Aerosol-generating article

Abstract

There is provided an aerosol-generating article (100) for use with an aerosol-generating device to generate an aerosol. The aerosol generating article (100) comprises an upper external surface (110), a lower external surface (120) and an aerosol-forming substrate hermetically isolated from an environment external to the aerosol-generating article. The aerosol-generating article (100) is defined by a length extending in an x- direction, a width extending in a y-direction, and a height extending in a z-direction. The upper and lower external surfaces (110, 120) are opposed and separated from each other in the z direction. The height is less than each of the width and the length.

Description

[0001] AEROSOL-GENERATING ARTICLE

[0002] The present disclosure relates to an aerosol-generating article comprising an aerosol-forming substrate.

[0003] A typical aerosol-generating article may appear similar to a conventional cigarette. For example, such an aerosol-generating article may be substantially cylindrical and comprise an aerosol-forming substrate and other components such as a mouthpiece filter element and a cooling element, all arranged together in the form of a rod and wrapped in a cigarette paper. Dimensions of typical aerosol-generating articles are often similar to the dimensions of conventional cigarettes.

[0004] However, a significant portion of the aerosol-forming substrate in these cylindrical aerosol-generating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-forming substrate contributes to the cost of manufacture and transport of the aerosol-generating article, but does not contribute to the aerosol delivered to an end user. This may be the case regardless of the way in which the aerosol-forming substrate is heated, for example regardless of whether a resistive or inductive heater is used and regardless of whether the aerosol-forming substrate is heated from the inside or the outside. Moreover, the components of these cylindrical aerosolgenerating articles normally need to have the same or very similar outer diameters so that they can be brought together, accurately positioned in co-axial alignment and wrapped in a cigarette paper. This can lead to increased cost and complexity of manufacture.

[0005] It is an aim of the present disclosure to provide an aerosol-generating article, in which a greater portion of an aerosol-forming substrate of the aerosol-generating article is sufficiently heated to form an aerosol during use. It is also an objective of the present disclosure to provide an aerosol-generating article that can be manufactured relatively efficiently and cheaply.

[0006] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising an aerosolforming substrate for producing an aerosol, the aerosol-generating article being a planar aerosol-generating article having a base defined by a length extending in an x direction, a width extending in a y direction, and a height extending in a z direction. The aerosol-forming substrate may be hermetically isolated from an environment external to the aerosol-generating article.

[0007] The hermetic isolation of the aerosol-forming substrate may facilitate maintaining freshness of the aerosol-forming substrate and avoid loss of aerosol-forming substrate from the article during transportation and storage of the article, i.e. prior to use of the aerosol-generating article in a usage session to deplete the aerosol-forming substate.

[0008] The height of the aerosol-generating article is less than both of the length and width of the aerosolgenerating article. For the purpose of the present disclosure, the “height” of the aerosol-generating article may also be referred to as the “thickness” of the aerosol-generating article.

[0009] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising an aerosolforming substrate for producing an aerosol, the aerosol-generating article comprising a substantially planar upper surface defined by a length extending in an x direction and a width extending in a y direction, and a substantially planar lower surface defined by a length extending in an x direction and a width extending in a y direction. The substantially planar upper surface and the substantially planar lower surface may be vertically spaced from each other by a height defined in a z direction. The aerosol-forming substrate may be hermetically isolated from an environment external to the aerosol-generating article.

[0010] The hermetic isolation of the aerosol-forming substrate may facilitate maintaining freshness of the aerosol-forming substrate and avoid loss of aerosol-forming substrate from the article during transportation and storage of the article, i.e. prior to use of the aerosol-generating article in a usage session to deplete the aerosol-forming substate.

[0011] Aerosol-generating articles according to the present disclosure may preferably be substantially flat articles or substantially planar articles. Such articles have a large base area relative to the volume of the article. In particular, the height of the aerosol-generating article may be less than 50 percent of both the length and width of the aerosol-generating article. Advantageously, a larger base area may provide greater surface area for heating by a planar heater of an aerosol-generating device. Advantageously, a smaller height may allow a smaller temperature gradient or difference across the height of the aerosol-generating article during heating. For example, where the base of the aerosol-generating article is in contact with, and heated by, a planar heater, there may be a smaller temperature difference between the base and an upper surface opposing the base if the spacing, or height, between the base and the upper surface is smaller. Advantageously, this may allow heating of a greater proportion of the aerosol-forming substrate of the aerosol-generating article to a temperature at which an aerosol is released, whilst minimising the risk of burning the hottest portion of the substrate closest to the heater. Alternatively, or in addition, this may reduce a time required to heat the aerosol-forming substrate sufficiently to release an aerosol.

[0012] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. By way of example, the aerosol-generating article may be as described in any of the preceding paragraphs of the present disclosure. The aerosol generating article may comprise an upper external surface, a lower external surface and an aerosol-forming substrate hermetically isolated from an environment external to the aerosol-generating article. The aerosolgenerating article may be defined by a length extending in an x-direction, a width extending in a y-direction, and a height extending in a z-direction. The upper and lower external surfaces may be opposed and separated from each other in the z direction, wherein the height is less than each of the width and the length.

[0013] The hermetic isolation of the aerosol-forming substrate may facilitate maintaining freshness of the aerosol-forming substrate and avoid loss of aerosol-forming substrate from the article during transportation and storage of the article, i.e. prior to use of the aerosol-generating article in a usage session to deplete the aerosol-forming substate.

[0014] The aerosol-generating article according to any of the aspects disclosed herein may comprise substantially planar upper and lower surfaces. The substantially planar upper and lower surfaces may be the upper and lower external surfaces described in the preceding paragraphs. A vertical separation between the substantially planar upper and lower surfaces may define a height (for example, a z dimension) of the aerosol-generating article. The height of the aerosol-generating article may be less than 5 millimetres, for example between 1 .5 millimetres and 5 millimetres, for example between 1 .5 millimetres and 4 millimetres, for example between 1 .5 millimetres and 3 millimetres, for example between 1 .5 millimetres and 2 millimetres. One or both of the substantially planar upper and lower surfaces may comprise an aerosol-forming substrate. The aerosol-generating article may comprise upper and lower layers, the upper layer forming the substantially planar upper surface and the lower layer forming the substantially planar lower surface. The upper and lower layers may form the respective upper and lower external surfaces described in the preceding paragraphs of the present disclosure. At least one of the upper and lower layers may comprise or consist of aerosol-forming substrate.

[0015] A cavity may be disposed between the upper external surface and the lower external surface.

[0016] The aerosol-generating article may further comprise a frame disposed between the upper external surface and the lower external surface. The frame may at least partially define the cavity.

[0017] Each of the upper and lower external surfaces may preferably be thinner than the frame.

[0018] The frame may have a height within a range of between 1 .5 mm and 5 mm, for example between 1 .5 millimetres and 4 millimetres, for example between 1 .5 millimetres and 3 millimetres.

[0019] At least part of the aerosol-forming substrate may be located within the cavity.

[0020] The aerosol-generating article may be configured such that the cavity is hermetically sealed from the environment outside of the aerosol-generating article. Where aerosol-forming substrate is disposed within the cavity, the hermetic isolation of the cavity may facilitate maintaining freshness of the aerosol-forming substrate and avoid loss of aerosol-forming substrate from the article during transportation and storage of the article, i.e. prior to use of the aerosol-generating article in a usage session to deplete the aerosolforming substate.

[0021] The aerosol-generating article may have an unbreached state in which the article is free of air openings defining an air-flow path through the aerosol-generating article. Preferably, at least one of the upper and lower external surfaces may comprise one or more predetermined regions configured to be breached to define one or more air openings therethrough in a breached state of the aerosol-generating article. Where an aerosol-forming substrate is located within the aerosol-generating article, the unbreached state facilitates ensuring that the aerosol-forming substrate remains contained within the article and hermetically isolated from the environment external to the article prior to use of the article. Conversely, breaching of the one or more predetermined regions of the upper and / or lower external surfaces to form the breached state may provide for air flow into and / or out of the aerosol-generating article.

[0022] The aerosol-generating article in the unbreached state is particularly suitable for packaging, storage and transportation of the aerosol-generating article, with the unbreached state helping to maintain freshness and avoid loss of aerosol-forming substrate from the article. It is envisaged that the aerosolgenerating article may remain in the unbreached state until shortly prior to commencement of a usage session by a consumer, at which point at least one of the upper and lower external surfaces may be breached at the location of the one or more predetermined regions to transform the article into the breached state ready for depletion of the substrate in a usage session.

[0023] In the breached state, the aerosol-generating article according to any of the aspects disclosed herein may have an air-flow path extending through the aerosol-generating article. For example, in the breached state the one or more openings may form part of an air-flow path through the aerosol-generating article; preferably, the air-flow path may extend through a or the cavity disposed between the upper external surface and the lower external surface of the aerosol-generating article. In the breached state, the aerosolgenerating article may have an air-flow path defined through the aerosol-generating article in an x / y plane from one side of the aerosol-generating article to the other side of the aerosol-generating article. In the breached state, the aerosol-generating article preferably may have a resistance to draw (RTD) of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in the direction of the air-flow path. Preferably, in the breached state, the aerosol-generating article may have a RTD of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in at least one direction in an x / y plane of the aerosol-generating article. An aerosol-generating article with a low resistance air-flow path may allow for superior air-flow management and allow aerosol to be extracted more efficiently from the aerosol-generating article and guided to a user.

[0024] Unless otherwise specified, the resistance to draw (RTD) is measured in accordance with ISO 6565- 2015. The RTD refers to the pressure required to force air through the full length of a component, such as the aerosol-generating article. The terms “pressure drop” or “draw resistance” of a component or article may also refer to the “resistance to draw”. Such terms generally refer to the measurements made in accordance with ISO 6565-2015 and are normally carried out at under test at a volumetric flow rate of about 17.5 millilitres per second at the output or downstream end of the measured component at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr) and a relative humidity of about 60%.

[0025] Preferably, the one or more predetermined regions of the upper and / or lower external surfaces may comprise weakening features. The presence of such weakening features may facilitate breaching of the upper and / or lower external surfaces at the location of the one or more predetermined regions. The weakening features may comprise regions of localised thinning and / or score lines of the upper and / or lower external surfaces.

[0026] The upper and lower external surfaces may each have a thickness of between 20 microns and 500 microns, for example between 20 microns and 150 microns, for example between 20 microns and 80 microns.

[0027] The upper and lower external surfaces may preferably be aligned perpendicular to a longitudinal axis of the article.

[0028] Preferably, the aerosol-generating article is bi-symmetric along any two of a length direction, a width direction and a height direction of the article. Such bi-symmetry in the aerosol-generating article may permit the aerosol-generating article to be inserted into a cavity of an aerosol-generating device in different orientations, whilst still ensuring that the aerosol-forming substrate of the article is able to be depleted during a usage session by the action (for example, a heating action) of the aerosol-generating device on the article. As discussed in later paragraphs, the aerosol-generating device may comprise a heater element, the heater element operable to impart heat to the aerosol-generating article in order to deplete the aerosolforming substrate. The aerosol-generating device may comprise a power source configured to electrically power the heater element. The power source is preferably a battery, for example a rechargeable battery.

[0029] A first predetermined region of at least one of the upper and lower external surfaces may be configured to be breached to define an air inlet opening of the aerosol-generating article. Similarly, a second predetermined region of at least one of the upper and lower external surfaces may be configured to be breached to define an air outlet opening of the aerosol-generating article.

[0030] On breaching of the article to define the air inlet opening and the air outlet opening, the air inlet opening and the air outlet opening may define part of an air-flow path through the aerosol-generating article. The first and second predetermined regions form part of the same one of the upper and lower external surfaces. In this manner, the air inlet opening and the air outlet opening may be formed through the same one of the upper and lower external surfaces of the aerosol-generating article.

[0031] Alternatively, the first predetermined region may form part of the upper external surface and the second predetermined region forms part of the lower external surface. In this manner, the air inlet opening and the air outlet opening may be formed in different ones of the upper and lower external surfaces of the aerosol-generating article.

[0032] Preferably, the first and second predetermined regions may be symmetrically located with respect to each other along a length direction of the aerosol-generating article.

[0033] Preferably, the first and second predetermined regions may be symmetrically located with respect to each other along a width direction of the aerosol-generating article.

[0034] Such symmetry in the positioning of the first and second predetermined regions may permit the aerosol-generating article to be inserted into an aerosol-generating device in multiple different orientations, whilst still ensuring that the aerosol-forming substrate of the article is able to be depleted during a usage session by the action of the aerosol-generating device on the article (for example, through heating of the aerosol-forming substrate).

[0035] The aerosol-generating article may further comprise a frame disposed between the upper external surface and the lower external surface. The frame may at least partially define a cavity, the frame comprising one or more cut outs positioned adjacent to the first and second predetermined regions of the upper and / or lower external surfaces. The cavity may be the same as the cavity described in previous paragraphs.

[0036] Preferably, the one or more cut outs may be in fluid communication with the cavity.

[0037] At least part of the aerosol-forming substrate may be located within the one or more cut-outs.

[0038] Preferably, one or more frangible capsules area are accommodated within the one or more cut outs. The one or more frangible capsules may comprise one or more of an aerosol-forming substrate and a flavour releasing element.

[0039] Advantageously, one or more predetermined regions of at least one of the upper and lower external surfaces may be configured to be breached to define one or more groups of ventilation holes. The one or more predetermined regions may be the same as or distinct from the predetermined regions discussed in preceding paragraphs of the present disclosure.

[0040] A pair of predetermined regions of at least one of the upper and lower external surfaces may be configured to be breached to define a corresponding pair of groups of ventilation holes.

[0041] Each one of the pair of predetermined regions may be symmetrically located with respect to each other along a length direction of the aerosol-generating article.

[0042] Each one of the pair of predetermined regions may be symmetrically located with respect to each other along a width direction of the aerosol-generating article.

[0043] The upper and lower external surfaces may be formed from one or more materials selected from the following list: paper, paperboard, cardboard, metal foil and an aerosol-forming substrate.

[0044] Preferably, the upper and lower external surfaces are configured to be impermeable, for example, being impermeable to water, for example being impermeable to air. Where the upper and lower external surfaces include a porous or permeable material, preferably the respective surface comprises an impermeable coating or film overlying the porous or permeable material, for example a polymer-based coating or film.

[0045] The upper and lower external surfaces may have a permeability of between 1 to 10 Coresta units, for example between 1 to 5 Coresta units, for example between 1 to 3 Coresta units.

[0046] Preferably, the upper and lower external surfaces are substantially planar. Alternatively, the upper and lower external surfaces may be outwardly convex.

[0047] At least one of the upper and lower external surfaces may comprise an aperture closed and sealed by a peelable membrane, wherein removal of the peelable membrane exposes the aperture to define an air opening there through. Closure of the aperture by the peelable membrane may assist in assuring that aerosol-forming substrate of the aerosol-generating article is hermetically sealed from the environment external to the aerosol-generating article. Conversely, removal of the peelable membrane to expose the aperture may break the hermetic seal, for example, the resulting air opening may define one of an air inlet and an air outlet of the aerosol-generating article.

[0048] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. By way of example, the aerosol-generating article may be as described in any of the preceding paragraphs of the present disclosure. The aerosol-generating article may comprise a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer. The aerosol-generating article may comprise an aerosolforming substrate hermetically isolated from an environment external to the aerosol-generating article.

[0049] The hermetic isolation of the aerosol-forming substrate may facilitate maintaining freshness of the aerosol-forming substrate and avoid loss of aerosol-forming substrate from the article during transportation and storage of the article, i.e. prior to use of the aerosol-generating article in a usage session to deplete the aerosol-forming substate.

[0050] The first planar layer may define one of the upper external surface and the lower external surface described in preceding paragraphs of the present disclosure, whereas the second planar layer may define the other of the upper external surface and the lower external surface.

[0051] At least one of the first planar layer, the second planar layer and the corrugated layer may comprise or consist of an aerosol-forming substrate.

[0052] A cavity may be disposed between the first planar layer and the second planar layer. The corrugated layer may be arranged within the cavity. The aerosol-generating article may be configured such that the cavity may be hermetically sealed from the environment outside of the aerosol-generating article.

[0053] The use of a corrugated structure in the aerosol-generating article may advantageously allow the production of an aerosol-generating article that has extremely low RTD (when the hermetic seal of the aerosol-generating article has been breached), while still being sufficiently rigid to for a user to handle. Further, use of a corrugated structure may allow a low density, low RTD (when the hermetic seal has been breached), aerosol-generating article to be produced using high speed production methods similar to those used for production of corrugated cardboard.

[0054] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. By way of example, the aerosol-generating article may be as described in any of the preceding paragraphs of the present disclosure. The aerosol-generating article may comprise a first planar external surface, a second planar external surface, a cavity and a frame. The frame is positioned between the first planar external surface and the second planar external surface. The frame at least partially defines the cavity. The aerosol-generating article comprises an aerosol-forming substrate hermetically isolated from an environment external to the aerosol-generating article.

[0055] The hermetic isolation of the aerosol-forming substrate may facilitate maintaining freshness of the aerosol-forming substrate and avoid loss of aerosol-forming substrate from the article during transportation and storage of the article, i.e. prior to use of the aerosol-generating article in a usage session to deplete the aerosol-forming substate.

[0056] The aerosol-generating article may be configured such that the cavity is hermetically sealed from the environment outside of the aerosol-generating article.

[0057] The first and second planar external surfaces may define the upper and lower external surfaces described in the preceding paragraphs of the present disclosure.

[0058] Preferably, an aerosol-forming substrate is positioned between the first planar external surface and the second planar external surface.

[0059] The frame may comprise a peripheral wall at least partially circumscribing or encircling the cavity. The frame may comprise a peripheral wall wholly circumscribing or encircling the cavity. Advantageously, the frame may allow the aerosol-generating article to be relatively thin whilst maintaining structural rigidity.

[0060] The aerosol-generating article may comprise a first planar external layer and a second planar external layer, in which the first planar external layer forms the first planar external surface and the second planar external layer forms the second planar external surface. Optionally, at least one of the first planar external layer, the second planar external layer, and the frame may comprise or consist of aerosol-forming substrate.

[0061] The cavity may be substantially empty.

[0062] Aerosol-forming substrate may be positioned within the cavity.

[0063] A corrugated layer may be positioned within the cavity.

[0064] The frame may be a planar frame.

[0065] The frame may have a height between 50 percent and 95 percent of the height of the aerosolgenerating article. The frame may have a height between 60 percent and 95 percent of the height of the aerosol-generating article. The frame may have a height between 70 percent and 95 percent of the height of the aerosol-generating article. The frame may have a height between 80 percent and 95 percent of the height of the aerosol-generating article.

[0066] The frame may have a height between 1 millimetre and 5.5 millimetres. The frame may have a height between 1 millimetre and 5 millimetres. Preferably, the frame may have a height between 1 .5 millimetres and 5 millimetres.

[0067] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0068] The frame may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may comprise cellulose fibres. The cellulosic material may be paper, paperboard, or cardboard. The frame may be made from or comprise a plant material, such as tobacco. The frame may be made entirely from a cellulosic material.

[0069] The frame may be a unitary component. Alternatively, the frame may comprise two or more layers. That is, the frame may have a laminated structure. The aerosol-generating article of any of the aspects of the present disclosure may have a length (for example, an x dimension) of between 10 millimetres and 100 millimetres, or between 10 millimetres and 50 millimetres, for example between 10 millimetres and 40 millimetres, for example between 12 millimetres and 30 millimetres, for example between 14 millimetres and 26 millimetres, for example between 16 millimetres and 24 millimetres, for example between 18 millimetres and 22 millimetres, for example about 18 millimetres, or about 19 millimetres, or about 20 millimetres, or about 21 millimetres, or about 22 millimetres.

[0070] The aerosol-generating article may have a width (for example, a y dimension) of between 5 millimetres and 20 millimetres, for example between 8 millimetres and 18 millimetres, for example between 10 millimetres and 16 millimetres, for example between 1 1 millimetres and 15 millimetres, for example between 12 millimetres and 14 millimetres, for example about 13 millimetres.

[0071] The aerosol-generating article may have a height (for example, a z dimension) of between 1 millimetres and 10 millimetres, for example between 1 .2 millimetres and 8 millimetres, for example between 1 .4 millimetres and 7 millimetres, for example between 1 .6 millimetres and 6 millimetres, for example between 1 .7 millimetres and 5 millimetres, for example about 1 .7 millimetres, or about 4.5 millimetres, or about 2 millimetres, or about 3 millimetres, or about 4 millimetres.

[0072] The aerosol-generating article of any of the aspects of the present disclosure when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof. Where the aerosol-generating article comprises substantially planar upper and lower surfaces, one or both of the upper and lower surfaces when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof. A perimeter of the aerosol-generating article when viewed in plan may be formed of a plurality of straight sides, a plurality of curved sides, or a combination of straight and curved sides. Where the aerosolgenerating article comprises substantially planar upper and lower surfaces, a perimeter of one or both of the upper and lower surfaces when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof.

[0073] The aerosol-generating article may consist entirely of aerosol-forming substrate. Alternatively, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-generating article.

[0074] The aerosol-forming substrate may comprise nicotine. Nicotine may be present in the form of a tobacco material or may be in the form of a nicotine extract.

[0075] The aerosol-forming substrate may comprise one or more organic materials such as tobacco, mint, tea and cloves. The aerosol-forming substrate may comprise one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenised tobacco such as cast leaf, extruded tobacco, expanded tobacco, aerosol-generating films and gel compositions.

[0076] The aerosol-forming substrate may comprise or consist of homogenised tobacco material, for example a reconstituted tobacco material or a cast leaf tobacco material.

[0077] The aerosol-forming substrate may be in the form of shredded aerosol-generating material. The shredded aerosol-generating material may comprise one or more of: strips and strands of aerosolgenerating material, such as strips and strands of tobacco or homogenised tobacco material. The shredded aerosol-generating material may be in the form of a shredded sheet of homogenised tobacco material. The aerosol-forming substrate may be cut filler. The aerosol-forming substrate may be tobacco cut filler. The cut filler may comprise one or more of bright tobacco, dark tobacco, aromatic tobacco and filler tobacco. Examples of bright tobaccos are Flue-Cured Brazil, Indian Flue-Cured, Chinese Flue-Cured, US Flue-Cured such as Virginia tobacco, and Flue-Cured from Tanzania. Examples of aromatic tobaccos are Oriental Turkey, Greek Oriental, semi-oriental tobacco but also Fire Cured, US Burley, such as Perique, and Rustica. Examples of dark tobacco are Dark Cured Brazil Galpao, Burley Malawi or other African Burley, Sun Cured or Air Cured Indonesian Kasturi. As used herein, the term “cut filler” is used to describe a blend of shredded plant material, such as tobacco plant material, including, in particular, one or more of leaf lamina, processed stems and ribs, homogenised plant material.

[0078] The aerosol-forming substrate may be in the form of a sheet of aerosol-generating material. As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenised tobacco material, such as a cast leaf sheet.

[0079] The aerosol-forming substrate may comprise a bound collection of strips, strands or particles of tobacco material. The aerosol-forming substrate may be in the form of a compressed plug of tobacco material; for example, in which a plug having a substantially circular cross-section in an initial state of the plug is compressed into a flatter cross-sectional profile in a subsequent state of the plug. The tobacco material may be enclosed by a wrapper. The aerosol-forming substrate may be in the form of strips, strands or particles of tobacco material bound together in a binder matrix.

[0080] The aerosol-forming substrate may comprise one or more aerosol-formers. Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosol-formers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; 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 for the aerosol-former to be or comprise one or both of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0081] The aerosol-forming substrate may have an aerosol-former content greater than or equal to 1 , 2, 5, 10, or 15 percent by weight on a dry weight basis. The aerosol-forming substrate may have an aerosolformer content greater than or equal to 15 percent by weight on a dry weight basis, for example greater than 20 by weight on a dry weight basis, or greater than 25 by weight on a dry weight basis, or greater than 30 by weight on a dry weight basis, or greater than 40 by weight on a dry weight basis, or greater than 50 by weight on a dry weight basis.

[0082] The aerosol-forming substrate may have an aerosol-former content less than or equal to 30 percent by weight on a dry weight basis, less than or equal to 25 percent by weight on a dry weight basis, or less than or equal to 20 percent by weight on a dry weight basis. That is, the aerosol-generating material may have an aerosol-former content less than or equal to 30 by weight on a dry weight basis, less than or equal to 25 by weight on a dry weight basis, or less than or equal to 20 by weight on a dry weight basis. The aerosol-forming substrate may have an aerosol-former content between 1 percent and 30 percent by weight on a dry weight basis, between 1 percent and 25 percent by weight on a dry weight basis, or between 1 percent and 20 percent by weight on a dry weight basis.

[0083] The aerosol-forming substrate may comprise at least 50 percent by weight of aerosol former, at least 60 percent by weight of aerosol former, or at least 70 percent by weight of aerosol former.

[0084] The aerosol-forming substrate may comprise less than or equal to 85 percent by weight of aerosol former, less than or equal to 80 percent by weight of aerosol former, or less than or equal to 75 percent by weight of aerosol former.

[0085] The aerosol-forming substrate may comprise between 50 percent and 85 percent by weight of aerosol former, between 50 percent and 80 percent by weight of aerosol former, or between 50 percent and 75 percent by weight of aerosol former.

[0086] The aerosol-forming substrate may comprise nicotine. The aerosol-forming substrate may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0087] The aerosol-forming substrate may comprise at least 0.5 percent by weight of nicotine, at least 1 percent by weight of nicotine, at least 1 .5 percent by weight of nicotine, or at least 2 percent by weight of nicotine.

[0088] The aerosol-forming substrate may comprise one or more flavourants. The one or more flavourants may comprise one or more of: one or more essential oils such as eugenol, peppermint oil and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and a herbaceous material. Suitable herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavourants may comprise a tobacco material.

[0089] The aerosol-forming substrate may comprise one or more botanicals. For example, the aerosolforming substrate may comprise about 1 to 90 %, for example about 15 to 55 %, preferably of about 20 to 35 %, of botanicals such as Clove, Echinacea sp., Fennel, Ginger, Hawthorn berry, Elderberry, Monarda, Mullein leaves, Nettle, Plantain, Turmeric, Yarrow, Rooibos, Star Anise, Thyme, Anethum, Chamomile and compounds of those.

[0090] The aerosol-forming substrate may have a moisture content of about 5 to 25%, preferably of about 7 to 15%, at final product state. For example, the aerosol-forming substrate may be a homogenised tobacco material with a moisture of about 5 to 25%, preferably of about 7 to 15%, at final product state.

[0091] The aerosol-forming substrate may comprise a binder. For example, the aerosol-forming substrate may comprise about 1 to 10%, preferably of about 1 to 5%, of a binder such as any of common gums or pectins used in food and beverage (F&B) industries. Preferred binders may be natural pectins, such as fruit, for example citrus, or tobacco pectins; guar gums, land locust bean gums, such as hydroxyethyl and / or hydroxypropyl of those; starches, such as modified or derivatized starches; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl, celluloses; dextran; and xanthan gum. A preferable binder is guar.

[0092] The aerosol-forming substrate may comprise, or consist of, a solid aerosol-forming material. The aerosol-forming substrate may comprise a liquid aerosol-forming material, for example a liquid aerosolforming material retained within a porous matrix. The aerosol-forming substrate may comprise a gel aerosol-forming material. According to the present disclosure, an aerosol-generating device for receiving an aerosolgenerating article as disclosed herein, or an aerosol-forming substrate as disclosed herein, may comprise a cavity dimensioned to receive at least a portion of the aerosol-generating article or aerosol-forming substrate, a heater or heating means, a power source for supplying power to the heater or heating means, and a controller to control supply of power to the heater or heating means. The aerosol-generating device is configured to heat an aerosol-forming substrate, for example an aerosol-forming substrate that is a component part of an aerosol-generating article, to form an aerosol, for example an inhalable aerosol.

[0093] The aerosol-generating device may preferably be configured to receive the entirety of the aerosolgenerating article such that the aerosol-generating article is wholly enclosed within the aerosol-generating device.

[0094] The cavity may comprise an opening into which a distal end of the aerosol-generating article can be inserted. The cavity may have any suitable cross-sectional shape. For example, the cavity may have a rectangular transverse cross-section, for example a rectangular cross-section having opposing top and bottom sides that are greater in length than left and right sides.

[0095] Preferably, at least one internal surface of the cavity is a heating surface configured to heat an aerosol-generating article. The heating surface may comprise a heater, for example a resistance heater, or an infra-red heater, or a susceptor configured to be heated by engagement with an inductor. The heating surface may comprise an inductor, for example the surface may comprise a coil arranged to generate a fluctuating electromagnetic field within a space of the cavity. The heating surface may be a surface that is permeable to a fluctuating electromagnetic field, such that an inductor arranged outside the cavity can project a fluctuating electromagnetic field through the heating surface to engage with a susceptor arranged within the cavity.

[0096] As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol.

[0097] As used herein, the term “aerosol-forming substrate” may refer to a substrate capable of releasing an aerosol or volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. An aerosol-forming substrate may comprise an aerosol-forming material. An aerosol-forming substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. An aerosol-forming substrate may conveniently be part of an aerosol-generating article or smoking article.

[0098] As used herein, the term “aerosol-generating device” may refer to a device for use with an aerosolgenerating article to enable the generation, or release, of an aerosol.

[0099] As used herein, the term “aerosol generating system” refers to a combination of an aerosolgenerating device and one or more aerosol-forming articles for use with the device. An aerosol-generating system may include additional components, such as a charging unit for recharging an on-board electric power supply in an electrically operated or electric aerosol-generating device.

[0100] As used herein, the term “aerosol former” may refer to any suitable known compound or mixture of compounds that, in use, facilitates formation of an aerosol. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-forming substrate or aerosol-generating article. As used herein with reference to the invention, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.

[0101] As used herein with reference to the invention, the terms “proximal”, “distal”, “upstream” and “downstream” are used to describe the relative positions of components, or portions of components, of the aerosol-generating article.

[0102] As used herein, the term “longitudinal” refers to the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. During use, air may be drawn through the aerosol-generating article in the longitudinal direction.

[0103] As used herein, the term “sheet” denotes a laminar element having a width and length substantially greater than the thickness thereof. The width of a sheet may be greater than 10 mm, preferably greater than 20 mm or 30 mm. In certain embodiments, sheets of material for use in forming aerosol-forming substrates as described herein may have a thickness of between 10 pm and about 1000 pm, for example between 10 pm and about 300 pm.

[0104] As used herein, the term “homogenised tobacco material” encompasses any tobacco material formed by the agglomeration of particles of tobacco material. Sheets or webs of homogenised tobacco material are formed by agglomerating particulate tobacco obtained by grinding or otherwise powdering of one or both of tobacco leaf lamina and tobacco leaf stems. In addition, homogenised tobacco material may comprise a minor quantity of one or more of tobacco dust, tobacco fines, and other particulate tobacco byproducts formed during the treating, handling and shipping of tobacco. The sheets of homogenised tobacco material may be produced by casting, extrusion, paper making processes or other any other suitable processes known in the art.

[0105] The term “cast leaf” is used herein to refer to a product made by a casting process that is based on casting a slurry comprising plant particles (for example, clove particles or tobacco particles and clove particles in a mixture) and a binder (for example, guar gum) onto a supportive surface, such as a belt conveyor, drying the slurry and removing the dried sheet from the supportive surface. An example of the casting or cast leaf process is described in, for example, US-A-5,724,998 for making cast leaf tobacco. In a cast leaf process, particulate plant materials are produced by pulverizing, grinding, or comminuting parts of the plant. The particles produced from one or more plants are mixed with a liquid component, typically water, to form a slurry. Other components in the slurry may include fibres, a binder and an aerosol former. The particulate plant materials may be agglomerated in the presence of the binder. The slurry is cast onto a supportive surface and dried into a sheet of homogenized plant material. Preferably, homogenized plant material used in articles according to the present invention may be produced by casting. Such homogenized plant material may comprise agglomerated particulate plant material.

[0106] As used herein, resistance to draw is expressed with the units of pressure “mm H2O” or “mm WG” or “mm of water gauge” and may be measured in accordance with ISO 6565:2002.

[0107] The invention is defined in the claims. However, below there is provided a non-exhaustive list of nonlimiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0108] Example Ex1 : An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol generating article comprising: an upper external surface; a lower external surface; and an aerosol-forming substrate hermetically isolated from an environment external to the aerosolgenerating article; the aerosol-generating article defined by a length extending in an x-direction, a width extending in a y-direction, and a height extending in a z-direction, the upper and lower external surfaces opposed and separated from each other in the z direction, wherein the height is less than each of the width and the length.

[0109] Example Ex2: An aerosol-generating article according to Ex1 , further comprising a cavity disposed between the upper external surface and the lower external surface.

[0110] Example Ex3: An aerosol-generating article according to Ex2, further comprising a frame disposed between the upper external surface and the lower external surface, wherein the frame at least partially defines the cavity.

[0111] Example Ex4: An aerosol generating article according to Ex3, wherein each of the upper and lower external surfaces are thinner than the frame.

[0112] Example Ex5: An aerosol-generating article according to either one of Ex3 or Ex4, wherein the frame has a height within a range of between 1 .5 mm and 5 mm, for example between 1 .5 millimetres and 4 millimetres, for example between 1 .5 millimetres and 3 millimetres.

[0113] Example Ex6: An aerosol-generating article according to any one of Ex2 to Ex5, wherein the article is configured such that the cavity is hermetically sealed from the environment outside of the aerosolgenerating article.

[0114] Example Ex7: An aerosol-generating article according to any one of Ex2 to Ex6, wherein at least part of the aerosol-forming substrate is located within the cavity.

[0115] Example Ex8: An aerosol-generating article according to any one of Ex1 to Ex7, wherein the aerosolgenerating article has an unbreached state in which the article is free of air openings defining an air-flow path through the aerosol-generating article.

[0116] Example Ex9: An aerosol-generating article according to Ex8, wherein at least one of the upper and lower external surfaces comprise one or more predetermined regions configured to be breached to define one or more air openings therethrough in a breached state of the aerosol-generating article.

[0117] Example Ex10: An aerosol-generating article according to Ex9, wherein in the breached state the one or more openings form part of an air-flow path through the aerosol-generating article, preferably the air-flow path extending through a or the cavity disposed between the upper external surface and the lower external surface.

[0118] Example Ex1 1 : An aerosol-generating article according to either one of Ex9 or Ex10, wherein the one or more predetermined regions of the upper and / or lower external surfaces comprise weakening features.

[0119] Example Ex12: An aerosol-generating article according to Ex1 1 , wherein the weakening features comprise regions of localised thinning and / or score lines of the upper and / or lower external surfaces.

[0120] Example Ex13: An aerosol-generating article according to any one of the preceding claims, wherein the upper and lower external surfaces each have a thickness of between 20 microns and 500 microns, for example between 20 microns and 150 microns, for example between 20 microns and 80 microns. Example Ex14: An aerosol-generating article according to any one of Ex1 to Ex13, wherein the upper and lower external surfaces are aligned perpendicular to a longitudinal axis of the article.

[0121] Example Ex15: An aerosol-generating article according to any one of Ex1 to Ex14, wherein the article is bi-symmetric along any two of a length direction, a width direction and a height direction of the article.

[0122] Example Ex16: An aerosol-generating article according to Ex9 or any example dependent thereon, wherein: a first predetermined region of at least one of the upper and lower external surfaces is configured to be breached to define an air inlet opening of the aerosol-generating article; and a second predetermined region of at least one of the upper and lower external surfaces is configured to be breached to define an air outlet opening of the aerosol-generating article.

[0123] Example Ex17: An aerosol-generating article according to Ex16, wherein on breaching of the article to define the air inlet opening and the air outlet opening, the air inlet opening and the air outlet opening define part of an air-flow path through the aerosol-generating article.

[0124] Example Ex18: An aerosol-generating article according to either one of Ex16 or Ex17, wherein the first and second predetermined regions form part of the same one of the upper and lower external surfaces.

[0125] Example Ex19: An aerosol-generating article according to either one of Ex16 or Ex17, wherein the first predetermined region forms part of one of the upper external surface and the lower external surface and the second predetermined region forms part of the other of the upper external surface and the lower external surface.

[0126] Example Ex20: An aerosol-generating article according to any one of Ex16 to Ex19, wherein the first and second predetermined regions are symmetrically located with respect to each other along a length direction of the aerosol-generating article.

[0127] Example Ex21 : An aerosol-generating article according to any one of Ex16 to Ex20, wherein the first and second predetermined regions are symmetrically located with respect to each other along a width direction of the aerosol-generating article.

[0128] Example Ex22: An aerosol-generating article according to any one of Ex16 to Ex21 , further comprising a frame disposed between the upper external surface and the lower external surface, wherein the frame at least partially defines a cavity, the frame comprising one or more cut outs positioned adjacent to the first and second predetermined regions of the upper and / or lower external surfaces.

[0129] Example Ex23: An aerosol-generating device according to Ex22, wherein the one or more cut outs are in fluid communication with the cavity.

[0130] Example Ex24: An aerosol-generating device according to either one of Ex22 or Ex23, wherein at least part of the aerosol-forming substrate is located within the one or more cut-outs.

[0131] Example Ex25: An aerosol-generating article according to any one of Ex22 to Ex24, comprising one or more frangible capsules accommodated within the one or more cut outs.

[0132] Example Ex26: An aerosol-generating article according to Ex25, wherein the one or more frangible capsules comprise one or more of an aerosol-forming substrate and a flavour releasing element.

[0133] Example Ex27: An aerosol-generating article according to any one of Ex1 to Ex26, wherein one or more predetermined regions of at least one of the upper and lower external surfaces is configured to be breached to define one or more groups of ventilation holes. Example Ex28: An aerosol-generating article according to Ex27, wherein a pair of predetermined regions of at least one of the upper and lower external surfaces is configured to be breached to define a corresponding pair of groups of ventilation holes.

[0134] Example Ex29: An aerosol-generating article according to Ex28, wherein each one of the pair of predetermined regions is symmetrically located with respect to each other along a length direction of the aerosol-generating article.

[0135] Example Ex30: An aerosol-generating article according to Ex28, wherein each one of the pair of predetermined regions is symmetrically located with respect to each other along a width direction of the aerosol-generating article.

[0136] Example Ex31 : An aerosol-generating article according to any one of Ex1 to Ex30, wherein the upper and lower external surfaces are formed from one or more materials selected from the following list: paper, paperboard, cardboard, metal foil and an aerosol-forming substrate.

[0137] Example Ex32: An aerosol-generating article according to any one of Ex1 to Ex31 , wherein the upper and lower external surfaces are configured to be impermeable, for example to be impermeable to water, for example to be impermeable to air.

[0138] Example Ex33: An aerosol-generating article according to any one of Ex1 to Ex32, wherein the upper and lower external surfaces are substantially planar.

[0139] Example Ex34: An aerosol-generating article according to any one of Ex1 to Ex32, wherein the upper and lower external surfaces are outwardly convex.

[0140] Example Ex35. An aerosol-generating article according to any one of Ex1 to Ex34, wherein at least one of the upper and lower external surfaces comprises an aperture closed and sealed by a peelable membrane, wherein removal of the peelable membrane exposes the aperture to define an air opening there through.

[0141] Examples will now be further described with reference to the figures in which:

[0142] Figure 1 is a perspective side view of an aerosol-generating article according to a first embodiment of the present disclosure;

[0143] Figure 2 is a perspective side view of an aerosol-generating article according to a second embodiment of the present disclosure, the aerosol-generating article being in an unbreached state;

[0144] Figure 3 is a perspective side view of the aerosol-generating article of figure 2 after transformation into a breached state;

[0145] Figure 4 is a perspective side view of an aerosol-generating article according to a third embodiment of the present disclosure, the aerosol-generating article being in an unbreached state;

[0146] Figure 5 is a perspective side view of the aerosol-generating article of figure 4 after transformation into a breached state;

[0147] Figure 6 is a schematic end view of an aerosol-generating article according to a fourth embodiment of the present disclosure;

[0148] Figure 7 is a schematic side view of the aerosol-generating article of figure 6;

[0149] Figure 8 is a schematic plan view of the aerosol-generating article of figure 6 in an unbreached state; Figure 9 is a schematic plan view of the aerosol-generating article of figure 6 in a breached state;

[0150] Figure 10 shows a schematic illustration of a corrugated element as used in the aerosol-generating article of figure 6; Figure 1 1 shows a perspective view of an aerosol-generating article according to a fifth embodiment of the present disclosure, the aerosol-generating article being in an unbreached state;

[0151] Figure 12 shows a perspective view of an aerosol-generating article of figure 1 1 after transformation into a breached state;

[0152] Figure 13 shows an exploded perspective view of the aerosol-generating article of figure 1 1 ;

[0153] Figure 14 shows a further exploded perspective view of the aerosol-generating article of figure 1 1 ;

[0154] Figure 15 shows a schematic transverse cross-sectional view of the aerosol-generating article of figure 1 1 ;

[0155] Figure 16 shows a schematic longitudinal cross-sectional view of the aerosol-generating article of figure 1 1 ;

[0156] Figure 17 shows an exploded perspective view of an aerosol-generating article according to a sixth embodiment of the present disclosure, the aerosol-generating article being in an unbreached state;

[0157] Figure 18 shows a perspective view of the aerosol-generating article of figure 17 after transformation into a breached state;

[0158] Figure 19 shows a schematic transverse cross-sectional view of the aerosol-generating article of figure 17;

[0159] Figure 20 shows a schematic lateral cross-sectional view of the aerosol-generating article of figure 17.

[0160] Figure 21 shows a perspective view of an aerosol-generating article according to a seventh embodiment of the present disclosure;

[0161] Figure 22 shows a schematic view of an aerosol-generating device according to an embodiment of the present disclosure, the device configured to engage with an aerosol-generating article, for example the aerosol-generating article of any of figures 1 to 21 ;

[0162] Figure 23 shows a schematic end view of the aerosol-generating device of figure 22;

[0163] Figure 24 is a schematic view showing an aerosol-generating article (for example, the aerosolgenerating article of any of figures 1 to 21 ) in engagement with the aerosol-generating device of figure 22.

[0164] Figure 25 is a schematic view of an alternative embodiment to that of figures 22 to 24, showing an aerosol-generating article in engagement with an aerosol-generating device.

[0165] Figure 1 illustrates a perspective side view of an aerosol-generating article 100 according to a first embodiment of the present disclosure. The aerosol-generating article 100 has upper and lower surfaces 1 10, 120 which are flat or planar.

[0166] The aerosol-generating article 100 comprises an aerosol-forming substrate (not shown). The aerosol-forming substrate is enclosed within an interior of the aerosol-generating article 100. A suitable aerosol-forming substrate may be homogenised tobacco.

[0167] The exterior of the aerosol-generating article 100 is configured such that the aerosol-forming substrate of the aerosol-generating article is hermetically sealed from the environment outside of (i.e. external to) the aerosol-generating article.

[0168] The aerosol-generating article 100 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (which may also be referred to as a thickness), extending in a z dimension, of 3.6 millimetres. Figure 2 illustrates a perspective side view of an aerosol-generating article 200 according to a second embodiment of the present disclosure, being a variant of aerosol-generating article 100. Features in common with aerosol-generating article 100 are referred to with like reference signs but commencing with numeral 2 instead of numeral 1 . Figure 2 illustrates the aerosol-generating article 200 in an unbreached state in which a hermetic seal is maintained between the interior and exterior of the aerosol-generating article. However, first, second and third regions 21 1 , 212, 213 (shown in broken outline in figure 2) are predetermined regions of the upper surface 210 intended to be subsequently breached to break the hermetic seal prior to commencing a usage session with the aerosol-generating article 200. The first and second regions 21 1 , 212 are circular and symmetrically spaced apart from each other on the upper surface 210 along a length direction (i.e. an x-direction) of the aerosol-generating article 200. The third region 213 extends linearly between lateral side edges of the upper surface 210 at the midpoint of the length of the upper surface. The upper and lower surfaces 210, 220 each have a uniform thickness of around 50 microns. The lower the thickness of the upper surface 210, the lower the force required to breach the upper surface at the location of the predetermined first, second and third regions 21 1 , 212, 213. In an alternative embodiment, score lines may be formed along the perimeter of the circular predetermined first and second regions 21 1 , 212 and along the linear predetermined third region 213. In such an alternative embodiment, the broken outlines shown for the predetermined first, second and third regions 21 1 , 212, 213 in figure 2 would also be representative of the score lines. The score lines would only partially extend through the thickness of the upper surface 210, thereby maintaining the hermetic seal between the interior and exterior of the aerosol-generating article 200. The score lines would reduce the force required to breach the upper surface 210. The unbreached state of the aerosol-generating article 200 illustrated in figure 2 is particularly suitable for packaging, transportation and storage of the article.

[0169] When a consumer wishes to prepare the aerosol-generating article 200 for use in a usage session, the consumer would first breach the upper surface 210 about the perimeter of the circular predetermined first and second regions 21 1 , 212 to form respective first and second circular openings 214, 215 through the upper surface 210 (as shown in figure 3). The consumer would also discontinuously breach the upper surface 210 along the path defined by the linear predetermined third region 213 to define a row of ventilation perforations 216 through the upper surface 210 (also shown in figure 3). The consumer may manually breach the circular predetermined first and second regions 21 1 , 212 to form the first and second circular openings 214, 215 by using a punch or suitable cutting tool (for example, a circular cutting tool). Similarly, the consumer may manually breach the linear predetermined third region 213 to form the row of ventilation perforations 216 by using a linear cutting tool having a plurality of spaced apart teeth. Markings may be printed on the upper surface 210 to indicate the location of the circular predetermined first and second regions 21 1 , 212 and / or the linear predetermined third region, thereby providing a visual cue as to which part of the upper surface 210 should be breached. In some embodiments, the upper surface 210 may be ruptured at the locations of the predetermined first, second and third regions 21 1 , 212, 213 in consequence of the aerosol-generating article 200 being inserted into a cavity of an aerosol-generating device; for example, the device having one or more cutting tools or protrusions adapted to engage with the upper surface 210 of the article to rupture the upper surface and thereby create the first and second circular openings 214, 215 and the ventilation perforations 216. Where score lines are defined in the upper surface 210 along the perimeter of the circular predetermined first and second regions 21 1 , 212 and the path of the linear predetermined third region 213 (as described in the preceding paragraph), the localised thinning of the upper surface 210 along the score lines reduces the force required to rupture the upper surface 210 and may also ensure that the upper surface 210 only or preferentially ruptures along the path defined by the score lines. First circular opening 214 defines an air inlet of the aerosol-generating article 200. Second circular opening 215 defines an air outlet of the aerosol-generating article 200. An air-flow path 217 is defined through the interior of the aerosol-generating article 200 between the air inlet 214 and the air-outlet 215. Arrows in figure 3 indicate the path taken by air in though the air inlet 214, along the air-flow path 217 and out of the air outlet 215. The first end 201 may define a distal end of the aerosol-generating article 200, and the second end 202 may define a proximal or mouth end of the aerosol-generating article. The air flow path 217 may be directed towards a mouth of a user to allow a user to inhale aerosol generated in consequence of heating of aerosol-forming substrate of the aerosol-generating article 200.

[0170] In an alternative embodiment to that of figures 2 and 3, one of the predetermined first and second regions 21 1 , 212 is located in the upper surface 210 and the other of the predetermined first and second regions 21 1 , 212 located in the lower surface 220. The predetermined third region 213 may be located in the upper surface 210 only (as shown in figure 2), in the lower surface 220 only, or in both of the upper and lower surfaces 210, 220. It will also be appreciated that the predetermined first and second regions 21 1 , 212 may have a shape other than circular; for example, being oval, elliptical, square, rectangular or any other shape.

[0171] Figure 4 illustrates a perspective side view of an aerosol-generating article 300 according to a third embodiment of the present disclosure, being a variant of aerosol-generating article 200. Features in common with aerosol-generating article 200 are referred to with like reference signs but commencing with numeral 3 instead of numeral 2. The aerosol-generating article 300 of figure 4 is in an unbreached state, in which a hermetic seal is maintained between the interior and exterior of the aerosol-generating article 300. The aerosol-generating article 300 of figure 4 differs from the aerosol-generating article 200 of figure 2 in that a peelable foil membrane 318 covers first and second openings 314, 315 and ventilation perforations 316 preformed through the upper surface 310 of the aerosol-generating article 300. The peelable foil membrane 318 has a layer of aluminium, with an adhesive provided on one or both of opposing sides of the membrane 318 and the upper surface 310 to peelably attach the membrane to the upper surface. The peelable foil membrane 318 covers the first and second openings 314, 315 and the ventilation perforations 316 from view and thereby retains the aerosol-generating article 300 in the unbreached state of figure 4. The first and second openings 314, 315 and ventilation perforations 316 are not shown in figure 4 due to being covered by the foil membrane 318, but are visible in figure 5 after removal of the membrane 318.

[0172] When a consumer wishes to prepare the aerosol-generating article 300 for use in a usage session, the consumer would engage their finger with a tab 319 of the peelable membrane 318 and pull the tab in the direction of the arrow shown in figure 4 to progressively remove the membrane from the upper surface 310. Removal of the peelable membrane 318 exposes the first and second openings 314, 315 and the ventilation perforations 316, thereby transforming the article 300 into a breached state, as shown in figure 5. The first and second openings 314, 315 define an air inlet and an air outlet of the aerosol-generating article 300. Arrows in figure 5 indicate the path taken by air into the air inlet 314, along air-flow path 317 defined through the interior of the aerosol-generating article 300 and out of the air outlet 315. Figures 6, 7, and 8 / 9 illustrate respectively an end view, a side view, and plan views of an aerosolgenerating article 400 according to a fourth embodiment of the present disclosure. The aerosol-generating article 400 comprises a planar upper layer 410, a planar lower layer 420, and an intermediate or separation layer 440 arranged between the upper layer 410 and lower layer 420.

[0173] The planar upper layer 410 is formed from a sheet of paper having a thickness of 300 microns. The planar lower layer 420 is formed from a sheet of paper having a thickness of 300 microns. The sheets of paper defining the upper and lower layers 410, 420 each incorporate a polymer film to make the respective layers 410, 420 essentially impermeable to the passage of water or air. The intermediate layer 440 is a corrugated element formed from a corrugated sheet of aerosol-forming substrate 445. A suitable aerosolforming substrate may be homogenised tobacco. Thus, the intermediate layer 440 may be formed from a corrugated sheet of homogenised tobacco material 445.

[0174] Figure 10 illustrates the corrugated sheet of aerosol-forming substrate 445. The corrugations have an amplitude 446 of 3 millimetres and a wavelength 447 of 3 millimetres. The sheet of aerosol-forming substrate 445 forming the intermediate layer 440 has a thickness of 150 microns.

[0175] Points of intersection 451 , 452 between the upper layer 410 and the intermediate layer 440 and between the lower layer 420 and the intermediate layer 440 comprise an adhesive that joins the respective layers.

[0176] The aerosol-generating article 400 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (or thickness), extending in a z dimension, of 3.6 millimetres.

[0177] Corrugations of the intermediate layer 440 form a first set of longitudinally extending channels 461 that are bounded by the upper layer 410 and the intermediate layer 440, and a second set of longitudinally extending channels 462 bounded by the lower layer 420 and the intermediate layer 440. The first and second sets of longitudinally extending channels 461 , 462 extend through the length of the aerosol-forming substrate between a proximal end 471 of the substrate 445 and a distal end 472 of the substrate 445.

[0178] Figure 8 shows the aerosol-generating article 400 in an unbreached state, in which a hermetic seal is maintained between the interior and exterior of the aerosol-generating article. First and second regions 41 1 , 412 (shown in broken outline in figure 8) are predetermined regions of the upper layer 410 intended to be subsequently breached to break the hermetic seal prior to commencing a usage session with the aerosol-generating article 400. The first and second regions 41 1 , 412 are circular and symmetrically spaced apart from each other on the upper layer 410 along a length direction (i.e. an x-direction) of the aerosolgenerating article 400. Although the upper layer 410 may be of uniform thickness, in an alternative embodiment score lines may be defined along the perimeter of the predetermined first and second regions 411 , 412 to reduce the force required to rupture the upper layer 410 and / or to ensure that the upper layer 410 is ruptured along a desired path (defined by the score lines). In such an alternative embodiment, the broken outlines shown in figure 8 for the circular predetermined first and second regions 41 1 , 412 of the upper layer 410 would be representative of the score lines.

[0179] As shown in figure 9, breaching of the upper layer 410 about the perimeter of the circular predetermined first and second regions 41 1 , 412 results in circular first and second openings 414, 415 being defined through the upper layer. The breached state of the aerosol-generating article 400 illustrated in figure 9 is suitable for commencing a usage session using the article. The first and second openings 414, 415 define an air inlet and an air outlet of the aerosol-generating article 400, with the openings positioned above one or more of the first set of longitudinally extending channels 461 . Arrows in figure 9 indicate the path taken by air into the air inlet 414, along an air-flow path 417 defined through the interior of the aerosolgenerating article 400 and out of the air outlet 415. The longitudinally extending channels 461 define an airflow path through the substrate 445. The porosity of the aerosol-generating article 400 along the air-flow path is in the region of 90 %. This provides a very low resistance to draw (RTD) of less than 5 mm H2O. In fact, the RTD is close to zero.

[0180] In an alternative embodiment to that of figures 8, 9, two circular predetermined regions (not shown) may be defined in the lower layer 420 to complement the circular predetermined first and second regions 41 1 , 412 defined in the upper layer 410. Breaching of the two predetermined regions in the lower layer 420 would provide third and fourth air openings (not shown) through the lower layer. So, in this alternative embodiment, breaching of the upper and lower layers 410, 420 at the locations of the circular predetermined regions would provide an air-flow path passing over both sides of the sheet of aerosol-forming substrate 445. Again, the porosity of the aerosol-generating article along the air-flow path is in the region of 90 %. This provides a very low resistance to draw (RTD) of less than 5 mm H2O. In fact, the RTD is close to zero. The aerosol-forming substrate 445 may be a sheet of any suitable aerosol-forming substrate.

[0181] During use of the aerosol-generating article 400 (including the alternative embodiment discussed in the preceding paragraphs), the aerosol-forming substrate 445 is heated up to cause the aerosol-forming substrate 445 to release volatile compounds, which are then entrained in air drawn into the channels 461 (and, for the alternative embodiment discussed above, into channels 462) via the distal end 472. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the channels 461 , 462 of the aerosol-generating article 400 via the proximal end 471 .

[0182] Figure 1 1 shows an aerosol-generating article 500 according to a fifth embodiment of the present disclosure. The aerosol-generating article 500 comprises a first planar external layer 524 forming a first planar external surface 521 , a second planar external layer 525 forming a second planar external surface 522, and a frame 550 positioned between the first planar external layer 524 and the second planar external layer 525. The second planar external surface 522 is positioned parallel to the first planar external surface 521 . First and second score lines 51 1 , 512 are defined in the first planar external surface 521 of the first planar external layer 524. Neither of the first and second score lines 51 1 , 512 penetrates the entire thickness of the first planar external layer 524, thereby maintaining a hermetic seal between the interior and exterior of the aerosol-generating article 500. Rather, the first and second score lines 51 1 , 512 define predetermined first and second regions of the first planar external layer 524 adapted for breaching to define respective air openings 514, 515 through the layer 524. The score lines 51 1 , 512 reduce the force required to breach the layer 524 and / or ensure that the layer 524 is breached along a desired path (defined by the score lines 51 1 , 512). However, it will be appreciated that the score lines are optional and that in an alternative embodiment, no score lines may be present. The aerosol-generating article 500 of figure 1 1 is an unbreached state.

[0183] As shown in figure 12, breaching of the first planar external layer 524 along each of the circular score lines 51 1 , 512 results in first and second openings 514, 515 being defined through the first planar external layer. The breached state of the aerosol-generating article 500 illustrated in figure 12 is suitable for commencing a usage session using the article. The first and second openings 513, 514 define an air inlet and an air outlet of the aerosol-generating article 500. Arrows in figure 12 indicate the path taken by air into the air inlet 514, along an air-flow path 517 defined through the interior of the aerosol-generating article 500 and out of the air outlet 515. The air-flow path 517 extends through a cavity 530 of the aerosol-generating article 500.

[0184] Figures 13 and 14 show exploded views of the aerosol-generating article 500 of figure 1 1 , being views of the aerosol-generating 500 in the unbreached state of figure 1 1 . The frame 550 circumscribes and at least partially defines cavity 530. Figure 13 shows the cavity 531 in an empty state. Figure 14 shows the cavity 530 filled with aerosol-forming substrate 540. Figures 15 and 16 show respective transverse and longitudinal cross-sectional views of the aerosol-generating article 500 when the cavity 530 is filled with aerosol-forming substrate 540.

[0185] The first planar external layer 524 and the second planar external layer 525 are made from cigarette paper having a thickness of 35 micrometres and are in physical contact, with and bonded to, the frame 550. The cigarette paper defining the first and second planar external layers 524, 525 each incorporate a polymer coating to make the respective layers 510, 520 essentially impermeable to water or air. The first planar external layer 524 overlies a first end of the cavity 530 and forms a first cavity end wall 531 . The second planar external layer 525 overlies a second end of the cavity 530 and forms a second cavity end wall 532, the second cavity end wall 532 being opposite to the first cavity end wall 531 . That is, the frame 550, the first planar external layer 524 and the second planar external layer 525 collectively define the cavity 530.

[0186] The frame 550 has a hollow cuboid shape and is made from cardboard. The frame 550 defines an aperture extending through the height (also referred to as the thickness) of the frame 550 and the aperture at least partially forms the cavity 530 of the aerosol-generating article 500. The frame 550 comprises a peripheral wall 551 that circumscribes the cavity 530. The peripheral wall 551 includes a front wall 552 and a back wall 553. In more detail, the peripheral wall 551 is defined by an inner transverse surface 554 of the frame 550 and an outer transverse surface 555 of the frame 550. The inner transverse surface 554 of the peripheral wall 551 at least partially defines a perimeter of the cavity 530. The outer transverse surface 555 of the peripheral wall 551 at least partially defines a perimeter of the aerosol-generating article 500. The peripheral wall 551 has a radial thickness measured between the inner transverse surface 554 of the frame 550 and the outer transverse surface 555 of the frame 550 of about 5 millimetres.

[0187] As shown in figures 14 to 16, an aerosol-forming substrate 540 is positioned within the cavity 530. The aerosol-forming substrate 540 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. As shown, the aerosolforming substrate 540 fills the entire volume of the cavity 530.

[0188] The aerosol-generating article 500 has a cuboid shape and has a height (or thickness) extending in a z dimension, as measured between the first planar external surface 521 and the second planar external surface 522, of 8 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The frame 550 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The cavity 530 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 30 millimetres and a length extending in an x dimension of 50 millimetres. Figure 17 shows an aerosol-generating article 600 according to a sixth embodiment of the present disclosure, in an unbreached state. Features in common with aerosol-generating article 500 are referred to with like reference signs but commencing with numeral 6 instead of numeral 5. Aerosol-generating article 600 differs from aerosol-generating article 500 in that the aerosol-forming substrate is in the form of a sheet of aerosol-generating material 640, in particular a corrugated sheet of homogenised tobacco material. Figures 19 and 20 show respective transverse and lateral cross-section views of the aerosol-generating article 600 of figures 17 / 18.

[0189] As shown in figure 17, first and second score lines 61 1 , 612 are defined in the first planar external surface 621 of the first planar external layer 624. The score lines 61 1 , 612 only partially extend through the thickness of the first planar external layer 624, thereby maintaining a hermetic seal between the interior and exterior of the aerosol-generating article 600. Again, it will be appreciated that the score lines are optional and that in an alternative embodiment, no score lines may be present. The aerosol-generating article 600 of figure 17 is an unbreached state.

[0190] As shown in figure 18, breaching of the first planar external layer 624 around each of the circular score lines 61 1 , 612 results in first and second openings 614, 615 being defined through the first planar external layer. The breached state of the aerosol-generating article 600 illustrated in figure 18 is suitable for commencing a usage session using the article. The first and second openings 614, 615 define an air inlet and an air outlet respectively of the aerosol-generating article 600. Arrows in figure 18 indicate the path taken by air into the air inlet 614, along an air-flow path 617 defined through the interior of the aerosolgenerating article 600 and out of the air outlet 615.

[0191] The corrugated sheet of homogenised tobacco material 640 comprises a plurality of parallel corrugations having a plurality of substantially parallel peaks 643 and troughs 644. The plurality of parallel corrugations are defined by a corrugation profile which, as seen in figure 19, is sinusoidal. The plurality of parallel corrugations have a corrugation wavelength of about 4.6 millimetres. The corrugation amplitude is approximately the same as the height (or thickness) of the cavity 630, as shown by the peaks 643 and troughs 644 coinciding with the first cavity end wall 631 and the second cavity end wall 632, respectively.

[0192] The plurality of parallel corrugations form a plurality of channels 645 between the sheet of aerosolgenerating material 640 and the first cavity end wall 631 , and a plurality of channels 646 between the sheet of aerosol-generating material 640 and the second cavity end wall 632. The plurality of channels 645, 646 extend in a longitudinal direction of the aerosol-generating article 600. The air-flow path 617 defined by breaching of the first planar external layer 624 extends along one or more of the channels 645.

[0193] In an alternative embodiment to that of figure 17, third and fourth score lines (not shown) may be defined in the second planar external layer 625 to complement the first and second score lines 61 1 , 612 defined in the first planar external layer 624. Breaching of the third and fourth score lines in the second planar external layer 625 would provide third and fourth air openings (not shown) through the second layer. In this alternative embodiment, breaching of the first and second planar external layers 624, 625 at the locations of the score lines defined in both layers would provide an air-flow path passing over both sides of the sheet of aerosol-generating material 640.

[0194] During use of each of the aerosol-generating articles 500, 600, the aerosol-forming substrate 540, 640 is heated up to cause the aerosol-forming substrate 540, 640 to release volatile compounds, which are then entrained in air drawn through the air inlet 514, 614 into the cavity 530, 630. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the aerosol-generating article 500, 600 through the air outlet 515, 615.

[0195] Figure 21 shows an aerosol-generating article 700 according to a seventh embodiment of the present disclosure, in an unbreached state. The aerosol-generating article 700 shares features in common with the aerosol-generating article 500 illustrated in figure 13. In particular, the aerosol-generating article 700 comprises a first planar external layer 724 forming a first planar external surface 721 , a second planar external layer 725 forming a second planar external surface 722, and a frame 750 positioned between the first planar external layer 724 and the second planar external layer 725. The second planar external surface 722 is positioned parallel to the first planar external surface 721 . First and second score lines 71 1 , 712 are defined in the first planar external surface 721 of the first planar external layer 724. The frame 750 includes first and second cut-outs 756, 757, the first and second cut-outs positioned adjacent to and in flow communication with opposite ends of the cavity 730 defined by the frame 750. The cut-outs 756, 757 are each sized to house a capsule 760 containing one or more of a flavouring agent and an aerosol-forming substrate such that the capsule is snugly fitted in the respective cut-out. The first and second score lines 711 , 712 are located over the cut-outs. The capsules 760 are formed of a frangible material such that when the first and second score lines 71 1 , 712 are breached by a cutting tool, the cutting tool may also contact and fracture the capsule, thereby releasing the flavouring compound and / or aerosol-forming substrate. For example, the capsules 760 may be formed from a plastic material.

[0196] Figures 22 and 23 illustrate an aerosol-generating device 8000 configured for use with an aerosolgenerating article 800 comprising or consisting of aerosol-forming substrate 840. The device 8000 is an elongate aerosol-generating device extending between a proximal end 8001 and a distal end 8002. The device 8000 comprises a battery 8010, a controller 8020 and a heater 8030 located within a housing 8040. The controller 8020 controls supply of power from the battery 8010 to the heater 8030. A cavity 8050 is defined in the device 8000, the cavity having an opening 8051 defined in the proximal end 8001 of the device. The opening 8051 is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosol-generating article 800. The cavity 8050 comprises an upper planar surface 8052 and a lower planar surface 8053. The heater 8030 is located in the lower planar surface 8053 to heat a lower surface of the aerosol-generating article 800 inserted into the cavity 8050. An air-flow path is configured to allow air to flow into the cavity 8050 from outside the device 8000.

[0197] Figure 24 illustrates the device 8000 of figure 22 in engagement with the aerosol-generating article 800. There is little tolerance between outer surfaces of the aerosol-generating article 800 and the internal surfaces of the cavity 8050. Thus, there is a snug fit between the aerosol-generating article 800 and the device 8000. As the RTD of the aerosol-generating article 800 is negligible, the RTD of the system formed by the combination of aerosol-generating article 800 and aerosol-generating device 8000 is controlled by the air-flow path defined within the device. When a user has inserted the aerosol-generating article 800 into the cavity 8050, the device 8000 can be operated. The heater 8030 heats a lower surface of the aerosolgenerating article 800, and as a result the aerosol-forming substrate 840 of the aerosol-generating article 800 is heated. Volatile components of the aerosol-forming substrate 840 are evaporated and condense in longitudinal air-flow channels defined within the aerosol-generating article 800 to form an aerosol. The user inhales the aerosol by drawing on the proximal end 801 of the aerosol-generating article 800. Once the aerosol-generating substrate 840 of the aerosol-generating article 800 has been depleted of volatile components, the aerosol-generating article is removed from the cavity 8050 of the device 8000 and disposed of. The aerosol-generating article 800 may be any one of the aerosol-generating articles 100, 200, 300, 400, 500, 600, 700 previously described or any other aerosol-generating article of the present disclosure.

[0198] Although figure 24 shows part of the aerosol-generating article 800 extending outside of the aerosolgenerating device 8000, in other embodiments the entirety of an aerosol-generating article may be wholly enclosed within an aerosol-generating device. By way of example, figure 25 illustrates an alternative embodiment to that of figure 24, with like features referred to by the same reference numbers but with the addition of a prime symbol ’. For the alternative embodiment of figure 25, the entirety of aerosol-generating article 800’ is enclosed within the interior of aerosol-generating device 8000’.

[0199] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term “about”. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number “A” is understood as “A” ± 10% of “A”. Within this context, a number “A” may be considered to include numerical values that are within general standard error for the measurement of the property that the number “A” modifies. The number “A”, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which “A” deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. The terms “in which” and “wherein” are used synonymously through this specification.

Claims

CLAIMS1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol generating article comprising: an upper external surface; a lower external surface; and an aerosol-forming substrate hermetically isolated from an environment external to the aerosol-generating article; the aerosol-generating article defined by a length extending in an x-direction, a width extending in a y-direction, and a height extending in a z-direction, the upper and lower external surfaces opposed and separated from each other in the z direction, wherein the height is less than each of the width and the length.

2. An aerosol-generating article according to claim 1 , further comprising a cavity disposed between the upper external surface and the lower external surface.

3. An aerosol-generating article according to claim 2, further comprising a frame disposed between the upper external surface and the lower external surface, wherein the frame at least partially defines the cavity.

4. An aerosol-generating article according to any one of claims 1 to 3, wherein the aerosolgenerating article has an unbreached state in which the article is free of air openings defining an air-flow path through the aerosol-generating article.

5. An aerosol-generating article according to claim 4, wherein at least one of the upper and lower external surfaces comprise one or more predetermined regions configured to be breached to define one or more air openings therethrough in a breached state of the aerosol-generating article.

6. An aerosol-generating article according to claim 5, wherein in the breached state the one or more openings form part of an air-flow path through the aerosol-generating article, preferably the airflow path extending through a or the cavity disposed between the upper external surface and the lower external surface.

7. An aerosol-generating article according to either one of claim 5 or claim 6, wherein the one or more predetermined regions of the upper and / or lower external surfaces comprise weakening features, preferably wherein the weakening features comprise regions of localised thinning and / or score lines of the upper and / or lower external surfaces.

8. An aerosol-generating article according to any one of claims 5 to 7, wherein a first predetermined region of at least one of the upper and lower external surfaces is configured to be breached to define an air inlet opening of the aerosol-generating article; and a second predetermined region of at least one of the upper and lower external surfaces is configured to be breached to define an air outlet opening of the aerosol-generating article.

9. An aerosol-generating article according to claim 8, wherein the first and second predetermined regions are symmetrically located with respect to each other along a length direction of the aerosol-generating article.

10. An aerosol-generating article according to either one of claim 8 or claim 9, wherein the first and second predetermined regions are symmetrically located with respect to each other along a width direction of the aerosol-generating article.11 . An aerosol-generating article according to any one of claims 8 to 10, further comprising a frame disposed between the upper external surface and the lower external surface, wherein the frame at least partially defines a cavity, the frame comprising one or more cut outs positioned adjacent to the first and second predetermined regions of the upper and / or lower external surfaces, preferably wherein the one or more cut outs are in fluid communication with the cavity.

12. An aerosol-generating device according to claim 11 , wherein at least part of the aerosol-forming substrate is located within the one or more cut-outs.

13. An aerosol-generating article according to either one of claim 11 or claim 12, comprising one or more frangible capsules accommodated within the one or more cut outs.

14. An aerosol-generating article according to any one of claims 1 to 13, wherein the upper and lower external surfaces are substantially planar.

15. An aerosol-generating article according to any one of claims 1 to 13, wherein the upper and lower external surfaces are outwardly convex.

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