Frame for aerosol-generating articles and method for forming the frame

Abstract

A frame (50) for an aerosol generating article (10). The frame (50) has a longitudinal axis (54). The frame (50) includes at least one wall surface comprising a web of sheet material. The web of sheet material has a length and a width, and the width of the web of sheet material extends substantially perpendicularly to the longitudinal axis (54) of the frame (50).

Description

Technology Field

[0001] The present disclosure relates to a frame of an aerosol generating article. The present disclosure also relates to an aerosol generating article comprising a frame. The present disclosure also relates to a method for manufacturing a frame of an aerosol generating article. The present disclosure also relates to a method for manufacturing an aerosol generating article having a frame. 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 located near or in contact with the aerosol generating substrate, causing the aerosol generating substrate to be heated to 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 precisely 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 an aerosol generating article in which a larger portion of the aerosol generating material is heated sufficiently to form an aerosol during use. Additionally, the object of the present disclosure is to provide an aerosol generating article that can be manufactured relatively efficiently and at a low cost.

[0006] According to the present disclosure, a frame for a planar aerosol generating device is provided. The frame may have a longitudinal axis. The frame may include at least one wall surface. The at least one wall surface may include a web of sheet material. The web of sheet material may have a length and a width. The width of the web of sheet material may extend substantially perpendicularly to the longitudinal axis of the frame.

[0007] According to the present disclosure, a frame of an aerosol generating article is provided. The frame has a longitudinal axis. The frame comprises at least one wall surface comprising a web of sheet material. The web of sheet material has a length and a width, and the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame.

[0008] Advantageously, the method includes the step of forming a frame for an aerosol generating article from a web of sheet material having length and width, wherein the width extends substantially perpendicularly to the longitudinal axis of the frame, thereby facilitating the inexpensive and simple manufacturing of the frame of an aerosol generating device on a production line.

[0009] According to the present disclosure, a frame for a planar aerosol generating device is provided. The frame may include at least one wall surface. The at least one wall surface may include a web of sheet material arranged in a laminated structure. The laminated structure includes a plurality of layers of the web of sheet material.

[0010] According to the present disclosure, a frame of an aerosol generating article is provided, comprising at least one wall surface, wherein the at least one wall surface comprises a web of sheet material arranged in a laminated structure. The laminated structure comprises a plurality of layers of the web of sheet material.

[0011] Advantageously, at least one wall surface of a frame of an aerosol generating article is formed from a web of sheet material arranged in a laminated structure comprising multiple layers of a web of sheet material, thereby facilitating the inexpensive and simple manufacturing of the frame of an aerosol generating article on a production line, and the frame has at least one wall surface having increased thickness and structural rigidity due to the laminated structure comprising multiple layers of a web of sheet material.

[0012] According to the present disclosure, a frame of an aerosol generating article is provided. The frame has a longitudinal axis. The frame comprises at least one wall surface comprising a web of sheet material arranged in a laminated structure. The laminated structure comprises a plurality of layers of a web of sheet material. The web of sheet material has a length and a width, and the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame.

[0013] The laminated structure of a web of sheet materials can be formed as an overlapping layer of the web of sheet materials. The laminated structure of a web of sheet materials can be formed as a layer of the web of sheet materials overlapping on itself.

[0014] A plurality of layers of a laminated structure of a web of sheet material may include any appropriate number of layers. For example, a plurality of layers of a layered structure may include at least 2, 3, 4, 5, or 6 layers of a web of sheet material.

[0015] In some preferred embodiments, the frame is composed of a single web of sheet material arranged in a laminated structure comprising a plurality of layers of a web of sheet material.

[0016] The frame may have any suitable shape and size. In some preferred embodiments, the frame is elongated. In some preferred embodiments, the frame is elongated and has a length in the direction of the longitudinal axis that is greater than other dimensions of the frame.

[0017] A web of sheet material may have a length, width, and thickness. The length of the web extends along the longitudinal axis of the web. The web is typically slender and has a length substantially greater than its width and thickness. The length of the web may be at least five times greater than its width and thickness, or at least ten times greater than its width and thickness. The length of the web may be essentially infinite relative to other dimensions of the web. The width of the web may extend along a lateral axis perpendicular to the longitudinal axis of the web. The thickness of the web may extend along a transverse axis perpendicular to both the longitudinal axis and the lateral axis of the web. The web is typically thin, having a thickness substantially smaller than its length and width. The thickness of the web may be at least five times smaller than its length and width, or at least ten times smaller than its length and width.

[0018] The web of the sheet material may have any suitable thickness. The web of the sheet material may have a thickness of at least 0.5 mm, or at least 1.0 mm, or at least 1.5 mm, or at least 2.0 mm, or at least 2.5 mm, or at least 3.0 mm, or at least 3.5 mm, or at least 4.0 mm, or at least 4.5 mm, or at least 5.0 mm. The web of the sheet material may have a thickness of 0.5 mm to 5.0 mm, or 1.0 mm to 4.5 mm, or 1.5 mm to 4.0 mm. The web of the sheet material may have a thickness of 5.0 mm or less, or 4.5 mm or less, or 4.0 mm or less, or 3.5 mm or less, or 3.0 mm or less.

[0019] When a web of sheet material forms a frame of an aerosol-generating article according to an embodiment of the present disclosure, the width of the web of sheet material may define the height of the frame. In these embodiments, the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame. In these embodiments, the width of the web of sheet material is substantially the same as the height of the frame and any frame aperture extending through the height of the frame.

[0020] The web of sheet material may be manufactured from or contain any suitable material. The web of sheet material may be manufactured from or contain biodegradable material. The web of sheet material may be manufactured entirely from biodegradable material. The web of sheet material may be manufactured from or contain a sheet of cellulose material. The cellulose material may contain cellulose fibers. The cellulose material may be paper, cardboard, or paperboard. The web of sheet material may be manufactured from or contain plant material such as tobacco. The web of sheet material may be manufactured entirely from cellulose material.

[0021] A frame can have a length extending in the x-direction. A frame can have a width extending in the y-direction. A frame can have a height extending in the z-direction.

[0022] The frame can be a flat frame.

[0023] In some preferred embodiments, the frame defines a frame aperture. The frame aperture may be a through passage extending through the height of the frame. The frame aperture may define at least a portion of the cavity of the aerosol-generating article. In some preferred embodiments, the frame aperture defines the cavity of 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, preferably the cross-section in the x / y plane is annular in shape.

[0024] The frame may include at least one aperture extending through the wall of the frame. The at least one aperture extending through the wall of the frame may provide an air inlet into the cavity. The at least one aperture extending through the wall of the frame may provide an air outlet from the cavity. The at least one aperture extending through the wall of the frame may form part of an airflow passage for an aerosol-generating article.

[0025] At least one wall surface of a frame comprising a web of sheet materials arranged in a laminated structure may include a plurality of apertures extending through the web of sheet materials. The plurality of apertures extending through the web of sheet materials may be aligned. The plurality of apertures extending through the web of sheet materials may be aligned to form an air inlet or an air outlet through the wall surface of the frame.

[0026] 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.

[0027] The frame may include an inner surface of the frame. The inner surface of the frame may extend horizontally, 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 height of the frame. The inner surface of the frame may surround or encircle the cavity.

[0028] 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.

[0029] 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.

[0030] The frame includes at least one wall surface. The frame may include any suitable number of wall surfaces. The frame may include a single wall surface. The frame may include multiple wall surfaces.

[0031] The frame includes at least one wall surface comprising a web of sheet material.

[0032] In some embodiments, at least one wall surface of the frame comprises a web of sheet material extending substantially perpendicularly to the longitudinal axis of the frame. Where at least one wall surface comprises a single layer of a web of sheet material extending substantially perpendicularly to the longitudinal axis of the frame, the thickness of the web of sheet material may form or define the thickness of at least one wall surface. In these embodiments, the thickness of the web of sheet material may extend into the x / y plane of the frame.

[0033] In some embodiments, at least one wall surface of the frame comprises a web of sheet material arranged in a laminated structure comprising a plurality of layers of the web of sheet material. In some of these embodiments, the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame, and the thickness of at least one wall surface may be formed or defined by the sum of the thicknesses of the plurality of layers of the web of sheet material.

[0034] The frame may include surrounding walls. The surrounding walls may surround or encircle at least a portion of the frame aperture. 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 height of the frame. The surrounding walls may surround or encircle the cavity.

[0035] At least one wall surface comprising a web of sheet material is or may comprise a periphery wall surface of the frame. The periphery wall surface may be defined or formed by at least one wall surface comprising a web of sheet material. The periphery wall surface is defined or formed by at least one wall surface comprising a web of sheet material, wherein the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame. The periphery wall surface may be defined or formed by at least one wall surface comprising a web of sheet material arranged in a laminated structure.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] The frame may include a front wall surface. The frame may include a rear wall surface. The front wall surface and the rear wall surface may be separated along the x-direction of the frame. The frame may include one or more wall surfaces. One or more side wall surfaces of the frame may extend between the front wall surface and the rear wall surface of the frame. The frame may include a first side wall surface and a second side wall surface facing the first side wall surface. The first side wall surface and the second side wall surface may be separated along the y-direction of the frame. The front wall surface, the rear wall surface, and one or more side wall surfaces may be peripheral wall surfaces of the frame.

[0043] The frame may be manufactured from or contain biodegradable material. The frame may be manufactured entirely from biodegradable material. The web of the sheet material may be manufactured from or contain biodegradable material. The web of the sheet material may be manufactured entirely from biodegradable material.

[0044] The frame may be manufactured from or contain a cellulose material. The cellulose material may contain a sheet of cellulose material. The web of the sheet material may be manufactured from or contain a sheet of cellulose material. The cellulose material may contain cellulose fibers. The cellulose material may be paper, cardboard, or paperboard. The frame may be manufactured from or contain a plant material such as tobacco. The frame may be manufactured entirely from a cellulose material. The web of the sheet material may be manufactured from or contain a plant material such as tobacco. The web of the sheet material may be manufactured entirely from a cellulose material.

[0045] 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.

[0046] 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.

[0047] The susceptor material may comprise one or more materials selected from a list consisting of aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite, in any form.

[0048] The frame may have a height of 50% or more of the height of the aerosol-generating article. The frame may have a height of 70% or more of the height of the aerosol-generating article. The frame may have a height of 90% or more of the height of the aerosol-generating article. The frame may have a height of 95% or more of the height of the aerosol-generating article.

[0049] The frame may have a height of 95% or less of the height of the aerosol-generating article. The frame may have a height of 90% or less of the height of the aerosol-generating article. The frame may have a height of 70% or less of the height of the aerosol-generating article.

[0050] The frame may have a height of 50% to 95% of the height of the aerosol-generating article. The frame may have a height of 70% to 95% of the height of the aerosol-generating article.

[0051] The frame may have a height of 1 mm or more, 2 mm or more, 3 mm or more, or 4 mm or more. The frame may have a height 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 height of 1 mm to 5.5 mm. Preferably, the frame may have a height of 1.5 mm to 5.5 mm.

[0052] 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.

[0053] 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.

[0054] 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 including layers having different compositions. Advantageously, the characteristics of each layer may be individually optimized depending on the relative distance between the layer and the aerosol generating substrate or heater of the aerosol generating device.

[0055] 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.

[0056] 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.

[0057] According to the present disclosure, a method for manufacturing a frame for an aerosol-generating article is provided. The method comprises the step of providing a web of sheet material. The method further comprises the step of superimposing the web of sheet material on itself to form a frame comprising at least one wall surface, wherein the at least one wall surface has a laminated structure comprising a plurality of layers of the web of sheet material.

[0058] Advantageously, the step of forming a laminated structure comprising multiple layers of a web of sheet material by overlapping sheets of web material on themselves to form at least one wall surface of a frame of an aerosol generating article can facilitate the inexpensive and simple manufacturing of a frame of an aerosol generating article, and in a production line, the frame has at least one wall surface having increased thickness and structural rigidity due to the laminated structure comprising multiple layers of a web of sheet material.

[0059] The formed frame may have a longitudinal axis, and the web of the sheet material has a length and a width, and the width of the web of the sheet material extends substantially perpendicular to the longitudinal axis of the frame. The formed frame may be slender and has a length in the direction of the longitudinal axis that is greater than other dimensions of the formed frame.

[0060] At least one wall surface having a layered structure may include any suitable number of layers. For example, at least one wall surface may have at least two layers of a web of sheet material or at least three layers of a web of sheet material. The formed frame may include one or more peripheral walls, and one or more peripheral walls are formed of a sheet of web material and have a layered structure including at least two layers of a web of sheet material or at least three layers of a web of sheet material.

[0061] In some embodiments, the overlapping of the web of sheet material may include winding the web of sheet material around a spindle. In some of these embodiments, the method further includes the step of removing a frame from the spindle. The method may include the step of removing a frame from the spindle such that the formed frame includes a frame aperture on which the web of sheet material is wound.

[0062] Advantageously, the steps of winding a web of sheet material around a spindle to form a frame, and removing the spindle before removing it from the frame to form a frame including a frame aperture in the space occupied by the spindle, can make the inexpensive and simple manufacturing of the frame of the aerosol generating article easier on a production line, and the frame has at least one wall surface having increased thickness and structural rigidity due to a laminated structure comprising multiple layers of a web of sheet material.

[0063] The spindle may have a longitudinal axis on which the web of sheet material is wound. The spindle may have a transverse cross-sectional shape perpendicular to the longitudinal axis of the spindle. The transverse cross-sectional shape of the spindle may be at least one of a circular, non-circular, elliptical, stadium shape, polygonal, triangular, rectangular, trapezoidal, pentagonal, or hexagonal shape. The transverse cross-sectional shape of the spindle may form the longitudinal cross-sectional shape of the frame aperture of the frame in the x / y plane of the frame. The transverse cross-sectional shape of the spindle may form the longitudinal cross-sectional shape of the cavity of the aerosol generating article in the x / y plane of the aerosol generating article. The spindle may have any suitable dimensions for the cavity as described below.

[0064] In some embodiments, the step of overlapping a web of sheet material onto itself to form a frame includes the step of compressing two or more of the overlapping layers of the web of sheet material together. Advantageously, compressing two or more of the overlapping layers of the web of sheet material together can further increase the structural rigidity of at least one wall surface of the frame.

[0065] In some embodiments, the method comprises the step of crimping a section of a web of sheet material to form a crimped section having wavy folds. In some of these embodiments, the crimped portion of the web of sheet material is compressed to compress the wavy folds of the crimped portion together. Advantageously, compressing a section of the web of sheet material to form a compressed section, and in particular compressing the wavy folds of the compressed portion together, can further increase the structural rigidity of at least one wall surface of the frame.

[0066] In some embodiments, the method includes the step of applying an adhesive to the surface of a web of sheet material before overlapping the web of sheet material onto itself. Overlapping the web of sheet material onto itself may include bringing the adhesive on the surface of the web of sheet material into contact with another surface of the web material.

[0067] If the above method includes the step of compressing a section of a web of sheet material to form a compressed section, the step of applying an adhesive may include applying the adhesive to one or more of the wavy folds of the compressed portion.

[0068] If the above method includes the step of compressing two or more of the overlapping layers of the web of the sheet material together, the method may include compressing the web of the sheet material having an adhesive applied in contact with another surface of the web material. Advantageously, compressing the surface of the web of the sheet material having an adhesive applied in contact with another surface of the web material can improve the adhesion of the surface of the web of the sheet material having an adhesive applied to another surface of the web of the sheet material.

[0069] The above method may further include the step of forming one or more apertures in a web of sheet material. The apertures may be formed in the web of sheet material in any suitable manner. For example, one or more apertures may be punched or cut from the web of sheet material.

[0070] The step of forming one or more apertures may occur at any appropriate time in the method. The step of forming one or more apertures may include the step of forming one or more apertures before the web of sheet material overlaps on itself. The step of forming one or more apertures may include the step of forming one or more apertures while the web of sheet material overlaps on itself. The step of forming one or more apertures may include the step of forming one or more apertures after the web of sheet material overlaps on itself.

[0071] If the above method includes the step of forming one or more apertures before overlapping the web of sheet material on itself, the step of overlapping the web of sheet material on itself may include the step of aligning two or more apertures. At least one wall surface of a frame having a laminated structure of the web of sheet material may include two or more aligned apertures. Two or more aligned apertures may form an air inlet of an aerosol-generating article. Two or more aligned apertures may form an air outlet of an aerosol-generating article.

[0072] If the overlap of the web of sheet material involves winding the web of sheet material around a spindle, winding the web of sheet material around a spindle may involve aligning two or more apertures.

[0073] If the overlap of the web of the sheet material includes compressing a section of the web of the sheet material to form a compressed section, forming one or more apertures in the web of the sheet material may include forming apertures in two or more of the wavy folds of the compressed section. The overlap of the web of the sheet material may further include the step of aligning apertures in two or more of the wavy folds of the compressed section.

[0074] Advantageously, forming one or more apertures before overlapping the web of sheet material on itself, and aligning two or more apertures when overlapping the web of sheet material on itself, can provide a reliable and inexpensive method for creating air inlets and outlets within the relatively thick walls of the frame.

[0075] In some embodiments, the web of the sheet material may have a pre-formed aperture. In these embodiments, the step of providing the web of the sheet material includes the step of providing the web of the sheet material having one or more pre-formed apertures.

[0076] In some embodiments, the method further comprises the step of arranging one or more elements in or over one or more apertures. One or more elements may include one or more of filter elements and meshes. Filter elements may include cellulose acetate. The step of arranging one or more elements in one or more apertures may be performed before the web of sheet material is superimposed on itself. The step of arranging one or more elements in one or more apertures may be performed after the web of sheet material is superimposed on itself.

[0077] The formed frame may include one or more apertures on its outer surface, such as air inlets and air outlets. The method may include the step of wrapping the formed frame with an outer wrapper. The outer wrapper may cover the outer surface of the frame. The outer wrapper may cover one or more apertures on the outer surface of the frame. The outer wrapper may cover the air inlets and air outlets of the frame. The outer wrapper may be removable from the frame. Advantageously, covering apertures such as air inlets and air outlets on the outer surface of the frame may help protect the aerosol-forming material in the cavity of the aerosol-generating article.

[0078] In some embodiments, the outer wrapper comprises a section of the web of the sheet material. In some embodiments, the formed frame and the outer wrapper are connected to a vulnerable area of ​​the web of the sheet material. Advantageously, the vulnerable area of ​​the web of the sheet material allows the user to easily separate or remove the outer wrapper from the frame when the outer wrapper is removed before using the aerosol-generating article. The vulnerable area may be weakened by any suitable means. For example, the vulnerable area may include a perforated area or a perforation line. For example, the vulnerable area may include an area or line having reduced thickness. The vulnerable area may be weakened by cutting, scoring, or punching using a blade, laser, punch, or any other suitable means to form a hole, perforation, or area of ​​reduced thickness.

[0079] The above method may further include the step of applying, forming, or providing a marker or tagant on the surface of a web of sheet material. The marker or tagant may be placed on the outer surface of a frame when the frame is formed. Advantageously, providing a marker or tagant on the surface of a web of sheet material may be a simple method of providing a marker or tagant on the surface of an aerosol generating article. If there is a marker or tagant on the surface of an aerosol generating article, it may advantageously provide a reliable means of identifying the aerosol generating article. If there is a marker or tagant on the surface of an aerosol generating article, it may provide a reliable means of authenticating the aerosol generating article to help identify counterfeit aerosol generating articles originating from unauthorized sources. In some embodiments, the step of applying, forming, or providing a marker or tagant on the surface of a web of sheet material may include the step of applying, forming, or providing a marker or tagant on the surface of a web of sheet material forming the outer surface of a frame, preferably the outer surface of an aerosol generating article.

[0080] In some embodiments, the step of overlaying a web of sheet material on itself includes the step of overlaying different numbers of layers of the web of sheet material in different sections of the frame. For example, the frame may include a wall surface having a first section having a laminated structure comprising a first number of layers of the web of sheet material and a second section having a laminated structure comprising a second number of layers of the web of sheet material, wherein the second number is different from the first number. Advantageously, by varying the number of layers of the web of sheet material forming different sections of the wall surface of the frame, the structure of the frame can be modified to optimize frame strength if necessary, and the cost and material used in the frame can be minimized. For example, a section of the frame requiring additional strength or stiffness may have a greater number of layers of the web of sheet material compared to other sections of the frame.

[0081] In some embodiments, the formed frame includes a frame aperture configured to receive an aerosol-forming substrate. In some embodiments, the formed frame includes a plurality of frame apertures. Where the formed frame includes a plurality of frame apertures, each frame aperture or one or more of the frame apertures may be configured to receive an aerosol-forming substrate.

[0082] In some embodiments, the step of providing a web of sheet material includes the step of providing a first web of a first sheet material and the step of providing a second web of a second sheet material. The second sheet material may be different from the first sheet material. The second sheet material may be the same as the first sheet material.

[0083] In some of these embodiments, the step of overlapping a web of sheet material on itself comprises the step of overlapping a first web of a first sheet material on itself and the step of overlapping a second web of a second sheet material on itself to form a frame having at least a first wall surface having a laminated structure, wherein the laminated structure comprises a plurality of layers of the first web of the first sheet material, the frame comprises at least a second wall surface having a laminated structure, and the laminated structure comprises a plurality of layers of the second web of the second sheet material.

[0084] In some of these embodiments, the method further comprises the step of overlapping a first web of a first sheet material with a second web of a second sheet material to form a combined web of sheet materials, and the step of overlapping the web of sheet materials on itself comprises the step of overlapping the combined web of sheet materials on itself.

[0085] Advantageously, the steps of providing a first web of a first sheet material and a second web of a second sheet material, and forming a frame from both the first sheet material and the second sheet material, allow the frame to benefit from the different properties of the first sheet material and the second sheet material.

[0086] According to the present disclosure, a frame of an aerosol generating article formed by the above-described method is provided.

[0087] According to the present disclosure, a method for manufacturing an aerosol generating article is provided, the method comprising the step of forming a frame for an aerosol generating article as described above.

[0088] A method for manufacturing an aerosol generating article further comprises the steps of: providing a first outer layer material sheet and a second outer layer material sheet; positioning a formed frame between the first outer layer material sheet and the second outer layer material sheet; and bonding the first outer layer material sheet and the second outer layer material sheet to the formed frame.

[0089] The step of bonding the first outer layer material sheet and the second outer layer material sheet to the formed frame above can be achieved by any suitable bonding means. In some preferred embodiments, an adhesive is applied to one of the frame, the first outer layer material sheet, and the second outer layer material sheet.

[0090] A method for manufacturing an aerosol generating article may further include the step of inserting an aerosol generating material into a cavity of the aerosol generating article, wherein the cavity is formed at least partially by the frame aperture of the frame.

[0091] A method for manufacturing an aerosol generating article comprises the steps of: providing a first outer layer material sheet and a second outer layer material sheet; providing a first aerosol generating material sheet and a second aerosol generating material sheet; positioning a formed frame between the first aerosol generating material sheet and the second aerosol generating material sheet; positioning the formed frame, the first aerosol generating material sheet, and the second aerosol generating material sheet between the first outer layer material sheet and the second outer layer material sheet; and further comprising the step of bonding one or more of the sheet materials to the formed frame.

[0092] According to the present disclosure, an aerosol generating article comprising a frame as described above is provided. According to the present disclosure, an aerosol generating article comprising a frame formed by the method described above is provided. The aerosol generating article may comprise one or more aerosol generating substrates. The aerosol generating article may comprise one or more aerosol generating substrates.

[0093] According to the present disclosure, an aerosol generating article is provided. The aerosol generating article is intended to be used in conjunction with an aerosol generating device to generate an aerosol. The aerosol generating article comprises one or more aerosol generating materials. The aerosol generating article comprises a cavity. The aerosol generating device comprises an air inlet and an air outlet. The aerosol generating article comprises an airflow passage extending between the air inlet and the air outlet through the cavity. The aerosol generating article comprises a first planar outer surface. The aerosol generating article comprises a second planar outer surface. The aerosol generating article comprises a frame as described above. The frame is located between the first planar outer surface and the second planar outer surface. The frame defines the cavity at least partially.

[0094] Advantageously, the frame can make the aerosol-generating article relatively thin while maintaining structural rigidity.

[0095] Advantageously, the first planar outer surface and the second planar outer surface allow good contact with an external heater, in particular with an external heater of an aerosol generating device, thereby providing optimal heating of the aerosol generating substrate.

[0096] Advantageously, the aerosol generating article of the present disclosure can be heated substantially along its entire length and width, thereby allowing the entire aerosol generating material to be heated sufficiently to generate an aerosol.

[0097] Advantageously, the aerosol generating article of the present disclosure can be manufactured by laminating sheet materials that can be achieved through a continuous manufacturing process, thereby making the aerosol generating article relatively easy and inexpensive to manufacture.

[0098] An aerosol-generating article may have a length extending in the x-direction. An aerosol-generating article may have a width extending in the y-direction. An aerosol-generating article may have a height extending in the z-direction.

[0099] The aerosol generating article may be a substantially flat aerosol generating article or a substantially planar aerosol generating article. In particular, the height of the aerosol generating article may be less than 50% of both the length and width of the aerosol generating article. Advantageously, the thinner height may provide a small temperature gradient or temperature difference over the height of the aerosol generating material during heating.

[0100] The aerosol generating article may have any suitable shape. 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.

[0101] The aerosol generating article may have a laminated structure, for example, the aerosol generating article may include or be formed of at least two layers. In particular, as discussed in more detail below, the aerosol generating article may include a frame and at least one of the following: a first outer layer, a second outer layer, a first aerosol generating substrate layer, and a second aerosol generating substrate layer.

[0102] A substantially entire aerosol-generating article, excluding one or more aerosol-generating materials and (if present) adhesive, may be paper or cardboard.

[0103] 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%.

[0104] One or more aerosol generating substrates may include an aerosol generating substrate layer. Advantageously, the aerosol generating substrate layer may be made thin, and thus can 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 device.

[0105] 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.

[0106] 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.

[0107] The aerosol generating substrate layer may be located 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] 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.

[0115] 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.

[0116] 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.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] 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㎛.

[0123] 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.

[0124] 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.

[0125] 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.

[0126] 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.

[0127] 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.

[0128] 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.

[0129] 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 height of the aerosol-generating article.

[0130] The aerosol-generating article may include an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may contain a hydrophobic material.

[0131] 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.

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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.

[0136] 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.

[0137] 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.

[0138] 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.

[0139] 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.

[0140] 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.

[0141] 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 be in physical contact with and bonded to the aerosol generating substrate layer or the second aerosol generating substrate layer.

[0142] 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.

[0143] 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.

[0144] 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.

[0145] 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.

[0146] 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.

[0147] 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㎛.

[0148] 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.

[0149] 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.

[0150] The cavity may have a height of 0.5 mm or more. The cavity may have a height of 1.5 mm or more. The cavity may have a height of 2.5 mm or more. The cavity may have a height of 3.5 mm or more.

[0151] The cavity may have a height of 4.5 mm or less. The cavity may have a height of 3.5 mm or less. The cavity may have a height of 2.5 mm or less. The cavity may have a height of 1.5 mm or less.

[0152] The cavity may have a height of 0.5 mm to 4.5 mm. The cavity may have a height of 1 mm to 4.5 mm. Preferably, the cavity may have a height of 2.8 mm to 3.3 mm.

[0153] 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 length of 30 mm or more. The cavity may have a length of 38 mm or more.

[0154] The cavity may have a length of 40 mm or less. The cavity may have a length of 34 mm or less. The cavity may have a length of 28 mm or less. The cavity may have a length of 22 mm or less. The cavity may have a length of 18 mm or less.

[0155] 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.

[0156] 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.

[0157] 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.

[0158] 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.

[0159] The cavity may have a length of 14 mm to 40 mm, a width of 4.5 mm to 13 mm, and a height of 0.5 mm to 4.5 mm.

[0160] Preferably, the cavity may have a length of 20 mm to 30 mm, a width of 7 mm to 10 mm, and a height of 2.5 mm to 4 mm.

[0161] Most preferably, the cavity may have a length of 26 mm, a width of 8 mm, and a height of 3.1 mm.

[0162] 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.

[0163] 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.

[0164] 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.

[0165] The common area can be practically empty.

[0166] 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.

[0167] An 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.

[0168] 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.

[0169] 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.

[0170] 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.

[0171] 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.

[0172] Multiple parallel ripples can be defined by a ripple profile, where the ripple profile is sinusoidal, triangular, rectangular, trapezoidal, toroidal, or parabolic.

[0173] 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.

[0174] 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.

[0175] 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.

[0176] 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.

[0177] 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.

[0178] 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.

[0179] 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.

[0180] 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.

[0181] 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.

[0182] 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.

[0183] 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.

[0184] The aerosol-forming substrate may comprise at least 50 weight% of an aerosol-forming agent, at least 60 weight% of an aerosol-forming agent, or at least 70 weight% of an aerosol-forming agent.

[0185] The aerosol-forming material may include 85 weight% or less of an aerosol-forming agent, 80 weight% or less of an aerosol-forming agent, or 75 weight% or less of an aerosol-forming agent.

[0186] The aerosol-forming substrate may comprise 50% to 85% by weight of an aerosol-forming agent, 50% to 80% by weight of an aerosol-forming agent, or 50% to 75% by weight of an aerosol-forming agent.

[0187] The aerosol generating material may contain at least 0.5 weight% nicotine, at least 1 weight% nicotine, at least 1.5 weight% nicotine, or at least 2 weight% nicotine. That is, the aerosol generating material may have a nicotine content of at least 0.5 weight%, at least 1 weight%, at least 1.5 weight%, or at least 2 weight%.

[0188] 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.

[0189] 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."

[0190] 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.

[0191] 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.

[0192] 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.

[0193] 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.

[0194] 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.

[0195] An air inlet may be defined by a peripheral wall surface of an aerosol-generating article. An air inlet may be defined by a front wall surface of an aerosol-generating article. An air inlet may be defined by a frame. An air inlet may extend through the frame. An air inlet may be defined by a wall surface of the frame. An air inlet may extend through a wall surface of the frame. An air outlet may extend through a peripheral wall surface of the frame. An air inlet may be defined by a peripheral wall surface of the frame. An air inlet may extend through a peripheral wall surface of the frame. An air inlet may be defined by at least one wall surface of the frame comprising a web of sheet material, the web of sheet material extending substantially perpendicular to the longitudinal axis of the frame. An air inlet may be defined by at least one wall surface of the frame comprising a web of sheet material arranged in a laminated structure. The web of sheet material may comprise a plurality of apertures, and an air inlet may be defined by a plurality of apertures within the web of sheet material. A web of sheet material may include a plurality of apertures, and an air inlet may be formed by a plurality of apertures within the web of sheet material.

[0196] An air outlet may be defined by the peripheral wall surface of the aerosol-generating article. 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. An air outlet may extend through the frame. An air outlet may be defined by a wall surface of the frame. An air outlet may extend through a wall surface of the frame. An air outlet may be defined by the peripheral wall surface of the frame. An air outlet may extend through the peripheral wall surface of the frame. An air outlet may be defined by at least one wall surface of the frame comprising a web of sheet material, the web of sheet material extending substantially perpendicular to the longitudinal axis of the frame. An air outlet may be defined by at least one wall surface of the frame comprising a web of sheet material arranged in a laminated structure. The web of sheet material may comprise a plurality of apertures, and an air outlet may be defined by a plurality of apertures within the web of sheet material. A web of sheet material may include a plurality of apertures, and an air outlet may be formed by a plurality of apertures within the web of sheet material.

[0197] 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.

[0198] 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.

[0199] 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.

[0200] 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.

[0201] 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.

[0202] 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.

[0203] 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.

[0204] 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.

[0205] 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 height lower than the height of the cavity. The air outlet may have a height lower than the height of the cavity.

[0206] 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.

[0207] One or both of the air inlet and the air outlet may have a height of 0.3 mm to 3 mm or 0.5 mm to 2 mm.

[0208] Preferably, the air inlet may have a width of 0.3 mm to 3 mm and a height of 0.3 mm to 3 mm.

[0209] Preferably, the air outlet may have a width of 0.3 mm to 3 mm and a height of 0.3 mm to 3 mm.

[0210] Advantageously, an aerosol generating article having an air outlet or air inlet having a width of 0.3 mm to 3 mm and a height of 0.3 mm to 3 mm can provide a relatively large inlet or outlet aperture 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.

[0211] The ratio of the width of the air inlet to the height of the air inlet may be 0.33 to 3. The ratio of the width of the air inlet to the height of the air inlet may be 0.5 to 1.5. The ratio of the width of the air inlet to the height of the air inlet may be 0.75 to 1.25.

[0212] The ratio of the width of the air outlet to the height of the air outlet may be 0.33 to 3. The ratio of the width of the air outlet to the height of the air outlet may be 0.5 to 1.5. The ratio of the width of the air outlet to the height of the air outlet may be 0.75 to 1.25.

[0213] 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.

[0214] 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.

[0215] The aerosol generating article may include a filter element located downstream of the aerosol forming substrate. The aerosol generating article may include a filter element located downstream of the cavity. The aerosol generating article may include a filter element located at least partially within the air outlet. The aerosol generating article may include a filter element located within the cavity and may be located at the downstream end of the cavity.

[0216] The aerosol generating article may include a filter element located upstream of the aerosol forming substrate. The aerosol generating article may include a filter element located upstream of the cavity. The aerosol generating article may include a filter element located at least partially within the air inlet. The aerosol generating article may include a filter element located within the cavity and may be located at the upstream end of the cavity.

[0217] 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.

[0218] The ratio between the length and height of an aerosol-generating article, and between the width and height of an 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.

[0219] The ratio between the length and height of the aerosol-generating article and between the width and height 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.

[0220] The ratio between the length and height of the aerosol-generating article and between the width and height 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.

[0221] 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.

[0222] 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.

[0223] 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.

[0224] 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.

[0225] 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.

[0226] 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.

[0227] 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.

[0228] 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.

[0229] 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.

[0230] Aerosol-generating articles may have a height 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.

[0231] Aerosol-generating articles may have a height 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.

[0232] The aerosol generating article may have a height 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.

[0233] 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.

[0234] 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.

[0235] 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.

[0236] 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.

[0237] 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.

[0238] 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.

[0239] As used herein, the term "transverse direction" refers to the direction extending between the first planar outer surface and the second planar outer surface. The transverse direction may also be referred to as the "z direction."

[0240] 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. The lateral direction may also be referred to as the "x-direction."

[0241] 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. The lateral direction may also be referred to as the "y-direction."

[0242] As used herein, the term "height" refers to the maximum dimension in the transverse direction of an aerosol-generating article or a component of an aerosol-generating article.

[0243] 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.

[0244] 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.

[0245] 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.

[0246] 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.

[0247] 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.

[0248] 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.

[0249] 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.

[0250] 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.

[0251] As used herein, the term "equivalent diameter" of an opening or aperture is used herein to denote the diameter of a circular opening.

[0252] 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 examples may be combined with any one or more features of other examples, embodiments, or aspects described herein.

[0253] EX1. A frame for an aerosol generating article, wherein the frame has a longitudinal axis and the frame comprises at least one wall surface, wherein the at least one wall surface comprises a web of sheet material having a length and a width, and the width of the web of sheet material extends substantially perpendicularly to the longitudinal axis.

[0254] EX2. A frame for an aerosol generating article comprising at least one wall surface, wherein the at least one wall surface comprises a web of sheet material arranged in a laminated structure, and the laminated structure comprises a plurality of layers of the web of sheet material.

[0255] EX3. A frame in EX2, wherein the plurality of layers comprises at least two layers or at least three layers.

[0256] EX4. A frame in EX2 or EX3, wherein the frame has a longitudinal axis, the web of the sheet material has a length and a width, and the width of the web of the sheet material extends substantially perpendicular to the longitudinal axis.

[0257] EX5. A frame in any one of EX1 to EX4, wherein the frame is elongated and has a length greater than other dimensions of the frame in the direction of the longitudinal axis.

[0258] EX6. An aerosol generating article comprising a frame according to any one of EX1 to EX5.

[0259] EX7. A method for manufacturing a frame for an aerosol-generating article, wherein the method comprises:

[0260] Step of providing a web of sheet material; and

[0261] A method comprising the step of overlapping a web of the sheet material on itself to form a frame including at least one wall surface, wherein the at least one wall surface has a laminated structure including a plurality of layers of the web of the sheet material.

[0262] EX8. A method according to EX7, wherein the formed frame has a longitudinal axis, the web of the sheet material has a length and a width, the width of the web of the sheet material extends substantially perpendicularly to the longitudinal axis of the frame, and optionally the formed frame is elongated and has a length greater than other dimensions of the formed frame in the direction of the longitudinal axis.

[0263] EX9. A method according to EX7 or EX8, wherein at least one wall surface having the laminated structure comprises at least two layers of the web of the sheet material or at least three layers of the web of the sheet material, optionally the formed frame comprises one or more peripheral wall surfaces, and the one or more peripheral wall surfaces have a laminated structure comprising at least two layers of the web of the sheet material or at least three layers of the web of the sheet material.

[0264] EX10. A method in any one of EX7 to EX9, wherein the step of overlapping the web of the sheet material comprises the step of winding the web of the sheet material around a spindle, and optionally the method further comprises the step of removing the frame from the spindle such that the formed frame includes a frame aperture on which the web of the sheet material is wound.

[0265] EX11. A method according to EX10, wherein the spindle has a longitudinal axis on which the web of the sheet material is wound, and the spindle has a transverse cross-sectional shape perpendicular to the longitudinal axis, and the transverse cross-sectional shape is at least one of a circular, non-circular, elliptical, stadium shape, polygonal, triangular, rectangular, trapezoidal, pentagonal, or hexagon.

[0266] EX12. A method in any one of EX7 to EX11, wherein the step of overlapping the web of the sheet material onto itself to form a frame comprises the step of compressing two or more of the overlapping layers of the web of the sheet material together.

[0267] EX13. A method in any one of EX7 to EX12, wherein the method further comprises the step of crimping a section of the web of the sheet material to form a crimped section having wavy folds, and optionally the crimped portion of the web of the sheet material is compressed to compress the wavy folds of the crimped portion together.

[0268] EX14. A method in any one of EX7 to EX13, wherein the method further comprises the step of applying an adhesive to the surface of the web of the sheet material before overlapping the web of the sheet material itself, and optionally the step of overlapping the web of the sheet material itself comprises the step of bringing the adhesive on the surface of the web of the sheet material into contact with another surface of the web of the sheet material.

[0269] EX15. A method in any one of EX7 to EX14, wherein the method further comprises the step of forming one or more apertures in a web of sheet material.

[0270] EX16. A method comprising, in EX15, at least one step of forming one or more apertures, the following steps: forming one or more apertures before the web of the sheet material overlaps itself; forming one or more apertures while the web of the sheet material overlaps itself; and forming one or more apertures after the web of the sheet material overlaps itself.

[0271] EX17. A method comprising, in any one of EX7 to EX16, the step of providing a web of the sheet material, the step of providing a web of the sheet material having one or more pre-formed apertures.

[0272] EX18. A method in any one of EX15 to EX17, wherein the method further comprises the step of arranging one or more elements within or on one or more of the apertures, and optionally, the one or more elements comprise one or more of a filter and a mesh.

[0273] EX19. A method in which, in any one of EX7 to EX18, the web of the sheet material comprises one of a cellulose material web (optional, the cellulose material is one of paper or cardboard) and a polymer material web.

[0274] EX20. A method in any one of EX7 to EX19, wherein the formed frame comprises one or more apertures on an outer surface, and the method comprises the step of wrapping the formed frame with a wrapper that covers the outer surface of the frame and covers the one or more apertures on the outer surface of the frame, optionally the wrapper comprises a section of the web of the sheet material, and optionally the formed frame and the wrapper are connected to a vulnerable area of ​​the web of the sheet material.

[0275] EX21. A method in any one of EX7 to EX20, wherein the method further comprises the step of applying, forming, or providing a marker or tagant on the surface of the web of the sheet material, and optionally, the marker or tagant is arranged on the outer surface of the frame when the frame is formed.

[0276] EX22. A method in any one of EX7 to EX21, wherein the step of overlapping the web of the sheet material on itself comprises the step of overlapping a different number of layers of the web of the sheet material in different sections of the frame, and optionally the formed frame comprises a first section comprising a first number of layers of the web of the sheet material and a second section comprising a second number of layers of the web of the sheet material, wherein the second number is different from the first number.

[0277] EX23. A method in any one of EX7 to EX22, wherein the formed frame comprises a frame aperture configured to receive an aerosol-forming substrate, and optionally the formed frame comprises a plurality of frame apertures, each frame aperture configured to receive an aerosol-forming substrate.

[0278] EX24. In any one of EX7 to EX23, the step of providing a web of the sheet material comprises the step of providing a first web of the first sheet material and the step of providing a second web of the second sheet material, and optionally, the method further comprises the step of forming a frame having at least a first wall surface having a laminated structure by overlapping the first web of the first sheet material on itself and overlapping the second web of the second sheet material on itself, wherein the laminated structure comprises a plurality of layers of the first web of the first sheet material, the frame comprises at least a second wall surface having a laminated structure, and the laminated structure comprises a plurality of layers of the second web of the second sheet material.

[0279] EX25. In any one of EX7 to EX24, the step of providing a web of the sheet material comprises the step of providing a first web of the first sheet material and the step of providing a second web of the second sheet material, optionally the method further comprises the step of overlapping the first web of the first sheet material with the second web of the second sheet material to form a combined web of the sheet material, and the step of overlapping the web of the sheet material itself comprises the step of overlapping the combined web of the sheet material itself.

[0280] EX26. A method for manufacturing an aerosol generating article, wherein the method comprises the step of forming a frame for an aerosol generating article according to any one of EX7 to EX25.

[0281] EX27. In EX26, the above method additionally

[0282] A step of providing a first outer layer material sheet and a second outer layer material sheet;

[0283] A step of positioning the formed frame between the first outer layer material sheet and the second outer layer material sheet; and

[0284] A method comprising the step of bonding between the first outer layer material sheet and the second outer layer material sheet to the frame formed above.

[0285] EX28. In EX26, the above method additionally

[0286] A step of providing a first outer layer material sheet and a second outer layer material sheet;

[0287] A step of providing a first aerosol generating material sheet and a second aerosol generating material sheet;

[0288] A step of positioning the formed frame between the first aerosol generating material sheet and the second aerosol generating material sheet;

[0289] A step of positioning the formed frame, the first aerosol generating material sheet, and the second aerosol generating material sheet between the first outer layer material sheet and the second outer layer material sheet; and

[0290] A method comprising the step of bonding one or more of the above sheet materials to the formed frame.

[0291] EX29. A frame of an aerosol-generating article formed by a method according to any one of EX7 to EX25. Brief explanation of the drawing

[0292] Now, embodiments will be further described with reference to the drawings. FIG. 1 shows a perspective view of an exemplary aerosol generating article suitable for including a frame according to the present disclosure. Figure 2 shows an exploded perspective view of the aerosol generating article of Figure 1. FIG. 3 shows an exploded perspective view of another exemplary aerosol generating article suitable for including a frame according to the present disclosure. FIG. 4 shows a perspective view of another exemplary aerosol generating article suitable for including a frame according to the present disclosure. FIG. 5 shows a perspective view of another exemplary aerosol generating article suitable for including a frame according to the present disclosure. FIG. 6 shows an exploded perspective view of another exemplary aerosol generating article suitable for including a frame according to the present disclosure. FIG. 7 shows a perspective view of another exemplary aerosol generating article suitable for including a frame according to the present disclosure. FIG. 8 shows a frame of an aerosol generating article according to one embodiment of the present disclosure. Figure 9 shows the frame of Figure 8 containing an aerosol generating material arranged within the frame aperture of the frame. FIG. 10 shows an aerosol generating article according to one embodiment of the present disclosure, and the aerosol generating article includes the frame of FIG. 8 and FIG. 9. FIG. 11 shows the frame of FIG. 8, and the frame includes an outer wrapper. Figure 12 shows the frame of Figure 11, with the outer wrapper removed. FIG. 13 shows another exemplary frame of an aerosol-generating article according to one embodiment of the present disclosure. FIG. 14 shows the frame of FIG. 13 containing an aerosol generating material arranged within the frame aperture of the frame. FIG. 15 illustrates a method for manufacturing a frame of an aerosol generating article according to one embodiment of the present disclosure. FIG. 16 shows a frame of an aerosol generating article according to one embodiment of the present disclosure. FIG. 17 shows the frame of FIG. 16 containing an aerosol generating material arranged within the frame aperture of the frame. FIG. 18 illustrates a method for manufacturing a frame of an aerosol generating article according to one embodiment of the present disclosure. FIG. 19 illustrates a method for manufacturing an aerosol generating article according to one embodiment of the present disclosure, and the aerosol generating article includes a frame according to one embodiment of the present disclosure. Figure 20 shows a plan view of the method of Figure 19. FIG. 21 shows a schematic cross-sectional view of an aerosol generating device according to the present disclosure. FIG. 22 shows a schematic cross-sectional view of the aerosol generating device of FIG. 21 connected to the aerosol generating article of the present disclosure. Specific details for implementing the invention

[0293] FIG. 1 illustrates an aerosol generating article (10) comprising a first planar outer layer (24) forming a first planar outer surface (21), a second planar outer layer (25) forming a second planar outer surface (22), and a frame (50) located 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).

[0294] The aerosol generating article (10) has a length extending in the x direction, a width extending in the y direction, and a height extending in the z direction. The aerosol generating article (10) has a length of 30 mm, a width of 10 mm, and a height of 3.1 mm.

[0295] 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 percent of both the length and width of the aerosol generating article (10). 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.

[0296] Figure 2 shows an exploded view of the aerosol generating article (10) of Figure 1.

[0297] 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.

[0298] 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 one or more outer surfaces of an aerosol generating article, such as a front wall surface (13) and a rear wall surface (14).

[0299] The frame (50) includes a perimeter wall (51) surrounding the cavity (30). More specifically, the perimeter wall surface (51) is defined by the frame inner surface (52) and the frame outer surface (53). The perimeter wall surface (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.

[0300] 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) defines at least a portion of the cavity (30). The second planar outer layer (25) defines at least a portion of the cavity (30).

[0301] The aerosol generating article (10) includes an air inlet (11) and an air outlet (12). The air inlet (11) and the air outlet (12) are defined by and extend through the peripheral wall surface (51) of the frame (50). The air inlet (11) and the air outlet (12) each have a rectangular cross-section, a width of 2 mm, and a thickness of 0.9 mm. An airflow passage extends through a cavity (30) between the air inlet (11) and the air outlet (12).

[0302] FIG. 3 shows an exploded view of an aerosol generating article similar to the aerosol generating article (10) of FIG. 1, except that the first planar outer layer (24) and the second planar outer layer (25) do not 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 shown, the aerosol generating substrate (40) fills the entire volume of the cavity (30). In the example of FIG. 3, the aerosol generating substrate (40) has a 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.

[0303] FIG. 4 shows 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).

[0304] FIG. 5 shows an aerosol generating article (10) similar to the aerosol generating article (10) of FIG. 1, except that the aerosol generating article (10) of FIG. 5 additionally includes 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 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.

[0305] 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) defines at least a portion of the cavity (30). The second aerosol generating layer (42) defines at least a portion of the cavity (30).

[0306] 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).

[0307] FIG. 6 shows 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) 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 shown, the aerosol generating substrate (40) fills the entire volume of the cavity (30). FIG. 7 shows 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 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).

[0308] FIG. 8 shows a frame (50) according to one embodiment of the present disclosure. The frame is suitable for use as a frame for an aerosol generating article, such as the aerosol generating article described above with reference to FIG. 1 to 7.

[0309] The frame (50) of FIG. 8 has a shape similar to the frame (50) of FIG. 1 through 7, generally having a rectangular prism shape, and has a length of 30 mm, a width of 10 mm, and a height of 2.7 mm. Unlike the frame (50) of FIG. 1 through 7, the frame (50) of FIG. 8 is formed from a single sheet of web material, which in this embodiment is a single sheet of cardboard. The frame (50) of FIG. 8 has a longitudinal axis (54), and the single sheet of web material has a length and a width, and the width of the web of the sheet material extends substantially perpendicular to the longitudinal axis of the frame. That is, the width of the web of the sheet material extends substantially in the z-direction. Thus, the width of the web of the sheet material defines the height of the frame (50). The width of the web of the sheet material is 2.7 mm, and the thickness of the web of the sheet material is 0.5 mm.

[0310] A web of sheet material is arranged in a laminated structure, and the laminated structure includes multiple layers of the web of sheet material. The laminated structure provides additional rigidity to the wall surface of the frame (50), and the section of the wall surface has a greater number of layers of the web of sheet material having greater rigidity.

[0311] The frame (50) includes a front portion (55) and a rear portion (56). Each of the front portion (55) and the rear portion (56) has a laminated structure formed of eight layers of a web of sheet material, the layers being folded backward in a zigzag pattern and compressed together. The front portion (55) and the rear portion (56) are wrapped by a peripheral portion of the web of sheet material to form a final frame (50) that defines a frame aperture (33) between the front portion (55) and the rear portion (56). Between the front portion (55) and the rear portion (56), a peripheral sidewall (57) on the opposite side of the frame aperture (33) also has a laminated structure, and the laminated structure of the peripheral sidewall (57) is formed of two layers of a web of sheet material.

[0312] The layers of the front portion (55) and the rear portion (56) each include an aperture (58) punched through a web of sheet material. The aperture (58) of the layer of the front portion (56) is aligned to form an air outlet (12) of the frame (50) and extends from the frame aperture (33) to the front wall (13) of the frame (50). The aperture (58) of the layer of the rear portion (56) is also aligned to form an air inlet (11) of the frame (50) and extends from the frame aperture (33) to the rear wall (14) of the frame (50).

[0313] The front portion (55) and rear portion (56) of the relatively thick frame (50), which consists of a relatively large number of layers of a web of sheet material compared to other sections of the aerosol generating article, provide increased rigidity to the frame at the front and rear, which helps the aerosol generating article maintain its shape when the aerosol generating article is inserted into and removed from the aerosol generating device. The front portion (55) and rear portion (56) of the relatively thick frame (50) allow the aligned aperture (58) to form a long air inlet (11) and a long air outlet (12), thereby enabling the resistance to suction (RTD) through the aerosol generating article to be precisely controlled.

[0314] FIG. 9 shows the frame (50) of FIG. 8 having a frame aperture (33) filled with an aerosol generating material (40).

[0315] FIG. 10 shows an aerosol generating article (10) comprising the frame (50) of FIG. 8 and FIG. 9. The aerosol generating article (10) comprises 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) located between the first planar outer layer (24) and the second planar outer layer (25). In the present embodiment, the first planar outer layer (24) and the second planar outer layer (25) are formed of paper such as cigarette paper.

[0316] FIGS. 11 and 12 illustrate the frame (50) of FIGS. 8 and 9, wherein the frame (50) further comprises an outer wrapper (23). The outer wrapper (23) surrounds the outer surface of the frame (50), including a front wall (12), a rear wall (11), and a peripheral side wall (57), and covers the air outlet (12) and air inlet (11) so that ambient air cannot reach the aerosol generating material (40) within the frame aperture (33). In this embodiment, the outer wrapper (23) is formed from a single web of the same sheet material as the rest of the frame (50) and is separable from the rest of the sheet material forming the frame at a vulnerable area (27). The vulnerable area (27) comprises a row of perforations extending along the width of the web of the sheet material, which allows the outer wrapper (23) to be easily torn from the rest of the web of the sheet material at the vulnerable area (27). The outer wrapper (23) is bonded to itself toward the free end (28) using an adhesive (not shown), and the free end (28) is configured to be grasped by a user to peel the outer wrapper (23) from the frame (50) and to tear the outer wrapper (23) away from the rest of the web of sheet material to form the rest of the frame (50) at the vulnerable area (27).

[0317] In some embodiments, the outer wrapper (23) may be formed of a material different from a web of sheet material such as paper, and the outer wrapper (23) may be removablely bonded to the frame (50), or once firmly wrapped around the wall surface of the frame (50), may be removablely bonded to itself over the air outlet (12) and air inlet (11).

[0318] FIG. 13 shows a schematic diagram of a method (100) for manufacturing a frame (50) according to one embodiment of the present disclosure, such as the frame (50) of FIG. 8 and FIG. 9. Generally, the method (100) comprises the steps of providing a web of sheet material, punching and crimping a portion of the web of sheet material, compressing the wavy folds of the crimped portion together, and winding the web of sheet material around a spindle to form a frame.

[0319] More specifically, the method (100) comprises the steps of feeding a web (101) of sheet material, which is cardboard in the present embodiment, from a bobbin (102) between a first pair of rollers (103), and punching an aperture (58) in the web (101) of sheet material using a punch (104). The method further comprises the steps of curing a portion of the web of sheet material containing the aperture (58) using a curing roller (105), and applying adhesive to the surface of the wavy portion of the cured portion using an adhesive applicator (106), which may be in the form of a sprayer or a brush. The web (101) of sheet material is fed over a spindle (108) via a roller (107), and the cured portion of the web (101) is compressed together against the spindle (108) using a pusher (109), and the overlapping layer of the cured portion is bonded together by adhesive. The spindle (108) rotates to wrap a subsequent portion of the web (101) around the spindle and the compressed coil portion of the web (101), and the web (101) is cut by an air blade (110) after a desired number of spindle (108) rotations to form a frame (50). As the frame (50) is pushed out from the spindle (108), the space previously occupied by the spindle (108) forms a frame aperture (33). The frame aperture (33) has the same cross-sectional shape and size as the spindle (108), and the aperture (58) punched in the web (101) is aligned along the longitudinal axis to form an air passage through the frame (50).

[0320] In some embodiments, the adhesive applicator (106) may be arranged within or around the crimp roller (105) or other crimp means so that the adhesive can be applied to the web of sheet material. Additionally, it is expected that the cardboard punched from the web of sheet material (101) can be collected and recycled.

[0321] FIG. 14 shows a frame (50) according to one embodiment of the present disclosure. The frame (50) is suitable for use as a frame for an aerosol generating article such as the aerosol generating article described above with reference to FIGS. 1 through 7. The frame (50) of FIG. 14 is similar to the frame (50) of FIG. 8 and FIG. 9, except that the frame (50) defines three frame apertures, namely a central frame aperture (33), a front frame aperture (34), and a rear frame aperture (35).

[0322] The frame (50) of FIG. 14 does not include the thick front and rear portions of the frame (50) of FIG. 8 and FIG. 9, but rather the frame (50) of FIG. 14 includes a front split wall (55) separating the central frame aperture (33) from the front frame aperture (34), and a rear split wall (56) separating the central frame aperture (33) from the rear frame aperture (35).

[0323] In this embodiment, the peripheral walls of the frame (50), including the front wall (13), the rear wall (14), the peripheral side wall (57), the front split wall (55), and the rear split wall (56), are all formed of two layers of a single web of sheet material, which is cardboard in this embodiment.

[0324] A single web of sheet material forming a front wall (13), a rear wall (14), a front split wall (55), and a rear split wall (56) each comprises an aperture (58) punched through the web of sheet material. The aperture (58) of the layer forming the front wall (13) is aligned to form an air outlet (12) of the frame (50), the aperture of the layer forming the rear wall (14) is aligned to form an air inlet (11) of the frame (50), the aperture (58) forming the front split wall (56) is aligned to form an air passage from the central frame aperture (33) to the front frame aperture (34), and the aperture (58) forming the rear split wall (35) is aligned to form an air passage from the rear frame aperture (35) to the central frame aperture (33). All apertures (58) within the web of the sheet material are aligned along the longitudinal axis (54) of the frame (50). An airflow passage is provided through the frame (50) from the air inlet (11) to the air outlet (12), through the rear frame aperture (35), the central frame aperture (33), and the front frame aperture (34), respectively, via the apertures (58) within the web of the sheet material.

[0325] FIG. 15 shows the frame (50) of FIG. 14 having a central frame aperture (33) filled with an aerosol generating material (40). In this embodiment, the front frame aperture (34) and the rear frame aperture (35) are not filled with an aerosol generating material, but are rather empty. The front frame aperture (34) and the rear frame aperture (35) help to control the resistance to inhalation (RTD) through the aerosol generating material, and the front frame aperture (34) helps to form an aerosol having desired characteristics by cooling the vapor released from the aerosol generating material, particularly when heated. In some embodiments, it is expected that at least one of the front frame aperture (34) and the rear frame aperture (35) may contain an element such as a filter or a flavoring agent.

[0326] FIG. 16 illustrates a frame (50) according to one embodiment of the present disclosure. The frame (50) is suitable for use as a frame for an aerosol generating article, such as the aerosol generating article described above with reference to FIGS. 1 through 7. The frame (50) of FIG. 16 is similar to the frame (50) of FIG. 8 and FIG. 9, except that the frame (50) does not include the thick front and rear portions (55, 56) of the frame (50) of FIG. 8 and 9. The frame (50) of FIG. 16 comprises a single web of sheet material surrounding a single frame aperture (33) in a laminated structure having two layers of a web of sheet material. Thus, the front wall (12), the rear wall (13), and the peripheral side wall (57) each have a laminated structure comprising two layers of a web of sheet material. The web of the sheet material is oriented such that the width of the web extends in the z-direction of the frame (50) and the thickness of the web extends in the xy-plane of the frame (50). Accordingly, the height of the frame (50) is equal to the width of the web, and the wall thickness of the frame (50) is equal to twice the thickness of the web.

[0327] The frame (50) of FIG. 16 includes an air inlet (11) and an air outlet (12) formed by aligned apertures (58) within a web of sheet material forming the frame (50). In this embodiment, the apertures (58) forming the air outlet (12) have a filter element applied thereon, so that the frame (50), and ultimately the aerosol generating article including the frame (50), have a filter at the air outlet (12).

[0328] FIG. 17 shows the frame (50) of FIG. 15 having an aerosol generating material (40) arranged within the frame aperture (33). In this embodiment, the frame aperture (33) is not filled with the aerosol generating material (40), but rather the frame aperture (33) is partially filled with the aerosol generating material in the central region of the frame aperture (33).

[0329] FIG. 18 shows a schematic diagram of a method (100) for manufacturing a frame (50) according to one embodiment of the present disclosure, such as the frame (50) of FIG. 16 and FIG. 17. Generally, the method (100) comprises the steps of providing a web of sheet material, punching an aperture in a portion of the web of sheet material, applying a filter element over a portion of the aperture, and winding the web of sheet material around a spindle to form a frame.

[0330] More specifically, the method (100) comprises the steps of feeding a web (101) of sheet material, which is cardboard in this embodiment, from a bobbin (102) between a first pair of rollers (103), and punching an aperture (58) in the web (101) of sheet material using a punch (104). The method further comprises the steps of applying an adhesive to the lower surface of the web of sheet material using an adhesive applicator (106), and applying a filter element in the form of a sheet of cellulose acetate tow using a filter element applicator (111) over the aperture (58) in the web (101) to form an air outlet (12) of the frame (50). An initial portion of the web of sheet material (101) is fed over a spindle (108) via a roller (107), and the spindle (108) rotates to wrap a subsequent portion of the web (101) around the spindle and the initial portion of the web (101). The web (101) is cut by an air blade (110) after a desired number of spindle (108) rotations to form a frame (50). As the frame (50) is pushed out of the spindle (108), the space previously occupied by the spindle (108) forms a frame aperture (33). The frame aperture (33) has the same cross-sectional shape and size as the spindle (108), and the aperture (58) punched in the web (101) is aligned along the longitudinal axis to form an air passage through the frame (50).

[0331] FIG. 19 shows a schematic diagram of a method (200) for manufacturing an aerosol generating article (10), such as the aerosol generating article (10) of FIG. 10. FIG. 20 shows a schematic plan view of the method of FIG. 19, but for illustrative purposes, the manufacturing equipment is not shown. Generally, the method comprises the steps of bonding a first outer layer material sheet (201) to a frame (50), filling a frame aperture (33) with an aerosol generating material, bonding a second outer layer material sheet to the frame (50), and punching the outer layer material sheet to form an aerosol generating article (10).

[0332] More specifically, the method (200) comprises the step of supplying a first outer layer material sheet (201), which is cigarette paper in the present embodiment, from a bobbin (202) between a first pair of rollers (203) and a second pair of rollers (204). The method further comprises the step of applying an adhesive (205) to the upper surface of the first outer layer material sheet (201) using a first adhesive applicator (206), and the step of introducing a frame (50) onto the adhesive (205) on the upper surface of the first outer layer material sheet (201) from a frame dispenser (207) to bond the frame (50) to the upper surface of the first outer layer material sheet (201). A frame (50) is introduced onto the upper surface of a first outer layer material sheet (201), wherein the xy plane of the frame (50) is parallel to the xy plane of the upper surface of the first outer layer material sheet (201) so that the first outer layer material sheet covers the open end of the frame aperture (33). The method further includes the steps of filling the frame aperture (33) with an aerosol generating substrate (40) using an aerosol generating material dispenser (208), and applying an adhesive (209) to the upper surface of the frame (50) using a second adhesive applicator (210). The above method further includes the step of supplying a second outer layer material sheet (211), which is also a cigarette paper in this embodiment, from a bobbin (212) between a third roller (213) and a second roller pair (204) onto an adhesive applied to the upper surface of a frame (50) to bond the second outer layer material sheet (209) to the upper surface of the frame (50). The method finally includes the step of punching around the frame (50) through the first outer layer material sheet (201) and the second outer layer material sheet (211) using a punch (214) to manufacture a formed aerosol generating article (10), leaving an aperture (215) on the remaining first and second outer layer material sheets (201, 211).

[0333] In some embodiments, rather than a continuous web of outer layer material being bonded to a frame (50) and an aerosol generating article (10) being formed by punching through an outer layer material sheet, it is expected that a pre-sized outer layer material sheet is bonded to a frame (50) to form an aerosol generating article (10).

[0334] FIG. 21 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).

[0335] FIG. 22 shows a schematic cross-sectional view of the aerosol generating device (90) of FIG. 21 connected to the aerosol generating article (10) of FIG. 1. 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).

[0336] 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. Within 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 percentages listed above, 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 frame for an aerosol generating article, wherein the frame has a longitudinal axis and the frame comprises at least one wall surface, wherein the at least one wall surface comprises a web of sheet material having a length and a width, and the width of the web of sheet material extends substantially perpendicularly to the longitudinal axis of the frame. Claim 2 A frame for an aerosol generating article comprising at least one wall surface, wherein the at least one wall surface comprises a web of sheet material arranged in a laminated structure, and the laminated structure comprises a plurality of layers of the web of sheet material. Claim 3 A frame according to paragraph 2, wherein the plurality of layers comprises at least two layers or at least three layers. Claim 4 A frame according to claim 2 or 3, wherein the frame has a longitudinal axis, the web of the sheet material has a length and a width, and the width of the web of the sheet material extends substantially perpendicularly to the longitudinal axis of the frame. Claim 5 A frame according to claim 1 or 4, wherein the frame is elongated and has a length greater than other dimensions of the frame in the direction of the longitudinal axis. Claim 6 An aerosol generating article comprising a frame according to any one of paragraphs 1 to 5. Claim 7 A method for manufacturing a frame for an aerosol generating article, the method comprising: providing a web of sheet material; and overlapping the web of sheet material on itself to form a frame comprising at least one wall surface, wherein the at least one wall surface has a laminated structure comprising a plurality of layers of the web of sheet material. Claim 8 A method according to claim 7, wherein the formed frame has a longitudinal axis, the web of the sheet material has a length and a width, the width of the web of the sheet material extends substantially perpendicularly to the longitudinal axis of the frame, and optionally the formed frame is elongated and has a length greater than other dimensions of the formed frame in the direction of the longitudinal axis. Claim 9 A method according to claim 7 or 8, wherein at least one wall surface having the laminated structure comprises at least two layers of the web of the sheet material or at least three layers of the web of the sheet material, optionally the formed frame comprises one or more peripheral wall surfaces, and the one or more peripheral wall surfaces have a laminated structure comprising at least two layers of the web of the sheet material or at least three layers of the web of the sheet material. Claim 10 A method according to any one of claims 7 to 9, wherein the step of overlapping the web of the sheet material comprises the step of winding the web of the sheet material around a spindle, and optionally the method further comprises the step of removing the frame from the spindle such that the formed frame includes a frame aperture on which the web of the sheet material is wound. Claim 11 A method according to claim 10, wherein the spindle has a longitudinal axis on which the web of the sheet material is wound, and the spindle has a transverse cross-sectional shape perpendicular to the longitudinal axis, and the transverse cross-sectional shape is at least one of a circular, non-circular, elliptical, stadium shape, polygonal, triangular, rectangular, trapezoidal, pentagonal, or hexagonal. Claim 12 A method according to any one of claims 7 to 11, wherein the step of overlapping the web of the sheet material onto itself to form a frame comprises the step of compressing two or more of the overlapping layers of the web of the sheet material together. Claim 13 A method according to any one of claims 7 to 12, wherein the method further comprises the step of crimping a section of the web of the sheet material to form a crimped section having wavy folds, and optionally the crimped portion of the web of the sheet material is compressed to compress the wavy folds of the crimped portion together. Claim 14 A method according to any one of claims 7 to 13, wherein the method further comprises the step of applying an adhesive to the surface of the web of the sheet material before overlapping the web of the sheet material itself, and optionally the step of overlapping the web of the sheet material itself comprises the step of bringing the adhesive on the surface of the web of the sheet material into contact with another surface of the web of the sheet material. Claim 15 A method according to any one of claims 7 to 14, wherein the method further comprises the step of forming one or more apertures in a web of the sheet material, and optionally the step of forming one or more apertures comprises at least one of the following steps: forming one or more apertures before the web of the sheet material overlaps itself; forming one or more apertures while the web of the sheet material overlaps itself; and forming one or more apertures after the web of the sheet material overlaps itself.

Images