile Properties - Part 2: Constant Rate of Elongation Method”. Further details of the test method are provided under the heading “Test Methods” herein.

The one or more sheets as described herein may each individually have a tensile strength at peak in a cross direction of between 50 N/m and 400 N/m or preferably between 150 N/m and 350 N/m, normalized to a thickness of a single sheet, whereby the thickness of the single sheet ranges from 215 pm to 275 pm. The one or more sheets as described herein may each individually have a tensile strength at peak in a machine direction of between 100 N/m and 800 N/m or preferably between 280 N/m and 620 N/m, normalized to a thickness of a single sheet, whereby the thickness of the single sheet ranges from 215 pm to 275 pm. The machine direction refers to the direction in which the sheet material would be rolled onto or unrolled from a bobbin and fed into a machine, while the cross direction is perpendicular to the machine direction. Such values of tensile strength make sheets and methods described herein particularly suitable for subsequent operations involving mechanical stresses.

The provision of a sheet having the levels of thickness, grammage and tensile strength as defined above advantageously optimises the machinability of the sheet to form the aerosolgenerating substrate and ensures that damage, such as tearing of the sheet, is avoided during high speed processing of the sheet.

As used herein, the term “gathered” denotes that the sheet of homogenised plant material or aerosol-generating film is convoluted, folded, or otherwise compressed or constricted substantially transversely to the cylindrical axis of a plug or a rod.

Preferably the one or more sheets may be in the form of one or more gathered sheets. Preferably the first segment comprises one or more gathered sheets of the homogenised plant material, circumscribed by a wrapper.

The sheet of homogenised plant material may preferably be gathered transversely relative to the longitudinal axis thereof and circumscribed with a wrapper to form a continuous rod or a plug. The continuous rod may be severed into a plurality of discrete rods or plugs. The wrapper may be a paper wrapper or a non-paper wrapper. Suitable paper wrappers for use in specific embodiments of the invention are known in the art and include, but are not limited to: cigarette papers; and filter plug wraps. Suitable non-paper wrappers for use in specific embodiments of the invention are known in the art and include, but are not limited to: metallic foils, metallic meshes, or homogenised tobacco materials. Homogenised tobacco wrappers are particularly suitable for use in embodiments wherein the aerosol-generating substrate comprises one or more sheets of first botanical material formed from non-tobacco botanical material in combination with a relatively low percentage by weight of tobacco particles.

The term “textured” is used to describe a sheet of homogenized plant material or aerosol-generating film that has been crimped, embossed, debossed, perforated or otherwise deformed. Textured aerosol-generating film may comprise a plurality of spaced-apart indentations, protrusions, perforations or a combination thereof.

As used herein, the term “crimped” is intended to be synonymous with the term “creped” and is used to describe a sheet of homogenized plant material or aerosol-generating film having a plurality of substantially parallel ridges or corrugations.

As used herein, the term “strand” describes an elongate element of material having a length that is substantially greater than the width and thickness thereof. The term “strand” should be considered to encompass strips, shreds and any other homogenised plant material or aerosol-generating film having a similar form. The strands of homogenised plant material or aerosol-generating film may be formed from a sheet of homogenised plant material or aerosol-generating film, for example by cutting or shredding, or by other methods, for example, by an extrusion method.

The sheet of homogenised plant material may be textured through crimping, embossing, perforating or otherwise texturing prior to gathering or being cut into shreds. Preferably the sheet of homogenised plant material is crimped prior to gathering, such that the homogenised plant material may be in the form of a crimped sheet, more preferably in the form of a gathered crimped sheet. Alternatively, the homogenised plant material may be in the form of a plurality of shreds, strands or strips. The shreds, strands or strips may be used to form a plug.

In some embodiments, the strands may be formed in situ within the aerosol-generating substrate as a result of the splitting or cracking of a sheet of homogenised plant material during formation of the aerosol-generating substrate, for example, as a result of crimping. The strands of homogenised plant material within the aerosol-generating substrate may be separate from each other. Alternatively, each strand of homogenised plant material within the aerosolgenerating substrate may be at least partially connected to an adjacent strand or strands along the length of the strands. For example, adjacent strands may be connected by one or more fibres. This may occur, for example, where the strands have been formed due to the splitting of a sheet of homogenised plant material during production of the aerosol-generating substrate, as described above.

Typically, the width of such shreds, strands or strips is about 5 mm, or about 4mm, or about 3 mm, or about 2 mm or less. The length of the shreds, strands or strips may be greater than about 5 mm, between about 5 mm to about 15 mm, about 8 mm to about 12 mm, or about 12 mm. The length of the shreds, strands or strips may be determined by the manufacturing process whereby a rod is cut into shorter plugs and the length of the shreds, strands or strips corresponds to the length of the plug. The shreds, strands or strips may be fragile which may result in breakage especially during transit. In such cases, the length of some of the shreds, strands or strips may be less than the length of the plug.

The plurality of strands preferably extend substantially longitudinally along the length of the aerosol-generating substrate, aligned with the longitudinal axis. Preferably, the plurality of strands are therefore aligned substantially parallel to each other. This provides a relatively uniform, regular structure which facilitates the insertion of an internal heater element into the aerosol-generating substrate and optimises the efficiency of heating.

The first segment may be in the form of a single plug of aerosol-generating substrate. Most preferably, the plug of aerosol-generating substrate may comprise one or more sheets of homogenised plant material. Preferably, the one or more sheets of homogenised plant material may be crimped such that it has a plurality of ridges or corrugations substantially parallel to the cylindrical axis of the plug. This advantageously facilitates gathering of the crimped sheet of homogenised plant material to form the plug. Preferably, the one or more sheets of homogenised plant material may be gathered. It will be appreciated that crimped sheets of homogenised plant material may alternatively or in addition have a plurality of substantially parallel ridges or corrugations disposed at an acute or obtuse angle to the cylindrical axis of the plug. The sheet may be crimped to such an extent that the integrity of the sheet becomes disrupted at the plurality of parallel ridges or corrugations causing separation of the material, and results in the formation of shreds, strands or strips of homogenised plant material.

As used herein, the term “nicotine” is used to describe nicotine, a nicotine base or a nicotine salt. In some embodiments in which the substrate may comprise a nicotine base or a nicotine salt, the amounts of nicotine recited herein are the amount of free base nicotine or amount of protonated nicotine, respectively.

Optionally, exogenous nicotine may be incorporated into the first substrate. The term “exogenous nicotine” refers to nicotine that is added to the botanical material as a distinct component from any nicotine that is intrinsically present in tobacco material (where present).

Exogenous nicotine may be incorporated in addition to a tobacco with low nicotine content, or as an alternative to tobacco in substrates intended to have a reduced or zero tobacco content. The exogenous nicotine may comprise one or more nicotine salts selected from the list consisting of nicotine citrate, nicotine pyruvate, nicotine bitartrate, nicotine pectates, nicotine alginates, and nicotine salicylate. The term “nicotine content” refers to the total nicotine content, that is to say, both the exogenous nicotine content and endogenous nicotine content that is intrinsically present in tobacco material (where present).

The first substrate may have a nicotine content of greater than or equal to about 0.5 percent by weight, greater than or equal to about 1 percent by weight, greater than or equal to about 1 .5 percent by weight, or greater than or equal to about 2 percent by weight. The first substrate may have an exogenous nicotine content of greater than or equal to about 0.5 percent by weight, greater than or equal to about 1 percent by weight, greater than or equal to about 1 .5 percent by weight, or greater than or equal to about 2 percent by weight.

The first substrate may have a nicotine content of less than or equal to about 10 percent by weight, less than or equal to about 8 percent by weight, less than or equal to about 6 percent by weight, or less than or equal to about 4 percent by weight. The first substrate may have an exogenous nicotine content of less than or equal to about 10 percent by weight, less than or equal to about 8 percent by weight, less than or equal to about 6 percent by weight, or less than or equal to about 4 percent by weight.

The first substrate may have a nicotine content of greater than or equal to about 0.5 percent by weight to less than or equal to about 10 percent by weight, greater than or equal to about 1 percent by weight to less than or equal to about 8 percent by weight, greater than or equal to about 1 .5 percent by weight to less than or equal to about 6 percent by weight, or greater than or equal to about 2 percent by weight to less than or equal to about 4 percent by weight, based on the total weight of the first substrate. The first substrate may have an exogenous nicotine content of greater than or equal to about 0.5 percent by weight to less than or equal to about 10 percent by weight, greater than or equal to about 1 percent by weight to less than or equal to about 8 percent by weight, greater than or equal to about 1 .5 percent by weight to less than or equal to about 6 percent by weight, or greater than or equal to about 2 percent by weight to less than or equal to about 4 percent by weight, based on the total weight of the first substrate.

The rod of aerosol-generating substrate further comprises a second segment.

The first segment and the second segment comprise different aerosol-generating substrates. This means that the first segment and the second segment generate different aerosols. In this manner a multisensorial experience may be delivered to the consumer while preserving the integrity of the non-tobacco botanical material flavour. As will be discussed further below, the first segment and the second segment may be heated separately and to different temperatures.

The first substrate comprises a first botanical material and the second substrate comprises a second botanical material. The first botanical material and the second botanical material may be different botanical materials.

The second substrate comprises a second botanical material. The second substrate comprises at least 10 percent by weight of aerosol former, based on the total weight of the second substrate.

The second botanical material may comprise at least 45 percent by weight of tobacco material, based on the dry weight of the second substrate. The second botanical material may comprise at least 45 percent by weight of tobacco material, based on the dry weight of the second botanical material.

The second substrate may comprise at least about 50 percent by weight, or at least about 60 percent by weight, or at least about 65 percent by weight, or at least about 70 percent by weight, or at least about 75 percent by weight of the tobacco material, based on the dry weight of the second substrate. The second substrate may comprise less than or equal to about 80 percent by weight of tobacco material, based on the dry weight of the second substrate. The second substrate may comprise between about 45 percent and about 80 percent, between about 50 percent and about 80 percent, between about 65 percent and about 80 percent, or between about 75 percent and about 80 percent, by weight of tobacco material, based on the dry weight of the second substrate.

The second botanical material may comprise at least about 50 percent by weight, or at least about 60 percent by weight, or at least about 65 percent by weight, or at least about 70 percent by weight, or at least about 75 percent by weight of the tobacco material, based on the dry weight of the second botanical material. The second botanical material may comprise less than or equal to about 80 percent by weight of tobacco material, based on the dry weight of the second botanical material. The second botanical material may comprise between about 45 percent and about 80 percent, between about 50 percent and about 80 percent, between about 65 percent and about 80 percent, or between about 75 percent and about 80 percent, by weight of tobacco material, based on the dry weight of the second botanical material. The second substrate comprises at least about 10 percent by weight of aerosol former, based on the total weight of the second substrate.

The second substrate comprises at least about 10 percent by weight aerosol former, on a dry weight basis. For example, the second substrate may have an aerosol former content of between about 10 percent and about 30 percent by weight on a dry weight basis, such as between about 10 percent and about 25 percent by weight on a dry weight basis, or between about 15 percent and about 20 percent by weight on a dry weight basis.

Suitable aerosol formers have been discussed above and include, but are not limited to: polyhydric alcohols, such as 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.

Preferably, the aerosol former may be or comprise glycerine.

Functionally, an aerosol former is a component that may be volatilized and may convey one or more of nicotine, tobacco flavour and non-tobacco flavour in an aerosol when the tobacco-containing botanical material is heated above the specific volatilization temperature of the aerosol former. Different aerosol formers vaporize at different temperatures. Thus, an aerosol former may be chosen based on its ability to remain stable at or around room temperature but volatize at a higher temperature, for example between 40-350°C.

The tobacco material of the second botanical material may be one or more of particulate tobacco material, ground tobacco material, shredded tobacco material, cut filler, homogenised tobacco material or cast leaf, as described above with respect to the first botanical material.

The tobacco material of the second botanical material comprises particles having a D90 value of at least 100 microns, as described above with respect to the first botanical material.

Optionally, the second botanical material comprises a relatively small amount of a second non-tobacco botanical material, such as between about 3 percent by weight and about 20 percent by weight of non-tobacco botanical material, based on the dry weight of the second substrate.

Optionally, the second botanical material comprises a relatively small amount of a second non-tobacco botanical material, such as between about 3 percent by weight and about 20 percent by weight of non-tobacco botanical material, based on the dry weight of the second botanical material.

The second non-tobacco botanical material may be different to the first non-tobacco botanical material.

The second non-tobacco botanical material may be selected from clove, star anise, eucalyptus, lavender, rosemary, chamomile, common sage, peppermint, verbena, lime, juniper, lemon myrtle, kaffir lime, geranium rosat, passion berry, tolu balsam, timur berry, coriander and tea. Unless otherwise mentioned herein, types, particle sizes and morphology of tobacco material and non-tobacco material in the second botanical material in the second substrate may be the same as parameters described above with respect to the first botanical material of the first substrate. Binders, fibres and other additives may be present in the second botanical material of the second substrate in the amounts and types as described above with respect to the first botanical material of the first substrate. Additionally, the thickness, grammage, tensile strength, and morphology and dimensions of shreds, strips, strands and sheets, and the dimensions of cut filler in the second botanical material may be the same as those described above with respect to the first botanical material, and so this description will not be repeated here.

In some embodiments, the second substrate may comprise an aerosol-generating film, the aerosol-generating film comprising one or more cellulose based film-forming agents and one or more aerosol formers. Preferably the aerosol-generating film comprises nicotine. Such a film may be substantially tobacco-free. Optionally, the film comprises a carboxylic acid. Preferably the aerosol former is glycerine.

The film may have a thickness of greater than or equal to 0.5 millimetres to less than or equal to 1 .2 millimetres. The film may have a basis weight of greater than or equal to 85 grams per square metre to less than or equal to 300 grams per square metre. The film may be formed by any suitable method, such as by batch casting, continuous casting or extrusion. The film may be self-supporting, disposed on a support or sandwiched between other materials. The film may be cut into strips or shreds that may be wrapped to form the second segment. The film may be textured or crimped. The film may be gathered to form the second segment.

As used herein, the term “film” is used to describe a solid aerosol-generating substrate having a thickness that is substantially less than the width or length thereof.

The term “cellulose based film-forming agent” is used to describe a cellulosic polymer capable, by itself or in the presence of an auxiliary thickening agent, of forming a continuous film.

Advantageously, the aerosol-generating film may comprise one or more cellulose based film-forming agents selected from carboxymethyl cellulose (CMC), ethylcellulose (EC), hydroxyethyl cellulose (HEC), hydroxyethyl methylcellulose (HEMC), hydroxypropyl cellulose (HPC), hydroxypropyl methylcellulose (HPMC), and methylcellulose (MC).

Preferably, the aerosol-generating film comprises carboxymethyl cellulose (CMC) and hydroxypropyl methylcellulose (HPMC).

Most preferably, the aerosol-generating film comprises hydroxypropyl methylcellulose (HPMC).

The one or more cellulose based film-forming agents may act as a binding agent for the aerosol-generating film. As used herein, the term “total cellulose based film-forming agent content” is used to describe the combined content of all cellulose based film-forming agents in the aerosolgenerating film.

The aerosol-generating film may have a total cellulose based film-forming agent content of between 15 percent by weight and 40 percent by weight, of between 20 percent by weight and 35 percent by weight, or of between 20 percent by weight and 30 percent by weight based on the total weight of the aerosol-generating film.

The aerosol-generating film comprises one or more aerosol formers.

Preferably, the one or more aerosol formers comprise one or more polyhydric alcohols selected from 1 ,3-butanediol, glycerine, 1 ,3-propanediol, propylene glycol, and triethylene glycol.

The aerosol-generating film may have a total aerosol former content of between 40 percent by weight and 62 percent by weight, of between 45 percent by weight and 60 percent by weight, of between 46 percent by weight and 60 percent by weight, of between 48 percent by weight and 58 percent by weight, of between 50 percent by weight and 58 percent by weight, of between 52 percent by weight and 56 percent by weight, or of between 52 percent by weight and 54 percent by weight based on the total weight of the aerosol-generating film.

The aerosol-generating film may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

The nicotine may comprise one or more nicotine salts. The one or more nicotine salts may be selected from the list consisting of nicotine lactate, nicotine citrate, nicotine pyruvate, nicotine bitartrate, nicotine benzoate, nicotine pectate, nicotine alginate, and nicotine salicylate.

The nicotine may comprise an extract of tobacco.

The aerosol generating film may have a nicotine content of greater than or equal to about 0.5 percent by weight to less than or equal to about 10 percent by weight, greater than or equal to about 1 percent by weight to less than or equal to about 8 percent by weight, greater than or equal to about 1 .5 percent by weight to less than or equal to about 6 percent by weight, or greater than or equal to about 2 percent by weight to less than or equal to about 4 percent by weight, based on the total weight of the aerosol-generating film.

Preferably, the aerosol-generating film may comprise one or more carboxylic acids. It has surprisingly been found that inclusion of one or more carboxylic acids in the aerosolgenerating film may advantageously improve the stability of the film during storage and inhibit corrosion of metal components of aerosol-generating articles. In particular, it has surprisingly been found that inclusion of one or more carboxylic acids in the aerosol-generating film may advantageously inhibit corrosion of the susceptor element within an aerosol-generating substrate. For example, the aerosol-generating film may comprise one or more carboxylic acids selected from acetic acid, adipic acid, benzoic acid, citric acid, fumaric acid, lactic acid, levulinic acid, malic acid, maleic acid, myristic acid, oxalic acid, and salicylic acid, stearic acid, succinic acid, undecanoic acid, and C1-C10 saturated alkyl mono-carboxylic acids.

Preferably, the aerosol-generating film comprises one or more carboxylic acids selected from fumaric acid, lactic acid, levulinic acid, maleic acid and malic acid. Advantageously, lactic acid and levulinic acid are particularly good carboxylic acids for creating nicotine salts.

The term “total carboxylic acid content” is used to describe the combined content of all carboxylic acids in the aerosol-generating film.

The aerosol-generating film may have a total carboxylic acid content of between 0.5 percent by weight and 8 percent by weight, or between 1 percent by weight and 6 percent by weight, or between 1.5 percent by weight and 6 precent by weight, or between 2 percent by weight and 4 percent by weight based on the total weight of the aerosol-generating film.

The aerosol-generating film may comprise one or more cellulose based strengthening agents.

Inclusion of one or more cellulose based strengthening agents in the aerosol-generating film may advantageously increase the tensile strength of the aerosol-generating film. An aerosol-generating film having a higher tensile strength may advantageously be less likely to deteriorate or break during manufacture and storage.

Advantageously, the aerosol-generating film may comprise one or more cellulose based strengthening agents selected from cellulose fibres, cellulose powder, and microcrystalline cellulose (MCC).

Preferably, the aerosol-generating film comprises cellulose fibres. Cellulose fibres may be particularly effective at increasing the tensile strength of the aerosol-generating film. The aerosol-generating film may comprise cellulose fibres having a length of between 0.2 millimetres and 2 millimetres, of between 0.5 millimetres and 1.8 millimetres, of between 0.7 millimetres and 1 .6 millimetres, or of between 0.9 millimetres and 1 .4 millimetres.

The term “total cellulose based strengthening agent content” is used to describe the combined content of all cellulose based strengthening agents in the aerosol-generating film.

The aerosol-generating film may have a total cellulose based strengthening agent content of between 5 percent by weight and 30 percent by weight, or between 10 percent by weight and 25 percent by weight, or between 15 percent by weight and 20 percent by weight based on the total weight of the aerosol-generating film.

The aerosol-generating film may comprise water.

The aerosol-generating film may have a water content of greater than or equal to 5 percent by weight, greater than or equal to 10 percent by weight, greater than or equal to 15 percent by weight, or greater than or equal to 17 percent by weight based on the total weight of the aerosol-generating film.

The aerosol-generating film may have a water content of less than or equal to 35 percent by weight, less than or equal to 30 percent by weight, or less than or equal to 25 percent by weight based on the total weight of the aerosol-generating film.

The aerosol-generating film may have a water content of between 5 percent by weight and 35 percent by weight, of between 10 percent by weight and 30 percent by weight, of between 15 percent by weight and 25 percent by weight, or of between 17 percent by weight and 25 percent by weight based on the total weight of the aerosol-generating film.

The rod of aerosol-generating substrate comprises a first segment.

Preferably the first segment is generally cylindrical, although other suitable shapes will be apparent to the skilled person and will also be described below.

The first segment has a length of less than 20 millimetres. More preferably, the first segment has a length of less than 18 millimetres. More preferably, the first segment has a length of less than 17 millimetres. More preferably, the first segment has a length of less than 15 millimetres. More preferably, the first segment has a length of less than 13 millimetres.

The first segment may have a length of at least 3 millimetres, or at least 6 millimetres, or at least 10 millimetres, or at least 12 millimetres.

For example, the first segment has a length of between 3 millimetres and 20 millimetres, or between 6 millimetres and 18 millimetres, or between 10 millimetres and 17 millimetres, or between 12 millimetres and 15 millimetres, or between 12 millimetres and 13 millimetres.

The “external diameter of the first segment” may be calculated as the average of a plurality of measurements of the diameter of the first segment taken at different locations along the length of the first segment.

Preferably, the first segment has an external diameter of at least about 2 millimetres.

More preferably, the first segment has an external diameter of at least about 5 millimetres.

More preferably, the first segment has an external diameter of at least about 6 millimetres.

Even more preferably, the first segment has an external diameter of at least about 7 millimetres.

The first segment preferably has an external diameter of less than or equal to about 12 millimetres. More preferably, the first segment has an external diameter of less than or equal to about 10 millimetres. Even more preferably, the first segment has an external diameter of less than or equal to about 8 millimetres.

In some embodiments, the first segment has an external diameter from about 3 millimetres to about 12 millimetres, or from about 5 millimetres to about 12 millimetres, or from about 6 millimetres to about 10 millimetres, or from about 7 millimetres to about 8 millimetres. In particularly preferred embodiments, the first segment has an external diameter of less than about 7.5 millimetres. By way of example, the first segment may an external diameter of about 7.2 millimetres.

The rod of aerosol generating substrate may comprise a second segment.

Preferably, the second segment is generally cylindrical. Preferably, the first segment and second segment are both generally cylindrical, although other suitable shapes will be apparent to the skilled person and will also be described below.

The first segment and the second segment may be arranged in an end-to-end manner in a longitudinal direction to form the rod of aerosol-generating substrate. The first segment may be immediately upstream of the second segment and abut the second segment. Alternatively, the second segment may be immediately upstream of the first segment and abut the first segment.

Preferably, the first segment and the second segment may be arranged such that the first segment may comprise a hollow channel defining a longitudinal cavity with the second segment received therein. Alternatively, the second segment may comprise a hollow channel defining a longitudinal cavity with the first segment received therein. For example, the first segment may be a tubular element located around the periphery of a hollow channel. The hollow channel may be substantially cylindrical. The second segment may be substantially cylindrical and received within the hollow channel. The second segment and the first segment may be arranged coaxially. The second segment may be the same length as the first segment. The second segment may occupy substantially all of the internal volume defined by the internal walls of the tubular first segment. The second segment may be held in place within the tubular first segment by a friction fit. Alternatively, the second segment may be a tubular element located around the periphery of a hollow channel, with the first segment being substantially cylindrical and received within the hollow channel, mutatis mutandis. Preferably, the cross section of the internal walls of the tubular element and the element received therein are both circular, although other geometries will be apparent to the skilled person, the element received therein being held in place by a friction fit. In such embodiments, the first segment and second segments are preferably the same length, which is also the length of the rod of aerosolgenerating substrate.

In other embodiments, the first segment and the second segment may be arranged such that the first segment is adjacent to the second segment in a transverse direction. Preferably the rod of aerosol generating substrate is cylindrical, and the first segment and second segment are each hemicylindrical and together occupy substantially all the volume of the cylindrical rod, or all the area of any given transverse cross section. Alternatively, the first segment and second segment may have transverse cross sections such that they form a major sector and minor sector of a transverse circular cross section of the cylindrical rod. The minor sector may be shaped like a wedge, or may be a quadrant of a transverse circular cross section of the cylindrical rod. The first segment and second segment may be a major segment of a transverse circular cross section of the cylindrical rod and a minor segment of a transverse circular cross section of the cylindrical rod. In such embodiments, the first segment has a first external surface in common with a first longitudinal external surface of the rod, and the second segment has a second external surface in common with a second longitudinal external surface of the rod. In such embodiments, the first segment and second segments are preferably the same length, which is also the length of the rod of aerosol-generating substrate.

The second segment has a length of less than 20 millimetres. More preferably, the first segment has a length of less than 18 millimetres. More preferably, the first segment has a length of less than 17 millimetres. More preferably, the first segment has a length of less than 14 millimetres. More preferably, the first segment has a length of less than 13 millimetres.

The second segment may have a length of at least 3 millimetres, or at least 6 millimetres, or at least 10 millimetres, or at least 12 millimetres.

For example, the second segment has a length of between 3 millimetres and 20 millimetres, or between 6 millimetres and 18 millimetres, or between 10 millimetres and 17 millimetres, or between 12 millimetres and 15 millimetres, or between 12 millimetres and 13 millimetres.

The “external diameter of the second segment” may be calculated as the average of a plurality of measurements of the diameter of the first segment taken at different locations along the length of the first segment.

Preferably, the second segment has an external diameter of at least about 2 millimetres. More preferably, the second segment has an external diameter of at least about 5 millimetres. More preferably, the second segment has an external diameter of at least about 6 millimetres. Even more preferably, the second segment has an external diameter of at least about 7 millimetres.

The second segment preferably has an external diameter of less than or equal to about 12 millimetres. More preferably, the second segment has an external diameter of less than or equal to about 10 millimetres. Even more preferably, the second segment has an external diameter of less than or equal to about 8 millimetres.

In some embodiments, the second segment has an external diameter from about 3 millimetres to about 12 millimetres, or from about 5 millimetres to about 12 millimetres, or from about 6 millimetres to about 10 millimetres, or from about 7 millimetres to about 8 millimetres.

In particularly preferred embodiments, the second segment has an external diameter of less than about 7.5 millimetres. By way of example, the second segment may an external diameter of about 7.2 millimetres. In some preferred embodiments, the rod of aerosol-generating substrate has a length of less than 20 millimetres. More preferably, the rod of aerosol-generating substrate has a length of less than 18 millimetres. More preferably, the rod of aerosol-generating substrate has a length of less than 15 millimetres. More preferably, the rod of aerosol-generating substrate has a length of less than 13 millimetres.

Preferably, the rod of aerosol-generating substrate has a length of at least 6 millimetres. More preferably, the rod of aerosol-generating substrate has a length of at least 10 millimetres. More preferably, the rod of aerosol-generating substrate has a length of at least 12 millimetres.

For example, the rod of aerosol-generating substrate has a length of between 6 millimetres and 20 millimetres, or between 10 millimetres and 18 millimetres, or between 12 millimetres and 17 millimetres.

The rod of aerosol-generating substrate preferably has an external diameter that is approximately equal to the external diameter of the aerosol-generating article.

The “external diameter of the rod of aerosol-generating substrate” may be calculated as the average of a plurality of measurements of the diameter of the rod of aerosol-generating substrate taken at different locations along the length of the rod of aerosol-generating substrate.

Preferably, the rod of aerosol-generating substrate has an external diameter of at least about 5 millimetres. More preferably, the rod of aerosol-generating substrate has an external diameter of at least about 6 millimetres. Even more preferably, the rod of aerosol-generating substrate has an external diameter of at least about 7 millimetres.

The rod of aerosol-generating substrate preferably has an external diameter of less than or equal to about 12 millimetres. More preferably, the rod of aerosol-generating substrate has an external diameter of less than or equal to about 10 millimetres. Even more preferably, the rod of aerosol-generating substrate has an external diameter of less than or equal to about 8 millimetres.

In some embodiments, the rod of aerosol-generating substrate has an external diameter from about 5 millimetres to about 12 millimetres, preferably from about 6 millimetres to about 12 millimetres, more preferably from about 7 millimetres to about 12 millimetres. In other embodiments, the rod of aerosol-generating substrate has an external diameter from about 5 millimetres to about 12 millimetres, preferably from about 6 millimetres to about 10 millimetres, more preferably from about 7 millimetres to about 10 millimetres. In further embodiments, the rod of aerosol-generating substrate has an external diameter from about 5 millimetres to about 8 millimetres, preferably from about 6 millimetres to about 8 millimetres, more preferably from about 7 millimetres to about 8 millimetres. In particularly preferred embodiments, the rod of aerosol-generating substrate has an external diameter of less than about 7.5 millimetres. By way of example, the rod of aerosolgenerating substrate may an external diameter of about 7.2 millimetres.

The rod of aerosol-generating substrate may be used in a wide variety of different aerosol-generating articles according to the invention. As defined below, the present invention provides an aerosol-generating article comprising a rod of aerosol-generating substrate, as described above.

Aerosol-generating articles of aerosol-generating systems according to the present invention may comprise a downstream section provided downstream of the rod of aerosolgenerating substrate. The downstream section is preferably located immediately downstream of the rod of aerosol-generating substrate. The downstream section of the aerosol-generating article preferably extends between the rod of aerosol-generating substrate and the downstream end of the aerosol-generating article. The downstream section may comprise one or more elements.

A length of the downstream section is preferably between 20 millimetres and 70 millimetres, or between 25 millimetres and 60 millimetres, or between 30 millimetres and 50 millimetres.

The downstream section may comprise one or more hollow tubular elements provided downstream of the rod of aerosol-generating substrate. The one or more hollow tubular elements may advantageously provide an aerosol-cooling element for the aerosol-generating article, and optionally, a support element for the aerosol-generating article.

A first hollow tubular element or aerosol-cooling element may be provided immediately downstream of the rod of aerosol generating substrate. Optionally, a second hollow tubular element or support element may be provided immediately downstream of the first hollow tubular element.

In some embodiments, the aerosol-generating article of the aerosol-generating systems according to the present invention comprises a ventilation zone at a location along the downstream section. In more detail, in those embodiments wherein the downstream section comprises a hollow tubular element, the ventilation zone is preferably provided at a location along the hollow tubular element.

The ventilation zone typically comprises a plurality of perforations through the peripheral wall of the hollow tubular element.

Preferably, the downstream section further comprises at least one downstream filter segment. The downstream filter segment is preferably located downstream of a hollow tubular element. The downstream filter segment preferably extends to a downstream end of the downstream section. The downstream filter segment is preferably located at the downstream end of the aerosol-generating article. The downstream filter segment is preferably a solid plug, and preferably formed of a fibrous filtration material. Particularly preferably, the downstream filter segment comprises a cellulose acetate filter segment formed of cellulose acetate tow. Preferably, the downstream filter segment is circumscribed by a plug wrap and connected to one or more of the adjacent upstream components of the aerosol-generating article by means of a tipping paper. Preferably, the downstream filter segment preferably has an external diameter that is approximately equal to the external diameter of the aerosol-generating article.

An aerosol-generating article according to the present disclosure preferably further comprises an upstream section provided upstream of the rod of aerosol-generating substrate. The upstream section is preferably located immediately upstream of the rod of aerosolgenerating substrate. The upstream section preferably extends between the upstream end of the aerosol-generating article and the rod of aerosol-generating substrate.

The upstream section preferably comprises at least one upstream element. The upstream element may be located upstream of the rod of aerosol-generating substrate.

The upstream element may advantageously prevent direct contact with the solid aerosol-generating substrate.

The upstream element may comprise a plug of porous material. For example, the upstream element may comprise a cellulose acetate plug. The upstream element may be formed of a hollow tubular segment defining a longitudinal cavity providing an unrestricted flow channel. The upstream element may have a length of between 1 millimetre and 10 millimetres, such as between 3 millimetres and 6 millimetres.

The aerosol-generating article preferably has an overall length of from 40 millimetres to 80 millimetres, or from 40 millimetres to about 70 millimetres, or from 40 millimetres to about 60 millimetres, or from 45 millimetres to about 80 millimetres, or from about 45 millimetres to about 70 millimetres, or from 45 millimetres to 60 millimetres, or from 50 millimetres to 80 millimetres, or from 50 millimetres to about 70 millimetres or from about 50 millimetres to about 60 millimetres. In an exemplary embodiment, an overall length of the aerosol-generating article is about 45 millimetres.

The aerosol-generating article preferably has an external diameter of from about 5 millimetres to about 12 millimetres, or from about 6 millimetres to about 12 millimetres, or from about 7 millimetres to about 12 millimetres, or from about 5 millimetres to about 10 millimetres, or from about 6 millimetres to about 10 millimetres, or from about 7 millimetres to about 10 millimetres, or from about 5 millimetres to about 8 millimetres, or from about 6 millimetres to about 8 millimetres, or from about 7 millimetres to about 8 millimetres. In other embodiments, the aerosol-generating article has an external diameter of less than 7 millimetres.

In particularly preferred embodiments, the aerosol-generating article further comprises a paper wrapper circumscribing the rod of aerosol-generating substrate and at least a portion of the hollow tubular element. Preferably one or more other components of the aerosolgenerating article are individually circumscribed by their own wrapper. Preferably the first segment is circumscribed by a plug wrap, and the second segment, if it is present, is circumscribed by a plug wrap.

In a preferred embodiment, the paper wrapper may have a grammage of 39 gsm. In a preferred embodiment, the paper wrapper may have a thickness of 45 micrometres.

As mentioned above, aerosol-generating systems according to the invention comprise an aerosol-generating article as described above and an aerosol-generating device configured to heat the aerosol-generating substrate of the aerosol-generating article, the aerosolgenerating device comprising and a heating chamber for receiving the aerosol-generating article. The heating chamber is configured to heat the first segment of the aerosol-generating article to a maximum temperature of 210 degrees Celsius.

The heating chamber may extend between an upstream end and a mouth, or downstream end. The upstream end of the heating chamber may be a closed end and the mouth, or downstream, end of the heating chamber may be an open end. An aerosolgenerating article may be inserted into the heating chamber via the open end of the heating chamber. The heating chamber may be cylindrical in shape so as to conform to the same shape of an aerosol-generating article.

The expression “received within” may refer to the fact that a component or element is fully or partially received within another component or element. For example, the expression “aerosol-generating article is received within the heating chamber” refers to the aerosolgenerating article being fully or partially received within the heating chamber of the aerosolgenerating article. When the aerosol-generating article is received within the heating chamber, the aerosol-generating article may abut the upstream end of the heating chamber. When the aerosol-generating article is received within the heating chamber, the aerosol-generating article may be in substantial proximity to the upstream end of the heating chamber. The upstream end of the heating chamber may be defined by an end-wall.

The length of the heating chamber may be the same as or greater than the length of the aerosol-generating substrate section. The length of the heating chamber may be the same as or greater than the combined length of the upstream section or element and rod of aerosolgenerating substrate section. Preferably, the length of the heating chamber is such that at least 75 percent of the length of the aerosol-generating substrate section is inserted or received within the heating chamber, when the aerosol-generating article is received with the aerosol-generating device. This maximises the length of the aerosol-generating substrate section along which the aerosol-generating substrate can be heated during use, thereby optimising the generation of aerosol from the aerosol-generating substrate and reducing nontobacco botanical and tobacco waste. The length of the heating chamber may be between 15 millimetres and 80 millimetres. Preferably, the length of the heating chamber is between 20 millimetres and 70 millimetres. More preferably, the length of the heating chamber is between 25 millimetres and 60 millimetres. More preferably, the length of the device is between 25 millimetres and 50 millimetres.

The length of the heating chamber may be between 25 millimetres and 29 millimetres. Preferably, the length of the heating chamber is between 25 millimetres and 29 millimetres. More preferably, the length of the heating chamber is between 26 millimetres and 29 millimetres. Even more preferably, the length of the heating chamber is 27 millimetres or 28 millimetres.

A diameter of the heating chamber may be between 4 millimetres and 10 millimetres. A diameter of the heating chamber may be between 5 millimetres and 9 millimetres. A diameter of the heating chamber may be between 6 millimetres and 8 millimetres. A diameter of the heating chamber may be between 6 millimetres and 7 millimetres.

A diameter of the heating chamber may be substantially the same as or greater than a diameter of the aerosol-generating article. A diameter of the heating chamber may be the same as a diameter of the aerosol-generating article in order to establish a tight fit with the aerosol-generating article.

The heating chamber may define a heating zone. The heating chamber may be sized to receive at least a portion of the first segment within the heating zone.

The heating chamber of the aerosol-generating device may comprise at least one heater. The at least one heater may be one or more of a resistive heater or an inductive heater. The at least one heater may be a first heater configured to heat the first segment of the aerosol-generating article to a maximum temperature of 210 degrees Celsius.

In embodiments in which a resistive heater is present, the aerosol-generating device may comprise a power supply configured to supply energy to the heater element, and a controller configured to control the supply of power to the heater assembly such that the heater element is heated with reference to a respective target temperature.

In embodiments in which a resistive heater is present, the resistive heater may be an internal resistive heater or an external resistive heater.

An internal resistive heater is configured to be used with an embodiment of the aerosolgenerating article in which the aerosol-generating substrate is located at a distal end of the rod. In use, the article is inserted into the heating chamber of the aerosol-generating device and a heater element, preferably in the form of a blade, is configured to penetrate the aerosolgenerating substrate and to heat the aerosol-generating substrate internally.

The heater element may comprise or be formed from any material with suitable electrical and mechanical properties. Suitable materials include but are not limited to: semiconductors such as doped ceramics, electrically “conductive” ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys and composite materials made of a ceramic material and a metallic material. Such composite materials may comprise doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum and metals from the platinum group. Examples of suitable metal alloys include stainless steel, constantan, nickel-, cobalt-, chromium-, aluminium- titanium- zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese- and iron-containing alloys, and super-alloys based on nickel, iron, cobalt, stainless steel, Timetai®, iron-aluminium based alloys and iron-manganese-aluminium based alloys. Timetai® is a registered trade mark of Titanium Metals Corporation. The heater elements may be coated with one or more electrical insulators. Preferred materials for the heater elements may be 304, 316, 304L, 316L, 18SR stainless steel, and graphite.

An internal resistive heater, as described above, has the advantage of direct contact between the substrate and the heater. However, the complexity and cost of the aerosolgenerating device can be reduced, and the robustness improved, if an external resistive heater is used. Preferably, in embodiments in which a resistive heater is present, an external resistive heater is used.

An external resistive heater may comprise a flexible heater assembly. The heater assembly may comprise at least one layer of flexible support material. The heater element may comprise at least one heater track deposited on to the at least one layer of flexible support material. The at least one heater track may form the heater element. The flexible support material may comprise or consist of polyimide.

In embodiments in which an inductive heater is present, the aerosol-generating device may comprise an induction element disposed around, or adjacent to, the heating zone in the heating chamber, a power supply, and a controller connected to the induction element and configured to provide an alternating electric current to the induction element to generate an alternating magnetic field within the heating zone. The alternating magnetic field causes the formation of eddy currents induced in a susceptor to heat the susceptor. As the susceptor is located in thermal contact with the aerosol-generating substrate, the aerosol-generating substrate is heated by the susceptor. As used herein, the term “susceptor” refers to a material that can convert electromagnetic energy into heat.

The induction element may be one or more inductor coils. When a single coil is present, the controller may control parameters to determine whether the single coil produces one or more alternating magnetic fields. Alternatively, the induction element may comprise at least a first coil and a second coil. The first coil may be actuatable to provide a first alternating magnetic field and a second coil may be actuatable to provide a second alternating magnetic field. The controller may control whether the first coil or the second coil is actuated to produce either the first alternating magnetic field or the second alternating magnetic field. In this manner, a first alternating magnetic field may, for example, cause preferential heating of a first segment comprising a first susceptor within the heating zone during a first period of time, and a second alternating magnetic field may cause preferential heating of a second segment comprising a second susceptor within the heating zone during a second period of time. Thus, while both first and second susceptor may be heated simultaneously, during the first period of time the first alternating current may couple with the first susceptor more efficiently than to the second susceptor, with the result that the temperature of the first susceptor is greater than that of the second susceptor for the first period of time, and during the second period of time the second alternating current may couple with the second susceptor more efficiently than to the first susceptor for the second period of time, with the result that the temperature of the second susceptor is greater than that of the first susceptor for the second period of time.

An alternating magnetic field having any specific frequency will produce a different inductive behaviour in different types of susceptor. For example, if the first and the second susceptor have different physical dimensions then their behaviour may differ when located within an alternating magnetic field, and one or other of the susceptors may heat to a higher temperature than the other of the susceptors. Likewise, inductive behaviour may differ if the shape of the first and second susceptor is different. Likewise, inductive behaviour may differ if the material of the first and second susceptor is different, for example if the resistivity or magnetic permeability of the first and second susceptor differs.

The first segment of the aerosol generating article according to the invention may comprise a first heating element. The first heating element may be a first susceptor.

The first susceptor may have any suitable shape. The first susceptor may circumscribe the first segment. The first susceptor may be in the form of a metallic wrapper or metallic mesh surrounding the first segment. Alternatively, the first susceptor may be circumscribed by the first segment. The first susceptor may be arranged substantially longitudinally within the first segment. The first susceptor may be in the form of a pin, rod, strip or blade. The first susceptor may be in the form of a solid wire or a hollow wire, or may comprise a plurality of solid wires or hollow wires. The plurality of solid wires or hollow wires may be provided in the form of a mesh or web. The first susceptor may be a corrugated strip or sheet, the corrugated strip or sheet in transverse cross-section forming a shape such as the letter “U”, the letter “V”, the letter “Z”, the letter “S”, the letter “C”, a sinusoidal wave, a triangular wave, a sawtooth wave or a square wave. The first susceptor may be a strip that is folded on itself, the fold intersecting a longitudinal axis at a single point, such that the strip is doubled in transverse cross-section. In preferred embodiments, the first susceptor is an elongate susceptor positioned in a radially central position within the segment, and extends along the longitudinal axis of the segment. Preferably, the first susceptor may have substantially the same length as the first segment comprising the first substrate, and may extend from the upstream end to the downstream end of the first segment.

When used for describing a susceptor, the term “elongate” means that the susceptor has a length dimension that is greater than its width dimension or its thickness dimension, for example greater than twice its width dimension or its thickness dimension. The first susceptor may be an elongate susceptor arranged substantially longitudinally within the first segment. This means that the length dimension of the elongate susceptor is arranged to be approximately parallel to the longitudinal direction of the segment, for example within plus or minus 10 degrees of parallel to the longitudinal direction of the segment.

If the susceptor has a constant cross-section, for example a circular cross-section, it has a preferable width or diameter from about 1 millimetre to about 5 millimetres.

If the susceptor has the form of a strip or blade, the strip or blade preferably has a rectangular shape having a width of preferably from about 2 millimetres to about 8 millimetres, more preferably from about 3 millimetres to about 6 millimetres. By way of example, a susceptor in the form of a strip of blade may have a width of about 4 millimetres.

The susceptor is preferably in the form of a strip or blade, has a substantially rectangular shape, and a thickness from about 55 micrometres to about 65 micrometres. More preferably, the susceptor has a thickness from about 57 micrometres to about 63 micrometres. Even more preferably, the susceptor has a thickness from about 58 micrometres to about 62 micrometres. In a particularly preferred embodiment, the susceptor has a thickness of about 60 micrometres.

The susceptor has a length of less than 20 millimetres. More preferably, the first segment has a length of less than 18 millimetres. More preferably, the susceptor has a length of less than 17 millimetres. More preferably, the first segment has a length of less than 15 millimetres. More preferably, the susceptor has a length of less than 13 millimetres.

The susceptor may have a length of at least 3 millimetres, or at least 6 millimetres, or at least 10 millimetres, or at least 12 millimetres.

For example, the susceptor has a length of between 3 millimetres and 20 millimetres, or between 6 millimetres and 18 millimetres, or between 10 millimetres and 17 millimetres, or between 12 millimetres and 15 millimetres, or between 12 millimetres and 13 millimetres.

The first segment comprises a first substrate comprising non-tobacco botanical material that is sensitive to overheating, in that heating the non-tobacco material to excessive temperatures may result in loss of its pleasing flavour, undesirable flavour characteristics and the formation of HPHCs. Therefore, the first susceptor preferably has a maximum operating temperature of 210 degrees Celsius. The first susceptor preferably has a maximum operating temperature of between 60 degrees Celsius and 210 degrees Celsius, such as between 80 degrees Celsius and 210 degrees Celsius.

The first susceptor may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the first segment comprising the first substrate comprising the first botanical material, while avoiding temperatures in excess of 210 degrees Celsius. A preferred susceptor may comprise or consist of a ferromagnetic material, for example a ferromagnetic alloy. Different materials will dissipate different amounts of energy when positioned within electromagnetic fields having similar values of frequency and field strength.

Thus, parameters of the susceptor such as material type, length, width, and thickness may all be altered to provide a desired power dissipation within a known electromagnetic field. Preferred susceptors may be heated to a temperature of less than or equal to 210 degrees Celsius.

Suitable susceptors may comprise a non-metallic core with a metal layer disposed on the non-metallic core, for example metallic tracks formed on a surface of a ceramic core. A susceptor may have a protective external layer, for example a protective ceramic layer or protective glass layer encapsulating the susceptor. The susceptor may comprise a protective coating formed by a glass, a ceramic, or an inert metal, formed over a core of susceptor material.

The susceptor is arranged in thermal contact with the aerosol-generating substrate. Thus, when the susceptor heats up the aerosol-generating substrate is heated up and an aerosol is formed. Preferably the susceptor is arranged in direct physical contact with the aerosol-generating substrate, for example within the aerosol-generating substrate.

In embodiments in which a second segment is present, the heating chamber is configured to heat the second segment of the aerosol-generating article to a maximum temperature of 350 degrees Celsius. The heating of the second segment to 350 degrees Celsius may occur simultaneously to the heating of the first segment to 210 degrees Celsius, or may occur sequentially with the heating of the first segment to 210 degrees Celsius.

The heating chamber may be sized to receive at least a portion of the second segment within the heating zone. The heating zone may comprise a first region to receive at least a portion of the first segment, and a second region to receive at least a portion of the second segment. Alternatively, the heating zone may receive both at least a portion of the first segment and at least a portion of the second segment within a first region. The at least one heater may be a first heater may be configured to heat both the first segment of the aerosolgenerating article to a maximum temperature of 210 degrees Celsius and the second segment of the aerosol-generating article to a maximum temperature of 350 degrees Celsius. The at least one heater may be a first heater configured to heat the first segment of the aerosol- generating article to a maximum temperature of 210 degrees, and a second heater configured to heat the second segment of the aerosol-generating article to a maximum temperature of 350 degrees Celsius.

In embodiments in which a second segment is present, the second segment may comprise a second heating element. The second heating element may be a second susceptor. The second susceptor may have any suitable shape. The second susceptor may circumscribe the second segment. The second susceptor may be in the form of a metallic wrapper or metallic mesh surrounding the second segment. Alternatively, the second susceptor may be circumscribed by the second segment. The second susceptor may be arranged substantially longitudinally within the second segment. The second susceptor may be in the form of a pin, rod, strip or blade. The second susceptor may be in the form of a solid wire or a hollow wire, or may comprise a plurality of solid wires or hollow wires. The plurality of solid wires or hollow wires may be provided in the form of a mesh or web. The second susceptor may be a corrugated strip or sheet, the corrugated strip or sheet in transverse cross-section forming a shape such as the letter “II”, the letter “V”, the letter “Z”, the letter “S”, the letter “C”, a sinusoidal wave, a triangular wave, a sawtooth wave or a square wave. The second susceptor may be a strip that is folded on itself, the fold intersecting a longitudinal axis at a single point, such that the strip is doubled in transverse cross-section. The second susceptor may be an elongate susceptor positioned in a radially central position within the segment, and extend along the longitudinal axis of the segment. The second susceptor may have substantially the same length as the second segment comprising the second substrate, and may extend from the upstream end to the downstream end of the second segment.

The second susceptor may be an elongate susceptor arranged substantially longitudinally within the second segment.

The second susceptor may have a cross section, width, thickness and length as described above with respect to the first susceptor.

The second susceptor may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the second segment comprising the second substrate comprising the second botanical material. Preferred susceptors comprise a metal or carbon.

A preferred susceptor may comprise or consist of a ferromagnetic material, for example a ferromagnetic alloy, ferritic iron, or a ferromagnetic steel or stainless steel. A suitable susceptor may be, or comprise, aluminium. Preferred susceptors may be formed from 400 series stainless steels, for example grade 410, or grade 420, or grade 430 stainless steel. Different materials will dissipate different amounts of energy when positioned within electromagnetic fields having similar values of frequency and field strength. Thus, parameters of the susceptor such as material type, length, width, and thickness may all be altered to provide a desired power dissipation within a known electromagnetic field. Preferred susceptors may be heated to a temperature in excess of 250 degrees Celsius.

The first segment and the second segment may be arranged in an end-to-end manner in a longitudinal direction. The first segment may comprise a first heating element. The second segment may comprise a second heating element. The first and second heating elements may be heated by one or more inductive heaters. The first heating element may be configured to heat the first segment to a maximum temperature of 210 degrees Celsius, while the second heating element may be configured to heat the second segment to a maximum temperature of 350 degrees Celsius. The first heating element may be a first susceptor arranged substantially longitudinally within the first segment. The first susceptor may be an elongate susceptor. The first susceptor may be an elongate susceptor positioned in a radially central position within the first segment, and extend along the longitudinal axis of the first segment. Alternatively, the first susceptor may be in the form of a metallic wrapper or metallic mesh surrounding the first segment. The second segment may comprise a second heating element. The second heating element may be a second susceptor, optionally an elongate susceptor arranged substantially longitudinally within the second segment. The second susceptor may be an elongate susceptor positioned in a radially central position within the second segment, and extend along the longitudinal axis of the second segment. Alternatively, the second susceptor may be in the form of a metallic wrapper or metallic mesh surrounding the second segment.

In another embodiment, the first segment may be heated by an inductive heater, as discussed above, while the second segment may be heated by a second heater in the form of an external resistive heater. In another embodiment still, the first segment may be heated by a first heater in the form of an external resistive heater, while the second segment comprises a heating element in the form of a susceptor heated by a second heater in the form of an inductive heater. Optionally an elongate susceptor may be arranged substantially longitudinally within the second segment, or the susceptor may be a metallic wrapper or metallic mesh surrounding the second segment. In yet another embodiment, both the first segment and the second segment are heated by a first external resistive heater and a second external resistive heater, respectively. The first external resistive heater may be configured to heat the first segment to a maximum temperature of 210 degrees Celsius, while the second external resistive heater may be configured to heat the second segment to a maximum temperature of 350 degrees Celsius.

The first segment and the second segment may be arranged such that the first segment may comprise a hollow channel defining a longitudinal cavity configured to receive the second segment therein. In a preferred embodiment, the second segment comprises a heating element. The heating element may be a susceptor arranged substantially longitudinally within the second segment. The susceptor may be an elongate susceptor. The susceptor may be an elongate susceptor positioned in a radially central position within the first segment, and extend along the longitudinal axis of the second segment. The susceptor may be configured to heat the second segment to a maximum temperature of 350 degrees Celsius. Alternatively, the second segment may be heated by an internal heating element in the form of a blade that penetrates the second segment and heats the second substrate to a maximum temperature of 350 degrees Celsius. There may be a heating gradient between the first and second segments, such that heat is dissipated as it moves through the second segment, and the first segment is thereby heated to a lower temperature than the second segment. In such arrangements, a heating element surrounding the first segment or an external heater surrounding the first segment may therefore both be absent. The susceptor or internal heating element within the second segment may be configured to heat both the second segment to a maximum temperature of 350 degrees Celsius and the first segment to a maximum temperature of 210 degrees Celsius. In alternative arrangements, the first segment may be heated by an external resistive heater configured to heat the first segment to a maximum temperature of 210 degrees Celsius. In yet another embodiment, the first segment may comprise a first heating element in the form of a first susceptor. The first susceptor may be in the form of a metallic wrapper or metallic mesh surrounding the first segment. The first heating element may be configured to heat the first segment to a maximum temperature of 210 degrees Celsius.

The first segment and the second segment may be arranged such that the second segment may comprise a hollow channel defining a longitudinal cavity configured to receive the first segment therein. In a preferred embodiment, the second segment comprises a heating element. The heating element may be a susceptor in the form of a metallic wrapper or metallic mesh. The susceptor may be configured to heat the second segment to a maximum temperature of 350 degrees Celsius. Alternatively, the second segment may be heated by an external heater surrounding the second segment that heats the second substrate to a maximum temperature of 350 degrees Celsius. There may be a heating gradient between the first and second segments, such that heat is dissipated as it moves through the second segment, and the first segment is thereby heated to a lower temperature than the second segment. In such arrangements, a heating element in the form of a susceptor arranged substantially longitudinally within the first segment or an internal heating element in the form of a blade that penetrates the first segment may therefore both be absent. The susceptor or external heating element surrounding the second segment may be configured to heat both the second segment to a maximum temperature of 350 degrees Celsius and the first segment to a maximum temperature of 210 degrees Celsius. In alternative arrangements, the first segment may comprise a first heating element, such as a susceptor arranged substantially longitudinally within the first segment. The susceptor may be an elongate susceptor. The susceptor may be an elongate susceptor positioned in a radially central position within the first segment, and extend along the longitudinal axis of the first segment. The susceptor may be configured to heat the first segment to a maximum temperature of 210 degrees Celsius. In yet another embodiment, the first segment may be heated by an internal heating element in the form of a blade that penetrates the first segment and heats the first substrate to a maximum temperature of 210 degrees Celsius.

The first segment and the second segment may be arranged such that the first segment is adjacent to the second segment in a transverse direction. In such arrangements, an elongate susceptor may be positioned in a radially central position between the first and second segments, extending along the longitudinal axis of the first and second segments. The elongate susceptor may have two opposing faces, a first face contacting the first substrate of the first segment, and a second face contacting the second substrate of the second segment. The first face may comprise a first face susceptor material and be configured to heat the first segment to a maximum temperature of 210 degrees Celsius. The second face may comprise a second face susceptor material and be configured to heat the second segment to a maximum temperature of 350 degrees Celsius.

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.

EX 1 . An aerosol-generating article comprising a rod of aerosol-generating substrate, the rod comprising a first segment and a second segment, the first segment comprising a first substrate and the second segment comprising a second substrate, wherein the first substrate comprises: a first botanical material, wherein the first botanical material comprises at least 40% by weight of a first non-tobacco botanical material, based on the total weight of the first botanical material; and at most 4% by weight of aerosol former, based on the total weight of the first substrate, wherein the non-tobacco botanical material is a particulate or shredded non-tobacco botanical material; and wherein the second substrate comprises: a second botanical material; and at least 10% by weight of aerosol former, based on the total weight of the second substrate, wherein the second substrate is different to the first substrate.

EX 2. An aerosol generating article according to EX 1 , wherein the aerosol former is one or more of polyhydric alcohols, such as 1 ,3-butanediol, glycerine, 1 ,3-propanediol, propylene glycol, and triethylene glycol; 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.

EX 3. An aerosol-generating article according to EX 1 or EX 2, wherein the first non- tobacco botanical material is selected from clove, star anise, eucalyptus, lavender, rosemary, chamomile, common sage, peppermint, verbena, lime, juniper, lemon myrtle, kaffir lime, geranium rosat, passion berry, tolu balsam, timur berry, coriander and tea.

EX 4. An aerosol-generating article according to EX 3, wherein the non-tobacco botanical material is selected from clove, star anise, eucalyptus, lavender, rosemary, common sage and peppermint.

EX 5. An aerosol-generating article according to any one of EX 1 to EX 4, wherein the first substrate comprises at least 45% by weight of the first botanical material, based on the dry weight of the first substrate.

EX 6. An aerosol-generating article according to any one of EX 1 to EX 5, wherein the first botanical material comprises a particulate plant material, a shredded plant material or a homogenised plant material.

EX 7. An aerosol-generating article according to EX 6, wherein the first botanical material comprises particles having a D90 value of at least 100 microns.

EX 8. An aerosol-generating article according to any one of EX 1 to EX 7, wherein the first substrate further comprises nicotine.

EX 9. An aerosol-generating article according to any one of EX 1 to EX 8, wherein the first botanical material further comprises less than 25% of tobacco material, based on the total weight of the first botanical material. EX 10. An aerosol-generating article according to EX 9, wherein the tobacco material is particulate tobacco material, ground tobacco material, shredded tobacco material, cut filler, homogenised tobacco material or cast leaf.

EX 11 . An aerosol-generating article according to EX 10, wherein the tobacco material comprises particles having a D90 value of at least 100 microns.

EX 12. An aerosol-generating article according to any one of EX 1 to EX 11 , wherein the first segment comprises a first heating element, and the first heating element is a first susceptor.

EX 13. An aerosol-generating article according to any one of EX 1 to EX 12, wherein the second botanical material comprises at least 45% by weight of tobacco material, based on the dry weight of the second substrate.

EX 14. An aerosol-generating article according to EX 13, wherein the tobacco material is particulate tobacco material, ground tobacco material, shredded tobacco material, cut filler, homogenised tobacco material or cast leaf.

EX 15. An aerosol-generating article according to EX 14, wherein the tobacco material comprises particles having a D90 value of at least 100 microns.

EX 16. An aerosol-generating article according to any preceding EX, wherein the second botanical material comprises between about 3 percent by weight and about 20 percent by weight of a second non-tobacco botanical material, based on the dry weight of the second substrate.

EX 17. An aerosol-generating article according to any of EX 1 to EX 12, wherein the second substrate comprises an aerosol generating film comprising: one or more cellulose based film-forming agents and one or more aerosol formers.

EX 18. An aerosol-generating article according to EX 17, wherein the aerosolgenerating film has a total aerosol former content of greater than or equal to 40 percent by weight.

EX 19. An aerosol generating article according to any preceding EX, wherein the first segment and a second segment are generally cylindrical.

EX 20. An aerosol generating article according to any preceding EX, wherein the first segment comprises a hollow channel defining a longitudinal cavity with the second segment received therein, or wherein the second segment comprises a hollow channel defining a longitudinal cavity with the first segment received therein.

EX 21. An aerosol generating article according to any one of EX 1 to EX 19, wherein the first segment and the second segment are arranged in an end-to-end manner in a longitudinal direction.

EX 22. An aerosol generating article according to any one of EX 1 to EX 19, wherein the first segment is adjacent to the second segment in a transverse direction. EX 23. An aerosol generating article according to any preceding EX, wherein the second segment comprises a second heating element, and the second heating element is a second susceptor.

EX 24. An aerosol-generating system comprising: an aerosol-generating article according to any one of EX 1 to EX 23; and an aerosol generating device comprising: a heating chamber for receiving the aerosol-generating article, the heating chamber configured to heat the first segment to a maximum temperature of 210 degrees Celsius.

EX 25. An aerosol-generating system according to EX 24, wherein the heating chamber is configured to heat the second segment to a maximum temperature of 350 degrees Celsius.

Examples will now be further described with reference to the drawings of the accompanying Figures in which:

Figure 1 is a schematic cross-sectional view of an aerosol-generating article;

Figure 2 is a schematic cross-sectional view of an aerosol-generating article;

Figure 3 is a schematic oblique view of a rod of aerosol-generating substrate including a first segment comprising a first substrate and a second segment comprising a second substrate arranged in an end-to-end manner in a longitudinal direction;

Figure 4 is a schematic oblique view of a rod of aerosol-generating substrate wherein the first segment comprises a hollow channel defining a longitudinal cavity configured to receive the second segment;

Figure 5 is a schematic oblique view of a rod of aerosol-generating substrate wherein the first segment is adjacent to the second segment in a transverse direction;

Figure 6 is a schematic cross-sectional view of an embodiment of an aerosol-generating system according to the second aspect of the invention; and

Figure 7 is a schematic cross-sectional view of another embodiment of an aerosolgenerating system according to the second aspect of the invention.

The aerosol-generating article 1 shown in Figure 1 comprises a rod of aerosolgenerating substrate 12. The rod comprises a first segment 32 comprising a first substrate 52. The first substrate 52 comprises non-tobacco botanical material, in this case a crimped and gathered sheet of homogenised peppermint plant material, in which aerosol former is substantially absent.

A first heating element 54 in the form of a first susceptor element 44 is located within the first segment 32. In more detail, the susceptor element 44 is arranged substantially longitudinally within the first segment 32, such as to be approximately parallel to the longitudinal direction of both the first segment 32 and the rod 12. As shown in the drawing of Figure 1 , the susceptor element 44 is positioned in a radially central position within the first segment 32 and extends effectively along the longitudinal axis of both the first segment 32 and the rod 12.

The susceptor element 44 extends all the way from an upstream end to a downstream end of both the first segment 32 and the rod 12. In effect, the susceptor element 44 has substantially the same length as both the first segment 32 and the rod 12 of aerosol-generating substrate.

There is a downstream section 14 located downstream of the rod of aerosol-generating substrate 12 and an upstream section 16 located upstream of the rod of aerosol-generating substrate 12. As shown in Figure 1 , the aerosol-generating article 1 has an upstream end 48 and a downstream end 20.

The downstream section 14 of the aerosol-generating article 1 comprises a support element 22 located immediately downstream of the rod of aerosol-generating substrate 12, an aerosol-cooling element 24 located immediately downstream of the support element 22, and a mouthpiece element 42 located immediately downstream of the aerosol-cooling element 24. The support element 22 and the aerosol-cooling element 24 together define an intermediate hollow section 50 of the aerosol-generating article 1.

The support element 22 comprises a first hollow tubular element 26. The first hollow tubular element 26 is in the form of a hollow cylindrical tube made of cellulose acetate. The first hollow tubular element 26 defines an internal cavity 28 that extends from an upstream end 30 of the first hollow tubular element to a downstream end 32 of the first hollow tubular element 20.

The aerosol-cooling element 24 comprises a second hollow tubular element 34. The second hollow tubular element 34 is in the form of a hollow cylindrical tube made of cellulose acetate. The second hollow tubular element 34 defines an internal cavity 36 that extends from an upstream end 38 of the second hollow tubular element to a downstream end 40 of the second hollow tubular element 34.

As shown by the dashed vertical line in Figure 1 , the aerosol-generating article 1 comprises a ventilation zone 60 provided at a location along the second hollow tubular element 34.

The mouthpiece element 42 is in the form of a cylindrical plug of low-density cellulose acetate.

The upstream section 16 of the aerosol-generating article 1 comprises an upstream element 46 located immediately upstream of the rod of aerosol-generating substrate 12.

The upstream element 46 is in the form of a cylindrical plug of cellulose acetate circumscribed by a stiff wrapper.

In use, a user draws on the mouthpiece element 42 of the aerosol-generating article 1 . When a user draws on the mouthpiece 42, air is drawn into the aerosol-generating article 1 through the upstream end 48. The drawn air passes through the upstream element 46 to the rod of aerosol-generating substrate 12. Heating of the rod of aerosol-generating substrate releases volatile and semi-volatile compounds, which form an aerosol that is entrained in the drawn air as it flows through the rod of aerosol-generating substrate 12. The drawn air and entrained aerosol pass through the intermediate hollow section 50 of the aerosol-generating article 1 , where they cool and condense. The cooled aerosol then passes through the mouthpiece element 42 of the aerosol-generating article 1 and into the mouth of the user.

The aerosol-generating article 1 shown in Figure 1 may be used with the aerosolgenerating system 7 shown in Figure 7.

The aerosol-generating article 2 shown in Figure 2 comprises a rod of aerosolgenerating substrate 212, comprising a first segment 232 comprising a first substrate 252. The first substrate 252 comprises non-tobacco botanical material, in this case a crimped and gathered sheet of homogenised peppermint plant material, in which aerosol former is substantially absent.

A downstream section 214 is located downstream of the rod of aerosol-generating substrate 212. As shown in Figure 2, the aerosol-generating article 2 has an upstream end 248 and a downstream end 220.

The downstream section 214 of the aerosol-generating article 2 comprises an aerosolcooling element 224 located immediately downstream of the rod of aerosol-generating substrate 212, and a mouthpiece element 242 located immediately downstream of the aerosolcooling element 224. The aerosol-cooling element 224 defines an intermediate hollow section 250 of the aerosol-generating article 2.

The aerosol-cooling element 224 comprises a hollow tubular element 234. The hollow tubular element 234 is in the form of a hollow cylindrical tube made of cellulose acetate. The hollow tubular element 234 defines an internal cavity 236 that extends from an upstream end 238 of the hollow tubular element to a downstream end 240 of the hollow tubular element 234.

The mouthpiece element 242 is in the form of a cylindrical plug of low-density cellulose acetate.

In use, a user draws on the mouthpiece element 242 of the aerosol-generating article 2. When a user draws on the mouthpiece 242, air is drawn into the aerosol-generating article 2 through the upstream end 218. The drawn air passes to the rod of aerosol-generating substrate 212. Heating of the rod of aerosol-generating substrate releases volatile and semivolatile compounds, which form an aerosol that is entrained in the drawn air as it flows through the rod of aerosol-generating substrate 212. The drawn air and entrained aerosol pass through the intermediate hollow section 250 of the aerosol-generating article 2, where they cool and condense. The cooled aerosol then passes through the mouthpiece element 242 of the aerosol-generating article 2 and into the mouth of the user. The rod of aerosol-generating substrate 3 shown in Figure 3 comprises a first segment 332 comprising a first substrate 352, and a second segment 362 comprising a second substrate 382. The first segment 332 and the second segment 362 are arranged in an end-to- end manner in a longitudinal direction. Second segment 362 is immediately downstream of first segment 332 and abuts first segment 332. The first substrate 352 comprises non-tobacco botanical material, in this case a crimped and gathered sheet of homogenised peppermint plant material, in which aerosol former is substantially absent. The second substrate 382 comprises homogenised tobacco material and glycerol as an aerosol former.

The rod of aerosol-generating substrate 4 shown in Figure 4 comprises a first segment 432 comprising a first substrate 452, and a second segment 462 comprising a second substrate 482. The first segment 432 comprises a hollow channel defining a longitudinal cavity configured to receive the second segment. The first substrate 452 comprises non-tobacco botanical material, in this case particulate clove material, in which aerosol former is substantially absent. The second substrate 482 comprises tobacco cut filler and glycerol as an aerosol former.

A second heating element 484 in the form of a susceptor element 464 is located within the second segment 462. Susceptor element 464 is arranged substantially longitudinally within the second segment 462, such as to be approximately parallel to the longitudinal direction of the second segment 462; is positioned in a radially central position within the second segment 462 and extends effectively along the longitudinal axis of the second segment 462; and extends all the way from an upstream end to a downstream end of the second segment 462. In effect, the susceptor element 464 has substantially the same length as the second segment 462.

A first heating element 454 in the form of a first susceptor element 444 may circumscribe the first segment 432. The first susceptor element 444 may be a metallic wrapper (not shown) circumscribing segment 432 over substantially all of its longitudinal surface area. Alternatively, first susceptor element 444 may be absent. In such cases, first substrate 452 is heated to a lower temperature than second substrate 482, either as a result of dissipation of heat that has moved through second substrate 482, or by an external heater (not shown).

The rod of aerosol-generating substrate 5 shown in Figure 5 comprises a first segment 532 comprising a first substrate 552, and a second segment 562 comprising a second substrate 582. The first segment 532 is adjacent to the second segment in a transverse direction. The first substrate 552 comprises non-tobacco botanical material, in this case a crimped and gathered sheet of homogenised common sage plant material, in which aerosol former is substantially absent. The second substrate 582 comprises ground tobacco material and glycerol as an aerosol former. Elongate susceptor element 544 has two opposing faces, a first face 564 contacting the first substrate 552 of the first segment 532, and a second face 584 contacting the second substrate 562 of the second segment 582. The first face 564 may comprise a first face susceptor material, with the first face susceptor material configured to inductively heat the first segment to a maximum temperature of 210 degrees Celsius when used in the system shown in Figure 7, for instance. The second face 584 may comprise a second face susceptor material, with the second face susceptor material configured to inductively heat the second segment to a maximum temperature of 350 degrees Celsius when used in the system shown in Figure 7, for instance.

Figure 6 is a schematic cross sectional view of an aerosol-generating system in accordance with the second aspect of the invention. An aerosol-generating device 6 comprises a cavity 600 for receiving an aerosol-generating article 601. The cavity 600 is formed by a stainless steel tube 612 and has at an upstream end a base 614.

An aerosol-generating article 601 is received in the cavity 600. The aerosol-generating article 600 contains aerosol-generating substrate 3, which is the same rod of aerosolgenerating substrate shown in Figure 3, with a first segment 332 and a second segment 362. As shown in Figure 6, the aerosol-generating article 601 and stainless steel tube 612 are configured such that a mouth end of the aerosol-generating article 610 protrudes out of the cavity 600 and out of the aerosol-generating device when the aerosol-generating article is received in the cavity 600. This mouth end forms a mouthpiece 610 on which a user of the aerosol-generating device may puff in use.

An aerosol-generating device 6 together with an aerosol-generating article 601 may be referred to as an aerosol-generating system.

The aerosol-generating device 6 further comprises a heating chamber with a heating zone. The heating zone comprises a first region that receives the first segment, and a second region that receives the second segment of the aerosol-generating substrate 3. The heating zone comprises a first heater 603 and a second heater 607. Both the first and second heater 603, 607 are multi-layer flexible heater assemblies. The first and second heater assemblies 603, 607 are bent around an upstream end of the stainless steel tube 612 to surround the upstream end.

The heater assemblies 603, 607 further comprise temperature sensors 604, 605. The temperature sensors 604, 605 are PtIOOO type temperature sensors. The temperature sensors 604, 605 are in thermal contact with heater tracks of the heater assemblies 603, 607 and are configured to measure the temperatures of the heater tracks of the heater assemblies 603, 607.

The aerosol-generating device 6 further comprises a power supply 606 in the form of a rechargeable battery. The power supply 606 and the temperature sensors 604, 605 of the heater assemblies 603, 607 are connected to a controller 608 of the aerosol-generating device 6 via electrical wires and connections not shown completely in the Figures. The power supply 606 is configured to power the heater assemblies 603, 607 and is connected to connectors of the heater tracks 602, 609 not shown in the Figures. The heating of the heater assembly 603 by the power supply 606 is controlled by the controller 608.

The controller 608 further comprises a timer not shown in the Figures.

An airflow channel 611 extends from an air inlet 613 of the aerosol-generating device 6. Upstream of the cavity, the airflow channel 611 is primarily defined by an airflow channel wall 616. Downstream of the airflow channel wall 616, the airflow channel 611 passes through an air inlet defined in the base 614 of the cavity. The airflow channel 611 then extends through the cavity 600. When an aerosol-generating article 601 is received in the cavity 600, the airflow channel 611 passes through the aerosol-generating article 601 and extends through the mouthpiece 204.

The aerosol-generating device may comprise further elements, not shown in the Figures, such as a button for activating the aerosol-generating device.

During use of the aerosol-generating system, an aerosol-generating article 601 is inserted to the cavity 600 by a user of the system. The user then activates the device. This may be by, for example, pressing a button or inhaling through the mouthpiece 610 of the aerosol-generating article which is detected by a puff sensor, not shown in the Figures.

Following activation, the controller 608 is configured to control the supply of power from the power supply 606 to the heater assembly 603 to cause the heating tracks 114 to heat up. The heat from the heating tracks 602, 609 is conducted to the aerosol-generating substrate 3 of the aerosol-generating article 601 through the stainless steel tube 612. This heating of the aerosol-generating substrate 3 results in vapour being generated that is released into air drawing into the aerosol-generating article 601 via the airflow channel 611. The vapour then cools and condenses into an aerosol. Thus, when a user inhales through the mouthpiece, the generated aerosol is drawn through the aerosol-generating article 601 to be inhaled by a user.

The control of the heating by the controller 608 is based on temperature signals received from the temperature sensors 604, 605 and timing signals received from the timer. The controller 608 is additionally or alternatively configured to limit the average power supplied by the power supply 606 so as to not to exceed a predetermined power level for each heater assembly 603, 607. In this manner, the first segment 332 may be heated to a maximum temperature of 210 degrees Celsius by the first heater assembly 603, and the second segment may be heated to a maximum temperature of 350 degrees Celsius by second heater assembly 607.

Figure 7 shows a schematic cross sectional view of an aerosol-generating system in accordance with the second aspect of the invention. The aerosol-generating system comprises an aerosol-generating device 7 and an aerosol-generating article 701 configured for use with the aerosol-generating device 7. The aerosol-generating article 701 includes a rod of aerosol-generating substrate 5 at its distal end. The rod of aerosol-generating substrate 5 is the same rod of aerosol-generating substrate shown in Figure 5, with a first segment 532, a second segment 562, and an elongate susceptor element 544 with two opposing faces each comprising different susceptor materials, a first face 564 contacting the first substrate 552 of the first segment 532, and a second face 584 contacting the second substrate 562 of the second segment 582.

The aerosol generating device 7 comprises a device housing 710 defining a heating chamber 720 and a heating zone for receiving the aerosol-generating article 701. The proximal end of the housing 710 has an insertion opening 725 through which the aerosolgenerating article 701 may be inserted into and removed from the chamber 720. An induction element 730 comprising a first inductor coil 731 and a second inductor coil 732 is arranged inside the aerosol-generating device 7 between an outer wall of the housing 710 and the chamber 720. The first inductor coil and second inductor coil 731 , 732 are helical inductor coils having a magnetic axis corresponding to the longitudinal axis of the chamber 720, which, in this embodiment, corresponds to the longitudinal axis of the aerosol-generating device 7. As shown in Figure 7, the induction element 730 is located adjacent to a distal portion of the chamber 720 and, in this embodiment, extends along part of the length of the chamber 720. In other embodiments, the induction element 730 may extend along all, or substantially all, of the length of the chamber 720, or may extend along part of the length of the chamber 720 and be located away from the distal portion of the chamber 720. For example, the first inductor coil 730 may extend along part of the length of the chamber 720 and be adjacent to a proximal portion of the chamber 720. The first inductor coil and second inductor coil 731 , 732 are each formed from a separate wire with a plurality of turns, or windings, extending along its length. The wire may have any suitable cross-sectional shape, such as square, oval, or triangular. In this embodiment, the wire has a circular cross-section. In other embodiments, the wire may have a flat cross-sectional shape. For example, the inductor coils may each be formed from a wire having a rectangular cross-sectional shape and wound such that the maximum width of the cross-section of the wire extends parallel to the magnetic axis of each inductor coil. Such flat inductor coils may allow the outer diameter of the inductor, and therefore the outer diameter of the aerosol-generating device, to be minimized.

The aerosol-generating device 7 also includes an internal electric power supply 740, for example a rechargeable battery, and a controller 750, for example a printed circuit board with circuitry, both located in a distal region of the housing 710. The controller 750 and the first inductor coil 730 both receive power from the power supply 740 via electrical connections (not shown) extending through the housing 710. Preferably, the chamber 720 is isolated from the first inductor coil 730 and the distal region of the housing 710, which contains the power source 740 and the controller 750, by a fluid-tight separation. Thus, electric components within the aerosol-generating device 7 may be kept separate from aerosol or residues produced within the chamber 720 by the aerosol generating process. This may also facilitate cleaning of the aerosol-generating device 7, since the chamber 720 may be made completely empty simply by removing the aerosol-generating article. This arrangement may also reduce the risk of damage to the aerosol-generating device, either during insertion of an aerosol-generating article or during cleaning, since no potentially fragile elements are exposed within the chamber 720. Ventilation holes (not shown) may be provided in the walls of the housing 710 to allow airflow into the chamber 720. Alternatively, or in addition, airflow may enter the chamber 720 at the opening 725 and flow along the length of the chamber 720 between the outer walls of the aerosol-generating article 701 and the inner walls of the chamber 720.

An elongate susceptor element 544 with two opposing faces each comprising different susceptor materials, a first face 564 contacting the first substrate 552 of the first segment 532, and a second face 584 contacting the second substrate 562 of the second segment 582 is positioned within the rod of aerosol generating substrate 5. The elongate susceptor element 544 is positioned in a radially central position between the first and second segments, 532, 562, extending along the longitudinal axis of the first and second segments 532, 562. The first face 564 and second face 584 of the elongate susceptor element 544 are parallel with each other, with the longitudinal axis of the chamber 720, and with the magnetic axis of the first inductor coil 730.

The aerosol-generating device 7 comprises an induction element 930 having two separately actuatable induction coils. A first induction coil 731 is configured to generate an alternating magnetic field having a frequency of between 3 and 5 MHz and a second induction coil 732 is configured to generate an alternating magnetic field having a frequency of between 7 and 10 MHz. The first induction coil 731 and the second induction coil 732 are linked to the controller 750 and can be separately and sequentially actuated.

The first face 564 of the susceptor element 544 is configured to heat more efficiently than the second face 584 of the susceptor element 544 when the first induction coil 731 is actuated. Thus, the first face 564 is configured to heat to a maximum temperature of about 210 degrees Celsius when the first induction coil 731 is actuated whereas the second susceptor element is configured to heat to a temperature lower than 210 degrees Celsius when the first induction coil is activated. In use, this means that aerosol may be generated from the first segment 532 in proximity to the first face but not from the second segment 562 in proximity to the second face. Conversely, the second face 584 is configured to heat more efficiently than the first face 564 when the second induction coil 732 is actuated. Thus, the second face 584 is configured to heat to a maximum temperature of about 350 degrees Celsius when the second induction coil 732 is actuated whereas the first face is configured to heat to a lower temperature when the second induction coil is activated. In use, this means that aerosol may be generated from the second segment 562 in proximity to the second face 584 but not from the first segment 532 in proximity to the first face 564.

By sequentially actuating the first susceptor element and the second susceptor element, a sequential heating of the first segment 532 and second segment 562 of the aerosol forming substrate may be achieved.

There are a number of parameters that may be altered to tune the susceptor element 544 to operate more efficiently at any particular frequency of alternating magnetic field. For example, the shape, size, magnetic permeability and resistivity may all be altered to change the manner in which eddy currents are generated within the susceptor and the efficiency of heating.

Claims

1 . An aerosol-generating article comprising a rod of aerosol-generating substrate, the rod comprising a first segment and a second segment, the first segment comprising a first substrate and the second segment comprising a second substrate, wherein the first substrate comprises: a first botanical material, wherein the first botanical material comprises at least 40% by weight of a first non-tobacco botanical material, based on the total weight of the first botanical material; and at most 4% by weight of aerosol former, based on the total weight of the first substrate, wherein the first non-tobacco botanical material is a particulate or shredded non-tobacco botanical material; and wherein the second substrate comprises: a second botanical material; and at least 10% by weight of aerosol former, based on the total weight of the second substrate, wherein the second substrate is different to the first substrate.

2. An aerosol generating article according to claim 1 , wherein the aerosol former is one or more of polyhydric alcohols, such as 1 ,3-butanediol, glycerine, 1 ,3-propanediol, propylene glycol, and triethylene glycol; 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.

3. An aerosol-generating article according to any preceding claim, wherein the first non- tobacco botanical material is selected from clove, star anise, eucalyptus, lavender, rosemary, chamomile, common sage, peppermint, verbena, lime, juniper, lemon myrtle, kaffir lime, geranium rosat, passion berry, tolu balsam, timur berry, coriander and tea.

4. An aerosol-generating article according to any preceding claim, wherein the first botanical material comprises a particulate plant material, a shredded plant material or a homogenised plant material.

5. An aerosol-generating article according to any preceding claim, wherein the first botanical material further comprises less than 25% of tobacco material, based on the total weight of the first botanical material.

6. An aerosol-generating article according to any preceding claim, wherein the first segment comprises a first heating element, and the first heating element is a first susceptor.

7. An aerosol-generating article according to any preceding claim, wherein the second botanical material comprises at least 45% by weight of tobacco material, based on the dry weight of the second substrate.

8. An aerosol-generating article according to any preceding claim, wherein the second botanical material comprises between about 3 percent by weight and about 20 percent by weight of a second non-tobacco botanical material, based on the dry weight of the second substrate.

9. An aerosol generating article according to any preceding claim, wherein the first segment and a second segment are generally cylindrical.

10. An aerosol generating article according to any preceding claim, wherein the first segment comprises a hollow channel defining a longitudinal cavity with the second segment received therein, or wherein the second segment comprises a hollow channel defining a longitudinal cavity with the first segment received therein.

11. An aerosol generating article according to any one of claims 1 to 9, wherein the first segment and the second segment are arranged in an end-to-end manner in a longitudinal direction.

12. An aerosol generating article according to any one of claims 1 to 9, wherein the first segment is adjacent to the second segment in a transverse direction.

13. An aerosol generating article according to any preceding claim, wherein the second segment comprises a second heating element, and the second heating element is a second susceptor.

14. An aerosol-generating system comprising: an aerosol-generating article according to any preceding claim; and an aerosol generating device comprising: a heating chamber for receiving the aerosol-generating article, the heating chamber configured to heat the first segment to a maximum temperature of 210 degrees Celsius.

15. An aerosol-generating system according to claim 14, wherein the heating chamber is configured to heat the second segment to a maximum temperature of 350 degrees Celsius.