Aerosol-generating article with outer corners

Abstract

An aerosol-generating article (10) is provided for use with an aerosol-generating device (90) to generate an aerosol. 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) comprises one or more aerosol-generating substrates (40, 41, 42). The aerosol-generating article (10) comprises a first outer planar surface (21) and a second outer planar surface (22) spaced apart from the first outer planar surface (21) in the z-direction. The aerosol-generating article (10) comprises a first outer corner (71) extending from the first outer planar surface (21) to the second outer planar surface (22). The first outer corner (71) connects a first end surface (73) of the aerosol-generating article (10) to a first side surface (74) of the aerosol-generating article (10). The first outer corner (71) is chamfered or rounded. An aerosol generating device (90) for use with the aerosol-generating article (10), an aerosol generation system including the aerosol-generating device (90) and the aerosol-generating article (10), and a method (1100) for manufacturing the aerosol-generating article (10) are also provided.

Description

[Technical Field]

[0001] The present disclosure relates to aerosol-generating articles. The present disclosure also relates to aerosol-generating devices for use with the aerosol-generating articles. The present disclosure also relates to aerosol-generating systems including the aerosol-generating devices and the aerosol-generating articles. The present disclosure also relates to methods of manufacturing aerosol-generating articles. [Background technology]

[0002] A typical aerosol-generating system includes an aerosol-generating device and an aerosol-generating article including an aerosol-generating substrate. In use, the aerosol-generating device is arranged to heat a heating element positioned near or in contact with the aerosol-generating substrate, thereby heating the aerosol-generating substrate and releasing volatile compounds. These volatile compounds are entrained in air drawn through the aerosol-generating article. When the volatile compounds cool, they condense to form an aerosol that can be inhaled by a consumer. Summary of the Invention [Problem to be solved by the invention]

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

[0004] However, during use, a large portion of the aerosol-generating substrate within these cylindrical aerosol-generating articles may not be heated sufficiently to form an aerosol. This is undesirable because the insufficiently heated portions of the aerosol-generating substrate contribute to the manufacturing and shipping costs of the aerosol-generating article but do not contribute to the aerosol delivered to the consumer. Furthermore, the components of these cylindrical aerosol-generating articles typically must have identical or very similar outer diameters so that they can be assembled together, precisely aligned axially, and packaged within cigarette paper. This increases cost and manufacturing complexity.

[0005] It is an object of the present disclosure to provide an aerosol-generating article in which a greater portion of the aerosol-generating substrate is heated sufficiently to form an aerosol during use. It is also an object of the present disclosure to provide an aerosol-generating article that can be manufactured more efficiently and more cheaply. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 shows a perspective view of an aerosol-generating article according to the present disclosure. [Figure 2] FIG. 2 shows an exploded perspective view of the aerosol-generating article of FIG. [Figure 3] FIG. 3 shows an exploded perspective view of an aerosol-generating article according to the present disclosure. [Figure 4] FIG. 4 shows a transverse cross-section of the aerosol-generating article of FIG. [Figure 5] FIG. 5 shows a longitudinal cross-section of the aerosol-generating article of FIG. [Figure 6] FIG. 6 shows an exploded perspective view of an aerosol-generating article according to the present disclosure. [Figure 7] FIG. 7 shows a transverse cross-section of the aerosol-generating article of FIG. [Figure 8] FIG. 8 shows a transverse cross-section of the aerosol-generating article of FIG. [Figure 9] FIG. 9 shows a perspective view of an aerosol-generating article according to the present disclosure. [Figure 10] FIG. 10 shows a perspective view of the aerosol-generating article of FIG. [Figure 11] FIG. 11 shows a perspective view of an aerosol-generating article according to the present disclosure. [Figure 12] FIG. 12 shows an exploded perspective view of the aerosol-generating article of FIG. [Figure 13] FIG. 13 shows an exploded perspective view of the aerosol-generating article of FIG. [Figure 14] FIG. 14 shows a perspective view of an aerosol-generating article according to the present disclosure. [Figure 15] FIG. 15 shows an exploded perspective view of the aerosol-generating article of FIG. [Figure 16] FIG. 16 shows an exploded perspective view of the aerosol-generating article of FIG. [Figure 17] FIG. 17 shows a perspective view of an aerosol-generating article according to the present disclosure. [Figure 18] FIG. 18 shows an exploded perspective view of the aerosol-generating article of FIG. [Figure 19] FIG. 19 shows an exploded perspective view of an aerosol-generating article according to the present disclosure. [Figure 20] FIG. 20 shows an exploded perspective view of an aerosol-generating article according to the present disclosure. [Figure 21] FIG. 21 shows an exploded perspective view of an aerosol-generating article according to the present disclosure. [Figure 22] FIG. 22 shows a perspective view of an aerosol-generating article according to the present disclosure. [Figure 23] FIG. 23 shows an exploded perspective view of the aerosol-generating article of FIG. [Figure 24] FIG. 24 shows an exploded perspective view of an aerosol-generating article according to the present disclosure. [Figure 25] FIG. 25 shows an exploded perspective view of an aerosol-generating article according to the present disclosure. [Figure 26]FIG. 26 shows an exploded perspective view of an aerosol-generating article according to the present disclosure. [Figure 27] FIG. 27 shows an exploded perspective view of an aerosol-generating article according to the present disclosure. [Figure 28] FIG. 28 shows an exploded perspective view of an aerosol-generating article according to the present disclosure. [Figure 29] FIG. 29 shows an exploded perspective view of an aerosol-generating article according to the present disclosure. [Figure 30] FIG. 30 shows a perspective view of an aerosol-generating article according to the present disclosure. [Figure 31] FIG. 31 shows a perspective view of the aerosol-generating article of FIG. [Figure 32] FIG. 32 shows a perspective view of an aerosol-generating article according to the present disclosure. [Figure 33] FIG. 33 shows a plan view of the aerosol-generating article of FIG. [Figure 34] FIG. 34 shows an exploded perspective view of the aerosol-generating article of FIG. [Figure 35] FIG. 35 shows a cross-sectional view of the aerosol-generating article of FIG. [Figure 36] FIG. 36 shows an exploded perspective view of an aerosol-generating article according to the present disclosure. [Figure 37] FIG. 37 shows a perspective view of an aerosol-generating article according to the present disclosure. [Figure 38] FIG. 38 shows a perspective view of an aerosol-generating article according to the present disclosure. [Figure 39] FIG. 39 shows a perspective view of an aerosol-generating article according to the present disclosure. [Figure 40] FIG. 40 shows a perspective view of an aerosol-generating article according to the present disclosure. [Figure 41] FIG. 41 shows a schematic cross-sectional view of an aerosol generating device according to the present disclosure. [Figure 42] FIG. 42 shows a schematic cross-sectional view of the aerosol-generating device of FIG. 41 engaged with an aerosol-generating article of the present disclosure. [Figure 43]FIG. 43 illustrates a method for making an aerosol-generating article according to the present disclosure. [Figure 44] FIG. 44 shows a plan view of the manufacturing method of FIG. [Figure 45] FIG. 45 illustrates a method for making an aerosol-generating article according to the present disclosure. [Figure 46] FIG. 46 shows a plan view of the manufacturing method of FIG. [Figure 47] FIG. 47 illustrates a method for making an aerosol-generating article according to the present disclosure. [Figure 48] FIG. 48 shows a plan view of the manufacturing method of FIG. [Figure 49] FIG. 49 illustrates a method for making an aerosol-generating article according to the present disclosure. [Figure 50] FIG. 50 shows a plan view of the manufacturing method of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0007] According to the present disclosure, there is provided an aerosol-generating article. The aerosol-generating article may 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 outer planar surface and a second outer planar surface.

[0008] The aerosol-generating article may comprise a cavity. The aerosol-generating article may comprise an air inlet. The aerosol-generating article may comprise an air outlet. The aerosol-generating article may comprise an airflow passage extending between the air inlet and the air outlet. The airflow passage may be positioned between a first planar outer surface and a second planar outer surface. The airflow passage may extend through the cavity between the air inlet and the air outlet. The aerosol-generating article may comprise a frame positioned between the first planar outer surface and the second planar outer surface. The frame may at least partially define the airflow passage. The frame may at least partially define the cavity.

[0009] Advantageously, the first planar outer surface and the second planar outer surface allow good contact of the aerosol-generating device with the outer heater, particularly with the planar outer heater, thereby providing optimal heating of the aerosol-generating substrate.

[0010] Advantageously, the first and second planar outer surfaces may provide a large surface area for heating by an external heater of the aerosol-generating device, thereby enabling the aerosol-generating substrate to be rapidly heated to a temperature sufficient to generate an aerosol.

[0011] Advantageously, the aerosol-generating articles of the present disclosure may be heated along substantially their entire length and along their entire width, thereby allowing the entire aerosol-generating substrate to be heated sufficiently to generate an aerosol.

[0012] Advantageously, the aerosol-generating articles of the present disclosure may be manufactured by laminating sheet materials, which may be accomplished by a continuous manufacturing process, resulting in aerosol-generating articles that are relatively easy and inexpensive to manufacture.

[0013] According to the present disclosure, there is provided an aerosol-generating article. The aerosol-generating article may be for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article may have 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 may comprise one or more aerosol-generating substrates. The aerosol-generating article may have a first outer planar surface. The aerosol-generating article may have a second outer planar surface. The second outer planar surface may be spaced apart from the first outer planar surface in the z-direction. The aerosol-generating article may have a first outer corner. The first outer corner may extend from the first outer planar surface to the second outer planar surface. The first outer corner may connect a first end surface of the aerosol-generating article to a first side surface of the aerosol-generating article. The first outer corner may be chamfered or rounded.

[0014] Also provided is an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article having a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction, one or more aerosol-generating substrates, a first outer planar surface and a second outer planar surface spaced from the first outer planar surface in the z-direction, and a first outer corner extending from the first outer planar surface to the second outer planar surface, the first outer corner connecting a first end face of the aerosol-generating article to a first side face of the aerosol-generating article, the first outer corner being chamfered or rounded.

[0015] Advantageously, by providing an aerosol-generating article having at least one outer corner extending from a first outer planar surface to a second outer planar surface and which is rounded or chamfered, it may be easier to insert the aerosol-generating article into an aerosol generating device.

[0016] Advantageously, by providing an aerosol-generating article having at least one outer corner extending from the first outer planar surface to the second outer planar surface and which is rounded or chamfered, the aerosol-generating article may be less susceptible to damage, particularly during insertion of the aerosol-generating article into an aerosol-generating device.

[0017] Advantageously, manufacturing of the aerosol-generating article may be made easier by providing the aerosol-generating article with at least one outer corner extending from the first outer planar surface to the second outer planar surface and which is rounded or chamfered.

[0018] The aerosol-generating article may have a length, a width and a thickness. The aerosol-generating article may have a length extending in the x-direction. The aerosol-generating article may have a width extending in the y-direction. The aerosol-generating article may have a thickness extending in the z-direction.

[0019] The aerosol-generating article may have an x / y plane. The x / y plane may extend through the geometric center of the aerosol-generating article. The x / y plane may define a plane of symmetry of the aerosol-generating article. The air inlet and air outlet may be symmetrical, e.g., have symmetrical shapes or positions, with respect to the x / y plane.

[0020] The aerosol-generating article may have an x / z plane. The x / z plane may extend through the geometric center of the aerosol-generating article. The x / z plane may define a plane of symmetry of the aerosol-generating article. The air inlet and air outlet may be symmetrical, e.g., have symmetrical shapes or positions, with respect to the x / z plane.

[0021] The aerosol-generating article may have a y / z plane. The y / z plane may extend through the geometric center of the aerosol-generating article. The y / z plane may define a plane of symmetry of the aerosol-generating article. The air inlet and air outlet may be symmetrical, e.g., have symmetrical shapes or positions, with respect to the y / z plane.

[0022] Advantageously, a symmetrical aerosol-generating article, or an article with symmetrically shaped or positioned air inlets and air outlets, may allow the aerosol-generating article to be inserted into an aerosol generating device in multiple orientations.

[0023] The aerosol-generating article may be a substantially flat or substantially planar aerosol-generating article. In particular, the thickness of the aerosol-generating article may be less than 50 percent compared to both the length and width of the aerosol-generating article. Advantageously, a thinner thickness may reduce the temperature gradient or difference across the thickness of the aerosol-generating substrate during heating. Advantageously, this may allow a greater proportion of the aerosol-generating substrate to be heated to the aerosol-emitting temperature, while minimizing the risk of burning the hottest portion of the aerosol-generating substrate closest to the heater. Advantageously, this may also reduce the time required to heat the aerosol-generating substrate sufficiently to emit an aerosol.

[0024] The aerosol-generating article may have a three-dimensional shape.

[0025] The aerosol-generating article may have a quadrilateral hexahedron shape. The aerosol-generating article may have a rectangular prism shape. The aerosol-generating article may have a cubic shape. The aerosol-generating article may have a cubic shape. The aerosol-generating article may have a rectangular prism shape. The aerosol-generating article may have a parallelepiped shape.

[0026] The aerosol-generating article may have a cylindrical shape. The aerosol-generating article may have a rectangular prism shape. The aerosol-generating article may have an elliptical cylindrical shape.

[0027] The aerosol-generating article may have an oval shape.

[0028] The aerosol-generating article may have a laminated structure, for example the aerosol-generating article may comprise or be formed from at least two layers, in particular the aerosol-generating article may 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, as described in more detail below.

[0029] At least 50% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 55% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 60% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 65% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 70% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 75% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 80% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 85% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 90% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material.

[0030] At least 50% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 55% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 60% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 65% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 70% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 75% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 80% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 85% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 90% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard.

[0031] Substantially the entire aerosol-generating article, except for one or more aerosol-generating substrates and adhesive (if present), may be paper or cardboard.

[0032] The aerosol-generating article may have a cellulose acetate content of less than 5 percent.The aerosol-generating article may have a cellulose acetate content of less than 3 percent.The aerosol-generating article may have a cellulose acetate content of less than 1 percent.

[0033] The frame may be a planar frame.

[0034] The frame may define a frame opening extending through the thickness of the frame. The frame opening may define or form an airflow passage for the aerosol-generating article. The frame opening may define or form a cavity for the aerosol-generating article. For example, the frame may have a hollow cubic shape or a square hollow tube shape. As a further example, the frame may have an annular-shaped cross-section, preferably an annular-shaped cross-section in the x / y plane. The cross-section may have an annular shape, such as a circular annular shape, an elliptical annular shape, a rectangular annular shape, or a square annular shape.

[0035] The frame may have a frame outer surface. The frame outer surface may extend transversely, for example, between a first outer planar surface and a second outer planar surface. The frame outer surface may at least partially define or form one or more outer surfaces of the aerosol-generating article. For example, the frame outer surface may at least partially define or form one or more outer walls of the aerosol-generating article. The frame outer surface may surround or enclose a frame opening. The frame outer surface may surround or enclose a cavity.

[0036] The frame may include an inner frame surface. The inner frame surface may extend transversely, for example, between a first outer planar surface and a second outer planar surface. The inner frame surface may define or form an outer wall of a frame opening. The inner frame surface may define or form an outer wall of a cavity. The inner frame surface may surround or enclose a frame opening that extends through the thickness of the frame. The outer frame surface may surround or enclose a cavity.

[0037] The outer frame surface may surround or encircle the inner frame surface. The inner and outer frame surfaces may be concentric with one another.

[0038] The frame may define or form at least 75 percent of the perimeter, in the x / y plane, of any cross-section of the aerosol-generating article extending through the frame. The frame may define or form at least 80 percent of the perimeter, in the x / y plane, of any cross-section of the aerosol-generating article extending through the frame. The frame may define or form at least 85 percent of the perimeter, in the x / y plane, of any cross-section of the aerosol-generating article extending through the frame. The frame may define or form at least 90 percent of the perimeter, in the x / y plane, of any cross-section of the aerosol-generating article extending through the frame. The frame may define or form at least 95 percent of the perimeter, in the x / y plane, of any cross-section of the aerosol-generating article extending through the frame. The frame may define or form at least 99 percent of the perimeter, in the x / y plane, of any cross-section of the aerosol-generating article extending through the frame.

[0039] Advantageously, providing a frame that forms at least 75 percent of the periphery of any cross-section of the aerosol-generating article extending through the frame in the x / y plane means that the frame extends around most of the aerosol-generating article, and therefore can provide good structural support for the aerosol-generating article.

[0040] Advantageously, providing a frame that forms at least 75 percent of the periphery of any cross-section of the aerosol-generating article extending through the frame in the x / y plane may mean that any air inlet or air outlet defined through the article is sized to provide satisfactory resistance to withdrawal for the aerosol-generating article.

[0041] Advantageously, in embodiments in which the aerosol-generating substrate is positioned within a cavity, providing a frame that forms at least 75 percent of the periphery of any cross-section of the aerosol-generating article extending through the frame in the x / y plane may enable the frame to act as a barrier to prevent the aerosol-generating article from being ejected from the aerosol-generating substrate.

[0042] The aerosol-generating article may have a cross-section extending through a frame in a first x / y plane. The frame may form at least 99 percent of the periphery of the cross-section in the first x / y plane. The frame may form at least 100 percent of the periphery of the cross-section in the first x / y plane.

[0043] The aerosol-generating article may have a cross-section extending through the frame in a second x / y plane spaced in the z-direction from the first x / y plane. The frame may form at least 99 percent of the periphery of the cross-section in the second x / y plane. The frame may form 100 percent of the periphery of the cross-section in the second x / y plane.

[0044] The air inlet may be positioned in the z direction between the first x / y plane and the second x / y plane, and the air outlet may be positioned in the z direction between the first x / y plane and the second x / y plane.

[0045] The frame may have a first portion that is at least 30% of the thickness of the frame. The first portion may be at least 50 percent of the thickness of the frame. The first portion may be at least 70 percent of the thickness of the frame. The first portion may be at least 90 percent of the thickness of the frame. The frame forms 100% of the periphery of any cross-section of the aerosol-generating article in the x / y plane that extends through the first portion of the frame.

[0046] The aerosol-generating article may comprise one or more outer walls extending between a first outer planar surface and a second outer planar surface. The one or more outer walls may collectively define the entire transverse outer area of ​​the aerosol-generating article. The frame may at least partially define each of the one or more outer walls.

[0047] One or more outer walls may surround or enclose the cavity.

[0048] The frame may define at least 60 percent of the total transverse outer area of ​​the aerosol-generating article. The frame may define at least 60 percent of the total transverse outer area of ​​the aerosol-generating article. The frame may define at least 70 percent of the total transverse outer area of ​​the aerosol-generating article. The frame may define at least 80 percent of the total transverse outer area of ​​the aerosol-generating article. The frame may define at least 90 percent of the total transverse outer area of ​​the aerosol-generating article.

[0049] The frame may include a peripheral wall. The peripheral wall may surround or enclose at least a portion of a frame opening extending through the thickness of the frame. The peripheral wall may surround or enclose at least a portion of a cavity. The peripheral wall may surround or enclose a frame opening extending through the thickness of the frame. The peripheral wall may surround or enclose a cavity. Advantageously, such a peripheral wall allows for a relatively large internal volume for the aerosol-generating substrate or aerosol formation, while providing structural strength to maintain the shape of the aerosol-generating article.

[0050] The peripheral wall may be defined or formed by an outer frame surface and an inner frame surface. The peripheral wall may at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The peripheral wall may define or form the outer wall of a frame opening. The peripheral wall may define or form the outer wall of a cavity.

[0051] The peripheral wall may have a radial thickness, which may be defined as the smallest distance between the outer surface of the frame and the inner surface of the frame, such as in the x / y plane.

[0052] The peripheral wall may have a radial thickness of 0.5 millimeters or more. The peripheral wall may have a radial thickness of 1 millimeter or more. The peripheral wall may have a radial thickness of 1.5 millimeters or more. The peripheral wall may have a radial thickness of 2 millimeters or more. The peripheral wall may have a radial thickness of 2.5 millimeters or more.

[0053] The peripheral wall may have a radial thickness of 4 millimeters or less. The peripheral wall may have a radial thickness of 3.5 millimeters or less. The peripheral wall may have a radial thickness of 3 millimeters or less. The peripheral wall may have a radial thickness of 2.5 millimeters or less. The peripheral wall may have a radial thickness of 2 millimeters or less.

[0054] The peripheral wall may have a radial thickness of 0.5 millimeters to 3.5 millimeters. The peripheral wall may have a radial thickness of 0.5 millimeters to 3 millimeters. The peripheral wall may have a radial thickness of 0.5 millimeters to 2.5 millimeters. The peripheral wall may have a radial thickness of 1 millimeter to 3 millimeters. The peripheral wall may have a radial thickness of 1 millimeter to 2 millimeters. Advantageously, a peripheral wall having a radial thickness of 0.5 millimeters to 3.5 millimeters has been found to provide good structural strength to the aerosol-generating article while avoiding the need for excessive amounts of material that could increase manufacturing costs. Advantageously, a radial thickness of 0.5 millimeters to 3.5 millimeters may limit the amount of heat that is undesirably transferred to the frame rather than to the aerosol-generating substrate.

[0055] The frame may be made from or may include a biodegradable material. The frame may be made entirely from a biodegradable material.

[0056] The frame may be made from or may include a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may include cellulose fibers. The cellulosic material may be paper, paperboard, or cardboard. The frame may be made from or may include a plant material, such as tobacco. The frame may be made entirely from a cellulosic material.

[0057] The cellulosic material may have a basis weight of 300 grams per square meter or greater. The cellulosic material may have a basis weight of 350 grams per square meter or greater. The cellulosic material may have a basis weight of 390 grams per square meter or greater. The cellulosic material may have a basis weight of 420 grams per square meter or greater. The cellulosic material may have a basis weight of 620 grams per square meter or greater. The cellulosic material may have a basis weight of 720 grams per square meter or greater. The cellulosic material may have a basis weight of 800 grams per square meter or greater.

[0058] The cellulosic material may have a basis weight of 900 grams per square meter or less. The cellulosic material may have a basis weight of 800 grams per square meter or less. The cellulosic material may have a basis weight of 720 grams per square meter or less. The cellulosic material may have a basis weight of 620 grams per square meter or less. The cellulosic material may have a basis weight of 420 grams per square meter or less. The cellulosic material may have a basis weight of 390 grams per square meter or less. The cellulosic material may have a basis weight of 350 grams per square meter or less.

[0059] The cellulosic material may have a basis weight of 300 grams per square meter to 900 grams per square meter. The cellulosic material may have a basis weight of 300 grams per square meter to 800 grams per square meter. The cellulosic material may have a basis weight of 350 grams per square meter to 800 grams per square meter. The cellulosic material may have a basis weight of 400 grams per square meter to 700 grams per square meter.

[0060] The frame may be made from or include a fibrous material. The frame may be made from one or more of natural fibers, synthetic fibers, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibers, nylon fibers, and ceramic fibers. The frame may include cellulose fibers.

[0061] The frame may comprise a hydrophobic region. The hydrophobic region may comprise hydrophobic groups covalently bonded to the frame. The hydrophobic region may be positioned on or form at least a portion of the inner surface of the frame. Advantageously, the hydrophobic region may prevent or limit degradation of the frame in areas where the frame regularly comes into contact with aerosols or liquids from the aerosol-generating substrate.

[0062] The hydrophobic region may be produced by a process comprising applying a liquid composition containing a fatty acid halide to a surface of the frame and maintaining the surface at a temperature of about 120° C. to about 180° C. The fatty acid halide reacts in situ with proton groups of the material in the hydrophobic region, resulting in the formation of a fatty acid ester.

[0063] The hydrophobic region may have a Cobb Water Absorption (ISO 535:1991) value (60 seconds) of 40 grams per square meter or less. The hydrophobic region may have a Cobb Water Absorption (ISO 535:1991) value (60 seconds) of 35 grams per square meter or less. The hydrophobic region may have a Cobb Water Absorption (ISO 535:1991) value (60 seconds) of 30 grams per square meter or less. The hydrophobic region may have a Cobb Water Absorption (ISO 535:1991) value (60 seconds) of about 25 grams per square meter or less.

[0064] The hydrophobic region may have a water contact angle of about 90 degrees or greater. The hydrophobic region may have a water contact angle of about 95 degrees or greater. The hydrophobic region may have a water contact angle of about 100 degrees or greater. The hydrophobic region may have a water contact angle of about 110 degrees or greater. The hydrophobic region may have a water contact angle of about 120 degrees or greater. The hydrophobic region may have a water contact angle of about 130 degrees or greater. The hydrophobic region may have a water contact angle of about 140 degrees or greater. The hydrophobic region may have a water contact angle of about 150 degrees or greater. The hydrophobic region may have a water contact angle of about 160 degrees or greater. The hydrophobic region may have a water contact angle of about 170 degrees or greater.

[0065] Hydrophobicity is determined using the TAPPI T558 om-97 test, and the results are presented as interfacial contact angles, reported in degrees, which can range from near 0 degrees to near 180 degrees. If no contact angle is specified with the term hydrophobicity, the contact angle of water is at least 90 degrees.

[0066] The hydrophobic region may have a water contact angle of 90 degrees or greater and a Cobb Water Absorption (ISO 535:1991) value (60 seconds) of 40 grams per square meter or less.

[0067] The aerosol-generating article may comprise one or more susceptor materials. The frame may comprise one or more susceptor materials. The one or more susceptor materials may be in thermal contact with the aerosol-generating substrate. The one or more susceptor materials may be in thermal contact with the airflow passage. The one or more susceptor materials may be in thermal contact with the cavity. The one or more susceptor materials may be positioned within or on an inner surface of the frame. The one or more susceptor materials may be incorporated within the material of the frame. For example, the one or more susceptor materials may be incorporated within the peripheral wall of the frame. Advantageously, the presence of the one or more susceptor materials may enable the aerosol-generating article, and thus the aerosol-generating substrate, to be heated by engaging a varying electromagnetic field generated by an inductor.

[0068] The one or more susceptor materials may be one or more particles, strips, threads, or wires of susceptor material. The one or more susceptor materials may be one or more sheets or layers of susceptor material. The one or more sheets or layers of susceptor material may be in the form of a mesh of susceptor material.

[0069] The susceptor material, regardless of form, may include one or more materials selected from the list consisting of aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0070] The frame may have a thickness of 50 percent or more of the thickness of the aerosol-generating article. The frame may have a thickness of 60 percent or more of the thickness of the aerosol-generating article. The frame may have a thickness of 70 percent or more of the thickness of the aerosol-generating article. The frame may have a thickness of 80 percent or more of the thickness of the aerosol-generating article. The frame may have a thickness of 90 percent or more of the thickness of the aerosol-generating article. The frame may have a thickness of 95 percent or more of the thickness of the aerosol-generating article.

[0071] The frame may have a thickness of 95 percent or less of the thickness of the aerosol-generating article. The frame may have a thickness of 90 percent or less of the thickness of the aerosol-generating article. The frame may have a thickness of 80 percent or less of the thickness of the aerosol-generating article. The frame may have a thickness of 70 percent or less of the thickness of the aerosol-generating article.

[0072] The frame may have a thickness between 50 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 60 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 70 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 80 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article.

[0073] The frame may have a thickness of 1 millimeter or more. The frame may have a thickness of 1.5 millimeters or more. The frame may have a thickness of 2 millimeters or more. The frame may have a thickness of 2.5 millimeters or more. The frame may have a thickness of 3 millimeters or more. The frame may have a thickness of 3.5 millimeters or more. The frame may have a thickness of 4 millimeters or more. The frame may have a thickness of 4.5 millimeters or more.

[0074] The frame may have a thickness of 5.5 millimeters or less. The frame may have a thickness of 5 millimeters or less. The frame may have a thickness of 4.5 millimeters or less. The frame may have a thickness of 4 millimeters or less. The frame may have a thickness of 3.5 millimeters or less. The frame may have a thickness of 3 millimeters or less. The frame may have a thickness of 2.5 millimeters or less. The frame may have a thickness of 2 millimeters or less. The frame may have a thickness of 1.5 millimeters or less.

[0075] The frame may have a thickness of 1 mm to 5.5 mm. The frame may have a thickness of 1 mm to 5 mm. Preferably, the frame may have a thickness of 1.5 mm to 5 mm.

[0076] The frame may have a length equal to that of the aerosol-generating article. The frame may have a length that is at least 90 percent of the length of the aerosol-generating article. The frame may have a length that is at least 95 percent of the length of the aerosol-generating article.

[0077] The frame may have a width equal to that of the aerosol-generating article. The frame may have a width that is at least 90 percent of the width of the aerosol-generating article. The frame may have a width that is at least 90 percent of the width of the aerosol-generating article.

[0078] The frame may be a monolithic component. Alternatively, the frame may comprise two or more layers, i.e., the frame may have a laminated structure. Advantageously, the properties of each layer may be individually optimized 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 frame to be manufactured to a desired thickness and allows the frame to be quickly adjusted to the desired thickness by adding or removing layers of sheet material. This avoids the need to manufacture a single sheet of material having the desired thickness for the frame, which can then simply be changed when the desired thickness of the frame changes.

[0079] The frame may comprise a first frame layer and a second frame layer. The first and second frame layers may be the only layers of the frame. That is, the frame may comprise up to two layers or exactly two layers. The first frame layer may be the upper frame layer and the second frame layer may be the lower frame layer.

[0080] The frame may 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 opening may be defined through both the first frame layer and the second frame layer.

[0081] The frame may include a first frame layer, a second frame layer, and a third frame layer. The second frame layer may be positioned between the first and third frame layers. The first, second, and third frame layers may be the only layers of the frame. That is, the frame may include up to three layers or exactly three layers. The first frame layer may be the upper frame layer, the second frame layer may be the middle frame layer, and the third frame layer may be the lower frame layer.

[0082] The first frame layer may be in physical contact with the second frame layer. The first frame layer may be adhesively bonded to the second frame layer. The bottom surface of the first frame layer may be adhesively bonded to the top surface of the second frame layer. The adhesive may extend around at least 90% of the perimeter of the intersection between the first and second frame layers. The adhesive may extend around at least 95% of the perimeter of the intersection between the first and second frame layers. The adhesive may extend around at least 99% of the perimeter of the intersection between the first and second frame layers.

[0083] The second frame layer may be in physical contact with the third frame layer. The second frame layer may be adhesively bonded to the third frame layer. The bottom surface of the second frame layer may be adhesively bonded to the top surface of the third frame layer. The adhesive may extend around at least 90% of the perimeter of the intersection between the second and third frame layers. The adhesive may extend around at least 95% of the perimeter of the intersection between the second and third frame layers. The adhesive may extend around at least 99% of the perimeter of the intersection between the second and third frame layers.

[0084] The frame may have a thickness that is equal to the sum of the thicknesses of the first frame layer, the second frame layer, and the third frame layer. A frame opening may be defined through the first planar layer, the second planar layer, and the third frame layer.

[0085] The first frame layer may be planar.

[0086] The first frame layer may define a first frame layer opening extending through the thickness of the first frame layer. The first frame layer opening may at least partially define or form a cavity in the aerosol-generating article. For example, the first frame layer may have a hollow cubic shape or a square hollow tube shape. As a further example, the first frame layer may have an annular cross-section, preferably an annular cross-section in the x / y plane. The cross-section may have an annular shape, such as a circular annular shape, an elliptical annular shape, a rectangular annular shape, or a square annular shape.

[0087] The first frame layer may have a first frame layer outer surface. The first frame layer outer surface may extend in a transverse direction, for example, between a first planar outer surface and a second planar outer surface. The first frame layer outer surface may at least partially define or form one or more outer surfaces of the aerosol-generating article. For example, the first frame layer outer surface may at least partially define or form one or more outer walls of the aerosol-generating article. The first frame layer outer surface may surround or enclose one or both of the first frame layer opening and the frame opening. The first frame layer outer surface may surround or enclose a cavity.

[0088] The first frame layer may include a first frame layer inner surface. The first frame layer inner surface may extend transversely, for example, between the first planar outer surface and the second planar outer surface. The first frame layer inner surface may define or form a first frame layer opening outer wall. The first frame layer inner surface may at least partially define or form a cavity outer wall. The first frame layer inner surface may surround or enclose one or both of the first frame layer opening and the frame opening. The first frame layer outer surface may surround or enclose a cavity.

[0089] The first frame layer outer surface may surround or encircle the first frame layer inner surface. The first frame layer inner surface and the first frame layer outer surface may be concentric with each other.

[0090] The first frame layer may include a first frame layer peripheral wall. The first frame layer peripheral wall may surround or enclose one or both of the frame opening and the first frame layer opening. The first frame layer peripheral wall may surround or enclose the cavity.

[0091] The first frame layer peripheral wall may be defined or formed by the first frame layer outer surface and the first frame layer inner surface. The first frame layer peripheral wall may at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The first frame layer peripheral wall may at least partially define or form the first frame layer opening outer wall. The first frame layer peripheral wall may at least partially define or form the cavity outer wall.

[0092] The first frame layer may be made of or may include any of the materials described above for the frame, for example, the first frame layer may comprise one or more susceptor materials.

[0093] The first frame layer may be made from, or may include, a biodegradable material. The first frame layer may be made entirely from a biodegradable material.

[0094] The first frame layer may be made from or may include a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may include cellulose fibers. The cellulosic material may be paper, paperboard, or cardboard. The first frame layer may be made from or may include a plant material, such as tobacco. The first frame layer may be made entirely from a cellulosic material.

[0095] The cellulosic material may have any basis weight or any basis weight range described above in connection with the frame.

[0096] The first frame layer may be made from a fibrous material, such as one or more of natural fibers, synthetic fibers, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibers, nylon fibers, and ceramic fibers.

[0097] If the frame has exactly two layers, the thickness of the first frame layer may be half (50 percent) of the frame thickness. The first frame layer may have substantially the same thickness as the second frame layer. If the frame has exactly three layers, the thickness of the first frame layer may be one-third (33.33 percent) of the frame thickness. The first frame layer may have substantially the same thickness as each of the second and third frame layers.

[0098] The first frame layer may have a thickness of 0.5 millimeters or more. The frame may have a thickness of 1 millimeter or more. The first frame layer may have a thickness of 1.5 millimeters or more. The first frame layer may have a thickness of 2 millimeters or more. The first frame layer may have a thickness of 2.5 millimeters or more.

[0099] The first frame layer may have a thickness of 3 millimeters or less. The first frame layer may have a thickness of 2.5 millimeters or less. The first frame layer may have a thickness of 2 millimeters or less. The first frame layer may have a thickness of 1.5 millimeters or less. The first frame layer may have a thickness of 1 millimeter or less.

[0100] The first frame layer may have a thickness of 0.5 mm to 3 mm. The first frame layer may have a thickness of 0.5 mm to 2.5 mm. The first frame layer may have a thickness of 1 mm to 2.5 mm.

[0101] The second frame layer may be planar.

[0102] The second frame layer may define a second frame layer opening extending through the thickness of the second frame layer. The second frame layer opening may at least partially define or form a cavity in the aerosol-generating article. For example, the second frame layer may have a hollow cubic shape or a square hollow tube shape. As a further example, the second frame layer may have an annular cross-section, preferably an annular cross-section in the x / y plane. The cross-section may have an annular shape, such as a circular annular shape, an elliptical annular shape, a rectangular annular shape, or a square annular shape.

[0103] The second frame layer may have a second frame layer outer surface. The second frame layer outer surface may extend in a transverse direction, for example, between the second planar outer surface and the second planar outer surface. The second frame layer outer surface may at least partially define or form one or more outer surfaces of the aerosol-generating article. For example, the second frame layer outer surface may at least partially define or form one or more outer walls of the aerosol-generating article. The second frame layer outer surface may surround or enclose one or both of the second frame layer opening and the frame opening. The second frame layer outer surface may surround or enclose a cavity.

[0104] The second frame layer may include a second frame layer inner surface. The second frame layer inner surface may extend transversely, for example, between the second planar outer surface and the second planar outer surface. The second frame layer inner surface may define or form a second frame layer opening outer wall. The second frame layer inner surface may at least partially define or form a cavity outer wall. The second frame layer inner surface may surround or enclose one or both of the second frame layer opening and the frame opening. The second frame layer outer surface may surround or enclose a cavity.

[0105] The second frame layer outer surface may surround or encircle the second frame layer inner surface. The second frame layer inner surface and the second frame layer outer surface may be concentric with each other.

[0106] The second frame layer may include a second frame layer peripheral wall that may surround or enclose one or both of the frame opening and the second frame layer opening, and that may surround or enclose a cavity.

[0107] The second frame layer peripheral wall may be defined or formed by the second frame layer outer surface and the second frame layer inner surface. The second frame layer peripheral wall may at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The second frame layer peripheral wall may at least partially define or form the second frame layer opening outer wall. The second frame layer peripheral wall may at least partially define or form the cavity outer wall.

[0108] The second frame layer may be made of or may include any of the materials described above for the frame, for example, the second frame layer may comprise one or more susceptor materials.

[0109] The second frame layer may be made from, or may include, a biodegradable material. The second frame layer may be made entirely from a biodegradable material.

[0110] The second frame layer may be made from or include a cellulosic material. The cellulosic material may include a sheet of cellulosic material. The cellulosic material may be paper, paperboard, or cardboard. The second frame layer may be made from or include a plant material, such as tobacco. The second frame layer may be made entirely from cellulosic material.

[0111] The cellulosic material may have any basis weight or any basis weight range described above in connection with the frame.

[0112] The second frame layer may be made from a fibrous material, such as one or more of natural fibers, synthetic fibers, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibers, nylon fibers, and ceramic fibers.

[0113] If the frame has exactly two layers, the second frame layer may have a thickness that is half (50 percent) the thickness of the frame. The second frame layer may have substantially the same thickness as the first frame layer. If the frame has exactly three layers, the second frame layer may have a thickness that is one-third (33.33 percent) the thickness of the frame. The second frame layer may have substantially the same thickness as the first and third frame layers.

[0114] The second frame layer may have a thickness of 0.5 millimeters or more. The frame may have a thickness of 1 millimeter or more. The second frame layer may have a thickness of 1.5 millimeters or more. The second frame layer may have a thickness of 2 millimeters or more. The second frame layer may have a thickness of 2.5 millimeters or more.

[0115] The second frame layer may have a thickness of 3 millimeters or less. The second frame layer may have a thickness of 2.5 millimeters or less. The second frame layer may have a thickness of 2 millimeters or less. The second frame layer may have a thickness of 1.5 millimeters or less. The second frame layer may have a thickness of 1 millimeter or less.

[0116] The second frame layer may have a thickness of 0.5 mm to 3 mm. The second frame layer may have a thickness of 0.5 mm to 2.5 mm. The second frame layer may have a thickness of 1 mm to 2.5 mm.

[0117] The third frame layer may be planar.

[0118] The third frame layer may define a third frame layer opening extending through the thickness of the third frame layer. The third frame layer opening may at least partially define or form a cavity in the aerosol-generating article. For example, the third frame layer may have a hollow cubic shape or a square hollow tube shape. As a further example, the third frame layer may have an annular cross-section, preferably an annular cross-section in the x / y plane. The cross-section may have an annular shape, such as a circular annular shape, an elliptical annular shape, a rectangular annular shape, or a square annular shape.

[0119] The third frame layer may have a third frame layer outer surface. The third frame layer outer surface may extend in a transverse direction, for example, between the third planar outer surface and the third planar outer surface. The third frame layer outer surface may at least partially define or form one or more outer surfaces of the aerosol-generating article. For example, the third frame layer outer surface may at least partially define or form one or more outer walls of the aerosol-generating article. The third frame layer outer surface may surround or enclose one or both of the third frame layer opening and the frame opening. The third frame layer outer surface may surround or enclose a cavity.

[0120] The third frame layer may include a third frame layer inner surface. The third frame layer inner surface may extend transversely, for example, between the third outer planar surface and the third outer planar surface. The third frame layer inner surface may define or form a third frame layer opening outer wall. The third frame layer inner surface may at least partially define or form a cavity outer wall. The third frame layer inner surface may surround or enclose one or both of the third frame layer opening and the frame opening. The third frame layer outer surface may surround or enclose a cavity.

[0121] The third frame layer outer surface may surround or encircle the third frame layer inner surface. The third frame layer inner surface and the third frame layer outer surface may be concentric with each other.

[0122] The third frame layer may include a third frame layer peripheral wall. The third frame layer peripheral wall may surround or enclose one or both of the frame opening and the third frame layer opening. The third frame layer peripheral wall may surround or enclose the cavity.

[0123] The third frame layer peripheral wall may be defined or formed by the third frame layer outer surface and the third frame layer inner surface. The third frame layer peripheral wall may at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The third frame layer peripheral wall may at least partially define or form the third frame layer opening outer wall. The third frame layer peripheral wall may at least partially define or form the cavity outer wall.

[0124] The third frame layer may be made of or may include any of the materials described above for the frame, for example, the third frame layer may comprise one or more susceptor materials.

[0125] The third frame layer may be made from, or may include, a biodegradable material. The third frame layer may be made entirely from a biodegradable material.

[0126] The third frame layer may be made from or include a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may be paper, paperboard, or cardboard. The third frame layer may be made from or include a plant material, such as tobacco. The third frame layer may be made entirely from cellulosic material.

[0127] The cellulosic material may have any basis weight or any basis weight range described above in connection with the frame.

[0128] The third frame layer may be made from a fibrous material, such as one or more of natural fibers, synthetic fibers, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibers, nylon fibers, and ceramic fibers.

[0129] If the frame has exactly three layers, the thickness of the third frame layer may be one-third (33.33 percent) of the thickness of the frame. The third frame layer may have substantially the same thickness as each of the first and second frame layers.

[0130] The third frame layer may have a thickness of 0.5 millimeters or more. The frame may have a thickness of 1 millimeter or more. The third frame layer may have a thickness of 1.5 millimeters or more. The third frame layer may have a thickness of 2 millimeters or more. The third frame layer may have a thickness of 2.5 millimeters or more.

[0131] The third frame layer may have a thickness of 3 millimeters or less. The third frame layer may have a thickness of 2.5 millimeters or less. The third frame layer may have a thickness of 2 millimeters or less. The third frame layer may have a thickness of 1.5 millimeters or less. The third frame layer may have a thickness of 1 millimeter or less.

[0132] The third frame layer may have a thickness of 0.5 mm to 3 mm. The third frame layer may have a thickness of 0.5 mm to 2.5 mm. The third frame layer may have a thickness of 1 mm to 2.5 mm.

[0133] One or more of the aerosol-generating substrates may comprise an aerosol-generating substrate layer. Advantageously, the aerosol-generating substrate layer can be made thin and therefore can be heated quickly to release volatile compounds, thereby forming an aerosol. Advantageously, the aerosol-generating substrate layer can be positioned in close proximity to the heater of the aerosol-generating substrate.

[0134] The aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any of the aerosol-generating materials described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any of the aerosol-generating materials described herein. The aerosol-generating substrate layer may be a sheet of aerosol-generating material or may be made entirely from a sheet of aerosol-generating material.

[0135] The aerosol-generating substrate layer may be positioned between the frame and the first planar outer surface. The aerosol-generating substrate layer may be positioned between the frame and the second planar outer surface. The aerosol-generating substrate layer may be in physical contact with the frame or may be adhered to the frame. The aerosol-generating substrate layer may be adhered to the frame with an adhesive.

[0136] The aerosol-generating substrate layer may be positioned between the frame and the outer wrapper, which is described in more detail below. The aerosol-generating substrate layer may be in physical contact with or adhered to both the frame and the outer wrapper. The aerosol-generating substrate layer may be adhered to both the frame and the outer wrapper by an adhesive.

[0137] The aerosol-generating substrate layer may be positioned between the frame and the first planar outer layer. The aerosol-generating substrate layer may be positioned between the frame and the second planar outer layer. The first and second planar outer layers are described in more detail below. The aerosol-generating substrate layer may be in physical contact with both the frame and the first planar outer layer, or may be adhered to both. The aerosol-generating substrate layer may be adhered to both the frame and the first planar outer layer with an adhesive. The aerosol-generating substrate layer may be in physical contact with both the frame and the second planar outer layer, or may be adhered to both. The aerosol-generating substrate layer may be adhered to both the frame and the second planar outer layer with an adhesive.

[0138] The aerosol-generating substrate layer may be on an end of the cavity. The aerosol-generating substrate layer may define or form a wall of the cavity, such as the first or second cavity end wall. Advantageously, the aerosol-generating substrate layer may therefore be within the airflow passage or may at least partially define or form the airflow passage, thereby enabling the emitted volatile compound to rapidly form an aerosol.

[0139] The one or more aerosol-generating substrates may comprise a first aerosol-generating substrate layer and a second aerosol-generating substrate layer. Advantageously, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may enable a satisfactory aerosol volume to be generated more quickly than when using a single aerosol-generating substrate layer.

[0140] The first aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any of the aerosol-generating materials described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any of the aerosol-generating materials described herein. The first aerosol-generating substrate layer may be a sheet of aerosol-generating material or may be made entirely from a sheet of aerosol-generating material.

[0141] The second aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any of the aerosol-generating materials described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any of the aerosol-generating materials described herein. The second aerosol-generating substrate layer may be a sheet of aerosol-generating material or may be made entirely from a sheet of aerosol-generating material.

[0142] The first aerosol-generating substrate layer may be positioned between the frame and the first planar outer surface. The first aerosol-generating substrate layer may be in physical contact with the frame or may be adhered to the frame. For example, the first aerosol-generating substrate layer may be in physical contact with the first frame layer or may be adhered to the first frame layer. The first aerosol-generating substrate layer may be adhered to the frame with an adhesive. The first aerosol-generating substrate layer may be adhered to the first frame layer with an adhesive. The bottom surface of the first aerosol-generating substrate layer may be adhered to the top surface of the first frame layer with an adhesive.

[0143] The first aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The first aerosol-generating substrate layer may be in physical contact with or adhered to both the frame and the outer wrapper. The first aerosol-generating substrate layer may be adhered to the frame and the outer wrapper by an adhesive.

[0144] The first aerosol-generating substrate layer may be positioned between the frame and the first planar outer layer. The first aerosol-generating substrate layer may be in physical contact with or adhered to both the frame and the first planar outer layer. The first aerosol-generating substrate layer may be adhered to the frame and the first planar outer layer by an adhesive.

[0145] The second aerosol-generating substrate layer may be positioned between the frame and the second planar outer surface. The second aerosol-generating substrate layer may be in physical contact with the frame or may be adhered to the frame. For example, the second aerosol-generating substrate layer may be in physical contact with the second frame layer or the third frame layer or may be adhered to the second frame layer or the third frame layer. The second aerosol-generating substrate layer may be adhered to the frame with an adhesive. The second aerosol-generating substrate layer may be adhered to the second frame layer or the third frame layer with an adhesive. The top surface of the second aerosol-generating substrate layer may be adhered to the bottom surface of the second frame layer or the third frame layer with an adhesive.

[0146] The second aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The second aerosol-generating substrate layer may be in physical contact with or adhered to both the frame and the outer wrapper. The second aerosol-generating substrate layer may be adhered to the frame and the outer wrapper by an adhesive.

[0147] The second aerosol-generating substrate layer may be positioned between the frame and the second planar outer layer. The second aerosol-generating substrate layer may be in physical contact with or adhered to both the frame and the second planar outer layer. The second aerosol-generating substrate layer may be adhered to the frame and the second planar outer layer by an adhesive.

[0148] The first and second aerosol-generating substrate layers may be on opposite ends of a cavity. The first and second aerosol-generating substrate layers may define or form opposite end walls of the cavity. That is, the frame, the first and second aerosol-generating substrate layers may collectively define the cavity. In other words, the cavity is defined by the frame, the first and second aerosol-generating substrate layers.

[0149] The aerosol-generating substrate layer may be a planar aerosol-generating substrate layer. The planar aerosol-generating substrate layer may extend in the x direction and in the y direction, i.e., the planar aerosol-generating substrate layer may extend in the x / y plane.

[0150] The first aerosol-generating substrate layer may be a first planar aerosol-generating substrate layer. The first planar aerosol-generating substrate layer may extend in the x direction and in the y direction, i.e. the first planar aerosol-generating substrate layer may extend in the x / y plane.

[0151] The second aerosol-generating substrate layer may be a second planar aerosol-generating substrate layer. The second planar aerosol-generating substrate layer may extend in the x direction and in the y direction, i.e., the second planar aerosol-generating substrate layer may extend in the x / y plane.

[0152] The aerosol-generating substrate layer may have a thickness of 100 micrometers or more. The aerosol-generating substrate layer may have a thickness of 200 micrometers or more. The aerosol-generating substrate layer may have a thickness of 300 micrometers or more. The aerosol-generating substrate layer may have a thickness of 400 micrometers or more. The aerosol-generating substrate layer may have a thickness of 500 micrometers or more.

[0153] The aerosol-generating substrate layer may have a thickness of 600 micrometers or less. The aerosol-generating substrate layer may have a thickness of 500 micrometers or less. The aerosol-generating substrate layer may have a thickness of 400 micrometers or less. The aerosol-generating substrate layer may have a thickness of 300 micrometers or less. The aerosol-generating substrate layer may have a thickness of 200 micrometers or less.

[0154] The aerosol-generating substrate layer may have a thickness of 100 micrometers to 600 micrometers. The aerosol-generating substrate layer may have a thickness of 200 micrometers to 500 micrometers. The aerosol-generating substrate layer may have a thickness of 200 micrometers to 400 micrometers. The aerosol-generating substrate layer may have a thickness of 200 micrometers to 300 micrometers.

[0155] One or both of the first and second aerosol-generating substrate layers may have a thickness of 100 micrometers or more. One or both of the first and second aerosol-generating substrate layers may have a thickness of 200 micrometers or more. One or both of the first and second aerosol-generating substrate layers may have a thickness of 300 micrometers or more. One or both of the first and second aerosol-generating substrate layers may have a thickness of 400 micrometers or more. One or both of the first and second aerosol-generating substrate layers may have a thickness of 500 micrometers or more.

[0156] One or both of the first and second aerosol-generating substrate layers may have a thickness of 600 micrometers or less. One or both of the first and second aerosol-generating substrate layers may have a thickness of 500 micrometers or less. One or both of the first and second aerosol-generating substrate layers may have a thickness of 400 micrometers or less. One or both of the first and second aerosol-generating substrate layers may have a thickness of 300 micrometers or less. One or both of the first and second aerosol-generating substrate layers may have a thickness of 200 micrometers or less.

[0157] One or both of the first and second aerosol-generating substrate layers may have a thickness of 100 micrometers to 600 micrometers. One or both of the first and second aerosol-generating substrate layers may have a thickness of 200 micrometers to 500 micrometers. One or both of the first and second aerosol-generating substrate layers may have a thickness of 200 micrometers to 400 micrometers. One or both of the first and second aerosol-generating substrate layers may have a thickness of 200 micrometers to 300 micrometers.

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

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

[0160] The second aerosol-generating substrate layer may have substantially the same length as the frame.The second aerosol-generating substrate layer may have substantially the same length as the aerosol-generating article.

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

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

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

[0164] The first planar outer surface may be a planar upper surface and the second planar outer surface may be a planar lower surface. The first planar outer surface may be a planar top surface and the second planar outer surface may be a planar bottom surface. The first planar outer surface may be a planar ceiling surface and the second planar outer surface may be a planar base surface.

[0165] The first planar outer surface may be positioned parallel to the second planar outer surface. The first planar outer surface may extend in the x-direction and in the y-direction, i.e., the first planar outer surface may extend in the x / y plane. The second planar outer surface may extend in the x-direction and in the y-direction, i.e., the second planar outer surface may extend in the x / y plane.

[0166] The second outer planar surface may be spaced apart from the first outer planar surface in the z-direction or transverse direction. The distance between the first and second outer planar surfaces in the z-direction or transverse direction may define the thickness of the aerosol-generating article. That is, the thickness of the aerosol-generating article may be defined by the perpendicular distance between the first and second outer planar surfaces.

[0167] The aerosol-generating article may include an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may comprise a hydrophobic material.

[0168] The outer wrapper may define or form a first planar outer surface. The outer wrapper may define or form a second planar outer surface. The outer wrapper may define or form both the first and second planar outer surfaces.

[0169] The outer wrapper may surround or enclose the frame. The outer wrapper may be in physical contact with the frame or may be adhered to the frame. The outer wrapper may overlie opposite ends of the cavity. The outer wrapper may define or form opposite end walls of the cavity, such as a first cavity end wall and a second cavity end wall. That is, the frame and outer wrapper may collectively define the cavity. In other words, the cavity is defined by the frame and the outer wrapper.

[0170] The outer wrapper may surround or enclose the frame and the aerosol-generating substrate layer, and may be in physical contact with or adhered to both the frame and the aerosol-generating substrate layer.

[0171] The outer wrapper may surround or enclose the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer, and may be in physical contact with or adhered to both the first and second aerosol-generating substrate layers.

[0172] The aerosol-generating article may comprise a first planar outer layer and a second planar outer layer. The first planar outer layer may be an upper layer and the second planar outer layer may be a lower layer. The first planar outer layer may be a top layer and the second planar outer layer may be a bottom layer. The first planar outer layer may be a ceiling layer and the second planar outer layer may be a base layer.

[0173] The first planar outer layer may define or form a first planar outer surface. The first planar outer layer may extend in the x-direction and in the y-direction, i.e., the first planar outer layer may extend in the x / y plane. The second planar outer layer may define or form a second planar outer surface. The second planar outer layer may extend in the x-direction and in the y-direction, i.e., the second planar outer layer may extend in the x / y plane.

[0174] The first planar outer layer may be in physical contact with the frame or may be adhered to the frame. The first planar outer layer may be adhesively adhered to the frame. The first planar outer layer may be adhesively adhered to the first frame layer. The bottom surface of the first planar outer layer may be adhesively adhered to the top surface of the first frame layer. The adhesive may extend around at least 90% of the perimeter of the intersection between the first planar outer layer and the frame. The adhesive may extend around at least 95% of the perimeter of the intersection between the first planar outer layer and the frame. The adhesive may extend around at least 99% of the perimeter of the intersection between the first planar outer layer and the frame.

[0175] The first outer planar layer may overlie an end of the cavity. The first outer planar layer may define or form a wall of the cavity, such as a first cavity end wall.

[0176] The second planar outer layer may be in physical contact with the frame or may be adhered to the frame. The second planar outer layer may be adhesively adhered to the frame. The second planar outer layer may be adhesively adhered to the second frame layer. The top surface of the second planar outer layer may be adhesively adhered to the bottom surface of the second frame layer. The second planar outer layer may be adhesively adhered to the third frame layer. The top surface of the second planar outer layer may be adhesively adhered to the bottom surface of the third frame layer. The adhesive may extend around at least 90% of the perimeter of the intersection between the second planar outer layer and the frame. The adhesive may extend around at least 95% of the perimeter of the intersection between the second planar outer layer and the frame. The adhesive may extend around at least 99% of the perimeter of the intersection between the second planar outer layer and the frame.

[0177] The second outer planar layer may overlie an end of the cavity. The second outer planar layer may define or form a wall of the cavity, such as a second cavity end wall.

[0178] The first and second planar outer layers may be on opposite ends of the cavity. The first and second planar outer layers may define or form opposite end walls of the cavity, such as a first cavity end wall and a second cavity end wall. That is, the frame, the first and second planar outer layers may collectively define the cavity. In other words, the cavity is defined by the frame, the first and second planar outer layers.

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

[0180] The second outer planar layer may be spaced, such as transversely, from the frame. For example, the aerosol-generating substrate layer or the second aerosol-generating substrate layer may be positioned between the second outer planar layer and the frame. The second outer planar layer may be in physical contact with the aerosol-generating substrate layer or the second aerosol-generating substrate layer, or may be adhered to the aerosol-generating substrate layer or the second aerosol-generating substrate layer. The second outer planar layer may be adhered to the aerosol-generating substrate layer or the second aerosol-generating substrate layer with an adhesive.

[0181] The first planar outer layer may be hydrophobic. The first planar outer layer may comprise a hydrophobic material. The second planar outer layer may be hydrophobic. The second planar outer layer may comprise a hydrophobic material.

[0182] Advantageously, the adhesive bonding the components of the aerosol-generating article together may provide a tight seal between the layers of the aerosol-generating article, and in particular, the adhesive bonding one or both of the first and second planar outer layers to the frame may provide a tight seal between the first planar outer layer and the frame, or between the second planar outer layer and the frame.

[0183] By providing a tight seal between the layers of the aerosol-generating article, air flow through the cavity may be improved. Improved airflow through the cavity may improve the user experience.

[0184] Advantageously, the use of adhesives to bond components of the aerosol-generating article together may provide the aerosol-generating article with greater structural integrity.

[0185] The adhesive may include a gum. The adhesive may include guar gum. The adhesive may include polyvinyl alcohol. The adhesive may include an aerosol-generating material. The adhesive may be comprised of an aerosol-generating material. For example, the adhesive may be a homogenized tobacco slurry. The adhesive may be or include flavorants and / or aerosol formers.

[0186] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may be made from a cellulosic material. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may include a cellulosic material. The cellulosic material may be paper, cardboard, wood, textile, natural fiber, or man-made fiber.

[0187] One or more of the outer wrapper, first planar outer layer, and second planar outer layer may be an aerosol-generating substrate containing an aerosol-generating material. One or more of the outer wrapper, first planar outer layer, and second planar outer layer may include an aerosol-generating material. The aerosol-generating material may be any of the aerosol-generating materials described herein. In particular, the aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any of the aerosol-generating materials described herein. Alternatively, one or more of the outer wrapper, first planar outer layer, and second planar outer layer may be completely free of aerosol-generating material, particularly in embodiments including an aerosol-generating substrate layer, first aerosol-generating substrate layer, second aerosol-generating substrate layer, or aerosol-generating substrate positioned within a cavity. For example, one or more of the outer wrapper, first planar outer layer, and second planar outer layer may be free of tobacco. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may be substantially nicotine-free.

[0188] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may comprise a paper material. For example, one or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may be paper, cardboard, cigarette paper, or tobacco paper.

[0189] The cellulosic material may have a basis weight of greater than 10 grams per square meter. The cellulosic material may have a basis weight of greater than 20 grams per square meter. The cellulosic material may have a basis weight of less than 30 grams per square meter. The cellulosic material may have a basis weight of less than 25 grams per square meter. The cellulosic material may have a basis weight of between 10 grams per square meter and 30 grams per square meter. The cellulosic material may have a basis weight of between 15 grams per square meter and 25 grams per square meter.

[0190] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may comprise paper components and non-paper components.

[0191] One or more of the outer wrapper, first planar outer layer, and second planar outer layer may exhibit a range of permeabilities, including non-permeability. Permeability is determined using international standard test method ISO 2965:2009, and results are expressed in cubic centimeters per minute per square centimeter, referred to as "CORESTA units." One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a permeability of 1 CORESTA unit to 10 CORESTA units. One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a permeability of 1 CORESTA unit to 5 CORESTA units. One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a permeability of 5 CORESTA units to 20 CORESTA units.

[0192] One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a thickness of 25 micrometers or greater. One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a thickness of 30 micrometers or greater. One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a thickness of 35 micrometers or greater. The outer wrapper may have a thickness of 40 micrometers or greater. One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a thickness of 45 micrometers or greater.

[0193] One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a thickness of 55 micrometers or less. One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a thickness of 50 micrometers or more. One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a thickness of 45 micrometers or more. One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a thickness of 40 micrometers or more. One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a thickness of 35 micrometers or more.

[0194] One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a thickness of 25 micrometers to 55 micrometers. One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a thickness of 25 micrometers to 45 micrometers. One or more of the outer wrapper, first planar outer layer, and second planar outer layer may have a thickness of 30 micrometers to 45 micrometers.

[0195] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have substantially the same length as the length of the frame. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have substantially the same length as the length of the aerosol-generating article. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length that is 90 percent or more of the length of the frame. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length that is 95 percent or more of the length of the frame.

[0196] One or more of the first and second planar outer layers may have substantially the same width as the width of the frame. One or more of the first and second planar outer layers may have substantially the same width as the width of the aerosol-generating article. One or more of the outer wrapper, first and second planar outer layers may have a width that is 90 percent or more of the width of the frame. One or more of the outer wrapper, first and second planar outer layers may have a width that is 95 percent or more of the width of the frame.

[0197] The cavity may include a first cavity end wall and a second cavity end wall opposite the first cavity end wall. The first cavity end wall may be defined or formed by an outer wrapper, a first planar outer layer, or a first aerosol-generating substrate layer. The second cavity end wall may be defined or formed by an outer wrapper, a second planar outer layer, or a second aerosol-generating substrate layer. The cavity may be enclosed by the first cavity end wall, the second cavity end wall, and a frame.

[0198] The cavity may include an outer cavity wall. The outer cavity wall may be defined or formed by the frame. The outer cavity wall may extend transversely. The outer cavity wall may extend transversely between the first cavity end wall and the second cavity end wall. The outer cavity wall may be defined or formed by an inner frame surface. The outer cavity wall may be defined or formed by a frame peripheral wall.

[0199] The cavity may have at least two corners extending between the first and second outer planar surfaces. The at least two corners may be chamfered, rounded, or cut off. Preferably, all corners of the cavity extending between the first and second outer planar surfaces are chamfered, rounded, or cut off.

[0200] Advantageously, a cavity with chamfered, rounded or cut-off corners may make it easier to heat the cavity. In particular, it may make it easier to heat an aerosol-generating substrate positioned inside the cavity. Advantageously, a cavity with chamfered, rounded or cut-off corners may make the aerosol-generating article stronger and less susceptible to damage. Advantageously, a cavity with chamfered, rounded or cut-off corners may make it easier to manufacture the aerosol-generating article.

[0201] The cavity may have substantially the same thickness as the thickness of the frame.

[0202] The cavity may have a thickness of 30 percent or more of the thickness of the aerosol-generating article. The cavity may have a thickness of 40 percent or more of the thickness of the aerosol-generating article. The cavity may have a thickness of 50 percent or more of the thickness of the aerosol-generating article. The cavity may have a thickness of 60 percent or more of the thickness of the aerosol-generating article. The cavity may have a thickness of 70 percent or more of the thickness of the aerosol-generating article. The cavity may have a thickness of 80 percent or more of the thickness of the aerosol-generating article. The cavity may have a thickness of 90 percent or more of the thickness of the aerosol-generating article. The cavity may have a thickness of 95 percent or more of the thickness of the aerosol-generating article.

[0203] The cavity may have a thickness of 95 percent or less of the thickness of the aerosol-generating article. The cavity may have a thickness of 90 percent or less of the thickness of the aerosol-generating article. The cavity may have a thickness of 80 percent or less of the thickness of the aerosol-generating article. The cavity may have a thickness of 70 percent or less of the thickness of the aerosol-generating article.

[0204] The cavity may have a thickness between 30 percent and 95 percent of the thickness of the aerosol-generating article. The cavity may have a thickness between 40 percent and 95 percent of the thickness of the aerosol-generating article. The cavity may have a thickness between 50 percent and 90 percent of the thickness of the aerosol-generating article. The cavity may have a thickness between 60 percent and 90 percent of the thickness of the aerosol-generating article. The cavity may have a thickness between 70 percent and 90 percent of the thickness of the aerosol-generating article. The cavity may have a thickness between 80 percent and 90 percent of the thickness of the aerosol-generating article.

[0205] The cavity may have a thickness of 0.5 millimeters or more. The cavity may have a thickness of 1 millimeter or more. The cavity may have a thickness of 1.5 millimeters or more. The cavity may have a thickness of 2 millimeters or more. The cavity may have a thickness of 2.5 millimeters or more. The cavity may have a thickness of 3 millimeters or more. The cavity may have a thickness of 3.5 millimeters or more. The cavity may have a thickness of 4 millimeters or more.

[0206] The cavity may have a thickness of 4.5 millimeters or less. The cavity may have a thickness of 4 millimeters or less. The cavity may have a thickness of 3.5 millimeters or less. The cavity may have a thickness of 2.5 millimeters or less. The cavity may have a thickness of 2 millimeters or less. The cavity may have a thickness of 1.5 millimeters or less.

[0207] The cavity may have a thickness of 0.5 mm to 4.5 mm. The cavity may have a thickness of 1 mm to 4.5 mm. The cavity may have a thickness of 2 mm to 4 mm. Preferably, the cavity may have a thickness of 2.8 mm to 3.3 mm.

[0208] The cavity may have a length of 30 percent or more of the length of the aerosol-generating article. The cavity may have a length of 40 percent or more of the length of the aerosol-generating article. The cavity may have a length of 50 percent or more of the length of the aerosol-generating article. The cavity may have a length of 60 percent or more of the length of the aerosol-generating article. The cavity may have a length of 70 percent or more of the length of the aerosol-generating article. The cavity may have a length of 80 percent or more of the length of the aerosol-generating article. The cavity may have a length of 90 percent or more of the length of the aerosol-generating article.

[0209] The cavity may have a length of 95 percent or less of the length of the aerosol-generating article. The cavity may have a length of 90 percent or less of the length of the aerosol-generating article. The cavity may have a length of 80 percent or less of the length of the aerosol-generating article. The cavity may have a length of 70 percent or less of the length of the aerosol-generating article. The cavity may have a length of 60 percent or less of the length of the aerosol-generating article. The cavity may have a length of 55 percent or less of the length of the aerosol-generating article.

[0210] The cavity may have a length of 30 to 95 percent of the length of the aerosol-generating article. The cavity may have a length of 40 to 95 percent of the length of the aerosol-generating article. The cavity may have a length of 50 to 90 percent of the length of the aerosol-generating article. The cavity may have a length of 55 to 90 percent of the length of the aerosol-generating article. The cavity may have a length of 60 to 90 percent of the length of the aerosol-generating article. The cavity may have a length of 70 to 90 percent of the length of the aerosol-generating article. The cavity may have a length of 80 to 90 percent of the length of the aerosol-generating article.

[0211] The cavity may have a length of 14 millimeters or more. The cavity may have a length of 16 millimeters or more. The cavity may have a length of 18 millimeters or more. The cavity may have a length of 22 millimeters or more. The cavity may have a thickness of 26 millimeters or more. The cavity may have a thickness of 30 millimeters or more. The cavity may have a thickness of 34 millimeters or more. The cavity may have a thickness of 38 millimeters or more.

[0212] The cavity may have a length of 40 millimeters or less. The cavity may have a length of 38 millimeters or less. The cavity may have a thickness of 34 millimeters or less. The cavity may have a thickness of 30 millimeters or less. The cavity may have a thickness of 28 millimeters or less. The cavity may have a thickness of 26 millimeters or less. The cavity may have a thickness of 22 millimeters or less. The cavity may have a thickness of 18 millimeters or less.

[0213] The cavity may have a length of 14 mm to 40 mm. The cavity may have a length of 14 mm to 38 mm. The cavity may have a length of 14 mm to 34 mm. The cavity may have a length of 14 mm to 30 mm. The cavity may have a length of 16 mm to 30 mm. The cavity may have a length of 18 mm to 30 mm. The cavity may have a length of 20 mm to 30 mm. The cavity may have a length of 24 mm to 28 mm.

[0214] The cavity may have a width of 30 percent or more of the width of the aerosol-generating article. The cavity may have a width of 40 percent or more of the width of the aerosol-generating article. The cavity may have a width of 50 percent or more of the width of the aerosol-generating article. The cavity may have a width of 60 percent or more of the width of the aerosol-generating article. The cavity may have a width of 70 percent or more of the width of the aerosol-generating article. The cavity may have a width of 80 percent or more of the width of the aerosol-generating article. The cavity may have a width of 90 percent or more of the width of the aerosol-generating article.

[0215] The cavity may have a width of 95 percent or less of the width of the aerosol-generating article. The cavity may have a width of 90 percent or less of the width of the aerosol-generating article. The cavity may have a width of 80 percent or less of the width of the aerosol-generating article. The cavity may have a width of 70 percent or less of the width of the aerosol-generating article. The cavity may have a width of 60 percent or less of the width of the aerosol-generating article. The cavity may have a width of 55 percent or less of the width of the aerosol-generating article.

[0216] The cavity may have a width of 30 to 95 percent of the width of the aerosol-generating article. The cavity may have a width of 40 to 95 percent of the width of the aerosol-generating article. The cavity may have a width of 50 to 90 percent of the width of the aerosol-generating article. The cavity may have a width of 50 to 95 percent of the width of the aerosol-generating article. The cavity may have a width of 60 to 90 percent of the width of the aerosol-generating article. The cavity may have a width of 70 to 90 percent of the width of the aerosol-generating article. The cavity may have a width of 80 to 90 percent of the width of the aerosol-generating article.

[0217] The cavity may have a width of 4.5 millimeters or more. The cavity may have a width of 5 millimeters or more. The cavity may have a width of 7 millimeters or more. The cavity may have a width of 9 millimeters or more. The cavity may have a width of 11 millimeters or more.

[0218] The cavity may have a width of 13 millimeters or less. The cavity may have a width of 13 millimeters or less. The cavity may have a width of 11 millimeters or less. The cavity may have a width of 9 millimeters or less. The cavity may have a width of 7 millimeters or less. The cavity may have a width of 5 millimeters or less.

[0219] The cavity may have a width of 4.5 mm to 13 mm. The cavity may have a width of 5 mm to 13 mm. The cavity may have a width of 7 mm to 10 mm. The cavity may have a width of 7.5 mm to 8.5 mm.

[0220] The cavity may have a length between 14 mm and 40 mm, a width between 4.5 mm and 13 mm, and a thickness between 0.5 mm and 4.5 mm.

[0221] Preferably, the cavity may have a length of 20 to 30 millimeters, a width of 7 to 10 millimeters, and a thickness of 2.5 to 4 millimeters.

[0222] Most preferably, the cavity may have a length of 26 millimeters, a width of 8 millimeters, and a thickness of 3.1 millimeters.

[0223] The cavity may have a volume of 30 cubic millimeters or more. The cavity may have a volume of 100 cubic millimeters or more. The cavity may have a volume of 200 cubic millimeters or more. The cavity may have a volume of 300 cubic millimeters or more. The cavity may have a volume of 400 cubic millimeters or more. The cavity may have a volume of 500 cubic millimeters or more. The cavity may have a volume of 600 cubic millimeters or more. The cavity may have a volume of 700 cubic millimeters or more. The cavity may have a volume of 800 cubic millimeters or more. The cavity may have a volume of 900 cubic millimeters or more. The cavity may have a volume of 1000 cubic millimeters or more. The cavity may have a volume of 1500 cubic millimeters or more. The cavity may have a volume of 2000 cubic millimeters or more. The cavity may have a volume of 2500 cubic millimeters or more. The cavity may have a volume of 3000 cubic millimeters or more.

[0224] The cavity may have a volume of 3500 cubic millimeters or less. The cavity may have a volume of 3000 cubic millimeters or less. The cavity may have a volume of 2500 cubic millimeters or less. The cavity may have a volume of 2000 cubic millimeters or less. The cavity may have a volume of 1500 cubic millimeters or less. The cavity may have a volume of 1000 cubic millimeters or less. The cavity may have a volume of 900 cubic millimeters or less. The cavity may have a volume of 800 cubic millimeters or less. The cavity may have a volume of 700 cubic millimeters or less. The cavity may have a volume of 600 cubic millimeters or less. The cavity may have a volume of 500 cubic millimeters or less. The cavity may have a volume of 400 cubic millimeters or less. The cavity may have a volume of 300 cubic millimeters or less.

[0225] The cavity may have a volume of 30 cubic millimeters to 3000 cubic millimeters. The cavity may have a volume of 30 cubic millimeters to 3000 cubic millimeters. The cavity may have a volume of 30 cubic millimeters to 2500 cubic millimeters. The cavity may have a volume of 30 cubic millimeters to 2350 cubic millimeters. The cavity may have a volume of 100 cubic millimeters to 2000 cubic millimeters. The cavity may have a volume of 100 cubic millimeters to 1500 cubic millimeters. The cavity may have a volume of 250 cubic millimeters to 1150 cubic millimeters. The cavity may have a volume of 100 cubic millimeters to 1000 cubic millimeters. The cavity may have a volume of 100 cubic millimeters to 900 cubic millimeters. The cavity may have a volume of 200 cubic millimeters to 800 cubic millimeters. Preferably, the cavity may have a volume of 300 to 700 cubic millimeters. The cavity may have a volume of 400 to 700 cubic millimeters. The cavity may have a volume of 500 to 700 cubic millimeters.

[0226] The cavity may have a volume of 1 percent or more of the external volume of the aerosol-generating article. The cavity may have a volume of 5 percent or more of the external volume of the aerosol-generating article. The cavity may have a volume of 1 percent or more of the external volume of the aerosol-generating article.

[0227] The cavity may have a volume that is 90 percent or less of the external volume of the aerosol-generating article. The cavity may have a volume that is 80 percent or less of the external volume of the aerosol-generating article. The cavity may have a volume that is 70 percent or less of the external volume of the aerosol-generating article.

[0228] The cavity may have a volume of between 1 percent and 90 percent of the external volume of the aerosol-generating article. The cavity may have a volume of between 5 percent and 80 percent of the external volume of the aerosol-generating article. The cavity may have a volume of between 10 percent and 70 percent of the external volume of the aerosol-generating article.

[0229] The cavity may be a first cavity. The aerosol-generating article may comprise a second cavity. The second cavity may be positioned between the first and second planar outer surfaces. The second cavity may have any of the features described in relation to the first cavity.

[0230] The frame may at least partially define or form a second cavity.

[0231] The frame may include a frame first opening extending through a thickness of the frame. The frame first opening may at least partially define or form a first cavity. The frame may define a frame second opening extending through a thickness of the frame. The frame second opening may at least partially define or form a second cavity.

[0232] The peripheral wall of the frame may comprise a frame first inner surface and a frame second inner surface, the frame first inner surface may define or form an outer wall of the first cavity, and the frame second inner surface may define or form an outer wall of the second cavity.

[0233] The frame may include a partition wall separating the first cavity from the second cavity. The partition wall may define or form an opening. The opening may extend from the first cavity to the second cavity. The opening may define or form at least a portion of an air flow passage between the air inlet and the air outlet.

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

[0235] The first and second planar outer layers may be on opposite ends of a first cavity. The first and second planar outer layers may be on opposite ends of a second cavity. The first and second planar outer layers may define or form opposite end walls of the first cavity. The first and second planar outer layers may define or form opposite end walls of a second cavity. That is, the frame, the first and second planar outer layers may collectively define a first cavity and a second cavity.

[0236] The first and second aerosol-generating substrate layers may be on opposite ends of a first cavity. The first and second aerosol-generating substrate layers may be on opposite ends of a second cavity. The first and second aerosol-generating substrate layers may define or form opposite end walls of the first cavity. The first and second aerosol-generating substrate layers may define or form opposite end walls of the second cavity. That is, the frame, the first and second aerosol-generating substrate layers may collectively define a first cavity and a second cavity.

[0237] The cavity, or the first cavity, may be substantially empty. The second cavity may be substantially empty.

[0238] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate positioned within a cavity. The aerosol-generating substrate positioned within a cavity may fill the cavity. Advantageously, providing an aerosol-generating substrate that fills the cavity allows the aerosol-generating substrate to provide mechanical support to the first and second outer planar surfaces. By providing additional mechanical support to the first and second outer planar surfaces, the rigidity of the aerosol-generating article may be improved.

[0239] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate positioned within the first cavity. The aerosol-generating substrate positioned within the cavity may fill the first cavity.

[0240] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate positioned within the second cavity.

[0241] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may include an aerosol-generating material. The aerosol-generating material may be any of the aerosol-generating materials described herein. For example, the aerosol-generating material may be in the form of shredded aerosol-generating material.

[0242] The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. For example, the sheet of aerosol-generating material may be a sheet of homogenized tobacco material.

[0243] The sheet of aerosol-generating material may extend across the entire length of the cavity, the first cavity, or the second cavity. The sheet of aerosol-generating material may extend across the entire width of the cavity, the first cavity, or the second cavity.

[0244] The sheet of aerosol-generating material may be an assembly of sheets of aerosol-generating material, i.e., the sheet of aerosol-generating material may be folded, folded, or otherwise compressed or contracted substantially perpendicular to the transverse direction of the aerosol-generating article.

[0245] The sheet of aerosol-generating material may be a crimped sheet of aerosol-generating material. The sheet of aerosol-generating material may be a corrugated sheet of aerosol-generating material. The crimped sheet of aerosol-generating material or the corrugated sheet of aerosol-generating material may comprise a plurality of parallel corrugations. For example, the crimped sheet of aerosol-generating material may comprise a plurality of substantially parallel peaks and valleys.

[0246] The plurality of parallel corrugations may be defined by a corrugation profile, where the corrugation profile may be sinusoidal, triangular, rectangular, trapezoidal, toroidal, or parabolic. The plurality of parallel corrugations may be defined by a corrugation wavelength and a corrugation amplitude. The corrugation wavelength may be 0.5 mm to 10 mm, for example, 1 mm to 10 mm, for example, 1.5 mm to 8 mm, for example, 2 mm to 6 mm, for example, 2.5 mm to 5 mm, or for example, 3 mm to 4 mm. The corrugation amplitude may be approximately the same as the thickness of the cavity.

[0247] The parallel corrugations may define or form channels between the sheet of aerosol-generating material and one or more walls of the cavity, the first cavity, and the second cavity. The channels may be longitudinally extending channels, i.e., the channels may extend in the longitudinal direction of the aerosol-generating article. The channels may be transversely extending channels, i.e., the channels may extend in the transverse direction of the aerosol-generating article. The channels may define or form at least a portion of an airflow passage extending between the air inlet and the air outlet of the aerosol-generating article.

[0248] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.05 milligrams per cubic millimeter or greater. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.1 milligrams per cubic millimeter or greater. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.15 milligrams per cubic millimeter or greater. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.2 milligrams per cubic millimeter or greater. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.3 milligrams per cubic millimeter or greater. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.4 milligrams per cubic millimeter or greater.

[0249] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.5 milligrams per cubic millimeter or less. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.4 milligrams per cubic millimeter or less. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.35 milligrams per cubic millimeter or less. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.3 milligrams per cubic millimeter or less.

[0250] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.05 milligrams per cubic millimeter to 0.5 milligrams per cubic millimeter. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.1 milligrams per cubic millimeter to 0.4 milligrams per cubic millimeter. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.1 milligrams per cubic millimeter to 0.3 milligrams per cubic millimeter. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a bulk density of 0.2 milligrams per cubic millimeter to 0.3 milligrams per cubic millimeter.

[0251] The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.3 or greater. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.4 or greater. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.5 or greater. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.6 or greater. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.7 or greater.

[0252] The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.9 or less. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.8 or less. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.7 or less. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.6 or less. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.5 or less.

[0253] The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.3 to 0.9. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.4 to 0.9. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.5 to 0.9. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.5 to 0.8. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a packed density of 0.5 to 0.7.

[0254] Advantageously, providing an aerosol-generating substrate with a high packing density within the cavity may provide mechanical support for the first and second outer planar surfaces. Providing additional mechanical support for the first and second outer planar surfaces may improve the rigidity of the aerosol-generating article. However, too high a packing density may restrict airflow through the aerosol-generating article and may provide unsatisfactory resistance to withdrawal of the aerosol-generating article.

[0255] Advantageously, by providing an aerosol-generating substrate within the cavity having a packing density of 0.3 or greater, thermal conductivity through the aerosol-generating substrate may be enhanced. Increasing thermal conductivity through the aerosol-generating substrate may reduce the time required to generate an aerosol.

[0256] Advantageously, providing an aerosol-generating substrate having a packing density of 0.9 grams per cubic centimeter or less positioned within the cavity may promote the formation of air flow channels within the aerosol-generating substrate during use of the aerosol-generating article. Increasing the air flow channels within the aerosol-generating substrate may improve evaporation of the aerosol-generating substrate. Increasing the air flow channels within the aerosol-generating substrate may also provide satisfactory withdrawal resistance.

[0257] Advantageously, providing an aerosol-generating substrate positioned within the cavity with a pack density of 0.9 grams per cubic centimeter or less may reduce the likelihood of the aerosol-generating substrate being compressed, which could increase the power required to heat the aerosol-generating substrate to a temperature sufficient to cause vaporization.

[0258] Thus, pack 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, promoting air flow channels within the aerosol-generating substrate, and providing satisfactory resistance to withdrawal of the aerosol-generating article.

[0259] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume of 150 cubic millimeters or more. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume of 200 cubic millimeters or more. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume of 250 cubic millimeters or more. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume of 350 cubic millimeters or more.

[0260] The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume of 1000 cubic millimeters or less. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume of 900 cubic millimeters or less. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume of 800 cubic millimeters or less. The aerosol-generating substrate positioned within the cavity, the first cavity, or the second cavity may have a volume of 700 cubic millimeters or less.

[0261] The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a volume of 100 cubic millimeters to 1000 cubic millimeters. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a volume of 200 cubic millimeters to 1000 cubic millimeters. The aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity may have a volume of 350 cubic millimeters to 650 cubic millimeters.

[0262] At least one of the one or more aerosol-generating substrates may have a density of 0.05 gram per cubic centimeter or more. At least one of the one or more aerosol-generating substrates may have a density of 0.1 gram per cubic centimeter or more. At least one of the one or more aerosol-generating substrates may have a density of 0.2 gram per cubic centimeter or more. At least one of the one or more aerosol-generating substrates may have a density of 0.3 gram per cubic centimeter or more. At least one of the one or more aerosol-generating substrates may have a density of 0.4 gram per cubic centimeter or more.

[0263] At least one of the one or more aerosol-generating substrates may have a density of 0.9 gram per cubic centimeter or less. At least one of the one or more aerosol-generating substrates may have a density of 0.8 gram per cubic centimeter or less. At least one of the one or more aerosol-generating substrates may have a density of 0.7 gram per cubic centimeter or less. At least one of the one or more aerosol-generating substrates may have a density of 0.6 gram per cubic centimeter or less. At least one of the one or more aerosol-generating substrates may have a density of 0.5 gram per cubic centimeter or less. At least one of the one or more aerosol-generating substrates may have a density of 0.4 gram per cubic centimeter or less. At least one of the one or more aerosol-generating substrates may have a density of 0.3 gram per cubic centimeter or less.

[0264] At least one of the one or more aerosol-generating substrates may have a density of 0.05 to 0.9 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates may have a density of 0.05 to 0.9 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates may have a density of 0.1 to 0.8 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates may have a density of 0.2 to 0.7 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates may have a density of 0.2 to 0.6 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates may have a density of 0.2 to 0.5 grams per cubic centimeter. At least one of the one or more aerosol-generating substrates may have a density of 0.2 to 0.4 grams per cubic centimeter.

[0265] At least one of the one or more aerosol-generating substrates referred to above in terms of density may be an aerosol-generating substrate layer, a first aerosol-generating substrate layer, a second aerosol-generating substrate layer, an aerosol-generating substrate positioned within a cavity or first cavity, or an aerosol-generating substrate positioned with a second cavity, or at least one of these. Preferably, at least one of the one or more aerosol-generating substrates referred to above in terms of density may be an aerosol-generating substrate positioned within a cavity or first cavity, or an aerosol-generating substrate positioned with a second cavity, or at least one of these.

[0266] The aerosol-generating substrate of an aerosol-generating article typically has a high density to facilitate heat conduction through the aerosol-generating substrate.

[0267] Advantageously, providing an aerosol-generating article with an aerosol-generating substrate having a relatively low density of 0.9 grams per cubic centimeter or less may enable the aerosol-generating article to include an aerosol-generating article of reduced mass. Reducing the mass of the aerosol-generating substrate may make the aerosol-generating article easier to handle and may also make it easier to manufacture.

[0268] Advantageously, by providing a low-density aerosol-generating substrate within 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 and second planar outer surfaces, efficient heating of the aerosol-generating substrate may be enabled while still providing the advantages of a low-density aerosol-generating substrate described above.

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

[0270] At least one of the one or more aerosol-generating substrates may have a mass of 500 milligrams or less. At least one of the one or more aerosol-generating substrates may have a mass of 400 milligrams or less. At least one of the one or more aerosol-generating substrates may have a mass of 300 milligrams or less. At least one of the one or more aerosol-generating substrates may have a mass of 250 milligrams or less. At least one of the one or more aerosol-generating substrates may have a mass of 230 milligrams or less. At least one of the one or more aerosol-generating substrates may have a mass of 200 milligrams or less. At least one of the one or more aerosol-generating substrates may have a mass of 180 milligrams or less. At least one of the one or more aerosol-generating substrates may have a mass of 170 milligrams or less. At least one of the one or more aerosol-generating substrates may have a mass of 150 milligrams or less. At least one of the one or more aerosol-generating substrates may have a mass of 110 milligrams or less. At least one of the one or more aerosol-generating substrates may have a mass of 80 milligrams or less. At least one of the one or more aerosol-generating substrates may have a mass of 50 milligrams or less.

[0271] At least one of the one or more aerosol-generating substrates may have a mass of 50 milligrams to 500 milligrams. At least one of the one or more aerosol-generating substrates may have a mass of 80 milligrams to 500 milligrams. At least one of the one or more aerosol-generating substrates may have a mass of 80 milligrams to 400 milligrams. At least one of the one or more aerosol-generating substrates may have a mass of 80 milligrams to 300 milligrams. At least one of the one or more aerosol-generating substrates may have a mass of 80 milligrams to 250 milligrams. At least one of the one or more aerosol-generating substrates may have a mass of 80 milligrams to 200 milligrams. At least one of the one or more aerosol-generating substrates may have a mass of 80 milligrams to 150 milligrams.

[0272] At least one of the one or more aerosol-generating substrates referred to above in terms of mass may be an aerosol-generating substrate layer, a first aerosol-generating substrate layer, a second aerosol-generating substrate layer, an aerosol-generating substrate positioned within a cavity or first cavity, or an aerosol-generating substrate positioned with a second cavity, or at least one of these. Preferably, at least one of the one or more aerosol-generating substrates referred to above in terms of mass may be an aerosol-generating substrate positioned within a cavity or first cavity, or an aerosol-generating substrate positioned with a second cavity, or at least one of these.

[0273] Advantageously, by providing an aerosol-generating article with an aerosol-generating substrate weighing 500 milligrams or less, the amount of structural support that needs to be provided to the aerosol-generating article may be reduced.

[0274] Advantageously, providing an aerosol-generating article with 50 milligrams or more of aerosol-generating substrate may allow the aerosol-generating substrate to provide some structural support to the aerosol-generating article.

[0275] Advantageously, providing an aerosol-generating article with a low mass of aerosol-generating substrate may result in better heating efficiency due to the relatively small mass of the aerosol-generating substrate to be heated. A relatively small mass of the aerosol-generating substrate is particularly advantageous during the first puff using the aerosol-generating article, as the first puff can be achieved much faster than when using an aerosol-generating article with a larger mass of aerosol-generating substrate.

[0276] Advantageously, by providing an aerosol-generating article with a low mass of aerosol-generating substrate, the total moisture content of the aerosol-generating substrate may be reduced, which may reduce the temperature of the first puff.

[0277] The length of the aerosol-generating article may be defined in the x-direction between the distal and proximal ends of the aerosol-generating article. The aerosol-generating article may be divided into a distal end portion and a proximal end portion along its length. The distal end portion may extend from the distal end for 50% of the length of the aerosol-generating article, and the proximal end portion may extend from the proximal end for 50% of the length of the aerosol-generating article.

[0278] The ratio of the mass of the one or more aerosol-generating substrates in the proximal end portion to the mass of the one or more aerosol-generating substrates in the distal end portion may be in the range 0.77 to 1.30.

[0279] The ratio of the mass of the one or more aerosol-generating substrates in the proximal end portion to the mass of the one or more aerosol-generating substrates in the distal end portion may 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.

[0280] The mass distribution of the one or more aerosol-generating substrates within the proximal end portion in the length direction of the proximal end portion may be symmetrical to the mass distribution of the one or more aerosol-generating substrates within the distal end portion in the length direction of the distal end portion relative to the midpoint of the length of the aerosol-generating article.

[0281] The one or more aerosol-generating substrates within the proximal end portion may be disposed across the width of the proximal end portion in first and second halves of the width of the proximal end portion, in which case the ratio of the mass of the one or more aerosol-generating substrates in the first half of the width of the proximal end portion to the mass of the aerosol-forming substrates in the second half of the width of the proximal end portion may be in the range 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 within the distal end portion may be disposed across the width of the distal end portion in first and second halves of the width of the distal end portion, and the ratio of the mass of the one or more aerosol-generating substrates in the first half of the width of the distal end portion to the mass of the one or more aerosol-generating substrates in the second half of the width of the distal end portion may be in the range 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 proximal end portion may be disposed across the height of the proximal end portion in first and second halves of the height of the proximal end portion, and the ratio of the mass of the one or more aerosol-generating substrates in the first half of the height of the proximal end portion to the mass of the one or more aerosol-generating substrates in the second half of the height of the proximal end portion may be in the range 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.

[0284] The one or more aerosol-generating substrates in the distal end portion may be disposed across the height of the distal end portion in first and second halves of the height of the distal end portion, and the ratio of the mass of the one or more aerosol-generating substrates in the first half of the height of the distal end portion to the mass of the one or more aerosol-generating substrates in the second half of the height of the distal end portion may be in the range 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.

[0285] The configuration of the proximal end portion may be symmetrical to the configuration of the distal end portion about the midpoint of the length of the aerosol-generating article.

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

[0287] The aerosol-generating article may comprise an outer wrapper, a frame, and an aerosol-generating substrate as described herein positioned within the cavity.

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

[0289] The aerosol-generating article may comprise an outer wrapper, a frame, and an aerosol-generating substrate layer. The cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the cavity.

[0290] The aerosol-generating article may comprise an outer wrapper, a first cavity, a second cavity, and an aerosol-generating substrate layer. The first cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the first cavity. The second cavity may be empty, or an aerosol-generating substrate as described herein may be positioned within the second cavity.

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

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

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

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

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

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

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

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

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

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

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

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

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

[0304] The aerosol-generating material may include one or more organic materials such as tobacco, mint, tea, and cloves. The aerosol-generating material may include one or more of herbal leaves, tobacco leaf, tobacco vein fragments, reconstituted tobacco, homogenized tobacco such as cast tobacco, extruded tobacco, expanded tobacco, aerosol-generating films, and gel compositions.

[0305] The aerosol-generating material may be in the form of shredded aerosol-generating material. The shredded aerosol-generating material may include one or more of strips and strands of aerosol-generating material, such as strips and strands of tobacco material or homogenized tobacco material. The shredded aerosol-generating material may be in the form of shredded sheets of homogenized tobacco material.

[0306] The aerosol-generating material may be cut filler. The aerosol-generating material may be tobacco cut filler. The cut filler may include one or more of bright tobacco, dark tobacco, aromatic tobacco, and filler tobacco. Examples of bright tobacco include Brazilian full-cured, Indian full-cured, Chinese full-cured, American full-cured tobacco such as Virginia tobacco, and Tanzanian full-cured. Examples of aromatic tobacco include Oriental Turkish, Greek Oriental, and Semi-Oriental tobacco, as well as fire-cured, US burley such as Perique, and rustica. Examples of dark tobacco include dark-cured Brazilian Galpao, Malawi or other African burley, and sun-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, among other things, leaf flakes, processed stems and veins, and homogenized plant material.

[0307] The cut filler suitable for use with the present invention may generally be similar to the cut filler used in conventional smoking articles. The cut width of the cut filler may preferably be 0.3 mm to 2.0 mm, or 0.5 mm to 1.2 mm, or 0.6 mm to 0.9 mm. Preferably, the strands have a length of about 10 mm to about 40 mm.

[0308] Preferably, the cut filler is impregnated with an aerosol former. The impregnation of the cut filler can be achieved by spraying or other suitable application methods. Preferably, the aerosol former in the cut filler comprises one or more of glycerol and propylene glycol. The aerosol former may be comprised of glycerol or propylene glycol, or a combination of glycerol and propylene glycol.

[0309] The aerosol-generating material may comprise homogenized plant material, and preferably, homogenized tobacco material.

[0310] As used herein, the term "homogenized plant material" includes any plant material formed by agglomeration of plant particles. For example, a sheet or web of homogenized tobacco material for an aerosol-generating substrate of the present invention may be formed by agglomerating particles of tobacco material obtained by crushing, grinding, or milling the plant material and, optionally, one or more of tobacco lamellae and tobacco stems. Homogenized plant material may be produced by casting, extrusion, a papermaking process, or any other suitable process known in the art.

[0311] The homogenized plant material may be in the form of one or more sheets.

[0312] The homogenized plant material may be in the form of a plurality of pellets or granules.

[0313] The homogenized plant material may be in the form of a plurality of strands, pieces, or shreds. As used herein, the term "strand" describes an elongated element of material having a length substantially greater than its width and thickness.

[0314] The aerosol-generating material may be in the form of a sheet of aerosol-generating material. As used herein, the term "sheet" describes a layered element having a width and length that are substantially greater than its thickness. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenized tobacco material, such as a cast leaf sheet.

[0315] The sheet of aerosol-generating material may have a basis weight of 100 grams per square meter to 600 grams per square meter.The sheet of aerosol-generating material may have a basis weight of 100 grams per square meter to 300 grams per square meter.

[0316] The sheet of aerosol-generating material may have a density of 0.3 grams per cubic centimeter or more. The sheet of aerosol-generating material may have a density of 0.4 grams per cubic centimeter or more. The sheet of aerosol-generating material may have a density of 0.5 grams per cubic centimeter or more. The sheet of aerosol-generating material may have a density of 0.6 grams per cubic centimeter or more. The sheet of aerosol-generating material may have a density of 0.7 grams per cubic centimeter or more. The sheet of aerosol-generating material may have a density of 0.8 grams per cubic centimeter or less.

[0317] The sheet of aerosol-generating material may have a density of 1.0 grams per cubic centimeter or less. The sheet of aerosol-generating material may have a density of 0.9 grams per cubic centimeter or less. The sheet of aerosol-generating material may have a density of 0.8 grams per cubic centimeter or less. The sheet of aerosol-generating material may have a density of 0.7 grams per cubic centimeter or less. The sheet of aerosol-generating material may have a density of 0.6 grams per cubic centimeter or less. The sheet of aerosol-generating material may have a density of 0.5 grams per cubic centimeter or less. The sheet of aerosol-generating material may have a density of 0.4 grams per cubic centimeter or less.

[0318] The sheet of aerosol-generating material may have a density of 0.3 grams per cubic centimeter to 1.3 grams per cubic centimeter. The sheet of aerosol-generating material may have a density of 0.3 grams per cubic centimeter to 1.0 grams per cubic centimeter. The sheet of aerosol-generating material may have a density of 0.4 grams per cubic centimeter to 1.0 grams per cubic centimeter. The sheet of aerosol-generating material may have a density of 0.4 grams per cubic centimeter to 0.9 grams per cubic centimeter. The sheet of aerosol-generating material may have a density of 0.5 grams per cubic centimeter to 0.9 grams per cubic centimeter.

[0319] The sheet of aerosol-generating material may contain 2.5 to 95 percent by weight of plant particles on a dry weight basis. The sheet of aerosol-generating material may contain 5 to 90 percent by weight of plant particles on a dry weight basis. The sheet of aerosol-generating material may contain 10 to 80 percent by weight of plant particles on a dry weight basis. The sheet of aerosol-generating material may contain 15 to 70 percent by weight of plant particles on a dry weight basis. The sheet of aerosol-generating material may contain 20 to 60 percent by weight of plant particles on a dry weight basis. The sheet of aerosol-generating material may contain 30 to 50 percent by weight of plant particles on a dry weight basis.

[0320] The sheet of aerosol-generating material may be a sheet of homogenized tobacco material comprising tobacco particles. The sheet of homogenized tobacco material may have a tobacco content of at least about 40 percent by weight on a dry weight basis. The sheet of homogenized tobacco material may have a tobacco content of at least about 50 percent by weight on a dry weight basis. The sheet of homogenized tobacco material may have a tobacco content of at least about 70 percent by weight on a dry weight basis. The sheet of homogenized tobacco material may have a tobacco content of at least about 90 percent by weight on a dry weight basis.

[0321] As used herein, the term "tobacco particles" may describe particles of any plant member of the genus Nicotiana. The term "tobacco particles" encompasses crushed or powdered tobacco flakes, crushed or powdered tobacco stems, tobacco powder, tobacco fines, and other particulate tobacco by-products formed during tobacco processing, handling, and shipping. In preferred embodiments, the tobacco particles are derived substantially entirely from tobacco flakes. In contrast, isolated nicotine and nicotine salts, although tobacco-derived compounds, are not considered tobacco particles for purposes of this disclosure and are not included in the proportion of particulate plant material.

[0322] The tobacco particles may be prepared from one or more varieties of tobacco plants. Any type of tobacco may be used in the blend. Examples of tobacco that may 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.

[0323] Flame-curing is a tobacco-curing method, particularly used for Virginia tobacco. In the flue-curing process, heated air is circulated through densely packed tobacco. In the first stage, the tobacco leaves yellow and wither. In the second stage, the leaf flakes dry completely. In the third stage, the leaf stems dry completely.

[0324] Burley tobacco plays an important role in many tobacco blends. Burley tobacco has a unique flavor and aroma, and also has the ability to absorb large amounts of casing.

[0325] Orient tobacco is a small-leaf, highly aromatic type of tobacco. However, Orient tobacco has a milder flavor compared to, for example, Burley. Therefore, Orient tobacco is typically used in a relatively small proportion in tobacco blends.

[0326] Kasturi, Madura, and Jatim are subspecies of sun-cured tobacco that may be used. Preferably, Kasturi tobacco and flue-cured tobacco are used in a blend to produce tobacco particles. Thus, the tobacco particles in the particulate plant material may comprise a blend of Kasturi tobacco and flue-cured tobacco.

[0327] The tobacco particles may have a nicotine content of at least about 2.5 weight percent based on dry weight. More preferably, the tobacco particles may have a nicotine content of at least about 3 weight percent based on dry weight, even more preferably at least about 3.2 weight percent, even more preferably at least about 3.5 weight percent, and most preferably at least about 4 weight percent.

[0328] The aerosol-generating material may contain one or more cannabinoid compounds, such as one or more of tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannabivarin (CBV), cannabidivarin (CBDV), tetrahydrocannabivarin (THCV), cannabichromene (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), and cannabicitran (CBT). It may be preferred that the cannabinoid compound is CBD or THC. It may be particularly preferred that the cannabinoid compound is CBD.

[0329] The aerosol-generating material may comprise one or more aerosol formers. Suitable aerosol formers are well known in the art and include, but are not limited to, one or more aerosol formers selected from polyhydric alcohols such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols such as glycerol monoacetate, glycerol diacetate, or glycerol triacetate; and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferred for the aerosol former to be or include one or both of glycerin and propylene glycol. The aerosol former may be composed of glycerin, propylene glycol, or a combination of glycerin and propylene glycol.

[0330] The aerosol-generating material may have an aerosol former content of 1 weight percent or more, 2 weight percent or more, 5 weight percent or more, 10 weight percent or more, or 15 weight percent or more on a dry weight basis. The aerosol-generating material may have an aerosol former content of 15 weight percent or more on a dry weight basis, such as 20 weight percent or more on a dry weight basis, or 25 weight percent or more on a dry weight basis, or 30 weight percent or more on a dry weight basis, or 40 weight percent or more on a dry weight basis, or 50 weight percent or more on a dry weight basis.

[0331] The aerosol-generating material may have an aerosol former content of 30 weight percent or less on a dry weight basis, 25 weight percent or less on a dry weight basis, or 20 weight percent or less on a dry weight basis. That is, the aerosol-generating material may have an aerosol former content of 30 weight percent or less on a dry weight basis, 25 weight percent or less on a dry weight basis, or 20 weight percent or less on a dry weight basis.

[0332] The aerosol-generating material may have an aerosol former content of from 1 weight percent to 30 weight percent on a dry weight basis, from 1 weight percent to 25 weight percent on a dry weight basis, or from 1 weight percent to 20 weight percent on a dry weight basis.

[0333] The aerosol-generating material may have an aerosol former content of from 5 weight percent to 30 weight percent on a dry weight basis, from 5 weight percent to 25 weight percent on a dry weight basis, or from 5 weight percent to 20 weight percent on a dry weight basis.

[0334] The aerosol-generating material may have an aerosol former content of from 10 weight percent to 30 weight percent on a dry weight basis, from 10 weight percent to 25 weight percent on a dry weight basis, or from 10 weight percent to 20 weight percent on a dry weight basis.

[0335] The aerosol-generating material may have an aerosol former content of from 15 weight percent to 30 weight percent on a dry weight basis, from 15 weight percent to 25 weight percent on a dry weight basis, or from 15 weight percent to 20 weight percent on a dry weight basis.

[0336] The aerosol-generating material may 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 may have an aerosol former content of 85 weight percent or less on a dry weight basis, 80 weight percent or less on a dry weight basis, or 75 weight percent or less on a dry weight basis.

[0338] The aerosol-generating material may have an aerosol former content of 50 to 85 weight percent on a dry weight basis, 50 to 80 weight percent on a dry weight basis, or 50 to 75 weight percent on a dry weight basis.

[0339] The aerosol-generating material may have an aerosol former content of 60 to 85 weight percent on a dry weight basis, 60 to 80 weight percent on a dry weight basis, or 60 to 75 weight percent on a dry weight basis.

[0340] The aerosol-generating material may have an aerosol former content of 70 to 85 weight percent on a dry weight basis, 70 to 80 weight percent on a dry weight basis, or 70 to 75 weight percent on a dry weight basis.

[0341] The aerosol-generating material may include hydroxypropyl methylcellulose.

[0342] Advantageously, including hydroxypropyl methylcellulose in the aerosol-generating material may help improve the manufacturing process of the aerosol-generating material. For example, hydroxypropyl methylcellulose may reduce the overall viscosity of the slurry mixed to make the aerosol-generating material. A low-viscosity slurry may flow more easily than a conventional slurry, making it easier to mix, transport, and handle during the manufacturing process.

[0343] The aerosol-generating material may have a hydroxypropyl methylcellulose content of 0.5 weight percent or greater. The aerosol-generating material may have a hydroxypropyl methylcellulose content of 1 weight percent or greater. The aerosol-generating material may have a hydroxypropyl methylcellulose content of 5 weight percent or greater. The aerosol-generating material may have a hydroxypropyl methylcellulose content of 10 weight percent or greater. The aerosol-generating material may have a hydroxypropyl methylcellulose content of 15 weight percent or greater. The aerosol-generating material may have a hydroxypropyl methylcellulose content of 20 weight percent or greater.

[0344] The aerosol-generating material may have a hydroxypropyl methylcellulose content of 50 percent by weight or less. The aerosol-generating material may have a hydroxypropyl methylcellulose content of 45 percent by weight or less. The aerosol-generating material may have a hydroxypropyl methylcellulose content of 40 percent by weight or less. The aerosol-generating material may have a hydroxypropyl methylcellulose content of 35 percent by weight or less. The aerosol-generating material may have a hydroxypropyl methylcellulose content of 30 percent by weight or less. The aerosol-generating material may have a hydroxypropyl methylcellulose content of 25 percent by weight or less. The aerosol-generating material may have a hydroxypropyl methylcellulose content of 20 percent by weight or less.

[0345] The aerosol-generating material may have a hydroxypropyl methylcellulose content of 0.5 weight percent to 50 weight percent.

[0346] The aerosol-generating material may include one or more cellulosic reinforcing agents. Advantageously, including a cellulosic reinforcing agent in the aerosol-generating material may increase the tensile strength of the aerosol-generating material. Aerosol-generating materials with greater tensile strength may be less likely to deteriorate or break, for example, during shipping or the manufacturing process.

[0347] The aerosol-generating material may have a cellulosic strengthening agent content of 0.5 weight percent or greater. The aerosol-generating material may have a cellulosic strengthening agent content of 1 weight percent or greater. The aerosol-generating material may have a cellulosic strengthening agent content of 0.5 weight percent or greater. The aerosol-generating material may have a cellulosic strengthening agent content of 5 weight percent or greater. The aerosol-generating material may have a cellulosic strengthening agent content of 10 weight percent or greater. The aerosol-generating material may have a cellulosic strengthening agent content of 15 weight percent or greater. The aerosol-generating material may have a cellulosic strengthening agent content of 20 weight percent or greater.

[0348] The aerosol-generating material may have a cellulosic strengthening agent content of 50 percent by weight or less. The aerosol-generating material may have a cellulosic strengthening agent content of 45 percent by weight or less. The aerosol-generating material may have a cellulosic strengthening agent content of 40 percent by weight or less. The aerosol-generating material may have a cellulosic strengthening agent content of 35 percent by weight or less. The aerosol-generating material may have a cellulosic strengthening agent content of 30 percent by weight or less. The aerosol-generating material may have a cellulosic strengthening agent content of 25 percent by weight or less.

[0349] The aerosol-generating material may have a cellulosic strengthening agent content of 0.5 to 50 percent by weight.The aerosol-generating material may have a cellulosic strengthening agent content of 0.5 to 40 percent by weight.

[0350] The one or more cellulosic reinforcing agents may comprise cellulose fibers. Advantageously, the inventors have found that cellulose fibers can be a particularly effective cellulosic reinforcing agent for increasing the tensile strength of the aerosol-generating material.

[0351] The aerosol-generating material may have a cellulose fiber content of 0.5 percent by weight or greater. The aerosol-generating material may have a cellulose fiber content of 1 percent by weight or greater. The aerosol-generating material may have a cellulose fiber content of 5 percent by weight or greater. The aerosol-generating material may have a cellulose fiber content of 10 percent by weight or greater. The aerosol-generating material may have a cellulose fiber content of 15 percent by weight or greater. The aerosol-generating material may have a cellulose fiber content of 20 percent by weight or greater.

[0352] The aerosol-generating material may have a cellulose fiber content of 50 percent by weight or less. The aerosol-generating material may have a cellulose fiber content of 45 percent by weight or less. The aerosol-generating material may have a cellulose fiber content of 40 percent by weight or less. The aerosol-generating material may have a cellulose fiber content of 35 percent by weight or less. The aerosol-generating material may have a cellulose fiber content of 30 percent by weight or less. The aerosol-generating material may have a cellulose fiber content of 25 percent by weight or less.

[0353] The aerosol-generating material may have a cellulose fiber content of 0.5 to 50 percent by weight.The aerosol-generating material may have a cellulose fiber content of 0.5 to 40 percent by weight.

[0354] The one or more cellulosic strengthening agents may include microcrystalline cellulose. Advantageously, the inventors have found that microcrystalline cellulose can be a particularly effective cellulosic strengthening agent for increasing the tensile strength of the aerosol-generating material.

[0355] The aerosol-generating material may have a microcrystalline cellulose content of 0.5 weight percent or more. The aerosol-generating material may have a microcrystalline cellulose content of 1 weight percent or more. The aerosol-generating material may have a microcrystalline cellulose content of 5 weight percent or more. The aerosol-generating material may have a microcrystalline cellulose content of 10 weight percent or more. The aerosol-generating material may have a microcrystalline cellulose content of 15 weight percent or more. The aerosol-generating material may have a microcrystalline cellulose content of 20 weight percent or more.

[0356] The aerosol-generating material may have a microcrystalline cellulose content of 50 percent by weight or less. The aerosol-generating material may have a microcrystalline cellulose content of 45 percent by weight or less. The aerosol-generating material may have a microcrystalline cellulose content of 40 percent by weight or less. The aerosol-generating material may have a microcrystalline cellulose content of 35 percent by weight or less. The aerosol-generating material may have a microcrystalline cellulose content of 30 percent by weight or less. The aerosol-generating material may have a microcrystalline cellulose content of 25 percent by weight or less.

[0357] The aerosol-generating material may have a microcrystalline cellulose content of 0.5 to 50 percent by weight.The aerosol-generating material may have a microcrystalline cellulose content of 0.5 to 40 percent by weight.

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

[0359] The aerosol-generating material may have a cellulose powder content of 0.5 percent by weight or greater. The aerosol-generating material may have a cellulose powder content of 1 percent by weight or greater. The aerosol-generating material may have a cellulose powder content of 0.5 percent by weight or greater. The aerosol-generating material may have a cellulose powder content of 5 percent by weight or greater. The aerosol-generating material may have a cellulose powder content of 10 percent by weight or greater. The aerosol-generating material may have a cellulose powder content of 15 percent by weight or greater. The aerosol-generating material may have a cellulose powder content of 20 percent by weight or greater.

[0360] The aerosol-generating material may have a cellulose powder content of 50 percent by weight or less. The aerosol-generating material may have a cellulose powder content of 45 percent by weight or less. The aerosol-generating material may have a cellulose powder content of 40 percent by weight or less. The aerosol-generating material may have a cellulose powder content of 35 percent by weight or less. The aerosol-generating material may have a cellulose powder content of 30 percent by weight or less. The aerosol-generating material may have a cellulose powder content of 25 percent by weight or less.

[0361] The aerosol-generating material may have a cellulose powder content of 0.5 to 50 percent by weight.The aerosol-generating material may have a cellulose powder content of 0.5 to 40 percent by weight.

[0362] The aerosol-generating material may include carboxymethyl cellulose.

[0363] Advantageously, the inventors have found that the use of carboxymethylcellulose can help reduce sticking of aerosol-generating materials when used in aerosol-generating articles.

[0364] The carboxymethylcellulose may include sodium carboxymethylcellulose. Advantageously, the inventors have found that sodium carboxymethylcellulose is a carboxymethylcellulose that can be particularly effective in preventing the sticking problems described above.

[0365] The aerosol-generating material may have a carboxymethylcellulose content of 0.5 weight percent or greater. The aerosol-generating material may have a carboxymethylcellulose content of 1 weight percent or greater. The aerosol-generating material may have a carboxymethylcellulose content of 5 weight percent or greater. The aerosol-generating material may have a carboxymethylcellulose content of 10 weight percent or greater.

[0366] The aerosol-generating material may have a carboxymethylcellulose content of 20 percent by weight or less. The aerosol-generating material may have a carboxymethylcellulose content of 15 percent by weight or less. The aerosol-generating material may have a carboxymethylcellulose content of 10 percent by weight or less. The aerosol-generating material may have a carboxymethylcellulose content of 8 percent by weight or less. The aerosol-generating material may have a carboxymethylcellulose content of 5 percent by weight or less.

[0367] The aerosol-generating material may have a carboxymethylcellulose content of 0.5 percent to 20 percent by weight.

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

[0369] The aerosol-generating material may comprise at least 0.5 weight percent nicotine, at least 1 weight percent nicotine, at least 1.5 weight percent nicotine, or at least 2 weight percent nicotine, i.e., the aerosol-generating material may have a nicotine content of at least 0.5 weight percent, at least 1 weight percent, at least 1.5 weight percent, or at least 2 weight percent.

[0370] The aerosol-generating material may include one or more flavoring agents. The one or more flavoring agents may include one or more essential oils, such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and herbal materials. Suitable herbal materials include herb leaves or other herbal materials derived from herbaceous plants, including, but not limited to, mints such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavoring agents may include tobacco materials.

[0371] The aerosol-generating material may have a moisture content of about 5% to 25%, preferably about 7% to 15%, in its final product state. For example, the aerosol-generating material may be a homogenized tobacco material having a moisture content of about 5% to 25%, preferably about 7% to 15%, in its final product state.

[0372] The aerosol-generating material may contain cellulose fibers. For example, the aerosol-generating material may contain about 1% to 15% cellulose fibers, preferably about 3% to 7% cellulose fibers. Preferably, the cellulose fibers have a length of about 10 μm to 250 μm, preferably about 10 μm to 120 μm.

[0373] The aerosol-generating material may contain organic fibers, such as non-tobacco fibers or tobacco fibers. For example, the aerosol-generating material may contain about 5% to 20%, preferably about 7% to 15%, tobacco fibers. The tobacco fibers are preferably derived from stems and / or stems and graded into fibers with lengths of about 10 μm to 350 μm, preferably about 10 μm to 180 μm. The aerosol-generating material may contain about 10% to 30%, preferably about 15% to 25%, non-tobacco organic fibers. For example, the organic fibers may be derived from cellulose, cotton, wood, by-product tea varieties, and tea industry by-product waste. The organic fibers are preferably about 10 μm to 400 μm in length, more preferably about 10 μm to 200 μm in length.

[0374] The aerosol-generating material may also contain a binder. For example, the aerosol-generating material may contain about 1% to 10%, preferably about 1% to 5%, of a binder, such as any of the common gums or pectins used in the food and beverage (F&B) industry. Preferred binders may be natural pectins or tobacco pectins, such as those from fruits such as citrus fruits; guar gum, land locust bean gum, and their hydroxyethyl and / or hydroxypropyl derivatives; starches, such as modified or derivatized starches; alginates; methylcellulose, ethylcellulose, ethylhydroxymethylcellulose, and carboxymethylcellulose; dextran; and xanthan gum. A preferred binder is guar. The binder may also be polyvinyl alcohol (PVOH).

[0375] The aerosol-generating material may include one or more botanical substances, such as, for example, about 15% to 55%, and preferably about 20% to 35%, of botanical substances such as clove, echinacea, fennel, ginger, hawthorn berry, elderberry, monarda, mullein leaf, nettle, plantain, turmeric, yarrow, and combinations thereof.

[0376] The aerosol-generating material may include organic plant extracts. For example, the aerosol-generating material may include about 1% to 15%, preferably about 2% to 7%, of any of the plant substances described above, menthol (dl-menthol, CHO, 2-isopropyl-5-methylcyclohexanol), such as that obtained from Calophyllum macrospermum, Mesosphaerum sidifolium, or other related plant varieties, and p-menthan-3-ol, an optional secondary alcohol as a diastereoisomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.

[0377] The aerosol-generating material may include about 0.5% to 5%, preferably about 1% to 3%, of a plant essential oil, such as a palm-based, coconut-based, or wood-based plant essential oil.

[0378] The aerosol-generating material may include particles of functional materials, such as particles of carbon, graphite, activated carbon, or expanded graphite. Such materials may, for example, increase the thermal conductivity of the aerosol-forming material and may improve the efficiency of aerosol generation.

[0379] The aerosol-generating material may be in the form of an aerosol-generating film comprising a cellulosic film-forming agent, nicotine, and an aerosol former. The aerosol-generating film may further comprise a cellulosic reinforcement agent. The aerosol-generating film may further comprise water, preferably less than 30 weight percent water.

[0380] As used herein, the term "film" is used to describe a solid layered element having a thickness that is less than its width or length. A film may be free-standing.

[0381] In the context of the present disclosure, the term "cellulosic film former" is used to describe a cellulosic polymer that can form a continuous film by itself or in the presence of an auxiliary thickener. Preferably, the cellulosic film former is selected from the group consisting of 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 cellulosic film former is HPMC.

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

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

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

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

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

[0387] Suitable gel compositions are described in International Publication No. WO-A-2021 / 170642.

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

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

[0390] The air inlet may have a round, circular, oval, square or rectangular cross-section. The air outlet may have a round, circular, oval, square or rectangular cross-section.

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

[0392] The air outlets may be defined by or through the first, second, or third frame layer. The air outlets may be defined by or through the first and second frame layers. The air outlets may be defined by or through the second and third frame layers. The air outlets may be defined by or through the first, second, and third frame layers. The air outlets may be defined by or through the first, second, and third frame layers.

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

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

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

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

[0397] The air inlet may have an equivalent diameter of 3 millimeters or less. The air inlet may have an equivalent diameter of 2.7 millimeters or less. The air inlet may have an equivalent diameter of 2.4 millimeters or less. The air inlet may have an equivalent diameter of 2.1 millimeters or less. The air inlet may have an equivalent diameter of 1.8 millimeters or less. The air inlet may have an equivalent diameter of 1.5 millimeters or less.

[0398] The air inlet may have an equivalent diameter of 0.1 mm to 3 mm. The air inlet may have an equivalent diameter of 0.1 mm to 2.4 mm. The air inlet may have an equivalent diameter of 0.4 mm to 2.1 mm. The air inlet may have an equivalent diameter of 0.4 mm to 1.8 mm. The air inlet may have an equivalent diameter of 0.7 mm to 1.5 mm. The air inlet may have an equivalent diameter of 1.0 mm to 1.5 mm.

[0399] The air outlet may have an equivalent diameter of 0.1 millimeters or greater. The air outlet may have an equivalent diameter of 0.4 millimeters or greater. The air outlet may have an equivalent diameter of 0.7 millimeters or greater. The air outlet may have an equivalent diameter of 1.0 millimeters or greater.

[0400] The air outlet may have an equivalent diameter of 3 millimeters or less. The air outlet may have an equivalent diameter of 2.7 millimeters or less. The air outlet may have an equivalent diameter of 2.4 millimeters or less. The air outlet may have an equivalent diameter of 2.1 millimeters or less. The air outlet may have an equivalent diameter of 1.8 millimeters or less. The air outlet may have an equivalent diameter of 1.5 millimeters or less.

[0401] The air outlet may have an equivalent diameter of 0.1 mm to 3 mm. The air outlet may have an equivalent diameter of 0.1 mm to 2.4 mm. The air outlet may have an equivalent diameter of 0.4 mm to 2.1 mm. The air outlet may have an equivalent diameter of 0.4 mm to 1.8 mm. The air outlet may have an equivalent diameter of 0.7 mm to 1.5 mm. The air outlet may have an equivalent diameter of 1.0 mm to 1.5 mm.

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

[0403] The air inlet may have a width of 0.3 mm to 3 mm. The air inlet may have a width of 0.5 mm to 2 mm.

[0404] The air inlet may have a thickness of 0.3 mm to 3 mm, and the air outlet may have a thickness of 0.5 mm to 2 mm.

[0405] Preferably, the air inlet may have a width of 0.3 mm to 3 mm and a thickness of 0.3 mm to 3 mm.

[0406] The air outlet may have a width of between 0.3 millimeters and 3 millimeters.The air outlet may have a width of between 0.5 millimeters and 2 millimeters.

[0407] The air outlet may have a thickness of between 0.3 millimeters and 3 millimeters.The air outlet may have a thickness of between 0.5 millimeters and 2 millimeters.

[0408] Preferably, the air outlet may have a width of 0.3 mm to 3 mm and a thickness of 0.3 mm to 3 mm.

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

[0410] Advantageously, an aerosol-generating article having an air outlet or air inlet with a width of 0.3 mm to 3 mm and a thickness of 0.3 mm to 3 mm may provide a relatively large inlet or outlet opening while allowing improved retention of the aerosol-generating substrate within the aerosol-generating article. Improved retention of the aerosol-generating substrate within the aerosol-generating article may reduce the risk of the aerosol-generating substrate becoming detached from the aerosol-generating article.

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

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

[0413] The aerosol-generating article may include one or more air inlets. The aerosol-generating article may include multiple air inlets. One or each of the air inlets may have one or more of the air inlet features described herein.

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

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

[0416] The aerosol-generating article may comprise a filter element positioned upstream of the aerosol-forming substrate. The aerosol-generating article may comprise a filter element positioned upstream of the cavity. The aerosol-generating article may comprise a filter element positioned at least partially within the air inlet. The aerosol-generating article may comprise a filter element positioned within the cavity, or may comprise a filter element positioned at the upstream end of the cavity.

[0417] The filter element may comprise one or more segments of fibrous filtering material. Suitable fibrous filtering materials are known to those skilled in the art. The filter element may comprise cellulose acetate.

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

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

[0420] The aerosol-generating article may include one or more side walls. The one or more side walls may include a first side wall and a second side wall, such as a left side wall and a right side wall. The first side wall and the second side wall may face each other. The one or more side walls may extend from the front wall to the rear wall. The one or more side walls may extend from a first outer planar surface to a second outer planar surface. The one or more side walls, such as the first and second side walls, may be defined by a frame, for example, by a peripheral wall of the frame.

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

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

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

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

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

[0426] The first end face and the first side face may form an interior angle of 90 degrees or less. The first end face and the second side face may form an interior angle of 90 degrees or less.

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

[0428] The first outer corner may be chamfered or may be rounded.

[0429] In embodiments in which the first outer corner is rounded, the first outer corner may have a radius of curvature. The radius of curvature of the first outer corner may be measured in the x / y plane. The radius of curvature of the first outer corner may be between 1.25 millimeters and 6.5 millimeters.

[0430] The radius of curvature of the first outer corner may be 50 percent or less of the width of the aerosol-generating article. The radius of curvature of the first outer corner may be 30 percent or less of the width of the aerosol-generating article. The radius of curvature of the first outer corner may be 20 percent or less of the width of the aerosol-generating article. The radius of curvature of the first outer corner may be 10 percent or less of the width of the aerosol-generating article.

[0431] The radius of curvature of the first outer corner may be 1 percent or more of the width of the aerosol-generating article. The radius of curvature of the first outer corner may be 5 percent or more of the width of the aerosol-generating article. The radius of curvature of the first outer corner may be 10 percent or more of the width of the aerosol-generating article.

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

[0433] In embodiments where the first outer corner is chamfered, the first outer corner may be chamfered at an angle between 30 and 60 degrees when measured from the first edge. The first outer corner may be chamfered at an angle between 40 and 50 degrees when measured from the first edge. The first outer corner may be chamfered at an angle of 45 degrees when measured from the first edge.

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

[0435] The aerosol-generating article may have a second outer corner extending from the first outer planar surface to the second outer planar surface, and the second outer corner may connect the first end surface of the aerosol-generating article to the second side surface of the aerosol-generating article.

[0436] The second outer corner may be chamfered or may be rounded.

[0437] In embodiments in which the second outer corner is rounded, the second outer corner may have a radius of curvature. The radius of curvature of the second outer corner may be measured in the x / y plane. The radius of curvature of the second outer corner may be between 1.25 millimeters and 6.5 millimeters.

[0438] The radius of curvature of the second outer corner may be 50 percent or less of the width of the aerosol-generating article. The radius of curvature of the second outer corner may be 30 percent or less of the width of the aerosol-generating article. The radius of curvature of the second outer corner may be 20 percent or less of the width of the aerosol-generating article. The radius of curvature of the second outer corner may be 10 percent or less of the width of the aerosol-generating article.

[0439] The radius of curvature of the second outer corner may be 1 percent or more of the width of the aerosol-generating article. The radius of curvature of the second outer corner may be 5 percent or more of the width of the aerosol-generating article. The radius of curvature of the second outer corner may be 10 percent or more of the width of the aerosol-generating article.

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

[0441] In embodiments in which both the first outer corner and the second outer corner are rounded, the radius of curvature of the first outer corner may 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 may be chamfered at an angle between 30 and 60 degrees when measured from the first edge. The second outer corner may be chamfered at an angle between 40 and 50 degrees when measured from the first edge. The second outer corner may be chamfered at an angle of 45 degrees when measured from the first edge.

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

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

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

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

[0447] The radius of curvature of the third outer corner may be 50 percent or less of the width of the aerosol-generating article. The radius of curvature of the third outer corner may be 30 percent or less of the width of the aerosol-generating article. The radius of curvature of the third outer corner may be 20 percent or less of the width of the aerosol-generating article. The radius of curvature of the third outer corner may be 10 percent or less of the width of the aerosol-generating article.

[0448] The radius of curvature of the third outer corner may be 1 percent or more of the width of the aerosol-generating article. The radius of curvature of the third outer corner may be 5 percent or more of the width of the aerosol-generating article. The radius of curvature of the third outer corner may be 10 percent or more of the width of the aerosol-generating article.

[0449] The radius of curvature of the third outer corner may be between 1 percent and 50 percent of the width of the aerosol-generating article. The radius of curvature of the third outer corner may be between 1 percent and 30 percent of the width of the aerosol-generating article. The radius of curvature of the third outer corner may be between 5 percent and 30 percent of the width of the aerosol-generating article. The radius of curvature of the third outer corner may be between 5 percent and 20 percent of the width of the aerosol-generating article.

[0450] In embodiments where the third outer corner is chamfered, the third outer corner may be chamfered at an angle between 30 and 60 degrees when measured from the second end face. The third outer corner may be chamfered at an angle between 40 and 50 degrees when measured from the third end face. The third outer corner may be chamfered at an angle of 45 degrees when measured from the third end face.

[0451] The aerosol-generating article may have a fourth outer corner extending from the first outer planar surface to the second outer planar surface, and the fourth outer corner may connect a second end surface of the aerosol-generating article to a second side surface of the aerosol-generating article.

[0452] The fourth outer corner may be chamfered or may be rounded.

[0453] In embodiments in which the fourth outer corner is rounded, the fourth outer corner may have a radius of curvature. The radius of curvature of the fourth outer corner may be measured in the x / y plane. The radius of curvature of the fourth outer corner may be between 1.25 millimeters and 6.5 millimeters.

[0454] The radius of curvature of the fourth outer corner may be 50 percent or less of the width of the aerosol-generating article. The radius of curvature of the fourth outer corner may be 30 percent or less of the width of the aerosol-generating article. The radius of curvature of the fourth outer corner may be 20 percent or less of the width of the aerosol-generating article. The radius of curvature of the fourth outer corner may be 10 percent or less of the width of the aerosol-generating article.

[0455] The radius of curvature of the fourth outer corner may be 1 percent or more of the width of the aerosol-generating article. The radius of curvature of the fourth outer corner may be 5 percent or more of the width of the aerosol-generating article. The radius of curvature of the fourth outer corner may be 10 percent or more of the width of the aerosol-generating article.

[0456] The radius of curvature of the fourth outer corner may be between 1 percent and 50 percent of the width of the aerosol-generating article. The radius of curvature of the fourth outer corner may be between 1 percent and 30 percent of the width of the aerosol-generating article. The radius of curvature of the fourth outer corner may be between 5 percent and 30 percent of the width of the aerosol-generating article. The radius of curvature of the fourth outer corner may be between 5 percent and 20 percent of the width of the aerosol-generating article.

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

[0458] Advantageously, by providing an aerosol-generating article having at least one outer corner extending from a first outer planar surface to a second outer planar surface and which is rounded or chamfered, it may be easier to insert the aerosol-generating article into an aerosol generating device.

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

[0460] Advantageously, manufacturing of the aerosol-generating article may be made easier by providing the aerosol-generating article with at least one outer corner extending from the first outer planar surface to the second outer planar surface and which is rounded or chamfered.

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

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

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

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

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

[0466] The length to width ratio of the aerosol-generating article may be from 1:1 to 10:1. The length to width ratio of the aerosol-generating article may be from 1.5:1 to 5:1. The length to width ratio of the aerosol-generating article may be from 1.5:1 to 4:1. The length to width ratio of the aerosol-generating article may be from 1.5:1 to 3:1. The length to width ratio of the aerosol-generating article may be from 2:1 to 4:1. The length to width ratio of the aerosol-generating article may be from 2:1 to 3:1.

[0467] The aerosol-generating article may have a length of 15 millimeters or more. The aerosol-generating article may have a length of 20 millimeters or more. The aerosol-generating article may have a length of 25 millimeters or more. The aerosol-generating article may have a length of 30 millimeters or more. The aerosol-generating article may have a length of 35 millimeters or more. The aerosol-generating article may have a length of 40 millimeters or more.

[0468] The aerosol-generating article may have a length of 45 millimeters or less. The aerosol-generating article may have a length of 40 millimeters or less. The aerosol-generating article may have a length of 35 millimeters or less. The aerosol-generating article may have a length of 30 millimeters or less.

[0469] The aerosol-generating article may have a length of 15 mm to 45 mm. The aerosol-generating article may have a length of 20 mm to 40 mm. The aerosol-generating article may have a length of 20 mm to 35 mm. The aerosol-generating article may have a length of 25 mm to 30 mm.

[0470] The aerosol-generating article may have a width of 3 millimeters or more. The aerosol-generating article may have a width of 5 millimeters or more. The aerosol-generating article may have a width of 7.5 millimeters or more. The aerosol-generating article may have a width of 9 millimeters or more. The aerosol-generating article may have a width of 11 millimeters or more. The aerosol-generating article may have a width of 13 millimeters or more.

[0471] The aerosol-generating article may have a width of 17 millimeters or less. The aerosol-generating article may have a width of 15 millimeters or less. The aerosol-generating article may have a width of 12.5 millimeters or less. The aerosol-generating article may have a width of 11 millimeters or less. The aerosol-generating article may have a width of 9 millimeters or less.

[0472] The aerosol-generating article may have a width of 3 mm to 17 mm. The aerosol-generating article may have a width of 5 mm to 15 mm. The aerosol-generating article may have a width of 7.5 mm to 12.5 mm. The aerosol-generating article may have a width of 9 mm to 11 mm.

[0473] The aerosol-generating article may have a thickness of 1 millimeter or more. The aerosol-generating article may have a thickness of 1.5 millimeters or more. The aerosol-generating article may have a thickness of 2 millimeters or more. The aerosol-generating article may have a thickness of 2.5 millimeters or more. The aerosol-generating article may have a thickness of 3 millimeters or more. The aerosol-generating article may have a thickness of 3.5 millimeters or more. The aerosol-generating article may have a thickness of 4 millimeters or more. The aerosol-generating article may have a thickness of 4.5 millimeters or more.

[0474] The aerosol-generating article may have a thickness of 5.5 millimeters or less. The aerosol-generating article may have a thickness of 5 millimeters or less. The aerosol-generating article may have a thickness of 4.5 millimeters or less. The aerosol-generating article may have a thickness of 4 millimeters or less. The aerosol-generating article may have a thickness of 3.5 millimeters or less. The aerosol-generating article may have a thickness of 3 millimeters or less. The aerosol-generating article may have a thickness of less than 2.5 millimeters. The aerosol-generating article may have a thickness of less than 2 millimeters.

[0475] The aerosol-generating article may have a thickness of from 1 mm to 5 mm. The aerosol-generating article may have a thickness of from 1.5 mm to 5 mm. The aerosol-generating article may have a thickness of from 2 mm to 4.5 mm. The aerosol-generating article may have a thickness of from 2.5 mm to 4 mm. The aerosol-generating article may have a thickness of from 3 mm to 3.5 mm.

[0476] The aerosol-generating article may have a length of between 15 millimeters and 45 millimeters, a width of between 5 millimeters and 15 millimeters, and a thickness of between 1 millimeter and 5 millimeters.

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

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

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

[0480] Advantageously, by providing an aerosol-generating article having a length of 15 mm to 45 mm, a width of 5 mm to 15 mm and a thickness of 1 mm to 5 mm, and with a cavity having a length of 14 mm to 40 mm, a width of 4.5 mm to 13 mm and a thickness of 0.5 mm to 4.5 mm, an aerosol-generating article may be provided which contains a large cavity and has a large cavity volume in proportion to the external volume of the aerosol-generating article.

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

[0482] The aerosol-generating article may have a resistance to draw (RTD) of 20 millimeters H2O or less. The aerosol-generating article may have a resistance to draw (RTD) of 10 millimeters H2O or less. The aerosol-generating article may have a resistance to draw (RTD) of 8 millimeters H2O or less. The aerosol-generating article may have a resistance to draw (RTD) of 6 millimeters H2O or less. The aerosol-generating article may have a resistance to draw (RTD) of 4 millimeters H2O or less. The aerosol-generating article may have a resistance to draw (RTD) of 2 millimeters H2O or less. The aerosol-generating article may have a resistance to draw (RTD) equal to or close to 0 millimeters H2O.

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

[0484] Unless otherwise specified, resistance to draw (RTD) is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through an aerosol-generating article between the air inlet and the air outlet. The terms "pressure drop" or "resistance to draw" of a component or article may also refer to "resistance to drawing." Such terms generally refer to ISO 6565-2015 measurements typically performed at test conditions of approximately 17.5 milliliters per second at the output or downstream end of the component being measured, at a temperature of approximately 22°C, a pressure of approximately 101 kPa (approximately 760 Torr), and a relative humidity of approximately 60 percent.

[0485] According to the present disclosure, there is provided a method for making an aerosol-generating article as described herein, the method comprising providing a first sheet of material, a second sheet of material, and a third sheet of material, forming an opening through the first sheet of material to form a frame, positioning the opening between the second sheet of material and the third sheet of material, and adhering the first sheet of material, the second sheet of material, and the third sheet of material together to form the aerosol-generating article.

[0486] According to the present disclosure, there is provided a method for manufacturing an aerosol-generating article as described herein. The method includes providing a sheet material comprising a first sheet of frame material, a first sheet of outer layer material, and a second sheet of outer layer material. The method includes forming an opening through the first sheet of frame material. The method includes positioning the first sheet of frame material and the opening between the first sheet of outer layer material and the second sheet of outer layer material. The method includes adhering the sheet materials to one another.

[0487] According to the present disclosure, there is provided a method for manufacturing an aerosol-generating article as described herein. The method includes providing a sheet material including a first sheet of frame material, a first sheet of aerosol-generating material, a second sheet of aerosol-generating material, a first sheet of outer layer material, and a second sheet of outer layer material. The method includes forming an opening through the first sheet of frame material. The method includes positioning the first sheet of frame material and the opening between the first sheet of aerosol-generating material and the second sheet of aerosol-generating material. The method includes positioning the first sheet of frame material, the opening, the first sheet of aerosol-generating material, and the second sheet of aerosol-generating material between the first sheet of outer layer material and the second sheet of outer layer material. The method includes bonding the sheet materials together.

[0488] According to the present disclosure, there is provided a method for manufacturing an aerosol-generating article as described herein. The method includes providing a sheet of material comprising a first sheet of frame material, a second sheet of frame material, a first sheet of outer layer material, and a second sheet of outer layer material. The method may also include bonding the first sheet of frame material and the second sheet of frame material to one another. The method may include, for example, forming an opening through the first sheet of frame material and the second sheet of frame material after the first sheet of frame material and the second sheet of frame material have been bonded. The method includes positioning the first sheet of frame material, the second sheet of frame material, and the opening between the first sheet of outer layer material and the second sheet of outer layer material. The method includes bonding the sheet materials to one another.

[0489] The present disclosure provides a method for manufacturing an aerosol-generating article as described herein. The method includes providing a sheet material including a first sheet of frame material, a second sheet of frame material, a first sheet of aerosol-generating material, a second sheet of aerosol-generating material, a first sheet of outer layer material, and a second sheet of outer layer material. The method may also include bonding the first sheet of frame material and the second sheet of frame material to one another. For example, the method may include forming an opening through the first sheet of frame material and the second sheet of frame material after the first sheet of frame material and the second sheet of frame material have been bonded. The method includes positioning the first sheet of frame material, the second sheet of frame material, and the opening between the first sheet of aerosol-generating material and the second sheet of aerosol-generating material. The method includes positioning the first sheet of frame material, the second sheet of frame material, the opening, the first sheet of aerosol-generating material, and the second sheet of aerosol-generating material between the first sheet of outer layer material and the second sheet of outer layer material. The method includes adhering sheets of material to one another.

[0490] According to the present disclosure, there is provided a method for manufacturing an aerosol-generating article as described herein. The method includes providing a sheet material including a first sheet of frame material, a second sheet of frame material, a third sheet of frame material, a first sheet of outer layer material, and a second sheet of outer layer material. The method may also include bonding the first sheet of frame material, the second sheet of frame material, and the third sheet of frame material to one another. The method may include, for example, forming an opening through the first sheet of frame material, the second sheet of frame material, and the third sheet of frame material after the first sheet of frame material, the second sheet of frame material, and the third sheet of frame material have been bonded. The method includes positioning the first sheet of frame material, the second sheet of frame material, the third sheet of frame material, and the opening between the first sheet of outer layer material and the second sheet of outer layer material. The method includes bonding the sheet materials to one another.

[0491] The present disclosure provides a method for manufacturing an aerosol-generating article as described herein. The method includes providing a sheet material including a first sheet of frame material, a second sheet of frame material, a third sheet of frame material, a first sheet of aerosol-generating material, a second sheet of aerosol-generating material, a first sheet of outer layer material, and a second sheet of outer layer material. The method may also include bonding the first sheet of frame material, the second sheet of frame material, and the third sheet of frame material to one another. The method may include, for example, forming an opening through the first sheet of frame material, the second sheet of frame material, and the third sheet of frame material after the first sheet of frame material, the second sheet of frame material, and the third sheet of frame material have been bonded. The method includes positioning the first sheet of frame material, the second sheet of frame material, the third sheet of frame material, and the opening between the first sheet of aerosol-generating material and the second sheet of aerosol-generating material. The method includes positioning a first sheet of frame material, a second sheet of frame material, a second sheet of aerosol-generating material, an opening, the first sheet of aerosol-generating material, and the second sheet of aerosol-generating material between the first sheet of outer layer material and the second sheet of outer layer material, and the method includes adhering the sheet materials to one another.

[0492] The methods of making an aerosol-generating article described herein may include the step of positioning an aerosol-generating substrate within an opening.

[0493] In the manufacturing methods described herein, one or more of the first sheet of frame material, the second sheet of frame material, and the third sheet of frame material may be a sheet of paper or cardboard.

[0494] In the manufacturing methods described herein, one or more of the first sheet of aerosol-generating material and the second sheet of aerosol-generating material may be a sheet of homogenized tobacco material.

[0495] In the manufacturing methods described herein, one or more of the first sheet of outer layer material and the second sheet of outer layer material may 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 dimensioned 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 for controlling the supply of power to the heater or heating means. The aerosol-generating device is configured to heat at least one of one or more aerosol-generating substrates to form an aerosol, for example, an inhalable aerosol. The aerosol-generating device may be configured to heat each of the one or more aerosol-generating substrates to form an aerosol, for example, an inhalable aerosol.

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

[0498] Preferably, at least one interior surface of the cavity of the aerosol-generating device is a heated surface configured to heat the aerosol-generating article. The heated surface may comprise a heater, such as a resistance heater, an infrared heater, or a susceptor configured to be heated by engaging an inductor. The heated surface may comprise an inductor, e.g., a coil arranged to generate a fluctuating electromagnetic field within the space of the cavity of the aerosol-generating device. The heated surface may be a surface that is transparent to the fluctuating electromagnetic field such that an inductor arranged outside the cavity projects the fluctuating electromagnetic field through the heated surface to engage a susceptor arranged inside the cavity of the aerosol-generating device.

[0499] Preferably, at least the bottom surface of the cavity of the aerosol-generating device is a heated surface configured to heat the aerosol-generating article. Optionally, both the bottom and top surfaces of the cavity of the aerosol-generating device are heated surfaces configured to heat the aerosol-generating article.

[0500] Preferably, at least the lower inner surface of the cavity of the aerosol generation device is substantially planar, and preferably both the lower and upper inner surfaces of the cavity of the aerosol generation device are substantially planar. Preferably, the upper and lower inner surfaces of the cavity of the aerosol generation device are arranged in a parallel relationship to each other.

[0501] Optionally, the upper and lower inner surfaces may converge along the length of the aerosol generating device cavity so that they are spaced slightly closer together at the distal end of the cavity than at the proximal end. This may enable the aerosol generating device cavity to grip an aerosol-generating article inserted therein. Side inner surfaces may converge in a similar manner to achieve the result of gripping the aerosol-generating article. The upper and lower inner surfaces of the aerosol generating device cavity and / or opposing side surfaces of the aerosol generating device cavity may converge by 1 to 10 degrees, for example, by 2 to 8 degrees, for example, by 3 to 6 degrees, for example, by 4 to 5 degrees, between the proximal end of the cavity and the distal end of the cavity.

[0502] In some embodiments, the lower and upper inner surfaces may be movable relative to one another. For example, the lower and upper inner surfaces may be configured to pivot relative to one another or to move up and down relative to one another. This may allow the aerosol-generating article to be easily inserted into the cavity of the aerosol-generating device while the cavity wall of the aerosol-generating device moves to hold the substrate or article in place for heating. For example, relative movement of the upper and lower inner surfaces may grip the aerosol-generating article between the two surfaces, facilitating heating of the article and assisting in proper positioning of the article within the device.

[0503] The cavity of the aerosol generating device may be defined by a longitudinal dimension or length, a transverse dimension or width, and a depth dimension or height, where the length and width are preferably greater than the height, e.g., at least twice as large as the height.

[0504] The aerosol generating device may include a heating surface with multiple separately operable heating zones, such as, for example, two separately operable heating zones, or three separately operable heating zones, or four separately operable heating zones, or five separately operable heating zones, or six separately operable heating zones. The multiple separately operable heating zones may be configured to operate independently, or may be configured to operate two or more zones at a time in any combination. In some embodiments, the multiple separately operable heating zones may be longitudinally spaced apart within the cavity. In some embodiments, the multiple separately operable heating zones may be transversely spaced apart within the cavity. Different heating zones may be spaced apart from one another both transversely and longitudinally. Different heating zones may be concentrically disposed with one another.

[0505] The aerosol generating device may comprise one or more resistive heaters, for example one or more resistive heaters integrated into the walls of the cavity.

[0506] The device may comprise one or more inductors, for example, integrated into a wall of the aerosol-generating device cavity or arranged to generate a fluctuating electromagnetic field within the wall of the aerosol-generating device cavity or within the interior of the aerosol-generating device cavity, wherein the one or more walls of the aerosol-generating device cavity comprise or consist of a susceptor material, such that the one or more walls of the cavity are heated by engagement with the fluctuating electromagnetic field, thereby heating an aerosol-generating article inserted within the cavity.

[0507] The aerosol-generating device may comprise one or more insertable heating elements for insertion into the aerosol-generating article and arranged to protrude into a cavity of the aerosol-generating device. The insertable heating elements may be resistance heaters. The insertable heating elements may be susceptors.

[0508] The aerosol generating device may comprise a device body. The device body may comprise a heater. The aerosol generating device may comprise a mouthpiece element. The device body may comprise a device body housing. The device body housing may define a cavity for receiving at least a portion of the aerosol-generating article. The device body and the mouthpiece element may be removably connectable. The mouthpiece element may be removably connectable to the device body, for example to the device body housing.

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

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

[0511] The device body may have a distal end and a proximal end. The cavity of the aerosol generation device may be defined in the proximal end of the device body. The mouthpiece element may have a distal end and a proximal end. The distal end of the mouthpiece element may be configured to be removably connected to the proximal end of the device body.

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

[0513] The aerosol generating device may include an air inlet, for example, in the device body or in one or both of the mouthpiece element. The device, for example, the mouthpiece element, may include an air outlet. The device may include an air flow path fluidly connecting the air inlet to the air outlet. The air flow path may extend through or beyond the cavity of the aerosol generating device. Thus, in use, the device may be configured such that when negative pressure is applied to the air outlet, for example, by a user sucking on the air outlet, air is drawn in through the air inlet and then flows over or through an aerosol-generating article received in the cavity, thereby entraining aerosol emitted from the aerosol-forming substrate of the article before being directed 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 may 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 that, in use, can be heated to generate and deliver to a consumer an inhalable aerosol.

[0516] As used herein, the term "aerosol-generating substrate" refers to a substrate that can release volatile compounds when heated, e.g., such compounds condense upon cooling to generate an aerosol in use.

[0517] As used herein, the term "aerosol-generating device" refers to a device that, in use, generates an aerosol by interacting with an aerosol-generating substrate of an aerosol-generating article, for example by heating such aerosol-generating substrate.

[0518] As used herein, the term "planar" generally refers to features formed within a single Euclidean plane and not wrapped or otherwise conformed to a curved or other non-planar shape. A planar surface may extend two-dimensionally within a single Euclidean plane. A planar object may extend substantially more in two dimensions within a single Euclidean plane than it does in three dimensions perpendicular to the plane. More specifically, a planar object may extend at least two times more, at least five times more, or at least ten times more in a first dimension and in a second dimension perpendicular to the first dimension than it does in a third dimension perpendicular to the first and second dimensions.

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

[0520] As used herein, the term "longitudinal" refers to a direction perpendicular to the transverse direction, for example, the direction between the front and rear walls of the aerosol-generating article.

[0521] As used herein, the term "lateral" refers to a direction perpendicular to the transverse direction and the longitudinal direction, for example, from a first sidewall to a second sidewall of an aerosol-generating article.

[0522] As used herein, the term "thickness" refers to the largest transverse dimension of an aerosol-generating article or of a component of an aerosol-generating article.

[0523] As used herein, the term "length" refers to the greatest longitudinal dimension of an aerosol-generating article or of a component of an aerosol-generating article.

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

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

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

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

[0528] As used herein, the term "aerosol former content" may refer to the aerosol former content in percent on a dry weight basis, unless otherwise specified.

[0529] As used herein, "susceptor" refers to an electrically conductive element that generates heat when exposed to a changing magnetic field, which may be the result of eddy currents induced in the susceptor element and / or as a result of hysteresis losses.

[0530] As used herein, the term "hydrophobic" refers to a surface that exhibits water repellency. One effective way to determine this is to measure the water contact angle. The "water contact angle" is the angle at which a liquid / vapor interface meets a solid surface and is traditionally measured through the liquid. It quantifies the wettability of a solid surface with a liquid using Young's equation.

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

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

[0533] [Example] The present invention is defined in the claims. However, the following provides a non-exhaustive list of non-limiting examples. Any one or more features of these examples may be combined with any one or more features of other examples, embodiments, or aspects described herein.

[0534] Example 1 1. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, comprising: a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction; one or more aerosol-generating substrates; a first outer planar surface and a second outer planar surface spaced apart from the first outer planar surface in the z-direction; a first outer corner extending from the first outer planar surface to the second outer planar surface, the first outer corner connecting a first end surface of the aerosol-generating article to a first side surface of the aerosol-generating article; The aerosol-generating article, wherein the first outer corner is chamfered or rounded. Example 2. 10. The aerosol-generating article of claim 1, wherein the first outer corner comprises a first corner surface connecting the first end surface to the second side surface. Example 3. An aerosol-generating article as described in Example 2, wherein the first end surface is connected to the first corner surface in a first corner transition region, and in any x / y plane, the first interior corner angle formed between a tangent to the first end surface in the first corner transition region and a tangent to the first corner surface in the first corner transition region is 90 degrees to 180 degrees. Example 4. An aerosol-generating article according to Example 3, wherein the first corner interior angle is 120 degrees to 180 degrees, preferably 130 degrees to 180 degrees. Example 5. An aerosol-generating article according to any one of Examples 1 to 4, wherein the first outer corner is rounded. Example 6 An aerosol-generating article as described in Example 5, wherein the radius of curvature of the first outer corner is between 1.25 millimeters and 6.5 millimeters. Example 7 An aerosol-generating article according to any one of Examples 1 to 4, wherein the first outer corner is chamfered. Example 8 8. The aerosol-generating article of Example 7, wherein the first outer corner is chamfered at an angle of 30 degrees to 60 degrees as measured from the first edge. Example 9. The aerosol-generating article of Example 7 or Example 8, wherein the first outer corner is chamfered at an angle of 40 degrees to 50 degrees as measured from the first edge. Example 10. An aerosol-generating article according to any one of Examples 7 to 9, wherein the first outer corner is chamfered at a 45 degree angle as measured from the first edge. Example 11 An aerosol-generating article described in any one of Examples 1 to 10, comprising a second outer corner extending from the first planar outer surface to the second planar outer surface, the second outer corner connecting the first end surface of the aerosol-generating article to the second side surface of the aerosol-generating article, and the second outer corner being chamfered or rounded. Example 12 12. The aerosol-generating article of claim 11, wherein the second outer corner comprises a second corner surface connecting the first end surface to the second side surface. Example 13 An aerosol-generating article as described in Example 12, wherein the first end surface is connected to the second corner surface in a second corner transition region, and in any x / y plane, the second corner interior angle formed between a tangent to the first end surface in the second corner transition region and a tangent to the second corner surface in the second corner transition region is 90 degrees to 180 degrees. Example 14. 14. The aerosol-generating article of Example 13, wherein the second interior corner angle is 120 degrees to 180 degrees, preferably 130 degrees to 180 degrees. Example 15. An aerosol-generating article according to any one of Examples 11 to 14, wherein the second outer corner is rounded. Example 16. 16. The aerosol-generating article of Example 15, wherein the radius of curvature of the second outer corner is 1.25 millimeters to 6.5 millimeters. Example 17. An aerosol-generating article according to any one of Examples 11 to 14, wherein the second outer corner is chamfered. Example 18. 18. The aerosol-generating article of Example 17, wherein the second outer corner is chamfered at an angle of 30 degrees to 60 degrees as measured from the first edge. Example 19. The aerosol-generating article of Example 17 or Example 18, wherein the second outer corner is chamfered at an angle of 40 degrees to 50 degrees as measured from the first edge. Example 20. An aerosol-generating article according to any one of Examples 17 to 19, wherein the second outer corner is chamfered at a 45 degree angle as measured from the first edge. Example 21. An aerosol-generating article according to any one of Examples 1 to 20, which comprises a cavity. Example 22. An aerosol-generating article as described in Example 21, wherein the cavity has at least two corners extending between the first planar outer surface and the second planar outer surface, and the at least two corners are rounded or chamfered. Example 23. An aerosol-generating article as described in Example 21 or Example 22, wherein all corners of the cavity extending between the first and second planar outer surfaces are rounded or chamfered. Example 24. a third outer corner extending from the first outer planar surface to the second outer planar surface, the third outer corner connecting the second end surface of the aerosol-generating article to the first side surface of the aerosol-generating article; a fourth outer corner extending from the first outer planar surface to the second outer planar surface, the fourth outer corner connecting the second end surface of the aerosol-generating article to the second side surface of the aerosol-generating article; An aerosol-generating article according to any one of Examples 1 to 23, wherein the third outer corner is chamfered or rounded and the fourth outer corner is chamfered or rounded. Example 25. 25. The aerosol-generating article of Example 24, wherein the second end surface is positioned opposite the first end surface. Example 26. The aerosol-generating article of example 24 or example 25, wherein the second end surface is positioned parallel to the first end surface. Example 27. The aerosol-generating article of any one of Examples 1 to 26, wherein the second side is positioned opposite the first side. Example 28. The aerosol-generating article of any one of Examples 1 to 27, wherein the second side is positioned parallel to the first side. Example 29. The aerosol-generating article of any one of Examples 1 to 28, wherein the first end face and the first side face form an interior angle of 90 degrees or less. Example 30. The aerosol-generating article of any one of Examples 1 to 29, wherein the first end surface and the second side surface form an interior angle of 90 degrees or less. Example 31. An aerosol-generating article according to any one of Examples 1 to 30, wherein the thickness of the aerosol-generating article is less than 50 percent of both the length and width of the aerosol-generating article. Example 32. An aerosol-generating article according to any one of Examples 1 to 31, comprising a frame positioned between a first outer planar surface and a second outer planar surface. Example 33. The aerosol-generating article of Example 32 when dependent on Example 21, wherein the frame at least partially defines a cavity. Example 34. The aerosol-generating article of Example 32 or Example 33 when dependent on Example 21, wherein the frame comprises a peripheral wall that surrounds or encloses the cavity. Example 35. An aerosol-generating article as described in Example 34, wherein the peripheral wall is formed by an inner frame surface and an outer frame surface, the inner frame surface defining an outer cavity wall, and the outer frame surface at least partially defining one or more outer walls of the aerosol-generating article. Example 36. 36. The aerosol-generating article of example 34 or example 35, wherein the peripheral wall has a radial thickness of 1 millimeter to 3 millimeters. Example 37. An aerosol-generating article according to any one of Examples 32 to 36, wherein the frame has a thickness that is 80 percent or more of the thickness of the aerosol-generating article. Example 38. An aerosol-generating article according to any one of Examples 32 to 37, wherein the frame has a thickness that is 80 to 95 percent of the thickness of the aerosol-generating article. Example 39. An aerosol-generating article according to any one of Examples 32 to 38, wherein the frame has a thickness of 1 millimeter to 5.5 millimeters. Example 40. The aerosol-generating article of any one of Examples 32 to 39, wherein the frame comprises a cellulosic material. Example 41. 41. The aerosol-generating article of example 40, wherein the cellulosic material has a basis weight of 300 grams per square meter to 900 grams per square meter. Example 42. The aerosol-generating article of example 40 or example 41, wherein the cellulosic material is paper, paperboard, or cardboard. Example 43. The aerosol-generating article of any one of Examples 32 to 42, wherein the frame is an integral component. Example 44. The aerosol-generating article of any one of Examples 32 to 42, wherein the frame comprises a first frame layer and a second frame layer. Example 45. 45. The aerosol-generating article of Example 44, wherein the first frame layer is adhered to the second frame layer by an adhesive. Example 46. The aerosol-generating article of example 44 or example 45, wherein the frame comprises a third frame layer. Example 47. 47. The aerosol-generating article of Example 46, wherein the second frame layer is positioned between the first frame layer and the third frame layer. Example 48. The aerosol-generating article of Example 46 or Example 47, wherein the second frame layer is adhered to the third frame layer by an adhesive. Example 49. An aerosol-generating article described in any one of Examples 1 to 48 when dependent on Example 21, 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. Example 50. 50. An aerosol-generating article as described in Example 49, wherein one or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer comprise an aerosol-generating material in the form of a sheet of aerosol-generating material. Example 51. An aerosol-generating article as described in Example 50, wherein the sheet of aerosol-generating material is a sheet of homogenized tobacco material. Example 52. 52. The aerosol-generating article of example 50 or example 51, wherein the sheet of aerosol-generating material comprises one or more aerosol formers, such as glycerin and / or propylene glycol. Example 53. An aerosol-generating article as claimed in any one of Examples 49 to 52, wherein the first and second aerosol-generating substrate layers define opposite end walls of a cavity. Example 54. An aerosol-generating article according to any one of Examples 49 to 53, wherein one or both of the first and second aerosol-generating substrate layers have a thickness of from 100 micrometers to 600 micrometers. Example 55. An aerosol-generating article as described in any one of Examples 49 to 54, wherein one or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer have substantially the same length as the length of the aerosol-generating article. Example 56. An aerosol-generating article as described in any one of Examples 49 to 55, wherein one or both of the first aerosol-generating substrate layer and the second aerosol-generating substrate layer have substantially the same width as the width of the aerosol-generating article. Example 57. The aerosol-generating article of any one of Examples 1 to 56, comprising an outer wrapper defining a first outer planar surface and a second outer planar surface. Example 58. An aerosol-generating article described in any one of Examples 1 to 56, comprising a first planar outer layer and a second planar outer layer, the first planar outer layer defining a first planar outer surface, and the second planar outer layer defining a second planar outer surface. Example 59. The aerosol-generating article of Example 58, when dependent on Example 21, wherein the first and second planar outer layers are on opposite ends of the cavity. Example 60. The aerosol-generating article of example 58 or example 59, wherein one or both of the first planar outer layer and the second planar outer layer comprises a cellulosic material. Example 61. 61. The aerosol-generating article of Example 60, wherein the cellulosic material is paper or cardboard. Example 62. An aerosol-generating article described in any one of Examples 58 to 61, wherein one or both of the first planar outer layer and the second planar outer layer have substantially the same length as the length of the aerosol-generating article. Example 63. An aerosol-generating article described in any one of Examples 58 to 62, wherein one or both of the first planar outer layer and the second planar outer layer have substantially the same width as the width of the aerosol-generating article. Example 64. An aerosol-generating article according to any one of Examples 1 to 36 when dependent on Example 21, wherein the one or more aerosol-generating substrates comprise an aerosol-generating substrate positioned within the cavity. Example 65. 65. An aerosol-generating article as described in Example 64, wherein the aerosol-generating substrate positioned within the cavity comprises an aerosol-generating material. Example 66. 66. The aerosol-generating article of example 65, wherein the aerosol-generating material is in the form of shredded aerosol-generating material. Example 67. An aerosol-generating article as described in Example 66, wherein the shredded aerosol-generating material comprises one or more strips and strands of aerosol-generating material, such as strips and strands of tobacco material or homogenized tobacco material. Example 68. The aerosol-generating article of any one of Examples 65 to 67, wherein the aerosol-generating material is a tobacco cut filler. Example 69. 66. The aerosol-generating article of claim 65, wherein the aerosol-generating material is in the form of a corrugated sheet of aerosol-generating material. Example 70. An aerosol-generating article as described in Example 69, wherein the corrugated sheet of aerosol-generating material has a plurality of parallel corrugations defining a plurality of channels between the sheet of aerosol-generating material and one or more walls of the cavity. Example 71. An aerosol-generating article as described in Example 70, wherein the plurality of channels are longitudinally extending channels. Example 72. An aerosol-generating article described in either Example 70 or Example 71, wherein the plurality of channels define at least a portion of an airflow passage extending between the air inlet and the air outlet of the aerosol-generating article. Example 73. The aerosol-generating article of any one of Examples 65 to 72, wherein the aerosol-generating material includes one or more aerosol formers, such as glycerin and / or propylene glycol. Example 74. The aerosol-generating article of any one of Examples 64 to 73, wherein the aerosol-generating substrate positioned within the cavity has a bulk density of 0.5 milligrams per cubic millimeter or less. Example 75. The aerosol-generating article of any one of Examples 64 to 74, wherein the aerosol-generating substrate positioned within the cavity has a pack density of 0.3 or greater. Example 76. The aerosol-generating article of any one of Examples 64 to 75, wherein the aerosol-generating substrate positioned within the cavity has a pack density of 0.9 or less. Example 77. The aerosol-generating article of any one of Examples 64 to 76, wherein the aerosol-generating substrate positioned within the cavity has a density of 0.9 grams per cubic centimeter or less. Example 78. The aerosol-generating article of any one of Examples 64 to 77, wherein the aerosol-generating substrate positioned within the cavity has a mass of 50 milligrams to 500 milligrams. Example 79. An aerosol-generating article as described in any one of Examples 1 to 78, comprising an air inlet and an air outlet, and an airflow passage extending through the cavity between the air inlet and the air outlet. Example 80. 80. The aerosol-generating article of Example 79, wherein the air inlet is defined by a frame. Example 81. The aerosol-generating article of Examples 79 to 80, wherein the air inlet has an equivalent diameter of 0.1 millimeters to 3 millimeters. Example 82. The aerosol-generating article of any one of Examples 79 to 81, wherein the air inlet has a width of 0.3 mm to 3 mm. Example 83. The aerosol-generating article of any one of Examples 79 to 82, wherein the air inlet has a thickness of 0.3 millimeters to 3 millimeters. Example 84. The aerosol-generating article of any one of Examples 79 to 83, wherein the air outlet is defined by a frame. Example 85. An aerosol-generating article according to any one of Examples 79 to 84, wherein the air outlet has an equivalent diameter of 0.1 millimeters to 3 millimeters. Example 86. An aerosol-generating article according to any one of Examples 79 to 85, wherein the air outlet has a width of 0.3 millimeters to 3 millimeters. Example 88. An aerosol-generating article according to any one of Examples 79 to 86, wherein the air outlet has a thickness of 0.3 millimeters to 3 millimeters. Example 89. An aerosol-generating article according to any one of Examples 1 to 88, wherein the ratio of the length to the thickness of the aerosol-generating article and the ratio of the width to the thickness of the aerosol-generating article are 2:1 to 15:1. Example 90. An aerosol-generating article according to any one of Examples 1 to 89, wherein the ratio between the length and width of the aerosol-generating article is 1:1 to 10:1. Example 91. The aerosol-generating article according to any one of Examples 1 to 90, wherein the aerosol-generating article has a length of 15 mm to 45 mm, for example 25 mm to 30 mm. Example 92. The aerosol-generating article according to any one of Examples 1 to 91, wherein the aerosol-generating article has a width of 3 mm to 17 mm, for example 9 mm to 11 mm. Example 93. The aerosol-generating article according to any one of Examples 1 to 92, wherein the aerosol-generating article has a thickness of 1 mm to 5.5 mm, for example 3 mm to 3.5 mm. Example 94. The aerosol-generating article according to any one of Examples 1 to 93, wherein the aerosol-generating article has a withdrawal resistance of 0 mmH2O to 9.9 mmH2O.

[0535] The embodiments will be further explained below with reference to the drawings.

[0536] 1 illustrates an aerosol-generating article 10 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 understood that in some embodiments, only one of the first planar outer layer 24 and the second planar outer layer 25 may comprise an aerosol-generating substrate. Alternatively, or additionally, the aerosol-generating substrate may be positioned anywhere within the aerosol-generating article 10.

[0537] 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 millimeters, a width of 10 millimeters, and a thickness of 3.1 millimeters.

[0538] 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.

[0539] The aerosol-generating article 10 is a substantially flat aerosol-generating article, i.e., a substantially planar aerosol-generating article. In particular, the thickness of the aerosol-generating article 10 is less than 50 percent of both the length and width of the aerosol-generating article. That is, the thickness is less than 15 millimeters (less than 50 percent of the length of the aerosol-generating article 10) and less than 5 millimeters (less than 50 percent of the width of the aerosol-generating article 10). The aerosol-generating article 10 has an overall rectangular parallelepiped shape and a laminated structure formed by a first planar outer layer 24, a frame 50, and a second planar outer layer 25. The first planar outer layer 24, the frame 50, and the second planar outer layer 25 are adhered to one another by an adhesive, in particular, guar gum, as will be described in detail below in connection with FIG. 2.

[0540] FIG. 2 shows an exploded view of the aerosol-generating article 10 of FIG.

[0541] Frame 50 has a length of 30 millimeters, a width of 10 millimeters, and a thickness of 2.7 millimeters. Frame 50 is made from cardboard and defines a frame opening that extends through the thickness of frame 50. The frame opening at least partially defines cavity 30. Cavity 30 has a length of 26 millimeters, a width of 6 millimeters, and a thickness of 2.7 millimeters. Cavity 30 therefore has a volume of approximately 421.2 cubic millimeters. In this embodiment, cavity 30 is substantially empty.

[0542] The frame 50 has an inner frame surface 52 extending in the z-direction or transversely between the first outer planar surface 21 and the second outer planar surface 22. The inner frame surface 52 defines an outer wall of the cavity. The frame 50 has an outer frame surface 53 extending in the z-direction or transversely between the first outer planar surface 21 and the second outer planar surface 22. The outer frame 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 outer frame surface 53 surrounds and is concentric with the inner frame surface 52. The frame 50 thus has a cross-section that is annular in shape in the x / y plane, and in particular, the cross-section is rectangular in shape.

[0543] Frame 50 includes a peripheral wall 51 that surrounds cavity 30. More specifically, peripheral wall 51 is defined by an inner frame surface 52 and an outer frame surface 53. Peripheral wall 51 has a radial thickness of approximately 2 millimeters as measured in the x / y plane between inner frame surface 52 and outer frame surface 53.

[0544] The first planar outer layer 24 and the second planar outer layer 25 have a thickness of 200 micrometers and are in physical contact with the frame 50. The first planar outer layer 24 and the second planar outer layer 25 are adhered to the frame by an adhesive 15. The first planar outer layer 24 overlies an end of the cavity 30, forming a first cavity end wall 31. The second planar outer layer 25 overlies the opposite end of the cavity 30, forming a second cavity end wall 32. Thus, the frame 50, the first planar outer layer 24, and the second planar outer layer 25 collectively define the cavity 30.

[0545] The air inlet 11 and the air outlet 12 are defined by and extend through a peripheral wall 51 of the frame 50. Each of the air inlet 11 and the air outlet 12 has a rectangular cross-section and a width of 2 millimeters and a thickness of 0.9 millimeters. An air flow passage extends through the cavity 30 between the air inlet 11 and the air outlet 12.

[0546] The frame forms at least 95 percent of the periphery of any cross section of the aerosol-generating article extending through the frame in the x / y plane. For example, the frame forms 100 percent of the periphery of the cross section of the aerosol-generating article 10 between the first planar outer layer 24 and the air outlet 12 in the x / y plane. On the other hand, the frame forms 95 percent of the periphery of the cross section of the aerosol-generating article extending through the air inlet 11 and the air outlet 12 in the x / y plane. This is because the periphery of such a cross section is formed by the frame, the width of the air inlet 11, and the width of the air outlet 12.

[0547] FIG. 3 shows an exploded view of an aerosol-generating article similar to the aerosol-generating article 10 of FIG. 1 , 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 weight percent on a dry weight basis. As shown, the aerosol-generating substrate 40 fills the entire volume of the cavity 30. In the example of FIG. 3 , the aerosol-generating substrate 40 has a pack density of about 0.87, a density of about 0.3 grams per cubic centimeter, and a mass of about 110 milligrams. In other examples, the aerosol-generating substrate 40 may have a different pack density, a different density, and a different mass. For example, the aerosol-generating substrate may have a pack density of 0.64, a density of 0.35 grams per cubic centimeter, and a mass of approximately 95 milligrams.

[0548] 4 and 5 show transverse and longitudinal cross-sections, respectively, of the aerosol-generating article of FIG.

[0549] Figure 6 shows an exploded view of an aerosol-generating article 10 similar to that of Figure 3, except that the aerosol-generating substrate 40 is in the form of a sheet of aerosol-generating material, and in particular a corrugated sheet of homogenized tobacco material. Figures 7 and 8 show transverse and lateral cross-sections, respectively, of the aerosol-generating article 10 of Figure 6.

[0550] The corrugated sheet of homogenized tobacco material comprises a plurality of parallel corrugations having substantially parallel peaks 43 and valleys 44. The parallel corrugations are defined by a sinusoidal corrugation profile, as seen in FIG. 7. The parallel corrugations have a corrugation wavelength of approximately 0.92 millimeters. The corrugation amplitude is approximately the same across the cavity thickness, as indicated by the coincidence of the peaks 43 and valleys 44 on the first cavity end wall 31 and the second cavity end wall 32, respectively.

[0551] The parallel corrugations form channels 45 between the sheet of aerosol-generating material and the first cavity end wall 31, and channels 46 between the sheet of aerosol-generating material and the second cavity end wall 32. The channels extend longitudinally through the aerosol-generating article 10 and define at least a portion of the airflow passageway extending between the air inlet 11 and the air outlet 12.

[0552] Figure 9 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figures 1, 3, and 6, except that the aerosol-generating article 10 of Figure 9 includes an outer wrapper 23 defining a first planar outer surface 21 and a second planar outer surface 22 instead of a first planar outer layer 24 and a second planar outer layer 25. For illustrative purposes, Figure 10 shows the aerosol-generating article 10 of Figure 9 with the outer wrapper 23 unwrapped to expose a portion of the peripheral wall 51 of the frame 50. The outer wrapper 23 is cigarette paper.

[0553] Figure 11 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1, except that the frame 50 of the aerosol-generating article 10 of Figure 11 includes a first frame layer 54 and a second frame layer 55. Figure 12 shows an exploded view of the first planar outer layer 24, frame 50, and second planar outer layer 25 of the aerosol-generating article 10 of Figure 11. Figure 13 shows yet another exploded view of the first planar outer layer 24, first frame layer 54, second frame layer 55, and second planar outer layer 25 of the aerosol-generating article 10 of Figure 11.

[0554] The first planar outer layer 24 is in physical contact with the first frame layer 54 and is bonded to the first frame layer 54 by adhesive 15. The first frame layer 54 is in physical contact with the second frame layer 55 and is bonded to the second frame layer 55 by adhesive 15. The second planar outer layer 25 is in physical contact with the second frame layer 55 and is bonded to the second frame layer 55 by adhesive 15.

[0555] The aerosol-generating article 10 has the same dimensions as the aerosol-generating article 10 in Figure 1. The frame 50 has the same dimensions as the frame 50 in Figure 1. The thickness of the frame 50 is equal to the sum of the thickness of the first frame layer 54 and the thickness of the second frame layer 55, and both 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.

[0556] Figure 14 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1, except that the frame 50 of the aerosol-generating article 10 of Figure 14 includes 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 shows 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 14. Figure 16 shows a still further 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 Figure 14.

[0557] The first planar outer layer 24 is in physical contact with the first frame layer 54 and is bonded to the first frame layer 54 by adhesive 15. The first frame layer 54 is in physical contact with the second frame layer 55 and is bonded to the second frame layer 55 by adhesive 15. The second frame layer 55 is in physical contact with the third frame layer 56 and is bonded to the second frame layer 55 by adhesive 15. The second planar outer layer 25 is in physical contact with the third frame layer 56 and is bonded to the second frame layer 56 by adhesive 15.

[0558] 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 1. 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.

[0559] FIG. 17 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of FIG. 1, except that the aerosol-generating article 10 of FIG. 17 further comprises a first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42. FIG. 18 shows an exploded view of the aerosol-generating article 10 of FIG. 17. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are formed from sheets of aerosol-generating material. Specifically, the first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 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 micrometers. That is, the aerosol-generating article 10 has a length of 30 millimeters, a width of 10 millimeters, and a thickness of 3.5 millimeters.

[0560] 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 adhered to the frame by adhesive 15. The first aerosol-generating substrate layer 41 overlies one end of the cavity 30 and forms a first cavity end wall 31. The second aerosol-generating layer 42 overlies the opposite end of the cavity 30 and forms a second cavity end wall 32. Thus, the frame 50, the first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 collectively define the cavity 30.

[0561] The first planar outer layer 24 is in physical contact with the first aerosol-generating substrate layer 41 and is adhered to the first aerosol-generating substrate layer 41 by adhesive 15. The second planar outer layer 25 is in physical contact with the second aerosol-generating substrate layer 42 and is adhered to the second aerosol-generating substrate layer 42 by adhesive 15.

[0562] The frame 50 is shown as a single component, however, the frame may be a two-layer frame as shown in FIG. 11 or a three-layer frame as shown in FIG.

[0563] Figure 19 shows an exploded view of an aerosol-generating article 10 similar to that of Figure 17, except that an aerosol-generating substrate 40 is positioned within the cavity 30 as described in connection with Figure 3. 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 weight percent on a dry weight basis. As shown, the aerosol-generating substrate 40 fills the entire volume of the cavity 30.

[0564] Figure 20 shows an exploded view of an aerosol-generating article 10 similar to that of Figure 19, except that the aerosol-generating substrate 40 is in the form of a sheet of aerosol-generating material, particularly a corrugated sheet of homogenized tobacco material as described in relation to Figure 6.

[0565] Figure 21 shows an exploded view of an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 19, except that the aerosol-generating article 10 further includes a filter element 60 positioned within the cavity 30.

[0566] The filter element 60 is positioned immediately upstream of the air outlet 12. The filter element 60 is made of cellulose acetate. The filter element 60 has a thickness and width that are approximately the same as the thickness and width, respectively, of the cavity 30. The filter element 60 has a length of approximately 6 millimeters. The aerosol-generating substrate 40 fills the remaining volume of the cavity 30.

[0567] Figure 22 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1, except that the aerosol-generating article 10 of Figure 22 includes a first cavity 33 and a second cavity 34. Figure 23 shows an exploded view of the aerosol-generating article 10 of Figure 22.

[0568] The first cavity 33 is substantially empty, and the second cavity 34 is also substantially empty. The first cavity 33 has a length of 12 millimeters, a width of 6 millimeters, and a thickness of 2.7 millimeters. The second cavity 34 has a length of 12 millimeters, a width of 6 millimeters, and a thickness of 2.7 millimeters.

[0569] Frame 50 defines a frame first opening extending through the thickness of frame 50, the frame first opening at least partially defining first cavity 33. Frame 50 defines a frame second opening extending through the thickness of frame 50, the frame second opening at least partially defining second cavity 34.

[0570] The frame 50 includes a partition wall 57 that separates the first cavity 33 from the second cavity 34. The partition wall 59 defines an opening that extends from the first cavity 33 to the second cavity 34. The opening in the partition wall 59 defines at least a portion of an air flow passage between the air inlet 11 and the air outlet 12.

[0571] 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.

[0572] Figure 24 shows an exploded view of an aerosol-generating article 10 similar to that of Figure 22, except that a first hollow aerosol-generating substrate 45 is positioned within the first cavity 33 and a second hollow aerosol-generating substrate 46 is positioned within the second cavity 34.

[0573] The first hollow aerosol-generating substrate 45 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. The first hollow aerosol-generating substrate 45 fills the entire volume of the first cavity 33. The second hollow aerosol-generating substrate 46 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. The second hollow aerosol-generating substrate 46 fills the entire volume of the second cavity 34. Figure 25 shows an exploded view of an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 24, except that the first hollow aerosol-generating substrate 45 is in the form of a sheet of aerosol-generating material, particularly a corrugated sheet of homogenized tobacco material, and the second hollow aerosol-generating substrate 46 is in the form of a sheet of aerosol-generating material, particularly a corrugated sheet of homogenized tobacco material.

[0574] Figure 26 shows an exploded view of an aerosol-generating article 10 similar to that of Figure 22, except that a first hollow aerosol-generating substrate 45 is positioned within the first cavity 33, a filter element 60 is positioned within the first cavity 33, and a second hollow aerosol-generating substrate 46 is positioned within the second cavity 34.

[0575] The filter element 60 is positioned immediately upstream of the air outlet 12. The filter element is made of cellulose acetate. The filter element 60 has a thickness and width that are approximately the same as the thickness and width, respectively, of the first cavity 33. The filter element 60 has a length of approximately 4 millimeters.

[0576] The first hollow aerosol-generating substrate 45 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 weight percent on a dry weight basis. The first hollow aerosol-generating substrate 45 fills the remaining volume of the first cavity 33. The second hollow aerosol-generating substrate 46 is identical to the second hollow aerosol-generating substrate 46 described in connection with Figure 25.

[0577] Figure 27 shows an exploded view of an aerosol-generating article 10 similar to that of Figure 22, except that a filter element 60 is positioned within the air outlet 12 and a second hollow 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 left empty. The second hollow aerosol-generating substrate 46 is identical to the second hollow aerosol-generating substrate 46 described in connection with Figure 24.

[0578] Figure 28 shows an exploded view of an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 22, except that the aerosol-generating article 10 further comprises a first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42 as described in relation to 17.

[0579] The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are formed from sheets of aerosol-generating material. In particular, they are sheets of homogenized tobacco material having an aerosol-former content of 5 weight percent on a dry mass basis. Each of the first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 has 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 micrometers. That is, the aerosol-generating article 10 has a length of 30 millimeters, a width of 10 millimeters, and a thickness of 3.5 millimeters.

[0580] 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 adhered to the frame by an adhesive 15. The first aerosol-generating substrate layer 41 overlies one end of the first cavity 33, and the second aerosol-generating substrate layer 42 overlies the 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 one end of the second cavity 34, and the second aerosol-generating substrate layer 42 overlies the 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.

[0581] Figure 29 shows an exploded view of an aerosol-generating article 10 similar to that of Figure 28, except that a first hollow aerosol-generating substrate 45 is positioned within the first cavity 33 and a second hollow aerosol-generating substrate 46 is positioned within the second cavity 34.

[0582] The first hollow aerosol-generating substrate 45 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. The first hollow aerosol-generating substrate 45 fills the entire volume of the first cavity 33. The second hollow aerosol-generating substrate 46 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. The second hollow aerosol-generating substrate 46 fills the entire volume of the second cavity 34.

[0583] Figure 30 shows an aerosol-generating article 10 similar to the aerosol-generating articles 10 of Figures 17 and 28, except that the aerosol-generating article 10 of Figure 30 includes an outer wrapper 23 defining a first planar outer surface 21 and a second planar outer surface 22 instead of a first planar outer layer 24 and a second planar outer layer 25. Figure 31 shows, for illustrative purposes, the aerosol-generating article 10 of Figure 30 with the outer wrapper 23 unwrapped to expose a portion of the peripheral wall 51 of the frame 50. The outer wrapper 23 is cigarette paper.

[0584] Figure 32 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1, except that the aerosol-generating article 10 of Figure 32 has a rounded first outer corner 71 and a rounded second outer corner 72. However, it will be understood that one or both of the first outer corner 71 and the second outer corner 72 may be chamfered. Figures 33 and 34 show a plan view and an exploded view, respectively, of the aerosol-generating article 10 of Figure 32.

[0585] The first outer corner 71 extends from the first outer planar surface 21 to the second outer planar surface 22 and includes a first corner surface 76 connected to a first end face 73 of the aerosol-generating article 10 and a first side face 74 of the aerosol-generating article 10. More specifically, the first end face 73 is connected to the first corner surface 76 at a first corner transition region 82. A first interior corner angle θ1 formed between a tangent 81 to the first end face 73 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.

[0586] The second outer corner 72 extends from the first outer planar surface 21 to the second outer planar surface 22 and includes a second corner surface 77 connected to a first end face 73 of the aerosol-generating article 10 and a second side face 75 of the aerosol-generating article 10. More specifically, 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 θ2 formed between a tangent 84 to the first end face 73 at the second corner transition region 85 and a tangent 86 to the second corner surface 77 at the second corner transition region 85 is between 90 degrees and 180 degrees.

[0587] Figure 35 shows a cross-sectional view in the x / y plane of the aerosol-generating article 10 of Figure 32, as viewed through the intersection between the first planar outer layer 24 and the frame 50. The cavity 30 has a first corner 35, a second corner 36, a third corner 37, and a fourth corner 38, each of which extends in the z direction and is rounded.

[0588] Figure 36 shows an exploded view of an aerosol-generating article similar to the aerosol-generating article 10 of Figure 32, except that an aerosol-generating substrate 40 is positioned within the cavity 30. The aerosol-generating substrate 40 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 weight percent 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, and in particular, a corrugated sheet of homogenized tobacco material, as described in connection with Figure 6.

[0589] Figure 37 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figures 32 and 36, 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.

[0590] Figure 38 shows an aerosol-generating article 10 similar to that of Figure 1, except that the air inlet 11 is defined by the first planar outer surface 21 and extends through the first planar outer layer 24.

[0591] Figure 39 shows an aerosol-generating article 10 similar to that of Figure 9, except that the air inlet 11 is defined by a first planar outer surface 21 and extends through the outer wrapper 23.

[0592] Figure 40 shows an aerosol-generating article 10 similar to that of Figure 17, 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.

[0593] FIG. 41 shows a schematic cross-sectional view of an aerosol generating device 90 configured for use with the aerosol-generating article 10 described herein. The aerosol generating device 90 is an elongated aerosol generating device extending between a proximal end 91 and a distal end 92. The aerosol generating device 90 includes a battery 93, a controller 94, a first heater 95, and a second heater 96 disposed within a housing 97. The controller 94 controls the power supply from the battery 93 to the first heater 95 and the second heater 96. A cavity 1000 is defined within the device 90, and the cavity 1000 has an opening 1010 defined within the proximal end 91 of the device 90. The opening 1010 is rectangular in shape and sized to accommodate the transverse cross-section of the aerosol-generating article 10. The cavity 1000 includes an upper planar surface 1020 and a lower planar surface 1030. A first heater 95 is disposed in the upper plane 1020 for heating a first outer planar surface 21 of an aerosol-generating article 10 inserted into the cavity 1000, and a second heater 96 is disposed in the lower plane 1030 for heating a second outer planar surface 22 of an aerosol-generating article 10 inserted into the cavity 1000. The device 90 includes an air inlet 98 defining an air flow path configured to allow air to flow from outside the device into the cavity 1000.

[0594] Figure 42 shows a schematic cross-sectional view of the aerosol-generating device 90 of Figure 41 engaged with the aerosol-generating article 10 of Figure 1. There is little tolerance between the first and second planar outer surfaces 21 and 22 of the aerosol-generating article 10 and the inner surfaces 1020 and 1030 of the cavity 1000. Thus, a tight fit exists between the aerosol-generating article 10 and the aerosol-generating device 90. When a consumer inserts the aerosol-generating article 10 into the cavity 1000, the device can be operated. 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, thereby heating the aerosol-generating substrate. Volatile components of the aerosol-generating substrate evaporate and condense within the cavity 30 of the aerosol-generating article 10, forming an aerosol. The consumer inhales the aerosol by pulling on the end of the aerosol-generating article 10 that includes the air outlet 12. After the aerosol-generating substrate is depleted of volatile components, the aerosol-generating article 10 is removed from the cavity 1000 and discarded.

[0595] Figure 43 illustrates a schematic diagram of a method 1100 for manufacturing an aerosol-generating article 10 described herein, and in particular, a method for manufacturing the aerosol-generating article 10 of Figure 3. The method involves perforating and bonding a first sheet 1201 of frame material, a first sheet 1301 of outer layer material, and a second sheet 1302 of outer layer material. Figure 44 illustrates a schematic plan view of the method of Figure 43, although for illustrative purposes, the manufacturing equipment is not shown. The dotted line 1101 in Figure 44 represents, for illustrative purposes, the final cross-sectional perimeter of the aerosol-generating article 10.

[0596] A first sheet 1201 of frame material is fed from a bobbin 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An aperture punching device 1105 punches a frame aperture 1400 through the first sheet of frame material 1201. The frame aperture 1400 at least partially defines the cavity 30 of the aerosol-generating article 10. An adhesive applicator 1106 applies adhesive to the bottom surface of the first sheet of frame material 1201. A first sheet 1301 of outer layer material is fed from the bobbin 1102 via rollers 1107 and is adhered to the first sheet of frame material 1201 by the adhesive applied to the bottom surface of the first sheet of frame material 1201. An aerosol-generating substrate feeder 1108 feeds an aerosol-generating substrate 40 into the frame aperture 1400. An adhesive applicator 1109 applies adhesive 1110 to the top surface of the first sheet of frame material 1201. A second sheet of outer layer material 1302 is fed from a bobbin 1102 via a roller 1107 and adhered to the first sheet of frame material 1201 by the adhesive 1110 applied to the top surface of the first sheet of frame material 1201. An opening punching device 1111 punches openings 1410 through the first sheet of frame material 1201, the first sheet of outer layer material 1301, and the second sheet of outer layer material 1302, thereby discharging the aerosol-generating article 10. The air inlets and air outlets may be formed before or after discharging the aerosol-generating article 10.

[0597] In some embodiments, one or more of the first sheet of frame material 1201, the first sheet of outer layer material 1301, and the second sheet of outer layer material 1302 comprise an aerosol-generating substrate, and thus the step of providing the aerosol-generating substrate 40 into the frame opening 1400 may be omitted.

[0598] Figure 45 illustrates a schematic diagram of a method 1100 for manufacturing an aerosol-generating article 10 described herein, particularly the method for manufacturing the aerosol-generating article 10 of Figure 17. The method includes perforating and adhering a first sheet 1201 of frame material, a first sheet 1501 of aerosol-generating material, a second sheet 1502 of aerosol-generating material, a first sheet 1301 of outer layer material, and a second sheet 1302 of outer layer material. Figure 46 illustrates a schematic plan view of the method of Figure 45, although for illustrative purposes, the manufacturing equipment is not shown. The dotted line 1101 in Figure 46 represents the final cross-sectional perimeter of the aerosol-generating article 10 for illustrative purposes.

[0599] A first sheet 1201 of frame material is fed from a bobbin 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An aperture punching device 1105 punches a frame aperture 1400 through the first sheet 1201 of frame material. The frame aperture 1400 will at least partially define the cavity 30 of the aerosol-generating article 10.

[0600] An adhesive applicator 1106 applies adhesive 1110 to the bottom surface of the first sheet of frame material 1201 and to the top surface of the first sheet of frame material 1201 .

[0601] A first sheet 1501 of aerosol-generating material is fed from a bobbin 1102 via roller 1107 and is adhered to the first sheet 1201 of frame material by adhesive applied to the bottom surface of the first sheet 1201 of frame material. A second sheet 1502 of aerosol-generating material is fed from a bobbin 1102 via roller 1107 and is adhered to the first sheet 1201 of frame material by adhesive 1110 applied to the top surface of the first sheet 1201 of frame material.

[0602] An adhesive applicator 1109 applies adhesive 1110 to the bottom surface of first sheet 1501 of aerosol-generating material and to the top surface of second sheet 1502 of aerosol-generating material.

[0603] A first sheet 1301 of outer layer material is dispensed from bobbin 1102 via roller 1107 and is adhered to the first sheet 1501 of aerosol-generating material by adhesive applied to the bottom surface of the first sheet 1501 of aerosol-generating material. A second sheet 1302 of outer layer material is dispensed from bobbin 1102 via roller 1107 and is adhered to the second sheet 1502 of aerosol-generating material by adhesive 1110 applied to the top surface of the second sheet 1502 of aerosol-generating material.

[0604] An opening punching device 1111 punches an opening 1410 through the first sheet of frame material 1201, the first sheet of aerosol-generating material 1501, the second sheet of aerosol-generating material 1502, the first sheet of outer layer material 1301, and the second sheet of outer layer material 1302, thereby discharging the aerosol-generating article 10. The air inlet and air outlet may be formed before or after discharging the aerosol-generating article 10.

[0605] Figure 47 illustrates a schematic diagram of a method 1100 for manufacturing an aerosol-generating article 10 as described herein, particularly for manufacturing the aerosol-generating article 10 of Figure 11 with an aerosol-generating substrate 40 positioned within a cavity 30. The method includes perforating and bonding a first sheet 1201 of frame material, a second sheet 1202 of frame material, a first sheet 1301 of outer layer material, and a second sheet 1302 of outer layer material. Figure 48 illustrates a schematic plan view of the method of Figure 47, although for illustrative purposes, the manufacturing equipment is not shown. The dotted line 1101 in Figure 48 represents the final cross-sectional periphery of the aerosol-generating article 10 for illustrative purposes.

[0606] A first sheet 1201 of frame material is fed from a bobbin 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An adhesive applicator 1106 applies adhesive 1110 to the top surface of the first sheet 1201 of frame material. A second sheet 1202 of frame material is fed from the bobbin 1102 via rollers 1107 and is adhered to the first sheet 1201 of frame material by the adhesive 1110 applied to the top surface of the first sheet 1201 of frame material.

[0607] An aperture punching device 1105 punches frame apertures 1400 through the first sheet of frame material 1201 and through the second sheet of frame material 1202. The frame apertures 1400 will at least partially define the cavity 30 of the aerosol-generating article 10.

[0608] An adhesive applicator 1106 applies adhesive to the bottom surface of the first sheet of frame material 1201. A first sheet of outer layer material 1301 is fed from a bobbin 1102 via a roller 1107 and adhered to the first sheet of frame material 1201 by the adhesive applied to the bottom surface of the first sheet of frame material 1201.

[0609] An aerosol-generating substrate feeder 1108 feeds an aerosol-generating substrate 40 into the frame opening 40. An adhesive applicator 1109 applies adhesive 1110 to the top surface of the second sheet of frame material 1202. A second sheet of outer layer material 1302 is fed from the bobbin 1102 via roller 1107 and is adhered to the second sheet of frame material 1202 by the adhesive 1110 applied to the top surface of the second sheet of frame material 1202.

[0610] An opening punching device 1111 punches openings 1410 through the first sheet of frame material 1201, the second sheet of frame material 1202, the first sheet of outer layer material 1301, and the second sheet of outer layer material 1302, thereby discharging the aerosol-generating article 10. The air inlets and air outlets may be formed before or after discharging the aerosol-generating article 10.

[0611] In some embodiments, one or more of the first sheet of frame material 1201, the first sheet of frame material 1202, the first sheet of outer layer material 1301, and the second sheet of outer layer material 1302 comprise an aerosol-generating substrate, and thus the step of providing the aerosol-generating substrate 40 into the frame opening 1400 may be omitted.

[0612] Figure 49 illustrates a schematic diagram of a method 1100 for manufacturing an aerosol-generating article 10 described herein, particularly for manufacturing the aerosol-generating article 10 of Figure 14 with an aerosol-generating substrate 40 positioned within a cavity 30. The method includes perforating and adhering a first sheet 1201 of frame material, a second sheet 1202 of frame material, a third sheet 1203 of frame material, a first sheet 1301 of outer layer material, and a second sheet 1302 of outer layer material. Figure 50 illustrates a schematic plan view of the method of Figure 49, although for illustrative purposes, the manufacturing equipment is not shown. The dotted line 1101 in Figure 50 represents the final cross-sectional periphery of the aerosol-generating article 10 for illustrative purposes.

[0613] A first sheet 1201 of frame material is fed from a bobbin 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An aperture punching device 1112 punches air inlet apertures 1610 and air outlet apertures 1620 through the first sheet 1201 of frame material.

[0614] An adhesive applicator 1106 applies adhesive 1110 to the bottom surface of the first sheet of frame material 1201 and to the top surface of the first sheet of frame material 1201 .

[0615] A second sheet of frame material 1202 is fed from a bobbin 1102 via roller 1107 and is adhered to the first sheet of frame material 1201 by adhesive applied to the bottom surface of the first sheet of frame material 1201. A third sheet of frame material 1203 is fed from a bobbin 1102 via roller 1102 and is adhered to the first sheet of frame material 1201 by adhesive 1110 applied to the top surface of the first sheet of frame material 1201.

[0616] An aperture punching device 1105 punches frame apertures 1400 through the first sheet of frame material 1201, through the second sheet of frame material 1202, and through the third sheet of frame material 1203. The frame apertures will at least partially define the cavity 30 of the aerosol-generating article 10.

[0617] An adhesive applicator 1106 applies adhesive to the bottom surface of the second sheet of frame material 1202. A first sheet of outer layer material 1301 is fed from the bobbin 1102 via roller 1107 and adhered to the second sheet of frame material 1202 by the adhesive applied to the bottom surface of the second sheet of frame material 1202.

[0618] An aerosol-generating substrate feeder 1108 feeds an aerosol-generating substrate 40 into the frame opening 1400. An adhesive applicator 1109 applies adhesive 1110 to the top surface of the third sheet of frame material 1203. A second sheet of outer layer material 1302 is fed from the bobbin 1102 via roller 1107 and is adhered to the third sheet of frame material 1203 by the adhesive 1110 applied to the top ...

Claims

1. 1. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, comprising: a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction; one or more aerosol-generating substrates; a first outer planar surface and a second outer planar surface spaced apart from the first outer planar surface in the z-direction; a first outer corner extending from the first outer planar surface to the second outer planar surface, the first outer corner connecting a first end surface of the aerosol-generating article to a first side surface of the aerosol-generating article; The aerosol-generating article, wherein the first outer corner is chamfered or rounded.

2. 2. The aerosol-generating article of claim 1, wherein the first outer corner comprises a first corner surface connecting the first end surface to the second side surface.

3. 3. The aerosol-generating article of claim 2, wherein the first end surface is connected to the first corner surface at a first corner transition region, and a first interior corner angle formed between a tangent to the first end surface at the first corner transition region and a tangent to the first corner surface at the first corner transition region in any x / y plane is between 90 degrees and 180 degrees.

4. 4. The aerosol-generating article according to claim 3, wherein the first interior corner angle is between 120 degrees and 180 degrees, preferably between 130 degrees and 180 degrees.

5. 5. The aerosol-generating article of claim 1, wherein the first outer corner is rounded and the radius of curvature of the first outer corner is between 1.25 millimeters and 6.5 millimeters.

6. 5. The aerosol-generating article according to claim 1, wherein the first outer corner is chamfered at an angle of between 30 degrees and 60 degrees as measured from the first end face.

7. 7. An aerosol-generating article as described in any one of claims 1 to 6, further comprising a second outer corner extending from the first outer planar surface to the second outer planar surface, the second outer corner connecting the first end face of the aerosol-generating article to a second side face of the aerosol-generating article, the second outer corner being chamfered or rounded.

8. The aerosol-generating article of claim 7, wherein the second outer corner comprises a second corner surface connecting the first end face to the second side face, the first end face being connected to the second corner surface at a second corner transition region, and a second interior corner angle formed between a tangent to the first end face at the second corner transition region and a tangent to the second corner surface at the second corner transition region in any x / y plane is between 90 degrees and 180 degrees.

9. 9. The aerosol-generating article according to claim 8, wherein the second interior corner angle is between 120 degrees and 180 degrees, preferably between 130 degrees and 180 degrees.

10. 10. The aerosol-generating article according to claim 7, wherein the second outer corner is rounded and the radius of curvature of the second outer corner is between 1.25 millimeters and 6.5 millimeters.

11. 10. The aerosol-generating article according to claim 7, wherein the second outer corner is chamfered at an angle of between 30 degrees and 60 degrees as measured from the first end face.

12. The aerosol-generating article according to any one of claims 1 to 11, which comprises a cavity.

13. 13. The aerosol-generating article of claim 12, wherein the cavity has at least two corners extending between the first outer planar surface and the second outer planar surface, and the at least two corners are rounded or chamfered.

14. 14. An aerosol-generating article as described in claim 12 or claim 13, wherein all corners of the cavity extending between the first outer planar surface and the second outer planar surface are rounded or chamfered.

15. An aerosol-generating article according to any one of claims 1 to 14, wherein the first end face and the first side face form an interior angle of 90 degrees or less, and preferably the first end face and the second side face form an interior angle of 90 degrees or less.

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