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) includes a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction. The aerosol-generating article (10) comprises an air inlet (11) and an air outlet (12). The aerosol-generating article (10) comprises an airflow passage extending between an air inlet (11) and an air outlet (12). The aerosol-generating article (10) comprises a cavity (30). The aerosol-generating article (10) comprises one or more aerosol-generating substrates (40, 41, 42). The aerosol-generating article (10) comprises a first planar outer surface (21) and a second planar outer surface (22) spaced apart from the first planar outer surface (21) in a z-direction. The aerosol-generating article (30) 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 frame (50) forms at least 75% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article (10) extending through the frame. 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

TECHNICAL FIELD

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

[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 in the vicinity of 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 air drawn through the aerosol-generating article. As the volatile compounds cool, they condense to form an aerosol which can be inhaled by a consumer.

[0003] A typical aerosol-generating article can appear similar to a conventional cigarette and have a similar size to a conventional cigarette. For example, such an aerosol-generating article can be substantially cylindrical and comprise an aerosol-generating substrate in addition to other components such as a mouthpiece filter element and a cooling element, which are arranged in the form of a rod and wrapped in cigarette paper.

[0004] However, a large proportion of the aerosol-generating substrate in these cylindrical aerosol-generating articles can not be sufficiently heated during use to form an aerosol. This is undesirable because the proportion of the aerosol-generating substrate that is not sufficiently heated 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 often need to have the same or very similar outer diameters so that they can be gathered together, accurately positioned in axial alignment and wrapped in cigarette paper. This can result in increased costs and complexity of manufacture. SUMMARY

[0005] It is an object of the present disclosure to provide an aerosol-generating article in which a larger proportion of the aerosol-generating substrate is sufficiently heated 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 cheaply.

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

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

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

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

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

[0011] Advantageously, the aerosol-generating article of the present disclosure can be manufactured by laminating a sheet material, which can be achieved by 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, there is provided an aerosol-generating article. The aerosol-generating article is for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article comprises a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction. The aerosol-generating article comprises an air inlet and an air outlet. The aerosol-generating article comprises an airflow pathway extending between the air inlet and the air outlet. The aerosol-generating article comprises a cavity. The aerosol-generating article comprises one or more aerosol-generating substrates. The aerosol-generating article comprises a first planar outer surface and a second planar outer surface spaced apart from the first planar outer surface in the z-direction. The aerosol-generating article comprises a frame positioned between the first planar outer surface and the second planar outer surface. The frame at least partially defines the cavity. The frame forms at least 75% of a perimeter of any cross-section of the aerosol-generating article extending through the x / y plane of the frame.

[0013] Advantageously, providing a frame that forms at least 75% of a perimeter of any cross-section of the aerosol-generating article extending through the x / y plane of the frame means that the frame extends around a substantial portion of the aerosol-generating article. As a result, the frame can provide good structural support to the aerosol-generating article.

[0014] Advantageously, providing a frame forming at least 75% of the perimeter of any cross-section extending through the x / y plane of the aerosol-generating article can mean that one or both of the air inlet and the air outlet has a size that provides a satisfactory draw resistance for the aerosol-generating article.

[0015] Advantageously, providing a frame forming at least 75% of the perimeter of any cross-section extending through the x / y plane of the aerosol-generating article can allow the frame to act as a barrier to prevent one or more aerosol-generating substrates from flowing out of the aerosol-generating article, particularly in embodiments in which the aerosol-generating substrates are positioned within the cavity.

[0016] The aerosol-generating article can have a length, a width, and a thickness. The aerosol-generating article can have a length extending in the x-direction. The aerosol-generating article can have a width extending in the y-direction. The aerosol-generating article can have a thickness extending in the z-direction.

[0017] The aerosol-generating article can comprise an x / y plane. The x / y plane can extend through the geometric centre of the aerosol-generating article. The x / y plane can define a plane of symmetry of the aerosol-generating article. The air inlet and the air outlet can be symmetrical about the x / y plane, for example having symmetrical shapes or positions.

[0018] The aerosol-generating article can comprise an x / z plane. The x / z plane can extend through the geometric centre of the aerosol-generating article. The x / z plane can define a plane of symmetry of the aerosol-generating article. The air inlet and the air outlet can be symmetrical about the x / z plane, for example having symmetrical shapes or positions.

[0019] The aerosol-generating article can comprise a y / z plane. The y / z plane can extend through the geometric centre of the aerosol-generating article. The y / z plane can define a plane of symmetry of the aerosol-generating article. The air inlet and the air outlet can be symmetrical about the y / z plane, for example having symmetrical shapes or positions.

[0020] Advantageously, a symmetrical aerosol-generating article or an article having symmetrical shapes or positioned air inlets and air outlets can allow the aerosol-generating article to be inserted into an aerosol-generating device in multiple orientations.

[0021] The aerosol-generating article can be a substantially flat aerosol-generating article or a substantially planar aerosol-generating article. In particular, the thickness of the aerosol-generating article can be less than 50% of both the length and the width of the aerosol-generating article. Advantageously, the smaller thickness can provide a small temperature gradient or temperature differential across the thickness of the aerosol-generating substrate during heating. Advantageously, this can allow a greater proportion of the aerosol-generating substrate to be heated to a temperature at which an aerosol is released, while minimising the risk of combustion of the aerosol-generating substrate in the hottest parts of the heater closest to the heater. Advantageously, this can also reduce the time required to heat the aerosol-generating substrate sufficiently to release an aerosol.

[0022] The aerosol-generating article can have a 3-dimensional shape.

[0023] The aerosol-generating article can have a tetragonal hexahedral shape. The aerosol-generating article can have a rectangular prismatic shape. The aerosol-generating article can have a cuboidal shape. The aerosol-generating article can have a rectangular cuboidal shape. The aerosol-generating article can have a rectangular cuboidal shape. The aerosol-generating article can have a parallelepiped shape.

[0024] The aerosol-generating article can have a cylindrical shape. The aerosol-generating article can have a right circular cylinder shape. The aerosol-generating article can have an elliptic cylinder shape.

[0025] The aerosol-generating article can have an oblong elliptic shape.

[0026] The aerosol-generating article can have a laminated structure, for example the aerosol-generating article can comprise or be formed from at least two layers. In particular, as discussed in more detail below, the aerosol-generating article can comprise at least two of: 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.

[0027] At least 50% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be paper or cardboard. At least 55% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be cellulosic material. At least 60% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be cellulosic material. At least 65% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be cellulosic material. At least 70% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be cellulosic material. At least 75% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be cellulosic material. At least 80% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be cellulosic material. At least 85% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be cellulosic material. At least 90% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be cellulosic material.

[0028] At least 50% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be paper or cardboard. At least 55% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be paper or cardboard. At least 60% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be paper or cardboard. At least 65% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be paper or cardboard. At least 70% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be paper or cardboard. At least 75% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be paper or cardboard. At least 80% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be paper or cardboard. At least 85% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be paper or cardboard. At least 90% of the mass of the aerosol-generating article other than the one or more aerosol-generating substrates can be paper or cardboard.

[0029] Substantially all of the aerosol-generating article other than the one or more aerosol-generating substrates and, if present, the binder can be paper or cardboard.

[0030] The aerosol-generating article can have a cellulose acetate content of less than 5%. The aerosol-generating article can have a cellulose acetate content of less than 3%. The aerosol-generating article can have a cellulose acetate content of less than 1%.

[0031] The frame can be a planar frame.

[0032] The frame can define a frame aperture extending through a thickness of the frame. The frame aperture can define or form an airflow passage of the aerosol-generating article. The frame aperture can define or form a cavity of the aerosol-generating article. For example, the frame can have a hollow cuboid shape or a square hollow tube shape. As a further example, the frame can 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 can have a ring band shape, such as a circular ring band shape, an elliptical ring band shape, a rectangular ring band shape or a square ring band shape.

[0033] The frame can comprise a frame outer surface. The frame outer surface can extend in the lateral direction, for example between the first planar outer surface and the second planar outer surface. The frame outer surface can at least partially define or form one or more outer surfaces of the aerosol-generating article. For example, the frame outer surface can at least partially define or form one or more outer walls of the aerosol-generating article. The frame outer surface can bound or surround the frame aperture. The frame outer surface can bound or surround the cavity.

[0034] The frame can comprise a frame inner surface. The frame inner surface can extend in the lateral direction, for example between the first planar outer surface and the second planar outer surface. The frame inner surface can define or form a frame aperture outer wall. The frame inner surface can define or form a cavity outer wall. The frame inner surface can bound or surround the frame aperture extending through a thickness of the frame. The frame outer surface can bound or surround the cavity.

[0035] The frame outer surface can bound or surround the frame inner surface. The frame inner surface and the frame outer surface can be concentric with each other.

[0036] The frame can define or form at least 75% of a perimeter of any cross-section of the aerosol-generating article. The cross-section can extend through the frame. The cross-section can be in the x / y plane.

[0037] The frame can define or form at least 75% of a perimeter of any cross-section of the aerosol-generating article extending through the frame in the x / y plane. The frame can define or form at least 80% of a perimeter of any cross-section of the aerosol-generating article extending through the frame in the x / y plane. The frame can define or form at least 85% of a perimeter of any cross-section of the aerosol-generating article extending through the frame in the x / y plane. The frame can define or form at least 90% of a perimeter of any cross-section of the aerosol-generating article extending through the frame in the x / y plane. The frame can define or form at least 95% of a perimeter of any cross-section of the aerosol-generating article extending through the frame in the x / y plane. The frame can define or form at least 99% of a perimeter of any cross-section of the aerosol-generating article extending through the frame in the x / y plane.

[0038] Advantageously, providing a frame forming at least 75% of the perimeter of any cross-section extending through an x / y plane of the aerosol-generating article means that the frame extends around a majority of the aerosol-generating article. Thus, the frame can provide good structural support for the aerosol-generating article.

[0039] Advantageously, providing a frame forming at least 75% of the perimeter of any cross-section extending through an x / y plane of the aerosol-generating article in which the aerosol-generating substrate is positioned within the cavity can mean that any air inlet or air outlet defined through the article has a size that provides a satisfactory draw resistance for the aerosol-generating article.

[0040] Advantageously, in embodiments in which the aerosol-generating substrate is positioned within the cavity, providing a frame forming at least 75% of the perimeter of any cross-section extending through an x / y plane of the aerosol-generating article in which the aerosol-generating substrate is positioned within the cavity can allow the frame to act as a barrier to prevent the aerosol-generating substrate from flowing out of the aerosol-generating article.

[0041] The aerosol-generating article can comprise a cross-section extending through a first x / y plane of the frame. The frame can form at least 99% of the perimeter of the cross-section in the first x / y plane. The frame can form at least 100% of the perimeter of the cross-section in the first x / y plane.

[0042] The aerosol-generating article can comprise a cross-section extending through a second x / y plane of the frame spaced apart from the first x / y plane in the z direction. The frame can form at least 99% of the perimeter of the cross-section in the second x / y plane. The frame can form 100% of the perimeter of the cross-section in the second x / y plane.

[0043] The air inlet can be positioned between the first x / y plane and the second x / y plane in the z direction. The air outlet can be positioned between the first x / y plane and the second x / y plane in the z direction.

[0044] The frame can comprise a first portion that is at least 30% of the thickness of the frame. The first portion can be at least 50% of the thickness of the frame. The first portion can be at least 70% of the thickness of the frame. The first portion can be at least 90% of the thickness of the frame. The frame forms 100% of the perimeter of any cross-section extending through an x / y plane of the aerosol-generating article of the first portion of the frame.

[0045] The aerosol-generating article can comprise one or more outer walls extending between the first planar outer surface and the second planar outer surface. The one or more outer walls can collectively define the entire lateral outer region of the aerosol-generating article. The frame can at least partially define each of the one or more outer walls.

[0046] The one or more outer walls can bound or encircle the cavity.

[0047] The frame can define at least 60% of the entire lateral outer region of the aerosol- generating article. The frame can define at least 60% of the entire lateral outer region of the aerosol- generating article. The frame can define at least 70% of the entire lateral outer region of the aerosol- generating article. The frame can define at least 80% of the entire lateral outer region of the aerosol- generating article. The frame can define at least 90% of the entire lateral outer region of the aerosol- generating article.

[0048] The frame can comprise a perimeter wall. The perimeter wall can bound or encircle at least a portion of the frame aperture extending through the thickness of the frame. The perimeter wall can bound or encircle at least a portion of the cavity. The perimeter wall can bound or encircle the frame aperture extending through the thickness of the frame. The perimeter wall can bound or encircle the cavity. Advantageously, such a perimeter wall allows for a relatively large internal volume of aerosol generating substrate or aerosol former, whilst providing structural strength to maintain the shape of the aerosol-generating article.

[0049] The perimeter wall can be defined or formed by a frame outer surface and a frame inner surface. The perimeter wall can at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The perimeter wall can define or form a frame aperture outer wall. The perimeter wall can define or form a cavity outer wall.

[0050] The perimeter wall can have a radial thickness. The radial thickness can be defined as the minimum distance (such as in the x / y plane) between the frame outer surface and the frame inner surface.

[0051] The perimeter wall can have a radial thickness greater than or equal to 0.5 millimetres. The perimeter wall can have a radial thickness greater than or equal to 1 millimetre. The perimeter wall can have a radial thickness greater than or equal to 1.5 millimetres. The perimeter wall can have a radial thickness greater than or equal to 2 millimetres. The perimeter wall can have a radial thickness greater than or equal to 2.5 millimetres.

[0052] The perimeter wall can have a radial thickness less than or equal to 4 millimetres. The perimeter wall can have a radial thickness less than or equal to 3.5 millimetres. The perimeter wall can have a radial thickness less than or equal to 3 millimetres. The perimeter wall can have a radial thickness less than or equal to 2.5 millimetres. The perimeter wall can have a radial thickness less than or equal to 2 millimetres.

[0053] The perimeter wall can have a radial thickness of between 0.5mm and 3.5mm. The perimeter wall can have a radial thickness of between 0.5mm and 3mm. The perimeter wall can have a radial thickness of between 0.5mm and 2.5mm. The perimeter wall can have a radial thickness of between 1mm and 3mm. The perimeter wall can have a radial thickness of between 1mm and 2mm. Advantageously, it has been found that a perimeter wall having a radial thickness of between 0.5mm and 3.5mm provides good structural strength to the aerosol generating article, whilst not using excess material which can increase manufacturing costs. Advantageously, a radial thickness of between 0.5mm and 3.5mm can limit the amount of heat which is undesirably transferred to the frame rather than the aerosol generating substrate.

[0054] The frame can be made of or comprise a biodegradable material. The frame can be made entirely of a biodegradable material.

[0055] The frame can be made of or comprise a cellulose material. The cellulose material can comprise a cellulose material sheet. The cellulose material can comprise cellulose fibres. The cellulose material can be paper, paperboard or cardboard. The frame can be made of or comprise a plant material, such as tobacco. The frame can be made entirely of a cellulose material.

[0056] The cellulose material can have a grammage of greater than or equal to 300g / m2. The cellulose material can have a grammage of greater than or equal to 350g / m2. The cellulose material can have a grammage of greater than or equal to 390g / m2. The cellulose material can have a grammage of greater than or equal to 420g / m2. The cellulose material can have a grammage of greater than or equal to 620g / m2. The cellulose material can have a grammage of greater than or equal to 720g / m2. The cellulose material can have a grammage of greater than or equal to 800g / m2.

[0057] The cellulose material can have a grammage of less than or equal to 900g / m2. The cellulose material can have a grammage of less than or equal to 800g / m2. The cellulose material can have a grammage of less than or equal to 720g / m2. The cellulose material can have a grammage of less than or equal to 620g / m2. The cellulose material can have a grammage of less than or equal to 420g / m2. The cellulose material can have a grammage of less than or equal to 390g / m2. The cellulose material can have a grammage of less than or equal to 350g / m2.

[0058] The cellulosic material can have a grammage of between 300 grams per square meter and 900 grams per square meter. The cellulosic material can have a grammage of between 300 grams per square meter and 800 grams per square meter. The cellulosic material can have a grammage of between 350 grams per square meter and 800 grams per square meter. The cellulosic material can have a grammage of between 400 grams per square meter and 700 grams per square meter.

[0059] The frame can be made of or include a fibrous material. The frame can be made of one or more of the following: natural fibers, synthetic fibers, polyesters, bonded polyolefins, polyethylene, dacron, polypropylene, biopolymer fibers, nylon fibers, and ceramic fibers. The frame can include cellulosic fibers.

[0060] The frame can include a hydrophobic region. The hydrophobic region can include a hydrophobic group covalently bonded to the frame. The hydrophobic region can be positioned on or form at least a portion of the inner surface of the frame. Advantageously, the hydrophobic region can prevent or limit degradation of the frame in areas where the frame is regularly contacted by aerosol or liquid from the aerosol generating substrate.

[0061] The hydrophobic region can be produced by a process including applying a liquid composition including a fatty acid halide to a surface of the frame and maintaining the surface at a temperature of about 120 degrees Celsius to about 180 degrees Celsius. The fatty acid halide reacts in situ with the proton groups of the material of the hydrophobic region, resulting in the formation of a fatty acid ester.

[0062] The hydrophobic region can have a Cobb Water Absorption (ISO 535:1991) value (at 60 seconds) of less than or equal to 40 grams per square meter. The hydrophobic region can have a Cobb Water Absorption (ISO 535:1991) value (at 60 seconds) of less than or equal to 35 grams per square meter. The hydrophobic region can have a Cobb Water Absorption (ISO 535:1991) value (at 60 seconds) of less than or equal to 30 grams per square meter. The hydrophobic region can have a Cobb Water Absorption (ISO 535:1991) value (at 60 seconds) of less than or equal to about 25 grams per square meter.

[0063] The hydrophobic region can have a water contact angle of greater than or equal to about 90 degrees. The hydrophobic region can have a water contact angle of greater than or equal to about 95 degrees. The hydrophobic region can have a water contact angle of greater than or equal to about 100 degrees. The hydrophobic region can have a water contact angle of greater than or equal to about 110 degrees. The hydrophobic region can have a water contact angle of greater than or equal to about 120 degrees. The hydrophobic region can have a water contact angle of greater than or equal to about 130 degrees. The hydrophobic region can have a water contact angle of greater than or equal to about 140 degrees. The hydrophobic region can have a water contact angle of greater than or equal to about 150 degrees. The hydrophobic region can have a water contact angle of greater than or equal to about 160 degrees. The hydrophobic region can have a water contact angle of greater than or equal to about 170 degrees.

[0064] Hydrophobicity is determined by utilizing the TAPPI T558 om-97 test and the results are presented as an interfacial contact angle and reported in "degrees" and can range from close to zero degrees to close to 180 degrees. When a contact angle is not specified along with the term hydrophobic, the water contact angle is at least 90 degrees.

[0065] The hydrophobic region can have a water contact angle of greater than or equal to 90 degrees and a Cobb water absorption (ISO 535:1991) value (at 60 seconds) of less than or equal to 40 grams per square meter.

[0066] The aerosol-generating article can comprise one or more susceptor materials. The frame can comprise one or more susceptor materials. The one or more susceptor materials can be in thermal contact with the aerosol-generating substrate. The one or more susceptor materials can be in thermal contact with the airflow pathway. The one or more susceptor materials can be in thermal contact with the cavity. The one or more susceptor materials can be positioned in or on the frame inner surface. The one or more susceptor materials can be comprised within the material of the frame. For example, the one or more susceptor materials can be comprised within the perimeter wall of the frame. Advantageously, the presence of the one or more susceptor materials can allow for heating of the aerosol-generating article, and thus the aerosol-generating substrate, by engagement with an oscillating electromagnetic field formed by the susceptor.

[0067] The one or more susceptor materials can be one or more susceptor material particles, strips, threads, or filaments. The one or more susceptor materials can be one or more susceptor material sheets or layers. The one or more susceptor material sheets or layers can be in the form of a susceptor material web.

[0068] The susceptor material in any form can comprise one or more materials selected from the group consisting of: aluminium, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0069] The frame can have a thickness greater than or equal to 50% of the thickness of the aerosol generating article. The frame can have a thickness greater than or equal to 60% of the thickness of the aerosol generating article. The frame can have a thickness greater than or equal to 70% of the thickness of the aerosol generating article. The frame can have a thickness greater than or equal to 80% of the thickness of the aerosol generating article. The frame can have a thickness greater than or equal to 90% of the thickness of the aerosol generating article. The frame can have a thickness greater than or equal to 95% of the thickness of the aerosol generating article.

[0070] The frame can have a thickness less than or equal to 95% of the thickness of the aerosol generating article. The frame can have a thickness less than or equal to 90% of the thickness of the aerosol generating article. The frame can have a thickness less than or equal to 80% of the thickness of the aerosol generating article. The frame can have a thickness less than or equal to 70% of the thickness of the aerosol generating article.

[0071] The frame can have a thickness between 50% of the thickness of the aerosol generating article and 95% of the thickness of the aerosol generating article. The frame can have a thickness between 60% of the thickness of the aerosol generating article and 95% of the thickness of the aerosol generating article. The frame can have a thickness between 70% of the thickness of the aerosol generating article and 95% of the thickness of the aerosol generating article. The frame can have a thickness between 80% of the thickness of the aerosol generating article and 95% of the thickness of the aerosol generating article.

[0072] The frame can have a thickness greater than or equal to 1 millimeter. The frame can have a thickness greater than or equal to 1.5 millimeters. The frame can have a thickness greater than or equal to 2 millimeters. The frame can have a thickness greater than or equal to 2.5 millimeters. The frame can have a thickness greater than or equal to 3 millimeters. The frame can have a thickness greater than or equal to 3.5 millimeters. The frame can have a thickness greater than or equal to 4 millimeters. The frame can have a thickness greater than or equal to 4.5 millimeters.

[0073] The frame can have a thickness less than or equal to 5.5 millimeters. The frame can have a thickness less than or equal to 5 millimeters. The frame can have a thickness less than or equal to 4.5 millimeters. The frame can have a thickness less than or equal to 4 millimeters. The frame can have a thickness less than or equal to 3.5 millimeters. The frame can have a thickness less than or equal to 3 millimeters. The frame can have a thickness less than 2.5 millimeters. The frame can have a thickness less than 2 millimeters. The frame can have a thickness less than 1.5 millimeters.

[0074] The frame can have a thickness between 1 millimeter and 5.5 millimeters. The frame can have a thickness between 1 millimeter and 5 millimeters. Preferably, the frame can have a thickness between 1.5 millimeters and 5 millimeters.

[0075] The frame can have a length equal to a length of the aerosol-generating article. The frame can have a length that is at least 90% of a length of the aerosol-generating article. The frame can have a length that is at least 95% of a length of the aerosol-generating article.

[0076] The frame can have a width equal to a width of the aerosol-generating article. The frame can have a width that is at least 90% of a width of the aerosol-generating article. The frame can have a width that is at least 90% of a width of the aerosol-generating article.

[0077] 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 individually optimised 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 produced 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 can then need to be changed if the desired thickness of the frame changes.

[0078] The frame can comprise a first frame layer and a second frame layer. The first frame layer and the second frame layer can be the only layers of the frame. That is, the frame can comprise no more than two layers or can comprise exactly two layers. The first frame layer can be an upper frame layer and the second frame layer can be a lower frame layer.

[0079] The frame can have a thickness equal to the sum of the thickness of the first frame layer and the thickness of the second frame layer. The frame aperture can be defined through both the first frame layer and the second frame layer.

[0080] The frame can comprise a first frame layer, a second frame layer and a third frame layer. The second frame layer can 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 can be the only layers of the frame. That is, the frame can comprise no more than three layers or can comprise exactly three layers. The first frame layer can be an upper frame layer, the second frame layer can be an intermediate frame layer and the third frame layer can be a lower frame layer.

[0081] The first frame layer can be in physical contact with the second frame layer. The first frame layer can be bonded to the second frame layer with an adhesive. A lower surface of the first frame layer can be bonded to an upper surface of the second frame layer with an adhesive. The adhesive can extend around at least 90% of a perimeter of an intersection between the first frame layer and the second frame layer. The adhesive can extend around at least 95% of a perimeter of an intersection between the first frame layer and the second frame layer. The adhesive can extend around at least 99% of a perimeter of an intersection between the first frame layer and the second frame layer.

[0082] The second frame layer can be in physical contact with the third frame layer. The second frame layer can be bonded to the third frame layer with an adhesive. The lower surface of the second frame layer can be bonded to the upper surface of the third frame layer with an adhesive. The adhesive can extend around at least 90% of the perimeter of the intersection between the second frame layer and the third frame layer. The adhesive can extend around at least 95% of the perimeter of the intersection between the second frame layer and the third frame layer. The adhesive can extend around at least 99% of the perimeter of the intersection between the second frame layer and the third frame layer.

[0083] The frame can have a thickness equal to the sum of the thickness of the first frame layer, the thickness of the second frame layer, and the thickness of the third frame layer. The frame aperture can be defined through the first planar layer, the second planar layer, and the third frame layer.

[0084] The first frame layer can be planar.

[0085] The first frame layer can define a first frame layer aperture extending through the thickness of the first frame layer. The first frame layer aperture can at least partially define or form a cavity of the aerosol-generating article. For example, the first frame layer can have a hollow cuboid shape or a square hollow tube shape. As a further example, the first frame layer can 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 can have a girdle shape, such as a circular girdle shape, an elliptical girdle shape, a rectangular girdle shape, or a square girdle shape.

[0086] The first frame layer can comprise a first frame layer outer surface. The first frame layer outer surface can extend in the lateral direction, for example between the first planar outer surface and the second planar outer surface. The first frame layer outer surface can at least partially define or form one or more outer surfaces of the aerosol-generating article. For example, the first frame layer outer surface can at least partially define or form one or more outer walls of the aerosol-generating article. The first frame layer outer surface can bound or encircle one or both of the first frame layer aperture and the frame aperture. The first frame layer outer surface can bound or encircle the cavity.

[0087] The first frame layer can comprise a first frame layer inner surface. The first frame layer inner surface can extend in the lateral direction, for example between the first planar outer surface and the second planar outer surface. The first frame layer inner surface can define or form a first frame layer aperture outer wall. The first frame layer inner surface can at least partially define or form a cavity outer wall. The first frame layer inner surface can bound or encircle one or both of the first frame layer aperture and the frame aperture. The first frame layer outer surface can bound or encircle the cavity.

[0088] The first frame layer outer surface can bound or encircle the first frame layer inner surface. The first frame layer inner surface and the first frame layer outer surface can be concentric with each other.

[0089] The first frame layer can comprise a first frame layer perimeter wall. The first frame layer perimeter wall can bound or encircle one or both of: the frame aperture and the first frame layer aperture. The first frame layer perimeter wall can bound or encircle the cavity.

[0090] The first frame layer perimeter wall can be defined or formed by a first frame layer outer surface and a first frame layer inner surface. The first frame layer perimeter wall can at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The first frame layer perimeter wall can at least partially define or form a first frame layer aperture outer wall. The first frame layer perimeter wall can at least partially define or form a cavity outer wall.

[0091] The first frame layer can be made of or comprise any of the materials described above in relation to the frame. For example, the first frame layer can comprise one or more susceptor materials.

[0092] The first frame layer can be made of or comprise a biodegradable material. The first frame layer can be made entirely of a biodegradable material.

[0093] The first frame layer can be made of or comprise a cellulose material. The cellulose material can comprise a cellulose material sheet. The cellulose material can comprise cellulose fibres. The cellulose material can be paper, paperboard or cardboard. The first frame layer can be made of or comprise a plant material, such as tobacco. The first frame layer can be made entirely of a cellulose material.

[0094] The cellulose material can have any of the grammage or grammage ranges described above in relation to the frame.

[0095] The first frame layer can be made of a fibrous material. The first frame layer can be made of one or more of: natural fibres, synthetic fibres, polyester, bonded polyolefin, polyethylene, dacron, polypropylene, biopolymer fibres, nylon fibres and ceramic fibres.

[0096] In the case where the frame comprises 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 comprises 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.

[0097] The first frame layer can have a thickness greater than or equal to 0.5 millimetres. The frame can have a thickness greater than or equal to 1 millimetre. The first frame layer can have a thickness greater than or equal to 1.5 millimetres. The first frame layer can have a thickness greater than or equal to 2 millimetres. The first frame layer can have a thickness greater than or equal to 2.5 millimetres.

[0098] The first frame layer can have a thickness less than or equal to 3 millimetres. The first frame layer can have a thickness less than or equal to 2.5 millimetres. The first frame layer can have a thickness less than or equal to 2 millimetres. The first frame layer can have a thickness less than or equal to 1.5 millimetres. The first frame layer can have a thickness less than or equal to 1 millimetre.

[0099] The first frame layer can have a thickness between 0.5 millimetres and 3 millimetres. The first frame layer can have a thickness between 0.5 millimetres and 2.5 millimetres. The first frame layer can have a thickness between 1 millimetre and 2.5 millimetres.

[0100] The second frame layer can be planar.

[0101] The second frame layer can define a second frame layer aperture extending through a thickness of the second frame layer. The second frame layer aperture can at least partially define or form a cavity of the aerosol-generating article. For example, the second frame layer can have a hollow cuboid shape or a square hollow tube shape. As a further example, the second frame layer can 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 can have a ring-belt shape, such as a circular ring-belt shape, an elliptical ring-belt shape, a rectangular ring-belt shape, or a square ring-belt shape.

[0102] The second frame layer can comprise a second frame layer outer surface. The second frame layer outer surface can extend in a lateral direction, for example between the second planar outer surface and the second planar outer surface. The second frame layer outer surface can at least partially define or form one or more outer surfaces of the aerosol-generating article. For example, the second frame layer outer surface can at least partially define or form one or more outer walls of the aerosol-generating article. The second frame layer outer surface can bound or encircle one or both of: the second frame layer aperture and the frame aperture. The second frame layer outer surface can bound or encircle the cavity.

[0103] The second frame layer can comprise a second frame layer inner surface. The second frame layer inner surface can extend in a lateral direction, for example between the second planar outer surface and the second planar outer surface. The second frame layer inner surface can define or form a second frame layer aperture outer wall. The second frame layer inner surface can at least partially define or form a cavity outer wall. The second frame layer inner surface can bound or encircle one or both of: the second frame layer aperture and the frame aperture. The second frame layer outer surface can bound or encircle the cavity.

[0104] The second frame layer outer surface can bound or encircle the second frame layer inner surface. The second frame layer inner surface and the second frame layer outer surface can be concentric with one another.

[0105] The second frame layer can comprise a second frame layer perimeter wall. The second frame layer perimeter wall can bound or encircle one or both of: the frame aperture and the second frame layer aperture. The second frame layer perimeter wall can bound or encircle the cavity.

[0106] The second frame layer perimeter wall can be defined or formed by a second frame layer outer surface and a second frame layer inner surface. The second frame layer perimeter wall can at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The second frame layer perimeter wall can at least partially define or form a second frame layer aperture outer wall. The second frame layer perimeter wall can at least partially define or form a cavity outer wall.

[0107] The second frame layer can be made of or comprise any of the materials described above in relation to the frame. For example, the second frame layer can comprise one or more susceptor materials.

[0108] The second frame layer can be made of or comprise a biodegradable material. The second frame layer can be made entirely of a biodegradable material.

[0109] The second frame layer can be made of or comprise a cellulose material. The cellulose material can comprise a cellulose material sheet. The cellulose material can be paper, paperboard or cardboard. The second frame layer can be made of or comprise a plant material, such as tobacco. The second frame layer can be made entirely of a cellulose material.

[0110] The cellulose material can have any of the grammage or grammage ranges described above in relation to the frame.

[0111] The second frame layer can be made of a fibrous material. The second frame layer can be made of one or more of: natural fibres, synthetic fibres, polyesters, bonded polyolefins, polyethylene, dacron, polypropylene, biopolymer fibres, nylon fibres and ceramic fibres.

[0112] In the case where the frame comprises exactly two layers, the second frame layer can have a thickness that is 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 comprises exactly three layers, the second frame layer can have a thickness that is 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.

[0113] The second frame layer can have a thickness greater than or equal to 0.5 millimetres. The frame can have a thickness greater than or equal to 1 millimetre. The second frame layer can have a thickness greater than or equal to 1.5 millimetres. The second frame layer can have a thickness greater than or equal to 2 millimetres. The second frame layer can have a thickness greater than or equal to 2.5 millimetres.

[0114] The second frame layer can have a thickness less than or equal to 3 millimetres. The second frame layer can have a thickness less than or equal to 2.5 millimetres. The second frame layer can have a thickness less than or equal to 2 millimetres. The second frame layer can have a thickness less than or equal to 1.5 millimetres. The second frame layer can have a thickness less than or equal to 1 millimetre.

[0115] The second frame layer can have a thickness between 0.5 millimetres and 3 millimetres. The second frame layer can have a thickness between 0.5 millimetres and 2.5 millimetres. The second frame layer can have a thickness between 1 millimetre and 2.5 millimetres.

[0116] The third frame layer can be planar.

[0117] The third frame layer can define a third frame layer aperture extending through a thickness of the third frame layer. The third frame layer aperture can at least partially define or form a cavity of the aerosol-generating article. For example, the third frame layer can have a hollow cuboid shape or a square hollow tube shape. As a further example, the third frame layer can 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 can have a girdle shape, such as a circular girdle shape, an elliptical girdle shape, a rectangular girdle shape, or a square girdle shape.

[0118] The third frame layer can comprise a third frame layer outer surface. The third frame layer outer surface can extend in a lateral direction, for example between the third planar outer surface and the third planar outer surface. The third frame layer outer surface can at least partially define or form one or more outer surfaces of the aerosol-generating article. For example, the third frame layer outer surface can at least partially define or form one or more outer walls of the aerosol-generating article. The third frame layer outer surface can bound or surround one or both of: the third frame layer aperture and the frame aperture. The third frame layer outer surface can bound or surround the cavity.

[0119] The third frame layer can comprise a third frame layer inner surface. The third frame layer inner surface can extend in a lateral direction, for example between the third planar outer surface and the third planar outer surface. The third frame layer inner surface can define or form a third frame layer aperture outer wall. The third frame layer inner surface can at least partially define or form a cavity outer wall. The third frame layer inner surface can bound or surround one or both of: the third frame layer aperture and the frame aperture. The third frame layer outer surface can bound or surround the cavity.

[0120] The third frame layer outer surface can bound or surround the third frame layer inner surface. The third frame layer inner surface and the third frame layer outer surface can be concentric with one another.

[0121] The third framework layer can comprise a third framework layer perimeter wall. The third framework layer perimeter wall can bound or encircle one or both of: the framework aperture and the third framework layer aperture. The third framework layer perimeter wall can bound or encircle the cavity.

[0122] The third framework layer perimeter wall can be defined or formed by a third framework layer outer surface and a third framework layer inner surface. The third framework layer perimeter wall can at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The third framework layer perimeter wall can at least partially define or form a third framework layer aperture outer wall. The third framework layer perimeter wall can at least partially define or form a cavity outer wall.

[0123] The third framework layer can be made of or comprise any of the materials described above in relation to the framework. For example, the third framework layer can comprise one or more susceptor materials.

[0124] The third framework layer can be made of or comprise a biodegradable material. The third framework layer can be made entirely of a biodegradable material.

[0125] The third framework layer can be made of or comprise a cellulosic material. The cellulosic material can comprise a cellulosic material sheet. The cellulosic material can be paper, paperboard or cardboard. The third framework layer can be made of or comprise a plant material, such as tobacco. The third framework layer can be made entirely of a cellulosic material.

[0126] The cellulosic material can have any of the grammage or grammage ranges described above in relation to the framework.

[0127] The third framework layer can be made of a fibrous material. The third framework layer can be made of one or more of: natural fibres, synthetic fibres, polyesters, bonded polyolefins, polyethylene, dacron, polypropylene, biopolymer fibres, nylon fibres and ceramic fibres.

[0128] In the case where the framework comprises exactly three layers, the thickness of the third framework layer can be one third (33.33%) of the thickness of the framework. The third framework layer can have substantially the same thickness as each of the first and second framework layers.

[0129] The third framework layer can have a thickness greater than or equal to 0.5 millimetres. The framework can have a thickness greater than or equal to 1 millimetre. The third framework layer can have a thickness greater than or equal to 1.5 millimetres. The third framework layer can have a thickness greater than or equal to 2 millimetres. The third framework layer can have a thickness greater than or equal to 2.5 millimetres.

[0130] The third frame layer can have a thickness less than or equal to 3 millimeters. The third frame layer can have a thickness less than or equal to 2.5 millimeters. The third frame layer can have a thickness less than or equal to 2 millimeters. The third frame layer can have a thickness less than or equal to 1.5 millimeters. The third frame layer can have a thickness less than or equal to 1 millimeter.

[0131] The third frame layer can have a thickness between 0.5 millimeters and 3 millimeters. The third frame layer can have a thickness between 0.5 millimeters and 2.5 millimeters. The third frame layer can have a thickness between 1 millimeter and 2.5 millimeters.

[0132] The one or more aerosol-generating substrates can comprise an aerosol-generating substrate layer. Advantageously, the aerosol-generating substrate layer can be made thin and thus heat up quickly and release volatile compounds to form an aerosol. Advantageously, the aerosol-generating substrate layer can be positioned proximate to the heater of the aerosol-generating substrate.

[0133] The aerosol-generating substrate layer can comprise an aerosol-generating material. The aerosol-generating material can be any of the aerosol-generating materials described herein. The aerosol-generating material can be in the form of an aerosol-generating material sheet. The aerosol-generating material sheet can be any of the aerosol-generating material sheets described herein. The aerosol-generating substrate layer can be an aerosol-generating material sheet and can be made entirely of an aerosol-generating material sheet.

[0134] The aerosol-generating substrate layer can be positioned between the frame and the first planar outer surface. The aerosol-generating substrate layer can be positioned between the frame and the second planar outer surface. The aerosol-generating substrate layer can be in physical contact with the frame and can be bonded to the frame. The aerosol-generating substrate layer can be bonded to the frame with an adhesive.

[0135] The aerosol-generating substrate layer can be positioned between the frame and the outer wrapper. The outer wrapper is discussed in more detail below. The aerosol-generating substrate layer can be in physical contact with both the frame and the outer wrapper and can be bonded to both the frame and the outer wrapper. The aerosol-generating substrate layer can be bonded to both the frame and the outer wrapper with an adhesive.

[0136] The aerosol-generating substrate layer can be positioned between the frame and the first planar outer layer. The aerosol-generating substrate layer can be positioned between the frame and the second planar outer layer. The first and second planar outer layers are discussed in more detail below. The aerosol-generating substrate layer can be in physical contact with both the frame and the first planar outer layer and can be bonded to both the frame and the first planar outer layer. The aerosol-generating substrate layer can be bonded to both the frame and the first planar outer layer with an adhesive. The aerosol-generating substrate layer can be in physical contact with both the frame and the second planar outer layer and can be bonded to both the frame and the second planar outer layer. The aerosol-generating substrate layer can be bonded to both the frame and the second planar outer layer with an adhesive.

[0137] The aerosol-generating substrate layer can overlie the end of the cavity. The aerosol-generating substrate layer can define or form a wall of the cavity, such as the first cavity end wall or the second cavity end wall. Advantageously, the aerosol-generating substrate layer can therefore be in or at least partially define or form the airflow pathway, thereby allowing the released volatile compounds to rapidly form an aerosol.

[0138] The one or more aerosol-generating substrates can 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 can allow a satisfactory volume of aerosol to be generated rapidly compared to using a single aerosol-generating substrate layer.

[0139] The first aerosol-generating substrate layer can comprise an aerosol- generating material. The aerosol-generating material can be any aerosol-generating material described herein. 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 described herein. The first aerosol-generating substrate layer can be and can be made entirely from an aerosol-generating material sheet.

[0140] The second aerosol-generating substrate layer can comprise an aerosol- generating material. The aerosol-generating material can be any aerosol-generating material described herein. 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 described herein. The second aerosol-generating substrate layer can be and can be made entirely from an aerosol-generating material sheet.

[0141] The first aerosol-generating substrate layer can be positioned between the frame and the first planar outer surface. The first aerosol-generating substrate layer can be in physical contact with the frame and can be bonded to the frame. For example, the first aerosol-generating substrate layer can be in physical contact with and can be bonded to the first frame layer. The first aerosol-generating substrate layer can be bonded to the frame with an adhesive. The first aerosol-generating substrate layer can be bonded to the first frame layer with an adhesive. The lower surface of the first aerosol-generating substrate layer can be bonded to the upper surface of the first frame layer with an adhesive.

[0142] The first aerosol-generating substrate layer can be positioned between the frame and the outer wrapper. The first aerosol-generating substrate layer can be in physical contact with both the frame and the outer wrapper and can be bonded to both the frame and the outer wrapper. The first aerosol-generating substrate layer can be bonded to the frame and the outer wrapper with an adhesive.

[0143] The first aerosol-generating substrate layer can be positioned between the frame and the first out-of-plane layer. The first aerosol-generating substrate layer can be in physical contact with both the frame and the first out-of-plane layer, and can be bonded to both the frame and the first out-of-plane layer. The first aerosol-generating substrate layer can be bonded to the frame and the first out-of-plane layer with an adhesive.

[0144] The second aerosol-generating substrate layer can be positioned between the frame and the second out-of-plane surface. The second aerosol-generating substrate layer can be in physical contact with the frame, and can be bonded to the frame. For example, the second aerosol-generating substrate layer can be in physical contact with the second frame layer or the third frame layer, and can be bonded to the second frame layer or the third frame layer. The second aerosol-generating substrate layer can be bonded to the frame with an adhesive. The second aerosol-generating substrate layer can be bonded to the second frame layer or the third frame layer with an adhesive. An upper surface of the second aerosol-generating substrate layer can be bonded to a lower surface of the second frame layer or the third frame layer with an adhesive.

[0145] The second aerosol-generating substrate layer can be positioned between the frame and the outer wrapper. The second aerosol-generating substrate layer can be in physical contact with both the frame and the outer wrapper, and can be bonded to both the frame and the outer wrapper. The second aerosol-generating substrate layer can be bonded to the frame and the outer wrapper with an adhesive.

[0146] The second aerosol-generating substrate layer can be positioned between the frame and the second out-of-plane layer. The second aerosol-generating substrate layer can be in physical contact with both the frame and the second out-of-plane layer, and can be bonded to both the frame and the second out-of-plane layer. The second aerosol-generating substrate layer can be bonded to the frame and the second out-of-plane layer with an adhesive.

[0147] The first aerosol-generating substrate layer and the second aerosol-generating substrate layer can overlie opposite ends of the cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer can define or form opposite end walls of the cavity. That is, the frame, the first aerosol-generating substrate layer, and the second aerosol-generating substrate layer can 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.

[0148] The aerosol-generating substrate layer can be a planar aerosol-generating substrate layer. The planar aerosol-generating substrate layer can extend in the x-direction and the y-direction. That is, the planar aerosol-generating substrate layer can extend in the x / y plane.

[0149] The first aerosol-generating substrate layer can be a first planar aerosol-generating substrate layer. The first planar aerosol-generating substrate layer can extend in the x-direction and the y-direction. That is, the first planar aerosol-generating substrate layer can extend in the x / y plane.

[0150] The second aerosol-generating substrate layer can be a second planar aerosol-generating substrate layer. The second planar aerosol-generating substrate layer can extend in the x-direction and the y-direction. That is, the second planar aerosol-generating substrate layer can extend in the x / y plane.

[0151] The aerosol-generating substrate layer can have a thickness of greater than or equal to 100 micrometres. The aerosol-generating substrate layer can have a thickness of greater than or equal to 200 micrometres. The aerosol-generating substrate layer can have a thickness of greater than or equal to 300 micrometres. The aerosol-generating substrate layer can have a thickness of greater than or equal to 400 micrometres. The aerosol-generating substrate layer can have a thickness of greater than or equal to 500 micrometres.

[0152] The aerosol-generating substrate layer can have a thickness of less than or equal to 600 micrometres. The aerosol-generating substrate layer can have a thickness of less than or equal to 500 micrometres. The aerosol-generating substrate layer can have a thickness of less than or equal to 400 micrometres. The aerosol-generating substrate layer can have a thickness of less than or equal to 300 micrometres. The aerosol-generating substrate layer can have a thickness of less than or equal to 200 micrometres.

[0153] The aerosol-generating substrate layer can have a thickness of between 100 micrometres and 600 micrometres. The aerosol-generating substrate layer can have a thickness of between 200 micrometres and 500 micrometres. The aerosol-generating substrate layer can have a thickness of between 200 micrometres and 400 micrometres. The aerosol-generating substrate layer can have a thickness of between 200 micrometres and 300 micrometres.

[0154] One or both of the first and second aerosol-generating substrate layers can have a thickness of greater than or equal to 100 micrometres. One or both of the first and second aerosol-generating substrate layers can have a thickness of greater than or equal to 200 micrometres. One or both of the first and second aerosol-generating substrate layers can have a thickness of greater than or equal to 300 micrometres. One or both of the first and second aerosol-generating substrate layers can have a thickness of greater than or equal to 400 micrometres. One or both of the first and second aerosol-generating substrate layers can have a thickness of greater than or equal to 500 micrometres.

[0155] One or both of the first and second aerosol-generating substrate layers can have a thickness less than or equal to 600 micrometres. One or both of the first and second aerosol-generating substrate layers can have a thickness less than or equal to 500 micrometres. One or both of the first and second aerosol-generating substrate layers can have a thickness less than or equal to 400 micrometres. One or both of the first and second aerosol-generating substrate layers can have a thickness less than or equal to 300 micrometres. One or both of the first and second aerosol-generating substrate layers can have a thickness less than or equal to 200 micrometres.

[0156] One or both of the first and second aerosol-generating substrate layers can have a thickness between 100 micrometres and 600 micrometres. One or both of the first and second aerosol-generating substrate layers can have a thickness between 200 micrometres and 500 micrometres. One or both of the first and second aerosol-generating substrate layers can have a thickness between 200 micrometres and 400 micrometres. One or both of the first and second aerosol-generating substrate layers can have a thickness between 200 micrometres and 300 micrometres.

[0157] The aerosol-generating substrate layer can have substantially the same length as the length of the frame. The aerosol-generating substrate layer can have substantially the same length as the length of the aerosol-generating article.

[0158] The first aerosol-generating substrate layer can have substantially the same length as the length of the frame. The first aerosol-generating substrate layer can have substantially the same length as the length of the aerosol-generating article.

[0159] The second aerosol-generating substrate layer can have substantially the same length as the length of the frame. The second aerosol-generating substrate layer can have substantially the same length as the length of the aerosol-generating article.

[0160] The aerosol-generating substrate layer can have substantially the same width as the width of the frame. The aerosol-generating substrate layer can have substantially the same width as the width of the aerosol-generating article.

[0161] The first aerosol-generating substrate layer can have substantially the same width as the width of the frame. The first aerosol-generating substrate layer can have substantially the same width as the width of the aerosol-generating article.

[0162] The second aerosol-generating substrate layer can have substantially the same width as the width of the frame. The second aerosol-generating substrate layer can have substantially the same width as the width of the aerosol-generating article.

[0163] The first planar outer surface can be a planar upper surface, and the second planar outer surface can be a planar lower surface. The first planar outer surface can be a planar top surface, and the second planar outer surface can be a planar bottom surface. The first planar outer surface can be a planar top panel surface, and the second planar outer surface can be a planar base surface.

[0164] The first planar outer surface can be positioned parallel to the second planar outer surface. The first planar outer surface can extend in the x-direction and the y-direction. That is, the first planar outer surface can extend in the x / y plane. The second planar outer surface can extend in the x-direction and the y-direction. That is, the second planar outer surface can extend in the x / y plane.

[0165] The second planar outer surface can be spaced apart from the first planar outer surface in the z-direction or the lateral direction. A distance between the first planar outer surface and the second planar outer surface in the z-direction or the lateral direction can define a thickness of the aerosol-generating article. That is, the thickness of the aerosol-generating article can be defined by the perpendicular distance between the first planar outer surface and the second planar outer surface.

[0166] The aerosol-generating article can include an outer wrapper. The outer wrapper can be hydrophobic. The outer wrapper can include a hydrophobic material.

[0167] The outer wrapper can define or form the first planar outer surface. The outer wrapper can define or form the second planar outer surface. The outer wrapper can define or form both the first planar outer surface and the second planar outer surface.

[0168] The outer wrapper can bound or surround the frame. The outer wrapper can be in physical contact with the frame and can be bonded to the frame. The outer wrapper can overlie opposite ends of the cavity. The outer wrapper can define or form opposite end walls of the cavity, such as a first cavity end wall and a second cavity end wall. That is, the frame and the outer wrapper can collectively define the cavity. In other words, the cavity is defined by the frame and the outer wrapper.

[0169] The outer wrapper can bound or surround the frame and the aerosol-generating substrate layer. The outer wrapper can be in physical contact with both the frame and the aerosol-generating substrate layer and can be bonded to both the frame and the aerosol-generating substrate layer.

[0170] The outer wrapper can bound or surround the frame, the first aerosol-generating substrate layer, and the second aerosol-generating substrate layer. The outer wrapper can be in physical contact with both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer and can be bonded to both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer.

[0171] The aerosol-generating article can comprise a first planar outer layer and a second planar outer layer. The first planar outer layer can be an upper layer and the second planar outer layer can be a lower layer. The first planar outer layer can be a top layer and the second planar outer layer can be a bottom layer. The first planar outer layer can be a top deck layer and the second planar outer layer can be a base layer.

[0172] The first planar outer layer can define or form a first planar outer surface. The first planar outer layer can extend in the x-direction and the y-direction. That is, the first planar outer layer can extend in the x / y plane. The second planar outer layer can define or form a second planar outer surface. The second planar outer layer can extend in the x-direction and the y-direction. That is, the second planar outer layer can extend in the x / y plane.

[0173] The first planar outer layer can be in physical contact with the frame and can be bonded to the frame. The first planar outer layer can be bonded to the frame with an adhesive. The first planar outer layer can be bonded to the first frame layer with an adhesive. The lower surface of the first planar outer layer can be bonded to the upper surface of the first frame layer with an adhesive. The adhesive can extend around at least 90% of the perimeter of the intersection between the first planar outer layer and the frame. The adhesive can extend around at least 95% of the perimeter of the intersection between the first planar outer layer and the frame. The adhesive can extend around at least 99% of the perimeter of the intersection between the first planar outer layer and the frame.

[0174] The first planar outer layer can overlie an end of the cavity. The first planar outer layer can define or form a wall of the cavity, such as a first cavity end wall.

[0175] The second planar outer layer can be in physical contact with the frame and can be bonded to the frame. The second planar outer layer can be bonded to the frame with an adhesive. The second planar outer layer can be bonded to the second frame layer with an adhesive. The upper surface of the second planar outer layer can be bonded to the lower surface of the second frame layer with an adhesive. The second planar outer layer can be bonded to the third frame layer with an adhesive. The upper surface of the second planar outer layer can be bonded to the lower surface of the third frame layer with an adhesive. The adhesive can extend around at least 90% of the perimeter of the intersection between the second planar outer layer and the frame. The adhesive can extend around at least 95% of the perimeter of the intersection between the second planar outer layer and the frame. The adhesive can extend around at least 99% of the perimeter of the intersection between the second planar outer layer and the frame.

[0176] The second planar outer layer can overlie an end of the cavity. The second planar outer layer can define or form a wall of the cavity, such as a second cavity end wall.

[0177] The first planar outer layer and the second planar outer layer can overlie opposite ends of the cavity. The first planar outer layer and the second planar outer layer can define or form opposite end walls of the cavity, such as a first cavity end wall and a second cavity end wall. That is, the frame, the first planar outer layer and the second planar outer layer can collectively define the cavity. In other words, the cavity is defined by the frame, the first planar outer layer and the second planar outer layer.

[0178] The first planar outer layer can be spaced apart from the frame, such as in the transverse direction. For example, an aerosol generating substrate layer or a first aerosol generating substrate layer can be positioned between the first planar outer layer and the frame. The first planar outer layer can be in physical contact with the aerosol generating substrate layer or the first aerosol generating substrate layer and can be bonded to the aerosol generating substrate layer or the first aerosol generating substrate layer. The first planar outer layer can be bonded to the aerosol generating substrate layer or the first aerosol generating substrate layer with an adhesive.

[0179] The second planar outer layer can be spaced apart from the frame, such as in the transverse direction. For example, an aerosol generating substrate layer or a second aerosol generating substrate layer can be positioned between the second planar outer layer and the frame. The second planar outer layer can be in physical contact with the aerosol generating substrate layer or the second aerosol generating substrate layer and can be bonded to the aerosol generating substrate layer or the second aerosol generating substrate layer. The second planar outer layer can be bonded to the aerosol generating substrate layer or the second aerosol generating substrate layer with an adhesive.

[0180] The first planar outer layer can be hydrophobic. The first planar outer layer can comprise a hydrophobic material. The second planar outer layer can be hydrophobic. The second planar outer layer can comprise a hydrophobic material.

[0181] Advantageously, the adhesive bonding the components of the aerosol generating article together can 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 can 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.

[0182] Providing a tight seal between the layers of the aerosol generating article can improve airflow through the cavity. Improving airflow through the cavity can improve the user experience.

[0183] Advantageously, bonding the components of the aerosol generating article together using an adhesive can provide an aerosol generating article with high structural integrity.

[0184] The adhesive can comprise a gum. The adhesive can comprise guar gum. The adhesive can comprise polyvinyl alcohol. The adhesive can comprise an aerosol generating material. The adhesive can consist of an aerosol generating material. For example, the adhesive can be a homogenised tobacco pulp. The adhesive can be or can comprise a flavourant and / or an aerosol former.

[0185] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer can be made of a cellulosic material. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer can include a cellulosic material. The cellulosic material can be paper, cardboard, wood, a textile, a natural fiber, or a man-made fiber.

[0186] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer can be an aerosol generating substrate comprising an aerosol generating material. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer can include an aerosol generating material. The aerosol generating material can be any of the aerosol generating materials 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 of the aerosol generating material sheets described herein. Alternatively, one or more of the outer wrapper, the first planar outer layer, and the second planar outer layer can not include any aerosol generating material, in particular in embodiments comprising an aerosol generating substrate layer, a first aerosol generating substrate layer, a second aerosol generating substrate layer, or an aerosol generating substrate positioned within the cavity. For example, one or more of the outer wrapper, the first planar outer layer, and the second planar outer layer can not include tobacco. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer can be substantially free of nicotine.

[0187] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer can include a paper material. For example, one or more of the outer wrapper, the first planar outer layer, and the second planar outer layer can be paper, cardboard, cigarette paper, or tobacco paper.

[0188] The cellulosic material can have a basis weight of greater than 10 grams per square meter. The cellulosic material can have a basis weight of greater than 20 grams per square meter. The cellulosic material can have a basis weight of less than 30 grams per square meter. The cellulosic material can have a basis weight of less than 25 grams per square meter. The cellulosic material can have a basis weight of between 10 grams per square meter and 30 grams per square meter. The cellulosic material can have a basis weight of between 15 grams per square meter and 25 grams per square meter.

[0189] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer can include paper and non-paper components.

[0190] One or more of the overwrap, the first planar outer layer, and the second planar outer layer can exhibit a range of permeability, including impermeable. Permeability is determined using the International Standard Test Method ISO 2965:2009, and the result is presented in cubic centimeters per minute per square centimeter, and is referred to as "CORESTA units." One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a permeability between 1 and 10 CORESTA units. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a permeability between 1 and 5 CORESTA units. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a permeability between 5 and 20 CORESTA units.

[0191] One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a thickness greater than or equal to 25 microns. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a thickness greater than or equal to 30 microns. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a thickness greater than or equal to 35 microns. The overwrap can have a thickness greater than or equal to 40 microns. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a thickness greater than or equal to 45 microns.

[0192] One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a thickness less than or equal to 55 microns. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a thickness greater than or equal to 50 microns. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a thickness greater than or equal to 45 microns. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a thickness greater than or equal to 40 microns. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a thickness greater than or equal to 35 microns.

[0193] One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a thickness between 25 microns and 55 microns. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a thickness between 25 microns and 45 microns. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a thickness between 30 microns and 45 microns.

[0194] One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a length that is substantially the same as a length of the frame. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a length that is substantially the same as a length of the aerosol generating article. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a length that is greater than or equal to 90% of a length of the frame. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a length that is greater than or equal to 95% of a length of the frame.

[0195] One or more of the first planar outer layer and the second planar outer layer can have a width that is substantially the same as a width of the frame. One or more of the first planar outer layer and the second planar outer layer can have a width that is substantially the same as a width of the aerosol generating article. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a width that is greater than or equal to 90% of a width of the frame. One or more of the overwrap, the first planar outer layer, and the second planar outer layer can have a width that is greater than or equal to 95% of a width of the frame.

[0196] The cavity can comprise a first cavity end wall and a second cavity end wall positioned opposite the first cavity end wall. The first cavity end wall can be defined or formed by the overwrap, the first planar outer layer, or the first aerosol generating substrate layer. The second cavity end wall can be defined or formed by the overwrap, the second planar outer layer, or the second aerosol generating substrate layer. The cavity can be enclosed by the first cavity end wall, the second cavity end wall, and the frame.

[0197] The cavity can comprise a cavity outer wall. The cavity outer wall can be defined or formed by the frame. The cavity outer wall can extend in the transverse direction. The cavity outer wall can extend in the transverse direction between the first cavity end wall and the second cavity end wall. The cavity outer wall can be defined or formed by an inner surface of the frame. The cavity outer wall can be defined or formed by a peripheral wall of the frame.

[0198] The cavity can have at least two corners extending between the first planar outer surface and the second planar outer surface. The at least two corners can 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.

[0199] Advantageously, a cavity having chamfered, rounded or filleted corners can make the cavity easier to heat. In particular, it can make it easier to heat the aerosol generating substrate positioned within the cavity. Advantageously, a cavity having chamfered, rounded or filleted corners can make the aerosol generating article more robust and less susceptible to damage. Advantageously, a cavity having chamfered, rounded or filleted corners can make the aerosol generating article easier to manufacture.

[0200] The cavity can have a thickness that is substantially the same as a thickness of the frame.

[0201] The cavity can have a thickness greater than or equal to 30% of the thickness of the aerosol-generating article. The cavity can have a thickness greater than or equal to 40% of the thickness of the aerosol-generating article. The cavity can have a thickness greater than or equal to 50% of the thickness of the aerosol-generating article. The cavity can have a thickness greater than or equal to 60% of the thickness of the aerosol-generating article. The cavity can have a thickness greater than or equal to 70% of the thickness of the aerosol-generating article. The cavity can have a thickness greater than or equal to 80% of the thickness of the aerosol-generating article. The cavity can have a thickness greater than or equal to 90% of the thickness of the aerosol-generating article. The cavity can have a thickness greater than or equal to 95% of the thickness of the aerosol-generating article.

[0202] The cavity can have a thickness less than or equal to 95% of the thickness of the aerosol-generating article. The cavity can have a thickness less than or equal to 90% of the thickness of the aerosol-generating article. The cavity can have a thickness less than or equal to 80% of the thickness of the aerosol-generating article. The cavity can have a thickness less than or equal to 70% of the thickness of the aerosol-generating article.

[0203] The cavity can have a thickness between 30% of the thickness of the aerosol-generating article and 95% of the thickness of the aerosol-generating article. The cavity can have a thickness between 40% of the thickness of the aerosol-generating article and 95% of the thickness of the aerosol-generating article. The cavity can have a thickness between 50% of the thickness of the aerosol-generating article and 90% of the thickness of the aerosol-generating article. The cavity can have a thickness between 60% of the thickness of the aerosol-generating article and 90% of the thickness of the aerosol-generating article. The cavity can have a thickness between 70% of the thickness of the aerosol-generating article and 90% of the thickness of the aerosol-generating article. The cavity can have a thickness between 80% of the thickness of the aerosol-generating article and 90% of the thickness of the aerosol-generating article.

[0204] The cavity can have a thickness greater than or equal to 0.5 millimetres. The cavity can have a thickness greater than or equal to 1 millimetre. The cavity can have a thickness greater than or equal to 1.5 millimetres. The cavity can have a thickness greater than or equal to 2 millimetres. The cavity can have a thickness greater than or equal to 2.5 millimetres. The cavity can have a thickness greater than or equal to 3 millimetres. The cavity can have a thickness greater than or equal to 3.5 millimetres. The cavity can have a thickness greater than or equal to 4 millimetres.

[0205] The cavity can have a thickness less than or equal to 4.5 millimetres. The cavity can have a thickness less than or equal to 4 millimetres. The cavity can have a thickness less than or equal to 3.5 millimetres. The cavity can have a thickness less than or equal to 2.5 millimetres. The cavity can have a thickness less than or equal to 2 millimetres. The cavity can have a thickness less than or equal to 1.5 millimetres.

[0206] The cavity can have a thickness between 0.5 millimetres and 4.5 millimetres. The cavity can have a thickness between 1 millimetre and 4.5 millimetres. The cavity can have a thickness between 2 millimetres and 4 millimetres. Preferably, the cavity can have a thickness between 2.8 millimetres and 3.3 millimetres.

[0207] The cavity can have a length greater than or equal to 30% of the length of the aerosol- generating article. The cavity can have a length greater than or equal to 40% of the length of the aerosol-generating article. The cavity can have a length greater than or equal to 50% of the length of the aerosol-generating article. The cavity can have a length greater than or equal to 60% of the length of the aerosol-generating article. The cavity can have a length greater than or equal to 70% of the length of the aerosol-generating article. The cavity can have a length greater than or equal to 80% of the length of the aerosol-generating article. The cavity can have a length greater than or equal to 90% of the length of the aerosol-generating article.

[0208] The cavity can have a length less than or equal to 95% of the length of the aerosol-generating article. The cavity can have a length less than or equal to 90% of the length of the aerosol-generating article. The cavity can have a length less than or equal to 80% of the length of the aerosol-generating article. The cavity can have a length less than or equal to 70% of the length of the aerosol-generating article. The cavity can have a length less than or equal to 60% of the length of the aerosol-generating article. The cavity can have a length less than or equal to 55% of the length of the aerosol-generating article.

[0209] The cavity can have a length between 30% and 95% of the length of the aerosol-generating article. The cavity can have a length between 40% and 95% of the length of the aerosol-generating article. The cavity can have a length between 50% and 90% of the length of the aerosol-generating article. The cavity can have a length between 55% and 90% of the length of the aerosol-generating article. The cavity can have a length between 60% and 90% of the length of the aerosol-generating article. The cavity can have a length between 70% and 90% of the length of the aerosol-generating article. The cavity can have a length between 80% and 90% of the length of the aerosol-generating article.

[0210] The cavity can have a length greater than or equal to 14 millimetres. The cavity can have a length equal to or greater than 16 millimetres. The cavity can have a length equal to or greater than 18 millimetres. The cavity can have a length greater than or equal to 22 millimetres. The cavity can have a thickness greater than or equal to 26 millimetres. The cavity can have a thickness greater than or equal to 30 millimetres. The cavity can have a thickness greater than or equal to 34 millimetres. The cavity can have a thickness greater than or equal to 38 millimetres.

[0211] The cavity can have a length less than or equal to 40 millimeters. The cavity can have a length less than or equal to 38 millimeters. The cavity can have a thickness less than or equal to 34 millimeters. The cavity can have a thickness less than or equal to 30 millimeters. The cavity can have a thickness less than or equal to 28 millimeters. The cavity can have a thickness less than or equal to 26 millimeters. The cavity can have a thickness less than or equal to 22 millimeters. The cavity can have a thickness less than or equal to 18 millimeters.

[0212] The cavity can have a length between 14 millimeters and 40 millimeters. The cavity can have a length between 14 millimeters and 38 millimeters. The cavity can have a length between 14 millimeters and 34 millimeters. The cavity can have a length between 14 millimeters and 30 millimeters. The cavity can have a length between 16 millimeters and 30 millimeters. The cavity can have a length between 18 millimeters and 30 millimeters. The cavity can have a length between 20 millimeters and 30 millimeters. The cavity can have a length between 24 millimeters and 28 millimeters.

[0213] The cavity can have a width greater than or equal to 30% of a width of the aerosol- generating article. The cavity can have a width greater than or equal to 40% of a width of the aerosol- generating article. The cavity can have a width greater than or equal to 50% of a width of the aerosol-generating article. The cavity can have a width greater than or equal to 60% of a width of the aerosol-generating article. The cavity can have a width greater than or equal to 70% of a width of the aerosol-generating article. The cavity can have a width greater than or equal to 80% of a width of the aerosol-generating article. The cavity can have a width greater than or equal to 90% of a width of the aerosol-generating article.

[0214] The cavity can have a width less than or equal to 95% of a width of the aerosol-generating article. The cavity can have a width less than or equal to 90% of a width of the aerosol-generating article. The cavity can have a width less than or equal to 80% of a width of the aerosol-generating article. The cavity can have a width less than or equal to 70% of a width of the aerosol-generating article. The cavity can have a width less than or equal to 60% of a width of the aerosol-generating article. The cavity can have a width less than or equal to 55% of a width of the aerosol-generating article.

[0215] The cavity can have a width between 30% and 95% of a width of the aerosol-generating article. The cavity can have a width between 40% and 95% of a width of the aerosol-generating article. The cavity can have a width between 50% and 90% of a width of the aerosol-generating article. The cavity can have a width between 50% and 95% of a width of the aerosol-generating article. The cavity can have a width between 60% and 90% of a width of the aerosol-generating article. The cavity can have a width between 70% and 90% of a width of the aerosol-generating article. The cavity can have a width between 80% and 90% of a width of the aerosol-generating article.

[0216] The cavity can have a width greater than or equal to 4.5 millimeters. The cavity can have a width greater than or equal to 5 millimeters. The cavity can have a width greater than or equal to 7 millimeters. The cavity can have a width greater than or equal to 9 millimeters. The cavity can have a width greater than or equal to 11 millimeters.

[0217] The cavity can have a width less than or equal to 13 millimeters. The cavity can have a width less than or equal to 13 millimeters. The cavity can have a width less than or equal to 11 millimeters. The cavity can have a width less than or equal to 9 millimeters. The cavity can have a width less than or equal to 7 millimeters. The cavity can have a width less than or equal to 5 millimeters.

[0218] The cavity can have a width between 4.5 millimeters and 13 millimeters. The cavity can have a width between 5 millimeters and 13 millimeters. The cavity can have a width between 7 millimeters and 10 millimeters. The cavity can have a width between 7.5 millimeters and 8.5 millimeters.

[0219] The cavity can have a length between 14 millimeters and 40 millimeters, a width between 4.5 millimeters and 13 millimeters, and a thickness between 0.5 millimeters and 4.5 millimeters.

[0220] Preferably, the cavity can have a length between 20 millimeters and 30 millimeters, a width between 7 millimeters and 10 millimeters, and a thickness between 2.5 millimeters and 4 millimeters.

[0221] Most preferably, the cavity can have a length of 26 millimeters, a width of 8 millimeters, and a thickness of 3.1 millimeters.

[0222] The cavity can have a volume greater than or equal to 30 cubic millimeters. The cavity can have a volume greater than or equal to 100 cubic millimeters. The cavity can have a volume greater than or equal to 200 cubic millimeters. The cavity can have a volume greater than or equal to 300 cubic millimeters. The cavity can have a volume greater than or equal to 400 cubic millimeters. The cavity can have a volume greater than or equal to 500 cubic millimeters. The cavity can have a volume greater than or equal to 600 cubic millimeters. The cavity can have a volume greater than or equal to 700 cubic millimeters. The cavity can have a volume greater than or equal to 800 cubic millimeters. The cavity can have a volume greater than or equal to 900 cubic millimeters. The cavity can have a volume greater than or equal to 1000 cubic millimeters. The cavity can have a volume greater than or equal to 1500 cubic millimeters. The cavity can have a volume greater than or equal to 2000 cubic millimeters. The cavity can have a volume greater than or equal to 2500 cubic millimeters. The cavity can have a volume greater than or equal to 3000 cubic millimeters.

[0223] 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.

[0224] 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.

[0225] 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.

[0226] 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.

[0227] 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.

[0228] The cavity can be a first cavity. The aerosol-generating article can comprise a second cavity. The second cavity can be positioned between the first planar outer surface and the second planar outer surface. The second cavity can have any of the features described in relation to the first cavity.

[0229] The frame can at least partially define or form the second cavity.

[0230] The frame can comprise a frame first aperture extending through a thickness of the frame. The frame first aperture can at least partially define or form the first cavity. The frame can define a frame second aperture extending through the thickness of the frame. The frame second aperture can at least partially define or form the second cavity.

[0231] The peripheral wall of the frame can comprise a frame first inner surface and a frame second inner surface. The frame first inner surface can define or form an outer wall of the first cavity. The frame second inner surface can define or form an outer wall of the second cavity.

[0232] The frame can comprise a partition wall separating the first cavity and the second cavity. The partition wall can define or form an aperture. The aperture can extend from the first cavity to the second cavity. The aperture can define or form at least a portion of an airflow pathway between the air inlet and the air outlet.

[0233] The overwrap can overlie opposite ends of the first cavity. The overwrap can overlie opposite ends of the second cavity. The overwrap can define or form opposite end walls of the first cavity. The overwrap can define or form opposite end walls of the second cavity. That is, the frame and the overwrap can collectively define the first cavity and the second cavity.

[0234] The first planar outer layer and the second planar outer layer can overlie opposite ends of the first cavity. The first planar outer layer and the second planar outer layer can overlie opposite ends of the second cavity. The first planar outer layer and the second planar outer layer can define or form opposite end walls of the first cavity. The first planar outer layer and the second planar outer layer can define or form opposite end walls of the second cavity. That is, the frame, the first planar outer layer and the second planar outer layer can collectively define the first cavity and the second cavity.

[0235] The first aerosol-generating substrate layer and the second aerosol-generating substrate layer can overlie opposite ends of the first cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer can overlie opposite ends of the second cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer can define or form opposite end walls of the first cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer can 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 can collectively define the first cavity and the second cavity.

[0236] The cavity or first cavity can be substantially empty. The second cavity can be substantially empty.

[0237] The one or more aerosol-generating substrates can comprise an aerosol-generating substrate positioned within the cavity. The aerosol-generating substrate positioned within the cavity can 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 can improve the rigidity of the aerosol-generating article.

[0238] The one or more aerosol-generating substrates can comprise an aerosol-generating substrate positioned within the first cavity. The aerosol-generating substrate positioned within the cavity can fill the first cavity.

[0239] The one or more aerosol-generating substrates can comprise an aerosol-generating substrate positioned within the second cavity.

[0240] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can comprise an aerosol-generating material. The aerosol-generating material can be any aerosol-generating material described herein. For example, the aerosol-generating material can be in the form of a shredded aerosol-generating material.

[0241] 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 described herein. For example, the aerosol-generating material sheet can be a homogenised tobacco material sheet.

[0242] The aerosol-generating material sheet can extend the entire length of the cavity, the first cavity, or the second cavity. The aerosol-generating material sheet can extend the entire width of the cavity, the first cavity, or the second cavity.

[0243] The aerosol-generating material sheet can be a gathered aerosol-generating material sheet. That is, the aerosol-generating material sheet can be rolled, folded, or otherwise compressed or constricted substantially perpendicular to the transverse direction of the aerosol-generating article.

[0244] The aerosol-generating material sheet can be a crimped aerosol-generating material sheet. The aerosol-generating material sheet can be a corrugated aerosol-generating material sheet. The crimped aerosol-generating material sheet or the corrugated aerosol-generating material sheet can comprise a plurality of parallel corrugations. For example, the crimped aerosol-generating material sheet can comprise a plurality of substantially parallel peaks and troughs.

[0245] The plurality of parallel corrugations can be defined by a corrugation profile, wherein the corrugation profile is sinusoidal, or triangular, or rectangular, or trapezoidal, or 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, for example between 1 mm and 10 mm, for example between 1.5 mm and 8 mm, for example between 2 mm and 6 mm, for example between 2.5 mm and 5 mm, for example between 3 mm and 4 mm. The corrugation amplitude can be substantially the same as the thickness of the cavity.

[0246] The plurality of parallel corrugations can 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 can be a plurality of longitudinally extending channels. That is, the plurality of channels can extend in a longitudinal direction of the aerosol generating article. The plurality of channels can be a plurality of laterally extending channels. That is, the plurality of channels can extend in a lateral direction of the aerosol generating article. The plurality of channels can define or form at least a portion of an airflow pathway extending between the air inlet and the air outlet of the aerosol generating article.

[0247] The aerosol generating substrate positioned within the cavity, the first cavity, or the second cavity can 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 can 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 can 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 can 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 can 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 can have a bulk density greater than or equal to 0.4 mg / mm3.

[0248] The aerosol generating substrate positioned within the cavity, the first cavity, or the second cavity can have a bulk density less than or equal to 0.5 mg / mm3. The aerosol generating substrate positioned within the cavity, the first cavity, or the second cavity can have a bulk density less than or equal to 0.4 mg / mm3. The aerosol generating substrate positioned within the cavity, the first cavity, or the second cavity can have a bulk density less than or equal to 0.35 mg / mm3. The aerosol generating substrate positioned within the cavity, the first cavity, or the second cavity can have a bulk density less than or equal to 0.3 mg / mm3.

[0249] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can have a bulk density between 0.05 milligrams per cubic millimeter and 0.5 milligrams per cubic millimeter. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can have a bulk density between 0.1 milligrams per cubic millimeter and 0.4 milligrams per cubic millimeter. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can have a bulk density between 0.1 milligrams per cubic millimeter and 0.3 milligrams per cubic millimeter. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can have a bulk density between 0.2 milligrams per cubic millimeter and 0.3 milligrams per cubic millimeter.

[0250] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can 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 can 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 can 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 can 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 can have a packing density greater than or equal to 0.7.

[0251] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can have a packing density less than or equal to 0.9. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can have a packing density less than or equal to 0.8. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can have a packing density less than or equal to 0.7. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can have a packing density less than or equal to 0.6. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can have a packing density less than or equal to 0.5.

[0252] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can 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 can 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 can 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 can 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 can have a packing density between 0.5 and 0.7.

[0253] Advantageously, providing the aerosol-generating substrate having a packing density greater than or equal to 0.3 within the cavity can facilitate heat conduction through the aerosol-generating substrate. An increase in heat conduction through the aerosol-generating substrate can decrease the time required to generate an aerosol.

[0254] Advantageously, providing the aerosol-generating substrate having a packing density greater than or equal to 0.3 within the cavity can facilitate heat conduction through the aerosol-generating substrate. An increase in heat conduction through the aerosol-generating substrate can decrease the time required to generate an aerosol.

[0255] Advantageously, providing the aerosol-generating substrate having a packing density less than or equal to 0.9 grams per cubic centimeter positioned within the cavity can facilitate the formation of airflow passages within the aerosol-generating substrate during use of the aerosol-generating article. Increasing the provision of airflow passages within the aerosol-generating substrate can improve vaporization of the aerosol-generating substrate. Increasing the provision of airflow passages within the aerosol-generating substrate can also provide a satisfactory draw resistance.

[0256] Advantageously, providing the aerosol-generating substrate having a packing density less than or equal to 0.9 grams per cubic centimeter positioned within the cavity 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.

[0257] Accordingly, the packing density can be a trade-off between heat conduction through the aerosol-generating substrate, providing mechanical support for the first and second planar outer surfaces, facilitating airflow passages within the aerosol-generating substrate, and providing a satisfactory draw resistance for the aerosol-generating article.

[0258] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can 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 can 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 can 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 can have a volume greater than or equal to 350 cubic millimeters.

[0259] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can be less than or equal to 1000 cubic millimeters. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can be less than or equal to 900 cubic millimeters. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can be less than or equal to 800 cubic millimeters. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can be less than or equal to 700 cubic millimeters.

[0260] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity can 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 can 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 can have a volume between 350 cubic millimeters and 650 cubic millimeters.

[0261] At least one of the one or more aerosol-generating substrates can have a density greater than or equal to 0.05 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates can have a density greater than or equal to 0.1 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates can have a density greater than or equal to 0.2 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates can have a density greater than or equal to 0.3 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates can have a density greater than or equal to 0.4 grams per cubic centimeter.

[0262] At least one of the one or more aerosol-generating substrates can have a density less than or equal to 0.9 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates can have a density less than or equal to 0.8 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates can have a density less than or equal to 0.7 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates can have a density less than or equal to 0.6 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates can have a density less than or equal to 0.5 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates can have a density less than or equal to 0.4 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates can have a density less than or equal to 0.3 grams per cubic centimeter.

[0263] At least one of the one or more aerosol-generating substrates can have a density of between 0.05 grams and 0.9 grams per cubic centimetre. At least one of the one or more aerosol-generating substrates can have a density of between 0.05 grams per cubic centimetre and 0.9 grams per cubic centimetre. At least one of the one or more aerosol-generating substrates can have a density of between 0.1 grams per cubic centimetre and 0.8 grams per cubic centimetre. At least one of the one or more aerosol-generating substrices can have a density of between 0.2 grams per cubic centimetre and 0.7 grams per cubic centimetre. At least one of the one or more aerosol-generating substrices can have a density of between 0.2 grams per cubic centimetre and 0.6 grams per cubic centimetre. At least one of the one or more aerosol-generating substrices can have a density of between 0.2 grams per cubic centimetre and 0.5 grams per cubic centimetre. At least one of the one or more aerosol-generating substrices can have a density of between 0.2 grams per cubic centimetre and 0.4 grams per cubic centimetre.

[0264] At least one of the one or more aerosol-generating substrates referred to above in relation to density can be, or can be at least one of, the aerosol-generating substrate layer, the first aerosol-generating substrate layer, the second aerosol-generating substrate layer, the aerosol-generating substrate positioned within the cavity or the first cavity, or the aerosol-generating substrate positioned within the second cavity. Preferably, at least one of the one or more aerosol-generating substrates referred to above in relation to density can be, or can be at least one of, the aerosol-generating substrate positioned within the cavity or the first cavity, or the aerosol-generating substrate positioned within the second cavity.

[0265] Aerosol-generating substrates in aerosol-generating articles typically have a high density in order to facilitate heat conduction through the aerosol-generating substrate.

[0266] Advantageously, providing an aerosol-generating article with an aerosol-generating substrate having a relatively low density of less than or equal to 0.9 grams per cubic centimetre can allow the aerosol-generating article to comprise a reduced mass of the aerosol-generating article. A reduced mass aerosol-generating substrate can make the aerosol-generating article easier to handle and easier to manufacture.

[0267] 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.

[0268] At least one of the one or more aerosol-generating substrates can have a mass greater than or equal to 50 milligrams. At least one of the one or more aerosol-generating substrates can have a mass greater than or equal to 80 milligrams. At least one of the one or more aerosol-generating substrates can have a mass greater than or equal to 110 milligrams. At least one of the one or more aerosol-generating substrates can have a mass greater than or equal to 150 milligrams. At least one of the one or more aerosol-generating substrates can have a mass greater than or equal to 170 milligrams. At least one of the one or more aerosol-generating substrates can have a mass greater than or equal to 180 milligrams. At least one of the one or more aerosol-generating substrates can have a mass greater than or equal to 200 milligrams. At least one of the one or more aerosol-generating substrates can have a mass greater than or equal to 230 milligrams. At least one of the one or more aerosol-generating substrates can have a mass greater than or equal to 250 milligrams. At least one of the one or more aerosol-generating substrates can have a mass greater than or equal to 300 milligrams. At least one of the one or more aerosol-generating substrates can have a mass greater than or equal to 400 milligrams.

[0269] At least one of the one or more aerosol-generating substrates can have a mass of less than or equal to 500 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of less than or equal to 400 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of less than or equal to 300 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of less than or equal to 250 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of less than or equal to 230 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of less than or equal to 200 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of less than or equal to 180 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of less than or equal to 170 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of less than or equal to 150 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of less than or equal to 110 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of less than or equal to 80 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of less than or equal to 50 milligrams.

[0270] At least one of the one or more aerosol-generating substrates can have a mass of between 50 milligrams and 500 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of between 80 milligrams and 500 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of between 80 milligrams and 400 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of between 80 milligrams and 300 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of between 80 milligrams and 250 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of between 80 milligrams and 200 milligrams. At least one of the one or more aerosol-generating substrates can have a mass of between 80 milligrams and 150 milligrams.

[0271] The at least one of the one or more aerosol-generating substriates mentioned above in relation to the mass can be the aerosol-generating substrate layer, the first aerosol-generating substrate layer, the second aerosol-generating substrate layer, the aerosol-generating substrate positioned within the cavity or the first cavity, or the aerosol-generating substrate positioned within the second cavity, or can be at least one of them. Preferably, the at least one of the one or more aerosol-generating substriates mentioned above in relation to the mass can be the aerosol-generating substrate positioned within the cavity or the first cavity, or the aerosol-generating substrate positioned within the second cavity, or can be at least one of them.

[0272] Advantageously, providing the aerosol-generating article with less than or equal to 500 milligrams of aerosol-generating substrate can reduce the amount of structural support that needs to be provided to the aerosol-generating article.

[0273] Advantageously, providing the aerosol-generating article with greater than or equal to 50 milligrams of aerosol-generating substrate can allow the aerosol-generating substrate to provide some structural support to the aerosol-generating article.

[0274] Advantageously, providing the aerosol-generating article with a low mass of aerosol-generating substrate can result in better heating efficiency as the mass of aerosol-generating substrate to be heated is relatively low. A relatively low mass of aerosol-generating substrate is particularly advantageous during a first puff with the aerosol-generating article as the first puff can be achieved much faster compared to with an aerosol-generating article having a high mass of aerosol-generating substrate.

[0275] Advantageously, providing the aerosol-generating article with a low mass of aerosol-generating substrate can reduce the total water content of the aerosol-generating substrate. Reducing the total water content of the aerosol-generating substrate can reduce the temperature of the first puff.

[0276] The length of the aerosol-generating article can be defined in the x-direction between the distal end and the proximal end of the aerosol-generating article. The aerosol-generating article can be divided into a distal portion and a proximal portion over its length. The distal portion can extend from the distal end for 50% of the length of the aerosol-generating article and the proximal portion can extend from the proximal end for 50% of the length of the aerosol-generating article.

[0277] The ratio of the mass of the one or more aerosol-generating substriates in the proximal portion to the mass of the one or more aerosol-generating substriates in the distal portion can be in the range of 0.77 and 1.30.

[0278] 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 can be in the range of 0.80 to 1.25, or 0.83 to 1.2, or 0.87 to 1.15, or 0.91 to 1.10 or 0.95 to 1.05.

[0279] The mass distribution of the one or more aerosol-generating substrates in the proximal portion in the longitudinal direction of the proximal portion can be symmetrical relative to the mass distribution of the one or more aerosol-generating substrates in the distal portion in the longitudinal direction of the distal portion relative to the midpoint of the length of the aerosol-generating article.

[0280] The 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 0.77 to 1.30, or 0.80 to 1.25, or 0.83 to 1.2, or 0.87 to 1.15, or 0.91 to 1.10 or 0.95 to 1.05.

[0281] The one or more aerosol-generating substrates in the distal portion can 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 can be in the range of 0.77 to 1.30, or 0.80 to 1.25, or 0.83 to 1.2, or 0.87 to 1.15, or 0.91 to 1.10 or 0.95 to 1.05.

[0282] The one or more aerosol-generating substrates in the proximal portion can be arranged across the height of the proximal portion in a first half and a second half of 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 can be in the range of 0.77 to 1.30, or 0.80 to 1.25, or 0.83 to 1.2, or 0.87 to 1.15, or 0.91 to 1.10 or 0.95 to 1.05.

[0283] The one or more aerosol-generating substrates in the distal portion can be arranged across a first half and a second half of a height of the distal portion. A ratio of a mass of the one or more aerosol-generating substrates in the first half of the height of the distal portion to a mass of the one or more aerosol-generating substrates in the second half of the height of the distal portion can be in a range of 0.77 and 1.30, or 0.80 and 1.25, or 0.83 and 1.2, or 0.87 and 1.15, or 0.91 and 1.10, or 0.95 and 1.05.

[0284] The structure of the proximal portion can be symmetrical to the structure of the distal portion with respect to a midpoint of a length of the aerosol-generating article.

[0285] The aerosol-generating article can comprise an outer wrapper and an aerosol- generating substrate as described herein positioned within the cavity.

[0286] The aerosol-generating article can comprise an outer wrapper, a frame, and an aerosol-generating substrate as described herein positioned within the cavity.

[0287] The aerosol-generating article can comprise an outer wrapper and an aerosol- generating substrate layer. The cavity can be empty or an aerosol-generating substrate as described herein can be positioned within the cavity.

[0288] The aerosol-generating article can comprise an outer wrapper, a frame, and an aerosol-generating substrate layer. The cavity can be empty or an aerosol-generating substrate as described herein can be positioned within the cavity.

[0289] The aerosol-generating article can comprise an outer wrapper, a first cavity, a second cavity, and an aerosol-generating substrate layer.

[0290] The first cavity can be empty or an aerosol-generating substrate as described herein can be positioned within the first cavity.

[0291] The second cavity can be empty or an aerosol-generating substrate as described herein can be positioned within the second cavity.

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

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

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

[0295] The aerosol-generating article can 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 can be empty or an aerosol-generating substrate as described herein can be positioned within the first cavity. The second cavity can be empty or an aerosol-generating substrate as described herein can be positioned within the second cavity.

[0296] The aerosol-generating article can 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 can be empty or an aerosol-generating substrate as described herein can be positioned within the first cavity. The second cavity can be empty or an aerosol-generating substrate as described herein can be positioned within the second cavity.

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

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

[0299] The aerosol-generating article can 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 can be empty or an aerosol-generating substrate as described herein can be positioned within the first cavity. The second cavity can be empty or an aerosol-generating substrate as described herein can be positioned within the second cavity.

[0300] The aerosol-generating article can 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 can be empty or an aerosol-generating substrate as described herein can be positioned within the first cavity. The second cavity can be empty or an aerosol-generating substrate as described herein can be positioned within the second cavity.

[0301] The aerosol-generating article can 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 can be empty or an aerosol-generating substrate as described herein can be positioned within the cavity.

[0302] The aerosol-generating article can 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 can be empty or an aerosol-generating substrate as described herein can be positioned within the cavity.

[0303] The aerosol-generating article can 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 can be empty or an aerosol-generating substrate as described herein can be positioned within the first cavity. The second cavity can be empty or an aerosol-generating substrate as described herein can be positioned within the second cavity.

[0304] The aerosol-generating article can 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 can be empty or an aerosol-generating substrate as described herein can be positioned within the first cavity. The second cavity can be empty or an aerosol-generating substrate as described herein can be positioned within the second cavity.

[0305] The aerosol-generating material can comprise one or more organic materials such as tobacco, mint, tea and clove. The aerosol-generating material can comprise one or more of the following: herbal plant leaves, tobacco leaves, shreds of tobacco ribbings, reconstituted tobacco, homogenised tobacco such as cast leaf, extruded tobacco, expanded tobacco, aerosol-generating films and gel compositions.

[0306] The aerosol-generating material can be in the form of shredded aerosol-generating material. The shredded aerosol-generating material can comprise one or more of the following: strips and strands of aerosol-generating material such as strips and strands of tobacco or homogenised tobacco material. The shredded aerosol-generating material can be in the form of a sheet of shredded homogenised tobacco material.

[0307] The aerosol-generating material can be cut filler. The aerosol-generating material can be tobacco cut filler. The cut filler can comprise one or more of flue-cured tobacco, sun-cured tobacco, Oriental tobacco and filler tobacco. Examples of flue-cured tobacco are Brazilian flue-cured, Indian flue-cured, Chinese flue-cured, American flue-cured such as Virginia tobacco and flue-cured tobacco from Tanzania. Examples of Oriental tobacco are Eastern Turky, Greek Oriental, semi-Oriental tobacco but also fire cured American Burley such as Perique and Rustica. Examples of sun-cured tobacco are dark cured Brazilian Galpao, Malawi Burley or other African Burley, sun cured cured or air cured Indonesian Kasturi. As used herein, the term“cut filler” is used to describe a blend of shredded plant material such as tobacco plant material, including in particular one or more of leaf, processed stem and rib, homogenised plant material.

[0308] Shredded filler suitable for use with the present application can be generally similar to shredded filler used for conventional smoking articles. The shredded filler can have a shredded width of between 0.3 millimetres and 2.0 millimetres, or between 0.5 millimetres and 1.2 millimetres, or between 0.6 millimetres and 0.9 millimetres. Preferably, the strands have a length of between about 10 millimetres and 40 millimetres.

[0309] Preferably, the shredded filler is impregnated with an aerosol-former. Impregnating the shredded filler can be done by spraying or by other suitable application methods. Preferably, the aerosol-former in the shredded filler comprises one or more of glycerol and propylene glycol. The aerosol-former can consist of glycerol or propylene glycol or a combination of glycerol and propylene glycol.

[0310] The aerosol-generating material can comprise homogenised plant material, preferably homogenised tobacco material.

[0311] As used herein, the term "homogenised plant material" includes any plant material formed from the agglomeration of particles of plant. For example, a sheet or web of homogenised tobacco material for use in the aerosol-generating substrate of the present application can be formed by agglomerating particles of tobacco material obtained by one or more of comminuting, milling or crushing plant material, and optionally tobacco lamina and tobacco lamina stems. The homogenised plant material can be produced by casting, extrusion, paper-making processes or any other suitable process known in the art.

[0312] The homogenised plant material can be in the form of one or more sheets.

[0313] The homogenised plant material can be in the form of a plurality of pellets or granules.

[0314] The homogenised plant material can be in the form of a plurality of strands, strips or shreds. As used herein, the term "strand" describes an elongate element of material having a length substantially greater than its width and thickness.

[0315] The aerosol-generating material can be in the form of a sheet of aerosol-generating material. As used herein, the term "sheet" describes a laminar element having a width and length substantially greater than its thickness. The sheet of aerosol-generating material can be a sheet of plant material. The sheet of aerosol-generating material can be a sheet of tobacco material. The sheet of aerosol-generating material can be a sheet of homogenised tobacco material, such as a cast leaf sheet.

[0316] The sheet of aerosol-generating material can have a grammage of between 100 grams per square metre and 600 grams per square metre. The sheet of aerosol-generating material can have a grammage of between 100 grams per square metre and 300 grams per square metre.

[0317] The sheet of aerosol-generating material can have a density of greater than or equal to 0.3 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of greater than or equal to 0.4 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of greater than or equal to 0.5 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of greater than or equal to 0.6 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of greater than or equal to 0.7 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of less than or equal to 0.8 grams per cubic centimetre.

[0318] The sheet of aerosol-generating material can have a density of less than or equal to 1.0 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of less than or equal to 0.9 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of less than or equal to 0.8 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of less than or equal to 0.7 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of less than or equal to 0.6 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of less than or equal to 0.5 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of less than or equal to 0.4 grams per cubic centimetre.

[0319] The sheet of aerosol-generating material can have a density of between 0.3 grams per cubic centimetre and 1.3 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of between 0.3 grams per cubic centimetre and 1.0 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of between 0.4 grams per cubic centimetre and 1.0 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of between 0.4 grams per cubic centimetre and 0.9 grams per cubic centimetre. The sheet of aerosol-generating material can have a density of between 0.5 grams per cubic centimetre and 0.9 grams per cubic centimetre.

[0320] The sheet of aerosol-generating material can comprise between 2.5% and 95% by weight of plant particles on a dry weight basis. The sheet of aerosol-generating material can comprise between 5% and 90% by weight of plant particles on a dry weight basis. The sheet of aerosol-generating material can comprise between 10% and 80% by weight of plant particles on a dry weight basis. The sheet of aerosol-generating material can comprise between 15% and 70% by weight of plant particles on a dry weight basis. The sheet of aerosol-generating material can comprise between 20% and 60% by weight of plant particles on a dry weight basis. The sheet of aerosol-generating material can comprise between 30% and 50% by weight of plant particles on a dry weight basis.

[0321] The sheet of aerosol-generating material can be a sheet of homogenised tobacco material comprising tobacco particles. The sheet of homogenised tobacco material can have a tobacco content of at least about 40% by weight on a dry weight basis. The sheet of homogenised tobacco material can have a tobacco content of at least about 50% by weight on a dry weight basis. The sheet of homogenised tobacco material can have a tobacco content of at least about 70% by weight on a dry weight basis. The sheet of homogenised tobacco material can have a tobacco content of at least about 90% by weight on a dry weight basis.

[0322] As used herein, the term "tobacco particles" can describe particles of any member of the Nicotiana genus of plants. The term "tobacco particles" includes ground or comminuted tobacco lamina, ground or comminuted tobacco lamina stems, tobacco dust, tobacco fines, and other particulate tobacco by-products formed during the handling, manipulation, and transportation of tobacco. In preferred embodiments, the tobacco particles are derived substantially entirely from tobacco lamina. In contrast, isolated nicotine and nicotine salts are compounds derived from tobacco but are not considered to be tobacco particles for the purposes of the present disclosure and are not included in the percentage of particulate plant material.

[0323] The tobacco particles can be prepared from one or more tobacco plants. Any type of tobacco can be used in the blend. Examples of types of tobacco that can be used include, but are not limited to, sun-cured tobacco, flue-cured tobacco, burley tobacco, Maryland tobacco, Oriental tobacco, Virginia tobacco, and other specialty tobaccos.

[0324] Flue-cured tobacco 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 leaves turn yellow and wilt. During the second stage, the lamina of the leaves is fully dried. During the third stage, the stems are fully dried.

[0325] Burley tobacco plays an important role in many tobacco blends. Burley tobacco has a distinctive flavour and aroma and also has the ability to absorb a large amount of casing.

[0326] Oriental tobacco is a type of tobacco that has small leaves and a high aromatic quality. However, the flavour of Oriental tobacco is milder than, for example, burley tobacco. As a result, a relatively small proportion of Oriental tobacco is typically used in tobacco blends.

[0327] 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 the blend to produce the tobacco particles. As a result, the tobacco particles in the particulate plant material can comprise a blend of Kasturi tobacco and flue-cured tobacco.

[0328] 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%, even more preferably at least about 3.2%, even more preferably at least about 3.5%, most preferably at least about 4% by weight on a dry weight basis.

[0329] The aerosol generating material can 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: polyhydric alcohols such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerol; esters of polyhydric alcohols such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or poly-carboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It can be particularly preferred for the aerosol former to be, or to include, one or both of glycerol and propylene glycol. The aerosol former can consist of glycerol or propylene glycol, or of a combination of glycerol and propylene glycol.

[0330] The aerosol generating material can have an aerosol former content of greater than or equal to 1%, 2%, 5%, 10%, or 15% by weight on a dry weight basis. The aerosol generating material can have an aerosol former content of greater than or equal to 15% by weight on a dry weight basis, for example greater than 20% by weight on a dry weight basis, or greater than 25% by weight on a dry weight basis, or greater than 30% by weight on a dry weight basis, or greater than 40% by weight on a dry weight basis, or greater than 50% by weight on a dry weight basis.

[0331] The aerosol generating material can have an aerosol former content of less than or equal to 30% by weight on a dry weight basis, less than or equal to 25% by weight on a dry weight basis, or less than or equal to 20% by weight on a dry weight basis. That is, the aerosol generating material can have an aerosol former content of less than or equal to 30% by weight on a dry weight basis, less than or equal to 25% by weight on a dry weight basis, or less than or equal to 20% by weight on a dry weight basis.

[0332] The aerosol generating material can have an aerosol former content of between 1% and 30% by weight on a dry weight basis, between 1% and 25% by weight on a dry weight basis, or between 1% and 20% by weight on a dry weight basis.

[0333] The aerosol generating material can have an aerosol former content of between 5% and 30% by weight on a dry weight basis, between 5% and 25% by weight on a dry weight basis, or between 5% and 20% by weight on a dry weight basis.

[0334] The aerosol generating material can have an aerosol former content of between 10 and 30 percent by weight on a dry weight basis, between 10 and 25 percent by weight on a dry weight basis, or between 10 and 20 percent by weight on a dry weight basis.

[0335] The aerosol generating material can have an aerosol former content of between 15 and 30 percent by weight on a dry weight basis, between 15 and 25 percent by weight on a dry weight basis, or between 15 and 20 percent by weight on a dry weight basis.

[0336] The aerosol generating material can have an aerosol former content of at least 50 percent by weight on a dry weight basis, at least 60 percent by weight on a dry weight basis, or at least 70 percent by weight on a dry weight basis.

[0337] The aerosol generating material can comprise an aerosol former content of less than or equal to 85 percent by weight on a dry weight basis, less than or equal to 80 percent by weight on a dry weight basis, or less than or equal to 75 percent by weight on a dry weight basis.

[0338] The aerosol generating material can comprise an aerosol former content of between 50 and 85 percent by weight on a dry weight basis, between 50 and 80 percent by weight on a dry weight basis, or between 50 and 75 percent by weight on a dry weight basis.

[0339] The aerosol generating material can comprise an aerosol former content of between 60 and 85 percent by weight on a dry weight basis, between 60 and 80 percent by weight on a dry weight basis, or between 60 and 75 percent by weight on a dry weight basis.

[0340] The aerosol generating material can comprise an aerosol former content of between 70 and 85 percent by weight on a dry weight basis, between 70 and 80 percent by weight on a dry weight basis, or between 70 and 75 percent by weight on a dry weight basis.

[0341] The aerosol generating material can comprise hydroxypropyl methylcellulose.

[0342] Advantageously, the inclusion of hydroxypropyl methylcellulose in the aerosol generating material can help to improve the manufacturing process of the aerosol generating material. For example, the hydroxypropyl methylcellulose can reduce the overall viscosity of the slurry that is mixed in the preparation of the aerosol generating material. A lower viscosity slurry can flow more easily compared to a conventional slurry, and a lower viscosity slurry is easier to mix, transfer, and handle during the manufacturing process.

[0343] The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of greater than or equal to 0.5% by weight. The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of greater than or equal to 1% by weight. The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of greater than or equal to 5% by weight. The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of greater than or equal to 10% by weight. The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of greater than or equal to 15% by weight. The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of greater than or equal to 20% by weight.

[0344] The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of less than or equal to 50% by weight. The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of less than or equal to 45% by weight. The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of less than or equal to 40% by weight. The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of less than or equal to 35% by weight. The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of less than or equal to 30% by weight. The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of less than or equal to 25% by weight. The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of less than or equal to 20% by weight.

[0345] The aerosol-generating material can comprise a hydroxypropyl methylcellulose content of between 0.5% and 50% by weight.

[0346] The aerosol-generating material can comprise one or more cellulose-based reinforcing agents. Advantageously, the inclusion of cellulose-based reinforcing agents in the aerosol-generating material can increase the tensile strength of the aerosol-generating material. Aerosol-generating materials with higher tensile strength can be less likely to degrade or break (for example during transportation or during the manufacturing process).

[0347] The aerosol-generating material can have a cellulose-based reinforcing agent content of greater than or equal to 0.5% by weight. The aerosol-generating material can have a cellulose-based reinforcing agent content of greater than or equal to 1% by weight. The aerosol-generating material can have a cellulose-based reinforcing agent content of greater than or equal to 0.5% by weight. The aerosol-generating material can have a cellulose-based reinforcing agent content of greater than or equal to 5% by weight. The aerosol-generating material can have a cellulose-based reinforcing agent content of greater than or equal to 10% by weight. The aerosol-generating material can have a cellulose-based reinforcing agent content of greater than or equal to 15% by weight. The aerosol-generating material can have a cellulose-based reinforcing agent content of greater than or equal to 20% by weight.

[0348] The aerosol-generating material can have a cellulose-based reinforcing agent content of less than or equal to 50% by weight. The aerosol-generating material can have a cellulose-based reinforcing agent content of less than or equal to 45% by weight. The aerosol-generating material can have a cellulose-based reinforcing agent content of less than or equal to 40% by weight. The aerosol-generating material can have a cellulose-based reinforcing agent content of less than or equal to 35% by weight. The aerosol-generating material can have a cellulose-based reinforcing agent content of less than or equal to 30% by weight. The aerosol-generating material can have a cellulose-based reinforcing agent content of less than or equal to 25% by weight.

[0349] The aerosol-generating material can have a cellulose-based reinforcing agent content of between 0.5% and 50% by weight. The aerosol-generating material can have a cellulose-based reinforcing agent content of between 0.5% and 40% by weight.

[0350] The one or more cellulose-based reinforcing agents can comprise cellulose fibres. Advantageously, the present inventors have found that cellulose fibres can be cellulose-based reinforcing agents which are particularly effective at increasing the tensile strength of the aerosol-generating material.

[0351] The aerosol-generating material can have a cellulose fibre content of greater than or equal to 0.5% by weight. The aerosol-generating material can have a cellulose fibre content of greater than or equal to 1% by weight. The aerosol-generating material can have a cellulose fibre content of greater than or equal to 5% by weight. The aerosol-generating material can have a cellulose fibre content of greater than or equal to 10% by weight. The aerosol-generating material can have a cellulose fibre content of greater than or equal to 15% by weight. The aerosol-generating material can have a cellulose fibre content of greater than or equal to 20% by weight.

[0352] The aerosol-generating material can have a cellulose fibre content of less than or equal to 50% by weight. The aerosol-generating material can have a cellulose fibre content of less than or equal to 45% by weight. The aerosol-generating material can have a cellulose fibre content of less than or equal to 40% by weight. The aerosol-generating material can have a cellulose fibre content of less than or equal to 35% by weight. The aerosol-generating material can have a cellulose fibre content of less than or equal to 30% by weight. The aerosol-generating material can have a cellulose fibre content of less than or equal to 25% by weight.

[0353] The aerosol-generating material can have a cellulose fibre content of between 0.5% and 50% by weight. The aerosol-generating material can have a cellulose fibre content of between 0.5% and 40% by weight.

[0354] The one or more cellulose-based reinforcing agents can comprise microcrystalline cellulose. Advantageously, the present inventors have found that microcrystalline cellulose can be a cellulose-based reinforcing agent which is particularly effective at increasing the tensile strength of the aerosol- generating material.

[0355] The aerosol-generating material can have a microcrystalline cellulose content of greater than or equal to 0.5 wt%. The aerosol-generating material can have a microcrystalline cellulose content of greater than or equal to 1 wt%. The aerosol-generating material can have a microcrystalline cellulose content of greater than or equal to 5 wt%. The aerosol-generating material can have a microcrystalline cellulose content of greater than or equal to 10 wt%. The aerosol-generating material can have a microcrystalline cellulose content of greater than or equal to 15 wt%. The aerosol-generating material can have a microcrystalline cellulose content of greater than or equal to 20 wt%.

[0356] The aerosol-generating material can have a microcrystalline cellulose content of less than or equal to 50 wt%. The aerosol-generating material can have a microcrystalline cellulose content of less than or equal to 45 wt%. The aerosol-generating material can have a microcrystalline cellulose content of less than or equal to 40 wt%. The aerosol-generating material can have a microcrystalline cellulose content of less than or equal to 35 wt%. The aerosol-generating material can have a microcrystalline cellulose content of less than or equal to 30 wt%. The aerosol-generating material can have a microcrystalline cellulose content of less than or equal to 25 wt%.

[0357] The aerosol-generating material can have a microcrystalline cellulose content of between 0.5 wt% and 50 wt%. The aerosol-generating material can have a microcrystalline cellulose content of between 0.5 wt% and 40 wt%.

[0358] The one or more cellulose-based reinforcing agents can comprise cellulose powder. Advantageously, the present inventors have found that cellulose powder can be a cellulose-based reinforcing agent which is particularly effective at increasing the tensile strength of the aerosol-generating material.

[0359] The aerosol-generating material can have a cellulose powder content of greater than or equal to 0.5 wt%. The aerosol-generating material can have a cellulose powder content of greater than or equal to 1 wt%. The aerosol-generating material can have a cellulose powder content of greater than or equal to 0.5 wt%. The aerosol-generating material can have a cellulose powder content of greater than or equal to 5 wt%. The aerosol-generating material can have a cellulose powder content of greater than or equal to 10 wt%. The aerosol-generating material can have a cellulose powder content of greater than or equal to 15 wt%. The aerosol-generating material can have a cellulose powder content of greater than or equal to 20 wt%.

[0360] The aerosol-generating material can have a cellulose powder content of less than or equal to 50% by weight. The aerosol-generating material can have a cellulose powder content of less than or equal to 45% by weight. The aerosol-generating material can have a cellulose powder content of less than or equal to 40% by weight. The aerosol-generating material can have a cellulose powder content of less than or equal to 35% by weight. The aerosol-generating material can have a cellulose powder content of less than or equal to 30% by weight. The aerosol-generating material can have a cellulose powder content of less than or equal to 25% by weight.

[0361] The aerosol-generating material can have a cellulose powder content of between 0.5% and 50% by weight. The aerosol-generating material can have a cellulose powder content of between 0.5% and 40% by weight.

[0362] The aerosol-generating material can comprise carboxymethyl cellulose.

[0363] Advantageously, the present inventors have found that the use of carboxymethyl cellulose can help to reduce the caking of the aerosol-generating material when used in an aerosol-generating article.

[0364] The carboxymethyl cellulose can comprise sodium carboxymethyl cellulose. Advantageously, the present inventors have found that sodium carboxymethyl cellulose is a carboxymethyl cellulose that can be particularly effective at preventing the above-mentioned caking problem.

[0365] The aerosol-generating material can have a carboxymethyl cellulose content of greater than or equal to 0.5% by weight. The aerosol-generating material can have a carboxymethyl cellulose content of greater than or equal to 1% by weight. The aerosol-generating material can have a carboxymethyl cellulose content of greater than or equal to 5% by weight. The aerosol-generating material can have a carboxymethyl cellulose content of greater than or equal to 10% by weight.

[0366] The aerosol-generating material can have a carboxymethyl cellulose content of less than or equal to 20% by weight. The aerosol-generating material can have a carboxymethyl cellulose content of less than or equal to 15% by weight. The aerosol-generating material can have a carboxymethyl cellulose content of less than or equal to 10% by weight. The aerosol-generating material can have a carboxymethyl cellulose content of less than or equal to 8% by weight. The aerosol-generating material can have a carboxymethyl cellulose content of less than or equal to 5% by weight.

[0367] The aerosol-generating material can have a carboxymethyl cellulose content of between 0.5% and 20% by weight.

[0368] The aerosol-generating material can comprise nicotine. The aerosol-generating material can comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0369] The aerosol generating material can comprise at least 0.5% by weight of nicotine, at least 1% by weight of nicotine, at least 1.5% by weight of nicotine, or at least 2% by weight of nicotine. That is, the aerosol generating material can 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.

[0370] The aerosol generating material can comprise one or more flavourants. The one or more flavourants can 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 material. Suitable herbal material includes leaves of a herb or other herbal material from a herb including but not limited to mint (such as peppermint and spearmint), lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme and szechuan pepper. The one or more flavourants can include tobacco material.

[0371] In the final product state, the aerosol generating material can have a moisture content of about 5% to 25%, preferably about 7% to 15%. For example, the aerosol generating material can be homogenised tobacco material having a moisture of about 5% to 25%, preferably about 7% to 15% in the final product state.

[0372] The aerosol generating material can include cellulose fibres. For example, the aerosol generating material can include about 1% to 15% cellulose fibres, preferably about 3% to 7% cellulose fibres. Preferably, the cellulose fibres can have a length of about 10 to 250 pm, preferably about 10 to 120 pm.

[0373] The aerosol generating material can include organic fibres such as non-tobacco fibres or tobacco fibres. For example, the aerosol generating material can include about 5% to 20%, preferably about 7% to 15% tobacco fibres. The tobacco fibres are preferably derived from stems and / or stalks which are fractionated into fibres having a length of about 10 to 350 pm, preferably about 10 to 180 pm. The aerosol generating material can include about 10% to 30%, preferably about 15% to 25% non-tobacco organic fibres. For example, the organic fibres can be derived from cellulose, cotton, wood, tea plant varieties which are by-products and by-process waste of the tea industry. The organic fibres preferably have a length of about 10 to 400 pm, preferably about 10 to 200 pm.

[0374] The aerosol generating material can comprise a binder. For example, the aerosol generating material can comprise 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. A preferred binder can be natural pectin (such as fruit, e.g. citrus) or tobacco pectin; guar gum, locust bean gum, hydroxyethyl and / or hydroxypropyl derivatives of these such as; starch, such as modified or derivatized starch; alginate; methyl, ethyl, ethyl hydroxymethyl and carboxymethyl cellulose; dextran; and xanthan gum. A preferred binder is guar gum. The binder can be polyvinyl alcohol (PVOH).

[0375] The aerosol generating material can comprise one or more botanical materials. For example, the aerosol generating material can comprise about 15 to 55%, preferably about 20 to 35%, of botanical material, such as Syzygium aromaticum, Eriodictyon spp., Foeniculum vulgare, Zingiber officinale, Crataegus spp. berries, Sambucus spp. berries, Monarda spp., Mullein leaf, Urtica spp., Plantago spp., Curcuma longa, Yarrow, and compounds of these.

[0376] The aerosol generating material can comprise organic botanical extracts. For example, the aerosol generating material can comprise about 1 to 15%, preferably about 2 to 7%, of any of the previously mentioned botanical materials, and any secondary alcohol such as menthol (dl-menthol, C10H20O, 2-isopropyl-5-methylcyclohexanol) and P-menthan-3-ol obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium or other related plant varieties, and P-menthan-3-ol which is a diastereomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.

[0377] The aerosol generating material can comprise a botanical essential oil, for example about 0.5 to 5%, preferably about 1 to 3%, of a botanical essential oil, for example such as palm kernel oil, coconut oil, and wood-based essential oils.

[0378] The aerosol generating material can comprise particles of a functional material, for example 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.

[0379] The aerosol generating material can be in the form of an aerosol generating film comprising a cellulose-based film-former, nicotine, and an aerosol-forming agent. The aerosol generating film can further comprise a cellulose-based reinforcing agent. The aerosol generating film can further comprise water, preferably 30% or less by weight of water.

[0380] As used herein, the term "film" is used to describe a solid, layered element whose thickness is less than its width or length. The film can be self-supporting.

[0381] In the context of the present disclosure, the term "cellulose-based film-former" is used to describe a cellulose polymer capable of forming a continuous film, either alone or in the presence of an auxiliary thickening agent. Preferably, the cellulose-based film-former is selected from hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethyl methylcellulose (HEMC), hydroxyethyl cellulose (HEC), hydroxypropyl cellulose (HPC), and combinations thereof. In a particularly preferred embodiment, the cellulose-based film-former is HPMC.

[0382] Suitable aerosol-generating films are described in WO-A-2020 / 207733 and WO-A-2022 / 074157.

[0383] Preferably, the aerosol-generating film comprises between 0.5 and 10 weight percent nicotine on a dry weight basis, or between 1 and 8 weight percent nicotine, or between 2 and 6 weight percent nicotine.

[0384] The aerosol-generating film can be a substantially tobacco-free aerosol-generating film.

[0385] The aerosol-generating material can comprise a gel composition comprising nicotine, at least one gelling agent, and an aerosol former. The gel composition is preferably substantially tobacco-free.

[0386] The preferred weight ranges for nicotine in the gel composition are the same as those defined above in relation to the aerosol-generating film.

[0387] Suitable gel compositions are described in WO-A-2021 / 170642.

[0388] The gel composition preferably comprises at least 50 weight percent aerosol former on a dry weight basis, more preferably at least 60 weight percent aerosol former, more preferably at least 70 weight percent aerosol former. The gel composition can comprise up to 80 weight percent aerosol former. The aerosol former in the gel composition is preferably glycerol.

[0389] The air inlet can be defined by a front wall of the aerosol-generating article. The air inlet can be defined by the frame and can extend through the frame. The air inlet can be defined by a peripheral wall of the frame. The air inlet can extend through the peripheral wall of the frame. The air outlet can be defined by a rear wall of the aerosol-generating article. The air outlet can be defined by the frame and can extend through the frame. The air outlet can be defined by a peripheral wall of the frame. The outlet can extend through the peripheral wall of the frame.

[0390] The air inlet can have a circular cross-section, a circular-shaped cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section. The air outlet can have a circular cross-section, a circular-shaped cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section.

[0391] The air inlet can be defined by, or extend through, the first frame layer, the second frame layer, or the third frame layer. The air inlet can be defined by, or extend through, the first frame layer and the second frame layer. The air inlet can be defined by, or extend through, the second frame layer and the third frame layer. The air inlet can be defined by, or extend through, the first frame layer, the second frame layer, and the third frame layer.

[0392] The air outlet can be defined by, or extend through, the first frame layer, the second frame layer, or the third frame layer. The air outlet can be defined by, or extend through, the first frame layer and the second frame layer. The air outlet can be defined by, or extend through, the second frame layer and the third frame layer. The air outlet can be defined by, or extend through, the first frame layer, the second frame layer, and the third frame layer.

[0393] The air inlet can be defined by, and can extend through, the first planar outer surface. The air inlet can be defined by, and can extend through, the outer wrapper. The air inlet can be defined by, and can extend through, the outer wrapper and the aerosol- generating substrate layer. The air inlet can be defined by, and can extend through, the outer wrapper and the first aerosol-generating substrate layer. The air inlet can be defined by, and can extend through, the first planar outer layer and the aerosol-generating substrate layer. The air inlet can be defined by, and can extend through, the first planar outer layer and the first aerosol-generating substrate layer.

[0394] The air inlet can be defined by, and can extend through, the second planar outer surface. The air inlet can be defined by, and can extend through, the outer wrapper and the second aerosol-generating substrate layer. The air inlet can be defined by, and can extend through, the second planar outer layer and the aerosol-generating substrate layer. The air inlet can be defined by, and can extend through, the second planar outer layer and the second aerosol-generating substrate layer.

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

[0396] The air outlet can be defined by the second planar outer surface and can extend through the second planar outer surface. The air outlet can be defined by the outer wrapper and the second aerosol-generating substrate layer and can extend through the outer wrapper and the second aerosol-generating substrate layer. The air outlet can be defined by the second planar outer layer and the aerosol-generating substrate layer and can extend through the second planar outer layer and the aerosol-generating substrate layer. The air outlet can be defined by the second planar outer layer and the second aerosol-generating substrate layer and can extend through the second planar outer layer and the second aerosol-generating substrate layer. The air inlet can have an equivalent diameter greater than or equal to 0.1 millimetres. The air inlet can have an equivalent diameter greater than or equal to 0.4 millimetres. The air inlet can have an equivalent diameter greater than or equal to 0.7 millimetres. The air inlet can have an equivalent diameter greater than or equal to 1.0 millimetres.

[0397] The air inlet can have an equivalent diameter less than or equal to 3 millimetres. The air inlet can have an equivalent diameter less than or equal to 2.7 millimetres. The air inlet can have an equivalent diameter less than or equal to 2.4 millimetres. The air inlet can have an equivalent diameter less than or equal to 2.1 millimetres. The air inlet can have an equivalent diameter less than or equal to 1.8 millimetres. The air inlet can have an equivalent diameter less than or equal to 1.5 millimetres.

[0398] The air inlet can have an equivalent diameter between 0.1 millimetres and 3 millimetres. The air inlet can have an equivalent diameter between 0.1 millimetres and 2.4 millimetres. The air inlet can have an equivalent diameter between 0.4 millimetres and 2.1 millimetres. The air inlet can have an equivalent diameter between 0.4 millimetres and 1.8 millimetres. The air inlet can have an equivalent diameter between 0.7 millimetres and 1.5 millimetres. The air inlet can have an equivalent diameter between 1.0 millimetres and 1.5 millimetres.

[0399] The air outlet can have an equivalent diameter greater than or equal to 0.1 millimeter. The air outlet can have an equivalent diameter greater than or equal to 0.4 millimeter. The air outlet can have an equivalent diameter greater than or equal to 0.7 millimeter. The air outlet can have an equivalent diameter greater than or equal to 1.0 millimeter.

[0400] The air outlet can have an equivalent diameter less than or equal to 3 millimeter. The air outlet can have an equivalent diameter less than or equal to 2.7 millimeter. The air outlet can have an equivalent diameter less than or equal to 2.4 millimeter. The air outlet can have an equivalent diameter less than or equal to 2.1 millimeter. The air outlet can have an equivalent diameter less than or equal to 1.8 millimeter. The air outlet can have an equivalent diameter less than or equal to 1.5 millimeter.

[0401] The air outlet can have an equivalent diameter between 0.1 millimeter and 3 millimeter. The air outlet can have an equivalent diameter between 0.1 millimeter and 2.4 millimeter. The air outlet can have an equivalent diameter between 0.4 millimeter and 2.1 millimeter. The air outlet can have an equivalent diameter between 0.4 millimeter and 1.8 millimeter. The air outlet can have an equivalent diameter between 0.7 millimeter and 1.5 millimeter. The air outlet can have an equivalent diameter between 1.0 millimeter and 1.5 millimeter.

[0402] The air inlet can have a width less than a width of the cavity. The air outlet can have a width less than a width of the cavity. The air inlet can have a thickness less than a thickness of the cavity. The air outlet can have a thickness less than a thickness of the cavity.

[0403] The air inlet can have a width between 0.3 millimeter and 3 millimeter. The air inlet can have a width between 0.5 millimeter and 2 millimeter.

[0404] The air inlet can have a thickness between 0.3 millimeter and 3 millimeter. The air outlet can have a thickness between 0.5 millimeter and 2 millimeter.

[0405] Preferably, the air inlet can have a width between 0.3 millimeter and 3 millimeter and a thickness between 0.3 millimeter and 3 millimeter.

[0406] The air outlet can have a width between 0.3 millimeter and 3 millimeter. The air outlet can have a width between 0.5 millimeter and 2 millimeter.

[0407] The air outlet can have a thickness between 0.3 millimeter and 3 millimeter. The air outlet can have a thickness between 0.5 millimeter and 2 millimeter.

[0408] Preferably, the air outlet can have a width between 0.3 millimeter and 3 millimeter and a thickness between 0.3 millimeter and 3 millimeter.

[0409] Advantageously, an aerosol-generating article having an air inlet or an air outlet with a width of between 0.3 millimetres and 3 millimetres and a thickness of between 0.3 millimetres and 3 millimetres can provide a good draw resistance through the aerosol-generating article.

[0410] Advantageously, an aerosol-generating article having an air inlet or an air outlet with a width of between 0.3 millimetres and 3 millimetres and a thickness of between 0.3 millimetres and 3 millimetres can provide a relatively large inlet or outlet opening while allowing improved retention of aerosol-generating substrate within the aerosol-generating article. Improved retention of aerosol-generating substrate within the aerosol-generating article can reduce the risk of aerosol-generating substrate falling out of the aerosol-generating article.

[0411] The ratio of the width of the air inlet to the thickness of the air inlet can be between 0.33 and 3. The ratio of the width of the air inlet to the thickness of the air inlet can be between 0.5 and 1.5. The ratio of the width of the air inlet to the thickness of the air inlet can be between 0.75 and 1.25.

[0412] The ratio of the width of the air outlet to the thickness of the air outlet can be between 0.33 and 3. The ratio of the width of the air outlet to the thickness of the air outlet can be between 0.5 and 1.5. The ratio of the width of the air outlet to the thickness of the air outlet can be between 0.75 and 1.25.

[0413] The aerosol-generating article can comprise one or more air inlets. The aerosol-generating article can comprise a plurality of air inlets. One or each of the air inlets can have one or more of the features of an air inlet described herein.

[0414] The aerosol-generating article can comprise one or more air outlets. The aerosol-generating article can comprise a plurality of air outlets. One or each of the air outlets can have one or more of the features of an air outlet described herein.

[0415] The aerosol-generating article can comprise a filter element positioned downstream of the aerosol-forming substrate. The aerosol-generating article can comprise a filter element positioned downstream of the cavity. The aerosol-generating article can comprise a filter element positioned at least partially within the air outlet. The aerosol-generating article can comprise a filter element positioned within the cavity and can be positioned at a downstream end of the cavity.

[0416] The aerosol-generating article can comprise a filter element positioned upstream of the aerosol-forming substrate. The aerosol-generating article can comprise a filter element positioned upstream of the cavity. The aerosol-generating article can comprise a filter element positioned at least partially within the air inlet. The aerosol-generating article can comprise a filter element positioned within the cavity and can be positioned at an upstream end of the cavity.

[0417] The filter element can comprise one or more segments of fibrous filter material. Suitable fibrous filter materials will be known to the skilled person. The filter element can comprise cellulose acetate.

[0418] The aerosol-generating article can comprise a front wall. The front wall can extend from the first planar outer surface to the second planar outer surface. That is, the front wall extends in the transverse direction. The front wall can be a downstream wall and can be referred to as a downstream wall. The front wall can be defined by the frame, for example by the perimeter wall of the frame.

[0419] The aerosol-generating article can comprise a rear wall. The rear wall can extend from the first planar outer surface to the second planar outer surface. That is, the rear wall extends in the transverse direction. The rear wall can be an upstream wall and can be referred to as an upstream wall. The rear wall can be defined by the frame, for example by the perimeter wall of the frame.

[0420] The aerosol-generating article can comprise one or more side walls. The one or more side walls can 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 can be opposite one another. The one or more side walls can extend from the front wall to the rear wall. The one or more side walls can extend from the first planar outer surface to the second planar outer surface. The one or more side walls, such as the first side wall and the second side wall, can be defined by the frame, for example by the perimeter wall of the frame.

[0421] Any two or more of the front wall, the rear wall, the one or more side walls can be integral with one another. Advantageously, this construction can provide a robust article that is easy to manufacture.

[0422] The aerosol-generating article can comprise a first end face. The first end face can extend from the first planar outer surface to the second planar outer surface. The first end face can be defined or formed by an outer wall of the aerosol-generating article, such as the front wall or the rear wall.

[0423] The aerosol-generating article can comprise a second end face. The second end face can extend from the first planar outer surface to the second planar outer surface. The second end face can be defined or formed by an outer wall or surface of the aerosol-generating article, such as the front wall or the rear wall. The second end face can be positioned opposite the first end face. The second end face can be parallel to the first end face.

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

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

[0426] The first end surface and the first side surface can form an interior angle equal to or less than 90 degrees. The first end surface and the second side surface can form an interior angle equal to or less than 90 degrees.

[0427] The aerosol-generating article can comprise a first exterior corner extending from the first planar outer surface to the second planar outer surface. The first exterior corner can connect the first end surface of the aerosol-generating article and the first side surface of the aerosol-generating article.

[0428] The first exterior corner can be chamfered or rounded.

[0429] In embodiments in which 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 millimetres and 6.5 millimetres.

[0430] The radius of curvature of the first exterior corner can be less than or equal to 50% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner can be less than or equal to 30% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner can be less than or equal to 20% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner can be less than or equal to 10% of the width of the aerosol-generating article.

[0431] The radius of curvature of the first exterior corner can be greater than or equal to 1% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner can be greater than or equal to 5% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner can be greater than or equal to 10% of the width of the aerosol-generating article.

[0432] The radius of curvature of the first exterior corner can be between 1% and 50% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner can be between 1% and 30% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner can be between 5% and 30% of the width of the aerosol-generating article. The radius of curvature of the first exterior corner can be between 5% and 20% of the width of the aerosol-generating article.

[0433] In embodiments where the first exterior corner is chamfered, the first exterior corner can be chamfered at an angle between 30 degrees and 60 degrees measured from the first end face. The first exterior corner can be chamfered at an angle between 40 degrees 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.

[0434] The first exterior corner can include a first corner surface connecting the first end face to the second side face. The first end face can connect to the first corner surface at a first corner transition region, and a first corner interior angle between a tangent to the first end face formed at the first corner transition region and a tangent to the first corner surface at the first corner transition region can be between 90 degrees and 180 degrees in any x / y plane. The first corner interior angle can be between 120 degrees and 180 degrees. The first corner interior angle can be between 130 degrees and 180 degrees.

[0435] The aerosol-generating article can include a second exterior corner extending from the first planar outer surface to the second planar outer surface. The second exterior corner can connect the first end face of the aerosol-generating article and the second side face of the aerosol-generating article.

[0436] The second exterior corner can be chamfered or rounded.

[0437] 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 an x / y plane. The radius of curvature of the second exterior corner can be between 1.25 millimeters and 6.5 millimeters.

[0438] The radius of curvature of the second exterior corner can be less than or equal to 50% of the width of the aerosol-generating article. The radius of curvature of the second exterior corner can be less than or equal to 30% of the width of the aerosol-generating article. The radius of curvature of the second exterior corner can be less than or equal to 20% of the width of the aerosol-generating article. The radius of curvature of the second exterior corner can be less than or equal to 10% of the width of the aerosol-generating article.

[0439] The radius of curvature of the second exterior corner can be greater than or equal to 1% of the width of the aerosol-generating article. The radius of curvature of the second exterior corner can be greater than or equal to 5% of the width of the aerosol-generating article. The radius of curvature of the second exterior corner can be greater than or equal to 10% of the width of the aerosol-generating article.

[0440] The radius of curvature of the second exterior corner can be between 1% and 50% of the width of the aerosol-generating article. The radius of curvature of the second exterior corner can be between 1% and 30% of the width of the aerosol-generating article. The radius of curvature of the second exterior corner can be between 5% and 30% of the width of the aerosol-generating article. The radius of curvature of the second exterior corner can be between 5% and 20% of the width of the aerosol-generating article.

[0441] In embodiments where both the first outer corner and the second outer corner are rounded, the radius of curvature of the first outer corner can be the same as the radius of curvature of the second outer corner.

[0442] In embodiments where the second outer corner is chamfered, the second outer corner can be chamfered at an angle between 30 degrees and 60 degrees measured from the first end face. The second outer corner can be chamfered at an angle between 40 degrees and 50 degrees measured from the first end face. The second outer corner can be chamfered at an angle of 45 degrees measured from the first end face.

[0443] The second outer corner can include a second corner surface connecting the first end face to the second side face. The first end face can connect to the second corner surface at a second corner transition region, and a second corner interior angle between a tangent to the first end face formed at the second corner transition region and a tangent to the second corner surface at the second corner transition region can be between 90 degrees and 180 degrees in any x / y plane. The second corner interior angle can be between 120 degrees and 180 degrees. The second corner interior angle can be between 130 degrees and 180 degrees.

[0444] The aerosol-generating article can include a third outer corner extending from the first planar outer surface to the second planar outer surface. The third outer corner can connect a second end face of the aerosol-generating article and a first side face of the aerosol-generating article.

[0445] The third outer corner can be chamfered or rounded.

[0446] In embodiments where the third outer corner is rounded, the third outer corner can have a radius of curvature. The radius of curvature of the third outer corner can be measured in an x / y plane. The radius of curvature of the third outer corner can be between 1.25 millimeters and 6.5 millimeters.

[0447] The radius of curvature of the third outer corner can be less than or equal to 50% of a width of the aerosol-generating article. The radius of curvature of the third outer corner can be less than or equal to 30% of the width of the aerosol-generating article. The radius of curvature of the third outer corner can be less than or equal to 20% of the width of the aerosol-generating article. The radius of curvature of the third outer corner can be less than or equal to 10% of the width of the aerosol-generating article.

[0448] The radius of curvature of the third outer corner can be greater than or equal to 1% of a width of the aerosol-generating article. The radius of curvature of the third outer corner can be greater than or equal to 5% of the width of the aerosol-generating article. The radius of curvature of the third outer corner can be greater than or equal to 10% of the width of the aerosol-generating article.

[0449] The radius of curvature of the third exterior corner can be between 1% and 50% of the width of the aerosol generating article. The radius of curvature of the third exterior corner can be between 1% and 30% of the width of the aerosol generating article. The radius of curvature of the third exterior corner can be between 5% and 30% of the width of the aerosol generating article. The radius of curvature of the third exterior corner can be between 5% and 20% of the width of the aerosol generating article.

[0450] In embodiments in which the third exterior corner is chamfered, the third exterior corner can be chamfered at an angle measured from the second end face of between 30 degrees and 60 degrees. The third exterior corner can be chamfered at an angle measured from the third end face of between 40 degrees and 50 degrees. The third exterior corner can be chamfered at an angle measured from the third end face of 45 degrees.

[0451] The aerosol generating article can include a fourth exterior corner extending from the first planar outer surface to the second planar outer surface. The fourth exterior corner can connect the second end face of the aerosol generating article and the second side face of the aerosol generating article.

[0452] The fourth exterior corner can be chamfered or rounded.

[0453] In embodiments in which 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 millimeters and 6.5 millimeters.

[0454] The radius of curvature of the fourth exterior corner can be less than or equal to 50% of the width of the aerosol generating article. The radius of curvature of the fourth exterior corner can be less than or equal to 30% of the width of the aerosol generating article. The radius of curvature of the fourth exterior corner can be less than or equal to 20% of the width of the aerosol generating article. The radius of curvature of the fourth exterior corner can be less than or equal to 10% of the width of the aerosol generating article.

[0455] The radius of curvature of the fourth exterior corner can be greater than or equal to 1% of the width of the aerosol generating article. The radius of curvature of the fourth exterior corner can be greater than or equal to 5% of the width of the aerosol generating article. The radius of curvature of the fourth exterior corner can be greater than or equal to 10% of the width of the aerosol generating article.

[0456] The radius of curvature of the fourth exterior corner can be between 1% and 50% of the width of the aerosol generating article. The radius of curvature of the fourth exterior corner can be between 1% and 30% of the width of the aerosol generating article. The radius of curvature of the fourth exterior corner can be between 5% and 30% of the width of the aerosol generating article. The radius of curvature of the fourth exterior corner can be between 5% and 20% of the width of the aerosol generating article.

[0457] In embodiments in which the fourth outer corner is chamfered, the fourth outer corner can be chamfered at an angle of between 30 degrees and 60 degrees measured from the second end face. The fourth outer corner can be chamfered at an angle of between 40 degrees and 50 degrees measured from the third end face. The fourth outer corner can be chamfered at an angle of 45 degrees measured from the third end face.

[0458] Advantageously, providing an aerosol-generating article having at least one outer corner extending from the first planar outer surface to the second planar outer surface that is rounded or chamfered can make the aerosol-generating article easier to insert into an aerosol-generating device.

[0459] Advantageously, providing an aerosol-generating article having at least one outer corner extending from the first planar outer surface to the second planar outer surface that is rounded or chamfered can make the aerosol-generating article less susceptible to damage, particularly during insertion of the aerosol-generating article into an aerosol-generating device.

[0460] Advantageously, providing an aerosol-generating article having at least one outer corner extending from the first planar outer surface to the second planar outer surface that is rounded or chamfered can make the aerosol-generating article easier to manufacture.

[0461] The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article can be greater than 2:1. The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article can be greater than 3:1. The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article can be greater than 4:1. The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article can be greater than 5:1. The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article can be greater than 10:1. The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article can be greater than 12:1. The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article can be greater than 15:1.

[0462] The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article can be less than 15:1. The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article can be less than 12:1. The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article can be less than 10:1. The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article can be less than 5:1. The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article can be less than 4:1. The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article can be less than 3:1. The ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article is less than 2.5:1.

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

[0464] The ratio between the length and the width of the aerosol-generating article can be greater than 1 :1. The ratio between the length and the width of the aerosol-generating article can be greater than 1.25:1. The ratio between the length and the width of the aerosol-generating article can be greater than 1.5:1. The ratio between the length and the width of the aerosol-generating article can be greater than 2:1. The ratio between the length and the width of the aerosol-generating article can be greater than 2.5:1. The ratio between the length and the width of the aerosol-generating article can be greater than 3:1. The ratio between the length and the width of the aerosol-generating article can be greater than 4:1. The ratio between the length and the width of the aerosol-generating article can be greater than 5:1.

[0465] The ratio between the length and the width of the aerosol-generating article can be less than 10:1. The ratio between the length and the width of the aerosol-generating article can be less than 8:1. The ratio between the length and the width of the aerosol-generating article can be less than 5:1. The ratio between the length and the width of the aerosol-generating article can be less than 4:1. The ratio between the length and the width of the aerosol-generating article can be less than 3.5:1. The ratio between the length and the width of the aerosol-generating article can be less than 3:1. The ratio between the length and the width of the aerosol-generating article can be less than 2.5:1. The ratio between the length and the width of the aerosol-generating article can be less than 2:1.

[0466] The ratio between the length and the width of the aerosol-generating article can be between 1 :1 and 10:1. The ratio between the length and the width of the aerosol-generating article can be between 1.5:1 and 5:1. The ratio between the length and the width of the aerosol-generating article can be between 1.5:1 and 4:1. The ratio between the length and the width of the aerosol-generating article can be between 1.5:1 and 3:1. The ratio between the length and the width of the aerosol-generating article can be between 2:1 and 4:1. The ratio between the length and the width of the aerosol-generating article can be between 2:1 and 3:1.

[0467] The aerosol-generating article can have a length greater than or equal to 15 millimetres. The aerosol-generating article can have a length greater than or equal to 20 millimetres. The aerosol-generating article can have a length greater than or equal to 25 millimetres. The aerosol-generating article can have a length greater than or equal to 30 millimetres. The aerosol-generating article can have a length greater than or equal to 35 millimetres. The aerosol-generating article can have a length greater than or equal to 40 millimetres.

[0468] The aerosol-generating article can have a length less than or equal to 45 millimetres. The aerosol-generating article can have a length less than or equal to 40 millimetres. The aerosol-generating article can have a length less than or equal to 35 millimetres. The aerosol-generating article can have a length less than or equal to 30 millimetres.

[0469] The aerosol-generating article can have a length between 15 millimetres and 45 millimetres. The aerosol-generating article can have a length between 20 millimetres and 40 millimetres. The aerosol-generating article can have a length between 20 millimetres and 35 millimetres. The aerosol-generating article can have a length between 25 millimetres and 30 millimetres.

[0470] The aerosol-generating article can have a width equal to or greater than 3 millimetres. The aerosol-generating article can have a width greater than or equal to 5 millimetres. The aerosol-generating article can have a width greater than or equal to 7.5 millimetres. The aerosol-generating article can have a width greater than or equal to 9 millimetres. The aerosol-generating article can have a width greater than or equal to 11 millimetres. The aerosol-generating article can have a width greater than or equal to 13 millimetres.

[0471] The aerosol-generating article can have a width less than or equal to 17 millimetres. The aerosol-generating article can have a width less than or equal to 15 millimetres. The aerosol-generating article can have a width less than or equal to 12.5 millimetres. The aerosol-generating article can have a width less than or equal to 11 millimetres. The aerosol-generating article can have a width less than or equal to 9 millimetres.

[0472] The aerosol-generating article can have a width between 3 millimetres and 17 millimetres. The aerosol-generating article can have a width between 5 millimetres and 15 millimetres. The aerosol-generating article can have a width between 7.5 millimetres and 12.5 millimetres. The aerosol-generating article can have a width between 9 millimetres and 11 millimetres.

[0473] The aerosol-generating article can have a thickness equal to or greater than 1 millimetre. The aerosol-generating article can have a thickness greater than or equal to 1.5 millimetres. The aerosol-generating article can have a thickness greater than or equal to 2 millimetres. The aerosol-generating article can have a thickness greater than or equal to 2.5 millimetres. The aerosol-generating article can have a thickness greater than or equal to 3 millimetres. The aerosol-generating article can have a thickness greater than or equal to 3.5 millimetres. The aerosol-generating article can have a thickness greater than or equal to 4 millimetres. The aerosol-generating article can have a thickness greater than or equal to 4.5 millimetres.

[0474] The aerosol-generating article can have a thickness less than or equal to 5.5 millimetres. The aerosol-generating article can have a thickness less than or equal to 5 millimetres. The aerosol-generating article can have a thickness less than or equal to 4.5 millimetres. The aerosol-generating article can have a thickness less than or equal to 4 millimetres. The aerosol-generating article can have a thickness less than or equal to 3.5 millimetres. The aerosol-generating article can have a thickness less than or equal to 3 millimetres. The aerosol-generating article can have a thickness less than or equal to 2.5 millimetres. The aerosol-generating article can have a thickness less than or equal to 2 millimetres.

[0475] The aerosol-generating article can have a thickness of between 1 millimetre and 5 millimetres. The aerosol-generating article can have a thickness of between 1.5 millimetres and 5 millimetres. The aerosol-generating article can have a thickness of between 2 millimetres and 4.5 millimetres. The aerosol-generating article can have a thickness of between 2.5 millimetres and 4 millimetres. The aerosol-generating article can have a thickness of between 3 millimetres and 3.5 millimetres.

[0476] The aerosol-generating article can have a length of between 15 millimetres and 45 millimetres, a width of between 5 millimetres and 15 millimetres, and a thickness of between 1 millimetre and 5 millimetres.

[0477] Preferably, the aerosol-generating article can have a length of between 20 millimetres and 30 millimetres, a width of between 7.5 millimetres and 12.5 millimetres, and a thickness of between 2.5 millimetres and 4 millimetres.

[0478] More preferably, the aerosol-generating article can have a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.1 millimetres.

[0479] Advantageously, providing an aerosol-generating article having a length of between 15 millimetres and 45 millimetres, a width of between 5 millimetres and 15 millimetres, and a thickness of between 1 millimetre and 5 millimetres can result in an aerosol-generating article having a high external surface to volume ratio. An aerosol-generating article having a high external surface to volume ratio can be heated more efficiently, which can result in better evaporation of aerosol-generating substrate stored within the aerosol-generating article. Better evaporation of aerosol-generating substrate stored within the aerosol-generating article can result in an improved user experience.

[0480] Advantageously, providing an aerosol-generating article having a length of between 15 millimetres and 45 millimetres, a width of between 5 millimetres and 15 millimetres, and a thickness of between 1 millimetre and 5 millimetres, wherein the cavity has a length of between 14 millimetres and 40 millimetres, a width of between 4.5 millimetres and 13 millimetres, and a thickness of between 0.5 millimetres and 4.5 millimetres, can result in an aerosol-generating article that accommodates a large cavity and has a high cavity volume that is proportional to the external volume of the aerosol-generating article.

[0481] The aerosol-generating article can have an external volume of between 75 cubic millimetres and 3375 cubic millimetres. The aerosol-generating article can have an external volume of between 375 cubic millimetres and 1750 cubic millimetres.

[0482] The aerosol-generating article can have a resistance to draw (RTD) of less than or equal to 20 millimeters H20. The aerosol-generating article can have a resistance to draw (RTD) of less than or equal to 10 millimeters H20. The aerosol-generating article can have a resistance to draw (RTD) of less than or equal to 8 millimeters H20. The aerosol-generating article can have a resistance to draw (RTD) of less than or equal to 6 millimeters H20. The aerosol-generating article can have a resistance to draw (RTD) of less than or equal to 4 millimeters H20. The aerosol-generating article can have a resistance to draw (RTD) of less than or equal to 2 millimeters H20. The aerosol-generating article can have a resistance to draw (RTD) of equal to or near zero millimeters H20.

[0483] The aerosol-generating article can have a resistance to draw (RTD) of between 0 millimeters H20 and 9.9 millimeters H20. The aerosol-generating article can have a resistance to draw (RTD) of between 1 millimeters H20 and 8 millimeters H20. The aerosol-generating article can have a resistance to draw (RTD) of between 2 millimeters H20 and 6 millimeters H20. The aerosol-generating article can have a resistance to draw (RTD) of between 3 millimeters H20 and 5 millimeters H20.

[0484] Unless otherwise specified, resistance to draw (RTD) is measured according to 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 term “pressure drop” or “draw resistance” of a component or article can also refer to “resistance to draw.” Such terms generally refer to measurements according to ISO 6565-2015, which are typically conducted in testing at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 torr), and a relative humidity of about 60%, at a volumetric flow rate of about 17.5 milliliters / second at the output or downstream end of the component being measured.

[0485] According to the present disclosure, there is provided a method of manufacturing an aerosol-generating article as described herein. 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 bonding the first sheet of material, the second sheet of material, and the third sheet of material to form the aerosol-generating article.

[0486] 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 comprising: a first frame material sheet, a first outer layer material sheet, and a second outer layer material sheet. The method comprises forming an aperture through the first frame material sheet. The method comprises positioning the first frame material sheet and the aperture between the first outer layer material sheet and the second outer layer material sheet. The method comprises bonding the sheet materials to one another.

[0487] 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 comprising: a first frame material sheet, a first aerosol-generating material sheet, a second aerosol-generating material sheet, a first outer layer material sheet, and a second outer layer material sheet. The method comprises forming an aperture through the first frame material sheet. The method comprises positioning the first frame material sheet and the aperture between the first aerosol-generating material sheet and the second aerosol-generating material sheet. The method comprises positioning the first frame material sheet, the aperture, the first aerosol-generating material sheet, and the second aerosol-generating material sheet between the first outer layer material sheet and the second outer layer material sheet. The method comprises bonding the sheet materials to one another.

[0488] 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 comprising: a first frame material sheet, a second frame material sheet, a first outer layer material sheet, and a second outer layer material sheet. The method can comprise bonding the first frame material sheet and the second frame material sheet to one another. The method comprises forming an aperture through the first frame material sheet and the second frame material sheet (e.g. after the first frame material sheet and the second frame material sheet have been bonded). The method comprises positioning the first frame material sheet, the second frame material sheet, and the aperture between the first outer layer material sheet and the second outer layer material sheet. The method comprises bonding the sheet materials to one another.

[0489] 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 comprising: a first frame material sheet, a second frame material sheet, a first aerosol-generating material sheet, a second aerosol-generating material sheet, a first outer layer material sheet, and a second outer layer material sheet. The method can comprise bonding the first frame material sheet and the second frame material sheet to each other. The method comprises forming an aperture through the first frame material sheet and the second frame material sheet, for example after the first frame material sheet and the second frame material sheet have been bonded. The method comprises positioning the first frame material sheet, the second frame material sheet, and the aperture between the first aerosol-generating material sheet and the second aerosol-generating material sheet. The method comprises positioning the first frame material sheet, the second frame material sheet, the aperture, the first aerosol-generating material sheet, and the second aerosol-generating material sheet between the first outer layer material sheet and the second outer layer material sheet. The method comprises bonding the sheet material 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 a 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 can comprise bonding the first frame material sheet, the second frame material sheet, and the third frame material sheet to each other. The method comprises forming an aperture through the first frame material sheet, the second frame material sheet, and the third frame material sheet, for example after the first frame material sheet, the second frame material sheet, and the third frame material sheet have been bonded. The method comprises positioning the first frame material sheet, the second frame material sheet, the third frame material sheet, and the aperture between the first outer layer material sheet and the second outer layer material sheet. The method comprises bonding the sheet material to each other.

[0491] 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 comprising: a first frame material sheet, a second frame material sheet, a third frame material sheet, a first aerosol-generating material sheet, a second aerosol-generating material sheet, a first outer layer material sheet, and a second outer layer material sheet. The method can comprise bonding the first frame material sheet, the second frame material sheet, and the third frame material sheet to one another. The method comprises forming an aperture through the first frame material sheet, the second frame material sheet, and the third frame material sheet, for example after the first frame material sheet, the second frame material sheet, and the third frame material sheet have been bonded. The method comprises positioning the first frame material sheet, the second frame material sheet, the third frame material sheet, and the aperture between the first aerosol-generating material sheet and the second aerosol-generating material sheet. The method comprises positioning the first frame material sheet, the second frame material sheet, the second aerosol-generating material sheet, the aperture, the first aerosol-generating material sheet, and the second aerosol-generating material sheet between the first outer layer material sheet and the second outer layer material sheet. The method comprises bonding the sheet material to one another.

[0492] The method of manufacturing an aerosol-generating article described herein can comprise the step of positioning an aerosol-generating substrate within the aperture.

[0493] One or more of the first frame material sheet, the second frame material sheet, the third frame material sheet in the method of manufacturing described herein can be a sheet of paper or cardboard.

[0494] One or more of the first aerosol-generating material sheet and the second aerosol-generating material sheet in the method of manufacturing described herein can be a sheet of homogenised tobacco material.

[0495] One or more of the first outer layer material sheet and the second outer layer material sheet in the method of manufacturing described herein can be a sheet of cigarette paper.

[0496] 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 means, a power supply for supplying power to the heater or heating means, and a controller to control the supply of power to the heater or heating means. The aerosol-generating device is configured to heat at least one of the one or more aerosol-generating substrates to form an aerosol, for example an inhalable aerosol. The aerosol-generating device can be configured to heat each of the one or more aerosol-generating substrates to form an aerosol, for example an inhalable aerosol.

[0497] The cavity of the aerosol-generating device can comprise an opening into which an end, such as a longitudinal end, of the aerosol-generating article can be inserted. The cavity of the aerosol-generating device can have any suitable cross-sectional shape. For example, the cavity of the aerosol-generating device can have a rectangular cross-section, for example a rectangular cross-section having opposite top and bottom sides that are longer than the left and right sides.

[0498] Preferably, at least one inner surface of the cavity of the aerosol-generating device is a heating surface configured to heat the aerosol-generating article. The heating surface can comprise a heater, such as an electrical resistance heater or an infrared heater, or a susceptor configured to be heated by engagement with an inductor. The heating surface can comprise an inductor, for example the surface can comprise a coil arranged to generate an oscillating electromagnetic field within the space of the cavity of the aerosol-generating device. The heating surface can be a surface that is permeable to the oscillating electromagnetic field, such that an inductor arranged outside of the cavity of the aerosol-generating device can project an oscillating electromagnetic field through the heating surface to engage with a susceptor arranged within the cavity of the aerosol-generating device.

[0499] 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.

[0500] 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 and upper inner surfaces of the cavity of the aerosol-generating device are substantially planar. Preferably, the upper and lower inner surfaces of the cavity of the aerosol-generating device are arranged in parallel relationship to one another.

[0501] Optionally, the upper and lower inner surfaces can converge along the length of the cavity of the aerosol-generating device, such that they are slightly closer together at the distal end of the cavity than at the proximal end of the cavity. This can allow the cavity of the aerosol-generating device to grip the aerosol-generating article inserted therein. The side inner surfaces can converge in a similar manner to achieve the result of gripping 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 can 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.

[0502] In some examples, the lower inner surface and the upper inner surface are movable relative to one another. For example, the lower inner surface and the upper inner surface can be configured to pivot relative to one another, or to move upwardly and downwardly relative to one another. This can 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 and lower inner surfaces can cause the aerosol-generating article to be clamped between the two surfaces to facilitate heating of the article and to help position the article appropriately within the device.

[0503] The cavity of the aerosol-generating device can be defined by a longitudinal dimension or length, a lateral 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.

[0504] The aerosol-generating device can 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 can be configured to be operated individually, or simultaneously in any combination of two or more zones. In some examples, the plurality of individually operable heating zones can be spaced longitudinally within the cavity. In some examples, the plurality of individually operable heating zones can be spaced laterally within the cavity. Different heating zones can be spaced laterally and longitudinally from one another. Different heating zones can be arranged concentrically relative to one another.

[0505] The aerosol-generating device can comprise one or more resistive heaters, for example one or more resistive heaters integrated into a wall of the cavity.

[0506] The device can comprise one or more inductors, for example one or more inductors integrated into a wall of the cavity of the aerosol-generating device or arranged to generate an oscillating electromagnetic field in or within a wall of the cavity of the aerosol-generating device. One or more walls of the cavity of the aerosol-generating device comprise or consist of susceptor material, such that the one or more walls of the cavity heat up when engaged with the oscillating electromagnetic field, thereby heating an aerosol-generating article inserted within the cavity.

[0507] The aerosol-generating device can comprise one or more insertable heating elements arranged to protrude into the cavity of the aerosol-generating device for insertion into an aerosol-generating article. The insertable heating element can be a resistive heater. The insertable heating element can be a susceptor.

[0508] An aerosol-generating device can comprise a device body. The device body can comprise a heater. The aerosol-generating device can comprise a mouthpiece element. The device body can comprise a device body housing. The device body housing can define a cavity for receiving at least a portion of an aerosol-generating article. The device body and the mouthpiece element can be releasably connectable. The mouthpiece element can be releasably connectable with the device body, for example the device body housing.

[0509] The mouthpiece element can be releasably connectable with the device body, for example the device body housing, between a connected position and a disconnected position. In the connected position, the cavity of the aerosol-generating device can be at least partially covered, for example by the mouthpiece element. In the disconnected position, the cavity of the aerosol-generating device can be at least partially exposed, for example to allow insertion of an article into the cavity of the aerosol-generating device. The mouthpiece element can be movable, for example pivotable, about a hinge relative to the device body, for example between a first position and a second position. In the first position, the cavity of the aerosol-generating device can be at least partially covered, for example by the mouthpiece element. In the second position, the cavity can be at least partially exposed, for example to allow insertion of an article into the cavity of the aerosol-generating device. Advantageously, covering the cavity of the aerosol-generating device or an article in the cavity of the aerosol-generating device can ensure that a majority of aerosol from the article travels along a desired flow path to the user, rather than escaping to the external environment.

[0510] The aerosol-generating device, for example the device body, can comprise a power source, such as a battery. In use, the power source can provide power to the heater. The device, for example the device body, can comprise a controller. The controller can be configured to control the power from the power source to the heater.

[0511] The device body can comprise a distal end and a proximal end. The cavity of the aerosol-generating device can be defined at the proximal end of the device body. The mouthpiece element can comprise a distal end and a proximal end. The distal end of the mouthpiece element can be configured to be releasably connectable to the proximal end of the device body.

[0512] The mouthpiece element, or at least a portion of the mouthpiece element, can be configured to be inserted into a user’s mouth. The proximal end of the mouthpiece element can be configured to be inserted into a user’s mouth.

[0513] The aerosol-generating device, for example one or both of the device body and the mouthpiece element, can comprise an air inlet. The device, for example the mouthpiece element, can comprise an air outlet. The device can comprise an airflow path fluidically connecting the air inlet to the air outlet. The airflow path can extend through and / or past the cavity of the aerosol-generating device. Thus, in use, the device can be configured such that when a negative pressure is applied to the air outlet, for example by a user drawing on the air outlet, air is drawn in through the air inlet, then past or through an aerosol-generating article received in the cavity, thereby entraining aerosol released from the aerosol-forming substrate of the article, and then out through the air outlet.

[0514] 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 can comprise a plurality of such articles for use with the aerosol-generating device.

[0515] As used herein, the term “aerosol-generating article” refers to an article comprising an aerosol-generating substrate. The article can be heated in use to generate an inhalable aerosol and to deliver it to a consumer.

[0516] As used herein, the term “aerosol-generating substrate” refers to a substrate capable of releasing volatile compounds (e.g. compounds that cool and condense to generate an aerosol in use) upon heating.

[0517] As used herein, the term “aerosol-generating device” refers to a device that interacts with (e.g. heats) an aerosol-generating substrate of an aerosol-generating article in use to generate an aerosol.

[0518] As used herein, the term “planar” refers to a feature that is generally formed in a single Euclidean plane and does not encircle 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. The extension of a planar object in two dimensions in a single Euclidean plane can be significantly greater than the extension in a third dimension perpendicular to the plane. More specifically, the extension of a planar object in a first dimension and a second dimension perpendicular to the first dimension can be at least two, five, or ten times greater than the extension of the object in a third dimension perpendicular to the first and second dimensions.

[0519] As used herein, the term “lateral” refers to a direction extending between a first planar outer surface and a second planar outer surface.

[0520] As used herein, the term “longitudinal” refers to a direction perpendicular to the lateral direction. For example, the direction between a front wall and a back wall of an aerosol-generating article.

[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 “thickness” refers to the maximum dimension of an aerosol-generating article or a component of an aerosol-generating article in the lateral direction.

[0523] As used herein, the term “length” refers to the maximum dimension of an aerosol-generating article or a component of an aerosol-generating article in the longitudinal direction.

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

[0525] As used herein, the terms "upstream" and "downstream" refer to the relative positions of components or portions of components of an aerosol-generating article with respect to the direction in which air or aerosol is conveyed through the aerosol-generating article during use.

[0526] As used herein, the term "bulk density" can refer to the total weight of aerosol- generating substrate divided by the total volume of the aerosol-generating substrate.

[0527] As used herein, the term "aerosol former" can refer to any suitable known compound or mixture of compounds that facilitates the formation of an aerosol in use. The aerosol can be a dense and stable aerosol. The aerosol can be substantially resistant to thermal degradation at the operating temperature of the aerosol-generating substrate or aerosol-generating article.

[0528] As used herein, unless otherwise stated, the term "aerosol former content" can refer to the content of aerosol former in percentage by dry weight.

[0529] As used herein, "susceptor" refers to a conductive element that heats up when subjected to a changing magnetic field. This can be a result of eddy currents induced in the susceptor element and / or hysteresis losses.

[0530] As used herein, the term "hydrophobic" refers to a surface exhibiting water repellent properties. One useful way of determining this is to measure the water contact angle. The "water contact angle" is the angle, conventionally measured through the liquid, at which the liquid / vapour interface meets a solid surface. It quantifies the wettability of a solid surface by a liquid via the Young equation.

[0531] As used herein, the term "equivalent diameter" of an opening or orifice is used herein to mean the diameter of a circular opening or orifice having the same cross-sectional area as the opening or orifice.

[0532] As used herein, the term "fill density" is a ratio of the total volume of components of an aerosol-generating substrate, such as solid and liquid components, positioned within a cavity, first cavity or second cavity to the volume of the cavity in which the aerosol-generating substrate is positioned.

[0533] The present application is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more features of these examples can be combined with any one or more features of another example, embodiment or aspect described herein.

[0534] Ex1. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising:

[0535] a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction;

[0536] an air inlet, an air outlet, and an airflow pathway extending between the air inlet and the air outlet;

[0537] a cavity;

[0538] one or more aerosol-generating substrates;

[0539] a first planar outer surface and a second planar outer surface spaced apart from the first planar outer surface in the z-direction;

[0540] a frame positioned between the first planar outer surface and the second planar outer surface, the frame at least partially defining the cavity; and

[0541] wherein the frame forms at least 75% of a perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame.

[0542] Ex2. An aerosol-generating article according to Ex1, wherein the frame forms at least 85% of a perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame.

[0543] Ex3. An aerosol-generating article according to Ex1 or Ex2, wherein the frame forms at least 95% of a perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame.

[0544] Ex4. An aerosol-generating article according to any of Exs 1 to 3, wherein the frame forms at least 99% of a perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame.

[0545] Ex5 An aerosol-generating article according to any of Exs 1 to 4, wherein the aerosol-generating article comprises a cross-section in a first x / y plane extending through the frame, and wherein the frame forms at least 99% of a perimeter of the cross-section in the first x / y plane, preferably the frame forms 100% of a perimeter of the cross-section in the first x / y plane.

[0546] Ex6. An aerosol-generating article according to Ex5, wherein the aerosol- generating article comprises a cross-section in a second x / y plane spaced apart from the first x / y plane in the z-direction extending through the frame, and wherein the frame forms at least 99% of the perimeter of the cross-section in the second x / y plane, preferably the frame forms 100% of the perimeter of the cross-section in the second x / y plane.

[0547] Ex7. An aerosol-generating article according to Ex6, wherein the air inlet is positioned in the z-direction between the first x / y plane and the second x / y plane.

[0548] Ex8. An aerosol-generating article according to Ex6 or Ex7, wherein the air outlet is positioned in the z-direction between the first x / y plane and the second x / y plane.

[0549] Ex9. An aerosol-generating article according to any of Exs 1 to 8, wherein the frame has a first portion which is at least 30% of the thickness of the frame and the frame forms 100% of the perimeter of any cross-section in an x / y plane of the aerosol- generating article extending through the first portion of the frame.

[0550] Ex10. An aerosol-generating article according to Ex9, wherein the first portion is at least 50% of the thickness of the frame.

[0551] Ex11. An aerosol-generating article according to Ex10, wherein the first portion is at least 70% of the thickness of the frame.

[0552] Ex12. An aerosol-generating article according to Ex11, wherein the first portion is at least 90% of the thickness of the frame.

[0553] Ex13. An aerosol-generating article according to any of Exs 1 to 12, wherein the frame has a thickness which is greater than or equal to 50% of the thickness of the aerosol-generating article.

[0554] Ex14. An aerosol-generating article according to any of Exs 1 to 13, wherein the frame has a thickness which is greater than or equal to 70% of the thickness of the aerosol-generating article.

[0555] Ex15. An aerosol-generating article according to any of Exs 1 to 14, wherein the frame has a thickness which is greater than or equal to 90% of the thickness of the aerosol-generating article.

[0556] Ex16. An aerosol-generating article according to any one of Exs 1 to 15, wherein the frame has a thickness that is less than or equal to 95% of the thickness of the aerosol- generating article.

[0557] Ex17. An aerosol-generating article according to any one of Exs 1 to 16, comprising one or more outer walls extending between the first planar outer surface and the second planar outer surface, the one or more outer walls collectively defining the entire lateral outer region of the aerosol-generating article, the frame at least partially defining each of the one or more outer walls.

[0558] Ex18. An aerosol-generating article according to Ex17, wherein the one or more outer walls bound or encircle the cavity.

[0559] Ex19. An aerosol-generating article according to Ex17 or Ex18, wherein the frame defines at least 60% of the entire lateral outer region of the aerosol-generating article.

[0560] Ex20. An aerosol-generating article according to any one of Exs 17 to 19, wherein the frame defines at least 70% of the entire lateral outer region of the aerosol-generating article.

[0561] Ex21. An aerosol-generating article according to any one of Exs 17 to 20, wherein the frame defines at least 80% of the entire lateral outer region of the aerosol-generating article.

[0562] Ex22. An aerosol-generating article according to any one of Exs 17 to 21, wherein the frame defines at least 90% of the entire lateral outer region of the aerosol-generating article.

[0563] Ex23. An aerosol-generating article according to any one of Exs 1 to 22, wherein the frame has a cross-section in the x / y plane that is annular in shape, such as a circular annular band shape, an elliptical annular band shape, a rectangular annular band shape, or a square annular band shape.

[0564] Ex24. An aerosol-generating article according to any one of Exs 1 to 23, wherein the frame defines one or both of the air inlet and the air outlet.

[0565] Ex25. An aerosol-generating article according to any one of Exs 1 to 24, wherein one or both of the air inlet and the air outlet has a width that is less than the width of the cavity.

[0566] Ex26. An aerosol-generating article according to any one of Exs 1 to 25, wherein one or both of the air inlet and the air outlet has a thickness that is less than the thickness of the cavity.

[0567] Ex27. An aerosol-generating article according to any one of Exs 1 to 26, wherein one or both of the air inlet and the air outlet has an equivalent diameter of less than or equal to 3 millimetres.

[0568] Ex28. An aerosol-generating article according to any one of Exs 1 to 27, wherein one or both of the air inlet and the air outlet has an equivalent diameter of less than or equal to 5 millimetres.

[0569] Ex29. An aerosol-generating article according to any one of Exs 1 to 28, wherein a thickness of the aerosol-generating article is less than 50% of both a length and a width of the aerosol-generating article.

[0570] Ex30. An aerosol-generating article according to any one of Exs 1 to 29, wherein the frame comprises a peripheral wall bounding or surrounding the cavity.

[0571] Ex31. An aerosol-generating article according to Ex30, wherein the peripheral wall is formed by a frame inner surface and a frame outer surface, and wherein the frame inner surface defines a cavity outer wall and the frame outer surface at least partially defines one or more outer walls of the aerosol-generating article.

[0572] Ex32. An aerosol-generating article according to Ex30 or Ex31, wherein the peripheral wall has a radial thickness of between 1 millimetres and 3 millimetres.

[0573] Ex33. An aerosol-generating article according to any one of Exs 1 to 32, wherein the frame has a thickness of between 1 millimetres and 5.5 millimetres.

[0574] Ex34. An aerosol-generating article according to any one of Exs 1 to 33, wherein the frame comprises a cellulosic material.

[0575] Ex35. An aerosol-generating article according to Ex34, wherein the cellulosic material has a grammage of between 300 grams per square metre and 900 grams per square metre.

[0576] Ex36. An aerosol-generating article according to Ex34 or Ex35, wherein the cellulosic material is paper, paperboard or cardboard.

[0577] Ex37. An aerosol-generating article according to any one of Exs 1 to 36, wherein the frame is a unitary component.

[0578] Ex38. An aerosol-generating article according to any one of Exs 1 to 36, wherein the frame comprises a first frame layer and a second frame layer.

[0579] Ex39. An aerosol-generating article according to Ex38, wherein the first frame layer is bonded to the second frame layer with an adhesive.

[0580] Ex40. An aerosol-generating article according to Ex38 or Ex39, wherein the frame comprises a third frame layer.

[0581] Ex41. An aerosol-generating article according to Ex40, wherein the second frame layer is positioned between the first frame layer and the third frame layer.

[0582] Ex42. An aerosol-generating article according to Ex40 or Ex41, wherein the second frame layer is bonded to the third frame layer with an adhesive.

[0583] Ex43. An aerosol-generating article according to any of Exs 1 to 42, wherein the one or more aerosol-generating substrates comprise 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.

[0584] Ex44. An aerosol-generating article according to Ex43, wherein one or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer comprises aerosol-generating material in the form of a sheet of aerosol-generating material.

[0585] Ex45. An aerosol-generating article according to Ex44, wherein the sheet of aerosol-generating material is a sheet of homogenised tobacco material.

[0586] Ex46. An aerosol-generating article according to Ex44 or Ex45, wherein the sheet of aerosol-generating material comprises one or more aerosol formers, such as one or both of glycerol and propylene glycol.

[0587] Ex47. An aerosol-generating article according to any of Exs 43 to 46, wherein the first aerosol-generating substrate layer and the second aerosol-generating substrate layer define opposing end walls of the cavity.

[0588] Ex48. An aerosol-generating article according to any of Exs 43 to 47, wherein one or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer has a thickness of between 100 micrometres and 600 micrometres.

[0589] Ex49. An aerosol-generating article according to any of Exs 43 to 48, wherein one or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer has a length that is substantially the same as a length of the aerosol-generating article.

[0590] Ex50. An aerosol-generating article according to any one of Ex43 to Ex49, wherein one or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer has a width that is substantially the same as a width of the aerosol-generating article.

[0591] Ex51. An aerosol-generating article according to any one of Ex1 to Ex50, 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.

[0592] Ex52. An aerosol-generating article according to Ex51, wherein the first planar outer layer and the second planar outer layer overlie opposite ends of the cavity.

[0593] Ex53. An aerosol-generating article according to Ex51 or Ex52, wherein one or both of the first planar outer layer and the second planar outer layer comprises a cellulosic material.

[0594] Ex54. An aerosol-generating article according to Ex53, wherein the cellulosic material is paper or cardboard.

[0595] Ex55. An aerosol-generating article according to any one of Ex51 to Ex54, wherein one or both of the first planar outer layer and the second planar outer layer has a length that is substantially the same as a length of the aerosol-generating article.

[0596] Ex56. An aerosol-generating article according to any one of Ex51 to Ex55, wherein one or both of the first planar outer layer and the second planar outer layer has a width that is substantially the same as a width of the aerosol-generating article.

[0597] Ex57. An aerosol-generating article according to any one of Ex1 to Ex56, wherein the cavity has a length that is between 30% and 95% of a length of the aerosol-generating article.

[0598] Ex58. An aerosol-generating article according to any one of Ex1 to Ex57, wherein the cavity has a width that is between 30% and 95% of a width of the aerosol-generating article.

[0599] Ex59. An aerosol-generating article according to any one of Ex1 to Ex58, wherein the cavity has a thickness that is between 30% and 95% of a thickness of the aerosol-generating article.

[0600] Ex60. An aerosol-generating article according to any one of Exl to Ex59, wherein the cavity has a length of between 14 millimetres and 40 millimetres, a width of between 4.5 millimetres and 13 millimetres, and a thickness of between 0.5 millimetres and 4.5 millimetres.

[0601] Ex61. An aerosol-generating article according to any one of Exl to Ex60, wherein the cavity has a length of between 20 millimetres and 30 millimetres, a width of between 7 millimetres and 10 millimetres, and a thickness of between 2.5 millimetres and 4 millimetres.

[0602] Ex62. An aerosol-generating article according to any one of Exl to Ex61, wherein the cavity is substantially empty.

[0603] Ex63. An aerosol-generating article according to any one of Exl to Ex61, wherein the one or more aerosol-generating substrates comprise an aerosol-generating substrate positioned within the cavity.

[0604] Ex64. An aerosol-generating article according to Ex63, wherein the aerosol-generating substrate positioned within the cavity comprises an aerosol-generating material.

[0605] Ex65. An aerosol-generating article according to Ex64, wherein the aerosol-generating material is in the form of shredded aerosol-generating material.

[0606] Ex66. An aerosol-generating article according to Ex65, wherein the shredded aerosol-generating material comprises one or more of the following: a strip and a strand of aerosol-generating material, such as a strip and a strand of tobacco or homogenised tobacco material.

[0607] Ex67. An aerosol-generating article according to any one of Ex64 to Ex66, wherein the aerosol-generating material is a tobacco cut filler.

[0608] Ex68. An aerosol-generating article according to Ex64, wherein the aerosol-generating material is in the form of a corrugated aerosol-generating material sheet.

[0609] Ex69. An aerosol-generating article according to Ex68, wherein the corrugated aerosol-generating material sheet comprises a plurality of parallel corrugations defining a plurality of channels between the aerosol-generating material sheet and the one or more walls of the cavity.

[0610] Ex70. An aerosol-generating article according to Ex69, wherein the plurality of channels are a plurality of longitudinally extending channels.

[0611] Ex71. An aerosol-generating article according to any one of Ex69 or Ex70, wherein the plurality of channels defines at least a portion of the airflow pathway extending between an air inlet and an air outlet of the aerosol-generating article.

[0612] Ex72. An aerosol-generating article according to any one of Ex63 to Ex71, wherein the aerosol-generating material comprises one or more aerosol formers, such as one or both of glycerol and propylene glycol.

[0613] Ex73. An aerosol-generating article according to any one of Ex63 to Ex72, wherein the aerosol-generating substrate positioned within the cavity has a bulk density less than or equal to 0.5 mg / mm3.

[0614] Ex74. An aerosol-generating article according to any one of Ex63 to Ex73, wherein the aerosol-generating substrate positioned within the cavity has a packing density greater than or equal to 0.3.

[0615] Ex75. An aerosol-generating article according to any one of Ex63 to Ex74, wherein the aerosol-generating substrate positioned within the cavity has a packing density less than or equal to 0.9.

[0616] Ex76. An aerosol-generating article according to any one of Ex63 to Ex75, wherein the aerosol-generating substrate positioned within the cavity has a density less than or equal to 0.9 g / cm3.

[0617] Ex77. An aerosol-generating article according to any one of Ex63 to Ex76, wherein the aerosol-generating substrate positioned within the cavity has a mass between 50 mg and 500 mg.

[0618] Ex78. An aerosol-generating article according to any one of Ex1 to Ex77, wherein the air inlet has a width between 0.3 mm and 3 mm.

[0619] Ex79. An aerosol-generating article according to any one of Ex1 to Ex78, wherein the air inlet has a thickness between 0.3 mm and 3 mm.

[0620] Ex80. An aerosol-generating article according to any one of Ex1 to Ex79, wherein the air outlet has a width between 0.3 mm and 3 mm.

[0621] Ex81. An aerosol-generating article according to any one of Ex1 to Ex80, wherein the air outlet has a thickness between 0.3 mm and 3 mm.

[0622] Ex82. An aerosol-generating article according to any one of Exs 1 to 81, wherein the ratio between the length and the thickness of the aerosol-generating article and the ratio between the width and the thickness of the aerosol-generating article is between 2:1 and 15:1.

[0623] Ex83. An aerosol-generating article according to any one of Exs 1 to 82, wherein the ratio between the length and the width of the aerosol-generating article is between 1 :1 and 10:1.

[0624] Ex84. An aerosol-generating article according to any one of Exs 1 to 83, wherein the aerosol-generating article has a length of between 15 millimetres and 45 millimetres, for example between 25 millimetres and 30 millimetres.

[0625] Ex85. An aerosol-generating article according to any one of Exs 1 to 84, wherein the aerosol-generating article has a width of between 3 millimetres and 17 millimetres, for example between 9 millimetres and 11 millimetres.

[0626] Ex86. An aerosol-generating article according to any one of Exs 1 to 85, wherein the aerosol-generating article has a thickness of between 1 millimetre and 5.5 millimetres, for example between 3 millimetres and 3.5 millimetres.

[0627] Ex87. An aerosol-generating article according to any one of Exs 1 to 86, wherein the aerosol-generating article has a draw resistance of between 0 millimetres H20 and 9.9 millimetres H20. BRIEF DESCRIPTION OF DRAWINGS

[0628] Examples will now be described further with reference to the drawings, in which:

[0629] Figure 1 a perspective view of an aerosol-generating article according to the disclosure is shown;

[0630] Figure 2 an exploded perspective view of an aerosol-generating article of Figure 1 is shown;

[0631] Figure 3 an exploded perspective view of an aerosol-generating article according to the disclosure is shown;

[0632] Figure 4 a transverse cross-sectional view of an aerosol-generating article of Figure 3 is shown;

[0633] Figure 5 a longitudinal cross-sectional view of an aerosol-generating article of Figure 3 is shown;

[0634] Figure 6shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0635] Figure 7 Shown Figure 6 a transverse cross-sectional view of an aerosol-generating article;

[0636] Figure 8 Shown Figure 6 a side cross-sectional view of an aerosol-generating article;

[0637] Figure 9 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0638] Figure 10 Shown Figure 9 A perspective view of an aerosol-generating article;

[0639] Figure 11 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0640] Figure 12 Shown Figure 11 an exploded perspective view of an aerosol-generating article;

[0641] Figure 13 Shown Figure 11 an exploded perspective view of an aerosol-generating article;

[0642] Figure 14 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0643] Figure 15 Shown Figure 14 an exploded perspective view of an aerosol-generating article;

[0644] Figure 16 Shown Figure 14 an exploded perspective view of an aerosol-generating article;

[0645] Figure 17 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0646] Figure 18 Shown Figure 17 an exploded perspective view of an aerosol-generating article;

[0647] Figure 19 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0648] Figure 20 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0649] Figure 21A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0650] Figure 22 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0651] Figure 23 A perspective view of an aerosol-generating article according to the present disclosure is shown; Figure 22 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0652] Figure 24 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0653] Figure 25 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0654] Figure 26 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0655] Figure 27 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0656] Figure 28 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0657] Figure 29 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0658] Figure 30 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0659] Figure 31 A perspective view of an aerosol-generating article according to the present disclosure is shown; Figure 30 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0660] Figure 32 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0661] Figure 33 A perspective view of an aerosol-generating article according to the present disclosure is shown; Figure 32 A plan view of an aerosol-generating article according to the present disclosure is shown;

[0662] Figure 34 A perspective view of an aerosol-generating article according to the present disclosure is shown; Figure 32 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0663] Figure 35 A perspective view of an aerosol-generating article according to the present disclosure is shown; Figure 32 A cross-sectional view of an aerosol-generating article according to the present disclosure is shown;

[0664] Figure 36 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0665] Figure 37 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0666] Figure 38 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0667] Figure 39 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0668] Figure 40 A perspective view of an aerosol-generating article according to the present disclosure is shown;

[0669] Figure 41 A schematic cross-sectional view of an aerosol-generating device according to the present disclosure is shown;

[0670] Figure 42 A schematic cross-sectional view of an aerosol-generating device according to the present disclosure is shown; Figure 41 engaged with an aerosol-generating article of the present disclosure is shown;

[0671] Figure 43 A method of manufacturing an aerosol-generating article according to the present disclosure is shown;

[0672] Figure 44 A method of manufacturing an aerosol-generating article according to the present disclosure is shown; Figure 43 A plan view of a method of manufacturing an aerosol-generating article according to the present disclosure is shown;

[0673] Figure 45 A method of manufacturing an aerosol-generating article according to the present disclosure is shown;

[0674] Figure 46 A method of manufacturing an aerosol-generating article according to the present disclosure is shown; Figure 45 A plan view of a method of manufacturing an aerosol-generating article according to the present disclosure is shown;

[0675] Figure 47 A method of manufacturing an aerosol-generating article according to the present disclosure is shown;

[0676] Figure 48 A method of manufacturing an aerosol-generating article according to the present disclosure is shown; Figure 47 A plan view of a method of manufacturing an aerosol-generating article according to the present disclosure is shown;

[0677] Figure 49 A method of manufacturing an aerosol-generating article according to the present disclosure is shown; and

[0678] Figure 50 A method of manufacturing an aerosol-generating article according to the present disclosure is shown; Figure 49 A plan view of a method of manufacturing an aerosol-generating article according to the present disclosure is shown. DETAILED DESCRIPTION

[0679] Figure 1An aerosol-generating article 10 is shown, comprising 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 comprise an aerosol-generating substrate comprising an aerosol-generating material, i.e. tobacco. However, it will be appreciated that in some embodiments only one of the first planar outer layer 24 and the second planar outer layer 25 can comprise the aerosol-generating substrate. Alternatively or additionally, the aerosol-generating substrate can be positioned elsewhere within the aerosol-generating article 10.

[0680] 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 millimetres, a width of 10 millimetres, and a thickness of 3.1 millimetres.

[0681] The first planar outer surface 21 and the second planar outer surface 22 extend in the x- and y-directions. 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 transverse direction. The distance between the first planar outer surface 21 and the second planar outer surface 22 in the z-direction or transverse direction corresponds to the thickness of the aerosol-generating article 10.

[0682] 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 millimetres (less than 50% of the length of the aerosol-generating article 10) and less than 5 millimetres (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 laminate structure formed by the first planar outer layer 24, the frame 50, and the second planar outer layer 25. As discussed in more detail below, the first planar outer layer 24, the frame 50, and the second planar outer layer 25 are bonded together with an adhesive, in particular guar gum. Figure 2 As discussed in more detail, the first planar outer layer 24, the frame 50, and the second planar outer layer 25 are bonded together with an adhesive, in particular guar gum.

[0683] Figure 2 An exploded view of the aerosol-generating article 10 is shown. Figure 1

[0684] ​The frame 50 has a length of 30 millimetres, a width of 10 millimetres and a thickness of 2.7 millimetres. The frame 50 is made of cardboard and defines a frame aperture extending through the thickness of the frame 50. The frame aperture at least partially forms the cavity 30. The cavity 30 has a length of 26 millimetres, a width of 6 millimetres and a thickness of 2.7 millimetres. Thus, the cavity 30 has a volume of about 421.2 cubic millimetres. In this embodiment, the cavity 30 is substantially empty.

[0685] The frame 50 has a frame inner surface 52 extending between the first planar outer surface 21 and the second planar outer surface 22 in the z-direction or lateral direction. The frame inner surface 52 defines a cavity outer wall. The frame 50 has a frame outer surface 53 extending between the first planar outer surface 21 and the second planar outer surface 22 in the z-direction or lateral direction. 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 which is annular in shape, in particular, the cross-section is a rectangular annular band shape.

[0686] The frame 50 comprises a peripheral wall 51 delimiting the cavity 30. In more detail, the peripheral wall 51 is defined by the frame inner surface 52 and the frame outer surface 52. The peripheral wall 51 has a radial thickness of about 2 millimetres (as measured in the x / y-plane between the frame inner surface 52 and the frame outer surface 53).

[0687] The first planar outer layer 24 and the second planar outer layer 25 have a thickness of 200 micrometres and are in physical contact with the frame 50. The first planar outer layer 24 and the second planar outer layer 25 are bonded to the frame with an adhesive 15. The first planar outer layer 24 overlies an end of the cavity 30 and forms a first cavity end wall 31. The second planar outer layer 25 overlies an opposite end of the cavity 30 and forms a second cavity end wall 32. That is, the frame 50, the first planar outer layer 24 and the second planar outer layer 25 collectively define the cavity 30.

[0688] 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 millimetres and a thickness of 0.9 millimetres. The airflow pathway extends through the cavity 30 between the air inlet 11 and the air outlet 12.

[0689] 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.

[0690] 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.

[0691] Figure 4 and 5 Shown respectively Figure 3 Transverse and longitudinal cross-sectional views of an aerosol-generating article.

[0692] Figure 6 Shown 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.

[0693] 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 7As seen in the cross-section, a plurality of parallel corrugations are defined by a corrugation profile, which is sinusoidal. The plurality of parallel corrugations has a corrugation wavelength of about 0.92 millimeters. The corrugation amplitude is approximately the same as the thickness of the cavity, as shown by the peaks 43 and valleys 44 coinciding with the first and second cavity end walls 31 and 32, respectively.

[0694] The plurality of parallel corrugations forms a plurality of channels 45 between the aerosol- generating material sheet and the first cavity end wall 31, and a plurality of channels 46 between the aerosol-generating material sheet and the second cavity end wall 32. The plurality of channels extends in the longitudinal direction of the aerosol-generating article 10 and forms at least a portion of the airflow passage extending between the air inlet 11 and the air outlet 12.

[0695] Figure 9 An aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1 , 3 and 6 is shown, except that Figure 9 the aerosol-generating article 10 of includes an outer wrapper 23 defining a first planar outer surface 21 and a second planar outer surface 22 in place of the first planar outer layer 24 and the second planar outer layer 25. For illustrative purposes, Figure 10 an aerosol-generating article 10 of Figure 9 is shown, wherein the outer wrapper 23 has been unwrapped to expose a portion of the peripheral wall 51 of the frame 50. The outer wrapper 23 is cigarette paper.

[0696] Figure 11 An aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1 is shown, except that Figure 11 the frame 50 of the aerosol-generating article 10 of includes a first frame layer 54 and a second frame layer 55. Figure 12 An 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 of Figure 11 is shown. Figure 13 A further 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 of Figure 11 is shown.

[0697] 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.

[0698] The aerosol-generating article 10 has the same dimensions as the aerosol-generating article 10 of Figure 1 . The frame 50 has the same dimensions as the frame 50 of Figure 1The 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.

[0699] 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.

[0700] 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.

[0701] 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 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.

[0702] 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 17Exploded 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.

[0703] 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.

[0704] 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.

[0705] 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 .

[0706] 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 3 The 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.

[0707] 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.

[0708] Figure 21 Shown with Figure 19an exploded view of an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1, except that the aerosol-generating article 10 also includes a filter element 60 positioned within the cavity 30.

[0709] 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 a width that are approximately the same as the thickness and the width of the cavity 30, respectively. The filter element 60 has a length of about 6 millimetres. The aerosol-generating substrate 40 fills the remaining volume of the cavity 30.

[0710] Figure 22 Figure 1 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1, except that the aerosol-generating article 10 includes a first cavity 33 and a second cavity 34. Figure 1 Figure 2 shows an exploded view of the aerosol-generating article 10 of Figure 1. Figure 22 Figure 3 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1, except that the aerosol-generating article 10 includes a first cavity 33 and a second cavity 34. Figure 23 Figure 4 shows an exploded view of the aerosol-generating article 10 of Figure 3. Figure 22 Figure 5 shows an exploded view of the aerosol-generating article 10 of Figure 3.

[0711] The first cavity 33 is substantially empty, and the second cavity 34 is substantially empty. The first cavity 33 has a length of 12 millimetres, a width of 6 millimetres, and a thickness of 2.7 millimetres. The second cavity 34 has a length of 12 millimetres, a width of 6 millimetres, and a thickness of 2.7 millimetres.

[0712] The frame 50 defines a frame first aperture extending through the thickness of the frame 50, and the frame first aperture at least partially forms the first cavity 33. The frame 50 defines a frame second aperture extending through the thickness of the frame 50, and the frame second aperture at least partially forms the second cavity 34.

[0713] The frame 50 includes a partition wall 57 separating the first cavity 33 and the second cavity 34. The partition wall 59 defines an aperture extending from the first cavity 33 to the second cavity 34. The aperture of the partition wall 59 defines at least a portion of the airflow passage between the air inlet 11 and the air outlet 12.

[0714] The first planar outer layer 24 overlies an end of the first cavity 33, and the second planar outer layer 25 overlies an opposite end of the first cavity 33. That is, the frame 50, the first planar outer layer 24, and the second planar outer layer 25 collectively define the first cavity 33. The first planar outer layer 24 overlies an end of the second cavity 34, and the second planar outer layer 25 overlies an opposite end of the second cavity 34. That is, the frame 50, the first planar outer layer 24, and the second planar outer layer 25 collectively define the second cavity 34.

[0715] Figure 24 Figure 1 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1, except that the aerosol-generating article 10 includes a first cavity 33 and a second cavity 34. Figure 22an exploded view of an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1, 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 crimped homogenised 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 crimped homogenised tobacco material.

[0716] The first cavity aerosol-generating substrate 45 comprises aerosol-generating material in the form of cut filler tobacco and has an aerosol former content of 5% by weight on a dry weight basis. The first cavity aerosol-generating substrate 45 fills the entire volume of the first cavity 33. The second cavity aerosol-generating substrate 46 comprises aerosol-generating material in the form of cut filler tobacco and has an aerosol former content of 5% by weight on a dry weight basis. The second cavity aerosol-generating substrate 46 fills the entire volume of the second cavity 34. Figure 25 Figure 1 shows an exploded view of an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1, 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 crimped homogenised 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 crimped homogenised tobacco material. Figure 24

[0717] Figure 26 Figure 1 shows an exploded view of an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1, 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 crimped homogenised 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 crimped homogenised tobacco material. Figure 22

[0718] 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 a width that are approximately the same as the thickness and the width of the first cavity 33, respectively. The filter element 60 has a length of about 4 millimetres.

[0719] The first cavity aerosol-generating substrate 45 comprises aerosol-generating material in the form of cut filler tobacco and has an aerosol former content of 5% by weight on a dry weight basis. The first cavity aerosol-generating substrate 45 fills the entire volume of the first cavity 33. The second cavity aerosol-generating substrate 46 comprises aerosol-generating material in the form of cut filler tobacco and has an aerosol former content of 5% by weight on a dry weight basis. The second cavity aerosol-generating substrate 46 fills the entire volume of the second cavity 34. Figure 25 The second cavity aerosol-generating substrate 46 is the same as the second cavity aerosol-generating substrate 46 described in relation to

[0720] Figure 27 Figure 1 shows an exploded view of an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1, 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 crimped homogenised 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 crimped homogenised tobacco material. 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.

[0721] 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.

[0722] 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.

[0723] 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.

[0724] 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 .

[0725] The first-chamber aerosol-generating substrate 45 comprises aerosol-generating material in the form of cut filler tobacco and has an aerosol former content of 5 percent by weight on a dry weight basis. The first-chamber aerosol-generating substrate 45 fills the entire volume of the first chamber 33. The second-chamber aerosol-generating substrate 46 comprises aerosol-generating material in the form of cut filler tobacco and has an aerosol former content of 5 percent by weight on a dry weight basis. The second-chamber aerosol-generating substrate 46 fills the entire volume of the second chamber 34.

[0726] Figure 30 An aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 17 and 28 differ in that Figure 30 The aerosol-generating article 10 of Figure 31 is shown Figure 30 with the outer wrapper 23 having been unwrapped to expose a portion of the peripheral wall 51 of the frame 50. The outer wrapper 23 is cigarette paper.

[0727] Figure 32 An aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1 differ in that Figure 32 The aerosol-generating article 10 of Figure 33 and 34 respectively show Figure 32 plan and exploded views of the aerosol-generating article 10 of

[0728] The first outer corner 71 extends from the first planar outer surface 21 to the second planar outer surface 22 and comprises 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 between a tangent 81 to the first end face 73 formed at the first corner transition region 82 and a tangent 83 to the first corner surface 76 at the first corner transition region 82 is between 90 degrees and 180 degrees.

[0729] The second outer corner 72 extends from the first planar outer surface 21 to the second planar outer surface 22 and comprises a second corner surface 77 connecting a first end face 73 of the aerosol-generating article 10 and a second side face 75 of the aerosol-generating article 10. In more detail, the first end face 73 is connected to the second corner surface 77 at a second corner transition region 85. A second corner interior angle Q2 between a tangent 84 of the first end face 73 formed at the second corner transition region 85 and a tangent 86 of the second corner surface 77 at the second corner transition region 85 is between 90 degrees and 180 degrees.

[0730] Figure 35 A cross-sectional view in the x / y plane of the aerosol-generating article 10 taken through the intersection between the first planar outer layer 24 and the frame 50 is shown. Figure 32 A cross-sectional view in the x / y plane of the aerosol-generating article 10 taken through the intersection between the first planar outer layer 24 and the frame 50 is shown.

[0731] Figure 36 An exploded view of an aerosol-generating article similar to the aerosol-generating article 10 of Figure 32 is shown, except that the aerosol-generating substrate 40 is positioned within the cavity 30. The aerosol-generating substrate 40 comprises aerosol-generating material in the form of a cut filler of tobacco and has an aerosol former 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, in particular a sheet of corrugated homogenized tobacco material as described in relation to Figure 6 .

[0732] Figure 37 An exploded view of an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 32 and 36 is shown, except that the aerosol-generating article 10 of Figure 37 further comprises a first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42 as described in relation to Figure 17 .

[0733] Figure 38 An exploded view of an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1 is shown, except that the air inlet 11 is defined by the first planar outer surface 21 and extends through the first planar outer layer 24.

[0734] Figure 39 An exploded view of an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 9 is shown, except that the air inlet 11 is defined by the first planar outer surface 21 and extends through the outer wrapper 23.

[0735] Figure 40 An aerosol-generating article 10 similar to that of Figure 17 is shown, 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.

[0736] 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 elongate aerosol-generating device extending between a proximal end 91 and a distal end 92. The aerosol-generating device 90 comprises 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 electrical 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 comprises an upper planar surface 1020 and a lower planar surface 1030. The 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 the 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 comprises an air inlet 98 defining an airflow path configured to allow air to flow from outside the device into the cavity 1000.

[0737] Figure 42 A schematic cross-sectional view of the aerosol-generating device 90 of Figure 1 engaged with the aerosol-generating article 10 of Figure 41 is shown. There is little tolerance between the first planar outer surface 21 and the second planar outer surface 22 of the aerosol-generating article 10 and the inner surfaces 1020, 1030 of the cavity 1000. As a result, there is a close fit between the aerosol-generating article 10 and the aerosol-generating device 90. The device can be operated when the consumer has inserted the aerosol-generating article 10 into the cavity 1000. The first heater 95 heats the first planar outer surface 21 of the aerosol-generating article 10 and the second heater 96 heats the second planar outer surface 22 of the aerosol-generating article and, as a result, the aerosol-generating substrate. The volatile components of the aerosol-generating substrate vaporise 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 comprising 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 discarded.

[0738] Figure 43 depicts a schematic diagram of a method of manufacturing 1100 an aerosol- generating article 10 as described herein (and in particular a method of manufacturing Figure 3 an aerosol-generating article 10 of the type shown in Figure 1). Figure 44 depicts a schematic plan view of Figure 43 the method, but the manufacturing appara...

Claims

1. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction; an air inlet, an air outlet, and an air flow passage extending between the air inlet and the air outlet; cavity; one or more aerosol-generating substrates; a first planar outer surface and a second planar outer surface spaced apart from the first planar outer surface in the z-direction; a frame positioned between the first planar outer surface and the second planar outer surface, the frame at least partially defining the cavity; and wherein the frame 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. 2 . An aerosol-generating article according to claim 1 , wherein the frame forms at least 85% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame.

3. An aerosol-generating article according to claim 1 or 2, wherein the frame forms at least 95% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the frame.

4. An aerosol-generating article according to any one of claims 1 to 3, wherein the aerosol-generating article comprises a cross-section in a first x / y plane extending through the frame, and wherein the frame forms at least 99% of the perimeter of the cross-section in the first x / y plane, preferably the frame forms 100% of the perimeter of the cross-section in the first x / y plane.

5. An aerosol-generating article according to claim 4, wherein the aerosol-generating article comprises a cross-section in a second x / y plane extending through the frame and spaced apart from the first x / y plane in the z direction, and wherein the frame forms at least 99% of the perimeter of the cross-section in the second x / y plane, preferably the frame forms 100% of the perimeter of the cross-section in the second x / y plane.

6. An aerosol-generating article according to claim 5, wherein one or both of the air inlet and the air outlet are positioned between the first x / y plane and the second x / y plane in the z-direction.

7. An aerosol-generating article according to any one of claims 1 to 6, wherein the frame has a first portion that is at least 30% of the thickness of the frame and the frame forms 100% of the perimeter of any cross-section in the x / y plane of the aerosol-generating article extending through the first portion of the frame.

8. An aerosol-generating article according to claim 7, wherein the first portion is at least 50% of the thickness of the frame.

9. An aerosol-generating article according to any one of claims 1 to 8, wherein the frame has a thickness greater than or equal to 70% of the thickness of the aerosol-generating article.

10. An aerosol generating article according to any one of claims 1 to 9, comprising one or more outer walls extending between the first planar outer surface and the second planar outer surface, the one or more outer walls collectively defining the entire lateral outer area of ​​the aerosol generating article, and the frame at least partially defining each of the one or more outer walls.

11. An aerosol-generating article according to claim 10, wherein the frame defines at least 60% of the entire laterally outer area of ​​the aerosol-generating article.

12. An aerosol-generating article according to any one of claims 1 to 11, 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.

13. An aerosol-generating article according to any one of claims 1 to 12, wherein one or both of the air inlet and the air outlet have an equivalent diameter of less than or equal to 3 mm.

14. An aerosol-generating article according to any one of claims 1 to 13, wherein the one or more aerosol-generating substrates comprises an aerosol-generating substrate positioned within the cavity.

15. An aerosol-generating article according to claim 14, wherein the aerosol-generating substrate positioned within the cavity comprises aerosol-generating material in the form of chopped aerosol-generating material.

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