Aerosol-generating article comprising frame

Abstract

An aerosol-generating article (10) for use with an aerosol-generating device (90) to generate an aerosol is provided. The aerosol-generating article (10) comprises a first planar outer surface (21) and a second planar outer surface (22). The aerosol-generating article (10) comprises a cavity (30). The aerosol-generating article (10) comprises a frame (50) positioned between a first planar outer surface (21) and a second planar outer surface (22). The frame (50) at least partially defines a cavity (30). The aerosol-generating article (10) comprises one or more aerosol-generating substrates (40, 41, 42). The aerosol-generating article (10) comprises an air outlet (12). The air outlet (12) has a width of between 0.3 mm and 3 mm and a thickness of between 0.3 mm and 3 mm. An aerosol-generating device (90) for use with an aerosol-generating article (10), an aerosol-generating system comprising an aerosol-generating device (90) and an aerosol-generating article (10), and a method of making (1100) an aerosol-generating article (10) are also provided.

Description

[0001] The present disclosure relates to an aerosol-generating article. The present disclosure also relates to an aerosol-generating device for use with the aerosol-generating article. The present disclosure also relates to an aerosol-generating system comprising the aerosol-generating article and the aerosol-generating device. The present disclosure also relates to a method of manufacturing an aerosol-generating article.

[0002] A typical aerosol-generating system comprises an aerosol-generating device and an aerosol-generating article comprising an aerosol-generating substrate. In use, the aerosol-generating device is arranged to heat a heating element positioned near or in contact with the aerosol-generating substrate, which heats the aerosol-generating substrate and releases volatile compounds. These volatile compounds are then entrained in the air drawn through the aerosol-generating article. As the volatile compounds cool, they condense to form an aerosol that can be inhaled by the consumer.

[0003] A typical aerosol-generating article may look similar to a conventional cigarette and have similar dimensions to a conventional cigarette. For example, such an aerosol-generating article may be substantially cylindrical and include an aerosol-generating substrate in addition to other components such as a mouthpiece filter element and a cooling element, the other components being arranged in the form of a strip and wrapped in cigarette paper.

[0004] However, a large portion of the aerosol-generating substrate in these cylindrical aerosol-generating articles may not be sufficiently heated during use to form an aerosol. This is undesirable because the insufficiently heated portion of the aerosol-generating substrate affects the manufacturing and shipping costs of the aerosol-generating article, but does not affect the aerosol delivered to the consumer. Furthermore, the components of these cylindrical aerosol-generating articles are typically required to have the same or very similar outer diameters so that they can be assembled together, accurately positioned in axial alignment, and wrapped in cigarette paper. This can lead to increased cost and complexity in manufacturing.

[0005] It is an object of the present disclosure to provide an aerosol-generating article in which a major portion of the aerosol-generating substrate is heated sufficiently during use to form an aerosol.It is also an object of the present disclosure to provide an aerosol-generating article that can be manufactured relatively efficiently and inexpensively.

[0006] According to the present disclosure, an aerosol-generating article is provided. The aerosol-generating article can be used with an aerosol-generating device to generate an aerosol. The aerosol-generating article includes one or more aerosol-generating substrates. The aerosol-generating article includes a first planar outer surface and a second planar outer surface.

[0007] The aerosol-generating article may include a cavity. The aerosol-generating article may include an air inlet. The aerosol-generating article may include an air outlet. The aerosol-generating article may include an airflow path extending between the air inlet and the air outlet. The airflow path may be positioned between a first planar outer surface and a second planar outer surface. The airflow path may extend through the cavity between the air inlet and the air outlet. The aerosol-generating article may include a frame positioned between the first planar outer surface and the second planar outer surface. The frame may at least partially define the airflow path. The frame may at least partially define the cavity.

[0008] Advantageously, the first and second planar outer surfaces allow good contact with an external heater of the aerosol-generating device, in particular a planar external heater, thereby providing optimal heating of the aerosol-generating substrate.

[0009] Advantageously, the first and second planar outer surfaces may provide a large surface area for heating by an external heater of the aerosol-generating device, thereby allowing the aerosol-generating substrate to be quickly heated to a temperature sufficient to generate an aerosol.

[0010] Advantageously, aerosol-generating articles of the present disclosure may be heated along substantially their entire length and width, thereby allowing the entire aerosol-generating substrate to be heated sufficiently to generate an aerosol.

[0011] Advantageously, aerosol-generating articles of the present disclosure may be manufactured by laminating sheet materials that can be achieved through a continuous manufacturing process, thereby resulting in an aerosol-generating article that is relatively easy and inexpensive to manufacture.

[0012] According to the present disclosure, an aerosol-generating article is provided. The aerosol-generating article can be used with an aerosol-generating device to generate an aerosol. The aerosol-generating article can include a first planar outer surface. The aerosol-generating article can include a second planar outer surface. The aerosol-generating article can include a cavity. The aerosol-generating article can include a frame. The frame can at least partially define the cavity. The aerosol-generating article can include one or more aerosol-generating substrates. The aerosol-generating article can include an air outlet. The air outlet can have a width between 0.3 mm and 3 mm. The air outlet can have a thickness between 0.3 mm and 3 mm.

[0013] Also provided is an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: a first planar outer surface; a second planar outer surface; a cavity; a frame at least partially defining the cavity; one or more aerosol-generating substrates; and an air outlet. The air outlet has a width between 0.3 mm and 3 mm, and the air outlet has a thickness between 0.3 mm and 3 mm.

[0014] An aerosol-generating article is provided. The aerosol-generating article can be used with an aerosol-generating device to generate an aerosol. The aerosol-generating article can include a first planar outer surface. The aerosol-generating article can include a second planar outer surface. The aerosol-generating article can include a cavity. The aerosol-generating article can include a frame. The frame can at least partially define the cavity. The aerosol-generating article can include one or more aerosol-generating substrates. The aerosol-generating article can include an air inlet. The air inlet can have a width between 0.3 mm and 3 mm. The air inlet can have a thickness between 0.3 mm and 3 mm.

[0015] Also provided is an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: a first planar outer surface; a second planar outer surface; a cavity; a frame at least partially defining the cavity; one or more aerosol-generating substrates; and an air inlet. The air inlet has a width between 0.3 mm and 3 mm, and the air inlet has a thickness between 0.3 mm and 3 mm.

[0016] Advantageously, the frame may allow the aerosol-generating article to be relatively thin while maintaining structural rigidity.

[0017] Advantageously, an aerosol-generating article having an air outlet having a width between 0.3 mm and 3 mm and a thickness between 0.3 mm and 3 mm can provide a relatively large outlet opening while allowing for improved retention of one or more aerosol-generating substrates within the aerosol-generating article. Improving retention of one or more aerosol-generating substrates within the aerosol-generating article can reduce the risk of the aerosol-generating substrate falling out of the aerosol-generating article.

[0018] Advantageously, an aerosol-generating article having an air outlet having a width between 0.3 mm and 3 mm and a thickness between 0.3 mm and 3 mm may provide good resistance to draw through the aerosol-generating article.

[0019] Advantageously, an aerosol-generating article having an air inlet having a width between 0.3 mm and 3 mm and a thickness between 0.3 mm and 3 mm can provide a relatively large inlet opening while allowing for improved retention of one or more aerosol-generating substrates within the aerosol-generating article. Improving retention of one or more aerosol-generating substrates within the aerosol-generating article can reduce the risk of the aerosol-generating substrate falling out of the aerosol-generating article.

[0020] Advantageously, an aerosol-generating article having an air inlet port having a width between 0.3 mm and 3 mm and a thickness between 0.3 mm and 3 mm may provide good resistance to draw through the aerosol-generating article.

[0021] The aerosol-generating article may have a length, a width, and a thickness. The aerosol-generating article may have a length extending in the x-direction. The aerosol-generating article may have a width extending in the y-direction. The aerosol-generating article may have a thickness extending in the z-direction.

[0022] The aerosol-generating article may comprise an x / y plane. The x / y plane may extend through the geometric center of the aerosol-generating article. The x / y plane may define a plane of symmetry for the aerosol-generating article. The air inlet and air outlet may be symmetrical about the x / y plane, for example having symmetrical shapes or positions.

[0023] The aerosol-generating article may include an x / z plane. The x / z plane may extend through the geometric center of the aerosol-generating article. The x / z plane may define a plane of symmetry for the aerosol-generating article. The air inlet and air outlet may be symmetrical about the x / z plane, for example having a symmetrical shape or position.

[0024] The aerosol-generating article may include a y / z plane. The y / z plane may extend through the geometric center of the aerosol-generating article. The y / z plane may define a plane of symmetry for the aerosol-generating article. The air inlet and air outlet may be symmetrical about the y / z plane, for example having a symmetrical shape or position.

[0025] Advantageously, a symmetrical aerosol-generating article, or an article having symmetrically shaped or positioned air inlets and air outlets, may allow the aerosol-generating article to be inserted into an aerosol-generating device in multiple orientations.

[0026] The aerosol-generating article may be a substantially flat aerosol-generating article or a substantially planar aerosol-generating article. In particular, the thickness of the aerosol-generating article may be less than 50% of both the length and width of the aerosol-generating article. Advantageously, the smaller thickness may provide a smaller temperature gradient or temperature difference across the thickness of the aerosol-generating substrate during heating. Advantageously, this may allow a larger proportion of the aerosol-generating substrate to be heated to a temperature at which the aerosol is released while minimizing the risk of burning the hottest portion of the aerosol-generating substrate closest to the heater. Advantageously, this may also reduce the time required to sufficiently heat the aerosol-generating substrate to release the aerosol.

[0027] The aerosol-generating article may have a 3-dimensional shape.

[0028] The aerosol-generating article may have a quadrilateral hexahedron shape. The aerosol-generating article may have a rectangular prism shape. The aerosol-generating article may have a cube shape. The aerosol-generating article may have a rectangular parallelepiped shape. The aerosol-generating article may have a rectangular parallelepiped shape. The aerosol-generating article may have a parallelepiped shape.

[0029] The aerosol-generating article may have a cylindrical shape. The aerosol-generating article may have a rectangular cylindrical shape. The aerosol-generating article may have an elliptical cylindrical shape.

[0030] The aerosol-generating article may have an oblong shape.

[0031] The aerosol-generating article may have a laminated structure, for example, the aerosol-generating article may comprise or be formed from at least two layers. In particular, as discussed in more detail below, the aerosol-generating article may comprise at least two of the following: a first outer layer, a second outer layer, a frame, a first frame layer, a second frame layer, a third frame layer, a first aerosol-generating substrate layer, and a second aerosol-generating substrate layer.

[0032] At least 50% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 55% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be cellulosic material. At least 60% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be cellulosic material. At least 65% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be cellulosic material. At least 70% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be cellulosic material. At least 75% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be cellulosic material. At least 80% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be cellulosic material. At least 85% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be cellulosic material. At least 90% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be cellulosic material.

[0033] At least 50% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates may be paper or cardboard. At least 55% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates may be paper or cardboard. At least 60% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates may be paper or cardboard. At least 65% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates may be paper or cardboard. At least 70% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates may be paper or cardboard. At least 75% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates may be paper or cardboard. At least 80% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates may be paper or cardboard. At least 85% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates may be paper or cardboard. At least 90% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates may be paper or cardboard.

[0034] Substantially all of the aerosol-generating article, excluding the aerosol-generating substrate(s) and, if present, the adhesive, may be paper or cardboard.

[0035] The aerosol-generating article may have a cellulose acetate content of less than 5%. The aerosol-generating article may have a cellulose acetate content of less than 3%. The aerosol-generating article may have a cellulose acetate content of less than 1%.

[0036] The frame may be a planar frame.

[0037] The frame may define a frame aperture extending through the thickness of the frame. The frame aperture may define or form an airflow path for the aerosol-generating article. The frame aperture may define or form a cavity for the aerosol-generating article. For example, the frame may have a hollow rectangular parallelepiped shape or a square hollow tube shape. As another example, the frame may have a cross-section that is annular in shape, preferably, the cross-section in the x / y plane is annular in shape. The cross-section may have an annular shape, such as a circular annular shape, an elliptical annular shape, a rectangular annular shape, or a square annular shape.

[0038] The frame may include a frame outer surface. The frame outer surface may extend in a transverse direction, for example, between a first planar outer surface and a second planar outer surface. The frame outer surface may at least partially define or form one or more outer surfaces of the aerosol-generating article. For example, the frame outer surface may at least partially define or form one or more outer walls of the aerosol-generating article. The frame outer surface may define or surround a frame aperture. The frame outer surface may define or surround a cavity.

[0039] The frame may include a frame inner surface. The frame inner surface may extend in a transverse direction, for example, between a first planar outer surface and a second planar outer surface. The frame inner surface may define or form an outer wall of a frame aperture. The frame inner surface may define or form an outer wall of a cavity. The frame inner surface may define or surround a frame aperture extending through the thickness of the frame. The frame outer surface may define or surround a cavity.

[0040] The frame outer surface may bound or surround the frame inner surface.The frame inner surface and the frame outer surface may be concentric with each other.

[0041] The frame may define or form at least 75% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame. The frame may define or form at least 80% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame. The frame may define or form at least 85% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame. The frame may define or form at least 90% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame. The frame may define or form at least 95% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame. The frame may define or form at least 99% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame.

[0042] Advantageously, providing a frame forming at least 75% of the perimeter of any cross-section extending in the x / y plane through the aerosol-generating article means that the frame extends around most of the aerosol-generating article.Thus, the frame may provide good structural support for the aerosol-generating article.

[0043] Advantageously, providing a frame forming at least 75% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame may mean that any air inlet or air outlet defined through the article is of a size that provides a satisfactory resistance to draw for the aerosol-generating article.

[0044] Advantageously, in embodiments in which the aerosol-generating substrate is positioned within a cavity, providing a frame that forms at least 75% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame can allow the frame to act as a barrier to prevent the aerosol-generating substrate from flowing out of the aerosol-generating article.

[0045] The aerosol-generating article may comprise a cross-section in a first x / y plane extending through a frame. The frame may form at least 99% of a perimeter of the cross-section in the first x / y plane. The frame may form at least 100% of a perimeter of the cross-section in the first x / y plane.

[0046] The aerosol-generating article may comprise a cross-section in a second x / y plane extending through the frame, spaced from the first x / y plane in the z-direction. The frame may form at least 99% of a perimeter of the cross-section in the second x / y plane. The frame may form 100% of a perimeter of the cross-section in the second x / y plane.

[0047] The air inlet may be positioned in the z-direction between the first x / y plane and the second x / y plane.The air outlet may be positioned in the z-direction between the first x / y plane and the second x / y plane.

[0048] The frame may comprise a first portion that is at least 30% of the thickness of the frame. The first portion may be at least 50% of the thickness of the frame. The first portion may be at least 70% of the thickness of the frame. The first portion may be at least 90% of the thickness of the frame. The frame forms 100% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article that extends through the first portion of the frame.

[0049] The aerosol-generating article may comprise one or more outer walls extending between a first planar outer surface and a second planar outer surface. The one or more outer walls may collectively define an entire lateral exterior area of ​​the aerosol-generating article. The frame may at least partially define each of the one or more outer walls.

[0050] One or more outer walls may define or surround the cavity.

[0051] The frame may define at least 60% of the entire lateral exterior area of ​​the aerosol-generating article. The frame may define at least 60% of the entire lateral exterior area of ​​the aerosol-generating article. The frame may define at least 70% of the entire lateral exterior area of ​​the aerosol-generating article. The frame may define at least 80% of the entire lateral exterior area of ​​the aerosol-generating article. The frame may define at least 90% of the entire lateral exterior area of ​​the aerosol-generating article.

[0052] The frame may include a peripheral wall. The peripheral wall may define or surround at least a portion of a frame aperture extending through the thickness of the frame. The peripheral wall may define or surround at least a portion of a cavity. The peripheral wall may define or surround a frame aperture extending through the thickness of the frame. The peripheral wall may define or surround the cavity. Advantageously, such a peripheral wall allows for a relatively large internal volume of the aerosol-generating substrate or aerosol former while providing structural strength to maintain the shape of the aerosol-generating article.

[0053] The peripheral wall may be defined or formed by the frame outer surface and the frame inner surface. The peripheral wall may at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The peripheral wall may define or form an outer wall of a frame aperture. The peripheral wall may define or form an outer wall of a cavity.

[0054] The peripheral wall may have a radial thickness.The radial thickness may be defined as the minimum distance between the outer surface of the frame and the inner surface of the frame (such as in the x / y plane).

[0055] The peripheral wall may have a radial thickness greater than or equal to 0.5 mm. The peripheral wall may have a radial thickness greater than or equal to 1 mm. The peripheral wall may have a radial thickness greater than or equal to 1.5 mm. The peripheral wall may have a radial thickness greater than or equal to 2 mm. The peripheral wall may have a radial thickness greater than or equal to 2.5 mm.

[0056] The peripheral wall may have a radial thickness of less than or equal to 4 mm. The peripheral wall may have a radial thickness of less than or equal to 3.5 mm. The peripheral wall may have a radial thickness of less than or equal to 3 mm. The peripheral wall may have a radial thickness of less than or equal to 2.5 mm. The peripheral wall may have a radial thickness of less than or equal to 2 mm.

[0057] The peripheral wall may have a radial thickness of between 0.5 mm and 3.5 mm. The peripheral wall may have a radial thickness of between 0.5 mm and 3 mm. The peripheral wall may have a radial thickness of between 0.5 mm and 2.5 mm. The peripheral wall may have a radial thickness of between 1 mm and 3 mm. The peripheral wall may have a radial thickness of between 1 mm and 2 mm. Advantageously, it has been found that a peripheral wall having a radial thickness of between 0.5 mm and 3.5 mm provides good structural strength for the aerosol-generating article without using excess material, which can increase manufacturing costs. Advantageously, a radial thickness of between 0.5 mm and 3.5 mm can limit the amount of heat that is undesirably transferred to the frame rather than the aerosol-generating substrate.

[0058] The frame may be made of or include a biodegradable material.The frame may be made entirely of a biodegradable material.

[0059] The frame may be made of or include a cellulosic material. The cellulosic material may include a sheet of cellulosic material. The cellulosic material may include cellulose fibers. The cellulosic material may be paper, paperboard, or cardboard. The frame may be made of or include a plant material such as tobacco. The frame may be made entirely of a cellulosic material.

[0060] The cellulosic material may have a grammage of greater than or equal to 300 g / m2. The cellulosic material may have a grammage of greater than or equal to 350 g / m2. The cellulosic material may have a grammage of greater than or equal to 390 g / m2. The cellulosic material may have a grammage of greater than or equal to 420 g / m2. The cellulosic material may have a grammage of greater than or equal to 620 g / m2. The cellulosic material may have a grammage of greater than or equal to 720 g / m2. The cellulosic material may have a grammage of greater than or equal to 800 g / m2.

[0061] The cellulosic material may have a grammage of less than or equal to 900 g / m2. The cellulosic material may have a grammage of less than or equal to 800 g / m2. The cellulosic material may have a grammage of less than or equal to 720 g / m2. The cellulosic material may have a grammage of less than or equal to 620 g / m2. The cellulosic material may have a grammage of less than or equal to 420 g / m2. The cellulosic material may have a grammage of less than or equal to 390 g / m2. The cellulosic material may have a grammage of less than or equal to 350 g / m2.

[0062] The cellulosic material may have a grammage between 300 g / m² and 900 g / m². The cellulosic material may have a grammage between 300 g / m² and 800 g / m². The cellulosic material may have a grammage between 350 g / m² and 800 g / m². The cellulosic material may have a grammage between 400 g / m² and 700 g / m².

[0063] The frame may be made of or include a fiber material. The frame may be made of one or more of the following: natural fibers, synthetic fibers, polyester, bonded polyolefins, polyethylene, dacron, polypropylene, biopolymer fibers, nylon fibers, and ceramic fibers. The frame may include cellulose fibers.

[0064] The framework may comprise a hydrophobic region. The hydrophobic region may comprise hydrophobic groups covalently bonded to the framework. The hydrophobic region may be located on or form at least a portion of the inner surface of the framework. Advantageously, the hydrophobic region may prevent or limit degradation of the framework in areas where the framework is regularly in contact with aerosol or liquid from the aerosol-generating substrate.

[0065] The hydrophobic regions can be produced by a process comprising applying a liquid composition comprising a fatty acid halide to the surface of the frame and maintaining the surface at a temperature of about 120 degrees C. to about 180 degrees C. The fatty acid halide reacts in situ with the proton groups of the material in the hydrophobic regions, resulting in the formation of fatty acid esters.

[0066] The hydrophobic region may have a Cobb water absorption (ISO 535:1991) value of less than or equal to 40 g / m2 (at 60 seconds). The hydrophobic region may have a Cobb water absorption (ISO 535:1991) value of less than or equal to 35 g / m2 (at 60 seconds). The hydrophobic region may have a Cobb water absorption (ISO 535:1991) value of less than or equal to 30 g / m2 (at 60 seconds). The hydrophobic region may have a Cobb water absorption (ISO 535:1991) value of less than or equal to about 25 g / m2 (at 60 seconds).

[0067] The hydrophobic region may have a water contact angle of greater than or equal to about 90 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 95 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 100 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 110 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 120 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 130 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 140 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 150 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 160 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 170 degrees.

[0068] Hydrophobicity is measured using the TAPPI T558 om-97 test, and the results are presented as the interfacial contact angle and are reported in degrees, and can range from approximately zero to approximately 180 degrees. When the contact angle is not specified along with the term hydrophobicity, the water contact angle is at least 90 degrees.

[0069] The hydrophobic region may have a water contact angle greater than or equal to 90 degrees and a Cobb water absorption (ISO 535:1991) value (at 60 seconds) less than or equal to 40 g / m 2 .

[0070] The aerosol-generating article may comprise one or more susceptor materials. The frame may comprise one or more susceptor materials. The one or more susceptor materials may be in thermal contact with the aerosol-generating substrate. The one or more susceptor materials may be in thermal contact with the airflow path. The one or more susceptor materials may be in thermal contact with the cavity. The one or more susceptor materials may be positioned in or on an inner surface of the frame. The one or more susceptor materials may be included within the material of the frame. For example, the one or more susceptor materials may be included within the peripheral wall of the frame. Advantageously, the presence of the one or more susceptor materials may allow the aerosol-generating article, and thereby the aerosol-generating substrate, to be heated by engaging with the fluctuating electromagnetic field formed by the inductor.

[0071] The one or more susceptor materials may be one or more susceptor material particles, strips, threads or filaments. The one or more susceptor materials may be one or more susceptor material sheets or layers. The one or more susceptor material sheets or layers may be in the form of a susceptor material web.

[0072] The susceptor material, in any form, may comprise one or more materials selected from the group consisting of aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0073] The frame may have a thickness greater than or equal to 50% of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 60% of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 70% of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 80% of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 90% of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 95% of the thickness of the aerosol-generating article.

[0074] The frame may have a thickness less than or equal to 95% of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 90% of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 80% of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 70% of the thickness of the aerosol-generating article.

[0075] The frame may have a thickness between 50% and 95% of the thickness of the aerosol-generating article. The frame may have a thickness between 60% and 95% of the thickness of the aerosol-generating article. The frame may have a thickness between 70% and 95% of the thickness of the aerosol-generating article. The frame may have a thickness between 80% and 95% of the thickness of the aerosol-generating article.

[0076] The frame may have a thickness greater than or equal to 1 mm. The frame may have a thickness greater than or equal to 1.5 mm. The frame may have a thickness greater than or equal to 2 mm. The frame may have a thickness greater than or equal to 2.5 mm. The frame may have a thickness greater than or equal to 3 mm. The frame may have a thickness greater than or equal to 3.5 mm. The frame may have a thickness greater than or equal to 4 mm. The frame may have a thickness greater than or equal to 4.5 mm.

[0077] The frame may have a thickness of less than or equal to 5.5 mm. The frame may have a thickness of less than or equal to 5 mm. The frame may have a thickness of less than or equal to 4.5 mm. The frame may have a thickness of less than or equal to 4 mm. The frame may have a thickness of less than or equal to 3.5 mm. The frame may have a thickness of less than or equal to 3 mm. The frame may have a thickness of less than 2.5 mm. The frame may have a thickness of less than 2 mm. The frame may have a thickness of less than 1.5 mm.

[0078] The frame may have a thickness between 1 mm and 5.5 mm. The frame may have a thickness between 1 mm and 5 mm. Preferably, the frame may have a thickness between 1.5 mm and 5 mm.

[0079] The frame may have a length equal to the length of the aerosol-generating article.The frame may have a length that is at least 90% of the length of the aerosol-generating article.The frame may have a length that is at least 95% of the length of the aerosol-generating article.

[0080] The frame may have a width equal to the width of the aerosol-generating article.The frame may have a width that is at least 90% of the width of the aerosol-generating article.The frame may have a width that is at least 90% of the width of the aerosol-generating article.

[0081] The frame can be a unitary component. Alternatively, the frame can comprise two or more layers. That is, the frame can have a laminated structure. Advantageously, the properties of each layer can be optimized individually, depending on the relative distance between the layer and the aerosol-generating substrate or the heater of the aerosol-generating device. Advantageously, the use of two or more layers allows the desired thickness of the frame to be created and quickly adjusted by adding or removing layers of sheet material. This can avoid the need to manufacture a single sheet of material having the desired thickness of the frame, which may then need to be changed when the desired thickness of the frame changes.

[0082] The frame may include a first frame layer and a second frame layer. The first frame layer and the second frame layer may be the only layers of the frame. That is, the frame may include no more than two layers or may include exactly two layers. The first frame layer may be an upper frame layer, and the second frame layer may be a lower frame layer.

[0083] The frame may have a thickness equal to the sum of a thickness of the first frame layer and a thickness of the second frame layer.A frame aperture may be defined through both the first frame layer and the second frame layer.

[0084] The frame may include a first frame layer, a second frame layer, and a third frame layer. The second frame layer may be positioned between the first frame layer and the third frame layer. The first frame layer, the second frame layer, and the third frame layer may be the only layers of the frame. That is, the frame may include no more than three layers or may include exactly three layers. The first frame layer may be an upper frame layer, the second frame layer may be an intermediate frame layer, and the third frame layer may be a lower frame layer.

[0085] The first frame layer may be in physical contact with the second frame layer. The first frame layer may be bonded to the second frame layer with an adhesive. The lower surface of the first frame layer may be bonded to the upper surface of the second frame layer with an adhesive. The adhesive may extend around at least 90% of the perimeter of the intersection between the first frame layer and the second frame layer. The adhesive may extend around at least 95% of the perimeter of the intersection between the first frame layer and the second frame layer. The adhesive may extend around at least 99% of the perimeter of the intersection between the first frame layer and the second frame layer.

[0086] The second frame layer may be in physical contact with the third frame layer. The second frame layer may be bonded to the third frame layer with an adhesive. The lower surface of the second frame layer may be bonded to the upper surface of the third frame layer with an adhesive. The adhesive may extend around at least 90% of the perimeter of the intersection between the second frame layer and the third frame layer. The adhesive may extend around at least 95% of the perimeter of the intersection between the second frame layer and the third frame layer. The adhesive may extend around at least 99% of the perimeter of the intersection between the second frame layer and the third frame layer.

[0087] The frame may have a thickness equal to the sum of a thickness of the first frame layer, a thickness of the second frame layer, and a thickness of the third frame layer.A frame aperture may be defined through the first planar layer, the second planar layer, and the third frame layer.

[0088] The first frame layer may be planar.

[0089] The first frame layer may define a first frame layer orifice extending through the thickness of the first frame layer. The first frame layer orifice may at least partially define or form a cavity of the aerosol-generating article. For example, the first frame layer may have a hollow cuboid shape or a square hollow tube shape. As another example, the first frame layer may have a cross-section that is annular in shape, preferably, the cross-section in the x / y plane is annular in shape. The cross-section may have an annular shape, such as a circular annular shape, an elliptical annular shape, a rectangular annular shape, or a square annular shape.

[0090] The first frame layer may include a first frame layer outer surface. The first frame layer outer surface may extend in a lateral direction, for example, between a first planar outer surface and a second planar outer surface. The first frame layer outer surface may at least partially define or form one or more outer surfaces of the aerosol-generating article. For example, the first frame layer outer surface may at least partially define or form one or more outer walls of the aerosol-generating article. The first frame layer outer surface may define or surround one or both of: a first frame layer aperture and a frame aperture. The first frame layer outer surface may define or surround a cavity.

[0091] The first frame layer may include a first frame layer inner surface. The first frame layer inner surface may extend in a transverse direction, for example, between a first planar outer surface and a second planar outer surface. The first frame layer inner surface may define or form an outer wall of a first frame layer aperture. The first frame layer inner surface may at least partially define or form an outer wall of a cavity. The first frame layer inner surface may define or surround one or both of: a first frame layer aperture and a frame aperture. The first frame layer outer surface may define or surround a cavity.

[0092] The first frame layer outer surface may define or surround the first frame layer inner surface.The first frame layer inner surface and the first frame layer outer surface may be concentric with each other.

[0093] The first frame layer may include a first frame layer peripheral wall. The first frame layer peripheral wall may define or surround one or both of: the frame aperture and the first frame layer aperture. The first frame layer peripheral wall may define or surround the cavity.

[0094] The first frame layer peripheral wall may be defined or formed by the first frame layer outer surface and the first frame layer inner surface. The first frame layer peripheral wall may at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The first frame layer peripheral wall may at least partially define or form an outer wall of the first frame layer orifice. The first frame layer peripheral wall may at least partially define or form an outer wall of the cavity.

[0095] The first frame layer may be made of or include any of the materials described above with respect to the frame.For example, the first frame layer may include one or more susceptor materials.

[0096] The first frame layer may be made of or include a biodegradable material. The first frame layer may be made entirely of a biodegradable material.

[0097] The first frame layer may be made of or include a cellulose material. The cellulose material may include a cellulose material sheet. The cellulose material may include cellulose fibers. The cellulose material may be paper, paperboard, or cardboard. The first frame layer may be made of or include a plant material such as tobacco. The first frame layer may be made entirely of a cellulose material.

[0098] The cellulosic material may have any grammage or range of grammages as described above with respect to the frame.

[0099] The first frame layer may be made of a fiber material. The first frame layer may be made of one or more of the following: natural fibers, synthetic fibers, polyester, bonded polyolefins, polyethylene, terylene, polypropylene, biopolymer fibers, nylon fibers, and ceramic fibers.

[0100] In the case where the frame includes exactly two layers, the thickness of the first frame layer can be half (50%) of the thickness of the frame. The first frame layer can have substantially the same thickness as the second frame layer. In the case where the frame includes exactly three layers, the thickness of the first frame layer can be one-third (33.33%) of the thickness of the frame. The first frame layer can have substantially the same thickness as each of the second frame layer and the third frame layer.

[0101] The first frame layer may have a thickness greater than or equal to 0.5 mm. The frame may have a thickness greater than or equal to 1 mm. The first frame layer may have a thickness greater than or equal to 1.5 mm. The first frame layer may have a thickness greater than or equal to 2 mm. The first frame layer may have a thickness greater than or equal to 2.5 mm.

[0102] The first frame layer may have a thickness of less than or equal to 3 mm. The first frame layer may have a thickness of less than or equal to 2.5 mm. The first frame layer may have a thickness of less than or equal to 2 mm. The first frame layer may have a thickness of less than or equal to 1.5 mm. The first frame layer may have a thickness of less than or equal to 1 mm.

[0103] The first frame layer may have a thickness between 0.5 mm and 3 mm. The first frame layer may have a thickness between 0.5 mm and 2.5 mm. The first frame layer may have a thickness between 1 mm and 2.5 mm.

[0104] The second frame layer may be planar.

[0105] The second frame layer may define a second frame layer orifice extending through the thickness of the second frame layer. The second frame layer orifice may at least partially define or form a cavity of the aerosol-generating article. For example, the second frame layer may have a hollow cuboid shape or a square hollow tube shape. As another example, the second frame layer may have a cross-section that is annular in shape, preferably, the cross-section in the x / y plane is annular in shape. The cross-section may have an annular shape, such as a circular annular shape, an elliptical annular shape, a rectangular annular shape, or a square annular shape.

[0106] The second frame layer may include a second frame layer outer surface. The second frame layer outer surface may extend in a transverse direction, for example, between the second planar outer surface and the second planar outer surface. The second frame layer outer surface may at least partially define or form one or more outer surfaces of the aerosol-generating article. For example, the second frame layer outer surface may at least partially define or form one or more outer walls of the aerosol-generating article. The second frame layer outer surface may define or surround one or both of the following: a second frame layer aperture and a frame aperture. The second frame layer outer surface may define or surround a cavity.

[0107] The second frame layer may include a second frame layer inner surface. The second frame layer inner surface may extend in a transverse direction, for example, between the second planar outer surface and the second planar outer surface. The second frame layer inner surface may define or form an outer wall of the second frame layer aperture. The second frame layer inner surface may at least partially define or form an outer wall of the cavity. The second frame layer inner surface may define or surround one or both of the following: the second frame layer aperture and the frame aperture. The second frame layer outer surface may define or surround the cavity.

[0108] The second frame layer outer surface may define or surround the second frame layer inner surface.The second frame layer inner surface and the second frame layer outer surface may be concentric with each other.

[0109] The second frame layer may include a second frame layer peripheral wall. The second frame layer peripheral wall may define or surround one or both of the following: a frame aperture and a second frame layer aperture. The second frame layer peripheral wall may define or surround a cavity.

[0110] The second frame layer peripheral wall may be defined or formed by the second frame layer outer surface and the second frame layer inner surface. The second frame layer peripheral wall may at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The second frame layer peripheral wall may at least partially define or form an outer wall of the second frame layer orifice. The second frame layer peripheral wall may at least partially define or form an outer wall of the cavity.

[0111] The second frame layer may be made of or include any of the materials described above with respect to the frame.For example, the second frame layer may include one or more susceptor materials.

[0112] The second frame layer may be made of or include a biodegradable material. The second frame layer may be made entirely of a biodegradable material.

[0113] The second frame layer can be made of or include a cellulose material. The cellulose material can include a cellulose material sheet. The cellulose material can be paper, paperboard, or cardboard. The second frame layer can be made of or include a plant material such as tobacco. The second frame layer can be made entirely of a cellulose material.

[0114] The cellulosic material may have any grammage or range of grammages as described above with respect to the frame.

[0115] The second frame layer may be made of a fiber material. The second frame layer may be made of one or more of the following: natural fibers, synthetic fibers, polyester, bonded polyolefins, polyethylene, terylene, polypropylene, biopolymer fibers, nylon fibers, and ceramic fibers.

[0116] In the case where the frame includes exactly two layers, the thickness of the second frame layer can be half (50%) of the thickness of the frame. The second frame layer can have substantially the same thickness as the first frame layer. In the case where the frame includes exactly three layers, the thickness of the second frame layer can be one-third (33.33%) of the thickness of the frame. The second frame layer can have substantially the same thickness as the first frame layer and the third frame layer.

[0117] The second frame layer may have a thickness greater than or equal to 0.5 mm. The frame may have a thickness greater than or equal to 1 mm. The second frame layer may have a thickness greater than or equal to 1.5 mm. The second frame layer may have a thickness greater than or equal to 2 mm. The second frame layer may have a thickness greater than or equal to 2.5 mm.

[0118] The second frame layer may have a thickness of less than or equal to 3 mm. The second frame layer may have a thickness of less than or equal to 2.5 mm. The second frame layer may have a thickness of less than or equal to 2 mm. The second frame layer may have a thickness of less than or equal to 1.5 mm. The second frame layer may have a thickness of less than or equal to 1 mm.

[0119] The second frame layer may have a thickness between 0.5 mm and 3 mm. The second frame layer may have a thickness between 0.5 mm and 2.5 mm. The second frame layer may have a thickness between 1 mm and 2.5 mm.

[0120] The third frame layer may be planar.

[0121] The third frame layer may define a third frame layer orifice extending through the thickness of the third frame layer. The third frame layer orifice may at least partially define or form a cavity of the aerosol-generating article. For example, the third frame layer may have a hollow rectangular parallelepiped shape or a square hollow tube shape. As another example, the third frame layer may have a cross-section that is annular in shape, preferably, the cross-section in the x / y plane is annular in shape. The cross-section may have an annular shape, such as a circular annular shape, an elliptical annular shape, a rectangular annular shape, or a square annular shape.

[0122] The third frame layer may include a third frame layer outer surface. The third frame layer outer surface may extend in a transverse direction, for example, between a third planar outer surface and a third planar outer surface. The third frame layer outer surface may at least partially define or form one or more outer surfaces of the aerosol-generating article. For example, the third frame layer outer surface may at least partially define or form one or more outer walls of the aerosol-generating article. The third frame layer outer surface may define or surround one or both of: a third frame layer aperture and a frame aperture. The third frame layer outer surface may define or surround a cavity.

[0123] The third frame layer may include a third frame layer inner surface. The third frame layer inner surface may extend in a transverse direction, for example, between the third planar outer surface and the third planar outer surface. The third frame layer inner surface may define or form an outer wall of the third frame layer aperture. The third frame layer inner surface may at least partially define or form an outer wall of the cavity. The third frame layer inner surface may define or surround one or both of the following: the third frame layer aperture and the frame aperture. The third frame layer outer surface may define or surround the cavity.

[0124] The third frame layer outer surface may define or surround the third frame layer inner surface.The third frame layer inner surface and the third frame layer outer surface may be concentric with each other.

[0125] The third frame layer may include a third frame layer peripheral wall. The third frame layer peripheral wall may define or surround one or both of the following: the frame aperture and the third frame layer aperture. The third frame layer peripheral wall may define or surround the cavity.

[0126] The third frame layer peripheral wall may be defined or formed by the third frame layer outer surface and the third frame layer inner surface. The third frame layer peripheral wall may at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The third frame layer peripheral wall may at least partially define or form an outer wall of the third frame layer orifice. The third frame layer peripheral wall may at least partially define or form an outer wall of the cavity.

[0127] The third frame layer may be made of or include any of the materials described above with respect to the frame.For example, the third frame layer may include one or more susceptor materials.

[0128] The third frame layer may be made of or include a biodegradable material. The third frame layer may be made entirely of a biodegradable material.

[0129] The third frame layer can be made of or include a cellulose material. The cellulose material can include a cellulose material sheet. The cellulose material can be paper, paperboard, or cardboard. The third frame layer can be made of or include a plant material such as tobacco. The third frame layer can be made entirely of a cellulose material.

[0130] The cellulosic material may have any grammage or range of grammages as described above with respect to the frame.

[0131] The third frame layer may be made of a fiber material. The third frame layer may be made of one or more of the following: natural fibers, synthetic fibers, polyester, bonded polyolefins, polyethylene, terylene, polypropylene, biopolymer fibers, nylon fibers, and ceramic fibers.

[0132] Where the frame comprises exactly three layers, the thickness of the third frame layer may be one third (33.33%) of the thickness of the frame.The third frame layer may have substantially the same thickness as each of the first and second frame layers.

[0133] The third frame layer may have a thickness greater than or equal to 0.5 mm. The frame may have a thickness greater than or equal to 1 mm. The third frame layer may have a thickness greater than or equal to 1.5 mm. The third frame layer may have a thickness greater than or equal to 2 mm. The third frame layer may have a thickness greater than or equal to 2.5 mm.

[0134] The third frame layer may have a thickness of less than or equal to 3 mm. The third frame layer may have a thickness of less than or equal to 2.5 mm. The third frame layer may have a thickness of less than or equal to 2 mm. The third frame layer may have a thickness of less than or equal to 1.5 mm. The third frame layer may have a thickness of less than or equal to 1 mm.

[0135] The third frame layer may have a thickness between 0.5 mm and 3 mm. The third frame layer may have a thickness between 0.5 mm and 2.5 mm. The third frame layer may have a thickness between 1 mm and 2.5 mm.

[0136] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate layer. Advantageously, the aerosol-generating substrate layer may be made thin and therefore heat up quickly and release volatile compounds to form an aerosol. Advantageously, the aerosol-generating substrate layer may be positioned proximate to the heater of the aerosol-generating substrate.

[0137] The aerosol-generating substrate layer may include an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any aerosol-generating material described herein. The aerosol-generating substrate layer may be a sheet of aerosol-generating material and may be made entirely of a sheet of aerosol-generating material.

[0138] The aerosol-generating substrate layer may be positioned between the frame and the first planar outer surface. The aerosol-generating substrate layer may be positioned between the frame and the second planar outer surface. The aerosol-generating substrate layer may be in physical contact with the frame and may be bonded to the frame. The aerosol-generating substrate layer may be bonded to the frame using an adhesive.

[0139] The aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The outer wrapper is discussed in more detail below. The aerosol-generating substrate layer may be in physical contact with both the frame and the outer wrapper, and may be bonded to both the frame and the outer wrapper. The aerosol-generating substrate layer may be bonded to both the frame and the outer wrapper using an adhesive.

[0140] The aerosol-generating substrate layer may be positioned between the frame and the first planar outer layer. The aerosol-generating substrate layer may be positioned between the frame and the second planar outer layer. The first planar outer layer and the second planar outer layer are discussed in more detail below. The aerosol-generating substrate layer may be in physical contact with both the frame and the first planar outer layer, and may be bonded to both the frame and the first planar outer layer. The aerosol-generating substrate layer may be bonded to both the frame and the first planar outer layer with an adhesive. The aerosol-generating substrate layer may be in physical contact with both the frame and the second planar outer layer, and may be bonded to both the frame and the second planar outer layer. The aerosol-generating substrate layer may be bonded to both the frame and the second planar outer layer with an adhesive.

[0141] The aerosol-generating substrate layer may overlie the ends of the cavity. The aerosol-generating substrate layer may define or form a wall of the cavity, such as a first cavity end wall or a second cavity end wall. Advantageously, the aerosol-generating substrate layer may thus be positioned within or at least partially define or form an airflow path, thereby allowing the released volatile compounds to rapidly form an aerosol.

[0142] The one or more aerosol-generating substrates may comprise a first aerosol-generating substrate layer and a second aerosol-generating substrate layer.Advantageously, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may allow a satisfactory volume of aerosol to be generated quickly compared to using a single aerosol-generating substrate layer.

[0143] The first aerosol-generating substrate layer may include an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any aerosol-generating material described herein. The first aerosol-generating substrate layer may be a sheet of aerosol-generating material and may be made entirely of a sheet of aerosol-generating material.

[0144] The second aerosol-generating substrate layer may include an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any aerosol-generating material described herein. The second aerosol-generating substrate layer may be, and may be made entirely of, a sheet of aerosol-generating material.

[0145] The first aerosol-generating substrate layer may be positioned between the frame and the first planar outer surface. The first aerosol-generating substrate layer may be in physical contact with the frame and may be bonded to the frame. For example, the first aerosol-generating substrate layer may be in physical contact with the first frame layer and may be bonded to the first frame layer. The first aerosol-generating substrate layer may be bonded to the frame with an adhesive. The first aerosol-generating substrate layer may be bonded to the first frame layer with an adhesive. The lower surface of the first aerosol-generating substrate layer may be bonded to the upper surface of the first frame layer with an adhesive.

[0146] The first aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The first aerosol-generating substrate layer may be in physical contact with, and may be bonded to, both the frame and the outer wrapper. The first aerosol-generating substrate layer may be bonded to the frame and the outer wrapper using an adhesive.

[0147] The first aerosol-generating substrate layer may be positioned between the frame and the first planar outer layer. The first aerosol-generating substrate layer may be in physical contact with both the frame and the first planar outer layer, and may be bonded to both the frame and the first planar outer layer. The first aerosol-generating substrate layer may be bonded to the frame and the first planar outer layer with an adhesive.

[0148] The second aerosol-generating substrate layer may be positioned between the frame and the second planar outer surface. The second aerosol-generating substrate layer may be in physical contact with the frame and may be bonded to the frame. For example, the second aerosol-generating substrate layer may be in physical contact with the second frame layer or the third frame layer and may be bonded to the second frame layer or the third frame layer. The second aerosol-generating substrate layer may be bonded to the frame with an adhesive. The second aerosol-generating substrate layer may be bonded to the second frame layer or the third frame layer with an adhesive. The upper surface of the second aerosol-generating substrate layer may be bonded to the lower surface of the second frame layer or the third frame layer with an adhesive.

[0149] The second aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The second aerosol-generating substrate layer may be in physical contact with both the frame and the outer wrapper and may be bonded to both the frame and the outer wrapper. The second aerosol-generating substrate layer may be bonded to the frame and the outer wrapper using an adhesive.

[0150] The second aerosol-generating substrate layer may be positioned between the frame and the second planar outer layer. The second aerosol-generating substrate layer may be in physical contact with both the frame and the second planar outer layer, and may be bonded to both the frame and the second planar outer layer. The second aerosol-generating substrate layer may be bonded to the frame and the second planar outer layer using an adhesive.

[0151] The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may overlie opposite ends of the cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may define or form opposite end walls of the cavity. In other words, the frame, the first aerosol-generating substrate layer, and the second aerosol-generating substrate layer may collectively define the cavity. In other words, the cavity is defined by the frame, the first aerosol-generating substrate layer, and the second aerosol-generating substrate layer.

[0152] The aerosol-generating substrate layer may be a planar aerosol-generating substrate layer. The planar aerosol-generating substrate layer may extend in the x-direction and the y-direction. That is, the planar aerosol-generating substrate layer may extend in the x / y plane.

[0153] The first aerosol-generating substrate layer may be a first planar aerosol-generating substrate layer. The first planar aerosol-generating substrate layer may extend in the x-direction and the y-direction. That is, the first planar aerosol-generating substrate layer may extend in the x / y plane.

[0154] The second aerosol-generating substrate layer may be a second planar aerosol-generating substrate layer. The second planar aerosol-generating substrate layer may extend in the x-direction and the y-direction. That is, the second planar aerosol-generating substrate layer may extend in the x / y plane.

[0155] The aerosol-generating substrate layer may have a thickness greater than or equal to 100 micrometers. The aerosol-generating substrate layer may have a thickness greater than or equal to 200 micrometers. The aerosol-generating substrate layer may have a thickness greater than or equal to 300 micrometers. The aerosol-generating substrate layer may have a thickness greater than or equal to 400 micrometers. The aerosol-generating substrate layer may have a thickness greater than or equal to 500 micrometers.

[0156] The aerosol-generating substrate layer may have a thickness of less than or equal to 600 micrometers. The aerosol-generating substrate layer may have a thickness of less than or equal to 500 micrometers. The aerosol-generating substrate layer may have a thickness of less than or equal to 400 micrometers. The aerosol-generating substrate layer may have a thickness of less than or equal to 300 micrometers. The aerosol-generating substrate layer may have a thickness of less than or equal to 200 micrometers.

[0157] The aerosol-generating substrate layer may have a thickness between 100 micrometers and 600 micrometers. The aerosol-generating substrate layer may have a thickness between 200 micrometers and 500 micrometers. The aerosol-generating substrate layer may have a thickness between 200 micrometers and 400 micrometers. The aerosol-generating substrate layer may have a thickness between 200 micrometers and 300 micrometers.

[0158] One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 100 micrometers. One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 200 micrometers. One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 300 micrometers. One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 400 micrometers. One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 500 micrometers.

[0159] One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness of less than or equal to 600 micrometers. One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness of less than or equal to 500 micrometers. One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness of less than or equal to 400 micrometers. One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness of less than or equal to 300 micrometers. One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness of less than or equal to 200 micrometers.

[0160] One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness between 100 micrometers and 600 micrometers. One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness between 200 micrometers and 500 micrometers. One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness between 200 micrometers and 400 micrometers. One or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness between 200 micrometers and 300 micrometers.

[0161] The aerosol-generating substrate layer may have substantially the same length as the length of the frame.The aerosol-generating substrate layer may have substantially the same length as the length of the aerosol-generating article.

[0162] The first aerosol-generating substrate layer may have substantially the same length as the length of the frame.The first aerosol-generating substrate layer may have substantially the same length as the length of the aerosol-generating article.

[0163] The second aerosol-generating substrate layer may have substantially the same length as the length of the frame.The second aerosol-generating substrate layer may have substantially the same length as the length of the aerosol-generating article.

[0164] The aerosol-generating substrate layer may have substantially the same width as the width of the frame.The aerosol-generating substrate layer may have substantially the same width as the width of the aerosol-generating article.

[0165] The first aerosol-generating substrate layer may have a width that is substantially the same as the width of the frame.The first aerosol-generating substrate layer may have a width that is substantially the same as the width of the aerosol-generating article.

[0166] The second aerosol-generating substrate layer may have a width that is substantially the same as the width of the frame.The second aerosol-generating substrate layer may have a width that is substantially the same as the width of the aerosol-generating article.

[0167] The first planar outer surface may be a planar upper surface, and the second planar outer surface may be a planar lower surface. The first planar outer surface may be a planar top surface, and the second planar outer surface may be a planar bottom surface. The first planar outer surface may be a planar top plate surface, and the second planar outer surface may be a planar base surface.

[0168] The first planar outer surface can be positioned parallel to the second planar outer surface. The first planar outer surface can extend in both the x-direction and the y-direction. In other words, the first planar outer surface can extend in the x / y plane. The second planar outer surface can extend in both the x-direction and the y-direction. In other words, the second planar outer surface can extend in the x / y plane.

[0169] The second planar outer surface may be spaced apart from the first planar outer surface in the z-direction or the lateral direction. The distance between the first planar outer surface and the second planar outer surface in the z-direction or the lateral direction may define the thickness of the aerosol-generating article. In other words, the thickness of the aerosol-generating article may be defined by the perpendicular distance between the first planar outer surface and the second planar outer surface.

[0170] The aerosol-generating article may comprise an outer packaging. The outer packaging may be hydrophobic. The outer packaging may comprise a hydrophobic material.

[0171] The outer wrapper may define or form a first planar outer surface. The outer wrapper may define or form a second planar outer surface. The outer wrapper may define or form both the first planar outer surface and the second planar outer surface.

[0172] The outer wrapper may define or surround the frame. The outer wrapper may be in physical contact with the frame and may be bonded to the frame. The outer wrapper may overlie opposite ends of the cavity. The outer wrapper may define or form opposite end walls of the cavity, such as a first cavity end wall and a second cavity end wall. In other words, the frame and the outer wrapper may jointly define the cavity. In other words, the cavity is defined by the frame and the outer wrapper.

[0173] The outer wrapper may bound or surround the frame and the aerosol-generating substrate layer.The outer wrapper may be in physical contact with both the frame and the aerosol-generating substrate layer, and may be bonded to both the frame and the aerosol-generating substrate layer.

[0174] The outer wrapper may define or surround the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer.The outer wrapper may be in physical contact with both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer and may be bonded to both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer.

[0175] The aerosol-generating article may comprise a first planar outer layer and a second planar outer layer. The first planar outer layer may be an upper layer, and the second planar outer layer may be a lower layer. The first planar outer layer may be a top layer, and the second planar outer layer may be a bottom layer. The first planar outer layer may be a top sheet layer, and the second planar outer layer may be a base layer.

[0176] The first planar outer layer may define or form a first planar outer surface. The first planar outer layer may extend in the x-direction and the y-direction. In other words, the first planar outer layer may extend in the x / y plane. The second planar outer layer may define or form a second planar outer surface. The second planar outer layer may extend in the x-direction and the y-direction. In other words, the second planar outer layer may extend in the x / y plane.

[0177] The first planar outer layer may be in physical contact with the frame and may be bonded to the frame. The first planar outer layer may be bonded to the frame with an adhesive. The first planar outer layer may be bonded to the first frame layer with an adhesive. The lower surface of the first planar outer layer may be bonded to the upper surface of the first frame layer with an adhesive. The adhesive may extend around at least 90% of the perimeter of the intersection between the first planar outer layer and the frame. The adhesive may extend around at least 95% of the perimeter of the intersection between the first planar outer layer and the frame. The adhesive may extend around at least 99% of the perimeter of the intersection between the first planar outer layer and the frame.

[0178] The first planar outer layer may overly an end of the cavity.The first planar outer layer may define or form a wall of the cavity, such as a first cavity end wall.

[0179] The second planar outer layer may be in physical contact with the frame and may be bonded to the frame. The second planar outer layer may be bonded to the frame with an adhesive. The second planar outer layer may be bonded to the second frame layer with an adhesive. The upper surface of the second planar outer layer may be bonded to the lower surface of the second frame layer with an adhesive. The second planar outer layer may be bonded to the third frame layer with an adhesive. The upper surface of the second planar outer layer may be bonded to the lower surface of the third frame layer with an adhesive. The adhesive may extend around at least 90% of the perimeter of the intersection between the second planar outer layer and the frame. The adhesive may extend around at least 95% of the perimeter of the intersection between the second planar outer layer and the frame. The adhesive may extend around at least 99% of the perimeter of the intersection between the second planar outer layer and the frame.

[0180] The second planar outer layer may overly an end of the cavity.The second planar outer layer may define or form a wall of the cavity, such as a second cavity end wall.

[0181] The first and second planar outer layers may overlie opposite ends of the cavity. The first and second planar outer layers may define or form opposite end walls of the cavity, such as a first cavity end wall and a second cavity end wall. In other words, the frame, the first and second planar outer layers may collectively define the cavity. In other words, the cavity is defined by the frame, the first and second planar outer layers.

[0182] The first planar outer layer may be spaced apart from the frame (such as in a transverse direction). For example, the aerosol-generating substrate layer or the first aerosol-generating substrate layer may be positioned between the first planar outer layer and the frame. The first planar outer layer may be in physical contact with the aerosol-generating substrate layer or the first aerosol-generating substrate layer and may be bonded to the aerosol-generating substrate layer or the first aerosol-generating substrate layer. The first planar outer layer may be bonded to the aerosol-generating substrate layer or the first aerosol-generating substrate layer with an adhesive.

[0183] The second planar outer layer may be spaced apart from the frame (such as in a transverse direction). For example, the aerosol-generating substrate layer or the second aerosol-generating substrate layer may be positioned between the second planar outer layer and the frame. The second planar outer layer may be in physical contact with the aerosol-generating substrate layer or the second aerosol-generating substrate layer and may be bonded to the aerosol-generating substrate layer or the second aerosol-generating substrate layer. The second planar outer layer may be bonded to the aerosol-generating substrate layer or the second aerosol-generating substrate layer with an adhesive.

[0184] The first planar outer layer may be hydrophobic. The first planar outer layer may include a hydrophobic material. The second planar outer layer may be hydrophobic. The second planar outer layer may include a hydrophobic material.

[0185] Advantageously, the adhesive bonding the components of the aerosol-generating article together may provide a tight seal between the layers of the aerosol-generating article. In particular, the adhesive bonding one or both of the first planar outer layer and the second planar outer layer to the frame may provide a tight seal between the first planar outer layer and the frame or a tight seal between the second planar outer layer and the frame.

[0186] Providing a tight seal between the layers of the aerosol-generating article may improve airflow through the cavity.Improving airflow through the cavity may improve the user experience.

[0187] Advantageously, the use of an adhesive to bond the components of an aerosol-generating article together may provide an aerosol-generating article with high structural integrity.

[0188] The binder may include a gum. The binder may include guar gum. The binder may include polyvinyl alcohol. The binder may include an aerosol-forming material. The binder may consist of an aerosol-forming material. For example, the binder may be a homogenized tobacco slurry. The binder may be or may include a flavoring and / or an aerosol-forming agent.

[0189] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may be made of a cellulosic material. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may include a cellulosic material. The cellulosic material may be paper, cardboard, wood, textiles, natural fibers, or man-made fibers.

[0190] One or more of the outer wrapper, the first plane outer layer and the second plane outer layer can be an aerosol generating matrix comprising an aerosol generating material. One or more of the outer wrapper, the first plane outer layer and the second plane outer layer can comprise an aerosol generating material. The aerosol generating material can be any aerosol generating material as described herein. In particular, the aerosol generating material can be in the form of an aerosol generating material sheet. The aerosol generating material sheet can be any aerosol generating material sheet as described herein. Alternatively, one or more of the outer wrapper, the first plane outer layer and the second plane outer layer can not comprise any aerosol generating material, particularly in the embodiment comprising an aerosol generating matrix layer, the first aerosol generating matrix layer, the second aerosol generating matrix layer or the aerosol generating matrix positioned in the cavity. For example, one or more of the outer wrapper, the first plane outer layer and the second plane outer layer can not comprise tobacco. One or more of the outer wrapper, the first plane outer layer and the second plane outer layer can be substantially free of nicotine.

[0191] One or more of the outer wrapper, the first planar outer layer and the second planar outer layer may comprise a paper material. For example, one or more of the outer wrapper, the first planar outer layer and the second planar outer layer may be paper, cardboard, cigarette paper or tobacco paper.

[0192] The cellulosic material may have a basis weight greater than 10 grams per square meter. The cellulosic material may have a basis weight greater than 20 grams per square meter. The cellulosic material may have a basis weight less than 30 grams per square meter. The cellulosic material may have a basis weight less than 25 grams per square meter. The cellulosic material may have a basis weight between 10 grams per square meter and 30 grams per square meter. The cellulosic material may have a basis weight between 15 grams per square meter and 25 grams per square meter.

[0193] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may include paper and non-paper components.

[0194] One or more in outer wrapper, the first plane outer layer and the second plane outer layer can show the permeability of certain scope, comprise impervious.Permeability utilizes international standard test method ISO 2965:2009 to determine, and result presents with cubic centimeters per minute every square centimeter, and is referred to as " CORESTA unit ". One or more in outer wrapper, the first plane outer layer and the second plane outer layer can have the permeability between 1 and 10 CORESTA units. One or more in outer wrapper, the first plane outer layer and the second plane outer layer can have the permeability between 1 and 5 CORESTA units. One or more in outer wrapper, the first plane outer layer and the second plane outer layer can have the permeability between 5 and 20 CORESTA units.

[0195] One or more of the outer packaging, the first planar outer layer, and the second planar outer layer may have a thickness greater than or equal to 25 microns. One or more of the outer packaging, the first planar outer layer, and the second planar outer layer may have a thickness greater than or equal to 30 microns. One or more of the outer packaging, the first planar outer layer, and the second planar outer layer may have a thickness greater than or equal to 35 microns. The outer packaging may have a thickness greater than or equal to 40 microns. One or more of the outer packaging, the first planar outer layer, and the second planar outer layer may have a thickness greater than or equal to 45 microns.

[0196] One or more of the outer packaging, the first plane outer layer, and the second plane outer layer may have a thickness less than or equal to 55 microns. One or more of the outer packaging, the first plane outer layer, and the second plane outer layer may have a thickness greater than or equal to 50 microns. One or more of the outer packaging, the first plane outer layer, and the second plane outer layer may have a thickness greater than or equal to 45 microns. One or more of the outer packaging, the first plane outer layer, and the second plane outer layer may have a thickness greater than or equal to 40 microns. One or more of the outer packaging, the first plane outer layer, and the second plane outer layer may have a thickness greater than or equal to 35 microns.

[0197] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness between 25 and 55 microns. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness between 25 and 45 microns. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness between 30 and 45 microns.

[0198] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length substantially the same as the length of the frame. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length substantially the same as the length of the aerosol-generating article. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length greater than or equal to 90% of the length of the frame. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length greater than or equal to 95% of the length of the frame.

[0199] One or more of the first planar outer layer and the second planar outer layer may have a width that is substantially the same as the width of the frame. One or more of the first planar outer layer and the second planar outer layer may have a width that is substantially the same as the width of the aerosol-generating article. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a width that is greater than or equal to 90% of the width of the frame. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a width that is greater than or equal to 95% of the width of the frame.

[0200] The cavity may include a first cavity end wall and a second cavity end wall positioned opposite the first cavity end wall. The first cavity end wall may be defined or formed by an outer wrapper, a first planar outer layer, or a first aerosol-generating substrate layer. The second cavity end wall may be defined or formed by an outer wrapper, a second planar outer layer, or a second aerosol-generating substrate layer. The cavity may be enclosed by the first cavity end wall, the second cavity end wall, and the frame.

[0201] The cavity may include an outer cavity wall. The outer cavity wall may be defined or formed by the frame. The outer cavity wall may extend in a transverse direction. The outer cavity wall may extend in a transverse direction between the first cavity end wall and the second cavity end wall. The outer cavity wall may be defined or formed by an inner surface of the frame. The outer cavity wall may be defined or formed by a peripheral wall of the frame.

[0202] The cavity may have at least two corners extending between the first planar outer surface and the second planar outer surface. The at least two corners may be chamfered or rounded or filleted. Preferably, all corners of the cavity extending between the first planar outer surface and the second planar outer surface are chamfered or rounded or filleted.

[0203] Advantageously, a cavity having chamfered, rounded, or radiused corners can make the cavity easier to heat. In particular, it can make it easier to heat an aerosol-generating substrate positioned within the cavity. Advantageously, a cavity having chamfered, rounded, or radiused corners can make an aerosol-generating article stronger and less susceptible to damage. Advantageously, a cavity having chamfered, rounded, or radiused corners can make an aerosol-generating article easier to manufacture.

[0204] The cavity may have a thickness substantially the same as a thickness of the frame.

[0205] The cavity may have a thickness greater than or equal to 30% of the thickness of the aerosol-generating article. The cavity may have a thickness greater than or equal to 40% of the thickness of the aerosol-generating article. The cavity may have a thickness greater than or equal to 50% of the thickness of the aerosol-generating article. The cavity may have a thickness greater than or equal to 60% of the thickness of the aerosol-generating article. The cavity may have a thickness greater than or equal to 70% of the thickness of the aerosol-generating article. The cavity may have a thickness greater than or equal to 80% of the thickness of the aerosol-generating article. The cavity may have a thickness greater than or equal to 90% of the thickness of the aerosol-generating article. The cavity may have a thickness greater than or equal to 95% of the thickness of the aerosol-generating article.

[0206] The cavity may have a thickness less than or equal to 95% of the thickness of the aerosol-generating article. The cavity may have a thickness less than or equal to 90% of the thickness of the aerosol-generating article. The cavity may have a thickness less than or equal to 80% of the thickness of the aerosol-generating article. The cavity may have a thickness less than or equal to 70% of the thickness of the aerosol-generating article.

[0207] The cavity may have a thickness between 30% and 95% of the thickness of the aerosol-generating article. The cavity may have a thickness between 40% and 95% of the thickness of the aerosol-generating article. The cavity may have a thickness between 50% and 90% of the thickness of the aerosol-generating article. The cavity may have a thickness between 60% and 90% of the thickness of the aerosol-generating article. The cavity may have a thickness between 70% and 90% of the thickness of the aerosol-generating article. The cavity may have a thickness between 80% and 90% of the thickness of the aerosol-generating article.

[0208] The cavity may have a thickness greater than or equal to 0.5 mm. The cavity may have a thickness greater than or equal to 1 mm. The cavity may have a thickness greater than or equal to 1.5 mm. The cavity may have a thickness greater than or equal to 2 mm. The cavity may have a thickness greater than or equal to 2.5 mm. The cavity may have a thickness greater than or equal to 3 mm. The cavity may have a thickness greater than or equal to 3.5 mm. The cavity may have a thickness greater than or equal to 4 mm.

[0209] The cavity may have a thickness of less than or equal to 4.5 mm. The cavity may have a thickness of less than or equal to 4 mm. The cavity may have a thickness of less than or equal to 3.5 mm. The cavity may have a thickness of less than or equal to 2.5 mm. The cavity may have a thickness of less than or equal to 2 mm. The cavity may have a thickness of less than or equal to 1.5 mm.

[0210] The cavity may have a thickness between 0.5 mm and 4.5 mm. The cavity may have a thickness between 1 mm and 4.5 mm. The cavity may have a thickness between 2 mm and 4 mm. Preferably, the cavity may have a thickness between 2.8 mm and 3.3 mm.

[0211] The cavity may have a length greater than or equal to 30% of the length of the aerosol-generating article. The cavity may have a length greater than or equal to 40% of the length of the aerosol-generating article. The cavity may have a length greater than or equal to 50% of the length of the aerosol-generating article. The cavity may have a length greater than or equal to 60% of the length of the aerosol-generating article. The cavity may have a length greater than or equal to 70% of the length of the aerosol-generating article. The cavity may have a length greater than or equal to 80% of the length of the aerosol-generating article. The cavity may have a length greater than or equal to 90% of the length of the aerosol-generating article.

[0212] The cavity may have a length less than or equal to 95% of the length of the aerosol-generating article. The cavity may have a length less than or equal to 90% of the length of the aerosol-generating article. The cavity may have a length less than or equal to 80% of the length of the aerosol-generating article. The cavity may have a length less than or equal to 70% of the length of the aerosol-generating article. The cavity may have a length less than or equal to 60% of the length of the aerosol-generating article. The cavity may have a length less than or equal to 55% of the length of the aerosol-generating article.

[0213] The cavity may have a length between 30% and 95% of the length of the aerosol-generating article. The cavity may have a length between 40% and 95% of the length of the aerosol-generating article. The cavity may have a length between 50% and 90% of the length of the aerosol-generating article. The cavity may have a length between 55% and 90% of the length of the aerosol-generating article. The cavity may have a length between 60% and 90% of the length of the aerosol-generating article. The cavity may have a length between 70% and 90% of the length of the aerosol-generating article. The cavity may have a length between 80% and 90% of the length of the aerosol-generating article.

[0214] The cavity may have a length greater than or equal to 14 mm. The cavity may have a length greater than or equal to 16 mm. The cavity may have a length greater than or equal to 18 mm. The cavity may have a length greater than or equal to 22 mm. The cavity may have a thickness greater than or equal to 26 mm. The cavity may have a thickness greater than or equal to 30 mm. The cavity may have a thickness greater than or equal to 34 mm. The cavity may have a thickness greater than or equal to 38 mm.

[0215] The cavity may have a length less than or equal to 40 mm. The cavity may have a length less than or equal to 38 mm. The cavity may have a thickness less than or equal to 34 mm. The cavity may have a thickness less than or equal to 30 mm. The cavity may have a thickness less than or equal to 28 mm. The cavity may have a thickness less than or equal to 26 mm. The cavity may have a thickness less than or equal to 22 mm. The cavity may have a thickness less than or equal to 18 mm.

[0216] The cavity may have a length between 14 mm and 40 mm. The cavity may have a length between 14 mm and 38 mm. The cavity may have a length between 14 mm and 34 mm. The cavity may have a length between 14 mm and 30 mm. The cavity may have a length between 16 mm and 30 mm. The cavity may have a length between 18 mm and 30 mm. The cavity may have a length between 20 mm and 30 mm. The cavity may have a length between 24 mm and 28 mm.

[0217] The cavity may have a width greater than or equal to 30% of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 40% of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 50% of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 60% of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 70% of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 80% of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 90% of the width of the aerosol-generating article.

[0218] The cavity may have a width less than or equal to 95% of the width of the aerosol-generating article. The cavity may have a width less than or equal to 90% of the width of the aerosol-generating article. The cavity may have a width less than or equal to 80% of the width of the aerosol-generating article. The cavity may have a width less than or equal to 70% of the width of the aerosol-generating article. The cavity may have a width less than or equal to 60% of the width of the aerosol-generating article. The cavity may have a width less than or equal to 55% of the width of the aerosol-generating article.

[0219] The cavity may have a width between 30% and 95% of the width of the aerosol-generating article. The cavity may have a width between 40% and 95% of the width of the aerosol-generating article. The cavity may have a width between 50% and 90% of the width of the aerosol-generating article. The cavity may have a width between 50% and 95% of the width of the aerosol-generating article. The cavity may have a width between 60% and 90% of the width of the aerosol-generating article. The cavity may have a width between 70% and 90% of the width of the aerosol-generating article. The cavity may have a width between 80% and 90% of the width of the aerosol-generating article.

[0220] The cavity may have a width greater than or equal to 4.5 mm. The cavity may have a width greater than or equal to 5 mm. The cavity may have a width greater than or equal to 7 mm. The cavity may have a width greater than or equal to 9 mm. The cavity may have a width greater than or equal to 11 mm.

[0221] The cavity may have a width less than or equal to 13 mm. The cavity may have a width less than or equal to 13 mm. The cavity may have a width less than or equal to 11 mm. The cavity may have a width less than or equal to 9 mm. The cavity may have a width less than or equal to 7 mm. The cavity may have a width less than or equal to 5 mm.

[0222] The cavity may have a width between 4.5 mm and 13 mm. The cavity may have a width between 5 mm and 13 mm. The cavity may have a width between 7 mm and 10 mm. The cavity may have a width between 7.5 mm and 8.5 mm.

[0223] The cavity may have a length between 14 mm and 40 mm, a width between 4.5 mm and 13 mm, and a thickness between 0.5 mm and 4.5 mm.

[0224] Preferably, the cavity may have a length between 20 and 30 mm, a width between 7 and 10 mm and a thickness between 2.5 and 4 mm.

[0225] Most preferably, the cavity may have a length of 26 mm, a width of 8 mm and a thickness of 3.1 mm.

[0226] The cavity may have a volume greater than or equal to 30 cubic millimeters. The cavity may have a volume greater than or equal to 100 cubic millimeters. The cavity may have a volume greater than or equal to 200 cubic millimeters. The cavity may have a volume greater than or equal to 300 cubic millimeters. The cavity may have a volume greater than or equal to 400 cubic millimeters. The cavity may have a volume greater than or equal to 500 cubic millimeters. The cavity may have a volume greater than or equal to 600 cubic millimeters. The cavity may have a volume greater than or equal to 700 cubic millimeters. The cavity may have a volume greater than or equal to 800 cubic millimeters. The cavity may have a volume greater than or equal to 900 cubic millimeters. The cavity may have a volume greater than or equal to 1000 cubic millimeters. The cavity may have a volume greater than or equal to 1500 cubic millimeters. The cavity may have a volume greater than or equal to 2000 cubic millimeters. The cavity may have a volume greater than or equal to 2500 cubic millimeters. The cavity may have a volume greater than or equal to 3000 cubic millimeters.

[0227] The cavity may have a volume less than or equal to 3500 cubic millimeters. The cavity may have a volume less than or equal to 3000 cubic millimeters. The cavity may have a volume less than or equal to 2500 cubic millimeters. The cavity may have a volume less than or equal to 2000 cubic millimeters. The cavity may have a volume less than or equal to 1500 cubic millimeters. The cavity may have a volume less than or equal to 1000 cubic millimeters. The cavity may have a volume less than or equal to 900 cubic millimeters. The cavity may have a volume less than or equal to 800 cubic millimeters. The cavity may have a volume less than or equal to 700 cubic millimeters. The cavity may have a volume less than or equal to 600 cubic millimeters. The cavity may have a volume less than or equal to 500 cubic millimeters. The cavity may have a volume less than or equal to 400 cubic millimeters. The cavity may have a volume less than or equal to 300 cubic millimeters.

[0228] The cavity may have a volume between 30 cubic millimeters and 3000 cubic millimeters. The cavity may have a volume between 30 cubic millimeters and 3000 cubic millimeters. The cavity may have a volume between 30 cubic millimeters and 2500 cubic millimeters. The cavity may have a volume between 30 cubic millimeters and 2350 cubic millimeters. The cavity may have a volume between 100 cubic millimeters and 2000 cubic millimeters. The cavity may have a volume between 100 cubic millimeters and 1500 cubic millimeters. The cavity may have a volume between 250 cubic millimeters and 1150 cubic millimeters. The cavity may have a volume between 100 cubic millimeters and 1000 cubic millimeters. The cavity may have a volume between 100 cubic millimeters and 900 cubic millimeters. The cavity may have a volume between 200 cubic millimeters and 800 cubic millimeters. Preferably, the cavity may have a volume between 300 cubic millimeters and 700 cubic millimeters. The cavity may have a volume between 400 cubic millimeters and 700 cubic millimeters. The cavity may have a volume between 500 cubic millimeters and 700 cubic millimeters.

[0229] The cavity may have a volume greater than or equal to 1% of the external volume of the aerosol-generating article. The cavity may have a volume greater than or equal to 5% of the external volume of the aerosol-generating article. The cavity may have a volume greater than or equal to 1% of the external volume of the aerosol-generating article.

[0230] The cavity may have a volume less than or equal to 90% of the external volume of the aerosol-generating article. The cavity may have a volume less than or equal to 80% of the external volume of the aerosol-generating article. The cavity may have a volume less than or equal to 70% of the external volume of the aerosol-generating article.

[0231] The cavity may have a volume between 1% and 90% of the external volume of the aerosol-generating article. The cavity may have a volume between 5% and 80% of the external volume of the aerosol-generating article. The cavity may have a volume between 10% and 70% of the external volume of the aerosol-generating article.

[0232] The cavity may be a first cavity. The aerosol-generating article may include a second cavity. The second cavity may be positioned between the first planar outer surface and the second planar outer surface. The second cavity may have any of the features described with respect to the first cavity.

[0233] The frame may at least partially define or form the second cavity.

[0234] The frame may include a first frame aperture extending through the thickness of the frame. The first frame aperture may at least partially define or form a first cavity. The frame may define a second frame aperture extending through the thickness of the frame. The second frame aperture may at least partially define or form a second cavity.

[0235] The peripheral wall of the frame may include a first inner surface of the frame and a second inner surface of the frame. The first inner surface of the frame may define or form an outer wall of the first cavity. The second inner surface of the frame may define or form an outer wall of the second cavity.

[0236] The frame may include a partition wall separating the first cavity and the second cavity. The partition wall may define or form an orifice. The orifice may extend from the first cavity to the second cavity. The orifice may define or form at least a portion of an airflow path between the air inlet and the air outlet.

[0237] The outer wrapper may overlie opposite ends of the first cavity. The outer wrapper may overlie opposite ends of the second cavity. The outer wrapper may define or form opposite end walls of the first cavity. The outer wrapper may define or form opposite end walls of the second cavity. In other words, the frame and the outer wrapper may jointly define the first cavity and the second cavity.

[0238] The first and second planar outer layers may overlie opposing ends of the first cavity. The first and second planar outer layers may overlie opposing ends of the second cavity. The first and second planar outer layers may define or form opposing end walls of the first cavity. The first and second planar outer layers may define or form opposing end walls of the second cavity. In other words, the frame, the first and second planar outer layers may collectively define the first and second cavities.

[0239] The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may overlie opposite ends of the first cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may overlie opposite ends of the second cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may define or form opposite end walls of the first cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may define or form opposite end walls of the second cavity. That is, the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may collectively define the first cavity and the second cavity.

[0240] The cavity or the first cavity may be substantially empty.The second cavity may be substantially empty.

[0241] The one or more aerosol-generating substrates may include an aerosol-generating substrate positioned within the cavity. The aerosol-generating substrate positioned within the cavity may fill the cavity. Advantageously, providing an aerosol-generating substrate that fills the cavity enables the aerosol-generating substrate to provide mechanical support to the first planar outer surface and the second planar outer surface. Providing additional mechanical support to the first planar outer surface and the second planar outer surface may improve the stiffness of the aerosol-generating article.

[0242] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate positioned within the first cavity.The aerosol-generating substrate positioned within the cavity may fill the first cavity.

[0243] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate positioned within the second cavity.

[0244] The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. For example, the aerosol-generating material may be in the form of chopped aerosol-generating material.

[0245] The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any aerosol-generating material sheet described herein. For example, the sheet of aerosol-generating material may be a sheet of homogenised tobacco material.

[0246] The sheet of aerosol-generating material may extend the entire length of the cavity, the first cavity or the second cavity.The sheet of aerosol-generating material may extend the entire width of the cavity, the first cavity or the second cavity.

[0247] The sheet of aerosol-generating material may be a sheet of gathered aerosol-generating material. That is, the sheet of aerosol-generating material may be rolled, folded or otherwise compressed or contracted substantially perpendicular to the transverse direction of the aerosol-generating article.

[0248] The sheet of aerosol-generating material may be a curled sheet of aerosol-generating material. The sheet of aerosol-generating material may be a corrugated sheet of aerosol-generating material. The curled sheet of aerosol-generating material or the corrugated sheet of aerosol-generating material may comprise a plurality of parallel corrugations. For example, the curled sheet of aerosol-generating material may comprise a plurality of substantially parallel peaks and valleys.

[0249] The plurality of parallel corrugations can be defined by a corrugation profile, wherein the corrugation profile is sinusoidal, triangular, rectangular, trapezoidal, annular, or parabolic. The plurality of parallel corrugations can be defined by a corrugation wavelength and a corrugation amplitude. The corrugation wavelength can be between 0.5 mm and 10 mm, such as between 1 mm and 10 mm, such as between 1.5 mm and 8 mm, such as between 2 mm and 6 mm, such as between 2.5 mm and 5 mm, such as between 3 mm and 4 mm. The corrugation amplitude can be approximately the same as the thickness of the cavity.

[0250] The plurality of parallel corrugations may define or form a plurality of channels between the sheet of aerosol-generating material and one or more walls of the cavity, the first cavity, and the second cavity. The plurality of channels may be a plurality of longitudinally extending channels. That is, the plurality of channels may extend in the longitudinal direction of the aerosol-generating article. The plurality of channels may be a plurality of laterally extending channels. That is, the plurality of channels may extend in the lateral direction of the aerosol-generating article. The plurality of channels may define or form at least a portion of an airflow pathway extending between an air inlet and an air outlet of the aerosol-generating article.

[0251] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density greater than or equal to 0.05 mg / mm3. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density greater than or equal to 0.1 mg / mm3. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density greater than or equal to 0.15 mg / mm3. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density greater than or equal to 0.2 mg / mm3. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density greater than or equal to 0.3 mg / mm3. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density greater than or equal to 0.4 mg / mm3.

[0252] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of less than or equal to 0.5 mg / mm3. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of less than or equal to 0.4 mg / mm3. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of less than or equal to 0.35 mg / mm3. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of less than or equal to 0.3 mg / mm3.

[0253] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density between 0.05 mg / mm3 and 0.5 mg / mm3. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density between 0.1 mg / mm3 and 0.4 mg / mm3. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density between 0.1 mg / mm3 and 0.3 mg / mm3. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density between 0.2 mg / mm3 and 0.3 mg / mm3.

[0254] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density greater than or equal to 0.3. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density greater than or equal to 0.4. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density greater than or equal to 0.5. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density greater than or equal to 0.6. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density greater than or equal to 0.7.

[0255] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density of less than or equal to 0.9. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density of less than or equal to 0.8. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density of less than or equal to 0.7. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density of less than or equal to 0.6. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density of less than or equal to 0.5.

[0256] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density between 0.3 and 0.9. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density between 0.4 and 0.9. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density between 0.5 and 0.9. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density between 0.5 and 0.8. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a packing density between 0.5 and 0.7.

[0257] Advantageously, providing an aerosol-generating substrate having a high packing density within the cavity can provide mechanical support to the first planar outer surface and the second planar outer surface. Providing additional mechanical support to the first planar outer surface and the second planar outer surface can improve the stiffness of the aerosol-generating article. However, excessively high packing density can restrict airflow through the aerosol-generating article and can provide the aerosol-generating article with unsatisfactory resistance to draw.

[0258] Advantageously, providing an aerosol-generating substrate having a packing density greater than or equal to 0.3 within the cavity may enhance heat conduction through the aerosol-generating substrate.Increased heat conduction through the aerosol-generating substrate may reduce the time required to generate an aerosol.

[0259] Advantageously, providing an aerosol-generating substrate positioned within the cavity and having a packing density of less than or equal to 0.9 g / cm3 can facilitate the formation of airflow channels within the aerosol-generating substrate during use of the aerosol-generating article. The provision of additional airflow channels within the aerosol-generating substrate can improve evaporation of the aerosol-generating substrate. The provision of additional airflow channels within the aerosol-generating substrate can also provide a satisfactory puff resistance.

[0260] Advantageously, providing an aerosol-generating substrate positioned within the cavity having a packing density less than or equal to 0.9 g / cm3 can reduce the likelihood of the aerosol-generating substrate becoming compacted. Compaction of the aerosol-generating substrate can increase the power required to heat the aerosol-generating substrate to a temperature sufficient to cause vaporization.

[0261] Thus, packing density may be a compromise between heat conduction through the aerosol-generating substrate, providing mechanical support to the first and second planar outer surfaces, promoting airflow channels within the aerosol-generating substrate, and providing a satisfactory resistance to draw for the aerosol-generating article.

[0262] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume greater than or equal to 150 cubic millimeters. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume greater than or equal to 200 cubic millimeters. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume greater than or equal to 250 cubic millimeters. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume greater than or equal to 350 cubic millimeters.

[0263] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may be less than or equal to 1000 cubic millimeters. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may be less than or equal to 900 cubic millimeters. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may be less than or equal to 800 cubic millimeters. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may be less than or equal to 700 cubic millimeters.

[0264] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume between 100 cubic millimeters and 1000 cubic millimeters. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume between 200 cubic millimeters and 1000 cubic millimeters. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume between 350 cubic millimeters and 650 cubic millimeters.

[0265] At least one of the one or more aerosol-generating substrates may have a density greater than or equal to 0.05 g / cm3. At least one of the one or more aerosol-generating substrates may have a density greater than or equal to 0.1 g / cm3. At least one of the one or more aerosol-generating substrates may have a density greater than or equal to 0.2 g / cm3. At least one of the one or more aerosol-generating substrates may have a density greater than or equal to 0.3 g / cm3. At least one of the one or more aerosol-generating substrates may have a density greater than or equal to 0.4 g / cm3.

[0266] At least one of the one or more aerosol-generating substrates may have a density of less than or equal to 0.9 g / cm3. At least one of the one or more aerosol-generating substrates may have a density of less than or equal to 0.8 g / cm3. At least one of the one or more aerosol-generating substrates may have a density of less than or equal to 0.7 g / cm3. At least one of the one or more aerosol-generating substrates may have a density of less than or equal to 0.6 g / cm3. At least one of the one or more aerosol-generating substrates may have a density of less than or equal to 0.5 g / cm3. At least one of the one or more aerosol-generating substrates may have a density of less than or equal to 0.4 g / cm3. At least one of the one or more aerosol-generating substrates may have a density of less than or equal to 0.3 g / cm3.

[0267] At least one of the one or more aerosol-generating substrates may have a density between 0.05 g / cm3 and 0.9 g / cm3. At least one of the one or more aerosol-generating substrates may have a density between 0.05 g / cm3 and 0.9 g / cm3. At least one of the one or more aerosol-generating substrates may have a density between 0.1 g / cm3 and 0.8 g / cm3. At least one of the one or more aerosol-generating substrates may have a density between 0.2 g / cm3 and 0.7 g / cm3. At least one of the one or more aerosol-generating substrates may have a density between 0.2 g / cm3 and 0.6 g / cm3. At least one of the one or more aerosol-generating substrates may have a density between 0.2 g / cm3 and 0.5 g / cm3. At least one aerosol-generating substrate of the one or more aerosol-generating substrates may have a density between 0.2 g / cm3 and 0.4 g / cm3.

[0268] At least one of the one or more aerosol-generating substrates mentioned above with respect to density may be an aerosol-generating substrate layer, a first aerosol-generating substrate layer, a second aerosol-generating substrate layer, an aerosol-generating substrate positioned within the cavity or the first cavity, or an aerosol-generating substrate positioned within the second cavity, or may be at least one of them. Preferably, at least one of the one or more aerosol-generating substrates mentioned above with respect to density may be an aerosol-generating substrate positioned within the cavity or the first cavity, or an aerosol-generating substrate positioned within the second cavity, or may be at least one of them.

[0269] The aerosol-generating substrate in an aerosol-generating article typically has a high density in order to facilitate heat conduction through the aerosol-generating substrate.

[0270] Advantageously, providing an aerosol-generating article with an aerosol-generating substrate having a relatively low density of less than or equal to 0.9 g / cm3 can allow the aerosol-generating article to comprise a reduced mass of the aerosol-generating article. The reduced mass of the aerosol-generating substrate can make the aerosol-generating article more convenient to handle and easier to manufacture.

[0271] Advantageously, providing a low density aerosol generating substrate in a cavity of an aerosol generating article comprising a first planar outer surface, a second planar outer surface and a frame positioned between the first planar outer surface and the second planar outer surface can allow for efficient heating of the aerosol generating substrate while still providing the advantages of a low density aerosol generating substrate as described above.

[0272] At least one of the one or more aerosol-generating substrates may have a mass greater than or equal to 50 mg. At least one of the one or more aerosol-generating substrates may have a mass greater than or equal to 80 mg. At least one of the one or more aerosol-generating substrates may have a mass greater than or equal to 110 mg. At least one of the one or more aerosol-generating substrates may have a mass greater than or equal to 150 mg. At least one of the one or more aerosol-generating substrates may have a mass greater than or equal to 170 mg. At least one of the one or more aerosol-generating substrates may have a mass greater than or equal to 180 mg. At least one of the one or more aerosol-generating substrates may have a mass greater than or equal to 200 mg. At least one of the one or more aerosol-generating substrates may have a mass greater than or equal to 230 mg. At least one of the one or more aerosol-generating substrates may have a mass greater than or equal to 250 mg. At least one of the one or more aerosol-generating substrates may have a mass greater than or equal to 300 mg.At least one of the one or more aerosol-generating substrates may have a mass greater than or equal to 400 mg.

[0273] At least one of the one or more aerosol-generating substrates may have a mass of less than or equal to 500 mg. At least one of the one or more aerosol-generating substrates may have a mass of less than or equal to 400 mg. At least one of the one or more aerosol-generating substrates may have a mass of less than or equal to 300 mg. At least one of the one or more aerosol-generating substrates may have a mass of less than or equal to 250 mg. At least one of the one or more aerosol-generating substrates may have a mass of less than or equal to 230 mg. At least one of the one or more aerosol-generating substrates may have a mass of less than or equal to 200 mg. At least one of the one or more aerosol-generating substrates may have a mass of less than or equal to 180 mg. At least one of the one or more aerosol-generating substrates may have a mass of less than or equal to 170 mg. At least one of the one or more aerosol-generating substrates may have a mass of less than or equal to 150 mg. At least one of the one or more aerosol-generating substrates may have a mass of less than or equal to 110 mg. At least one of the one or more aerosol-generating substrates may have a mass of less than or equal to 80 mg. At least one of the one or more aerosol-generating substrates may have a mass of less than or equal to 50 mg.

[0274] At least one of the one or more aerosol-generating substrates may have a mass between 50 mg and 500 mg. At least one of the one or more aerosol-generating substrates may have a mass between 80 mg and 500 mg. At least one of the one or more aerosol-generating substrates may have a mass between 80 mg and 400 mg. At least one of the one or more aerosol-generating substrates may have a mass between 80 mg and 300 mg. At least one of the one or more aerosol-generating substrates may have a mass between 80 mg and 250 mg. At least one of the one or more aerosol-generating substrates may have a mass between 80 mg and 200 mg. At least one of the one or more aerosol-generating substrates may have a mass between 80 mg and 150 mg.

[0275] At least one of the one or more aerosol-generating substrates mentioned above with respect to mass may be an aerosol-generating substrate layer, a first aerosol-generating substrate layer, a second aerosol-generating substrate layer, an aerosol-generating substrate positioned within the cavity or the first cavity, or an aerosol-generating substrate positioned within the second cavity, or may be at least one of them. Preferably, at least one of the one or more aerosol-generating substrates mentioned above with respect to mass may be an aerosol-generating substrate positioned within the cavity or the first cavity, or an aerosol-generating substrate positioned within the second cavity, or may be at least one of them.

[0276] Advantageously, providing an aerosol-generating article with less than or equal to 500 mg of an aerosol-generating substrate may reduce the amount of structural support that needs to be provided to the aerosol-generating article.

[0277] Advantageously, providing the aerosol-generating article with greater than or equal to 50 mg of an aerosol-generating substrate may allow the aerosol-generating substrate to provide some structural support to the aerosol-generating article.

[0278] Advantageously, providing an aerosol-generating article with a low-mass aerosol-generating substrate can result in better heating efficiency because the mass of the aerosol-generating substrate to be heated is relatively low. A relatively low-mass aerosol-generating substrate is particularly advantageous during a first puff with an aerosol-generating article because the first puff can be achieved much faster than with an aerosol-generating article having a high-mass aerosol-generating substrate.

[0279] Advantageously, providing an aerosol-generating article with a low mass aerosol-generating substrate may reduce the total water content of the aerosol-generating substrate.Reducing the total water content of the aerosol-generating substrate may reduce the temperature of the first puff.

[0280] The length of the aerosol-generating article may be defined in the x-direction between the distal end and the proximal end of the aerosol-generating article. The aerosol-generating article may be divided into a distal portion and a proximal portion along its length. The distal portion may extend from the distal end up to 50% of the length of the aerosol-generating article, and the proximal portion may extend from the proximal end up to 50% of the length of the aerosol-generating article.

[0281] The ratio of the mass of the one or more aerosol-generating substrates in the proximal portion to the mass of the one or more aerosol-generating substrates in the distal portion may be in the range between 0.77 and 1.30.

[0282] The ratio of the mass of one or more aerosol-generating substrates in the proximal portion to the mass of one or more aerosol-generating substrates in the distal portion may be in the range of between 0.80 and 1.25, or between 0.83 and 1.2, or between 0.87 and 1.15, or between 0.91 and 1.10 or between 0.95 and 1.05.

[0283] The mass distribution of the one or more aerosol-generating substrates in the proximal portion in the longitudinal direction of the proximal portion may be symmetrical with respect to the midpoint of the length of the aerosol-generating article and the mass distribution of the one or more aerosol-generating substrates in the distal portion in the longitudinal direction of the distal portion.

[0284] One or more aerosol generating substrates in the proximal portion can be arranged across the width of the proximal portion in a first half and a second half of the width of the proximal portion, wherein the ratio of the mass of the one or more aerosol generating substrates in the first half of the width of the proximal portion to the mass of the aerosol forming substrate in the second half of the width of the proximal portion can be in the range of between 0.77 and 1.30, or between 0.80 and 1.25, or between 0.83 and 1.2, or between 0.87 and 1.15, or between 0.91 and 1.10 or between 0.95 and 1.05.

[0285] The one or more aerosol-generating substrates in the distal portion may be arranged across the width of the distal portion in a first half and a second half of the width of the distal portion. The ratio of the mass of the one or more aerosol-generating substrates in the first half of the width of the distal portion to the mass of the one or more aerosol-generating substrates in the second half of the width of the distal portion may be in a range of between 0.77 and 1.30, or between 0.80 and 1.25, or between 0.83 and 1.2, or between 0.87 and 1.15, or between 0.91 and 1.10, or between 0.95 and 1.05.

[0286] The one or more aerosol-generating substrates in the proximal portion may be arranged in a first half and a second half of the height of the proximal portion across the height of the proximal portion. The ratio of the mass of the one or more aerosol-generating substrates in the first half of the height of the proximal portion to the mass of the one or more aerosol-generating substrates in the second half of the height of the proximal portion may be in a range of between 0.77 and 1.30, or between 0.80 and 1.25, or between 0.83 and 1.2, or between 0.87 and 1.15, or between 0.91 and 1.10, or between 0.95 and 1.05.

[0287] The one or more aerosol-generating substrates in the distal portion may be arranged in a first half and a second half of the height of the distal portion across the height of the distal portion. The ratio of the mass of the one or more aerosol-generating substrates in the first half of the height of the distal portion to the mass of the one or more aerosol-generating substrates in the second half of the height of the distal portion may be in a range of between 0.77 and 1.30, or between 0.80 and 1.25, or between 0.83 and 1.2, or between 0.87 and 1.15, or between 0.91 and 1.10, or between 0.95 and 1.05.

[0288] The structure of the proximal portion may be symmetrical to the structure of the distal portion relative to a midpoint of the length of the aerosol-generating article.

[0289] The aerosol-generating article may comprise an outer wrapper and an aerosol-generating substrate as described herein positioned within a cavity.

[0290] The aerosol-generating article may comprise an outer wrapper, a frame, and an aerosol-generating substrate as described herein positioned within a cavity.

[0291] The aerosol-generating article may comprise an outer wrapper and an aerosol-generating substrate layer.The cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the cavity.

[0292] The aerosol-generating article may comprise an outer wrapper, a frame and an aerosol-generating substrate layer.The cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the cavity.

[0293] The aerosol-generating article may comprise an outer wrapper, a first cavity, a second cavity, and an aerosol-generating substrate layer. The first cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the first cavity. The second cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the second cavity.

[0294] The aerosol-generating article may comprise an outer wrapper, a frame, a first cavity, a second cavity, and an aerosol-generating substrate layer. The first cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the first cavity. The second cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the second cavity.

[0295] The aerosol-generating article may comprise an outer wrapper, a first aerosol-generating substrate layer and a second aerosol-generating substrate layer.The cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the cavity.

[0296] The aerosol-generating article may comprise an outer wrapper, a frame, a first aerosol-generating substrate layer and a second aerosol-generating substrate layer.The cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the cavity.

[0297] The aerosol-generating article may comprise an outer wrapper, a first aerosol-generating substrate layer, a second aerosol-generating substrate layer, a first cavity, and a second cavity. The first cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the first cavity. The second cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the second cavity.

[0298] The aerosol-generating article may comprise an outer wrapper, a frame, a first aerosol-generating substrate layer, a second aerosol-generating substrate layer, a first cavity, and a second cavity. The first cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the first cavity. The second cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the second cavity.

[0299] The aerosol-generating article may comprise a first planar outer layer, a second planar outer layer and an aerosol-generating substrate layer.The cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the cavity.

[0300] The aerosol-generating article may comprise a first planar outer layer, a second planar outer layer, a frame and an aerosol-generating substrate layer.The cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the cavity.

[0301] The aerosol-generating article may comprise a first planar outer layer, a second planar outer layer, an aerosol-generating substrate layer, a first cavity, and a second cavity. The first cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the first cavity. The second cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the second cavity.

[0302] The aerosol-generating article may comprise a first planar outer layer, a second planar outer layer, a frame, an aerosol-generating substrate layer, a first cavity, and a second cavity. The first cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the first cavity. The second cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the second cavity.

[0303] The aerosol-generating article may comprise a first planar outer layer, a second planar outer layer, a first aerosol-generating substrate layer, and a second aerosol-generating substrate layer.The cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the cavity.

[0304] The aerosol-generating article may comprise a first planar outer layer, a second planar outer layer, a frame, a first aerosol-generating substrate layer, and a second aerosol-generating substrate layer.The cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the cavity.

[0305] The aerosol-generating article may comprise a first planar outer layer, a second planar outer layer, a first aerosol-generating substrate layer, a second aerosol-generating substrate layer, a first cavity, and a second cavity. The first cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the first cavity. The second cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the second cavity.

[0306] The aerosol-generating article may comprise a first planar outer layer, a second planar outer layer, a frame, a first aerosol-generating substrate layer, a second aerosol-generating substrate layer, a first cavity, and a second cavity. The first cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the first cavity. The second cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the second cavity.

[0307] The aerosol-generating material may comprise one or more organic materials such as tobacco, mint, tea and cloves. The aerosol-generating material may comprise one or more of: herb leaves, tobacco leaves, shredded tobacco ribs, reconstituted tobacco, homogenized tobacco such as cast leaf, extruded tobacco, expanded tobacco, aerosol-generating films and gel compositions.

[0308] The aerosol-generating material may be in the form of chopped aerosol-generating material. The chopped aerosol-generating material may include one or more of the following: strips and strands of aerosol-generating material, such as strips and strands of tobacco or homogenized tobacco material. The chopped aerosol-generating material may be in the form of a chopped sheet of homogenized tobacco material.

[0309] The aerosol-generating material can be shredded filler. The aerosol-generating material can be shredded tobacco filler. The shredded filler can include one or more of flue-cured tobacco, sun-cured tobacco, oriental tobacco, and filler tobacco. Examples of flue-cured tobacco include Brazilian flue-cured tobacco, Indian flue-cured tobacco, Chinese flue-cured tobacco, American flue-cured tobacco (such as Virginia tobacco), and flue-cured tobacco from Tanzania. Examples of oriental tobacco include Oriental Turkish, Greek Oriental, and semi-Oriental tobaccos, but also flame-cured American Burley, such as Perique and Rustica. Examples of sun-cured tobacco include dark-cured Brazilian Galpao, Malawi Burley or other African Burley, and sun-cured or air-cured Indonesian Kasturi. As used herein, the term "shredded filler" is used to describe a blend of chopped plant material (such as tobacco plant material), particularly including one or more of leaves, processed stems and ribs, and homogenized plant material.

[0310] The cut filler that is suitable for using together with the present invention can be similar to the cut filler that is used for conventional smoking article substantially.The cut width of cut filler is preferably between 0.3 millimeter and 2.0 millimeters, or between 0.5 millimeter and 1.2 millimeters, or between 0.6 millimeter and 0.9 millimeter.Preferably, stock has the length between about 10 millimeters and 40 millimeters.

[0311] Preferably, the shredded filler is impregnated with an aerosol-forming agent. Impregnation of the shredded filler can be accomplished by spraying or by other suitable application methods. Preferably, the aerosol-forming agent in the shredded filler comprises one or more of glycerol and propylene glycol. The aerosol-forming agent can be composed of glycerol, propylene glycol, or a combination of glycerol and propylene glycol.

[0312] The aerosol-forming material may comprise homogenised plant material, preferably homogenised tobacco material.

[0313] As used herein, the term "homogenized plant material" includes any plant material formed by the agglomeration of plant particles. For example, a homogenized tobacco material sheet or web for use in the aerosol-generating substrate of the present invention may be formed by agglomerating particles of tobacco material obtained by comminuting, grinding or crushing plant material and optionally one or more of tobacco leaves and tobacco stems. The homogenized plant material may be produced by casting, extrusion, papermaking, or any other suitable process known in the art.

[0314] The homogenised plant material may be in the form of one or more sheets.

[0315] The homogenized plant material may be in the form of a plurality of pellets or microparticles.

[0316] The homogenised plant material may be in the form of a plurality of strands, strips or chips.As used herein, the term "strand" describes an elongate element of material, the length of which is significantly greater than its width and thickness.

[0317] The aerosol-generating material may be in the form of a sheet of aerosol-generating material. As used herein, the term "sheet" describes a laminar element whose width and length are significantly greater than its thickness. The aerosol-generating material sheet may be a sheet of plant material. The aerosol-generating material sheet may be a sheet of tobacco material. The aerosol-generating material sheet may be a sheet of homogenized tobacco material, such as cast lamina.

[0318] The sheet of aerosol-generating material may have a grammage of between 100 g / m2 and 600 g / m2.The sheet of aerosol-generating material may have a grammage of between 100 g / m2 and 300 g / m2.

[0319] The sheet of aerosol-generating material may have a density greater than or equal to 0.3 g / cm3. The sheet of aerosol-generating material may have a density greater than or equal to 0.4 g / cm3. The sheet of aerosol-generating material may have a density greater than or equal to 0.5 g / cm3. The sheet of aerosol-generating material may have a density greater than or equal to 0.6 g / cm3. The sheet of aerosol-generating material may have a density greater than or equal to 0.7 g / cm3. The sheet of aerosol-generating material may have a density less than or equal to 0.8 g / cm3.

[0320] The sheet of aerosol-generating material may have a density of less than or equal to 1.0 g / cm3. The sheet of aerosol-generating material may have a density of less than or equal to 0.9 g / cm3. The sheet of aerosol-generating material may have a density of less than or equal to 0.8 g / cm3. The sheet of aerosol-generating material may have a density of less than or equal to 0.7 g / cm3. The sheet of aerosol-generating material may have a density of less than or equal to 0.6 g / cm3. The sheet of aerosol-generating material may have a density of less than or equal to 0.5 g / cm3. The sheet of aerosol-generating material may have a density of less than or equal to 0.4 g / cm3.

[0321] The sheet of aerosol-generating material may have a density between 0.3 g / cm3 and 1.3 g / cm3. The sheet of aerosol-generating material may have a density between 0.3 g / cm3 and 1.0 g / cm3. The sheet of aerosol-generating material may have a density between 0.4 g / cm3 and 1.0 g / cm3. The sheet of aerosol-generating material may have a density between 0.4 g / cm3 and 0.9 g / cm3. The sheet of aerosol-generating material may have a density between 0.5 g / cm3 and 0.9 g / cm3.

[0322] The sheet of aerosol-generating material may comprise between 2.5% and 95% by weight of plant particles on a dry basis. The sheet of aerosol-generating material may comprise between 5% and 90% by weight of plant particles on a dry basis. The sheet of aerosol-generating material may comprise between 10% and 80% by weight of plant particles on a dry basis. The sheet of aerosol-generating material may comprise between 15% and 70% by weight of plant particles on a dry basis. The sheet of aerosol-generating material may comprise between 20% and 60% by weight of plant particles on a dry basis. The sheet of aerosol-generating material may comprise between 30% and 50% by weight of plant particles on a dry basis.

[0323] The aerosol generating material sheet can be a homogenized tobacco material sheet comprising tobacco particles. The homogenized tobacco material sheet can have a tobacco content of at least about 40 % by weight on a dry basis. The homogenized tobacco material sheet can have a tobacco content of at least about 50 % by weight on a dry basis. The homogenized tobacco material sheet can have a tobacco content of at least about 70 % by weight on a dry basis. The homogenized tobacco material sheet can have a tobacco content of at least about 90 % by weight on a dry basis.

[0324] As used herein, the term "tobacco particles" can describe particles of any plant member of the Nicotiana genus. The term "tobacco particles" includes ground or pulverized tobacco leaves, ground or pulverized tobacco stems, tobacco dust, tobacco fines, and other granular tobacco by-products formed during the processing, handling, and transportation of tobacco. In a preferred embodiment, the tobacco particles are substantially all derived from tobacco leaves. By contrast, isolated nicotine and nicotine salts are compounds derived from tobacco, but are not considered to be tobacco particles for the purposes of this disclosure and are not included in the percentage of granular plant material.

[0325] Tobacco particles can be prepared by one or more tobacco plants. Any type of tobacco can be used in a blend. The example of spendable tobacco type includes but is not limited to sun-cured tobacco, flue-cured tobacco, burley tobacco, Maryland tobacco (Marylandtobacco), Oriental tobacco (Oriental tobacco), Virginia tobacco (Virginia tobacco) and other special tobaccos.

[0326] Flue-curing is a method of curing tobacco, particularly used with Virginia tobacco. During the curing process, heated air is circulated through densely packed tobacco. During the first stage, the tobacco leaves turn yellow and wilt. During the second stage, the leaves are completely dried. During the third stage, the leaf stems are completely dried.

[0327] Burley tobacco plays an important role in many tobacco blends. Burley tobacco has a distinctive flavor and aroma, and also has the ability to absorb large amounts of casing.

[0328] Oriental tobacco is a type of tobacco with small leaves and high aromatic qualities. However, the flavor of Oriental tobacco is milder than, for example, Burley tobacco. Therefore, a relatively small proportion of Oriental tobacco is typically used in tobacco blends.

[0329] Kasturi, Madura and Jatim are all subtypes of sun-cured tobacco that can be used. Preferably, Kasturi tobacco and flue-cured tobacco can be used in a blend to produce tobacco particles. Therefore, the tobacco particles in the granular plant material can include a blend of Kasturi tobacco and flue-cured tobacco.

[0330] The tobacco particles can have a nicotine content of at least about 2.5% by weight on a dry weight basis. More preferably, the tobacco particles can have a nicotine content of at least about 3% by weight on a dry weight basis, even more preferably at least about 3.2% by weight, even more preferably at least about 3.5% by weight, and most preferably at least about 4% by weight.

[0331] The aerosol-generating material may comprise one or more aerosol formers. Suitable aerosol formers are well known in the art and include, but are not limited to, one or more aerosol formers selected from the group consisting of polyols such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butylene glycol, and glycerol; esters of polyols such as mono-, di-, or triacetate of glycerol; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferred for the aerosol former to be one or both of glycerol and propylene glycol or to include one or both of glycerol and propylene glycol. The aerosol former may consist of glycerol or propylene glycol or a combination of glycerol and propylene glycol.

[0332] The aerosol-generating material may have an aerosol-forming agent content of greater than or equal to 1 wt%, 2 wt%, 5 wt%, 10 wt% or 15 wt% on a dry weight basis. The aerosol-generating material may have an aerosol-forming agent content of greater than or equal to 15 wt% on a dry weight basis, for example, greater than 20 wt% on a dry weight basis, or greater than 25 wt% on a dry weight basis, or greater than 30 wt% on a dry weight basis, or greater than 40 wt% on a dry weight basis, or greater than 50 wt% on a dry weight basis.

[0333] The aerosol-generating material may have an aerosol-former content of less than or equal to 30 wt% on a dry basis, less than or equal to 25 wt% on a dry basis, or less than or equal to 20 wt% on a dry basis. That is, the aerosol-generating material may have an aerosol-former content of less than or equal to 30 wt% on a dry basis, less than or equal to 25 wt% on a dry basis, or less than or equal to 20 wt% on a dry basis.

[0334] The aerosol-generating material may have an aerosol-former content of between 1 wt% and 30 wt% on a dry weight basis, between 1 wt% and 25 wt% on a dry weight basis, or between 1 wt% and 20 wt% on a dry weight basis.

[0335] The aerosol-generating material may have an aerosol-former content of between 5 wt% and 30 wt% on a dry weight basis, between 5 wt% and 25 wt% on a dry weight basis or between 5 wt% and 20 wt% on a dry weight basis.

[0336] The aerosol-generating material may have an aerosol-former content of between 10 wt% and 30 wt% on a dry basis, between 10 wt% and 25 wt% on a dry basis or between 10 wt% and 20 wt% on a dry basis.

[0337] The aerosol-generating material may have an aerosol-former content of between 15 wt% and 30 wt% on a dry basis, between 15 wt% and 25 wt% on a dry basis or between 15 wt% and 20 wt% on a dry basis.

[0338] The aerosol-generating material may have an aerosol-former content of at least 50 wt% on a dry weight basis, at least 60 wt% on a dry weight basis or at least 70 wt% on a dry weight basis.

[0339] The aerosol-generating material may comprise an aerosol-former content of less than or equal to 85 wt% on a dry basis, less than or equal to 80 wt% on a dry basis, or less than or equal to 75 wt% on a dry basis.

[0340] The aerosol-generating material may comprise an aerosol-former content of between 50 wt% and 85 wt% on a dry weight basis, between 50 wt% and 80 wt% on a dry weight basis, or between 50 wt% and 75 wt% on a dry weight basis.

[0341] The aerosol-generating material may comprise an aerosol-former content of between 60 wt% and 85 wt% on a dry weight basis, between 60 wt% and 80 wt% on a dry weight basis, or between 60 wt% and 75 wt% on a dry weight basis.

[0342] The aerosol-generating material may comprise an aerosol-former content of between 70 wt% and 85 wt% on a dry weight basis, between 70 wt% and 80 wt% on a dry weight basis, or between 70 wt% and 75 wt% on a dry weight basis.

[0343] The aerosol-forming material may comprise hydroxypropyl methylcellulose.

[0344] Advantageously, including hydroxypropyl methylcellulose in an aerosol-generating material can help improve the manufacturing process of the aerosol-generating material. For example, hydroxypropyl methylcellulose can reduce the overall viscosity of the slurry mixed when preparing the aerosol-generating material. Compared to conventional slurries, lower viscosity slurries can flow more easily and are easier to mix, transfer, and handle during the manufacturing process.

[0345] The aerosol-generating material may comprise a hydroxypropyl methylcellulose content of greater than or equal to 0.5% by weight. The aerosol-generating material may comprise a hydroxypropyl methylcellulose content of greater than or equal to 1% by weight. The aerosol-generating material may comprise a hydroxypropyl methylcellulose content of greater than or equal to 5% by weight. The aerosol-generating material may comprise a hydroxypropyl methylcellulose content of greater than or equal to 10% by weight. The aerosol-generating material may comprise a hydroxypropyl methylcellulose content of greater than or equal to 15% by weight. The aerosol-generating material may comprise a hydroxypropyl methylcellulose content of greater than or equal to 20% by weight.

[0346] The aerosol-generating material may comprise a hydroxypropyl methylcellulose content of less than or equal to 50% by weight. The aerosol-generating material may comprise a hydroxypropyl methylcellulose content of less than or equal to 45% by weight. The aerosol-generating material may comprise a hydroxypropyl methylcellulose content of less than or equal to 40% by weight. The aerosol-generating material may comprise a hydroxypropyl methylcellulose content of less than or equal to 35% by weight. The aerosol-generating material may comprise a hydroxypropyl methylcellulose content of less than or equal to 30% by weight. The aerosol-generating material may comprise a hydroxypropyl methylcellulose content of less than or equal to 25% by weight. The aerosol-generating material may comprise a hydroxypropyl methylcellulose content of less than or equal to 20% by weight.

[0347] The aerosol-generating material may comprise a hydroxypropylmethylcellulose content of between 0.5% and 50% by weight.

[0348] The aerosol-generating material may comprise one or more cellulose-based strengthening agents. Advantageously, the inclusion of a cellulose-based strengthening agent in the aerosol-generating material may increase the tensile strength of the aerosol-generating material. Aerosol-generating materials with higher tensile strength may be less likely to degrade or break (e.g., during transportation or during the manufacturing process).

[0349] The aerosol-generating material may have a cellulose-based strengthening agent content of greater than or equal to 0.5% by weight. The aerosol-generating material may have a cellulose-based strengthening agent content of greater than or equal to 1% by weight. The aerosol-generating material may have a cellulose-based strengthening agent content of greater than or equal to 0.5% by weight. The aerosol-generating material may have a cellulose-based strengthening agent content of greater than or equal to 5% by weight. The aerosol-generating material may have a cellulose-based strengthening agent content of greater than or equal to 10% by weight. The aerosol-generating material may have a cellulose-based strengthening agent content of greater than or equal to 15% by weight. The aerosol-generating material may have a cellulose-based strengthening agent content of greater than or equal to 20% by weight.

[0350] The aerosol-generating material may have a cellulose-based strengthening agent content of less than or equal to 50% by weight. The aerosol-generating material may have a cellulose-based strengthening agent content of less than or equal to 45% by weight. The aerosol-generating material may have a cellulose-based strengthening agent content of less than or equal to 40% by weight. The aerosol-generating material may have a cellulose-based strengthening agent content of less than or equal to 35% by weight. The aerosol-generating material may have a cellulose-based strengthening agent content of less than or equal to 30% by weight. The aerosol-generating material may have a cellulose-based strengthening agent content of less than or equal to 25% by weight.

[0351] The aerosol generating material may have a cellulose based strength agent content of between 0.5 wt% and 50 wt%.The aerosol generating material may have a cellulose based strength agent content of between 0.5 wt% and 40 wt%.

[0352] The one or more cellulose-based strengthening agents may comprise cellulose fibres. Advantageously, the present inventors have found that cellulose fibres may be a cellulose-based strengthening agent that is particularly effective in increasing the tensile strength of an aerosol-generating material.

[0353] The aerosol-generating material may have a cellulose fiber content of greater than or equal to 0.5% by weight. The aerosol-generating material may have a cellulose fiber content of greater than or equal to 1% by weight. The aerosol-generating material may have a cellulose fiber content of greater than or equal to 5% by weight. The aerosol-generating material may have a cellulose fiber content of greater than or equal to 10% by weight. The aerosol-generating material may have a cellulose fiber content of greater than or equal to 15% by weight. The aerosol-generating material may have a cellulose fiber content of greater than or equal to 20% by weight.

[0354] The aerosol-generating material may have a cellulose fiber content of less than or equal to 50% by weight. The aerosol-generating material may have a cellulose fiber content of less than or equal to 45% by weight. The aerosol-generating material may have a cellulose fiber content of less than or equal to 40% by weight. The aerosol-generating material may have a cellulose fiber content of less than or equal to 35% by weight. The aerosol-generating material may have a cellulose fiber content of less than or equal to 30% by weight. The aerosol-generating material may have a cellulose fiber content of less than or equal to 25% by weight.

[0355] The aerosol-generating material may have a cellulose fibre content of between 0.5 and 50 wt%.The aerosol-generating material may have a cellulose fibre content of between 0.5 and 40 wt%.

[0356] The one or more cellulose-based strengthening agents may comprise microcrystalline cellulose.Advantageously, the present inventors have found that microcrystalline cellulose may be a cellulose-based strengthening agent that is particularly effective in increasing the tensile strength of an aerosol-generating material.

[0357] The aerosol-generating material may have a microcrystalline cellulose content of greater than or equal to 0.5% by weight. The aerosol-generating material may have a microcrystalline cellulose content of greater than or equal to 1% by weight. The aerosol-generating material may have a microcrystalline cellulose content of greater than or equal to 5% by weight. The aerosol-generating material may have a microcrystalline cellulose content of greater than or equal to 10% by weight. The aerosol-generating material may have a microcrystalline cellulose content of greater than or equal to 15% by weight. The aerosol-generating material may have a microcrystalline cellulose content of greater than or equal to 20% by weight.

[0358] The aerosol-generating material may have a microcrystalline cellulose content of less than or equal to 50% by weight. The aerosol-generating material may have a microcrystalline cellulose content of less than or equal to 45% by weight. The aerosol-generating material may have a microcrystalline cellulose content of less than or equal to 40% by weight. The aerosol-generating material may have a microcrystalline cellulose content of less than or equal to 35% by weight. The aerosol-generating material may have a microcrystalline cellulose content of less than or equal to 30% by weight. The aerosol-generating material may have a microcrystalline cellulose content of less than or equal to 25% by weight.

[0359] The aerosol-generating material may have a microcrystalline cellulose content of between 0.5 and 50 wt%.The aerosol-generating material may have a microcrystalline cellulose content of between 0.5 and 40 wt%.

[0360] The one or more cellulose-based strengthening agents may comprise cellulose powder.Advantageously, the present inventors have found that cellulose powder may be a cellulose-based strengthening agent that is particularly effective in increasing the tensile strength of the aerosol-generating material.

[0361] The aerosol-generating material may have a cellulose powder content of greater than or equal to 0.5% by weight. The aerosol-generating material may have a cellulose powder content of greater than or equal to 1% by weight. The aerosol-generating material may have a cellulose powder content of greater than or equal to 0.5% by weight. The aerosol-generating material may have a cellulose powder content of greater than or equal to 5% by weight. The aerosol-generating material may have a cellulose powder content of greater than or equal to 10% by weight. The aerosol-generating material may have a cellulose powder content of greater than or equal to 15% by weight. The aerosol-generating material may have a cellulose powder content of greater than or equal to 20% by weight.

[0362] The aerosol-generating material may have a cellulose powder content of less than or equal to 50% by weight. The aerosol-generating material may have a cellulose powder content of less than or equal to 45% by weight. The aerosol-generating material may have a cellulose powder content of less than or equal to 40% by weight. The aerosol-generating material may have a cellulose powder content of less than or equal to 35% by weight. The aerosol-generating material may have a cellulose powder content of less than or equal to 30% by weight. The aerosol-generating material may have a cellulose powder content of less than or equal to 25% by weight.

[0363] The aerosol generating material may have a cellulose powder content of between 0.5 and 50 wt%.The aerosol generating material may have a cellulose powder content of between 0.5 and 40 wt%.

[0364] The aerosol-forming material may comprise carboxymethyl cellulose.

[0365] Advantageously, the present inventors have found that the use of carboxymethylcellulose can help reduce encrustation of aerosol-generating materials when used in aerosol-generating articles.

[0366] The carboxymethylcellulose may comprise sodium carboxymethylcellulose. Advantageously, the present inventors have found that sodium carboxymethylcellulose is a carboxymethylcellulose that may be particularly effective in preventing the above-mentioned crusting problem.

[0367] The aerosol-generating material may have a carboxymethyl cellulose content of greater than or equal to 0.5 wt%. The aerosol-generating material may have a carboxymethyl cellulose content of greater than or equal to 1 wt%. The aerosol-generating material may have a carboxymethyl cellulose content of greater than or equal to 5 wt%. The aerosol-generating material may have a carboxymethyl cellulose content of greater than or equal to 10 wt%.

[0368] The aerosol-generating material may have a carboxymethyl cellulose content of less than or equal to 20% by weight. The aerosol-generating material may have a carboxymethyl cellulose content of less than or equal to 15% by weight. The aerosol-generating material may have a carboxymethyl cellulose content of less than or equal to 10% by weight. The aerosol-generating material may have a carboxymethyl cellulose content of less than or equal to 8% by weight. The aerosol-generating material may have a carboxymethyl cellulose content of less than or equal to 5% by weight.

[0369] The aerosol-generating material may have a carboxymethylcellulose content of between 0.5% and 20% by weight.

[0370] The aerosol-generating material may comprise nicotine. The aerosol-generating material may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0371] The aerosol-generating material may comprise at least 0.5% by weight nicotine, at least 1% by weight nicotine, at least 1.5% by weight nicotine, or at least 2% by weight nicotine. That is, the aerosol-generating material may have a nicotine content of at least 0.5% by weight, at least 1% by weight, at least 1.5% by weight, or at least 2% by weight.

[0372] The aerosol-generating material may comprise one or more flavoring agents. The one or more flavoring agents may comprise one or more of the following: one or more essential oils, such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and herbal materials. Suitable herbal materials include herb leaves or other herbal materials from herbal plants, including but not limited to mint (such as peppermint and spearmint), lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavoring agents may comprise tobacco materials.

[0373] In the final product state, the aerosol-generating material may have a moisture content of about 5% to 25%, preferably about 7% to 15%. For example, the aerosol-generating material may be a homogenized tobacco material having a moisture content of about 5% to 25%, preferably about 7% to 15% in the final product state.

[0374] The aerosol-generating material may comprise cellulose fibers. For example, the aerosol-generating material may comprise about 1% to 15% cellulose fibers, preferably about 3% to 7% cellulose fibers. Preferably, the cellulose fibers may have a length of about 10 to 250 μm, preferably about 10 to 120 μm.

[0375] The aerosol-generating material may comprise organic fibers, such as non-tobacco fibers or tobacco fibers. For example, the aerosol-generating material may comprise approximately 5% to 20%, preferably approximately 7% to 15%, tobacco fibers. The tobacco fibers are preferably derived from stems and / or stalks, which are graded into fibers having a length of approximately 10 to 350 μm, preferably approximately 10 to 180 μm. The aerosol-generating material may comprise approximately 10% to 30%, preferably approximately 15% to 25%, of non-tobacco organic fibers. For example, the organic fibers may be derived from cellulose, cotton, wood, tea plant varieties that are by-products and by-process waste of the tea industry. The organic fibers preferably have a length of approximately 10 to 400 μm, preferably approximately 10 to 200 μm.

[0376] The aerosol-generating material may include a binder. For example, the aerosol-generating material may include about 1% to 10%, preferably about 1% to 5%, of a binder, such as any of the common gums or pectins used in the food and beverage (F&B) industry. Preferred binders may be natural pectins (such as fruit, e.g., citrus) or tobacco pectins; guar gum, locust bean gum, such as hydroxyethyl and / or hydroxypropyl derivatives of these; starches, such as modified or derivatized starches; alginates; methyl, ethyl, ethylhydroxymethyl, and carboxymethyl cellulose; dextran; and xanthan gum. A preferred binder is guar gum. The binder may be polyvinyl alcohol (PVOH).

[0377] The aerosol-generating material may comprise one or more plant materials. For example, the aerosol-generating material may comprise about 15% to 55%, preferably about 20% to 35%, of a plant material such as cloves, echinacea, cumin, ginger, hawthorn berries, elderberries, horse mint, mullein leaves, nettles, plantain, turmeric, yarrow, and compounds thereof.

[0378] The aerosol-generating material may comprise an organic plant extract. For example, the aerosol-generating material may comprise about 1% to 15%, preferably about 2% to 7%, of any of the previously mentioned plant materials, as well as menthol (dl-menthol, C10H20O, 2-isopropyl-5-methylcyclohexanol) obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium or other related plant species, and p-menthan-3-ol, which is any secondary alcohol such as a diastereomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.

[0379] The aerosol-generating material may comprise a plant essential oil, for example about 0.5% to 5%, preferably about 1% to 3% of a plant essential oil, for example plant essential oils such as palm oil, coconut oil and wood-based oil.

[0380] The aerosol-forming material may comprise particles of a functional material, such as particles of carbon, graphite, activated carbon or expanded graphite. Such materials may, for example, increase the thermal conductivity of the aerosol-forming material and improve the efficiency of aerosol generation.

[0381] The aerosol-generating material may be in the form of an aerosol-generating film comprising a cellulose-based film-forming agent, nicotine and an aerosol-forming agent. The aerosol-generating film may further comprise a cellulose-based strengthening agent. The aerosol-generating film may further comprise water, preferably 30% by weight or less of water.

[0382] As used herein, the term "film" is used to describe a solid laminar element whose thickness is less than its width or length. A film may be self-supporting.

[0383] In the context of the present disclosure, the term "cellulose-based film-forming agent" is used to describe a cellulose polymer capable of forming a continuous film, either alone or in the presence of an auxiliary thickener. Preferably, the cellulose-based film-forming agent is selected from hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethylmethylcellulose (HEMC), hydroxyethylcellulose (HEC), hydroxypropyl cellulose (HPC), and combinations thereof. In a particularly preferred embodiment, the cellulose-based film-forming agent is HPMC.

[0384] Suitable aerosol-generating membranes are described in WO-A-2020 / 207733 and WO-A-2022 / 074157.

[0385] Preferably, the aerosol-generating film comprises between 0.5 wt% and 10 wt% nicotine, or between 1 wt% and 8 wt% nicotine or between 2 wt% and 6 wt% nicotine on a dry weight basis.

[0386] The aerosol-generating film may be a substantially tobacco-free aerosol-generating film.

[0387] The aerosol-generating material may comprise a gel composition comprising nicotine, at least one gelling agent and an aerosol-former. The gel composition is preferably substantially free of tobacco.

[0388] The preferred weight ranges for nicotine in the gel composition are the same as those defined above for the aerosol-forming film.

[0389] Suitable gel compositions are described in WO-A-2021 / 170642.

[0390] The gel composition preferably comprises at least 50% by weight of an aerosol former, more preferably at least 60% by weight of an aerosol former, more preferably at least 70% by weight of an aerosol former, based on dry weight. The gel composition may comprise up to 80% by weight of an aerosol former. The aerosol former in the gel composition is preferably glycerol.

[0391] The air inlet may be defined by a front wall of the aerosol-generating article. The air inlet may be defined by the frame and may extend through the frame. The air inlet may be defined by a peripheral wall of the frame. The air inlet may extend through the peripheral wall of the frame. The air outlet may be defined by a rear wall of the aerosol-generating article. The air outlet may be defined by the frame and may extend through the frame. The air outlet may be defined by a peripheral wall of the frame. The outlet may extend through the peripheral wall of the frame.

[0392] The air inlet may have a circular cross-section, a circular cross-section, an oval cross-section, a square cross-section or a rectangular cross-section. The air outlet may have a circular cross-section, a circular cross-section, an oval cross-section, a square cross-section or a rectangular cross-section.

[0393] The air inlet may be defined by the first frame layer, the second frame layer, or the third frame layer, or may be defined as passing through the first frame layer, the second frame layer, or the third frame layer. The air inlet may be defined by the first frame layer and the second frame layer, or may be defined as passing through the first frame layer and the second frame layer. The air inlet may be defined by the second frame layer and the third frame layer, or may be defined as passing through the second frame layer and the third frame layer. The air inlet may be defined by the first frame layer, the second frame layer, and the third frame layer, or may be defined as passing through the first frame layer, the second frame layer, and the third frame layer.

[0394] The air outlet may be defined by the first frame layer, the second frame layer, or the third frame layer, or may be defined as passing through the first frame layer, the second frame layer, or the third frame layer. The air outlet may be defined by the first frame layer and the second frame layer, or may be defined as passing through the first frame layer and the second frame layer. The air outlet may be defined by the second frame layer and the third frame layer, or may be defined as passing through the second frame layer and the third frame layer. The air outlet may be defined by the first frame layer, the second frame layer, and the third frame layer, or may be defined as passing through the first frame layer, the second frame layer, and the third frame layer.

[0395] The air inlet may be defined by the first planar outer surface and may extend through the first planar outer surface. The air inlet may be defined by the outer wrapper and may extend through the outer wrapper. The air inlet may be defined by the outer wrapper and the aerosol-generating substrate layer and may extend through the outer wrapper and the aerosol-generating substrate layer. The air inlet may be defined by the outer wrapper and the first aerosol-generating substrate layer and may extend through the outer wrapper and the first aerosol-generating substrate layer. The air inlet may be defined by the first planar outer layer and the aerosol-generating substrate layer and may extend through the first planar outer layer and the aerosol-generating substrate layer. The air inlet may be defined by the first planar outer layer and the first aerosol-generating substrate layer and may extend through the first planar outer layer and the first aerosol-generating substrate layer.

[0396] The air inlet may be defined by the second planar outer surface and may extend through the second planar outer surface. The air inlet may be defined by the outer wrapper and the second aerosol-generating substrate layer and may extend through the outer wrapper and the second aerosol-generating substrate layer. The air inlet may be defined by the second planar outer layer and the aerosol-generating substrate layer and may extend through the second planar outer layer and the aerosol-generating substrate layer. The air inlet may be defined by the second planar outer layer and the second aerosol-generating substrate layer and may extend through the second planar outer layer and the second aerosol-generating substrate layer.

[0397] The air outlet may be defined by the first planar outer surface and may extend through the first planar outer surface. The air outlet may be defined by the outer wrapper and may extend through the outer wrapper. The air outlet may be defined by the outer wrapper and the aerosol-generating substrate layer and may extend through the outer wrapper and the aerosol-generating substrate layer. The air outlet may be defined by the outer wrapper and the first aerosol-generating substrate layer and may extend through the outer wrapper and the first aerosol-generating substrate layer. The air outlet may be defined by the first planar outer layer and the aerosol-generating substrate layer and may extend through the first planar outer layer and the aerosol-generating substrate layer. The air outlet may be defined by the first planar outer layer and the first aerosol-generating substrate layer and may extend through the first planar outer layer and the first aerosol-generating substrate layer.

[0398] The air outlet may be defined by the second planar outer surface and may extend through the second planar outer surface. The air outlet may be defined by the outer wrapper and the second aerosol-generating substrate layer and may extend through the outer wrapper and the second aerosol-generating substrate layer. The air outlet may be defined by the second planar outer layer and the aerosol-generating substrate layer and may extend through the second planar outer layer and the aerosol-generating substrate layer. The air outlet may be defined by the second planar outer layer and the second aerosol-generating substrate layer and may extend through the second planar outer layer and the second aerosol-generating substrate layer. The air inlet may have an equivalent diameter greater than or equal to 0.1 mm. The air inlet may have an equivalent diameter greater than or equal to 0.4 mm. The air inlet may have an equivalent diameter greater than or equal to 0.7 mm. The air inlet may have an equivalent diameter greater than or equal to 1.0 mm.

[0399] The air inlet may have an equivalent diameter of less than or equal to 3 mm. The air inlet may have an equivalent diameter of less than or equal to 2.7 mm. The air inlet may have an equivalent diameter of less than or equal to 2.4 mm. The air inlet may have an equivalent diameter of less than or equal to 2.1 mm. The air inlet may have an equivalent diameter of less than or equal to 1.8 mm. The air inlet may have an equivalent diameter of less than or equal to 1.5 mm.

[0400] The air inlet may have an equivalent diameter between 0.1 mm and 3 mm. The air inlet may have an equivalent diameter between 0.1 mm and 2.4 mm. The air inlet may have an equivalent diameter between 0.4 mm and 2.1 mm. The air inlet may have an equivalent diameter between 0.4 mm and 1.8 mm. The air inlet may have an equivalent diameter between 0.7 mm and 1.5 mm. The air inlet may have an equivalent diameter between 1.0 mm and 1.5 mm.

[0401] The air outlet may have an equivalent diameter greater than or equal to 0.1 mm. The air outlet may have an equivalent diameter greater than or equal to 0.4 mm. The air outlet may have an equivalent diameter greater than or equal to 0.7 mm. The air outlet may have an equivalent diameter greater than or equal to 1.0 mm.

[0402] The air outlet may have an equivalent diameter of less than or equal to 3 mm. The air outlet may have an equivalent diameter of less than or equal to 2.7 mm. The air outlet may have an equivalent diameter of less than or equal to 2.4 mm. The air outlet may have an equivalent diameter of less than or equal to 2.1 mm. The air outlet may have an equivalent diameter of less than or equal to 1.8 mm. The air outlet may have an equivalent diameter of less than or equal to 1.5 mm.

[0403] The air outlet may have an equivalent diameter between 0.1 mm and 3 mm. The air outlet may have an equivalent diameter between 0.1 mm and 2.4 mm. The air outlet may have an equivalent diameter between 0.4 mm and 2.1 mm. The air outlet may have an equivalent diameter between 0.4 mm and 1.8 mm. The air outlet may have an equivalent diameter between 0.7 mm and 1.5 mm. The air outlet may have an equivalent diameter between 1.0 mm and 1.5 mm.

[0404] The air inlet may have a width less than the width of the cavity. The air outlet may have a width less than the width of the cavity. The air inlet may have a thickness less than the thickness of the cavity. The air outlet may have a thickness less than the thickness of the cavity.

[0405] The air inlet may have a width of between 0.3 mm and 3 mm. The air inlet may have a width of between 0.5 mm and 2 mm.

[0406] The air inlet may have a thickness between 0.3 mm and 3 mm. The air outlet may have a thickness between 0.5 mm and 2 mm.

[0407] Preferably, the air inlet may have a width between 0.3 mm and 3 mm and a thickness between 0.3 mm and 3 mm.

[0408] The air outlet may have a width between 0.3 mm and 3 mm. The air outlet may have a width between 0.5 mm and 2 mm.

[0409] The air outlet may have a thickness between 0.3 mm and 3 mm. The air outlet may have a thickness between 0.5 mm and 2 mm.

[0410] Preferably, the air outlet may have a width between 0.3 mm and 3 mm and a thickness between 0.3 mm and 3 mm.

[0411] Advantageously, an aerosol-generating article having an air inlet or air outlet with a width between 0.3 mm and 3 mm and a thickness between 0.3 mm and 3 mm may provide good resistance to draw through the aerosol-generating article.

[0412] Advantageously, an aerosol-generating article having an air outlet or air inlet having a width between 0.3 mm and 3 mm and a thickness between 0.3 mm and 3 mm can provide a relatively large inlet or outlet opening while allowing for improved retention of the aerosol-generating substrate within the aerosol-generating article. Improving retention of the aerosol-generating substrate within the aerosol-generating article can reduce the risk of the aerosol-generating substrate falling out of the aerosol-generating article.

[0413] The ratio of the width of the air inlet to the thickness of the air inlet may be between 0.33 and 3. The ratio of the width of the air inlet to the thickness of the air inlet may be between 0.5 and 1.5. The ratio of the width of the air inlet to the thickness of the air inlet may be between 0.75 and 1.25.

[0414] The ratio of the width of the air outlet to the thickness of the air outlet may be between 0.33 and 3. The ratio of the width of the air outlet to the thickness of the air outlet may be between 0.5 and 1.5. The ratio of the width of the air outlet to the thickness of the air outlet may be between 0.75 and 1.25.

[0415] The aerosol-generating article may comprise one or more air inlets. The aerosol-generating article may comprise a plurality of air inlets. One or each of the air inlets may have one or more of the features of the air inlets described herein.

[0416] The aerosol-generating article may comprise one or more air outlets. The aerosol-generating article may comprise a plurality of air outlets. One or each of the air outlets may have one or more of the characteristics of the air outlets described herein.

[0417] The aerosol-generating article may comprise a filter element positioned downstream of the aerosol-forming substrate. The aerosol-generating article may comprise a filter element positioned downstream of the cavity. The aerosol-generating article may comprise a filter element positioned at least partially within the air outlet. The aerosol-generating article may comprise a filter element positioned within the cavity and may be positioned at a downstream end of the cavity.

[0418] The aerosol-generating article may comprise a filter element positioned upstream of the aerosol-forming substrate. The aerosol-generating article may comprise a filter element positioned upstream of the cavity. The aerosol-generating article may comprise a filter element positioned at least partially within the air inlet. The aerosol-generating article may comprise a filter element positioned within the cavity and may be positioned at an upstream end of the cavity.

[0419] The filter element may comprise one or more sections of fibrous filter material. Suitable fibrous filter materials will be known to the skilled person. The filter element may comprise cellulose acetate.

[0420] The aerosol-generating article may comprise a front wall. The front wall may extend from a first planar outer surface to a second planar outer surface. That is, the front wall extends in a transverse direction. The front wall may be, and may be referred to as, a downstream wall. The front wall may be defined by a frame, for example, by a peripheral wall of the frame.

[0421] The aerosol-generating article may comprise a rear wall. The rear wall may extend from a first planar outer surface to a second planar outer surface. That is, the rear wall extends in a transverse direction. The rear wall may be, and may be referred to as, an upstream wall. The rear wall may be defined by a frame, for example, by a peripheral wall of the frame.

[0422] The aerosol-generating article may comprise one or more side walls. The one or more side walls may comprise a first side wall and a second side wall, such as a left side wall and a right side wall. The first side wall and the second side wall may be opposite each other. The one or more side walls may extend from a front wall to a rear wall. The one or more side walls may extend from a first planar outer surface to a second planar outer surface. The one or more side walls, such as the first side wall and the second side wall, may be defined by a frame, for example, by a peripheral wall of the frame.

[0423] Any two or more of the front wall, the rear wall, the one or more side walls may be integral with each other. Advantageously, this structure may provide a robust article that is easy to manufacture.

[0424] The aerosol-generating article may comprise a first end face. The first end face may extend from a first planar outer surface to a second planar outer surface. The first end face may be defined or formed by an outer wall of the aerosol-generating article, such as a front wall or a rear wall.

[0425] The aerosol-generating article may include a second end surface. The second end surface may extend from the first planar outer surface to the second planar outer surface. The second end surface may be defined or formed by an outer wall or surface of the aerosol-generating article, such as a front wall or a rear wall. The second end surface may be positioned opposite the first end surface. The second end surface may be parallel to the first end surface.

[0426] The aerosol-generating article may comprise a first side. The first side may extend from a first planar outer surface to a second planar outer surface. The first side may be defined or formed by an outer wall of the aerosol-generating article, such as a first sidewall or a second sidewall. The first side may extend from a first end face to a second end face.

[0427] The aerosol-generating article may include a second side. The second side may extend from the first planar outer surface to the second planar outer surface. The second side may be defined or formed by an outer wall of the aerosol-generating article (such as the first sidewall or the second sidewall). The second side may extend from the first end face to the second end face. The second side may be positioned opposite the first side. The second side may be parallel to the first side.

[0428] The first end surface and the first side surface may form an internal angle equal to or less than 90 degrees. The first end surface and the second side surface may form an internal angle equal to or less than 90 degrees.

[0429] The aerosol-generating article may comprise a first external corner extending from the first planar external surface to the second planar external surface.The first external corner may connect the first end face of the aerosol-generating article and the first side face of the aerosol-generating article.

[0430] The first outer corner may be chamfered or rounded.

[0431] In embodiments where the first exterior corner is rounded, the first exterior corner can have a radius of curvature. The radius of curvature of the first exterior corner can be measured in the x / y plane. The radius of curvature of the first exterior corner can be between 1.25 mm and 6.5 mm.

[0432] The radius of curvature of the first exterior corner may be less than or equal to 50% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner may be less than or equal to 30% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner may be less than or equal to 20% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner may be less than or equal to 10% of the width of the aerosol-generating article.

[0433] The radius of curvature of the first exterior corner may be greater than or equal to 1% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner may be greater than or equal to 5% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner may be greater than or equal to 10% of the width of the aerosol-generating article.

[0434] The radius of curvature of the first exterior corner may be between 1% and 50% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner may be between 1% and 30% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner may be between 5% and 30% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner may be between 5% and 20% of the width of the aerosol-generating article.

[0435] In embodiments where the first exterior corner is chamfered, the first exterior corner can be chamfered at an angle between 30 and 60 degrees measured from the first end face. The first exterior corner can be chamfered at an angle between 40 and 50 degrees measured from the first end face. The first exterior corner can be chamfered at an angle of 45 degrees measured from the first end face.

[0436] The first exterior corner may include a first corner surface connecting the first end face to the second side face. The first end face may connect to the first corner surface at a first corner transition region, and a first corner interior angle formed between a tangent to the first end face at the first corner transition region and a tangent to the first corner surface at the first corner transition region in any x / y plane may be between 90 degrees and 180 degrees. The first corner interior angle may be between 120 degrees and 180 degrees. The first corner interior angle may be between 130 degrees and 180 degrees.

[0437] The aerosol-generating article may comprise a second external corner extending from the first planar external surface to the second planar external surface.The second external corner may connect the first end face of the aerosol-generating article and the second side face of the aerosol-generating article.

[0438] The second outer corner may be chamfered or rounded.

[0439] In embodiments where the second exterior corner is rounded, the second exterior corner can have a radius of curvature. The radius of curvature of the second exterior corner can be measured in the x / y plane. The radius of curvature of the second exterior corner can be between 1.25 mm and 6.5 mm.

[0440] The radius of curvature of the second outer corner may be less than or equal to 50% of the width of the aerosol-generating article. The radius of curvature of the second outer corner may be less than or equal to 30% of the width of the aerosol-generating article. The radius of curvature of the second outer corner may be less than or equal to 20% of the width of the aerosol-generating article. The radius of curvature of the second outer corner may be less than or equal to 10% of the width of the aerosol-generating article.

[0441] The radius of curvature of the second outer corner may be greater than or equal to 1% of the width of the aerosol-generating article. The radius of curvature of the second outer corner may be greater than or equal to 5% of the width of the aerosol-generating article. The radius of curvature of the second outer corner may be greater than or equal to 10% of the width of the aerosol-generating article.

[0442] The radius of curvature of the second outer corner may be between 1% and 50% of the width of the aerosol-generating article. The radius of curvature of the second outer corner may be between 1% and 30% of the width of the aerosol-generating article. The radius of curvature of the second outer corner may be between 5% and 30% of the width of the aerosol-generating article. The radius of curvature of the second outer corner may be between 5% and 20% of the width of the aerosol-generating article.

[0443] In embodiments where both the first exterior corner and the second exterior corner are rounded, the radius of curvature of the first exterior corner may be the same as the radius of curvature of the second exterior corner.

[0444] In embodiments where the second exterior corner is chamfered, the second exterior corner can be chamfered at an angle between 30 and 60 degrees measured from the first end face. The second exterior corner can be chamfered at an angle between 40 and 50 degrees measured from the first end face. The second exterior corner can be chamfered at an angle of 45 degrees measured from the first end face.

[0445] The second exterior corner may include a second corner surface connecting the first end surface to the second side surface. The first end surface may connect to the second corner surface at a second corner transition region, and a second corner interior angle formed between a tangent line to the first end surface at the second corner transition region and a tangent line to the second corner surface at the second corner transition region in any x / y plane may be between 90 degrees and 180 degrees. The second corner interior angle may be between 120 degrees and 180 degrees. The second corner interior angle may be between 130 degrees and 180 degrees.

[0446] The aerosol-generating article may comprise a third external corner extending from the first planar external surface to the second planar external surface.The third external corner may connect the second end face of the aerosol-generating article and the first side face of the aerosol-generating article.

[0447] The third outer corner may be chamfered or rounded.

[0448] In embodiments where the third exterior corner is rounded, the third exterior corner can have a radius of curvature. The radius of curvature of the third exterior corner can be measured in the x / y plane. The radius of curvature of the third exterior corner can be between 1.25 mm and 6.5 mm.

[0449] The radius of curvature of the third exterior corner may be less than or equal to 50% of the width of the aerosol-generating article. The radius of curvature of the third exterior corner may be less than or equal to 30% of the width of the aerosol-generating article. The radius of curvature of the third exterior corner may be less than or equal to 20% of the width of the aerosol-generating article. The radius of curvature of the third exterior corner may be less than or equal to 10% of the width of the aerosol-generating article.

[0450] The radius of curvature of the third exterior corner may be greater than or equal to 1% of the width of the aerosol-generating article. The radius of curvature of the third exterior corner may be greater than or equal to 5% of the width of the aerosol-generating article. The radius of curvature of the third exterior corner may be greater than or equal to 10% of the width of the aerosol-generating article.

[0451] The radius of curvature of the third exterior corner may be between 1% and 50% of the width of the aerosol-generating article. The radius of curvature of the third exterior corner may be between 1% and 30% of the width of the aerosol-generating article. The radius of curvature of the third exterior corner may be between 5% and 30% of the width of the aerosol-generating article. The radius of curvature of the third exterior corner may be between 5% and 20% of the width of the aerosol-generating article.

[0452] In embodiments where the third exterior corner is chamfered, the third exterior corner can be chamfered at an angle between 30 and 60 degrees measured from the second end face. The third exterior corner can be chamfered at an angle between 40 and 50 degrees measured from the third end face. The third exterior corner can be chamfered at an angle of 45 degrees measured from the third end face.

[0453] The aerosol-generating article may comprise a fourth external corner extending from the first planar external surface to the second planar external surface.The fourth external corner may connect the second end face of the aerosol-generating article and the second side face of the aerosol-generating article.

[0454] The fourth outer corner may be chamfered or rounded.

[0455] In embodiments where the fourth exterior corner is rounded, the fourth exterior corner can have a radius of curvature. The radius of curvature of the fourth exterior corner can be measured in the x / y plane. The radius of curvature of the fourth exterior corner can be between 1.25 mm and 6.5 mm.

[0456] The radius of curvature of the fourth exterior corner may be less than or equal to 50% of the width of the aerosol-generating article. The radius of curvature of the fourth exterior corner may be less than or equal to 30% of the width of the aerosol-generating article. The radius of curvature of the fourth exterior corner may be less than or equal to 20% of the width of the aerosol-generating article. The radius of curvature of the fourth exterior corner may be less than or equal to 10% of the width of the aerosol-generating article.

[0457] The radius of curvature of the fourth exterior corner may be greater than or equal to 1% of the width of the aerosol-generating article. The radius of curvature of the fourth exterior corner may be greater than or equal to 5% of the width of the aerosol-generating article. The radius of curvature of the fourth exterior corner may be greater than or equal to 10% of the width of the aerosol-generating article.

[0458] The radius of curvature of the fourth exterior corner may be between 1% and 50% of the width of the aerosol-generating article. The radius of curvature of the fourth exterior corner may be between 1% and 30% of the width of the aerosol-generating article. The radius of curvature of the fourth exterior corner may be between 5% and 30% of the width of the aerosol-generating article. The radius of curvature of the fourth exterior corner may be between 5% and 20% of the width of the aerosol-generating article.

[0459] In embodiments where the fourth exterior corner is chamfered, the fourth exterior corner can be chamfered at an angle between 30 and 60 degrees measured from the second end face. The fourth exterior corner can be chamfered at an angle between 40 and 50 degrees measured from the third end face. The fourth exterior corner can be chamfered at an angle of 45 degrees measured from the third end face.

[0460] Advantageously, providing an aerosol-generating article with at least one external corner extending from a first planar outer surface to a second planar outer surface that is rounded or chamfered may make the aerosol-generating article easier to insert into an aerosol-generating device.

[0461] Advantageously, providing an aerosol-generating article having at least one external corner extending from a first planar outer surface to a second planar outer surface that is rounded or chamfered may make the aerosol-generating article less susceptible to damage, particularly during insertion of the aerosol-generating article into an aerosol-generating device.

[0462] Advantageously, providing an aerosol-generating article having at least one external corner extending from a first planar outer surface to a second planar outer surface that is rounded or chamfered may make the aerosol-generating article easier to manufacture.

[0463] The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be greater than 2:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be greater than 3:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be greater than 4:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be greater than 5:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be greater than 10:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be greater than 12:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be greater than 15:1.

[0464] The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be less than 15:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be less than 12:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be less than 10:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be less than 5:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be less than 4:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be less than 3:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be less than 2.5:1.

[0465] The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be between 2:1 and 15:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be between 2:1 and 12:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be between 2:1 and 10:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be between 3:1 and 10:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be between 4:1 and 10:1. The ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article may be between 5:1 and 10:1.

[0466] The ratio between the length and width of the aerosol-generating article may be greater than 1:1. The ratio between the length and width of the aerosol-generating article may be greater than 1.25:1. The ratio between the length and width of the aerosol-generating article may be greater than 1.5:1. The ratio between the length and width of the aerosol-generating article may be greater than 2:1. The ratio between the length and width of the aerosol-generating article may be greater than 2.5:1. The ratio between the length and width of the aerosol-generating article may be greater than 3:1. The ratio between the length and width of the aerosol-generating article may be greater than 4:1. The ratio between the length and width of the aerosol-generating article may be greater than 5:1.

[0467] The ratio between the length and width of the aerosol-generating article may be less than 10:1. The ratio between the length and width of the aerosol-generating article may be less than 8:1. The ratio between the length and width of the aerosol-generating article may be less than 5:1. The ratio between the length and width of the aerosol-generating article may be less than 4:1. The ratio between the length and width of the aerosol-generating article may be less than 3.5:1. The ratio between the length and width of the aerosol-generating article may be less than 3:1. The ratio between the length and width of the aerosol-generating article may be less than 2.5:1. The ratio between the length and width of the aerosol-generating article may be less than 2:1.

[0468] The ratio between the length and width of the aerosol-generating article may be between 1:1 and 10:1. The ratio between the length and width of the aerosol-generating article may be between 1.5:1 and 5:1. The ratio between the length and width of the aerosol-generating article may be between 1.5:1 and 4:1. The ratio between the length and width of the aerosol-generating article may be between 1.5:1 and 3:1. The ratio between the length and width of the aerosol-generating article may be between 2:1 and 4:1. The ratio between the length and width of the aerosol-generating article may be between 2:1 and 3:1.

[0469] The aerosol-generating article may have a length greater than or equal to 15 mm. The aerosol-generating article may have a length greater than or equal to 20 mm. The aerosol-generating article may have a length greater than or equal to 25 mm. The aerosol-generating article may have a length greater than or equal to 30 mm. The aerosol-generating article may have a length greater than or equal to 35 mm. The aerosol-generating article may have a length greater than or equal to 40 mm.

[0470] The aerosol-generating article may have a length less than or equal to 45 mm. The aerosol-generating article may have a length less than or equal to 40 mm. The aerosol-generating article may have a length less than or equal to 35 mm. The aerosol-generating article may have a length less than or equal to 30 mm.

[0471] The aerosol-generating article may have a length between 15 mm and 45 mm. The aerosol-generating article may have a length between 20 mm and 40 mm. The aerosol-generating article may have a length between 20 mm and 35 mm. The aerosol-generating article may have a length between 25 mm and 30 mm.

[0472] The aerosol-generating article may have a width greater than or equal to 3 mm. The aerosol-generating article may have a width greater than or equal to 5 mm. The aerosol-generating article may have a width greater than or equal to 7.5 mm. The aerosol-generating article may have a width greater than or equal to 9 mm. The aerosol-generating article may have a width greater than or equal to 11 mm. The aerosol-generating article may have a width greater than or equal to 13 mm.

[0473] The aerosol-generating article may have a width of less than or equal to 17 mm. The aerosol-generating article may have a width of less than or equal to 15 mm. The aerosol-generating article may have a width of less than or equal to 12.5 mm. The aerosol-generating article may have a width of less than or equal to 11 mm. The aerosol-generating article may have a width of less than or equal to 9 mm.

[0474] The aerosol-generating article may have a width of between 3 mm and 17 mm. The aerosol-generating article may have a width of between 5 mm and 15 mm. The aerosol-generating article may have a width of between 7.5 mm and 12.5 mm. The aerosol-generating article may have a width of between 9 mm and 11 mm.

[0475] The aerosol-generating article may have a thickness of 1 mm or greater. The aerosol-generating article may have a thickness of 1.5 mm or greater. The aerosol-generating article may have a thickness of 2 mm or greater. The aerosol-generating article may have a thickness of 2.5 mm or greater. The aerosol-generating article may have a thickness of 3 mm or greater. The aerosol-generating article may have a thickness of 3.5 mm or greater. The aerosol-generating article may have a thickness of 4 mm or greater. The aerosol-generating article may have a thickness of 4.5 mm or greater.

[0476] The aerosol-generating article may have a thickness of less than or equal to 5.5 mm. The aerosol-generating article may have a thickness of less than or equal to 5 mm. The aerosol-generating article may have a thickness of less than or equal to 4.5 mm. The aerosol-generating article may have a thickness of less than or equal to 4 mm. The aerosol-generating article may have a thickness of less than or equal to 3.5 mm. The aerosol-generating article may have a thickness of less than or equal to 3 mm. The aerosol-generating article may have a thickness of less than 2.5 mm. The aerosol-generating article may have a thickness of less than 2 mm.

[0477] The aerosol-generating article may have a thickness between 1 mm and 5 mm. The aerosol-generating article may have a thickness between 1.5 mm and 5 mm. The aerosol-generating article may have a thickness between 2 mm and 4.5 mm. The aerosol-generating article may have a thickness between 2.5 mm and 4 mm. The aerosol-generating article may have a thickness between 3 mm and 3.5 mm.

[0478] The aerosol-generating article may have a length of between 15 and 45 mm, a width of between 5 and 15 mm and a thickness of between 1 and 5 mm.

[0479] Preferably, the aerosol-generating article may have a length of between 20 and 30 mm, a width of between 7.5 and 12.5 mm and a thickness of between 2.5 and 4 mm.

[0480] More preferably, the aerosol-generating article may have a length of 30 mm, a width of 10 mm and a thickness of 3.1 mm.

[0481] Advantageously, providing an aerosol-generating article having a length between 15 mm and 45 mm, a width between 5 mm and 15 mm, and a thickness between 1 mm and 5 mm can produce an aerosol-generating article having a high outer surface to volume ratio. Aerosol-generating articles having a high outer surface to volume ratio can be heated more efficiently, which can result in better evaporation of an aerosol-generating substrate stored within the aerosol-generating article. Better evaporation of an aerosol-generating substrate stored within the aerosol-generating article can result in an improved user experience.

[0482] Advantageously, providing an aerosol generating article having a length between 15 mm and 45 mm, a width between 5 mm and 15 mm and a thickness between 1 mm and 5 mm (wherein the cavity has a length between 14 mm and 40 mm, a width between 4.5 mm and 13 mm and a thickness between 0.5 mm and 4.5 mm) can produce an aerosol generating article that accommodates a large cavity and has a high cavity volume proportional to the external volume of the aerosol generating article.

[0483] The aerosol-generating article may have an external volume of between 75 cubic millimeters and 3375 cubic millimeters.The aerosol-generating article may have an external volume of between 375 cubic millimeters and 1750 cubic millimeters.

[0484] The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 20 mm H2O. The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 10 mm H2O. The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 8 mm H2O. The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 6 mm H2O. The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 4 mm H2O. The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 2 mm H2O. The aerosol-generating article may have a resistance to draw (RTD) equal to or approaching zero mm H2O.

[0485] The aerosol-generating article may have a resistance to draw (RTD) between 0 mm HO and 9.9 mm HO. The aerosol-generating article may have a resistance to draw (RTD) between 1 mm HO and 8 mm HO. The aerosol-generating article may have a resistance to draw (RTD) between 2 mm HO and 6 mm HO. The aerosol-generating article may have a resistance to draw (RTD) between 3 mm HO and 5 mm HO.

[0486] Unless otherwise stated, resistance to draw (RTD) is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through an aerosol-generating article between an air inlet and an air outlet. The terms "pressure drop" or "draw resistance" of a component or article may also refer to "resistance to draw." Such terms generally refer to measurements in accordance with ISO 6565-2015, which are typically conducted in a test at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr), and a relative humidity of about 60%, with a volumetric flow rate of about 17.5 ml / s at the output or downstream end of the measuring component.

[0487] According to the present disclosure, a method of making an aerosol-generating article as described herein is provided. The method comprises providing a first sheet of material, a second sheet of material, and a third sheet of material; forming an aperture through the first sheet of material to form a frame; positioning the aperture between the second sheet of material and the third sheet of material; and combining the first sheet of material, the second sheet of material, and the third sheet of material to form the aerosol-generating article.

[0488] According to the present disclosure, a method of manufacturing an aerosol-generating article as described herein is provided. The method comprises providing sheet materials, the sheet materials comprising: a first sheet of frame material, a first sheet of outer layer material, and a second sheet of outer layer material. The method comprises forming an aperture through the first sheet of frame material. The method comprises positioning the first sheet of frame material and the aperture between the first sheet of outer layer material and the second sheet of outer layer material. The method comprises bonding the sheet materials to each other.

[0489] According to the present disclosure, there is provided a method of manufacturing an aerosol-generating article as described herein. The method comprises providing sheet materials, the sheet materials comprising: a first sheet of frame material, a first sheet of aerosol-generating material, a second sheet of aerosol-generating material, a first sheet of outer layer material, and a second sheet of outer layer material. The method comprises forming an orifice through the first sheet of frame material. The method comprises positioning the first sheet of frame material and the orifice between the first sheet of aerosol-generating material and the second sheet of aerosol-generating material. The method comprises positioning the first sheet of frame material, the orifice, the first sheet of aerosol-generating material, and the second sheet of aerosol-generating material between the first sheet of outer layer material and the second sheet of outer layer material. The method comprises bonding the sheet materials to each other.

[0490] According to the present disclosure, there is provided a method of manufacturing an aerosol generating article as described herein. The method comprises providing sheet material, the sheet material comprising: a first sheet of frame material, a second sheet of frame material, a first sheet of outer layer material, and a second sheet of outer layer material. The method may comprise bonding the first sheet of frame material and the second sheet of frame material to one another. The method comprises (e.g., after the first sheet of frame material and the second sheet of frame material have been bonded) forming an orifice through the first sheet of frame material and the second sheet of frame material. The method comprises positioning the first sheet of frame material, the second sheet of frame material, and the orifice between the first sheet of outer layer material and the second sheet of outer layer material. The method comprises bonding the sheet materials to one another.

[0491] According to the present disclosure, there is provided a method of manufacturing an aerosol-generating article as described herein. The method comprises providing sheet material, the sheet material comprising: a first sheet of frame material, a second sheet of frame material, a first sheet of aerosol-generating material, a second sheet of aerosol-generating material, a first sheet of outer layer material, and a second sheet of outer layer material. The method may comprise bonding the first sheet of frame material and the second sheet of frame material to one another. The method comprises (e.g., after the first sheet of frame material and the second sheet of frame material have been bonded) forming an orifice through the first sheet of frame material and the second sheet of frame material. The method comprises positioning the first sheet of frame material, the second sheet of frame material, and the orifice between the first sheet of aerosol-generating material and the second sheet of aerosol-generating material. The method comprises positioning the first sheet of frame material, the second sheet of frame material, the orifice, the first sheet of aerosol-generating material, and the second sheet of aerosol-generating material between the first sheet of outer layer material and the second sheet of outer layer material. The method comprises bonding the sheet materials to one another.

[0492] According to the present disclosure, there is provided a method of manufacturing an aerosol generating article as described herein. The method comprises providing a sheet material, the sheet material comprising: a first frame material sheet, a second frame material sheet, a third frame material sheet, a first outer layer material sheet and a second outer layer material sheet. The method may comprise combining the first frame material sheet, the second frame material sheet and the third frame material sheet to one another. The method comprises (e.g. after the first frame material sheet, the second frame material sheet and the third frame material sheet have been combined) forming an orifice through the first frame material sheet, the second frame material sheet and the third frame material sheet. The method comprises positioning the first frame material sheet, the second frame material sheet, the third frame material sheet and the orifice between the first outer layer material sheet and the second outer layer material sheet. The method comprises combining the sheet materials to one another.

[0493] According to the present disclosure, there is provided a method of manufacturing an aerosol-generating article as described herein. The method comprises providing a sheet material, the sheet material comprising: a first sheet of frame material, a second sheet of frame material, a third sheet of frame material, a first sheet of aerosol-generating material, a second sheet of aerosol-generating material, a first sheet of outer layer material, and a second sheet of outer layer material. The method may comprise combining the first sheet of frame material, the second sheet of frame material, and the third sheet of frame material to one another. The method comprises (e.g., after the first sheet of frame material, the second sheet of frame material, and the third sheet of frame material have been combined) forming an orifice through the first sheet of frame material, the second sheet of frame material, and the third sheet of frame material. The method comprises positioning the first sheet of frame material, the second sheet of frame material, the third sheet of frame material, and the orifice between the first sheet of aerosol-generating material and the second sheet of aerosol-generating material. The method comprises positioning a first sheet of frame material, a second sheet of frame material, a second sheet of aerosol-generating material, an orifice, the first sheet of aerosol-generating material and the second sheet of aerosol-generating material between the first sheet of outer layer material and the second sheet of outer layer material. The method comprises bonding the sheet materials to each other.

[0494] Methods of making aerosol-generating articles described herein may comprise the step of positioning an aerosol-generating substrate within an orifice.

[0495] One or more of the first, second and third frame material sheets in the manufacturing methods described herein may be sheets of paper or cardboard.

[0496] One or more of the first and second sheets of aerosol-generating material in the manufacturing methods described herein may be sheets of homogenised tobacco material.

[0497] One or more of the first and second outer layer material sheets in the manufacturing methods described herein may be cigarette paper sheets.

[0498] According to the present disclosure, there is provided an aerosol generating device for receiving an aerosol generating article as disclosed herein. The aerosol generating device comprises a cavity sized to receive at least a portion of the aerosol generating article. The aerosol generating device comprises a heater or heating device, a power supply for supplying power to the heater or heating device, and a controller for controlling the supply of power to the heater or heating device. The aerosol generating device is configured to heat at least one aerosol generating substrate of one or more aerosol generating substrates to form an aerosol, such as an inhalable aerosol. The aerosol generating device may be configured to heat each of the one or more aerosol generating substrates to form an aerosol, such as an inhalable aerosol.

[0499] The cavity of the aerosol-generating device may comprise an opening into which an end (such as a longitudinal end) of the aerosol-generating article may be inserted. The cavity of the aerosol-generating device may have any suitable cross-sectional shape. For example, the cavity of the aerosol-generating device may have a rectangular cross-section, for example a rectangular cross-section having opposing top and bottom sides that are greater in length than left and right sides.

[0500] Preferably, at least one interior surface of the cavity of the aerosol-generating device is a heating surface configured to heat the aerosol-generating article. The heating surface may comprise a heater (e.g., a resistive heater or an infrared heater) or a susceptor configured to be heated by engagement with an inductor. The heating surface may comprise an inductor, for example, the surface may comprise a coil arranged to generate a fluctuating electromagnetic field within the space of the cavity of the aerosol-generating device. The heating surface may be a surface transparent to the fluctuating electromagnetic field, such that an inductor arranged outside the cavity can project the fluctuating electromagnetic field through the heating surface to engage with a susceptor arranged within the cavity of the aerosol-generating device.

[0501] Preferably, at least the lower surface of the cavity of the aerosol-generating device is a heating surface configured to heat the aerosol-generating article. Optionally, both the lower and upper surfaces of the cavity of the aerosol-generating device are heating surfaces configured to heat the aerosol-generating article.

[0502] Preferably, at least the lower inner surface of the cavity of the aerosol-generating device is a substantially planar surface, preferably wherein both the lower inner surface and the upper inner surface of the cavity of the aerosol-generating device are substantially planar. Preferably, the upper inner surface and the lower inner surface of the cavity of the aerosol-generating device are arranged in a parallel relationship to each other.

[0503] Optionally, the upper and lower inner surfaces may converge along the length of the cavity of the aerosol-generating device so that they are slightly closer together at the distal end of the cavity than at the proximal end of the cavity. This may allow the cavity of the aerosol-generating device to clamp an aerosol-generating article inserted therein. The side inner surfaces may converge in a similar manner to achieve the result of clamping the aerosol-generating article. The upper and lower inner surfaces of the cavity of the aerosol-generating device and / or the opposing side surfaces of the cavity of the aerosol-generating device may converge between the proximal end of the cavity and the distal end of the cavity by 1 to 10 degrees, for example, 2 to 8 degrees, for example, 3 to 6 degrees, for example, 4 to 5 degrees.

[0504] In some examples, the lower inner surface and the upper inner surface are movable relative to each other. For example, the lower inner surface and the upper inner surface may be configured to pivot relative to each other, or to move upward and downward relative to each other. This may allow the aerosol-generating article to be easily inserted into the cavity of the aerosol-generating device while allowing the cavity walls of the aerosol-generating device to move to hold the substrate or article in position to be heated. For example, relative movement of the upper inner surface and the lower inner surface may cause the aerosol-generating article to be clamped between the two surfaces to facilitate heating of the article and help properly position the article within the device.

[0505] The cavity of the aerosol generating device may be defined by a longitudinal dimension or length, a transverse dimension or width, and a depth dimension or height.The length and width are preferably greater in magnitude than the height, for example at least twice the magnitude of the height.

[0506] The aerosol generating device may comprise a heating surface comprising a plurality of individually operable heating zones, for example two individually operable heating zones, or three individually operable heating zones, or four individually operable heating zones, or five individually operable heating zones, or six individually operable heating zones. The plurality of individually operable heating zones may be configured to be operated individually, or to operate simultaneously in any combination of two or more zones. In some instances, the plurality of individually operable heating zones may be spaced longitudinally within the cavity. In some instances, the plurality of individually operable heating zones may be spaced laterally within the cavity. Different heating zones may be spaced laterally and longitudinally from each other. Different heating zones may be arranged concentrically relative to each other.

[0507] The aerosol generating device may comprise one or more resistive heaters, for example one or more resistive heaters integrated into the wall of the chamber.

[0508] The device may comprise one or more susceptors, for example one or more susceptors integrated into a wall of a cavity of the aerosol-generating device or arranged to generate a fluctuating electromagnetic field in or within a wall of the cavity of the aerosol-generating device. The one or more walls of the cavity of the aerosol-generating device comprise or consist of a susceptor material such that the one or more walls of the cavity heat up when engaged with the fluctuating electromagnetic field, thereby heating an aerosol-generating article inserted into the cavity.

[0509] The aerosol-generating device may comprise one or more insertable heating elements arranged to protrude into a cavity of the aerosol-generating device for insertion into an aerosol-generating article. The insertable heating element may be a resistive heater. The insertable heating element may be a susceptor.

[0510] The aerosol-generating device may include a device body. The device body may include a heater. The aerosol-generating device may include a mouthpiece element. The device body may include a device body housing. The device body housing may define a cavity for receiving at least a portion of the aerosol-generating article. The device body and the mouthpiece element may be releasably connected. The mouthpiece element may be releasably connected to the device body (e.g., the device body housing).

[0511] The mouthpiece element may be releasably connectable to the device body (e.g. the device body housing) between a connected position and a disconnected position. In the connected position, the cavity of the aerosol generating device may, for example, be at least partially covered by the mouthpiece element. In the disconnected position, the cavity of the aerosol generating device may be at least partially exposed, for example to allow an article to be inserted into the cavity of the aerosol generating device. The mouthpiece element may, for example, be movable about a hinge relative to the device body between a first position and a second position, for example, be pivotable. In the first position, the cavity of the aerosol generating device may, for example, be at least partially covered by the mouthpiece element. In the second position, the cavity may be at least partially exposed, for example to allow an article to be inserted into the cavity of the aerosol generating device. Advantageously, covering the cavity of the aerosol generating device or the article in the cavity of the aerosol generating device may ensure that most of the aerosol from the article travels along a desired flow path to the user, rather than escaping to the external environment.

[0512] The aerosol generating device (e.g., the device body) may include a power source such as a battery. In use, the power source may provide power to the heater. The device (e.g., the device body) may include a controller. The controller may be configured to control the power from the power source to the heater.

[0513] The device body may comprise a distal end and a proximal end. The cavity of the aerosol generating device may be defined at the proximal end of the device body. The mouthpiece element may comprise a distal end and a proximal end. The distal end of the mouthpiece element may be configured to releasably connect to the proximal end of the device body.

[0514] The mouthpiece element or at least a portion of the mouthpiece element may be configured to be inserted into the mouth of a user.The proximal end of the mouthpiece element may be configured to be inserted into the mouth of a user.

[0515] The aerosol generating device (e.g. one or both of the device body and the mouthpiece element) may comprise an air inlet. The device (e.g. the mouthpiece element) may comprise an air outlet. The device may comprise an air flow path fluidly connecting the air inlet to the air outlet. The air flow path may extend through and / or pass through the cavity of the aerosol generating device. Thus, in use, the device may be configured such that when negative pressure is applied to the air outlet, for example by a user drawing on the air outlet, air is drawn in through the air inlet, then passes through or through the aerosol generating article received in the cavity, thereby entraining aerosol released from the aerosol-forming substrate of the article, and then exiting through the air outlet.

[0516] According to the present disclosure, an aerosol-generating system comprises an aerosol-generating device as disclosed herein and an aerosol-generating article as disclosed herein. The system may comprise a plurality of such articles for use with the aerosol-generating device.

[0517] As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-generating substrate. The article may be heated in use to generate an inhalable aerosol and deliver it to a consumer.

[0518] As used herein, the term "aerosol-generating substrate" refers to a substrate that is capable of releasing volatile compounds upon heating, such as compounds that cool and condense to generate an aerosol during use.

[0519] As used herein, the term "aerosol-generating device" refers to a device that, in use, interacts with (eg, heats) an aerosol-generating substrate of an aerosol-generating article to generate an aerosol.

[0520] As used herein, the term "planar" refers to a feature that is generally formed in a single Euclidean plane and does not wrap around or otherwise conform to fit a curved or other non-planar shape. A planar surface can extend in two dimensions in a single Euclidean plane. A planar object can extend significantly further in two dimensions in a single Euclidean plane than in a third dimension perpendicular to the plane. More specifically, a planar object can extend at least two, five, or ten times further in a first dimension and a second dimension perpendicular to the first dimension than in a third dimension perpendicular to the first and second dimensions.

[0521] As used herein, the term "lateral" refers to a direction extending between a first planar outer surface and a second planar outer surface.

[0522] As used herein, the term "longitudinal" refers to a direction perpendicular to the transverse direction, for example, the direction between the front and back walls of an aerosol-generating article.

[0523] As used herein, the term "lateral" refers to a direction perpendicular to the transverse direction and the longitudinal direction, for example, the direction from a first sidewall to a second sidewall of an aerosol-generating article.

[0524] As used herein, the term "thickness" refers to the largest dimension of an aerosol-generating article or a component of an aerosol-generating article in the transverse direction.

[0525] As used herein, the term "length" refers to the largest dimension of an aerosol-generating article or a component of an aerosol-generating article in the longitudinal direction.

[0526] As used herein, the term "width" refers to the largest dimension of an aerosol-generating article or a component of an aerosol-generating article in the lateral direction.

[0527] As used herein, the terms "upstream" and "downstream" refer to the relative position of a component or portion of a component of an aerosol-generating article with respect to the direction in which air or aerosol is transported through the aerosol-generating article during use.

[0528] As used herein, the term "bulk density" may refer to the total weight of the aerosol-generating substrate divided by the total volume of the aerosol-generating substrate.

[0529] As used herein, the term "aerosol former" may refer to any suitable known compound or mixture of compounds that promotes the formation of an aerosol in use. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-generating substrate or aerosol-generating article.

[0530] As used herein, unless otherwise specified, the term "aerosol former content" may refer to the aerosol former content in percentage on a dry weight basis.

[0531] As used herein, a "susceptor" refers to a conductive element that heats up when subjected to a changing magnetic field. This may be the result of eddy currents and / or hysteresis losses induced in the susceptor element.

[0532] As used herein, the term "hydrophobicity" refers to a surface exhibiting water-repellent properties. A useful way to determine this is to measure the water contact angle. The "water contact angle" is the angle, conventionally measured, across a liquid when a liquid / vapor interface encounters a solid surface. It quantifies the wettability of a solid surface by a liquid via Young's equation.

[0533] As used herein, the term "equivalent diameter" of an opening or orifice is used herein to refer to the diameter of a circular opening or orifice having the same cross-sectional area as the opening or orifice.

[0534] As used herein, the term "packing density" refers to the ratio of the total volume of components (such as solid and liquid components) of the aerosol-generating substrate positioned within a cavity, first cavity or second cavity, to the volume of the cavity in which the aerosol-generating substrate is positioned.

[0535] The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment or aspect described herein.

[0536] Ex1. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising:

[0537] a first planar outer surface;

[0538] a second planar outer surface;

[0539] cavity;

[0540] a frame at least partially defining the cavity; and

[0541] One or more aerosol-generating substrates.

[0542] Ex2. An aerosol-generating article according to Ex1, wherein the thickness of the aerosol-generating article is less than 50% of both the length and the width of the aerosol-generating article.

[0543] Ex2. An aerosol-generating article according to Ex1 or Ex2, wherein the frame comprises a peripheral wall defining or surrounding the cavity.

[0544] Ex3. An aerosol-generating article according to Ex2, wherein the peripheral wall is formed by a frame inner surface and a frame outer surface, and wherein the frame inner surface defines an outer wall of the cavity, and the frame outer surface at least partially defines one or more outer walls of the aerosol-generating article.

[0545] Ex4. An aerosol-generating article according to Ex2 or Ex3, wherein the peripheral wall has a radial thickness of between 1 mm and 3 mm.

[0546] Ex5. An aerosol-generating article according to any one of Ex1 to Ex4, wherein the frame has a thickness greater than or equal to 80% of the thickness of the aerosol-generating article.

[0547] Ex6. An aerosol-generating article according to any one of Ex1 to Ex5, wherein the frame has a thickness between 80% and 95% of the thickness of the aerosol-generating article.

[0548] Ex7. An aerosol-generating article according to any one of Ex1 to Ex6, wherein the frame has a thickness between 1 mm and 5.5 mm.

[0549] Ex8. An aerosol-generating article according to any one of Ex1 to Ex7, wherein the frame comprises a cellulosic material.

[0550] Ex9. An aerosol-generating article according to Ex8, wherein the cellulosic material has a grammage between 300 g / m2 and 900 g / m2.

[0551] Ex 10. An aerosol-generating article according to Ex 8 or Ex 9, wherein the cellulosic material is paper, paperboard or cardboard.

[0552] Ex11. An aerosol-generating article according to any one of Ex1 to Ex10, wherein the frame is a unitary component.

[0553] Ex12. An aerosol-generating article according to any one of Ex1 to Ex10, wherein the frame comprises a first frame layer and a second frame layer.

[0554] Ex 13. An aerosol-generating article according to Ex 12, wherein the first frame layer is bonded to the second frame layer with an adhesive.

[0555] Ex 14. An aerosol-generating article according to Ex 12 or Ex 13, wherein the frame comprises a third frame layer.

[0556] Ex15. An aerosol-generating article according to Ex14, wherein the second frame layer is positioned between the first frame layer and the third frame layer.

[0557] Ex 16. An aerosol-generating article according to Ex 14 or Ex 15, wherein the second frame layer is bonded to the third frame layer with an adhesive.

[0558] Ex17. An aerosol-generating article according to any one of Ex1 to Ex16, wherein the one or more aerosol-generating substrates include a first aerosol-generating substrate layer positioned between the first planar outer surface and the frame, and a second aerosol-generating substrate layer positioned between the second planar outer surface and the frame.

[0559] Ex18. An aerosol-generating article according to Ex17, wherein one or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer comprises an aerosol-generating material in the form of a sheet of aerosol-generating material.

[0560] Ex19. An aerosol-generating article according to Ex18, wherein the sheet of aerosol-generating material is a sheet of homogenised tobacco material.

[0561] Ex20. An aerosol-generating article according to Ex18 or Ex19, wherein the sheet of aerosol-generating material comprises one or more aerosol-forming agents, such as one or both of glycerol and propylene glycol.

[0562] Ex21. An aerosol-generating article according to any one of Ex18 to Ex20, wherein the first aerosol-generating substrate layer and the second aerosol-generating substrate layer define opposite end walls of the cavity.

[0563] Ex22. An aerosol-generating article according to any one of Ex18 to Ex21, wherein one or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer have a thickness between 100 micrometers and 600 micrometers.

[0564] Ex23. An aerosol-generating article according to any one of Ex18 to Ex22, wherein one or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer have a length substantially the same as the length of the aerosol-generating article.

[0565] Ex24. An aerosol-generating article according to any one of Ex18 to Ex23, wherein one or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer have a width that is substantially the same as the width of the aerosol-generating article.

[0566] Ex25. An aerosol-generating article according to any one of Ex1 to Ex24, comprising an outer wrapper defining the first planar outer surface and the second planar outer surface.

[0567] Ex26. An aerosol-generating article according to any one of Ex1 to Ex24, comprising a first planar outer layer and a second planar outer layer, wherein the first planar outer layer defines the first planar outer surface, and the second planar outer layer defines the second planar outer surface.

[0568] Ex27. An aerosol-generating article according to Ex26, wherein the first planar outer layer and the second planar outer layer overlie opposite ends of the cavity.

[0569] Ex28. An aerosol-generating article according to Ex26 or Ex27, wherein one or both of the first planar outer layer and the second planar outer layer comprises a cellulosic material.

[0570] Ex29. An aerosol-generating article according to Ex28, wherein the cellulosic material is paper or cardboard.

[0571] Ex30. An aerosol-generating article according to any one of Ex26 to Ex29, wherein one or both of the first planar outer layer and the second planar outer layer have a length substantially the same as the length of the aerosol-generating article.

[0572] Ex31. An aerosol-generating article according to any one of Ex26 to Ex30, wherein one or both of the first planar outer layer and the second planar outer layer have a width that is substantially the same as the width of the aerosol-generating article.

[0573] Ex32. An aerosol-generating article according to any one of Ex1 to Ex31, wherein the cavity has a length between 30% and 95% of the length of the aerosol-generating article.

[0574] Ex33. An aerosol-generating article according to any one of Ex1 to Ex32, wherein the cavity has a width between 30% and 95% of the width of the aerosol-generating article.

[0575] Ex34. An aerosol-generating article according to any one of Ex1 to Ex33, wherein the cavity has a thickness between 30% and 95% of the thickness of the aerosol-generating article.

[0576] Ex35. An aerosol-generating article according to any one of Ex1 to Ex34, wherein the cavity has a length between 14 mm and 40 mm, a width between 4.5 mm and 13 mm, and a thickness between 0.5 mm and 4.5 mm.

[0577] Ex36. An aerosol-generating article according to any one of Ex1 to Ex35, wherein the cavity has a length between 20 mm and 30 mm, a width between 7 mm and 10 mm, and a thickness between 2.5 mm and 4 mm.

[0578] Ex37. An aerosol-generating article according to any one of Ex1 to Ex36, wherein the cavity is substantially empty.

[0579] Ex38. An aerosol-generating article according to any one of Ex1 to Ex36, wherein the one or more aerosol-generating substrates comprises an aerosol-generating substrate positioned within the cavity.

[0580] Ex39. An aerosol-generating article according to Ex38, wherein the aerosol-generating substrate positioned within the cavity comprises an aerosol-generating material.

[0581] Ex40. An aerosol-generating article according to Ex39, wherein the aerosol-generating material is in the form of chopped aerosol-generating material.

[0582] Ex41. An aerosol-generating article according to Ex40, wherein the shredded aerosol-generating material comprises one or more of: strips and strands of aerosol-generating material, such as strips and strands of tobacco or homogenised tobacco material.

[0583] Ex42. An aerosol-generating article according to any one of Ex39 to Ex41, wherein the aerosol-generating material is tobacco cut filler.

[0584] Ex43. An aerosol-generating article according to Ex39, wherein the aerosol-generating material is in the form of a corrugated sheet of aerosol-generating material.

[0585] Ex44. An aerosol-generating article according to Ex43, wherein the corrugated sheet of aerosol-generating material comprises a plurality of parallel corrugations defining a plurality of channels between the sheet of aerosol-generating material and one or more walls of the cavity.

[0586] Ex45. An aerosol-generating article according to Ex44, wherein the plurality of channels is a plurality of longitudinally extending channels.

[0587] Ex46. An aerosol-generating article according to any one of Ex39 to Ex45, wherein the aerosol-generating material comprises one or more aerosol formers, such as one or both of glycerol and propylene glycol.

[0588] Ex47. An aerosol-generating article according to any one of Ex38 to Ex46, wherein the aerosol-generating substrate positioned within the cavity has a bulk density less than or equal to 0.5 mg / mm3.

[0589] Ex48. An aerosol-generating article according to any one of Ex38 to Ex47, wherein the aerosol-generating substrate positioned within the cavity has a packing density greater than or equal to 0.3.

[0590] Ex49. An aerosol-generating article according to any one of Ex38 to Ex48, wherein the aerosol-generating substrate positioned within the cavity has a packing density less than or equal to 0.9.

[0591] Ex50. An aerosol-generating article according to any one of Ex38 to Ex49, wherein the aerosol-generating substrate positioned within the cavity has a density less than or equal to 0.9 g / cm3.

[0592] Ex51. An aerosol-generating article according to any one of Ex38 to Ex50, wherein the aerosol-generating substrate positioned within the cavity has a mass less than or equal to 500 mg.

[0593] Ex52. An aerosol-generating article according to any one of Ex1 to Ex51, comprising an air inlet.

[0594] Ex53. An aerosol-generating article according to Ex52, wherein the air inlet is defined by the frame.

[0595] Ex54. An aerosol-generating article according to Ex52 or Ex53, wherein the air inlet has an equivalent diameter between 0.1 mm and 3 mm.

[0596] Ex55. An aerosol-generating article according to any one of Ex52 to Ex54, wherein the air inlet has a width between 0.3 mm and 3 mm.

[0597] Ex56. An aerosol-generating article according to any one of Ex52 to Ex55, wherein the air inlet has a thickness between 0.3 mm and 3 mm.

[0598] Ex57. An aerosol-generating article according to any one of Ex1 to Ex56, comprising an air outlet.

[0599] Ex58. An aerosol-generating article according to Ex57, wherein the air outlet is defined by the frame.

[0600] Ex59. An aerosol-generating article according to Ex57 or Ex58, wherein the air outlet has an equivalent diameter between 0.1 mm and 3 mm.

[0601] Ex60. An aerosol-generating article according to any one of Ex57 to Ex59, wherein the air outlet has a width between 0.3 mm and 3 mm.

[0602] Ex61. An aerosol-generating article according to any one of Ex57 to Ex60, wherein the air outlet has a thickness between 0.3 mm and 3 mm.

[0603] Ex62. An aerosol-generating article according to any one of Ex1 to Ex61, wherein the ratio between the length and thickness of the aerosol-generating article and the ratio between the width and thickness of the aerosol-generating article are between 2:1 and 15:1.

[0604] Ex63. An aerosol-generating article according to any one of Ex1 to Ex62, wherein the ratio between the length and the width of the aerosol-generating article is between 1:1 and 10:1.

[0605] Ex64. An aerosol-generating article according to any one of Ex1 to Ex63, wherein the aerosol-generating article has a length between 15 mm and 45 mm, for example between 25 mm and 30 mm.

[0606] Ex65. An aerosol-generating article according to any one of Ex1 to Ex64, wherein the aerosol-generating article has a width between 3 mm and 17 mm, for example between 9 mm and 11 mm.

[0607] Ex66. An aerosol-generating article according to any one of Ex1 to Ex65, wherein the aerosol-generating article has a thickness between 1 mm and 5.5 mm, for example between 3 mm and 3.5 mm.

[0608] Ex67. An aerosol-generating article according to any one of Ex1 to Ex66, wherein the aerosol-generating article has a resistance to draw of between 0 mm H20 and 9.9 mm H20.

[0609] Ex68. An aerosol-generating article according to Ex55, wherein the air inlet has a width between 0.5 mm and 2 mm.

[0610] Ex69. An aerosol-generating article according to Ex56, wherein the air inlet has a thickness between 0.5 mm and 2 mm.

[0611] Ex70. An aerosol-generating article according to any one of Ex55, Ex56, Ex68 or Ex69, wherein the ratio of the width of the air inlet to the thickness of the air inlet is between 0.33 and 3.

[0612] Ex71. An aerosol-generating article according to Ex70, wherein a ratio of a width of the air inlet to a thickness of the air inlet is between 0.5 and 1.5.

[0613] Ex72. An aerosol-generating article according to Ex71, wherein a ratio of a width of the air inlet to a thickness of the air inlet is between 0.75 and 1.25.

[0614] Ex73. An aerosol-generating article according to any one of Ex52 to Ex56 or Ex68 to 72, wherein the air inlet has a circular cross-section, a circular cross-section, an oval cross-section, a square cross-section or a rectangular cross-section.

[0615] Ex74. An aerosol-generating article according to Ex60, wherein the air outlet has a width between 0.5 mm and 2 mm.

[0616] Ex75. An aerosol-generating article according to Ex61, wherein the air outlet has a thickness between 0.5 mm and 2 mm.

[0617] Ex76. An aerosol-generating article according to any one of Ex60, Ex61, Ex74 or Ex75, wherein the ratio of the width of the air outlet to the thickness of the air outlet is between 0.33 and 3.

[0618] Ex77. An aerosol-generating article according to Ex76, wherein a ratio of the width of the air outlet to the thickness of the air outlet is between 0.5 and 1.5.

[0619] Ex78. An aerosol-generating article according to Ex77, wherein a ratio of the width of the air outlet to the thickness of the air outlet is between 0.75 and 1.25.

[0620] Ex79. An aerosol-generating article according to any one of Ex57 to Ex61 or Ex74 to Ex78, wherein the air outlet has a circular cross-section, a circular cross-section, an oval cross-section, a square cross-section or a rectangular cross-section.

[0621] Examples will now be further described with reference to the accompanying drawings, in which:

[0622] Figure 1 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0623] Figure 2 Shown Figure 1 an exploded perspective view of an aerosol-generating article;

[0624] Figure 3 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0625] Figure 4 Shown Figure 3 a transverse cross-sectional view of an aerosol-generating article;

[0626] Figure 5 Shown Figure 3 a longitudinal cross-sectional view of an aerosol-generating article;

[0627] Figure 6 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0628] Figure 7 Shown Figure 6 a transverse cross-sectional view of an aerosol-generating article;

[0629] Figure 8 Shown Figure 6 a side cross-sectional view of an aerosol-generating article;

[0630] Figure 9 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0631] Figure 10 Shown Figure 9 a perspective view of an aerosol-generating article;

[0632] Figure 11 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0633] Figure 12 Shown Figure 11 an exploded perspective view of an aerosol-generating article;

[0634] Figure 13 Shown Figure 11an exploded perspective view of an aerosol-generating article;

[0635] Figure 14 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0636] Figure 15 Shown Figure 14 an exploded perspective view of an aerosol-generating article;

[0637] Figure 16 Shown Figure 14 an exploded perspective view of an aerosol-generating article;

[0638] Figure 17 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0639] Figure 18 Shown Figure 17 an exploded perspective view of an aerosol-generating article;

[0640] Figure 19 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0641] Figure 20 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0642] Figure 21 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0643] Figure 22 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0644] Figure 23 Shown Figure 22 an exploded perspective view of an aerosol-generating article;

[0645] Figure 24 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0646] Figure 25 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0647] Figure 26 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0648] Figure 27 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0649] Figure 28 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0650] Figure 29 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0651] Figure 30 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0652] Figure 31 Shown Figure 30 a perspective view of an aerosol-generating article;

[0653] Figure 32 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0654] Figure 33 Shown Figure 32 a plan view of an aerosol-generating article;

[0655] Figure 34 Shown Figure 32 an exploded perspective view of an aerosol-generating article;

[0656] Figure 35 Shown Figure 32 a cross-sectional view of an aerosol-generating article;

[0657] Figure 36 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0658] Figure 37 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0659] Figure 38 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0660] Figure 39 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0661] Figure 40 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0662] Figure 41 shows a schematic cross-sectional view of an aerosol generating device according to the present disclosure;

[0663] Figure 42 Shown is an aerosol-generating article engaged with the present disclosure Figure 41 a schematic cross-sectional view of an aerosol generating device;

[0664] Figure 43 A method of manufacturing an aerosol-generating article according to the present disclosure is shown;

[0665] Figure 44 Shown Figure 43A plan view of a manufacturing method;

[0666] Figure 45 A method of manufacturing an aerosol-generating article according to the present disclosure is shown;

[0667] Figure 46 Shown Figure 45 A plan view of a manufacturing method;

[0668] Figure 47 A method of manufacturing an aerosol-generating article according to the present disclosure is shown;

[0669] Figure 48 Shown Figure 47 A plan view of a manufacturing method;

[0670] Figure 49 A method of manufacturing an aerosol-generating article according to the present disclosure is shown; and

[0671] Figure 50 Shown Figure 49 A plan view of the manufacturing method.

[0672] Figure 1 An aerosol-generating article 10 is shown that includes a first planar outer layer 24 forming a first planar outer surface 21, a second planar outer layer 25 forming a second planar outer surface 22, and a frame 50 positioned between the first planar outer layer 24 and the second planar outer layer 25. Both the first planar outer layer 24 and the second planar outer layer 25 include an aerosol-generating substrate that includes an aerosol-generating material, i.e., tobacco. However, it should be understood that in some embodiments, only one of the first planar outer layer 24 and the second planar outer layer 25 may include an aerosol-generating substrate. Alternatively or additionally, the aerosol-generating substrate may be positioned elsewhere within the aerosol-generating article 10.

[0673] The aerosol-generating article 10 has a length extending in the x-direction, a width extending in the y-direction and a thickness extending in the z-direction.The aerosol-generating article 10 has a length of 30 mm, a width of 10 mm and a thickness of 3.1 mm.

[0674] The first planar outer surface 21 and the second planar outer surface 22 extend in the x-direction and the y-direction. That is, the first planar outer surface 21 and the second planar outer surface 22 extend in the x / y plane. The first planar outer surface 21 is positioned parallel to the second planar outer surface 22, and the first planar outer surface 21 is spaced apart from the second planar outer surface 22 in the z-direction or the lateral direction. The distance between the first planar outer surface 21 and the second planar outer surface 22 in the z-direction or the lateral direction corresponds to the thickness of the aerosol-generating article 10.

[0675] The aerosol-generating article 10 is a substantially flat aerosol-generating article or a substantially planar aerosol-generating article. In particular, the thickness of the aerosol-generating article 10 is less than 50% of both the length and the width of the aerosol-generating article. That is, the thickness is less than 15 mm (less than 50% of the length of the aerosol-generating article 10) and less than 5 mm (less than 50% of the width of the aerosol-generating article 10). The aerosol-generating article 10 has a generally rectangular cuboid shape and a laminated structure formed by a first planar outer layer 24, a frame 50, and a second planar outer layer 25. As described below with respect to Figure 2 Discussed in greater detail, the first planar outer layer 24, the frame 50, and the second planar outer layer 25 are bonded together using an adhesive, specifically guar gum.

[0676] Figure 2 Shown Figure 1 An exploded view of the aerosol-generating article 10 is shown.

[0677] Frame 50 has a length of 30 mm, a width of 10 mm, and a thickness of 2.7 mm. Frame 50 is made of cardboard and defines a frame aperture that extends through the thickness of frame 50. Frame aperture at least partially forms cavity 30. Cavity 30 has a length of 26 mm, a width of 6 mm, and a thickness of 2.7 mm. Therefore, cavity 30 has a volume of approximately 421.2 cubic millimeters. In this embodiment, cavity 30 is substantially empty.

[0678] The frame 50 has a frame inner surface 52 extending in the z-direction, or lateral direction, between the first planar outer surface 21 and the second planar outer surface 22. The frame inner surface 52 defines an outer wall of the cavity. The frame 50 has a frame outer surface 53 extending in the z-direction, or lateral direction, between the first planar outer surface 21 and the second planar outer surface 22. The frame outer surface 53 at least partially defines one or more outer surfaces of the aerosol-generating article, such as the front wall 13 and the rear wall 14. The frame outer surface 53 surrounds the frame inner surface 52 and is concentric with the frame inner surface. Thus, the frame 50 has a cross-section in the x / y plane that is annular in shape, and in particular, the cross-section is a rectangular annular band.

[0679] The frame 50 includes a peripheral wall 51 that bounds the cavity 30. In more detail, the peripheral wall 51 is defined by a frame inner surface 52 and a frame outer surface 53. The peripheral wall 51 has a radial thickness (as measured in the x / y plane between the frame inner surface 52 and the frame outer surface 53) of approximately 2 mm.

[0680] The first and second planar outer layers 24, 25 have a thickness of 200 microns and are in physical contact with the frame 50. The first and second planar outer layers 24, 25 are bonded to the frame with adhesive 15. The first planar outer layer 24 overlies the end of the cavity 30 and forms a first cavity end wall 31. The second planar outer layer 25 overlies the opposite end of the cavity 30 and forms a second cavity end wall 32. That is, the frame 50, the first and second planar outer layers 24, 25 collectively define the cavity 30.

[0681] The air inlet 11 and the air outlet 12 are defined by and extend through the peripheral wall 51 of the frame 50. The air inlet 11 and the air outlet 12 each have a rectangular cross-section, a width of 2 mm, and a thickness of 0.9 mm. An air flow path extends between the air inlet 11 and the air outlet 12 through the cavity 30.

[0682] The frame forms at least 95% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article that extends through the frame. For example, the frame forms 100% of the perimeter of a cross-section in the x / y plane of the aerosol-generating article 10 taken between the first planar outer layer 24 and the air outlet 12. On the other hand, the frame forms 95% of the perimeter of a cross-section in the x / y plane of the aerosol-generating article that extends through the air inlet 11 and the air outlet 12. This is because the perimeter of this cross-section is formed by the frame, the width of the air inlet 11, and the width of the air outlet 12.

[0683] Figure 3 Shown with Figure 1 10, except that the first planar outer layer 24 and the second planar outer layer 25 do not include an aerosol-generating substrate. Instead, an aerosol-generating substrate 40 is positioned within the cavity 30. The aerosol-generating substrate 40 includes an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5% by weight on a dry weight basis. As shown, the aerosol-generating substrate 40 fills the entire volume of the cavity 30. Figure 3 In the example of FIG. 4 , the aerosol-generating substrate 40 has a packing density of approximately 0.87, a density of approximately 0.3 g / cm3, and a mass of approximately 110 mg. In another example, the aerosol-generating substrate 40 can have a different packing density, a different density, and a different mass. For example, the aerosol-generating substrate can have a packing density of 0.64, a density of 0.35 g / cm3, and a mass of approximately 95 mg.

[0684] Figure 4 and 5 Shown respectively Figure 3 Transverse and longitudinal cross-sectional views of an aerosol-generating article.

[0685] Figure 6Shown with Figure 3 1 is an exploded view of an aerosol-generating article 10 similar to that of 1, except that the aerosol-generating substrate 40 is in the form of a sheet of aerosol-generating material, in particular a sheet of corrugated homogenised tobacco material. Figure 7 and 8 Shown respectively Figure 6 Transverse cross-sectional view and side cross-sectional view of the aerosol-generating article 10.

[0686] The sheet of corrugated homogenised tobacco material comprises a plurality of parallel corrugations having a plurality of substantially parallel peaks 43 and valleys 44. Figure 7 As can be seen in FIG, a plurality of parallel corrugations are defined by a corrugation profile, which is sinusoidal. The plurality of parallel corrugations have a corrugation wavelength of approximately 0.92 mm. As indicated by peaks 43 and valleys 44 coinciding with the first and second cavity end walls 31 and 32, respectively, the corrugation amplitude is approximately the same as the cavity thickness.

[0687] The plurality of parallel corrugations form a plurality of channels 45 between the sheet of aerosol-generating material and the first chamber end wall 31, and a plurality of channels 46 between the sheet of aerosol-generating material and the second chamber end wall 32. The plurality of channels extend in the longitudinal direction of the aerosol-generating article 10 and form at least a portion of an airflow passage extending between the air inlet 11 and the air outlet 12.

[0688] Figure 9 Shown with Figure 1 、 3 An aerosol-generating article 10 similar to the aerosol-generating article 10 of 6, except that Figure 9 The aerosol-generating article 10 includes an outer wrapper 23 defining a first planar outer surface 21 and a second planar outer surface 22 instead of the first planar outer layer 24 and the second planar outer layer 25. For illustrative purposes, Figure 10 Shown Figure 9 FIG4 is an aerosol-generating article 10 of the embodiment of the present invention, wherein the outer wrapper 23 has been unfolded to expose a portion of the peripheral wall 51 of the frame 50. The outer wrapper 23 is cigarette paper.

[0689] Figure 11 Shown with Figure 1 The aerosol-generating article 10 is similar to the aerosol-generating article 10, except that Figure 11 The frame 50 of the aerosol-generating article 10 comprises a first frame layer 54 and a second frame layer 55 . Figure 12 Shown Figure 11 Exploded view of the first planar outer layer 24, the frame 50 and the second planar outer layer 25 of the aerosol-generating article 10. Figure 13 Shown Figure 111 . Still another exploded view of the first planar outer layer 24 , the first frame layer 54 , the second frame layer 55 , and the second planar outer layer 25 of the aerosol-generating article 10 .

[0690] The first planar outer layer 24 is in physical contact with the first frame layer 54 and is bonded together with adhesive 15. The first frame layer 54 is in physical contact with the second frame layer 55 and is bonded together with adhesive 15. The second planar outer layer 25 is in physical contact with the second frame layer 55 and is bonded together with adhesive 15.

[0691] The aerosol-generating article 10 has Figure 1 The frame 50 has the same dimensions as the aerosol generating article 10. Figure 1 The frame 50 has the same size as the frame 50. The thickness of the frame 50 is equal to the sum of the thicknesses of the first frame layer 54 and the second frame layer 55, and both the first frame layer and the second frame layer have the same thickness. The air inlet 11 and the air outlet 12 are formed by both the first frame layer 54 and the second frame layer 55.

[0692] Figure 14 Shown with Figure 1 The aerosol-generating article 10 is similar to the aerosol-generating article 10, except that Figure 14 The frame 50 of the aerosol-generating article 10 comprises a first frame layer 54 , a second frame layer 55 and a third frame layer 56 positioned between the first frame layer 54 and the second frame layer 55 . Figure 15 Shown Figure 14 Exploded view of the first planar outer layer 24, the frame 50 and the second planar outer layer 25 of the aerosol-generating article 10. Figure 16 Shown Figure 14 1 . Still another exploded view of the first planar outer layer 24, the first frame layer 54, the second frame layer 55, the third frame layer 56, and the second planar outer layer 25 of the aerosol-generating article 10 of FIG.

[0693] The first planar outer layer 24 is in physical contact with the first frame layer 54 and is bonded together with the adhesive 15. The first frame layer 54 is in physical contact with the second frame layer 55 and is bonded together with the adhesive 15. The second frame layer 55 is in physical contact with the third frame layer 56 and is bonded together with the adhesive 15. The second planar outer layer 25 is in physical contact with the third frame layer 56 and is bonded together with the adhesive 15.

[0694] The aerosol-generating article 10 has Figure 1 The frame 50 has the same dimensions as the aerosol generating article 10. Figure 1The frame 50 has the same size as the frame 50 in FIG. The thickness of the frame 50 is equal to the sum of the thicknesses of the first frame layer 54, the second frame layer 55 and the third frame layer 56. The air inlet 11 and the air outlet 12 extend through the second frame layer 55.

[0695] Figure 17 Shown with Figure 1 The aerosol-generating article 10 is similar to the aerosol-generating article 10, except that Figure 17 The aerosol-generating article 10 further comprises a first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42 . Figure 18 Shown Figure 17 Exploded view of an aerosol-generating article 10. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are formed from a sheet of aerosol-generating material. In particular, the sheet of homogenized tobacco material has an aerosol-forming agent content of 5% by weight on a dry weight basis. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 each have a length equal to the length of the aerosol-generating article 10, a width equal to the width of the aerosol-generating article 10, and a thickness of 200 microns. In other words, the aerosol-generating article 10 has a length of 30 mm, a width of 10 mm, and a thickness of 3.5 mm.

[0696] The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are in physical contact with the frame 50 and are bonded to the frame with the adhesive 15. The first aerosol-generating substrate layer 41 overlies an end of the cavity 30 and forms a first cavity end wall 31. The second aerosol-generating substrate layer 42 overlies an opposite end of the cavity 30 and forms a second cavity end wall 32. That is, the frame 50, the first aerosol-generating substrate layer 41, and the second aerosol-generating substrate layer 42 collectively define the cavity 30.

[0697] The first planar outer layer 24 is in physical contact with the first aerosol-generating substrate layer 41 and is bonded together with the adhesive 15. The second planar outer layer 25 is in physical contact with the second aerosol-generating substrate layer 42 and is bonded together with the adhesive 15.

[0698] The frame 50 is depicted as a unitary component. However, the frame may be Figure 11 The two-layer framework shown in Figure 14 The three-layer framework shown in .

[0699] Figure 19 Shown with Figure 17 An exploded view of an aerosol-generating article 10 similar to that of FIG. 1 , except that the aerosol-generating substrate 40 is not as shown in FIG. 1 . Figure 3The depicted position is within the cavity 30. The aerosol-generating substrate 40 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 wt% on a dry weight basis. As shown, the aerosol-generating substrate 40 fills the entire volume of the cavity 30.

[0700] Figure 20 Shown with Figure 19 An exploded view of an aerosol-generating article 10 similar to that of FIG. 1 , except that the aerosol-generating substrate 40 is in the form of a sheet of aerosol-generating material, particularly as described with respect to FIG. Figure 6 A form of sheet of corrugated homogenised tobacco material is described.

[0701] Figure 21 Shown with Figure 19 FIG. 1 is an exploded view of an aerosol-generating article 10 similar to FIG. 1 , except that the aerosol-generating article 10 further includes a filter element 60 positioned within the cavity 30 .

[0702] The filter element 60 is positioned immediately upstream of the air outlet 12. The filter element 60 is made of cellulose acetate. The filter element 60 has a thickness and width that are approximately the same as the thickness and width of the cavity 30, respectively. The filter element 60 has a length of approximately 6 mm. The aerosol-generating substrate 40 fills the remaining volume of the cavity 30.

[0703] Figure 22 Shown with Figure 1 The aerosol-generating article 10 is similar to the aerosol-generating article 10, except that Figure 22 The aerosol-generating article 10 comprises a first cavity 33 and a second cavity 34 . Figure 23 Shown Figure 22 An exploded view of the aerosol-generating article 10 is shown.

[0704] The first cavity 33 is substantially hollow, and the second cavity 34 is substantially hollow. The first cavity 33 has a length of 12 mm, a width of 6 mm, and a thickness of 2.7 mm. The second cavity 34 has a length of 12 mm, a width of 6 mm, and a thickness of 2.7 mm.

[0705] Frame 50 defines a frame first aperture extending through the thickness of frame 50, and the frame first aperture at least partially forms first cavity 33. Frame 50 defines a frame second aperture extending through the thickness of frame 50, and the frame second aperture at least partially forms second cavity 34.

[0706] Frame 50 includes a partition wall 57 that separates first cavity 33 from second cavity 34. Partition wall 59 defines an aperture extending from first cavity 33 to second cavity 34. The aperture of partition wall 59 defines at least a portion of the air flow path between air inlet 11 and air outlet 12.

[0707] First planar outer layer 24 overlies an end of first cavity 33, and second planar outer layer 25 overlies an opposite end of first cavity 33. That is, frame 50, first planar outer layer 24, and second planar outer layer 25 collectively define first cavity 33. First planar outer layer 24 overlies an end of second cavity 34, and second planar outer layer 25 overlies an opposite end of second cavity 34. That is, frame 50, first planar outer layer 24, and second planar outer layer 25 collectively define second cavity 34.

[0708] Figure 24 Shown with Figure 22 An exploded view of an aerosol-generating article 10 similar to that of FIG. 1 , except that a first-cavity aerosol-generating substrate 45 is positioned within the first cavity 33 and a second-cavity aerosol-generating substrate 46 is positioned within the second cavity 34 .

[0709] First-chamber aerosol-generating substrate 45 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5% by weight on a dry weight basis. First-chamber aerosol-generating substrate 45 fills the entire volume of first chamber 33. Second-chamber aerosol-generating substrate 46 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5% by weight on a dry weight basis. Second-chamber aerosol-generating substrate 46 fills the entire volume of second chamber 34. Figure 25 Shown with Figure 24 The invention provides an exploded view of an aerosol-generating article 10 similar to that of the invention, except that the first cavity aerosol-generating substrate 45 is in the form of a sheet of aerosol-generating material, in particular a sheet of corrugated homogenized tobacco material, and the second cavity aerosol-generating substrate 46 is in the form of a sheet of aerosol-generating material, in particular a sheet of corrugated homogenized tobacco material.

[0710] Figure 26 Shown with Figure 22 An exploded view of an aerosol-generating article 10 similar to that of , except that the first-cavity aerosol-generating substrate 45 is positioned within the first cavity 33 , the filter element 60 is positioned within the first cavity 33 , and the second-cavity aerosol-generating substrate 46 is positioned within the second cavity 34 .

[0711] The filter element 60 is positioned immediately upstream of the air outlet 12. The filter element is made of cellulose acetate. The filter element 60 has a thickness and width that are approximately the same as the thickness and width of the first cavity 33, respectively. The filter element 60 has a length of approximately 4 mm.

[0712] The first cavity aerosol generating substrate 45 comprises an aerosol generating material in the form of tobacco cut filler and has an aerosol former content of 5 wt% on a dry weight basis. The first cavity aerosol generating substrate 45 fills the remaining volume of the first cavity 33. The second cavity aerosol generating substrate 46 is connected to the second cavity aerosol generating substrate 46. Figure 25 The second cavity aerosol-generating substrate 46 is the same as described.

[0713] Figure 27 Shown with Figure 22 FIG1 is an exploded view of an aerosol-generating article 10 similar to that of FIG1 , except that a filter element 60 is positioned within the air outlet 12 and a second-cavity aerosol-generating substrate 46 is positioned within the second cavity 34. The filter element 60 is made of cellulose acetate and has the same dimensions as the air outlet 12. The first cavity 33 is empty. The second-cavity aerosol-generating substrate 46 is the same as that described with respect to FIG1 . Figure 24 The second cavity aerosol-generating substrate 46 is the same as described.

[0714] Figure 28 Shown with Figure 22 An exploded view of an aerosol-generating article 10 similar to that of the aerosol-generating article 10, except that the aerosol-generating article 10 further includes Figure 17 A first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42 are depicted.

[0715] The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are formed from a sheet of aerosol-generating material. Specifically, the sheet of homogenized tobacco material has an aerosol-forming agent content of 5% by weight on a dry weight basis. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 each have a length equal to the length of the aerosol-generating article 10, a width equal to the width of the aerosol-generating article 10, and a thickness of 200 microns. In other words, the aerosol-generating article 10 has a length of 30 mm, a width of 10 mm, and a thickness of 3.5 mm.

[0716] The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are in physical contact with the frame 50 and are bonded to the frame with the adhesive 15. The first aerosol-generating substrate layer 41 overlies an end of the first cavity 33, and the second aerosol-generating substrate layer 42 overlies an opposite end of the first cavity 33. That is, the frame 50, the first aerosol-generating substrate layer 41, and the second aerosol-generating substrate layer 42 collectively define the first cavity 33. The first aerosol-generating substrate layer 41 overlies an end of the second cavity 34, and the second aerosol-generating substrate layer 42 overlies an opposite end of the second cavity 34. That is, the frame 50, the first aerosol-generating substrate layer 41, and the second aerosol-generating substrate layer 42 collectively define the second cavity 34.

[0717] Figure 29 Shown with Figure 28 An exploded view of an aerosol-generating article 10 similar to that of FIG. 1 , except that a first-cavity aerosol-generating substrate 45 is positioned within the first cavity 33 and a second-cavity aerosol-generating substrate 46 is positioned within the second cavity 34 .

[0718] First-chamber aerosol-generating substrate 45 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5% by weight on a dry weight basis. First-chamber aerosol-generating substrate 45 fills the entire volume of first chamber 33. Second-chamber aerosol-generating substrate 46 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5% by weight on a dry weight basis. Second-chamber aerosol-generating substrate 46 fills the entire volume of second chamber 34.

[0719] Figure 30 Shown with Figure 17 and 28 The aerosol-generating article 10 is similar to the aerosol-generating article 10, except that Figure 30 The aerosol-generating article 10 includes an outer wrapper 23 defining a first planar outer surface 21 and a second planar outer surface 22 instead of the first planar outer layer 24 and the second planar outer layer 25. For illustrative purposes, Figure 31 Shown Figure 30 FIG4 is an aerosol-generating article 10 of the embodiment of the present invention, wherein the outer wrapper 23 has been unfolded to expose a portion of the peripheral wall 51 of the frame 50. The outer wrapper 23 is cigarette paper.

[0720] Figure 32 Shown with Figure 1 The aerosol-generating article 10 is similar to the aerosol-generating article 10, except that Figure 32 The aerosol-generating article 10 comprises a first external corner 71 and a second external corner 72 that are rounded. However, it should be understood that one or both of the first external corner 71 and the second external corner 72 may be chamfered. Figure 33 and34 Shown respectively Figure 32 A plan view and an exploded view of an aerosol-generating article 10 are provided.

[0721] The first exterior corner 71 extends from the first planar exterior surface 21 to the second planar exterior surface 22 and includes a first corner surface 76 connecting a first end face 73 of the aerosol-generating article 10 and a first side face 74 of the aerosol-generating article 10. In more detail, the first end face 73 connects to the first corner surface 76 at a first corner transition region 82. A first corner interior angle θ1 formed between a tangent line 81 to the first end face 73 at the first corner transition region 82 and a tangent line 83 to the first corner surface 76 at the first corner transition region 82 is between 90 degrees and 180 degrees.

[0722] The second exterior corner 72 extends from the first planar exterior surface 21 to the second planar exterior surface 22 and includes a second corner surface 77 connecting the first end face 73 of the aerosol-generating article 10 and the second side 75 of the aerosol-generating article 10. In more detail, the first end face 73 connects to the second corner surface 77 at a second corner transition region 85. A second corner interior angle θ2 formed between a tangent line 84 to the first end face 73 at the second corner transition region 85 and a tangent line 86 to the second corner surface 77 at the second corner transition region 85 is between 90 degrees and 180 degrees.

[0723] Figure 35 A cross-sectional view taken through the intersection between the first planar outer layer 24 and the frame 50 is shown. Figure 32 1. A cross-sectional view in the x / y plane of an aerosol-generating article 10 of FIG. 1. The cavity 30 comprises a first corner 35, a second corner 36, a third corner 37 and a fourth corner 38, each of which extends in the z-direction and is rounded.

[0724] Figure 36 Shown with Figure 32 10, except that an aerosol-generating substrate 40 is positioned within the cavity 30. The aerosol-generating substrate 40 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-forming agent content of 5% by weight on a dry weight basis. The aerosol-generating substrate 40 fills the entire volume of the cavity 30. In other embodiments, the aerosol-generating substrate 40 is in the form of a sheet of aerosol-generating material, particularly as described with respect to Figure 6 A form of sheet of corrugated homogenised tobacco material is described.

[0725] Figure 37 Shown with Figure 32 and 36 The aerosol-generating article 10 is similar to the aerosol-generating article 10, except that Figure 37The aerosol generating article 10 further comprises the following Figure 17 A first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42 are depicted.

[0726] Figure 38 Shown with Figure 1 An aerosol-generating article 10 of is similar to an aerosol-generating article 10 , except that the air inlet 11 is defined by the first planar outer surface 21 and extends through the first planar outer layer 24 .

[0727] Figure 39 Shown with Figure 9 An aerosol-generating article 10 similar to that of , except that the air inlet 11 is defined by the first planar outer surface 21 and extends through the outer wrapper 23 .

[0728] Figure 40 Shown with Figure 17 An aerosol-generating article 10 is similar to an aerosol-generating article 10 of , except that the air inlet 11 is defined by the first planar outer surface 21 and extends through the first planar outer layer 24 and the first aerosol-generating substrate layer 41 .

[0729] Figure 41 A schematic cross-sectional view of an aerosol-generating device 90 configured for use with the aerosol-generating article 10 described herein is shown. The aerosol-generating device 90 is an elongated aerosol-generating device extending between a proximal end 91 and a distal end 92. The aerosol-generating device 90 includes a battery 93, a controller 94, a first heater 95, and a second heater 96 located within a housing 97. The controller 94 controls the supply of power from the battery 93 to the first heater 95 and the second heater 96. A cavity 1000 is defined in the device 90, the cavity 1000 having an opening 1010 defined in the proximal end 91 of the device 90. The opening 1010 is rectangular in shape and is sized to accommodate the cross-section of the aerosol-generating article 10. The cavity 1000 includes an upper planar surface 1020 and a lower planar surface 1030. A first heater 95 is located in the upper planar surface 1020 to heat the first planar outer surface 21 of the aerosol-generating article 10 inserted into the cavity 1000, and a second heater 96 is located in the lower planar surface 1030 to heat the second planar outer surface 22 of the aerosol-generating article 10 inserted into the cavity 1000. The device 90 includes an air inlet 98 defining an air flow path configured to allow air to flow from outside the device into the cavity 1000.

[0730] Figure 42 Shown with Figure 1 The aerosol-generating article 10 is joined to Figure 41Schematic cross-sectional view of an aerosol-generating device 90. There is virtually no tolerance between the first and second planar outer surfaces 21, 22 of the aerosol-generating article 10 and the inner surfaces 1020, 1030 of the cavity 1000. Thus, there is a snug fit between the aerosol-generating article 10 and the aerosol-generating device 90. Once a consumer has inserted the aerosol-generating article 10 into the cavity 1000, the device can be operated. A first heater 95 heats the first planar outer surface 21 of the aerosol-generating article 10, and a second heater 96 heats the second planar outer surface 22 of the aerosol-generating article, thereby heating the aerosol-generating substrate. Volatile components of the aerosol-generating substrate evaporate and condense in the cavity 30 of the aerosol-generating article 10 to form an aerosol. The consumer inhales the aerosol by drawing on the end of the aerosol-generating article 10 that includes the air outlet 12. Once the aerosol-generating substrate has been depleted of volatile components, the aerosol-generating article 10 is removed from the cavity 1000 and disposed of.

[0731] Figure 43 A method of manufacturing 1100 an aerosol-generating article 10 as described herein (and in particular, manufacturing Figure 3 The method includes stamping and combining a first sheet of frame material 1201, a first sheet of outer layer material 1301 and a second sheet of outer layer material 1302. Figure 44 Depicts Figure 43 A schematic plan view of the method is shown, but for illustrative purposes, the manufacturing equipment is not depicted. Figure 44 The dashed line 1101 in FIG. 1 is for illustrative purposes and represents the final cross-sectional perimeter of the aerosol-generating article 10 .

[0732] A first sheet of frame material 1201 is fed from a reel 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An aperture punching device 1105 punches a frame aperture 1400 through the first sheet of frame material 1201. The frame aperture 1400 will at least partially form the cavity 30 of the aerosol-generating article 10. An adhesive applicator 1106 applies adhesive to the lower surface of the first sheet of frame material 1201. A first sheet of outer layer material 1301 is fed from the reel 1102 via rollers 1107 and is bonded to the first sheet of frame material 1201 by the adhesive applied to the lower surface of the first sheet of frame material 1201. An aerosol-generating substrate dispensing device 1108 dispenses an aerosol-generating substrate 40 into the frame aperture 1400. An adhesive applicator 1109 applies adhesive 1110 to the upper surface of the first sheet of frame material 1201. The second outer layer material sheet 1302 is fed from a reel 1102 via rollers 1107 and is bonded to the first frame material sheet 1201 by adhesive 1110 applied to the upper surface of the first frame material sheet 1201. An aperture punching device 1111 punches apertures 1410 through the first frame material sheet 1201, the first outer layer material sheet 1301, and the second outer layer material sheet 1302 to eject the aerosol-generating article 10. The air inlet and air outlet may be formed before or after the aerosol-generating article 10 has been ejected.

[0733] In some embodiments, one or more of the first sheet of frame material 1201 , the first sheet of outer layer material 1301 and the second sheet of outer layer material 1302 comprise an aerosol-generating substrate.Thus, the step of dispensing the aerosol-generating substrate 40 into the frame aperture 1400 may be skipped.

[0734] Figure 45 A method of manufacturing 1100 an aerosol-generating article 10 as described herein (and in particular, manufacturing Figure 17 The method includes stamping and combining a first sheet of frame material 1201, a first sheet of aerosol-generating material 1501, a second sheet of aerosol-generating material 1502, a first sheet of outer layer material 1301, and a second sheet of outer layer material 1302. Figure 46 Depicts Figure 45 A schematic plan view of the method is shown, but for illustrative purposes, the manufacturing equipment is not depicted. Figure 46 The dashed line 1101 in FIG. 1 is for illustrative purposes and represents the final cross-sectional perimeter of the aerosol-generating article 10 .

[0735] A first sheet of frame material 1201 is fed from a reel 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An aperture punching device 1105 punches a frame aperture 1400 through the first sheet of frame material 1201. The frame aperture 1400 will at least partially form the cavity 30 of the aerosol-generating article 10.

[0736] Adhesive applying device 1106 applies adhesive 1110 to the lower surface of first frame material sheet 1201 and the upper surface of first frame material sheet 1201 .

[0737] The first aerosol-generating material sheet 1501 is fed from the reel 1102 via the roller 1107 and is bonded to the first frame material sheet 1201 by the adhesive applied to the lower surface of the first frame material sheet 1201. The second aerosol-generating material sheet 1502 is fed from the reel 1102 via the roller 1107 and is bonded to the first frame material sheet 1201 by the adhesive 1110 applied to the upper surface of the first frame material sheet 1201.

[0738] The adhesive application device 1109 applies adhesive 1110 to the lower surface of the first aerosol-generating material sheet 1501 and the upper surface of the second aerosol-generating material sheet 1502 .

[0739] The first outer layer material sheet 1301 is fed from the reel 1102 via the roller 1107 and is bonded to the first aerosol-generating material sheet 1501 by the adhesive applied to the lower surface of the first aerosol-generating material sheet 1501. The second outer layer material sheet 1302 is fed from the reel 1102 via the roller 1107 and is bonded to the second aerosol-generating material sheet 1502 by the adhesive 1110 applied to the upper surface of the second aerosol-generating material sheet 1502.

[0740] The orifice punching device 1111 punches an orifice 1410 through the first sheet of frame material 1201, the first sheet of aerosol-generating material 1501, the second sheet of aerosol-generating material 1502, the first sheet of outer layer material 1301 and the second sheet of outer layer material 1302 to facilitate ejection of the aerosol-generating article 10. The air inlet and air outlet may be formed before or after the aerosol-generating article 10 has been ejected.

[0741] Figure 47 A method of manufacturing 1100 an aerosol-generating article 10 as described herein (and in particular, manufacturing an aerosol-generating substrate 40 positioned within a cavity 30) is depicted. Figure 11The method includes stamping and combining a first sheet of frame material 1201, a second sheet of frame material 1202, a first sheet of outer layer material 1301 and a second sheet of outer layer material 1302. Figure 48 Depicts Figure 47 A schematic plan view of the method is shown, but for illustrative purposes, the manufacturing equipment is not depicted. Figure 48 The dashed line 1101 in FIG. 1 is for illustrative purposes and represents the final cross-sectional perimeter of the aerosol-generating article 10 .

[0742] A first frame material sheet 1201 is fed from a reel 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An adhesive applying device 1106 applies an adhesive 1110 to the upper surface of the first frame material sheet 1201. A second frame material sheet 1202 is fed from the reel 1102 via rollers 1107 and is bonded to the first frame material sheet 1201 by the adhesive 1110 applied to the upper surface of the first frame material sheet 1201.

[0743] The aperture punching device 1105 punches a frame aperture 1400 through the first and second sheets of frame material 1201, 1202. The frame aperture 1400 will at least partially form the cavity 30 of the aerosol-generating article 10.

[0744] Adhesive applying device 1106 applies adhesive to the lower surface of first frame material sheet 1201. First outer layer material sheet 1301 is fed from reel 1102 via roller 1107 and bonded to first frame material sheet 1201 by the adhesive applied to its lower surface.

[0745] The aerosol-generating substrate dispensing device 1108 dispenses the aerosol-generating substrate 40 into the frame aperture 40. The adhesive applying device 1109 applies an adhesive 1110 to the upper surface of the second frame material sheet 1202. The second outer layer material sheet 1302 is fed from the reel 1102 via the roller 1107 and is bonded to the second frame material sheet 1202 by the adhesive 1110 applied to the upper surface of the second frame material sheet 1202.

[0746] The aperture punching means 1111 punches an aperture 1410 through the first sheet 1201, the second sheet 1202, the first sheet 1301 and the second sheet 1302 of outer layer material to facilitate ejection of the aerosol-generating article 10. The air inlet and air outlet may be formed before or after the aerosol-generating article 10 has been ejected.

[0747] In some embodiments, one or more of the first sheet of frame material 1201, the second sheet of frame material 1202, the first sheet of outer layer material 1301 and the second sheet of outer layer material 1302 comprise an aerosol-generating substrate. Thus, the step of dispensing the aerosol-generating substrate 40 into the frame aperture 1400 may be skipped.

[0748] Figure 49 A method of manufacturing 1100 an aerosol-generating article 10 as described herein (and in particular, manufacturing an aerosol-generating substrate 40 positioned within a cavity 30) is depicted. Figure 14 The method includes stamping and combining a first sheet of frame material 1201, a second sheet of frame material 1202, a third sheet of frame material 1203, a first sheet of outer layer material 1301, and a second sheet of outer lay...

Claims

1. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: a first planar outer surface; a second planar outer surface; cavity; a frame at least partially defining the cavity; one or more aerosol-generating substrates; as well as Air outlet, wherein the air outlet has a width between 0.3 mm and 3 mm, and Wherein the air outlet has a thickness between 0.3 mm and 3 mm.

2. An aerosol-generating article according to claim 1, wherein the air outlet has a width of between 0.5 mm and 2 mm.

3. An aerosol-generating article according to claim 1 or claim 2, wherein the air outlet has a thickness of between 0.5 mm and 2 mm. 4 . The aerosol-generating article according to claim 1 , wherein a ratio of the width of the air outlet to the thickness of the air outlet is between 0.33 and 3.

5. An aerosol-generating article according to claim 4, wherein a ratio of the width of the air outlet to the thickness of the air outlet is between 0.5 and 1.

5.

6. An aerosol-generating article according to any one of claims 1 to 5, wherein the frame comprises a peripheral wall defining or surrounding the cavity.

7. An aerosol-generating article according to claim 6, wherein the air outlet extends through the peripheral frame.

8. An aerosol-generating article according to any one of claims 1 to 7, wherein the air outlet has a circular cross-section, a circular cross-section, an oval cross-section, a square cross-section or a rectangular cross-section.

9. An aerosol-generating article according to any one of claims 1 to 8, comprising an air inlet and an air flow passage extending through the cavity between the air inlet and the air outlet.

10. An aerosol-generating article according to claim 9, wherein the air inlet has a width of between 0.3 mm and 3 mm.

11. An aerosol-generating article according to any one of claim 9 or claim 10, wherein the air inlet has a thickness of between 0.3 mm and 3 mm. 12 . The aerosol-generating article according to claim 9 , wherein the ratio of the width of the air inlet to the thickness of the air inlet is between 0.33 and 3.

13. An aerosol-generating article according to claim 12, wherein a ratio of the width of the air inlet to the thickness of the air inlet is between 0.5 and 1.

5.

14. An aerosol-generating article according to any one of claims 9 to 13, wherein the air inlet has a circular cross-section, a circular cross-section, an oval cross-section, a square cross-section or a rectangular cross-section.

15. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: a first planar outer surface; a second planar outer surface; cavity; a frame at least partially defining the cavity; one or more aerosol-generating substrates; as well as Air inlet, wherein the air inlet has a width between 0.3 mm and 3 mm, and Wherein the air inlet has a thickness between 0.3 mm and 3 mm.

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