Method for manufacturing an aerosol-generating article including a frame

Abstract

A method for manufacturing an aerosol generating article (10) for use with an aerosol generating device to generate an aerosol is provided, the method comprising: providing a first frame material continuous sheet (1201) and an additional material continuous sheet; forming a frame core layer by forming a frame aperture (1400) through the first frame material continuous sheet (1201); positioning the additional material continuous sheet below the first frame material continuous sheet (1201); and joining the additional material continuous sheet and the first frame material continuous sheet (1201) to form a stacked structure of an aerosol generating article (10) including a frame core layer.

Description

Technology Field

[0001] The present disclosure relates to a method for manufacturing an aerosol generating article of a type intended for use with an aerosol generating device to generate an aerosol, for example, upon heating. The present disclosure relates to an aerosol generating article obtainable by said method, and also relates to an aerosol generating system comprising an aerosol generating article and an aerosol generating device. Background Technology

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

[0003] Conventional aerosol generating articles may look similar to conventional cigarettes and may have similar dimensions. For example, such aerosol generating articles may be substantially cylindrical and may include an aerosol generating material in addition to other components such as a mouthpiece filter element and a cooling element arranged in the form of rods and wrapped in cigarette paper.

[0004] However, a significant portion of the aerosol generating material within these cylindrical aerosol generating articles may not be heated sufficiently to form an aerosol during use. This is undesirable because the insufficiently heated portion of the aerosol generating material contributes to the manufacturing and transportation costs of the aerosol generating article but does not contribute to the aerosol delivered to the consumer. Additionally, the components of these cylindrical aerosol generating articles generally need to have the same or very similar outer diameters so that they can be joined, positioned accurately in axial alignment, and wrapped in cigarette paper. This can increase manufacturing costs and complexity.

[0005] The object of the present disclosure is to provide a method for manufacturing an aerosol generating article in which a larger portion of the aerosol generating substrate is heated sufficiently to form an aerosol during use. Additionally, the object of the present disclosure is to provide a method for manufacturing an aerosol generating article that can be implemented in a relatively efficient and inexpensive manner. Furthermore, it would be desirable to provide a method for manufacturing an aerosol generating article that can be implemented in existing devices without extensive modifications.

[0006] The present disclosure relates to a method for manufacturing an aerosol generating article for use with an aerosol generating device to generate an aerosol.

[0007] The above method may include a first step of providing a first frame material continuous sheet and an additional material continuous sheet.

[0008] The above method may include a second step of forming a frame core layer by forming a frame aperture through a first frame material continuous sheet.

[0009] The above method may include a third step of positioning an additional material continuous sheet below a first frame material continuous sheet.

[0010] The above method may include a fourth step of bonding an additional material continuous sheet and a first frame material continuous sheet to form a laminated structure of an aerosol generating article including a frame core layer.

[0011] As discussed below, the method may include one or more additional steps comprising providing one or more additional material continuous sheets. The method may also include one or more additional steps of bonding one or more additional material continuous sheets, a first frame material continuous sheet, and additional material continuous sheets to form a laminated structure of an aerosol generating article comprising a frame core layer.

[0012] According to the present disclosure, a method for manufacturing an aerosol generating article for use with an aerosol generating device to generate an aerosol is provided. The method comprises: providing a first frame material continuous sheet and an additional material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the additional material continuous sheet below the first frame material continuous sheet; and joining the additional material continuous sheet and the first frame material continuous sheet to form a laminated structure of the aerosol generating article comprising the frame core layer.

[0013] Advantageously, the method according to the present disclosure enables the manufacture of an aerosol-generating article by laminating a continuous sheet of material through an automated process, resulting in an aerosol-generating article that is relatively easy and inexpensive to manufacture. Since the continuous sheet of material can be fed, laminated, and bonded at high speed (e.g. by an adhesive), the method according to the present application is suitable for mass production of aerosol-generating articles.

[0014] Advantageously, the frame of the aerosol-generating article is formed from a frame core layer. Advantageously, the frame can provide structural support for the generated aerosol-generating article. In particular, the frame can make the aerosol-generating article relatively thin while maintaining structural rigidity. By adjusting parameters such as the thickness and basis weight of the first frame material continuous sheet, it may advantageously be possible to control the rigidity of the frame and the overall structural strength of the aerosol-generating article.

[0015] Advantageously, the aperture of the frame core layer may define at least a portion of the airflow passage through the aerosol generating article. Additionally, the aperture of the frame core layer may define at least a portion of the internal cavity of the aerosol generating article where the aerosol generating substrate may be provided. By adjusting the thickness of the first frame material continuous sheet, it may advantageously be possible to control the volume of the internal cavity of the aerosol generating article.

[0016] In a specific preferred embodiment to be described in more detail below, the method may include the step of forming a laminated frame structure comprising a frame core layer by providing one or more additional frame material continuous sheets to be combined with a first frame material continuous sheet. Consequently, the laminated frame structure forms part of the laminated structure of an aerosol generating article. The one or more additional frame material continuous sheets can advantageously impart increased structural strength and stability to the aerosol generating article. Additionally, different sheet materials may be combined to impart desirable properties to the frame.

[0017] In a preferred embodiment to be described in more detail below, the method comprises the step of forming an air inlet and an air outlet of an aerosol generating article. Thus, a predetermined path for airflow through the aerosol generating article can be defined. More preferably, the step of forming the air inlet and the air outlet of the aerosol generating article comprises the step of establishing fluid communication between the air inlet and the air outlet through an internal cavity of the aerosol generating article. Thus, an aerosol generating material located within the cavity can advantageously be exposed to airflow through the aerosol generating article during use.

[0018] In a specific embodiment, the method may include the step of punching an air inlet aperture or an air outlet hole, or both, in one or more of the first frame material sheet and any additional frame material sheets. The air inlet aperture and the air outlet aperture formed in one or more sheets of frame material advantageously define at least partially the air inlet and the air outlet of the aerosol generating article. As will be discussed in more detail below, a certain preferred embodiment of the method according to the present invention advantageously allows for providing an air inlet or an air outlet, or both, at a precisely controlled location within the aerosol generating article in a manner that is relatively easy and inexpensive to control.

[0019] The additional material sheet may advantageously provide a surface of the aerosol generating article exposed to an airflow passage extending through the internal cavity of the aerosol generating article. The additional material sheet may advantageously provide a surface for supporting an aerosol generating substrate disposed within the internal cavity of the aerosol generating article. In a specific embodiment in which the additional material sheet comprises the aerosol generating substrate, the additional material sheet may advantageously provide a source of aerosol species exposed to an airflow passage extending through the internal cavity of the aerosol generating article.

[0020] Advantageously, the method according to the present disclosure may provide an aerosol generating article having one or more substantially flat outer surfaces, which, by allowing good contact with an external heater of an aerosol generating device, provides optimal heating of an aerosol generating substrate forming part of the aerosol generating article. For example, an aerosol generating article obtained by the method according to the present disclosure may be heated substantially along its entire length and width, thereby allowing the entire aerosol generating substrate forming part of the aerosol generating article to be heated sufficiently to generate an aerosol.

[0021] The method according to the present disclosure can be implemented in an existing apparatus configured for handling continuous sheet materials, supplying adhesive, cutting continuous sheet materials, etc., without extensive modification.

[0022] As used herein, the term "aerosol generating article" refers to an article comprising an aerosol generating material. The article can be heated upon use to generate an inhalable aerosol and deliver it to a consumer.

[0023] As used herein, the term "aerosol generating material" refers to a material capable of releasing a volatile compound upon heating, for example, a compound that generates an aerosol upon cooling and condensation when in use.

[0024] As used herein, the term "aerosol generating device" refers to a device that, when in use, interacts with an aerosol generating substrate of an aerosol generating article to generate an aerosol, for example, by heating it.

[0025] As used herein, the term “planar” may generally refer to a feature formed on a single Euclidean plane that is not wrapped around a curved non-planar shape or other non-planar shape, or otherwise is not conformed to be fitted with it. A planar surface extends two dimensions in a single Euclidean plane. A planar object extends two dimensions in a single Euclidean plane substantially further than at a third dimension perpendicular to the plane. More specifically, a planar object may extend at least two, five, or ten times further to a first dimension and a second dimension perpendicular to the first dimension than to a third dimension perpendicular to the first dimension.

[0026] As used herein, the term "transverse direction" refers to the direction extending between the first planar outer surface and the second planar outer surface.

[0027] As used herein, the term "longitudinal direction" refers to a direction perpendicular to the transverse direction. For example, it is the direction between the front and rear walls of an aerosol-generating article.

[0028] As used herein, the term "lateral direction" refers to a direction perpendicular to the transverse and longitudinal directions. For example, it is the direction from the first side wall to the second side wall of an aerosol-generating article.

[0029] As used herein, the term "thickness" refers to the maximum dimension in the transverse direction of an aerosol-generating article or a component of an aerosol-generating article.

[0030] As used herein, the term "length" refers to the maximum longitudinal dimension of an aerosol-generating article or a component of an aerosol-generating article.

[0031] As used herein, the term "width" refers to the maximum lateral dimension of an aerosol-generating article or a component of an aerosol-generating article.

[0032] As used herein, the terms “upstream” and “downstream” refer to the relative positions of a component or part of a component of an aerosol generating article with respect to the direction in which air or aerosol is transported through the aerosol generating article during use.

[0033] As used herein, the term "bulk density" may refer to the total weight of an aerosol generating material divided by the bulk volume of the aerosol generating material.

[0034] As used herein, the term "aerosol-forming agent" 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.

[0035] As used herein, the term "aerosol-forming agent content" may refer to the aerosol-forming agent content as a percentage based on dry weight, unless otherwise specified.

[0036] As used herein, "susceptor" refers to a conductive element that heats up when affected by a variable magnetic field. This may be the result of eddy currents and / or hysteresis losses induced within the susceptor element.

[0037] As used herein, the term "hydrophobic" refers to a surface that exhibits water repellency. One useful method for determining hydrophobicity is to measure the water contact angle. The "water contact angle" is the angle at which the liquid / vapor interface meets the solid surface, typically measured through a liquid. The water contact angle quantifies the wettability of a solid surface by a liquid using Young's equation.

[0038] As used herein, the term "equivalent diameter" of an opening or aperture is used herein to denote the diameter of a circular opening or aperture having the same cross-sectional area as the opening or aperture.

[0039] An aerosol generating article obtained by the method according to the present disclosure may comprise one or more aerosol generating materials.

[0040] An aerosol-generating article obtained by the method according to the present disclosure 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.

[0041] The aerosol generating article obtained by the method according to the present disclosure may be a substantially flat aerosol generating article or a substantially planar aerosol generating article. In particular, the thickness of the aerosol generating article may be less than 50% of both the length and width of the aerosol generating article. Advantageously, a thinner thickness may provide a small temperature gradient or temperature difference across the thickness of the aerosol generating substrate during heating.

[0042] The aerosol generating article may have a quadrilateral cuboid shape. The aerosol generating article may have a right-angled prism shape. The aerosol generating article may have a rectangular prism shape. The aerosol generating article may have a cylindrical shape. The aerosol generating article may have a right-angled cylindrical shape.

[0043] The aerosol generating article obtained by the method according to the present disclosure may generally have a laminated structure, for example, the aerosol generating article may comprise or be formed therefrom at least two layers.

[0044] More specifically, the aerosol generating article may include at least a frame core layer and an additional layer.

[0045] The frame core layer forms the frame of the aerosol-generating article (alone or in combination with one or more additional frame layers, as described below). The characteristics of the frame of the aerosol-generating article will be discussed in more detail below.

[0046] The additional layer may be a second frame layer. The frame core layer and the second frame layer may be bonded to form a laminated frame structure. The aerosol generating article may additionally include a third frame layer. The frame core layer, the second frame layer, and the third frame layer may be bonded to form a laminated frame structure.

[0047] The additional layer may be a first outer layer. With reference to an aerosol generating article having a laminated structure, the term “outer layer” is used herein to denote a layer of the aerosol generating article that is at least partially exposed to the outside of the aerosol generating article. That is, the surface of the outer layer defines at least a portion of the outer surface of the aerosol generating article.

[0048] The additional layer may be a first inner layer. With reference to an aerosol generating article having a laminated structure, the term “inner layer” is used herein to denote a layer of material that generally does not form part of the frame and is not exposed to the outside of the aerosol generating article. That is, the inner layer is contained between two other adjacent layers of the laminated structure. In an example of a method in which the additional layer is the first inner layer, it will be understood that at least an outer layer is provided and bonded to the first inner layer and the frame to complete the laminated structure of the aerosol generating article.

[0049] In one example, the aerosol generating article may include a frame core layer and a first outer layer.

[0050] In one example, the aerosol generating article may include a frame core layer, a first inner layer, and a first outer layer, wherein the first inner layer is arranged between the frame core layer and the first outer layer.

[0051] In one example, the aerosol generating article may include a frame core layer, a first outer layer, and a second outer layer, wherein the frame core layer is arranged between the first outer layer and the second outer layer.

[0052] In one example, the aerosol generating article may include: a frame core layer, a first inner layer, a first outer layer, and a second outer layer; wherein the frame core layer is arranged between the first outer layer and the second outer layer, and the first inner layer is arranged between the frame core layer and the first outer layer or between the frame core layer and the second outer layer.

[0053] In one example, the aerosol generating article may include: a frame core layer, a first inner layer, a second inner layer, a first outer layer, and a second outer layer; wherein the frame core layer is arranged between the first outer layer and the second outer layer; the first inner layer is arranged between the frame core layer and the first outer layer; and the second inner layer is arranged between the frame core layer and the second outer layer.

[0054] In one example, the aerosol generating article may include a laminated frame structure, a first inner layer, and a first outer layer, wherein the first inner layer is arranged between the laminated frame structure and the first outer layer. The laminated frame structure may include a frame core layer and a second frame layer. The laminated frame structure may include a frame core layer, a second frame layer, and a third frame layer, wherein the core frame layer is included between the second frame layer and the third frame layer.

[0055] In one example, the aerosol generating article may include a laminated frame structure, a first outer layer, and a second outer layer, wherein the laminated frame structure is arranged between the first outer layer and the second outer layer. The laminated frame structure may include a frame core layer and a second frame layer. The laminated frame structure may include a frame core layer, a second frame layer, and a third frame layer, wherein the frame core layer is included between the second frame layer and the third frame layer.

[0056] In one example, the aerosol generating article may include: a laminated frame structure, a first inner layer, a first outer layer, and a second outer layer; the laminated frame structure is arranged between the first outer layer and the second outer layer, and the first inner layer is arranged between the laminated frame structure and the first outer layer. The laminated frame structure may include a frame core layer and a second frame layer. The laminated frame structure may include a frame core layer, a second frame layer, and a third frame layer, wherein the frame core layer is included between the second frame layer and the third frame layer.

[0057] In one example, the aerosol generating article may include: a laminated frame structure, a first inner layer, a second inner layer, a first outer layer, and a second outer layer; the laminated frame structure is arranged between the first outer layer and the second outer layer; the first inner layer is arranged between the laminated frame structure and the first outer layer; and the second inner layer is arranged between the laminated frame structure and the second outer layer. The laminated frame structure may include a frame core layer and a second frame layer. The laminated frame structure may include a frame core layer, a second frame layer, and a third frame layer, wherein the frame core layer is included between the second frame layer and the third frame layer.

[0058] Referring to the stacked frame structure, any one of the core frame layer, the first frame layer, and the second frame layer may be provided in a stacked form in sequence (if present).

[0059] That is, the core frame layer itself may include at least two layers of frame material. In one example, the core frame layer itself may include three layers of frame material.

[0060] Similarly, the second frame layer itself may include at least two layers of frame material. In one example, the second frame layer may include three layers of frame material.

[0061] In a similar manner, the third frame layer itself may include at least two layers of frame material. In one example, the third frame layer may include three layers of frame material.

[0062] In a preferred example, the laminated frame structure comprises a frame core layer, a second frame layer, and a third frame layer, wherein the frame core layer is included between the first frame layer and the second frame layer, and each of the frame core layer, the second frame layer, and the third frame layer comprises two layers of frame material. That is, the laminated structure comprises six layers of frame material.

[0063] In another preferred example, the laminated frame structure comprises a frame core layer, a second frame layer, and a third frame layer, wherein the frame core layer is included between the first frame layer and the second frame layer, and each of the frame core layer, the second frame layer, and the third frame layer comprises three layers of frame material. That is, the laminated structure comprises nine layers of frame material.

[0064] Therefore, the total thickness of the frame or laminated frame structure can be adjusted and controlled by selecting a frame material sheet or layer having a specific thickness.

[0065] For example, nine layers of frame material, each having a thickness of 0.33 mm, can be combined to form a laminated frame structure having a (total) thickness of 3 mm.

[0066] Similarly, six layers of frame material, each having a thickness of 0.5 mm, can be combined to form a laminated frame structure having a (total) thickness of 3 mm.

[0067] Referring to the method according to the present disclosure, the term “protective layer” refers to a layer of material provided on an outer layer of an aerosol-generating article and removable from the aerosol-generating article before use.

[0068] Accordingly, in one example, the method according to the present disclosure may provide a product comprising an aerosol generating article having a laminated structure consistent with the foregoing description and a first protective layer removablely arranged on a first outer layer of the aerosol generating article. Another example of the method according to the present disclosure may provide a product comprising an aerosol generating article having a laminated structure consistent with the foregoing description, a first protective layer removablely arranged on a first outer layer of the aerosol generating article, and a second protective layer removablely arranged on a second outer layer of the aerosol generating article.

[0069] As used herein with reference to the method according to the present disclosure, the terms “frame material sheet” and “frame sheet material” are used to refer to a sheet material for forming a layer of a frame of an aerosol generating material or a laminated frame structure of an aerosol generating article consistent with the foregoing description.

[0070] As used herein with reference to the method according to the present disclosure, the term “continuous” is used to denote a sheet of material that is continuously extended in the longitudinal direction, such as a sheet of material supplied when unwound from a bobbin, for example. A framed continuous sheet of material has a first side edge and an opposing second side edge that define a longitudinal length and a transverse width between them. The framed continuous sheet of material has a thickness substantially perpendicular to both the length and the width.

[0071] As used herein with reference to the method according to the present disclosure, the terms “inner layer material sheet” and “inner layer sheet material” are used to refer to a sheet material for forming an inner layer of an aerosol generating material consistent with the foregoing description.

[0072] As used herein with reference to the method according to the present disclosure, the terms “outer layer material sheet” and “outer layer sheet material” are used to refer to a sheet material for forming an outer layer of an aerosol generating material consistent with the foregoing description.

[0073] As used herein with reference to the method according to the present disclosure, the terms “protective layer material sheet” and “protective layer sheet material” are used to refer to a sheet material for providing a protective layer over an outer layer of an aerosol generating material consistent with the foregoing description.

[0074] A substantially whole of the aerosol-generating article obtained by the method according to the present disclosure may be paper or cardboard, except for one or more aerosol-generating substrates (if present) and an adhesive (if present).

[0075] Aerosol-generating articles may have a cellulose acetate content of less than 5%. Aerosol-generating articles may have a cellulose acetate content of less than 3%. Aerosol-generating articles may have a cellulose acetate content of less than 1%.

[0076] As briefly described above, an example of a method for manufacturing an aerosol generating article according to the present disclosure comprises: providing a first frame material continuous sheet and an additional material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the additional material continuous sheet below the first frame material continuous sheet; and joining the additional material continuous sheet and the first frame material continuous sheet to form a laminated structure of the aerosol generating article comprising the frame core layer.

[0077] In the context of the present disclosure, as used with reference to the example of a method for manufacturing an aerosol-generating article described below, the expression “step of bonding a first frame material continuous sheet and a material continuous sheet” is used to describe a step in which a bond is formed—e.g. by an adhesive—so that the first frame material continuous sheet and the material continuous sheet are laminated together.

[0078] In some examples, the expression "step of bonding the first frame material continuous sheet and the material continuous sheet" means that the material continuous sheet is directly bonded to the first frame material continuous sheet. That is, the material continuous sheet is placed adjacent to the first frame material continuous sheet, and a bond is directly established between the material continuous sheet and the first frame material continuous sheet. For example, an adhesive may be provided between the material continuous sheet and the first frame material continuous sheet.

[0079] However, more generally, the expression "step of bonding the first frame material continuous sheet and the material continuous sheet" means that the material continuous sheet is bonded directly or indirectly to the first frame material continuous sheet. That is, the material continuous sheet may not be placed adjacent to the first frame material continuous sheet, because—as described in more detail below with reference to specific embodiments—the laminated structure includes one or more material intermediate continuous sheets contained between the first frame material continuous sheet and an additional frame material continuous sheet, wherein the one or more material intermediate continuous sheets are bonded to the first frame material continuous sheet beforehand. Thus, the expression "step of bonding the first frame material continuous sheet and the material continuous sheet" may mean that a direct bond is established between the material continuous sheet and one or more material intermediate continuous sheets. For example, an adhesive may be provided between the material continuous sheet and one or more material intermediate continuous sheets. Consequently, an indirect bond is established between the material continuous sheet and the first frame material sheet.

[0080] In the aerosol generating article obtained by the above method, the frame core layer provides or forms a part of a planar frame. A frame aperture extending through the frame core layer may define or form a part of the airflow passage of the aerosol generating article. A frame aperture extending through the frame core layer may define or form a part of the internal cavity of the aerosol generating article.

[0081] Generally, the planar frame of an aerosol generating article comprises a first planar surface (e.g., a bottom surface) and a second planar surface (e.g., a top surface). The planar frame may include an outer surface around the frame. The outer surface around the frame may extend transversely, for example, between the first outer surface around the frame and the second outer surface around the frame. The outer surface around the frame may at least partially define or form one or more outer surfaces of the aerosol generating article. For example, the outer surface around the frame may at least partially define or form one or more periphery walls of the aerosol generating article. The outer surface around the frame may surround or encircle the frame aperture. The outer surface around the frame may surround or encircle an internal cavity.

[0082] A planar frame may include an inner surface of the frame. The inner surface of the frame may extend in a transverse direction, for example, between a first planar surface and a second planar surface. The inner surface of the frame may define or at least form a portion of the wall surface surrounding the frame aperture. The inner surface of the frame may define or at least form a portion of the wall surrounding the inner cavity. The outer surface surrounding the frame may surround or encircle the inner surface of the frame. The inner surface of the frame and the outer surface surrounding the frame may be concentric with each other.

[0083] In the aforementioned example, the first planar surface of the frame core layer may define or at least partially form the first planar surface of the planar frame, whereas the second planar surface of the frame core layer may define or at least partially form the second planar surface of the planar frame.

[0084] In another example described above, the aerosol generating article comprises a stacked frame structure, and the first planar surface and the second planar surface of the planar frame may be defined by a corresponding planar surface of one of the frame layers forming the stacked frame structure according to a specific arrangement of the frame layers.

[0085] More specifically, in an aerosol generating article in which a laminated frame structure comprises a frame core layer and a second frame layer, the planar surface of the frame core layer may define or at least partially form a first planar surface of the planar frame, while the planar surface of the second frame layer may define or at least partially form a second planar surface of the planar frame.

[0086] Similarly, in an aerosol generating article in which the stacked frame structure comprises the frame core layer, the second frame layer, and the third frame layer, and the frame core layer is included between the second frame layer and the third frame layer, the planar surface of the second frame layer may define or at least partially form the first planar surface of the planar frame, whereas the planar surface of the third frame layer may define or at least partially form the second planar surface of the planar frame.

[0087] In some embodiments of the above method, the additional material continuous sheet is a second frame material continuous sheet.

[0088] That is, the above method comprises: providing a first frame material continuous sheet and a second material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the second frame material continuous sheet below the first frame material continuous sheet; and bonding the second frame material continuous sheet and the frame core layer to form a laminated structure of an aerosol generating article.

[0089] A laminated frame structure is formed by joining a second frame material continuous sheet and a first frame material continuous sheet. The laminated frame structure includes a frame core layer and a second frame layer.

[0090] The first frame material continuous sheet and the second frame material continuous sheet may differ by at least one characteristic, such as sheet thickness or sheet composition, for example. Accordingly, the step of bonding the first frame material continuous sheet and the second frame material continuous sheet can advantageously provide a laminated structure that benefits from a combination of different characteristics.

[0091] In an embodiment where the additional material continuous sheet is a second frame material continuous sheet, the step of joining the additional material continuous sheet and the first frame material continuous sheet may be performed before the step of forming a frame by forming a frame aperture through the first frame material continuous sheet. That is, the step of forming a frame aperture through the first frame material continuous sheet may be performed after the stacked frame structure is formed. Accordingly, the step of forming a frame aperture through the first frame material continuous sheet may be performed such that the frame aperture extends through both the first frame material continuous sheet and the second frame material continuous sheet.

[0092] Alternatively, in an embodiment where the additional material continuous sheet is a second frame material continuous sheet, the step of joining the additional material continuous sheet and the first frame material continuous sheet may be performed after the step of forming a frame aperture through the first frame material continuous sheet. Thus, the second frame material continuous sheet joined to the first frame material continuous sheet may provide a bottom surface for a cavity of an aerosol-generating article that is at least partially partitioned by the frame aperture.

[0093] In an embodiment where the additional material continuous sheet is a second frame material continuous sheet, the method may further include the steps of providing a third frame material continuous sheet, positioning the third frame material continuous sheet on a first frame material continuous sheet; and bonding the third frame material continuous sheet and the first frame material continuous sheet. By bonding the third frame material continuous sheet and the first frame material continuous sheet, a laminated frame structure comprising three layers of sheet material may advantageously be formed. More specifically, the laminated frame structure comprises a frame core layer, a second frame layer, and a third frame layer.

[0094] In one example, the method comprises the step of positioning a third frame material continuous sheet on a first frame material continuous sheet. Consequently, the second frame material continuous sheet and the third frame material continuous sheet are bonded to opposite sides of the first frame material continuous sheet, and thus, in a laminated frame structure, the first frame material continuous sheet is contained between the second frame material continuous sheet and the third frame material continuous sheet. Thus, a frame of an aerosol generating article can be obtained, wherein the frame core layer is contained between the second frame layer and the third frame layer.

[0095] In another example, the method includes the step of positioning a third frame material continuous sheet below a second frame material continuous sheet. Consequently, the first frame material continuous sheet, the second frame material continuous sheet, and the third frame material continuous sheet are bonded together so that the second frame material continuous sheet and the third frame material continuous sheet are arranged on the same side of the first frame material continuous sheet. Thus, in the laminated frame structure, the second frame material continuous sheet is contained between the first frame material continuous sheet and the third frame material continuous sheet. Thus, a frame of an aerosol generating article can be obtained, wherein the second frame layer is contained between the frame core layer and the third frame layer.

[0096] A continuous third sheet of continuous frame material may be different from at least one of a first continuous sheet of frame material and a second continuous sheet of frame material. Accordingly, the step of joining the first continuous sheet of frame material, the second continuous sheet of frame material, and the third continuous sheet of frame material can advantageously provide a laminated frame structure that benefits from a combination of different characteristics.

[0097] In an embodiment comprising the steps of providing a third frame material continuous sheet and joining the third frame material continuous sheet and the first frame material continuous sheet, the step of joining the third frame material continuous sheet and the first frame material continuous sheet may be performed before the step of forming a frame aperture through the first frame material continuous sheet, and after or simultaneously with the step of joining the second frame material continuous sheet and the first frame material continuous sheet. Accordingly, the step of forming a frame aperture through the first frame material continuous sheet may be performed such that the frame aperture extends through both the first frame material continuous sheet and the second and third frame material continuous sheets.

[0098] Alternatively, in an embodiment comprising the steps of providing a third frame material continuous sheet and joining the third frame material continuous sheet and the first frame material continuous sheet, the step of joining the third frame material continuous sheet and the first frame material continuous sheet may be performed after the step of forming a frame aperture through the first frame material continuous sheet to form a frame core layer. Thus, the additional material continuous sheet joined to the first frame material continuous sheet may provide a bottom surface for the cavity of the aerosol generating article that is at least partially partitioned by the frame aperture. Thus, when the second frame material continuous sheet and the third frame material continuous sheet are joined to the opposite side of the first frame material continuous sheet, the second frame material continuous sheet and the third frame material continuous sheet joined to the first frame material continuous sheet may provide a bottom surface and a top surface, respectively, for the cavity of the aerosol generating article that is at least partially partitioned by the frame aperture.

[0099] Referring to the method according to the present disclosure described above, in some examples, the step of providing a first continuous sheet of frame material comprises: providing a first continuous laminate layer of the first frame material and a second continuous laminate layer of the first frame material; positioning the second continuous laminate layer of the first frame material below the first continuous laminate layer of the first frame material; and bonding the first continuous laminate layer of the frame material and the second continuous laminate layer of the first frame material to form a first continuous sheet of frame material.

[0100] In another example, the steps of: providing a first continuous laminate layer of the first frame material, a second continuous laminate layer of the first frame material, and a third continuous laminate layer of the first frame material; positioning the first continuous laminate layer of the first frame material between the second continuous laminate layer of the first frame material and the third continuous laminate layer of the first frame material; and bonding the first continuous laminate layer of the first frame material, the second continuous laminate layer of the first frame material, and the third continuous laminate layer of the first frame material to form a first frame material continuous sheet.

[0101] Referring to the method according to the present disclosure described above, when a second frame sheet material continuous sheet is combined with a first frame material continuous sheet, in some examples, the step of providing the second frame material continuous sheet comprises: providing a first continuous laminate layer of the second frame material and a second continuous laminate layer of the second frame material; positioning the second continuous laminate layer of the second frame material below the first continuous laminate layer of the second frame material; and bonding the first continuous laminate layer of the second frame material and the second continuous laminate layer of the second frame material to form a second frame material continuous sheet.

[0102] In another example, the method includes the steps of: providing a first continuous laminate layer of the second frame material, a second continuous laminate layer of the second frame material, and a third continuous laminate layer of the second frame material; positioning the first continuous laminate layer of the second frame material between the second continuous laminate layer of the second frame material and the third continuous laminate layer of the second frame material; and bonding the first continuous laminate layer of the second frame material, the second continuous laminate layer of the second frame material, and the third continuous laminate layer of the second frame material to form a second frame material continuous sheet.

[0103] Referring to the method according to the present disclosure described above, a second frame sheet material continuous sheet and a third frame material continuous sheet are combined with a first frame material continuous sheet, and in some examples, the step of providing the third frame material continuous sheet comprises: providing a first continuous laminate layer of the third frame material and a second continuous laminate layer of the third frame material; positioning the second continuous laminate layer of the third frame material below the first continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material and the second continuous laminate layer of the third frame material to form the third frame material continuous sheet.

[0104] In another example, the step of providing a third frame material continuous sheet comprises: providing a first continuous laminate layer of the third frame material, a second continuous laminate layer of the third frame material, and a third continuous laminate layer of the third frame material; positioning the first continuous laminate layer of the third frame material between the second continuous laminate layer of the third frame material and the third continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material, the second continuous laminate layer of the third frame material, and the third continuous laminate layer of the third frame material to form a third frame material continuous sheet.

[0105] Preferably, the method according to the present disclosure further comprises the step of forming an air inlet and an air outlet of an aerosol generating article. More preferably, the step of forming an air inlet and an air outlet of an aerosol generating article comprises the step of establishing fluid communication between the air inlet and the air outlet through an internal cavity of the aerosol generating article, wherein the internal cavity is at least partially defined by a frame aperture within a frame core layer.

[0106] In one example, the step of forming the air inlet and air outlet of the aerosol generating article may be performed after the frame core layer is formed. In particular, the step of forming the air inlet and air outlet of the aerosol generating article may be performed after a laminated frame structure including the frame core layer is formed as described above.

[0107] Alternatively, the air inlet and air outlet of the aerosol generating article may be formed together with a frame core layer or, more generally, with a laminated frame structure comprising a frame core layer. That is, the method may include an additional step of forming the air inlet and air outlet of the aerosol generating article simultaneously with the formation of the frame—whether the frame comprises only a frame core layer or a frame having a laminated frame structure consistent with the foregoing description.

[0108] To this end, the method according to the present invention may include the step of forming an air inlet aperture or an air outlet aperture, or both, through a first continuous sheet of frame material. Accordingly, a frame core layer is obtained that includes not only the frame aperture but also one or both of the air inlet aperture and the air outlet aperture.

[0109] One or both of the frame aperture, air inlet aperture, and air outlet aperture may advantageously be formed to ultimately define a continuous passage extending through the frame core layer. For example, in the step of forming the air inlet aperture or the air outlet aperture or both through a first frame material continuous sheet, the air inlet aperture and the air outlet aperture may be formed to define an uninterrupted passage extending through the frame core layer from the air inlet aperture to the air outlet aperture.

[0110] In an embodiment in which an additional material continuous sheet is a second frame material continuous sheet and a laminated frame structure comprising a frame core layer and a second frame layer is formed, the method may include the step of forming an air inlet aperture or an air outlet aperture, or both, through only the first frame material continuous sheet. Accordingly, in the laminated frame structure, the air inlet or the air outlet, or both, may be formed such that the air inlet or the air outlet, or both, extend through the frame core layer but not through the second frame layer.

[0111] Alternatively, in an embodiment in which an additional material continuous sheet is a second frame material continuous sheet and a laminated frame structure comprising a frame core layer and a second frame layer is formed, the method may include the step of forming an air inlet aperture or an air outlet aperture, or both, through both the first frame material continuous sheet and the second frame material continuous sheet. Thus, in the laminated frame structure, the air inlet or the air outlet, or both, may be formed so that the air inlet or the air outlet, or both, extend through both layers of the laminated frame structure.

[0112] These alternatives provide a desirable degree of adaptability in which the size of the air inlet or the size of the air outlet, or both, can be adjusted. For example, in an embodiment where the frame aperture is formed through both a first continuous sheet of frame material and a second continuous sheet of frame material, the method can be conveniently configured to form an air inlet or an air outlet, or both, having the same height as the frame aperture. Alternatively, the method can be equally conveniently adapted to form an air inlet or an air outlet, or both, having a different height relative to the frame aperture. For example, the air inlet or the air outlet, or both, may extend through a single layer of the stacked frame structure, whereas the frame aperture may extend through multiple layers of the stacked frame structure, or It is the opposite. there is.

[0113] In an embodiment in which an additional material continuous sheet is a second frame material continuous sheet and a third frame material continuous sheet is provided and bonded to another sheet of frame material, and a laminated frame structure comprising a frame core layer, a second frame layer, and a third frame layer is formed, the method may include the step of forming an air inlet aperture or an air outlet aperture, or both, through only the first frame material continuous sheet. Accordingly, in the laminated frame structure, the air inlet or the air outlet, or both, may be formed so as to extend through the frame core layer but not through either the second frame layer or the third frame layer.

[0114] This may be advantageous in that the second frame layer and the third frame layer can at least partially form a planar surface that partitions an air inlet or an air outlet or both. More specifically, the first frame layer and the second frame layer can define a slit-shaped air inlet (outlet) together with an air inlet (outlet) aperture.

[0115] Alternatively, in an embodiment in which an additional material continuous sheet is provided as a second frame material continuous sheet and a third frame material continuous sheet is provided to be bonded to another sheet of frame material, and a laminated frame structure comprising a frame core layer, a second frame layer, and a third frame layer is formed, the method may include the step of forming an air inlet aperture or an air outlet aperture, or both, through all of the first frame material continuous sheet, the second frame material continuous sheet, and the third frame material continuous sheet. Thus, in the laminated frame structure, the air inlet or the air outlet, or both, may be formed so that the air inlet or the air outlet, or both, extend through all three layers of the laminated frame structure.

[0116] These alternatives provide an additional desirable degree of adaptability in which the size of the air inlet or the size of the air outlet, or both, can be adjusted.

[0117] A continuous sheet of frame material having a frame core layer and any additional layer of a frame laminated structure formed thereon may be manufactured from or include a biodegradable material. A continuous sheet of frame material having a frame core layer and any additional layer of a frame laminated structure formed thereon may be manufactured entirely from a biodegradable material.

[0118] A continuous sheet of frame material, having a frame core layer and any additional layer of the frame laminated structure formed therein, may be manufactured from or contain a cellulose material. The cellulose material may contain cellulose fibers. The cellulose material may be paper, paperboard, or cardboard. A continuous sheet of frame material, having a frame core layer and any additional layer of the frame laminated structure formed therein, may be manufactured from or contain a plant material such as tobacco. The frame may be manufactured entirely from a cellulose material.

[0119] Preferably, the method according to the present invention includes the step of providing a first outer layer material continuous sheet.

[0120] More preferably, the method includes the step of providing a first outer layer material continuous sheet and a second outer layer material continuous sheet.

[0121] Additionally, the method preferably includes the step of positioning a first frame material continuous sheet and a second frame material sheet between a first outer layer material continuous sheet and a second outer layer material continuous sheet.

[0122] Preferably, the method further includes the step of bonding a first outer layer material continuous sheet, a second outer layer material continuous sheet, and a frame core layer.

[0123] Accordingly, it is advantageously possible to provide an aerosol generating article having a laminated structure that is not exposed to the outside of the aerosol generating article, whether the frame comprises only a frame-frame core layer or a frame having a laminated frame structure consistent with the foregoing description. This is because the first outer layer material continuous sheet and the second outer layer material continuous sheet each form the first outer layer and the second outer layer of the laminated structure of the article.

[0124] Accordingly, the first outer layer material continuous sheet and the second outer layer material continuous sheet advantageously define or at least partially form the first planar surface (e.g., bottom surface) and the second planar surface (e.g., top surface) of the aerosol generating article. Thus, it may be possible to customize the surface characteristics of the aerosol generating article by selecting a suitable outer layer sheet material.

[0125] Referring to the method according to the present disclosure comprising the provision of an outer layer material continuous sheet, the expression “step of positioning a first frame material continuous sheet and a second material continuous sheet between the first outer layer material continuous sheet and the second outer layer material continuous sheet” may indicate a step in which the first outer layer material continuous sheet is actually positioned directly below the second material continuous sheet and the second outer layer material continuous sheet is actually positioned directly above the first frame material continuous sheet. However, the expression “step of positioning a first frame material continuous sheet and a second material continuous sheet between the first outer layer material continuous sheet and the second outer layer material continuous sheet” is more generally intended to indicate a step in which the first frame material continuous sheet, along with any additional continuous layer of frame material provided to form a laminated frame structure including a frame core layer, and any inner layer material continuous sheet provided as described in detail below, are sandwiched between the first outer layer material continuous sheet and the second outer layer material continuous sheet.

[0126] For example, one or both of the first outer layer material continuous sheet and the second outer layer material continuous sheet may include a wrapper material. The outer layer of the aerosol generating article including the wrapper material may also be represented as an outer wrapper.

[0127] In some examples, one or both of the outer wrappers may be hydrophobic. One or both of the first outer layer material continuous sheet and the second outer layer material continuous sheet may include a hydrophobic material.

[0128] More generally, one or both of the first outer layer material continuous sheet and the second outer layer material continuous sheet may comprise or be manufactured from a cellulose material. The cellulose material may be paper, cigarette paper, tobacco paper, cardboard, wood, fabric, natural fiber, or artificial fiber.

[0129] In some examples, one or both of the first outer layer material continuous sheet and the second outer layer material continuous sheet may comprise or be manufactured from an aerosol generating substrate comprising an aerosol generating material. The aerosol generating material may be any aerosol generating material of the type described in more detail below. 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 sheet of aerosol generating material described herein.

[0130] One or both of the first outer layer material continuous sheet and the second outer layer material continuous sheet may have a thickness of 25㎛ or more, 30㎛ or more, 35㎛ or more, 40㎛ or more, or 45㎛ or more.

[0131] One or both of the first outer layer material continuous sheet and the second outer layer material continuous sheet may have a thickness of 55㎛ or less, 50㎛ or less, 45㎛ or less, 40㎛ or less, or 35㎛ or less.

[0132] One or both of the first outer layer material continuous sheet and the second outer layer material continuous sheet may have a thickness of 25㎛ to 55㎛, 25㎛ to 45㎛, or 30㎛ to 45㎛.

[0133] In some embodiments of the above method, the additional material continuous sheet is a first inner layer material continuous sheet.

[0134] That is, the above method comprises: a step of providing a first frame material continuous sheet and a first inner layer material continuous sheet; a step of forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; a step of positioning the first inner layer material continuous sheet below the first frame material continuous sheet; and a step of bonding the first inner layer material continuous sheet and the first frame material continuous sheet to form a laminated structure of an aerosol generating article.

[0135] Accordingly, an aerosol generating article having a laminated structure can be advantageously obtained, wherein an inner layer of a non-frame material can be provided adjacent to a frame core layer. This may have the advantage that a material having certain desirable characteristics can be directly exposed to an internal cavity at least partially defined by the frame aperture.

[0136] For example, the first inner layer material continuous sheet may comprise an aerosol generating substrate, or the first inner layer material continuous sheet may be an aerosol generating material continuous sheet (e.g., a sheet of homogenized tobacco material). As the first inner layer material continuous sheet, which is directly bonded below the frame aperture, defines or at least partially forms the bottom surface of the inner cavity of the aerosol generating article, the aerosol generating substrate or material contained in the first inner layer material continuous sheet may advantageously be exposed to the interior of the cavity and to an airflow passage extending between the inlet and outlet of the aerosol generating article through the cavity. In another example, the first inner layer material continuous sheet may comprise a susceptor material. This may be advantageous in that such an inner layer comprising a susceptor material can be used to supply heat to an aerosol generating substrate that may be provided within the inner cavity defined at least partially by the frame aperture, as described in more detail below.

[0137] In certain embodiments, the method further comprises the steps of providing a second inner layer material continuous sheet, positioning the second inner layer material continuous sheet on a first frame material continuous sheet, and joining the second inner layer material continuous sheet and the first frame material continuous sheet.

[0138] Accordingly, an aerosol generating article having a stacked structure can be advantageously obtained, wherein the frame core layer is included between two inner layers of non-frame material.

[0139] The first inner layer material continuous sheet and the second inner layer material continuous sheet may differ by at least one characteristic, for example, sheet composition. For example, one of the first inner layer material continuous sheet and the second inner layer material continuous sheet may include an aerosol generating material, while the other of the first inner layer material continuous sheet and the second inner layer material continuous sheet does not include an aerosol generating material. One of the first inner layer material continuous sheet and the second inner layer material continuous sheet may include an aerosol generating material, while the other of the first inner layer material continuous sheet and the second inner layer material continuous sheet includes a susceptor material. Accordingly, the step of bonding the inner first frame material continuous sheet, the first inner layer material continuous sheet and the inner second frame material continuous sheet may advantageously provide a laminated structure that benefits from a combination of different characteristics.

[0140] It will be apparent from the foregoing description that the method according to the present disclosure is advantageously adaptable to providing an aerosol generating article having a stacked structure of varying complexity, including a frame. In fact, with reference to specific embodiments of the method according to the present disclosure, specific steps previously described may be combined to advantageously adapt the resulting method to form an aerosol generating article having a more complex stacked structure.

[0141] For example, a specific step previously described with reference to an embodiment of a method configured to form an aerosol generating article comprising a stacked frame structure may be combined with the step described above with reference to an embodiment of a method configured to form an aerosol generating article comprising an inner layer of a non-frame material.

[0142] In one example, the method according to the present invention comprises: providing a first frame material continuous sheet and a second frame material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the second frame material continuous sheet below the first frame material continuous sheet; joining the second frame material continuous sheet and the first frame material continuous sheet to form a stacked frame structure; and further providing a first inner layer material continuous sheet; positioning the first inner layer material continuous sheet below the stacked frame structure; joining the first inner layer material continuous sheet and the stacked frame structure; optionally providing a second inner layer material continuous sheet; positioning the second inner layer material continuous sheet above the stacked frame structure; and joining the second inner layer material continuous sheet and the stacked frame structure to form a stacked structure of the aerosol generating article.

[0143] This example of the method according to the present disclosure is advantageously configured to provide an aerosol generating article having a double-layer laminated frame structure combined with one or two layers of an internal sheet material.

[0144] Additionally, the specific steps described above in relation to the step of forming an outer layer of an aerosol-generating article may advantageously be combined with examples of the method according to the present disclosure. Thus, the method is:

[0145] The method may further include the steps of: providing a first outer layer material continuous sheet and a second outer layer material continuous sheet; positioning the laminated frame structure, a first inner layer material continuous sheet, and optionally a second inner layer material continuous sheet between the first outer layer material continuous sheet and the second outer layer material continuous sheet; and joining the first outer layer material continuous sheet, the second outer layer material continuous sheet, and the laminated frame structure to form a laminated structure of an aerosol generating article.

[0146] In another example, the method according to the present invention comprises: providing a first frame material continuous sheet and a second frame material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the second frame material continuous sheet below the first frame material continuous sheet; joining the second frame material continuous sheet and the first frame material continuous sheet; providing a third frame material continuous sheet; joining the third frame material continuous sheet and the first frame material continuous sheet to form a stacked frame structure; and additionally, providing a first inner layer material continuous sheet; positioning the first inner layer material continuous sheet below the stacked frame structure; joining the first inner layer material continuous sheet and the stacked frame structure; optionally providing a second inner layer material continuous sheet, positioning the second inner layer material continuous sheet above the stacked frame structure, and joining the second inner layer material continuous sheet and the stacked frame structure to form a stacked structure of an aerosol generating article.

[0147] This example of the method according to the present disclosure is advantageously configured to provide an aerosol generating article having a three-layer laminated frame structure combined with one or two layers of an inner sheet material.

[0148] Additionally, the specific steps described above in relation to the step of forming an outer layer of an aerosol-generating article may advantageously be combined with examples of the method according to the present disclosure. Thus, the method is:

[0149] The method may further include the steps of: providing a first outer layer material continuous sheet and a second outer layer material continuous sheet; positioning the laminated frame structure, the first inner layer material continuous sheet, and optionally the second inner layer material continuous sheet between the first outer layer material continuous sheet and the second outer layer material continuous sheet; and joining the first outer layer material continuous sheet, the three-layer laminated frame structure, and optionally the second outer layer material continuous sheet to form a laminated structure of an aerosol generating article.

[0150] It will be obvious to those skilled in the art that the above-described method can be further adapted to form aerosol generating articles having a much more complex structure, such as those comprising multiple layers of inner sheet material having different characteristics, for different purposes, or both.

[0151] Any one of the methods discussed in the foregoing description may further include the step of providing a continuous sheet of a first protective layer material that can be removed from an aerosol-generating article before use.

[0152] More specifically, the method according to the present disclosure may further include the steps of: providing a first protective layer material continuous sheet; positioning the first protective layer material continuous sheet on a frame core layer and an additional material continuous sheet; and optionally, removably bonding the first protective layer material continuous sheet and the frame core layer.

[0153] Referring to the method according to the present disclosure, the expression “step of positioning a first protective layer material continuous sheet on a frame core layer” may indicate a step in which the first protective layer material continuous sheet is actually arranged directly on the frame core layer. However, the expression “step of positioning a first protective layer material continuous sheet on a frame core layer” is more generally intended to indicate a step in which the first protective layer material continuous sheet is arranged not only on the frame core layer but also on any other continuous sheet positioned on the frame core layer to form a laminated structure of an aerosol generating article. This includes any additional frame material continuous sheet, any inner layer material continuous sheet, and any outer layer material continuous sheet, which may be combined with the frame core layer according to an embodiment of the method according to the foregoing description.

[0154] Advantageously, the step of placing a continuous sheet of protective layer material over all layers of the laminated structure of the aerosol generating article has the advantage that the aerosol generating article can be provided to a consumer in a configuration that helps preserve specific characteristics of the aerosol generating article, for example, during transport and storage. The protective layer can generally be separated from the aerosol generating article, for example, immediately before use.

[0155] Materials suitable for forming a protective layer will be known to those skilled in the art.

[0156] When a laminated structure comprising continuous sheets of material provided, positioned, and bonded as described above is formed, one or more aerosol-generating articles can be obtained by punching one or more apertures through each of two or more continuous sheets of material. Accordingly, one or more aerosol-generating articles can be discharged from the remainder of the laminated structure.

[0157] Advantageously, individual aerosol generating articles can be conveniently provided so that consumers can use them as they are or after removing any protective layer where present. The obtained individual aerosol generating articles

[0158] Alternatively, as described above, one or more weakened lines of severance may be formed through a laminated structure comprising continuous sheets of material that are provided and positioned to be aligned with one another, thereby making one or more aerosol-generating articles separable from the remainder of the laminated structure.

[0159] In one example, the method according to the present invention comprises: providing a first frame material continuous sheet and an additional material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the additional material continuous sheet below the first frame material continuous sheet; joining the additional material continuous sheet and the first frame material continuous sheet to form a stacked structure of the aerosol generating article; and punching an aperture through the first frame material continuous sheet and the additional frame material continuous sheet to discharge the aerosol generating article.

[0160] In another example, the method according to the present invention comprises: providing a first frame material continuous sheet and an additional material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the additional material continuous sheet below the first frame material continuous sheet; joining the additional material continuous sheet and the first frame material continuous sheet to form a stacked structure of the aerosol generating article; and forming a brittle cutting line through the first frame material continuous sheet and the additional material continuous sheet to make the aerosol generating article separable from the remainder of the first frame material continuous sheet and the additional material continuous sheet.

[0161] In one example, the method according to the present invention comprises: providing a first frame material continuous sheet and a second frame material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the second frame material continuous sheet below the first frame material continuous sheet; joining the second frame material continuous sheet and the first frame material continuous sheet to form a stacked structure of an aerosol generating article; and punching an aperture through the first frame material continuous sheet and the second frame material continuous sheet to discharge the aerosol generating article.

[0162] In another example, the method according to the present invention comprises: providing a first frame material continuous sheet and a second frame material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the second frame material continuous sheet below the first frame material continuous sheet; joining the second frame material continuous sheet and the first frame material continuous sheet to form a stacked frame structure of an aerosol generating article; and forming a brittle cutting line through the first frame material continuous sheet and the second frame material continuous sheet to make the aerosol generating article separable from the remainder of the first frame material continuous sheet and the second frame material continuous sheet.

[0163] In one example, the method according to the present invention comprises: providing a first frame material continuous sheet and a second frame material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the second frame material continuous sheet below the first frame material continuous sheet; joining the second frame material continuous sheet and the first frame material continuous sheet; providing a third frame material continuous sheet; joining the third frame material continuous sheet and the first frame material continuous sheet to form a stacked frame structure of an aerosol generating article; and punching an aperture through the first frame material continuous sheet, the second frame material continuous sheet, and the third frame material continuous sheet to discharge the aerosol generating article.

[0164] In another example, the method according to the present invention comprises: providing a first frame material continuous sheet and a second frame material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the second frame material continuous sheet below the first frame material continuous sheet; joining the second frame material continuous sheet and the first frame material continuous sheet; providing a third frame material continuous sheet; joining the third frame material continuous sheet and the first frame material continuous sheet to form a stacked frame structure of an aerosol generating article; and forming a brittle cutting line through the first frame material continuous sheet, the second frame material continuous sheet and the third frame material continuous sheet so that the aerosol generating article can be separated from the remainder of the first frame material continuous sheet and the second frame material continuous sheet.

[0165] In one example, the method according to the present invention comprises: providing a first frame material continuous sheet and a first inner layer material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the first inner layer material continuous sheet below the first frame material continuous sheet; joining the first inner layer material continuous sheet and the first frame material continuous sheet to form a stacked structure of the aerosol generating article; and punching an aperture through the first frame material continuous sheet and the first inner layer material continuous sheet to discharge the aerosol generating article.

[0166] In another example, the method according to the present invention comprises: providing a first frame material continuous sheet and a first inner layer material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the first inner layer material continuous sheet below the first frame material continuous sheet; joining the first inner layer material continuous sheet and the first frame material continuous sheet to form a stacked structure of the aerosol generating article; and forming a brittle cutting line through the first frame material continuous sheet and the first inner layer material continuous sheet so that the aerosol generating article can be separated from the remainder of the first frame material continuous sheet and the second frame material continuous sheet.

[0167] In one example, the method according to the present invention comprises: providing a first frame material continuous sheet and a first inner layer material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the first inner layer material continuous sheet below the first frame material continuous sheet; joining the first inner layer material continuous sheet and the first frame material continuous sheet; providing a second inner layer material continuous sheet; positioning the second inner layer material continuous sheet above the first frame material continuous sheet; and joining the second inner layer material continuous sheet and the first frame material continuous sheet to form a stacked structure of the aerosol generating article; and punching an aperture through the first frame material continuous sheet, the first inner layer material continuous sheet, and the second inner layer material continuous sheet to discharge the aerosol generating article.

[0168] In another example, the method according to the present invention comprises: providing a first frame material continuous sheet and a first inner layer material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the first inner layer material continuous sheet below the first frame material continuous sheet; joining the first inner layer material continuous sheet and the first frame material continuous sheet; providing a second inner layer material continuous sheet; positioning the second inner layer material continuous sheet above the first frame material continuous sheet; and joining the second inner layer material continuous sheet and the first frame material continuous sheet to form a stacked structure of the aerosol generating article; and forming a brittle cutting line through the first frame material continuous sheet, the first inner layer material continuous sheet, and the second inner layer material continuous sheet so that the aerosol generating article can be separated from the remainder of the first frame material continuous sheet, the first inner layer material continuous sheet, and the second inner layer material continuous sheet.

[0169] In one example, the method according to the present invention comprises: providing a first frame material continuous sheet and an additional material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the additional material continuous sheet below the first frame material continuous sheet; joining the additional material continuous sheet and the first frame material continuous sheet; providing a first outer layer material continuous sheet and a second outer layer material continuous sheet; positioning the first frame material continuous sheet and the additional material continuous sheet between the first outer layer material continuous sheet and the second outer layer material continuous sheet; joining the first outer layer material continuous sheet, the second outer layer material continuous sheet and the first frame material continuous sheet to form a stacked structure of the aerosol generating article; and punching an aperture through the first frame material continuous sheet, the additional material continuous sheet, the first outer layer material continuous sheet and the second outer layer material continuous sheet to discharge the aerosol generating article.

[0170] In another example, the method according to the present invention comprises: providing a first frame material continuous sheet and an additional material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the additional material continuous sheet below the first frame material continuous sheet; joining the additional material continuous sheet and the first frame material continuous sheet; providing a first outer layer material continuous sheet and a second outer layer material continuous sheet; positioning the first frame material continuous sheet and the additional material continuous sheet between the first outer layer material continuous sheet and the second outer layer material continuous sheet; joining the first outer layer material continuous sheet, the second outer layer material continuous sheet and the first frame material continuous sheet to form a stacked structure of the aerosol generating article. and includes the step of forming a brittle cutting line through the first frame material continuous sheet, the additional material continuous sheet, the first outer layer material continuous sheet, and the second outer layer material continuous sheet so that the aerosol generating article can be separated from the remainder of the first frame material continuous sheet, the additional material continuous sheet, the first outer layer material continuous sheet, and the second outer layer material continuous sheet.

[0171] In one example, the method according to the present invention comprises: providing a first frame material continuous sheet and a second frame material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the second frame material continuous sheet below the first frame material continuous sheet; joining the second frame material continuous sheet and the first frame material continuous sheet; providing a third frame material continuous sheet; positioning the third frame material continuous sheet above the first frame material continuous sheet; joining the third frame material continuous sheet to the first frame material continuous sheet to form a stacked frame structure; providing a first inner layer material continuous sheet; positioning the first inner layer material continuous sheet below the stacked frame structure; joining the first inner layer material continuous sheet and the stacked frame structure; providing a second inner layer material continuous sheet; positioning the second inner layer material continuous sheet above the stacked frame structure; joining the second inner layer material continuous sheet and the stacked frame structure; The method comprises the steps of: providing a first outer layer material continuous sheet and a second outer layer material continuous sheet; positioning the first inner layer material continuous sheet, the stacked frame structure, and the second inner layer material continuous sheet between the first outer layer material continuous sheet and the second outer layer material continuous sheet; joining the first outer layer material continuous sheet, the second outer layer material continuous sheet, and the stacked frame structure to form an aerosol generating article; and punching an aperture through the first outer layer material continuous sheet, the first inner layer material continuous sheet, the stacked frame structure, the second inner layer material continuous sheet, and the second outer layer material continuous sheet to discharge the aerosol generating article.

[0172] In another example, the method according to the present invention comprises: providing a first frame material continuous sheet and a second frame material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the second frame material continuous sheet below the first frame material continuous sheet; joining the second frame material continuous sheet and the first frame material continuous sheet; providing a third frame material continuous sheet; positioning the third frame material continuous sheet above the first frame material continuous sheet; joining the third frame material continuous sheet to the first frame material continuous sheet to form a stacked frame structure; providing a first inner layer material continuous sheet; positioning the first inner layer material continuous sheet below the stacked frame structure; joining the first inner layer material continuous sheet and the stacked frame structure; providing a second inner layer material continuous sheet; positioning the second inner layer material continuous sheet above the stacked frame structure; joining the second inner layer material continuous sheet and the stacked frame structure; A step of providing a first outer layer material continuous sheet and a second outer layer material continuous sheet; a step of positioning the first inner layer material continuous sheet, the stacked frame structure, and the second inner layer material continuous sheet between the first outer layer material continuous sheet and the second outer layer material continuous sheet; and a step of bonding the first outer layer material continuous sheet, the second outer layer material continuous sheet, and the stacked frame structure to form an aerosol generating article;The method includes the step of forming a brittle cutting line through the first outer layer material continuous sheet, the first inner layer material continuous sheet, the stacked frame structure, the second inner layer material continuous sheet, and the second outer layer material continuous sheet, thereby enabling an aerosol-generating article to be separated from the remainder of the first outer layer material continuous sheet, the first inner layer material continuous sheet, the stacked frame structure, the second inner layer material continuous sheet, and the second outer layer material continuous sheet.

[0173] The method according to the present disclosure has been described above with reference to the manufacture of an aerosol-generating article. However, it will be apparent that the method can be implemented to manufacture a plurality of aerosol-generating articles at high speed and in large quantities. A sequence of manufacturing steps consistent with the description above can be replicated, for example, in succession so that individual aerosol-generating articles are formed in sequence.

[0174] A method for scaling up production may further include a step of replicating in parallel a sequence of steps consistent with the foregoing description so that a plurality of substantially identical aerosol-generating articles can be formed at once. For example, in the method according to the present disclosure, the step of forming a frame [core layer] by forming a frame aperture through a first continuous sheet of frame material may include the step of forming an array of frame apertures through the first continuous sheet of frame material to provide a continuous blank for forming a plurality of frames [core layers] of corresponding aerosol-generating articles.

[0175] It will be obvious to those skilled in the art that other manufacturing steps described above can be easily applied to this setup. For example, the step of forming an aperture through an additional continuous sheet of frame material may also be modified to include the step of forming an array of apertures in a similar manner. This applies equally to the step of forming an inlet aperture or an outlet aperture, or both, within the continuous sheet of frame material. The steps of punching an aperture through a layer of a laminated structure to discharge an aerosol-generating article and forming a brittle line through a layer of a laminated structure to make the aerosol-generating article separable from the rest of the laminated structure may be similarly modified to include an array of apertures or an array of brittle lines in a similar manner.

[0176] In the method according to the present disclosure, the thickness of the aerosol-generating article is preferably less than 50% of both the length and width of the aerosol-generating article.

[0177] Preferably, the frame has a thickness of at least 80% of the thickness of the aerosol-generating article. The thickness of the frame is substantially given by the combined thickness of the continuous sheets of frame material used to form the frame of the aerosol-generating article. Accordingly, in certain embodiments, the thickness of the frame substantially corresponds to the thickness of the first continuous sheet of frame material, i.e., the thickness of the frame core layer. In other embodiments, the thickness of the frame substantially corresponds to the sum of the thickness of the first continuous sheet of frame material and the thickness of any additional continuous sheet of frame material that is combined with the first continuous sheet of frame material to form a laminated frame structure.

[0178] In the method according to the present disclosure, the first frame material continuous sheet preferably comprises paper, paperboard, or cardboard.

[0179] The thickness of the first frame material continuous sheet may be 0.6 mm or less. In some embodiments, the thickness of the first frame material continuous sheet may be 0.5 mm or less. For example, the thickness of the first frame material continuous sheet may be 0.35 mm or less.

[0180] The thickness of the first frame material continuous sheet may be at least 0.1 mm. In some embodiments, the thickness of the first frame material continuous sheet may be at least 0.2 mm, preferably at least 0.25 mm.

[0181] In a specific embodiment, the thickness of the first frame material continuous sheet may be 0.1 mm to 0.5 mm, preferably 0.2 mm to 0.5 mm, and more preferably 0.25 mm to 0.5 mm.

[0182] In another embodiment, the thickness of the first frame material continuous sheet may be 0.1 mm to 0.35 mm, preferably 0.2 mm to 0.35 mm, more preferably 0.25 mm to 0.35 mm.

[0183] In an embodiment in which a first frame material continuous sheet is combined with at least an additional frame material continuous sheet to form a laminated frame structure, the thickness of any additional frame material continuous sheet may be 0.5 mm or less, and in some embodiments, 0.35 mm or less. The thickness of the additional frame material continuous sheet may be at least 0.1 mm. In some embodiments, the thickness of the additional frame material continuous sheet may be at least 0.2 mm, preferably at least 0.25 mm. In a specific embodiment, the thickness of the additional frame material continuous sheet may be 0.1 mm to 0.5 mm, preferably 0.2 mm to 0.5 mm, more preferably 0.25 mm to 0.5 mm. In another embodiment, the thickness of the additional continuous sheet may be 0.1 mm to 0.35 mm, preferably 0.2 mm to 0.35 mm, more preferably 0.25 mm to 0.35 mm.

[0184] A stacked frame structure can be formed by combining multiple continuous sheets of frame material, all having the same thickness. Alternatively, continuous sheets of frame material having different thicknesses can be combined to form a stacked frame structure.

[0185] For example, a laminated frame structure with a thickness of 3 mm can be formed by combining six continuous sheets of frame material, each having a thickness of 0.5 mm. In an alternative example, a laminated frame structure with a thickness of 3 mm can be formed by combining three continuous sheets of frame material, each having a thickness of 1 mm. In a further alternative example, a laminated frame structure with a thickness of 3 mm can be formed by combining three continuous sheets of frame material, each having a thickness of 0.33 mm, and four continuous sheets of frame material, each having a thickness of 0.5 mm.

[0186] In an embodiment in which a first frame material continuous sheet, a second frame material continuous sheet, and a third frame material continuous sheet are combined to form a laminated frame structure, and each of the first frame material continuous sheet, the second frame material continuous sheet, and the third frame material continuous sheet are formed as a single layer of frame material, the thickness of each frame material continuous sheet may be, for example, 1 mm and the basis weight may be 500 gsm to 700 gsm.

[0187] In an embodiment in which a first frame material continuous sheet, a second frame material continuous sheet, and a third frame material continuous sheet are combined to form a laminated frame structure, and each of the first frame material continuous sheet, the second frame material continuous sheet, and the third frame material continuous sheet is formed as two layers of frame material, the thickness of each layer of frame material may have, for example, a thickness of 0.5 mm and a basis weight of 250 gsm to 380 gsm.

[0188] In an embodiment in which a first frame material continuous sheet, a second frame material continuous sheet, and a third frame material continuous sheet are combined to form a laminated frame structure, and each of the first frame material continuous sheet, the second frame material continuous sheet, and the third frame material continuous sheet is formed as three layers of frame material, the thickness of each layer of frame material may have, for example, a thickness of 0.3 mm and a basis weight of 170 gsm to 230 gsm.

[0189] The basis weight of the first frame material continuous sheet may be 700 gsm or less. In some embodiments, the basis weight of the first frame material continuous sheet may be 500 gsm or less. In one example, the basis weight of the first frame material continuous sheet may be 400 gsm or less, for example, 380 gsm or less.

[0190] The basis weight of the first frame material continuous sheet may be at least 100 gsm. Preferably, the basis weight of the first frame material continuous sheet may be at least 200 gsm. More preferably, the basis weight of the first frame material continuous sheet may be at least 250 gsm.

[0191] The width of the first frame material continuous sheet may be at least 10 mm, preferably at least 20 mm, more preferably at least 25 mm. In some embodiments, the width of the first frame material continuous sheet may be at least 50 mm. In one example, the width of the first frame material continuous sheet may be at least 100 mm, e.g. at least 150 mm or at least 200 mm.

[0192] In a specific embodiment, the width of the continuous sheet of frame material may be up to 1200 mm, preferably up to 1000 mm, for example up to 960 mm, more preferably up to 720 mm.

[0193] A method consistent with the foregoing description allows for a significant degree of control over the content of the aerosol-generating article. In particular, as discussed in relation to the provision of one or more continuous sheets of inner layer material, the method according to the present disclosure enables the inclusion of an aerosol-generating material within a laminated structure of the aerosol-generating article. This enables an advantageous configuration in which the aerosol-generating material is exposed to an airflow passage extending through the aerosol-generating article.

[0194] The method according to the present disclosure may further include the step of distributing an aerosol generating material into a frame aperture.

[0195] Advantageously, this method enables further control and adjustment of the content of aerosol-generating materials within the aerosol-generating article in addition to the opportunities already provided by the laminated structure of the article. In effect, this makes it possible to combine different types of aerosol-generating materials within a single aerosol-generating article, allowing different aerosol release mechanisms to be utilized to provide consistent delivery to consumers and optionally generate novel flavor profiles, etc.

[0196] In a specific embodiment comprising the step of distributing an aerosol generating material into a frame aperture, the method may further comprise the step of compressing the aerosol generating material within a cavity of an aerosol generating article, wherein the cavity is at least partially partitioned by the peripheral surface of the frame aperture.

[0197] In a specific embodiment, the aerosol generating substrate is in the form of a crushed aerosol generating material. For example, the crushed aerosol generating material may include: one or more strips and strands of aerosol generating material, such as strips and strands of tobacco or homogenized tobacco material.

[0198] In a specific embodiment, the aerosol generating substrate is in the form of a plurality of granules, beads, pellets, or flakes of an aerosol generating material.

[0199] In some embodiments, the aerosol generating material may be in the form of a wavy sheet of the aerosol generating material.

[0200] Preferably, the aerosol generating substrate comprises one or more aerosol forming agents, such as glycerin and propylene glycol, or both.

[0201] The aerosol generating material may have a bulk density of 0.5 mg / mm³ or less.

[0202] The aerosol generating material located within the cavity may have a packing density of 0.9 or less.

[0203] The characteristics of the aerosol-generating article obtainable by the method according to the present invention are described in more detail below.

[0204] The frame can be a flat frame.

[0205] The frame may define a frame aperture that extends through the thickness of the frame. The frame aperture may define or form an airflow passage for the aerosol-generating article. The frame aperture may define or form a cavity for the aerosol-generating article. For example, the frame may have a hollow rectangular shape or a square hollow tube shape. As a further embodiment, the frame may have a cross-section that is annular in shape, and preferably, the cross-section in the x / y plane is annular in shape.

[0206] The frame may include an outer surface of the frame. The outer surface of the frame may extend transversely, for example, between a first planar outer surface and a second planar outer surface. The outer surface of the frame may at least partially define or form one or more outer surfaces of an aerosol-generating article. For example, the outer surface of the frame may at least partially define or form one or more outer wall surfaces of an aerosol-generating article. The outer surface of the frame may surround or encircle the frame aperture. The outer surface of the frame may surround or encircle the cavity.

[0207] The frame may include an inner surface of the frame. The inner surface of the frame may extend transversely, for example, between a first planar outer surface and a second planar outer surface. The inner surface of the frame may define or form an outer wall of the frame aperture. The inner surface of the frame may define or form an outer wall of the cavity. The inner surface of the frame may surround or encircle the frame aperture extending through the thickness of the frame. The outer surface of the frame may surround or encircle the cavity.

[0208] The outer surface of the frame may surround or encircle the inner surface of the frame. The inner surface of the frame and the outer surface of the frame may be concentric with each other.

[0209] The aerosol generating article may include one or more outer wall surfaces extending between a first planar outer surface and a second planar outer surface. The one or more outer wall surfaces may collectively define the entire transverse outer area of ​​the aerosol generating article. A frame may define at least partially each of the one or more outer wall surfaces. The one or more outer wall surfaces may surround or enclose a cavity. A frame may define at least 60%, at least 70%, at least 80%, or at least 90% of the entire transverse outer area of ​​the aerosol generating article.

[0210] The frame may include surrounding walls. The surrounding walls may surround or encircle at least a portion of the frame aperture extending through the thickness of the frame. The surrounding walls may surround or encircle at least a portion of the cavity. The surrounding walls may surround or encircle the frame aperture extending through the thickness of the frame. The surrounding walls may surround or encircle the cavity.

[0211] The periphery wall surface may be defined or formed by the frame's outer surface and the frame's inner surface. The periphery wall surface may at least partially define or form one or more outer surfaces or walls of the aerosol-generating article. The periphery wall surface may define or form the frame aperture's outer wall surface. The periphery wall surface may define or form the cavity's outer wall surface.

[0212] The surrounding walls may have a radial thickness. The radial thickness can be defined, for example, as the minimum distance between the outer surface of the frame and the inner surface of the frame in the x / y plane.

[0213] The surrounding wall surface may have a radial thickness of 0.5 mm or more. The surrounding wall surface may have a radial thickness of 1.5 mm or more. The surrounding wall surface may have a radial thickness of 2.5 mm or more.

[0214] The surrounding wall surface may have a radial thickness of 3.5 mm or less. The surrounding wall surface may have a radial thickness of 2.5 mm or less.

[0215] The surrounding wall surface may have a radial thickness of 0.5 mm to 3.5 mm. The surrounding wall surface may have a radial thickness of 0.5 mm to 2.5 mm.

[0216] Advantageously, a peripheral wall having a radial thickness of 0.5 mm to 3.5 mm has been found to provide good structural strength to the aerosol generating article without using an excess amount of material that could increase manufacturing costs, and can limit the amount of heat unintentionally transferred to the frame rather than the aerosol generating substrate.

[0217] The frame may be manufactured from or contain biodegradable materials. The frame may be manufactured entirely from biodegradable materials.

[0218] The frame may be manufactured from or contain a cellulose material. The cellulose material may contain a sheet of cellulose material. The cellulose material may contain cellulose fibers. The cellulose material may be paper, paperboard, or cardboard. The frame may be manufactured from or contain a plant material such as tobacco. The frame may be manufactured entirely from a cellulose material.

[0219] The aerosol generating article may include one or more susceptor materials. The frame may include one or more susceptor materials. One or more susceptor materials may be in thermal contact with the aerosol generating substrate. One or more susceptor materials may be in thermal contact with the cavity. One or more susceptor materials may be incorporated within the material of the frame. For example, one or more susceptor materials may be incorporated within the peripheral wall surface of the frame.

[0220] One or more susceptor materials may be one or more particles, strips, threads, or wires of the susceptor material. One or more susceptor materials may be one or more sheets or layers of the susceptor material. One or more sheets or layers of the susceptor material may be in the form of a mesh of the susceptor material.

[0221] The susceptor material may comprise, in any form, 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.

[0222] The frame may have a thickness of 50% or more of the thickness of the aerosol-generating article. The frame may have a thickness of 70% or more of the thickness of the aerosol-generating article. The frame may have a thickness of 90% or more of the thickness of the aerosol-generating article. The frame may have a thickness of 95% or more of the thickness of the aerosol-generating article.

[0223] The frame may have a thickness of 95% or less of the thickness of the aerosol-generating article. The frame may have a thickness of 90% or less of the thickness of the aerosol-generating article. The frame may have a thickness of 70% or less of the thickness of the aerosol-generating article.

[0224] The frame may have a thickness of 50% to 95% of the thickness of the aerosol-generating article. The frame may have a thickness of 70% to 95% of the thickness of the aerosol-generating article.

[0225] The frame may have a thickness of 1 mm or more, 2 mm or more, 3 mm or more, or 4 mm or more. The frame may have a thickness of 5.5 mm or less, 4.5 mm or less, 3.5 mm or less, 2.5 mm or less, or 1.5 mm or less. The frame may have a thickness of 1 mm to 5.5 mm. Preferably, the frame may have a thickness of 1.5 mm to 5.5 mm.

[0226] The frame may have a length equal to the length of the aerosol-generating article. The frame may have a length of at least 90% of the length of the aerosol-generating article. The frame may have a length of at least 95% of the length of the aerosol-generating article.

[0227] The frame may have a width equal to the width of the aerosol-generating article. The frame may have a width that is at least 90% of the width of the aerosol-generating article.

[0228] The frame may be a single component. Alternatively, the frame may include two or more layers. That is, the frame may have a laminated structure. Advantageously, the characteristics of each layer may be individually optimized according to the relative distance between the layer and the aerosol generating substrate or heater of the aerosol generating device.

[0229] A frame may include a first frame layer and a second frame layer. The first frame layer and the second frame layer may be the only layers of the frame. That is, the frame may include two or fewer layers, or exactly two layers. A frame aperture may be defined through both the first frame layer and the second frame layer.

[0230] The frame may include a first frame layer, a second frame layer, and a third frame layer. The second frame layer may be located between the first frame layer and the third frame layer. The first frame layer, the second frame layer, and the third frame layer may be the only layers of the frame. That is, the frame may include three or fewer layers, or exactly three layers.

[0231] One or more aerosol generating substrates may include an aerosol generating substrate layer. Advantageously, the aerosol generating substrate layer may be made thin so as to rapidly heat and release a volatile compound to form an aerosol. Advantageously, the aerosol generating substrate layer may be located close to a heater of the aerosol generating substrate.

[0232] The aerosol generating substrate layer may comprise an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. The aerosol generating material may be in the form of a sheet of aerosol generating material. The sheet of aerosol generating material may be any sheet of aerosol generating material described herein. The aerosol generating substrate layer may be a sheet of aerosol generating material and may be manufactured entirely therefrom.

[0233] The aerosol generating substrate layer may be located between the frame and the first planar outer surface. The aerosol generating substrate layer may be located between the frame and the second planar outer surface. The aerosol generating substrate layer may be in physical contact with the frame and may be bonded to the frame.

[0234] The aerosol generating substrate layer may be positioned between the frame and the outer wrapper. The outer wrapper is discussed in more detail below. The aerosol generating substrate layer may physically contact both the frame and the outer wrapper and may be bonded thereto.

[0235] The aerosol generating substrate layer may be located between the frame and the first planar outer layer. The aerosol generating substrate layer may be located between the frame and the second planar outer layer. The first planar outer layer and the second planar outer layer are discussed in more detail below. The aerosol generating substrate layer may be in physical contact with both the frame and the first planar outer layer and may be bonded thereto. The aerosol generating substrate layer may be in physical contact with both the frame and the second planar outer layer and may be bonded thereto.

[0236] The aerosol generating substrate layer may be placed over the end of the cavity. The aerosol generating substrate layer may define or form a wall surface of the cavity, such as a first cavity end wall surface or a second cavity end wall surface. Accordingly, advantageously, the aerosol generating substrate layer may be within an airflow passage or may at least partially define or form an airflow passage, thereby enabling the released volatile compound to rapidly form an aerosol.

[0237] One or more aerosol generating substrates may include a first aerosol generating substrate layer and a second aerosol generating substrate layer. Advantageously, the first and second aerosol generating substrate layers can rapidly generate a satisfactory volume of aerosol compared to using a single aerosol generating substrate layer.

[0238] The first aerosol generating substrate may include an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. The aerosol generating material may be in the form of a sheet of aerosol generating material. The sheet of aerosol generating material may be any sheet of aerosol generating material described herein. The first aerosol generating substrate layer may be a sheet of aerosol generating material and may be manufactured entirely therefrom.

[0239] The second aerosol generating substrate layer may include an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. The aerosol generating material may be in the form of a sheet of aerosol generating material. The sheet of aerosol generating material may be any sheet of aerosol generating material described herein. The second aerosol generating substrate layer may be a sheet of aerosol generating material and may be manufactured entirely therefrom.

[0240] The first aerosol generating substrate layer may be located between the frame and the first planar outer surface. The first aerosol generating substrate layer may be in physical contact with the frame and may be bonded to the frame.

[0241] The first aerosol generating substrate layer may be located between the frame and the outer wrapper. The first aerosol generating substrate layer may physically contact both the frame and the outer wrapper and may be bonded thereto.

[0242] The first aerosol generating substrate layer may be located between the frame and the first planar outer layer. The first aerosol generating substrate layer may be in physical contact with both the frame and the first planar outer layer and may be bonded thereto.

[0243] The second aerosol generating substrate layer may be located between the frame and the second planar outer surface. The second aerosol generating substrate layer may be in physical contact with the frame and may be bonded to the frame.

[0244] The second aerosol generating substrate layer may be located between the frame and the outer wrapper. The second aerosol generating substrate layer may physically contact both the frame and the outer wrapper and may be bonded thereto.

[0245] The second aerosol generating substrate layer may be located between the frame and the second planar outer layer. The second aerosol generating substrate layer may be in physical contact with both the frame and the second planar outer layer and may be bonded thereto.

[0246] The first aerosol generating substrate layer and the second aerosol generating substrate layer may be placed on opposite ends of the cavity. The first aerosol generating substrate layer and the second aerosol generating substrate layer may define or form the wall surface of the opposite ends of the cavity. That is, the frame, the first aerosol generating substrate layer, and the second aerosol generating substrate layer may collectively define the cavity.

[0247] One or more of the aerosol generating substrate layer, the first aerosol generating substrate layer, and the second aerosol generating substrate layer may have a thickness of 100㎛ or more, 200㎛ or more, 300㎛ or more, 400㎛ or more, or 500㎛ or more.

[0248] One or more of the aerosol generating substrate layer, the first aerosol generating substrate layer, and the second aerosol generating substrate layer may have a thickness of 600㎛ or less, 500㎛ or less, 400㎛ or less, 300㎛ or less, or 300㎛ or less.

[0249] One or more of the aerosol generating substrate layer, the first aerosol generating substrate layer, and the second aerosol generating substrate layer may have a thickness of 100㎛ to 600㎛, 200㎛ to 500㎛, 200㎛ to 400㎛, or 200㎛ to 300㎛.

[0250] The aerosol generating substrate layer may have a length substantially equal to the length of the frame. The aerosol generating substrate layer may have a length substantially equal to the length of the aerosol generating article.

[0251] The first aerosol generating substrate layer may have a length substantially equal to the length of the frame. The first aerosol generating substrate layer may have a length substantially equal to the length of the aerosol generating article.

[0252] The second aerosol generating substrate layer may have a length substantially equal to the length of the frame. The second aerosol generating substrate layer may have a length substantially equal to the length of the aerosol generating article.

[0253] The aerosol generating substrate layer may have a width substantially equal to the width of the frame. The aerosol generating substrate layer may have a width substantially equal to the width of the aerosol generating article.

[0254] The first aerosol generating substrate layer may have a width substantially equal to the width of the frame. The first aerosol generating substrate layer may have a width substantially equal to the width of the aerosol generating article.

[0255] The second aerosol generating substrate layer may have a width substantially equal to the width of the frame. The second aerosol generating substrate layer may have a width substantially equal to the width of the aerosol generating article.

[0256] 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 positioned parallel to the second planar outer surface. The first planar outer surface may extend in the x / y plane. The second planar outer surface may extend in the x / y plane. The second planar outer surface may be spaced apart from the first planar outer surface in the z direction or the transverse direction. The distance between the first planar outer surface and the second planar outer surface in the z direction or the transverse direction may define the thickness of the aerosol-generating article.

[0257] The aerosol-generating article may include an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may contain a hydrophobic material.

[0258] The outer wrapper may define or form a first planar outer surface. The outer wrapper may define or form a second planar outer surface. The outer wrapper may define or form both the first planar outer surface and the second planar outer surface.

[0259] The outer wrapper may surround or encircle the frame. The outer wrapper may physically contact the frame and may be bonded to the frame. The outer wrapper may be placed over the opposing end of the cavity. The outer wrapper may define or form opposing end walls of the cavity, such as a first cavity end wall and a second cavity end wall. That is, the frame and the outer wrapper may collectively define the cavity.

[0260] The outer wrapper may surround or encircle the frame and the aerosol generating substrate layer. The outer wrapper may physically contact both the frame and the aerosol generating substrate layer and may be bonded thereto.

[0261] The outer wrapper may surround or enclose the frame, the first aerosol generating substrate layer, and the second aerosol generating substrate layer. The outer wrapper may physically contact both the first aerosol generating substrate layer and the second aerosol generating substrate layer and may be bonded thereto.

[0262] The aerosol generating article may include 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.

[0263] The first planar outer layer may define or form a first planar outer surface. 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 / y plane.

[0264] The first planar outer layer can physically contact the frame and can be bonded to the frame. The first planar outer layer can be placed over the end of the cavity. The first planar outer layer can define or form a wall surface of the cavity such as the wall surface of the first cavity end.

[0265] The second planar outer layer can physically contact the frame and can be bonded to the frame. The second planar outer layer can be placed over the end of the cavity. The second planar outer layer can define or form a wall surface of the cavity, such as the wall surface of the second cavity end.

[0266] The first planar outer layer and the second planar outer layer may be placed on the opposing ends of the cavity. The first planar outer layer and the second planar outer layer may define or form the opposing end walls of the cavity, such as the first cavity end wall and the second cavity end wall. That is, the frame, the first planar outer layer, and the second planar outer layer may collectively define the cavity.

[0267] The first planar outer layer may be spaced apart from the frame, for example, in the horizontal direction. For example, the aerosol generating substrate layer or the first aerosol generating substrate layer may be located between the first planar outer layer and the frame. The first planar outer layer may be in physical contact with the aerosol generating substrate layer or the first aerosol generating substrate layer and may be bonded thereto.

[0268] The second planar outer layer may be spaced apart from the frame, for example, in the horizontal direction. For example, the aerosol generating substrate layer or the second aerosol generating substrate layer may be located between the second planar outer layer and the frame. The second planar outer layer may physically contact the aerosol generating substrate layer or the second aerosol generating substrate layer and may be bonded thereto.

[0269] The first planar outer layer may be hydrophobic. The first planar outer layer may include a hydrophobic material. The second planar outer layer may be hydrophobic. The second planar outer layer may include a hydrophobic material.

[0270] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may include a cellulose material or may be manufactured from a cellulose material. The cellulose material may be paper, cigarette paper, tobacco paper, cardboard, wood, fabric, natural fiber, or artificial fiber.

[0271] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may be an aerosol generating substrate comprising an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. In particular, the aerosol generating material may be in the form of a sheet of the aerosol generating material. The sheet of the aerosol generating material may be any sheet of the aerosol generating material described herein. Alternatively, one or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may not include any aerosol generating material, particularly in an embodiment comprising an aerosol generating substrate layer, a first aerosol generating substrate layer, a second aerosol generating substrate layer, or an aerosol generating substrate located within a cavity. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may be substantially nicotine-free.

[0272] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness of 25㎛ or more, 30㎛ or more, 35㎛ or more, 40㎛ or more, or 45㎛ or more.

[0273] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness of 55㎛ or less, 50㎛ or less, 45㎛ or less, 40㎛ or less, or 35㎛ or less.

[0274] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a thickness of 25㎛ to 55㎛, 25㎛ to 45㎛, or 30㎛ to 45㎛.

[0275] One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length substantially equal to the length of the frame. One or more of the outer wrapper, the first planar outer layer, and the second planar outer layer may have a length substantially equal to the length of the aerosol-generating article.

[0276] One or more of the first planar outer layer and the second planar outer layer may have a width substantially equal to the width of the frame. One or more of the first planar outer layer and the second planar outer layer may have a width substantially equal to the width of the aerosol-generating article.

[0277] The cavity may have a thickness of 0.5 mm or more. The cavity may have a thickness of 1.5 mm or more. The cavity may have a thickness of 2.5 mm or more. The cavity may have a thickness of 3.5 mm or more.

[0278] The cavity may have a thickness of 4.5 mm or less. The cavity may have a thickness of 3.5 mm or less. The cavity may have a thickness of 2.5 mm or less. The cavity may have a thickness of 1.5 mm or less.

[0279] 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. Preferably, the cavity may have a thickness of 2.8 mm to 3.3 mm.

[0280] The cavity may have a length of 14 mm or more. The cavity may have a length of 18 mm or more. The cavity may have a length of 22 mm or more. The cavity may have a thickness of 30 mm or more. The cavity may have a thickness of 38 mm or more.

[0281] The cavity may have a length of 40 mm or less. The cavity may have a thickness of 34 mm or less. The cavity may have a thickness of 28 mm or less. The cavity may have a thickness of 22 mm or less. The cavity may have a thickness of 18 mm or less.

[0282] The cavity may have a length of 14 mm to 40 mm. The cavity may have a length of 14 mm to 34 mm. The cavity may have a length of 24 mm to 28 mm.

[0283] The cavity may have a width of 4.5 mm or more. The cavity may have a width of 7 mm or more. The cavity may have a width of 11 mm or more.

[0284] The cavity may have a width of 13 mm or less. The cavity may have a width of 11 mm or less. The cavity may have a width of 7 mm or less. The cavity may have a width of 5 mm or less.

[0285] The cavity may have a width of 4.5 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.

[0286] The cavity may have 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.

[0287] Preferably, the cavity may have a length of 20 mm to 30 mm, a width of 7 mm to 10 mm, and a thickness of 2.5 mm to 4 mm.

[0288] Most preferably, the cavity may have a length of 26 mm, a width of 8 mm, and a thickness of 3.1 mm.

[0289] The cavity may have a volume of 30 mm³ or more, 100 mm³ or more, 300 mm³ or more, 500 mm³ or more, 700 mm³ or more, 900 mm³ or more, 1000 mm³ or more, 2000 mm³ or more, or 30 mm³ or more.

[0290] The cavity may have a volume of 3500 mm³ or less, 2500 mm³ or less, 1500 mm³ or less, 1000 mm³ or less, 800 mm³ or less, 600 mm³ or less, 500 mm³ or less, 400 mm³ or less, or 300 mm³ or less.

[0291] The cavity may have a volume of 30 mm³ to 3500 mm³. The cavity may have a volume of 30 mm³ to 2500 mm³. The cavity may have a volume of 100 mm³ to 1500 mm³. The cavity may have a volume of 100 mm³ to 1000 mm³.

[0292] The common area can be practically empty.

[0293] One or more aerosol generating materials may include an aerosol generating material located within a cavity. The aerosol generating material located within the cavity may fill the cavity.

[0294] The aerosol generating material located within the cavity may include an aerosol generating material. The aerosol generating material may be any aerosol generating material described herein. For example, the aerosol generating material may be in the form of a crushed aerosol generating material.

[0295] The aerosol generating material may be in the form of a sheet of the aerosol generating material. The sheet of the aerosol generating material may be any sheet of the aerosol generating material described herein. For example, the sheet of the aerosol generating material may be a sheet of homogenized tobacco material.

[0296] A sheet of aerosol-generating material can extend along the entire length of the cavity. A sheet of aerosol-generating material can extend along the entire width of the cavity.

[0297] The sheet of aerosol generating material may be a corrugated sheet of aerosol generating material. That is, the sheet of aerosol generating material may be wavy, folded, otherwise compressed or shrunk substantially perpendicular to the transverse direction of the aerosol generating article.

[0298] The sheet of aerosol generating material may be a crimped sheet of aerosol generating material. The sheet of aerosol generating material may be a wavy sheet of aerosol generating material. The crimped sheet of aerosol generating material or the wavy sheet of aerosol generating material may include a plurality of parallel wavy folds. For example, the crimped sheet of aerosol generating material may include a plurality of substantially parallel peaks and valleys.

[0299] Multiple parallel ripples can be defined by a ripple profile, where the ripple profile is sinusoidal, triangular, rectangular, trapezoidal, toroidal, or parabolic.

[0300] Multiple parallel wavy folds may define or form multiple channels between a sheet of aerosol-generating material and one or more walls of a cavity. The multiple channels may be multiple longitudinally extending channels. The multiple channels may be multiple laterally extending channels. The multiple channels may define or form at least a portion of an airflow passage extending between an air inlet and an air outlet of an aerosol-generating article.

[0301] 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 herb leaves, tobacco leaves, tobacco rib pieces, reconstituted tobacco, homogenized tobacco such as cast leaves, extruded tobacco, puffed tobacco, aerosol generating films, and gel compositions.

[0302] The aerosol generating material may be in the form of a shredded aerosol generating material. The shredded aerosol generating material may include: one or more strips and strands of the aerosol generating material, such as strips and strands of tobacco or homogenized tobacco material. The shredded aerosol generating material may be in the form of shredded sheets of homogenized tobacco material.

[0303] The aerosol-generating material may be a cut grass. The aerosol-generating material may be tobacco cut grass. As used herein, the term “cut grass” is used to describe a blend of shredded plant material, such as tobacco plant material, homogenized plant material, comprising one or more of leaf blades, processed stems, and ribs in particular.

[0304] The aerosol generating material may be in the form of a sheet of the aerosol generating material. As used herein, the term “sheet” describes a laminated element in which the width and length are substantially greater than the thickness. The sheet of the aerosol generating material may be a sheet of plant material. The sheet of the aerosol generating material may be a sheet of tobacco material. The sheet of the aerosol generating material may be a sheet of homogenized tobacco material, such as a cast leaf sheet.

[0305] The aerosol generating material may comprise one or more aerosol-forming agents. Suitable aerosol-forming agents are known in the art and include, but are not limited to, polyhydric alcohols such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable that the aerosol-forming agent be one or both of glycerin and propylene glycol, or comprise them. The aerosol-forming agent may consist of glycerin or propylene glycol, or a combination of glycerin and propylene glycol.

[0306] The aerosol generating material may have an aerosol forming agent content of 1, 2, 5, 10, or 15 weight percent or more based on dry weight. The aerosol generating material may have an aerosol forming agent content of 15 weight percent or more based on dry weight, for example, exceeding 20 weight percent based on dry weight, or exceeding 25 weight percent based on dry weight, or exceeding 30 weight percent based on dry weight, or exceeding 40 weight percent based on dry weight, or exceeding 50 weight percent based on dry weight.

[0307] The aerosol generating material may have an aerosol forming agent content of 30% by weight or less based on dry weight, 25% by weight or less based on dry weight, or 20% by weight or less based on dry weight.

[0308] The aerosol generating material may have an aerosol forming agent content of 5% to 30% by weight based on dry weight, 5% to 25% by weight based on dry weight, or 5% to 20% by weight based on dry weight.

[0309] The aerosol generating material may have an aerosol forming agent content of 10% to 30% by weight based on dry weight, 10% to 25% by weight based on dry weight, or 10% to 20% by weight based on dry weight.

[0310] The aerosol generating material may contain nicotine. The aerosol generating material may contain natural nicotine, synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0311] The aerosol generating material may contain at least 0.5% by weight of nicotine, at least 1% by weight of nicotine, at least 1.5% by weight of nicotine, or at least 2% by weight of nicotine. That is, the aerosol generating material may have a nicotine content of at least 0.5% by weight, at least 1% by weight, at least 1.5% by weight, or at least 2% by weight.

[0312] The aerosol generating material may be in the form of multiple beads. The multiple beads may have an average particle diameter of 0.1 mm to 4 mm, for example, 0.5 mm to 4 mm.

[0313] The term "bead" refers to distinct solid particles formed from an aerosol-generating substrate. Beads may have a round shape, typically spherical. Other terms may be used to define the substrate, such as "granule."

[0314] Providing an aerosol-generating material as multiple beads can offer specific advantages. Beads can be handled more easily than other aerosol-forming substrates, such as fine powders or bits. Since beads flow easily, they can reliably and consistently fill the cavity of an aerosol-generating article during manufacturing. This can enable a consistent and reproducible amount of aerosol-generating material to be loaded into each article during manufacturing. Beads can also be cleaner to handle than powders and bits, which can cause dust in the factory and leak from the aerosol-generating article during transport or use. By selecting beads with appropriate bead size and a suitable particle size distribution, the airflow through the cavity of the aerosol-generating article can be controlled more reproducibly, so to speak, than in the case of bits.

[0315] When a particle is not perfectly spherical but its diameter is referred to, the term "diameter" may refer to the largest dimension of the particle. Alternatively, the term "diameter" may refer to the diameter of a perfectly spherical particle having the same volume as a non-spherical particle.

[0316] The term "average particle diameter" as used herein may refer to the number average particle diameter. Other methods for determining the average particle diameter are known. Thus, the average particle diameter may be, for example, the volume average particle diameter.

[0317] The aerosol generating material may be in the form of a wrapped body of the aerosol generating material, and the wrapped body includes a wrapper that at least partially surrounds the aerosol generating material.

[0318] The wrapped body of the aerosol generating material may occupy 15% to 100% of the internal volume of the cavity. The wrapped body of the aerosol generating material may occupy 30% to 100% of the internal volume of the cavity. The wrapped body of the aerosol generating material may occupy 50% to 100% of the internal volume of the cavity. The wrapped body of the aerosol generating material may occupy 50% to 80% of the internal volume of the cavity. The wrapped body of the aerosol generating material may occupy 50% to 70% of the internal volume of the cavity.

[0319] An air inlet may be defined by the front wall surface of the aerosol-generating article. An air inlet may be defined by a frame and may extend through the frame. An air inlet may be defined by the periphery wall surface of the frame. An air inlet may extend through the periphery wall surface of the frame. An air outlet may be defined by the rear wall surface of the aerosol-generating article. An air outlet may be defined by a frame and may extend through the frame. An air outlet may be defined by the periphery wall surface of the frame. An outlet may extend through the periphery wall surface of the frame.

[0320] The air inlet may have a round cross-section, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section. The air outlet may have a round cross-section, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section.

[0321] An air inlet may be defined by a first planar outer surface and may extend through it. An air inlet may be defined by an outer wrapper and may extend through it. An air inlet may be defined by an outer wrapper and an aerosol generating substrate layer and may extend through it. An air inlet may be defined by an outer wrapper and a first aerosol generating substrate layer and may extend through it. An air inlet may be defined by a first planar outer layer and an aerosol generating substrate layer and may extend through it. An air inlet may be defined by a first planar outer layer and a first aerosol generating substrate layer and may extend through it.

[0322] An air inlet may be defined by a second planar outer surface and may extend through it. An air inlet may be defined by an outer wrapper and a second aerosol generating substrate layer and may extend through it. An air inlet may be defined by a second planar outer layer and an aerosol generating substrate layer and may extend through it. An air inlet may be defined by a second planar outer layer and a second aerosol generating substrate layer and may extend through it.

[0323] An air outlet can be defined by a first planar outer surface and can be extended through it. An air outlet can be defined by an outer wrapper and can be extended through it. An air outlet can be defined by an outer wrapper and an aerosol generating substrate layer and can be extended through it. An air outlet can be defined by an outer wrapper and a first aerosol generating substrate layer and can be extended through it. An air outlet can be defined by a first planar outer layer and an aerosol generating substrate layer and can be extended through it. An air outlet can be defined by a first planar outer layer and a first aerosol generating substrate layer and can be extended through it.

[0324] An air outlet may be defined by a second planar outer surface and may extend through it. An air outlet may be defined by an outer wrapper and a second aerosol generating substrate layer and may extend through it. An air outlet may be defined by a second planar outer layer and an aerosol generating substrate layer and may extend through it. An air outlet may be defined by a second planar outer layer and a second aerosol generating substrate layer and may extend through it.

[0325] One or both of the air inlet and air outlet may have an equivalent diameter of 0.1 mm or more, 0.4 mm or more, 0.7 mm or more, or 1.0 mm or more.

[0326] One or both of the air inlet and the air outlet may have an equivalent diameter of 3 mm or less, 2.7 mm or less, 2.4 mm or less, or 2.1 mm or less. The air inlet may have an equivalent diameter of 2.7 mm or less, 1.8 mm or less, or 1.5 mm or less.

[0327] One or both of the air inlet and the air outlet may have an equivalent diameter of 0.1 mm to 3 mm, 0.1 mm to 2.4 mm, 0.4 mm to 2.1 mm, 0.4 mm to 1.8 mm, 0.7 mm to 1.5 mm, or 1.0 mm to 1.5 mm.

[0328] The air inlet may have a width narrower than the width of the cavity. The air outlet may have a width narrower than the width of the cavity. The air inlet may have a thickness thinner than the thickness of the cavity. The air outlet may have a thickness thinner than the thickness of the cavity.

[0329] One or both of the air inlet and the air outlet may have a width of 0.3 mm to 3 mm or 0.5 mm to 2 mm.

[0330] One or both of the air inlet and the air outlet may have a thickness of 0.3 mm to 3 mm or 0.5 mm to 2 mm.

[0331] 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.

[0332] 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.

[0333] Advantageously, an aerosol generating article having an air outlet or air inlet having a width of 0.3 mm to 3 mm and a thickness of 0.3 mm to 3 mm can provide a relatively large inlet or outlet opening while allowing improved retention of the aerosol generating material within the aerosol generating article. Improved retention of the aerosol generating material within the aerosol generating article can reduce the risk of the aerosol generating material falling out of the aerosol generating article.

[0334] The ratio of the width of the air inlet to the thickness of the air inlet may be 0.33 to 3. The ratio of the width of the air inlet to the thickness of the air inlet may be 0.5 to 1.5. The ratio of the width of the air inlet to the thickness of the air inlet may be 0.75 to 1.25.

[0335] 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.

[0336] An aerosol generating article may include a plurality of air inlets. One or each of the air inlets may have one or more of the features of the air inlets described herein.

[0337] An aerosol generating article may include a plurality of air outlets. One or each of the air outlets may have one or more of the features of the air outlets described herein.

[0338] The aerosol generating article may include a filter element located downstream of an aerosol forming substrate. The aerosol generating article may include a filter element located downstream of a cavity. The aerosol generating article may include a filter element located at least partially within an air outlet. The aerosol generating article may include a filter element located within a cavity and may be located at the downstream end of the cavity.

[0339] The aerosol generating article may include a filter element located upstream of an aerosol forming substrate. The aerosol generating article may include a filter element located upstream of a cavity. The aerosol generating article may include a filter element located at least partially within an air inlet. The aerosol generating article may include a filter element located within a cavity and may be located at the upstream end of the cavity.

[0340] The filter element may comprise one or more filter segments of a fibrous filtration material. Suitable fibrous filtration materials will be known to those skilled in the art. The filter element may comprise cellulose acetate.

[0341] The ratio between the length and thickness of the aerosol-generating article and between the width and thickness of the aerosol-generating article may be greater than 2:1, greater than 5:1, greater than 10:1, greater than 12:1, or greater than 15:1.

[0342] The ratio between the length and thickness of the aerosol-generating article and between the width and thickness of the aerosol-generating article may be less than 15:1, less than 12:1, less than 10:1, less than 5:1, or less than 2.5:1.

[0343] The ratio between the length and thickness of the aerosol-generating article and between the width and thickness of the aerosol-generating article may be 2:1 to 15:1, 2:1 to 12:1, 2:1 to 10:1, or 5:1 to 10:1.

[0344] The ratio between the length and width of an aerosol-generating article may be greater than 1:1, greater than 2:1, greater than 3:1, greater than 4:1, or greater than 5:1.

[0345] The ratio between the length and width of an aerosol-generating article may be less than 10:1, less than 8:1, less than 5:1, less than 4:1, less than 3:1, or less than 2:1.

[0346] The ratio between the length and width of the aerosol-generating article may be 1:1 to 10:1, 1:1 to 5:1, 1:1 to 4:1, 1:1 to 3:1, 2:1 to 4:1, or 2:1 to 3:1.

[0347] Aerosol-generating articles may have a length of 15 mm or more, 20 mm or more, 25 mm or more, 30 mm or more, 35 mm or more, or 40 mm or more.

[0348] Aerosol-generating articles may have a length of 45 mm or less, 40 mm or less, 35 mm or less, or 30 mm or less.

[0349] The aerosol generating article may have a length of 15 mm to 45 mm, 20 mm to 40 mm, 20 mm to 35 mm, or 25 mm to 30 mm.

[0350] Aerosol-generating articles may have a width of 3 mm or more, greater than 5 mm, greater than 7.5 mm, greater than 9 mm, greater than 11 mm, or greater than 13 mm.

[0351] Aerosol-generating articles may have a width of 17 mm or less, 15 mm or less, 12.5 mm or less, 11 mm or less, or 9 mm or less.

[0352] The aerosol generating article may have a width of 3 mm to 17 mm, 5 mm to 15 mm, 7.5 mm to 12.5 mm, or 9 mm to 11 mm.

[0353] Aerosol-generating articles may have a thickness of 1 mm or more, 1.5 mm or more, 2 mm or more, 2.5 mm or more, 3 mm or more, 3.5 mm or more, 4 mm or more, or 4.5 mm or more.

[0354] Aerosol-generating articles may have a thickness of 5.5 mm or less, 5 mm or less, 4.5 mm or less, 4 mm or less, 3.5 mm or less, 3 mm or less, 2.5 mm or less, or 2 mm or less.

[0355] The aerosol generating article may have a thickness of 1 mm to 5 mm, 1.5 mm to 5 mm, 2 mm to 4.5 mm, 2.5 mm to 4 mm, or 3 mm to 3.5 mm.

[0356] According to the present disclosure, an aerosol generating device for receiving an aerosol generating article as described herein is provided. 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 source for supplying power to the heater or heating means, and a controller for controlling the power supply 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, e.g., an inhalable aerosol. The aerosol generating device may be configured to heat each of one or more aerosol generating substrates to form an aerosol, e.g., an inhalable aerosol.

[0357] 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 include a plurality of such articles for use with the aerosol generating device.

[0358] The present invention is defined in the claims. However, a non-limiting, non-comprehensive list of embodiments is provided below. Any one or more features of these embodiments may be combined with any one or more features of other embodiments, embodiments, or aspects described herein.

[0359] Example EX1. A method for manufacturing an aerosol generating article for use with an aerosol generating device to generate an aerosol, the method comprising: providing a first frame material continuous sheet and an additional material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the additional material continuous sheet below the first frame material continuous sheet; and joining the additional material continuous sheet and the first frame material continuous sheet to form a laminated structure of the aerosol generating article including the frame core layer.

[0360] Example EX2. A method according to Example EX1, wherein the additional material continuous sheet is a second frame material continuous sheet, the first frame material continuous sheet and the second frame material continuous sheet form a laminated frame structure, and the step of joining the additional material continuous sheet and the first frame material continuous sheet is performed before the step of forming the frame core layer by forming a frame aperture through the first frame material continuous sheet.

[0361] Example EX 3. In Example EX 2, the method wherein the frame aperture is formed to extend through both the first frame material continuous sheet and the second frame material continuous sheet.

[0362] Example EX 4. A method according to Example EX 1, wherein the additional material continuous sheet is a second frame material continuous sheet, the first frame material continuous sheet and the second frame material continuous sheet form a laminated frame structure, and the step of joining the additional material continuous sheet and the first frame material continuous sheet is performed after the step of forming a frame core layer by forming a frame aperture through the first frame material continuous sheet.

[0363] Example EX 5. In any one of Examples EX 2 to EX 4, the method further comprises: providing a third frame material continuous sheet; and joining the third frame material continuous sheet and the first frame material continuous sheet to form a laminated structure of the aerosol generating article, wherein the first frame material continuous sheet, the second frame material continuous sheet, and the third frame material continuous sheet form the laminated frame structure.

[0364] Example EX 6. In Example EX 5, the step of bonding the third frame material continuous sheet and the first frame material continuous sheet is performed before the step of forming the frame core layer by forming a frame aperture through the first frame material continuous sheet, and after or simultaneously with the step of bonding the second frame material continuous sheet and the first frame material continuous sheet.

[0365] Example EX 7. In Example EX 6, the method wherein the frame aperture is formed to extend through the first frame material continuous sheet, the second frame material continuous sheet, and the third frame material continuous sheet.

[0366] Example EX 8. A method comprising, in any one of Examples EX 1 to EX 7, the step of providing a first continuous sheet of frame material: providing a first continuous laminate layer of the first frame material and a second continuous laminate layer of the first frame material; positioning the second continuous laminate layer of the first frame material below the first continuous laminate layer of the first frame material; and bonding the first continuous laminate layer of the frame material and the second continuous laminate layer of the first frame material to form the first continuous sheet of frame material.

[0367] Example EX 9. A method comprising, in any one of Examples EX 1 to EX 7, the step of providing a first continuous sheet of a first frame material, the step of providing a first continuous laminate layer of the first frame material, a second continuous laminate layer of the first frame material, and a third continuous laminate layer of the first frame material; the step of positioning the first continuous laminate layer of the first frame material between the second continuous laminate layer of the first frame material and the third continuous laminate layer of the first frame material; and the step of bonding the first continuous laminate layer of the first frame material, the second continuous laminate layer of the first frame material, and the third continuous laminate layer of the first frame material to form the first continuous sheet of the first frame material.

[0368] Example EX 10. A method comprising, in any one of Examples EX 2 to EX 7, the step of providing a second frame material continuous sheet: providing a first continuous laminate layer of the second frame material and a second continuous laminate layer of the second frame material; positioning the second continuous laminate layer of the second frame material below the first continuous laminate layer of the second frame material; and bonding the first continuous laminate layer of the second frame material and the second continuous laminate layer of the second frame material to form the second frame material continuous sheet.

[0369] Example EX 11. A method comprising, in any one of Examples EX2 to EX7, the step of providing a second frame material continuous sheet, the step of providing a first continuous laminate layer of the second frame material, a second continuous laminate layer of the second frame material, and a third continuous laminate layer of the second frame material; the step of positioning the first continuous laminate layer of the second frame material between the second continuous laminate layer of the second frame material and the third continuous laminate layer of the second frame material; and the step of bonding the first continuous laminate layer of the second frame material, the second continuous laminate layer of the second frame material, and the third continuous laminate layer of the second frame material to form the second frame material continuous sheet.

[0370] Example EX 12. A method comprising, in any one of Examples EX 5 to EX 7, the step of providing a third frame material continuous sheet: providing a first continuous laminate layer of the third frame material and a second continuous laminate layer of the third frame material; positioning the second continuous laminate layer of the third frame material below the first continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material and the second continuous laminate layer of the third frame material to form the third frame material continuous sheet.

[0371] Example EX 13. A method comprising, in any one of Examples EX 5 to EX 7, the step of providing a third frame material continuous sheet: providing a first continuous laminate layer of the third frame material, a second continuous laminate layer of the third frame material, and a third continuous laminate layer of the third frame material; positioning the first continuous laminate layer of the third frame material between the second continuous laminate layer of the third frame material and the third continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material, the second continuous laminate layer of the third frame material, and the third continuous laminate layer of the third frame material to form the third frame material continuous sheet.

[0372] Example EX 14. A method comprising, in any one of the prior embodiments, the step of forming an air inlet and an air outlet of the aerosol generating article.

[0373] Example EX 15. In Example EX 14, the step of forming an air inlet and an air outlet of the aerosol generating article comprises establishing a fluid connection between the air inlet and the air outlet through an internal cavity of the aerosol generating article, wherein the internal cavity is at least partially defined by the frame aperture.

[0374] Example EX 16. A method comprising, in any one of Examples EX 1 to EX 13, further comprising the step of forming an air inlet aperture or an air outlet aperture or both through the first frame material continuous sheet.

[0375] Example EX 17. A method comprising, in any one of Examples EX 2 to EX 7 and Examples EX 11 to EX 13, further comprising the step of forming an air inlet aperture or an air outlet aperture or both through the second frame material continuous sheet.

[0376] Example EX 18. A method comprising, in any one of Examples EX 5 to EX 7, EX 12 and EX 13, further comprising the step of forming an air inlet aperture or an air outlet aperture or both through the third frame material continuous sheet.

[0377] Example EX 19. A method in any one of Examples EX 16 to EX 18, wherein the step of forming an air inlet aperture or an air outlet aperture or both through the first frame material continuous sheet is performed before the step of forming a laminated structure of the aerosol generating article comprising the frame core layer by joining the second frame material continuous sheet and the first frame material continuous sheet.

[0378] Example EX 20. A method in which, in Example EX 17 or EX 18, the step of forming an air inlet aperture or an air outlet aperture or both through the second frame material continuous sheet is performed before the step of bonding the second frame material continuous sheet and the first frame material continuous sheet to form a laminated structure of the aerosol generating article comprising the frame core layer.

[0379] Example EX 21. In Example EX 18, the step of forming an air inlet aperture or an air outlet aperture or both through the third frame material continuous sheet is performed before the step of bonding the first frame material continuous sheet and the third frame material continuous sheet to form a laminated structure of the aerosol generating article comprising the frame core layer.

[0380] Example EX 22. A method further comprising, in any one of the prior embodiments, the step of providing a first outer layer material continuous sheet and a second outer layer material continuous sheet; the step of positioning the first frame material continuous sheet and the additional material continuous sheet between the first outer layer material continuous sheet and the second outer layer material continuous sheet; and the step of bonding the first outer layer material continuous sheet, the second outer layer material continuous sheet, the first frame material continuous sheet and the additional material continuous sheet to form a laminated structure of the aerosol generating article.

[0381] Example EX 23. In Example EX1, the additional material continuous sheet is a first inner layer material continuous sheet, method.

[0382] Example EX 24. A method further comprising, in Example EX 23, the step of providing a second inner layer material continuous sheet; the step of positioning the second inner layer material continuous sheet on the first frame material continuous sheet; and the step of bonding the second inner layer material continuous sheet and the frame to form a laminated structure of the aerosol generating article.

[0383] Example EX 25. A method according to Example EX 23 or EX 24, wherein the first inner layer material continuous sheet is a sheet of aerosol generating material.

[0384] Example EX 26. Method in Example EX 23 or EX 24, wherein the first inner layer material continuous sheet is a sheet comprising a cellulose material, preferably paper or cardboard.

[0385] Example EX 27. A method according to Example EX 24, wherein at least one of the first inner layer material continuous sheet and the second inner layer material continuous sheet is a sheet of an aerosol generating material.

[0386] Example EX 28. In Example EX 24, the method wherein at least one of the first inner layer material continuous sheet and the second inner layer material continuous sheet is a sheet comprising a cellulose material, preferably paper or cardboard.

[0387] Example EX 29. A method comprising, in any one of Examples EX 1 to EX 28, the step of providing a first protective layer material continuous sheet; the step of positioning the first protective layer material continuous sheet on the first frame material continuous sheet and the additional material continuous sheet; and optionally the step of bonding the first protective layer material continuous sheet and the first frame material continuous sheet.

[0388] Example EX 30. A method comprising, in any one of Examples EX 1 to EX 29, the step of providing a first protective layer material continuous sheet and a second protective layer material continuous sheet; the step of positioning the first frame material continuous sheet and the additional material continuous sheet between the first protective layer material continuous sheet and the second protective layer material continuous sheet; and optionally the step of bonding the first protective layer material continuous sheet, the second protective layer material continuous sheet, and the first frame material continuous sheet.

[0389] Example EX 31. A method for manufacturing an aerosol generating article for use with an aerosol generating device to generate an aerosol, the method comprising: providing a first frame material continuous sheet and a second frame material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the second frame material continuous sheet below the first frame material continuous sheet; and bonding the second frame material continuous sheet to the frame core layer to form a stacked frame structure of the aerosol generating article.

[0390] Example EX 32. A method further comprising, in Example EX 31, the step of providing a third frame material continuous sheet; the step of positioning the third frame material continuous sheet on the first frame material continuous sheet; and the step of bonding the third frame material continuous sheet and the first frame material sheet to form a laminated frame structure of the aerosol generating article.

[0391] Example EX 33. A method according to Example EX 31 or EX 32, wherein the step of providing a first continuous sheet of frame material comprises: providing a first continuous laminate layer of the first frame material and a second continuous laminate layer of the first frame material; positioning the second continuous laminate layer of the first frame material below the first continuous laminate layer of the first frame material; and bonding the first continuous laminate layer of the frame material and the second continuous laminate layer of the first frame material to form the first continuous sheet of frame material.

[0392] Example EX 34. A method according to Example EX 31 or EX 32, wherein the step of providing a first continuous sheet of frame material comprises: providing a first continuous laminate layer of the first frame material, a second continuous laminate layer of the first frame material, and a third continuous laminate layer of the first frame material; positioning the first continuous laminate layer of the first frame material between the second continuous laminate layer of the first frame material and the third continuous laminate layer of the first frame material; and bonding the first continuous laminate layer of the first frame material, the second continuous laminate layer of the first frame material, and the third continuous laminate layer of the first frame material to form the first continuous sheet of frame material.

[0393] Example EX 35. A method according to Example EX 31 or EX 32, wherein the step of providing a second frame material continuous sheet comprises: providing a first continuous laminate layer of the second frame material and a second continuous laminate layer of the second frame material; positioning the second continuous laminate layer of the second frame material below the first continuous laminate layer of the second frame material; and bonding the first continuous laminate layer of the second frame material and the second continuous laminate layer of the second frame material to form the second frame material continuous sheet.

[0394] Example EX 36. A method according to Example EX 31 or EX 32, wherein the step of providing a second frame material continuous sheet comprises: providing a first continuous laminate layer of the second frame material, a second continuous laminate layer of the second frame material, and a third continuous laminate layer of the second frame material; positioning the first continuous laminate layer of the second frame material between the second continuous laminate layer of the second frame material and the third continuous laminate layer of the second frame material; and bonding the first continuous laminate layer of the second frame material, the second continuous laminate layer of the second frame material, and the third continuous laminate layer of the second frame material to form the second frame material continuous sheet.

[0395] Example EX 37. In Example EX 32, the step of providing a third frame material continuous sheet comprises: providing a first continuous laminate layer of the third frame material and a second continuous laminate layer of the third frame material; positioning the second continuous laminate layer of the third frame material below the first continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material and the second continuous laminate layer of the third frame material to form the third frame material continuous sheet.

[0396] Example EX 38. In Example EX 32, the step of providing a third frame material continuous sheet comprises: providing a first continuous laminate layer of the third frame material, a second continuous laminate layer of the third frame material, and a third continuous laminate layer of the third frame material; positioning the first continuous laminate layer of the third frame material between the second continuous laminate layer of the third frame material and the third continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material, the second continuous laminate layer of the third frame material, and the third continuous laminate layer of the third frame material to form the third frame material continuous sheet.

[0397] Example EX 39. A method comprising, in any one of Examples EX 31 to EX 38, further comprising the step of forming an air inlet and an air outlet of the aerosol generating article.

[0398] Example EX 40. In Example EX 39, the step of forming an air inlet and an air outlet of the aerosol generating article comprises establishing a fluid connection between the air inlet and the air outlet through an internal cavity of the aerosol generating article, wherein the internal cavity is at least partially defined by the frame aperture.

[0399] Example EX 41. A method further comprising, in any one of Examples EX 31 to EX 40, the step of providing a first inner layer material continuous sheet; the step of positioning the first inner layer material continuous sheet below the stacked frame structure; and the step of bonding the first inner layer material continuous sheet and the stacked frame structure to form a stacked structure of the aerosol generating article.

[0400] Example EX 42. A method further comprising, in any one of Examples EX 31 to EX 40, the step of providing a first inner layer material continuous sheet; the step of positioning the first inner layer material continuous sheet on the laminated frame structure; and the step of bonding the first inner layer material continuous sheet and the laminated frame structure to form a laminated structure of the aerosol generating article.

[0401] Example EX 43. A method comprising, in any one of Examples EX 31 to EX 40, the step of providing a first inner layer material continuous sheet; the step of positioning the first inner layer material continuous sheet on the stacked frame structure; the step of providing a second inner layer material continuous sheet; the step of positioning the second inner layer material continuous sheet below the stacked frame structure; and the step of joining the first inner layer material continuous sheet, the second inner layer material continuous sheet, and the stacked frame structure to form a stacked structure of the aerosol generating article.

[0402] Example EX 44. A method comprising, in any one of Examples EX 31 to EX 40, the step of providing a first outer layer material continuous sheet and a second outer layer material continuous sheet; the step of positioning the laminated frame structure between the first outer layer material continuous sheet and the second outer layer material continuous sheet; and the step of bonding the laminated frame structure, the first outer layer material continuous sheet and the second outer layer material continuous sheet to form a laminated structure of the aerosol generating article.

[0403] Example EX 45. A method further comprising, in Example EX 41 or EX 42, the step of providing a first outer layer material continuous sheet and a second outer layer material continuous sheet; the step of positioning the laminated frame structure and the first inner layer material continuous sheet between the first outer layer material continuous sheet and the second outer layer material continuous sheet; and the step of bonding the laminated frame structure, the first inner layer material continuous sheet, the first outer layer material continuous sheet and the second outer layer material continuous sheet to form a laminated structure of the aerosol generating article.

[0404] Example EX 46. A method further comprising, in Example EX 43, the step of providing a first outer layer material continuous sheet and a second outer layer material continuous sheet; the step of positioning the laminated frame structure, the first inner layer material continuous sheet and the second inner layer material continuous sheet between the first outer layer material continuous sheet and the second outer layer material continuous sheet; and the step of bonding the laminated frame structure, the first inner layer material continuous sheet, the second inner layer material continuous sheet, the first outer layer material continuous sheet and the second outer layer material continuous sheet to form a laminated structure of the aerosol generating article.

[0405] Example EX 47. In any one of the prior embodiments, the step of forming a frame core layer by forming a frame aperture through the first frame material continuous sheet comprises the step of providing a continuous blank for forming a plurality of frames of a corresponding aerosol generating article by forming an array of frame apertures through the first frame material continuous sheet.

[0406] Example EX48. A method in which, in any one of the previous embodiments, the thickness of the aerosol generating article is less than 50% of both the length and width of the aerosol generating article.

[0407] Example EX 49. A method in which, in any one of the previous embodiments, the thickness of the frame core layer accounts for 80% or more of the thickness of the aerosol generating article.

[0408] Example EX 50. A method in any one of Examples EX 2 to EX 5, wherein the thickness of the laminated frame structure occupies 80% or more of the thickness of the aerosol generating article.

[0409] Example EX 51. A method in any one of the previous embodiments, wherein the frame core layer has a thickness of 80% to 95% of the thickness of the aerosol generating article.

[0410] Example EX 52. A method in any one of Examples EX 2 to EX 5, wherein the thickness of the laminated frame structure occupies 80% to 95% of the thickness of the aerosol generating article.

[0411] Example EX 53. A method in which, in any one of the previous embodiments, the first frame material continuous sheet comprises paper, paperboard, or cardboard.

[0412] Example EX 54. A method in which, in any one of the previous embodiments, the thickness of the first frame material continuous sheet is 0.6 mm or less.

[0413] Example EX 55. A method in which, in any one of the previous embodiments, the basis weight of the first frame material continuous sheet is 380 gsm or less.

[0414] Example EX 56. A method in which, in any one of the previous embodiments, the basis weight of the first frame material continuous sheet is at least 100 gsm.

[0415] Example EX 57. A method in which, in any one of the previous embodiments, the width of the first frame material continuous sheet is at least 25 mm.

[0416] Example EX 58. A method in which, in any one of the previous embodiments, the width of the first frame material continuous sheet is at least 200 mm.

[0417] Example EX 59. A method comprising, in any one of the prior embodiments, further comprising the step of distributing an aerosol generating material into the frame aperture.

[0418] Example EX 60. A method according to Example EX 58, comprising the step of compressing the aerosol generating material within the cavity of the aerosol generating article, wherein the cavity is at least partially partitioned by the peripheral surface of the frame aperture.

[0419] Example EX 61. A method according to Example EX 58 or EX 59, wherein the aerosol generating substrate is in the form of a crushed aerosol generating material.

[0420] Example EX 62. In EX60, the crushed aerosol generating material comprises one or more of strips and strands of aerosol generating material, such as strips and strands of tobacco or homogenized tobacco material.

[0421] Example EX 63. A method according to Example EX 59 or EX 60, wherein the aerosol generating substrate is in the form of a wavy sheet of an aerosol generating material.

[0422] Example EX 64 A method according to Example EX 59 or EX 60, wherein the aerosol generating substrate is in the form of a plurality of granules, beads, pellets, or flakes of an aerosol generating material.

[0423] Example EX 65. A method in any one of Examples EX 59 to EX 64, wherein the aerosol generating substrate comprises one or more aerosol forming agents, such as glycerin and propylene glycol, or both.

[0424] Example EX 66. A method in any one of EX 59 to EX 64, wherein the aerosol generating substrate has a bulk density of 0.5 mg / mm³ or less.

[0425] Example EX 67. A method in which, in any one of EX 59 to EX 64, the aerosol generating substrate located within the cavity has a packing density of 0.9 or less. Brief explanation of the drawing

[0426] Hereinafter, embodiments will be further described with reference to the drawings. FIG. 1a shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 1b shows an exploded perspective view of the aerosol generating article of FIG. A; FIG. 1c shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 2 shows an exploded perspective view of the aerosol generating article of FIG. 1c; FIG. 3 shows an exploded perspective view of an aerosol generating article according to the present disclosure; FIG. 4 shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 5 shows a perspective view of an aerosol-generating article according to the present disclosure; FIG. 6 shows an exploded perspective view of an aerosol-generating article according to the present disclosure; FIG. 7 shows a perspective view of an aerosol generating article according to the present disclosure; FIG. 8 shows a schematic cross-sectional view of an aerosol generating device according to the present disclosure; FIG. 9 shows a schematic cross-sectional view of the aerosol generating device of FIG. 8 engaging with the aerosol generating article of the present disclosure; FIG. 10 shows a method for manufacturing an aerosol-generating article according to the present disclosure; FIG. 11 shows a plan view of the manufacturing method of FIG. 10; FIG. 12 shows a method for manufacturing an aerosol-generating article according to the present disclosure; FIG. 13 shows a plan view of the manufacturing method of FIG. 12; FIG. 14 shows a method for manufacturing an aerosol-generating article according to the present disclosure; FIG. 15 shows a plan view of the manufacturing method of FIG. 14; FIG. 16 illustrates a method for manufacturing an aerosol-generating article according to the present disclosure; and Figure 17 shows a plan view of the manufacturing method of Figure 16. Specific details for implementing the invention

[0427] FIG. 1a shows an aerosol generating article (10) obtainable from a method according to the present disclosure. The aerosol generating article comprises a first planar outer layer (22) forming a first planar outer surface (25), and a frame (50) positioned on the first planar outer layer (22).

[0428] The aerosol generating article (10) has a length extending in the x direction, a width extending in the y direction, and a thickness extending in the z direction. The aerosol generating article (10) has a length of 30 mm, a width of 10 mm, and a thickness of 2.9 mm.

[0429] The aerosol generating article (10) is substantially flat or substantially planar aerosol generating article. In particular, the thickness of the aerosol generating article (10) is less than 50% of both the length and width of the aerosol generating article. The aerosol generating article (10) has a shape that is generally rectangular and has a laminated structure formed by a first planar outer layer (22) and a frame (50). The first planar outer layer (22) and the frame (50) are bonded together with an adhesive, in particular guar gum, as will be discussed in more detail below in relation to FIG. 1b.

[0430] FIG. 1b shows an exploded view of the aerosol generating article (10) of FIG. 1c.

[0431] The frame (50) has a length of 30 mm, a width of 10 mm, and a thickness of 2.7 mm. The frame (50) is made of cardboard and defines a frame aperture that extends through the thickness of the frame (50). The frame aperture forms at least partially a cavity (30). The cavity (30) has a length of 26 mm, a width of 6 mm, and a thickness of 2.7 mm. Thus, the cavity (30) has a volume of approximately 421.2 mm³. In this embodiment, the cavity (30) is substantially empty. The first planar outer layer (22) defines a cavity end surface (32) that closes the cavity (30) at one end.

[0432] The frame (50) has an inner frame surface (52) extending in the z-direction or transverse direction between the first planar outer surface (21) and the second planar outer surface (22). The inner frame surface (52) defines a cavity outer wall. The frame (50) has an outer frame surface (53) extending in the z-direction or transverse direction between the first planar outer surface (21) and the second planar outer surface (22). The outer frame surface (53) defines at least one or more outer surfaces of an aerosol generating article, such as a front wall (13) and a rear wall (14).

[0433] The frame (50) includes a perimeter wall (51) surrounding the cavity (30). More specifically, the perimeter wall (51) is defined by the frame inner surface (52) and the frame outer surface (53). The perimeter wall (51) has a radial thickness of about 2 mm when measured between the frame inner surface (52) and the frame outer surface (53) in the x / y plane.

[0434] The first planar outer layer (22) has a thickness of 200 μm and is in physical contact with the frame (50). The first planar outer layer (22) is bonded to the frame (50) with an adhesive (15). The first planar outer layer (22) is placed over the end of the cavity (30) and forms the first cavity end wall surface (32). That is, the frame (50) and the first planar outer layer (22) collectively partition the cavity (30).

[0435] The air inlet (11) and air outlet (12) are defined by the peripheral wall surface (51) of the frame (50) and extend through it. The air inlet (11) and air outlet (12) each have a rectangular cross-section, a width of 2 mm, and a thickness of 0.9 mm. An airflow passage extends through a cavity (30) between the air inlet (11) and the air outlet (12).

[0436] In one example, the first planar outer layer (22) comprises a cellulose material such as cardboard or paper.

[0437] In another example, the first planar outer layer (22) includes an aerosol generating substrate containing an aerosol generating material, namely tobacco.

[0438] As an alternative to or in addition to the first planar outer layer (22) comprising an aerosol generating substrate, an aerosol generating material may be located elsewhere within the aerosol generating article (10). For example, the aerosol generating material may be located within a cavity (30). The arrangement of the aerosol generating material within the cavity of the aerosol generating article obtainable from the method according to the present disclosure is described in more detail below with reference to the embodiments of FIGS. 3 through 6.

[0439] The aerosol generating article (10) of FIG. 1c is intended to be used with an aerosol generating device comprising a device cavity into which the aerosol generating (10) can be inserted. The device cavity is shaped and sized to accommodate the aerosol generating article (10). The inner wall of the device cavity is configured to rest over the cavity (30) to substantially close the cavity (30).

[0440] That is, when an aerosol generating article (10) is received within the device cavity, the inner wall surface of the device cavity defines a second cavity end wall surface facing the cavity end wall surface (32). As a result, during use, the cavity (30) is partitioned by the cavity end wall surface (32), the frame (50), and the inner wall surface of the device cavity.

[0441] Accordingly, when the user inhales the air outlet (12) during use, the airflow passes through the air inlet (11), crosses the cavity (30), passes over the heated aerosol generating material contained in or exposed to the cavity (30), and is inhaled, and is delivered to the air outlet (12) as an airflow containing aerosol.

[0442] FIG. 1c 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, namely 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 located elsewhere within the aerosol generating article (10).

[0443] The aerosol generating article (10) has a length extending in the x direction, a width extending in the y direction, and a thickness extending in the z direction. The aerosol generating article (10) has a length of 30 mm, a width of 10 mm, and a thickness of 3.1 mm.

[0444] The aerosol generating article (10) is substantially flat or substantially planar. In particular, the thickness of the aerosol generating article (10) is less than 50% of both the length and width of the aerosol generating article. The aerosol generating article (10) has a shape that is generally rectangular and has 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 bonded together using an adhesive, in particular guar gum, as will be discussed in more detail below in relation to FIG. 2.

[0445] FIG. 2 shows an exploded view of the aerosol generating article (10) of FIG. 1c.

[0446] The frame (50) has a length of 30 mm, a width of 10 mm, and a thickness of 2.7 mm. The frame (50) is made of cardboard and defines a frame aperture that extends through the thickness of the frame (50). The frame aperture forms at least partially a cavity (30). The cavity (30) has a length of 26 mm, a width of 6 mm, and a thickness of 2.7 mm. Thus, the cavity (30) has a volume of approximately 421.2 mm³. In this embodiment, the cavity (30) is substantially empty.

[0447] The frame (50) has an inner frame surface (52) extending in the z-direction or transverse direction between the first planar outer surface (21) and the second planar outer surface (22). The inner frame surface (52) defines a joint outer wall surface. The frame (50) has an outer frame surface (53) extending in the z-direction or transverse direction between the first planar outer surface (21) and the second planar outer surface (22). The outer frame surface (53) defines at least partially one or more outer surfaces of an aerosol generating article, such as a front wall (13) and a rear wall (14).

[0448] The frame (50) includes a perimeter wall (51) surrounding the cavity (30). More specifically, the perimeter wall (51) is defined by the frame inner surface (52) and the frame outer surface (53). The perimeter wall (51) has a radial thickness of about 2 mm when measured between the frame inner surface (52) and the frame outer surface (53) in the x / y plane.

[0449] The first planar outer layer (24) and the second planar outer layer (25) have a thickness of 200 μm and are in physical contact with the frame (50). The first planar outer layer (24) and the second planar outer layer (25) are bonded to the frame with an adhesive (15). The first planar outer layer (24) is placed over the end of the cavity (30) and forms the first cavity end wall (31). The second planar outer layer (25) is placed over the opposite end of the cavity (30) and forms the second cavity end wall (32). That is, the frame (50), the first planar outer layer (24), and the second planar outer layer (25) collectively define the cavity (30).

[0450] The air inlet (11) and air outlet (12) are defined by and extend through the peripheral wall surface (51) of the frame (50). The air inlet (11) and air outlet (12) each have a rectangular cross-section, a width of 2 mm, and a thickness of 0.9 mm. An airflow passage extends through a cavity (30) between the air inlet (11) and the air outlet (12).

[0451] FIG. 3 illustrates an exploded view of an aerosol generating article similar to the aerosol generating article (10) of FIG. 1c, except that the first planar outer layer (24) and the second planar outer layer (25) do not contain an aerosol generating substrate. Instead, the aerosol generating substrate (40) is located within the cavity (30). The aerosol generating substrate (40) contains an aerosol generating material in the form of a tobacco stick and has an aerosol forming agent content of 5% by weight based on dry weight. As illustrated, 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 packing density of about 0.87, a density of about 0.3 grams / cubic centimeter, and a mass of about 110 milligrams. In other examples, the aerosol generating substrate (40) may have a different packing density, a different density, and a different mass. For example, the aerosol generating material may have a packing density of 0.64, a density of 0.35 grams / cubic centimeter, and a mass of about 95 milligrams.

[0452] FIG. 4 illustrates an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 1 and FIG. 3, except that the aerosol generating article (10) of FIG. 4 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).

[0453] FIG. 5 illustrates an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 1c, except that the aerosol generating article (10) of FIG. 5 further comprises a first aerosol generating substrate layer (41) and a second aerosol generating substrate layer (42). The first aerosol generating substrate layer (41) and the second aerosol generating substrate layer (42) are formed from sheets of an aerosol generating material. In particular, the sheets of homogenized tobacco material have an aerosol forming agent content of 5% by weight based on dry weight. The first aerosol generating substrate layer (41) and the second aerosol generating substrate layer (42) each have a length equal to the length of the aerosol generating article (10), a width equal to the width of the aerosol generating article (10), and a thickness of 200 μm. That is, the aerosol generating article (10) has a length of 30 mm, a width of 10 mm, and a thickness of 3.5 mm.

[0454] The first aerosol generating substrate layer (41) and the second aerosol generating substrate layer (42) are in physical contact with the frame (50) and are bonded to the frame with an adhesive (15). The first aerosol generating substrate layer (41) is placed over the end of the cavity (30) and forms the first cavity end wall surface (31). The second aerosol generating layer (42) is placed over the opposite end of the cavity (30) and forms the second cavity end wall surface (32). That is, the frame (50), the first aerosol generating substrate layer (41), and the second aerosol generating substrate layer (42) collectively define the cavity (30).

[0455] The first planar outer layer (24) is physically in contact with the first aerosol generating substrate layer (41) and is bonded together with an adhesive (15). The second planar outer layer (25) is physically in contact with the second aerosol generating substrate layer (42) and is bonded together with an adhesive (15).

[0456] FIG. 6 illustrates an exploded view of an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 5, except that the aerosol generating substrate (40) is located within the cavity (30) as described in relation to FIG. 3. The aerosol generating substrate (40) comprises an aerosol generating material in the form of a tobacco stick and has an aerosol forming agent content of 5% by weight based on dry weight. As illustrated, the aerosol generating substrate (40) fills the entire volume of the cavity (30). FIG. 7 illustrates an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 5, except that the aerosol generating article (10) of FIG. 7 comprises 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).

[0457] FIG. 8 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) located 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 in the device (90), and the cavity (1000) has an opening (1010) defined at the proximal end (91) of the device (90). The opening (1010) is rectangular in shape and is dimensioned to accommodate a cross-section of the aerosol generating article (10). The cavity (1000) includes an upper planar surface (1020) and a lower planar surface (1030). A first heater (95) is located on the upper planar surface (1020) to heat the first planar outer surface (21) of an aerosol generating article (10) inserted into the cavity (1000), and a second heater (96) is located on the lower planar surface (1030) to heat the second planar outer surface (22) of an aerosol generating article (10) inserted into the cavity (1000). The device (90) includes an air inlet (98) that defines an airflow path configured to allow air to flow from outside the device into the cavity (1000).

[0458] FIG. 9 shows a schematic cross-sectional view of the aerosol generating device (90) of FIG. 8 that engages with the aerosol generating article (10) of FIG. 1c. There is almost no tolerance between the first planar outer surface (21) and the second planar outer surface (22) of the aerosol generating article (10) and the inner surface (1020, 1030) of the cavity (1000). Therefore, there is a tight fit 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, and as a result, the aerosol generating material is heated. The volatile components of the aerosol generating material evaporate and condense within the cavity (30) of the aerosol generating article (10) to form an aerosol. A consumer inhales the aerosol by sucking on the end of the aerosol generating article (10) which includes an air outlet (12). Once the volatile components in the aerosol generating material are depleted, the aerosol generating article (10) is removed from the cavity (1000) and disposed of.

[0459] FIG. 10 illustrates a schematic diagram of a method (1100) for manufacturing an aerosol generating article (10) as described herein, in particular a method for manufacturing an aerosol generating article (10) of FIG. 3. The method comprises the step of punching and joining a first frame material sheet (1201), a first outer layer material sheet (1301), and a second outer layer material sheet (1302). FIG. 11 illustrates a schematic plan view of the method of FIG. 10, but for illustrative purposes, the manufacturing equipment is not shown. The dashed line (1101) in FIG. 11 is for illustrative purposes and represents the final cross-sectional perimeter of the aerosol generating article (10).

[0460] A first frame material sheet (1201) is supplied 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 frame material sheet (1201). The frame aperture (1400) will at least partially form a cavity (30) of an aerosol generating article (10). An adhesive application device (1106) applies adhesive to the lower surface of the first frame material sheet (1201). A first outer layer material sheet (1301) is supplied from a bobbin (1102) through a roller (1107) and is bonded to the first frame material sheet (1201) by the adhesive applied to the lower surface of the first frame material sheet (1201). An aerosol generating material distribution device (1108) distributes an aerosol generating material (40) into a frame aperture (1400). An adhesive application device (1109) applies an adhesive (1110) to the upper surface of a first frame material sheet (1201). A second outer layer material sheet (1302) is supplied from a bobbin (1102) via a roller (1107) and bonded to the first frame material sheet (1201) by the adhesive (1110) applied to the upper surface of the first frame material sheet (1201). An aperture punching device (1111) punches the aperture (1410) through the first frame material sheet (1201), the first outer layer material sheet (1301), and the second outer layer material sheet (1302) to discharge an aerosol generating article (10). The air inlet and air outlet can be formed before or after the aerosol generating article (10) is discharged.

[0461] In some embodiments, one or more of the first frame material sheet (1201), the first outer layer material sheet (1301), and the second outer layer material sheet (1302) comprise an aerosol generating substrate. Accordingly, the step of distributing the aerosol generating substrate (40) into the frame aperture (1400) may be skipped.

[0462] FIG. 12 illustrates a schematic diagram of a method (1100) for manufacturing an aerosol generating article as described herein, in particular a method for manufacturing an aerosol generating article comprising a first inner layer comprising an aerosol generating substrate and a second inner layer comprising an aerosol generating substrate. The first inner layer and the second inner layer are in contact with a frame of the article and are bonded to the frame with an adhesive. The first inner layer is placed over one end of the cavity and forms a first cavity end wall. The second inner layer is placed over the opposite end of the cavity and forms a second cavity end wall. That is, the frame, the first inner layer, and the second inner layer collectively define the cavity. The frame, the first inner layer, and the second inner layer are positioned in turn between the first outer layer and the second outer layer.

[0463] The method includes the step of punching and bonding a first frame material sheet (1201), a first aerosol generating material sheet (1501), a second aerosol generating material sheet (1502), a first outer layer material sheet (1301), and a second outer layer material sheet (1302). FIG. 13 illustrates a schematic plan view of the method of FIG. 12, but for the sake of illustration, the manufacturing equipment is not shown. The dashed line (1101) in FIG. 13 is for illustration purposes and represents the final cross-sectional perimeter of the aerosol generating article (10).

[0464] A first frame material sheet (1201) is supplied 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 frame material sheet (1201). The frame aperture (1400) will at least partially form a cavity (30) of an aerosol-generating article (10).

[0465] The adhesive application device (1106) applies the adhesive (1110) to the lower surface of the first frame material sheet (1201) and the upper surface of the first frame material sheet (1201).

[0466] A first aerosol generating material sheet (1501) is supplied from a bobbin (1102) via a roller (1107) and bonded to the first frame material sheet (1201) by an adhesive applied to the lower surface of the first frame material sheet (1201). A second aerosol generating material sheet (1502) is supplied from a bobbin (1102) via a roller (1107) and bonded to the first frame material sheet (1201) by an adhesive (1110) applied to the upper surface of the first frame material sheet (1201).

[0467] The adhesive application device (1109) applies the adhesive (1110) to the lower surface of the first aerosol generating material sheet (1501) and the upper surface of the second aerosol generating material sheet (1502).

[0468] The first outer layer material sheet (1301) is supplied from the bobbin (1102) via the roller (1107) and bonded to the first aerosol generating material sheet (1501) by an adhesive applied to the lower surface of the first aerosol generating material sheet (1501). The second outer layer material sheet (1302) is supplied from the bobbin (1102) via the roller (1107) and bonded to the second aerosol generating material sheet (1502) by an adhesive (1110) applied to the upper surface of the second aerosol generating material sheet (1502).

[0469] The aperture punching device (1111) punches an aperture (1410) through a first frame material sheet (1201), a first aerosol generating material sheet (1501), a second aerosol generating material sheet (1502), a first outer layer material sheet (1301), and a second outer layer material sheet (1302) to discharge an aerosol generating article (10). An air inlet and an air outlet may be formed before or after the aerosol generating article (10) is discharged.

[0470] FIG. 14 illustrates a schematic diagram of a method for manufacturing an aerosol-generating article (1100) as described herein, in particular a method for manufacturing an aerosol-generating article comprising an aerosol-generating substrate located within a cavity.

[0471] More specifically, the article obtained by the manufacturing method (1100) of FIG. 14 comprises a frame having a stacked frame structure. The stacked frame structure comprises a frame core layer and a second frame layer. Additionally, the aerosol generating article comprises a first outer layer and a second outer layer, and the frame is included between the first outer layer and the second outer layer.

[0472] The method includes the step of punching and joining a first frame material sheet (1201), a second frame material sheet (1202), a first outer layer material sheet (1301), and a second outer layer material sheet (1302). FIG. 15 illustrates a schematic plan view of the method of FIG. 14, but for the sake of example, the manufacturing equipment is not shown. The dashed line (1101) in FIG. 15 is for example and represents the final cross-sectional perimeter of the aerosol generating article (10).

[0473] A first frame material sheet (1201) is supplied from a bobbin (1102) between a first pair of rollers (1103) and a second pair of rollers (1104). An adhesive application device (1106) applies an adhesive (1110) to the upper surface of the first frame material sheet (1201). A second frame material sheet (1202) is supplied from the bobbin (1102) through a roller (1107) and is bonded to the first frame material sheet (1201) by the adhesive (1110) applied to the upper surface of the first frame material sheet (1201).

[0474] The aperture punching device (1105) punches a frame aperture (1400) through the first frame material sheet (1201) and the second frame material sheet (1202). The frame aperture (1400) will at least partially form a cavity (30) of the aerosol generating article (10).

[0475] The adhesive application device (1106) applies adhesive to the lower surface of the first frame material sheet (1201). The first outer layer material sheet (1301) is supplied from the bobbin (1102) through the roller (1107) and is bonded to the first frame material sheet (1201) by the adhesive applied to the lower surface of the first frame material sheet (1201).

[0476] The aerosol generating material distribution device (1108) distributes the aerosol generating material (40) into the frame aperture (40). The adhesive application device (1109) applies the adhesive (1110) to the upper surface of the second frame material sheet (1202). The second outer layer material sheet (1302) is supplied from the bobbin (1102) via the roller (1107) and is bonded to the second frame material sheet (1202) by the adhesive (1110) applied to the upper surface of the second frame material sheet (1202).

[0477] The aperture punching device (1111) punches an aperture (1410) through a first frame material sheet (1201), a second frame material sheet (1202), a first outer layer material sheet (1301), and a second outer layer material sheet (1302) to discharge an aerosol-generating article (10). An air inlet and an air outlet may be formed before or after the aerosol-generating article (10) is discharged.

[0478] In some embodiments, one or more of the first frame material sheet (1201), the second frame material sheet (1202), the second outer layer material sheet (1301), and the second outer layer material sheet (1302) comprise an aerosol generating substrate. Accordingly, the step of distributing the aerosol generating substrate (40) into the frame aperture (1400) may be skipped.

[0479] FIG. 16 illustrates a schematic diagram of a method (1100) for manufacturing an aerosol generating article as described herein, in particular a method for manufacturing an aerosol generating article comprising an aerosol generating substrate located within a cavity.

[0480] More specifically, the article obtained by the manufacturing method (1100) of FIG. 16 comprises a frame having a stacked frame structure. The frame comprises a frame core layer, a second frame layer, and a third frame layer. The frame core layer is included between the second frame layer and the third frame layer. Additionally, the aerosol generating article comprises a first outer layer and a second outer layer, and the frame is included between the first outer layer and the second outer layer.

[0481] The method includes the step of punching and bonding a first frame material sheet (1201), a second frame material sheet (1202), a third frame material sheet (1203), a first outer layer material sheet (1301), and a second outer layer material sheet (1302). FIG. 17 illustrates a schematic plan view of the method of FIG. 16, but for the sake of example, the manufacturing equipment is not shown. The dashed line (1101) in FIG. 17 is for example and represents the final cross-sectional perimeter of the aerosol generating article (10).

[0482] The first frame material sheet (1201) is supplied from the bobbin (1102) between the first pair of rollers (1103) and the second pair of rollers (1104). The aperture punching device (1112) punches an air inlet aperture (1610) and an air outlet aperture (1620) through the first frame material sheet (1201).

[0483] The adhesive application device (1106) applies the adhesive (1110) to the lower surface of the first frame material sheet (1201) and the upper surface of the first frame material sheet (1201).

[0484] The first frame material sheet (1202) is supplied from the bobbin (1102) through the roller (1107) and bonded to the first frame material sheet (1201) by an adhesive applied to the lower surface of the first frame material sheet (1201). The third frame material sheet (1203) is supplied from the bobbin (1102) through the roller (1102) and bonded to the first frame material sheet (1201) by an adhesive (1110) applied to the upper surface of the first frame material sheet (1201).

[0485] The aperture punching device (1105) punches a frame aperture (1400) through a first frame material sheet (1201), a second frame material sheet (1202), and a third frame material sheet (1203). The frame aperture will at least partially form a cavity (30) of an aerosol generating article (10).

[0486] The adhesive application device (1106) applies adhesive to the lower surface of the second frame material sheet (1202). The first outer layer material sheet (1301) is supplied from the bobbin (1102) through the roller (1107) and is bonded to the second frame material sheet (1202) by the adhesive applied to the lower surface of the second frame material sheet (1202).

[0487] The aerosol generating material distribution device (1108) distributes the aerosol generating material (40) into the frame aperture (1400). The adhesive application device (1109) applies the adhesive (1110) to the upper surface of the third frame material sheet (1203). The second outer layer material sheet (1302) is supplied from the bobbin (1102) via the roller (1107) and is bonded to the third frame material sheet (1203) by the adhesive (1110) applied to the upper surface of the third frame material sheet (1203).

[0488] The aperture punching machine (1111) punches an aperture (1410) through a first frame material sheet (1201), a second frame material sheet (1202), a third frame material sheet (1203), a first outer layer material sheet (1301), and a second outer layer material sheet (1302) to discharge an aerosol-generating article (10).

[0489] For the purposes of this description and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, etc., shall be understood in all cases to be modified by the term “about.” Additionally, all ranges include the disclosed maximum and minimum points and contain any intermediate ranges that may or may not be specifically enumerated herein. Accordingly, in this context, the number A is understood as 10% of A ± A. In this context, the number A may be considered to include numerical values ​​within the general standard error for measuring the characteristic that the number A modifies. In some examples used in the appended claims, the number A may deviate by the aforementioned percentages, provided that the amount of deviation from A does not substantially affect the basic and novel feature(s) of the claimed invention. Additionally, all ranges include the disclosed maximum and minimum points and contain any intermediate ranges that may or may not be specifically enumerated herein.

Claims

Claim 1 A method for manufacturing an aerosol generating article for use with an aerosol generating device to generate an aerosol, the method comprising: providing a first frame material continuous sheet and an additional material continuous sheet; forming a frame core layer by forming a frame aperture through the first frame material continuous sheet; positioning the additional material continuous sheet below the first frame material continuous sheet; and joining the additional material continuous sheet and the first frame material continuous sheet to form a laminated structure of the aerosol generating article including the frame core layer. Claim 2 A method according to claim 1, wherein the additional material continuous sheet is a second frame material continuous sheet, the first frame material continuous sheet and the second frame material continuous sheet form a laminated frame structure, and the step of joining the additional material continuous sheet and the first frame material continuous sheet is performed before the step of forming the frame core layer by forming a frame aperture through the first frame material continuous sheet. Claim 3 A method according to paragraph 2, wherein the frame aperture is formed to extend through both the first frame material continuous sheet and the second frame material continuous sheet. Claim 4 A method according to claim 1, wherein the additional material continuous sheet is a second frame material continuous sheet, the first frame material continuous sheet and the second frame material continuous sheet form a stacked frame structure, and the step of joining the additional material continuous sheet and the first frame material continuous sheet is performed after the step of forming a frame core layer by forming a frame aperture through the first frame material continuous sheet. Claim 5 In any one of claims 2 to 4, the method further comprises: providing a third frame material continuous sheet; and joining the third frame material continuous sheet and the first frame material continuous sheet to form a laminated structure of the aerosol generating article, wherein the first frame material continuous sheet, the second frame material continuous sheet and the third frame material continuous sheet form the laminated frame structure. Claim 6 A method according to any one of claims 1 to 5, wherein the step of providing the first continuous sheet of a frame material comprises: providing a first continuous laminate layer of the first frame material and a second continuous laminate layer of the first frame material; positioning the second continuous laminate layer of the first frame material below the first continuous laminate layer of the first frame material; and bonding the first continuous laminate layer of the frame material and the second continuous laminate layer of the first frame material to form the first continuous sheet of the frame material. Claim 7 A method according to any one of claims 2 to 5, wherein the step of providing a second frame material continuous sheet comprises: providing a first continuous laminate layer of the second frame material and a second continuous laminate layer of the second frame material; positioning the second continuous laminate layer of the second frame material below the first continuous laminate layer of the second frame material; and bonding the first continuous laminate layer of the second frame material and the second continuous laminate layer of the second frame material to form the second frame material continuous sheet. Claim 8 In claim 5, the step of providing a third frame material continuous sheet comprises: providing a first continuous laminate layer of the third frame material and a second continuous laminate layer of the third frame material; positioning the second continuous laminate layer of the third frame material below the first continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material and the second continuous laminate layer of the third frame material to form the third frame material continuous sheet. Claim 9 A method according to any one of claims 1 to 8, further comprising the step of forming an air inlet aperture or an air outlet aperture or both through the first frame material continuous sheet. Claim 10 In claim 9, the step of forming an air inlet aperture or an air outlet aperture or both through the first frame material continuous sheet is performed before the step of joining the second material continuous sheet and the first frame material continuous sheet to form a laminated structure of the aerosol generating article comprising the frame core layer. Claim 11 A method according to any one of claims 1 to 10, further comprising: providing a first outer layer material continuous sheet and a second outer layer material continuous sheet; positioning the first frame material continuous sheet and the additional material continuous sheet between the first outer layer material continuous sheet and the second outer layer material continuous sheet; and joining the first outer layer material continuous sheet, the second outer layer material continuous sheet, the first frame material continuous sheet, and the additional material continuous sheet to form a laminated structure of the aerosol generating article. Claim 12 A method according to claim 1, wherein the additional material continuous sheet is a first inner layer material continuous sheet. Claim 13 In paragraph 13, the method wherein the first inner layer material continuous sheet is a sheet of aerosol generating material. Claim 14 A method comprising, in any one of claims 1 to 13, further a step of distributing an aerosol generating material into the frame aperture. Claim 15 In paragraph 14, the method wherein the aerosol generating material is in the form of a plurality of granules, beads, pellets, or flakes of the aerosol generating material.

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