Frame for an aerosol-generating article and method of forming a frame

Abstract

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

Description

[0001] FRAME FOR AN AEROSOL-GENERATING ARTICLE AND METHOD OF FORMING A FRAME

[0002] The present disclosure relates to a frame of an aerosol-generating article. The present disclosure also relates to an aerosol-generating article comprising a frame. The present disclosure also relates to a method of manufacturing a frame of an aerosol-generating article. The present disclosure also relates to a method of manufacturing an aerosol-generating article having a frame.

[0003] A typical aerosol-generating system comprises an aerosol-generating device and an aerosol-generating article comprising an aerosol-generating substrate. In use, the aerosolgenerating device is arranged to heat a heating element that is positioned near, or in contact with, the aerosol-generating substrate which causes the aerosol-generating substrate to heat up and release volatile compounds. These volatile compounds are then entrained in air that is drawn through the aerosol-generating article. As the volatile compounds cool, they condense to form an aerosol that can be inhaled by a consumer.

[0004] A typical aerosol-generating article may appear similar and have similar dimensions to a conventional cigarette. For example, such an aerosol-generating article may be substantially cylindrical and comprise an aerosol-generating substrate in addition to other components such as mouthpiece filter element and a cooling element, which are arranged in the form of a rod and wrapped in a cigarette paper.

[0005] However, a significant portion of the aerosol-generating 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-generating substrate contributes to the cost of manufacture and transport of the aerosol-generating article but does not contribute to the aerosol delivered to the consumer. 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 axial alignment and wrapped in a cigarette paper. This can lead to increased cost and complexity of manufacture.

[0006] It is an objective of the present disclosure to provide an aerosol-generating article in which a greater portion of the aerosol-generating substrate 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.

[0007] According to the present disclosure, there is provided a frame for an aerosol-generating article. The frame may have a longitudinal axis. The frame may comprise at least one wall. The at least one wall may comprise a web of sheet material. The web of sheet material may have a length and a width. The width of the web of sheet material may extend substantially perpendicular to the longitudinal axis of the frame.

[0008] According to the present disclosure, there is provided a frame of an aerosol-generating article. The frame has a longitudinal axis. The frame comprises at least one wall comprising a web of sheet material. The web of sheet material has a length and a width, and the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame.

[0009] Advantageously, forming the frame for an aerosol-generating article from a web of sheet material having a length and a width, wherein the width extends substantially perpendicular to the longitudinal axis of the frame, may facilitate inexpensive and straightforward manufacturing of the frame of an aerosol-generating device, on a production line.

[0010] According to the present disclosure, there is provided a frame for an aerosol-generating article. The frame may comprise at least one wall. The at least one wall may comprise a web of sheet material arranged in a laminar structure. The laminar structure comprises a plurality of layers of the web of sheet material.

[0011] According to the present disclosure, there is provided a frame of an aerosol-generating article comprising at least one wall, the at least one wall comprising a web of sheet material arranged in a laminar structure. The laminar structure comprises a plurality of layers of the web of sheet material.

[0012] Advantageously, forming at least one wall of a frame of an aerosol-generating article from a sheet of web material arranged in a laminar structure comprising a plurality of layers of the web of sheet material may facilitate inexpensive and straightforward manufacture of a frame of an aerosolgenerating article, on a production line, the frame having at least one wall with increased thickness and structural rigidity due to the laminar structure comprising a plurality of layers of the web of sheet material.

[0013] According to the present disclosure, there is provided a frame of an aerosol-generating article. The frame has a longitudinal axis. The frame comprises at least one wall comprising a web of sheet material arranged in a laminar structure. The laminar structure comprises a plurality of layers of the web of sheet material. The web of sheet material has a length and a width, and the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame.

[0014] The laminar structure of the web of sheet material may be formed from overlapping layers of the web of sheet material. The laminar structure of the web of sheet material may be formed from layers of the web of sheet material overlapped on itself. The plurality of layers of the laminar structure of the web of sheet material may comprise any suitable number of layers. For example, the plurality of layers of the laminar structure may comprise at least two, three, four, five, or six layers of the web of sheet material.

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

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

[0017] The web of sheet material may have a length, a width, and a thickness. The length of the web extends along a longitudinal axis of the web. The web is typically elongate, having a length that is substantially larger than the width of the web and the thickness of the web. The length of the web may be at least 5 times greater than the width and the thickness of the web, or at least 10 times greater than the width and the thickness of the web. The length of the web may be, essentially, infinite compared to the other dimensions of the web. The width of the web may extend along a lateral axis, perpendicular to the longitudinal axis of the web. The thickness of the web may extend along a transverse axis, perpendicular to the longitudinal axis of the web, and perpendicular to the lateral axis of the web. The web is typically thin, having a thickness that is substantially smaller than the length of the web and the width of the web. The thickness of the web may be at least 5 times smaller than the length and the width of the web, or at least 10 times smaller than the length and the width of the web.

[0018] The web of sheet material may have any suitable thickness. The web of sheet material may have a thickness of at least 0.5 millimetres, or at least 1 .0 millimetres, or at least 1 .5 millimetres, or at least 2.0 millimetres, or at least 2.5 millimetres, or at least 3.0 millimetres, or at least 3.5 millimetres, or at least 4.0 millimetres, or at least 4.5 millimetres, or at least 5.0 millimetres. The web of sheet material may have a thickness of between 0.5 millimetres and 5.0 millimetres, or between 1.0 millimetres, and 4.5 millimetres, or between 1.5 millimetres and 4.0 millimetres. The web of sheet material may have a thickness of no more than 5.0 millimetres, or no more than 4.5 millimetres, or no more than 4.0 millimetres, or no more than 3.5 millimetres, or no more than 3.0 millimetres.

[0019] When the web of sheet material forms a frame of an aerosol-generating article according to embodiments of the disclosure, the width of the web of sheet material may define the height of the frame. In these embodiments, the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame. In these embodiments, the width of the web of sheet material is substantially the same as the height of the frame, and any frame aperture extending through the height of the frame. The web of sheet material may be made from or comprise any suitable material. The web of sheet material may be made from or comprise a biodegradable material. The web of sheet material may be made entirely from a biodegradable material. The web of sheet material may be made from or comprise a sheet of cellulosic material. The cellulosic material may comprise cellulose fibres. The cellulosic material may be paper, paperboard, or cardboard. The web of sheet material may be made from or comprise a plant material, such as tobacco. The web of sheet material may be made entirely from a cellulosic material.

[0020] The frame may have a length extending in an x-direction. The frame may have a width extending in a y-direction. The frame may have a height extending in a z-direction.

[0021] The frame may be a planar frame.

[0022] In some preferred embodiments, the frame defines a frame aperture. The frame aperture may be a through-passage extending through the height of the frame. The frame aperture may define at least a portion of the cavity of the aerosol-generating article. In some preferred embodiments, the frame aperture defines the cavity of the aerosol-generating article. For example, the frame may have a hollow cuboid shape or a square hollow tube shape. As a further example, the frame may have a cross-section that is annular in shape, preferably the cross-section in an x / y plane is annular in shape.

[0023] The frame may comprise at least one aperture extending through a wall of the frame. The at least one aperture extending through a wall of the frame may provide an air inlet into the cavity. The at least one aperture extending through a wall of the frame may provide an air outlet from the cavity. The at least one aperture extending through a wall of the frame may form a portion of the airflow passage of the aerosol-generating article.

[0024] The at least one wall of the frame comprising the web of sheet material arranged in a laminar structure may comprise a plurality of apertures extending through the web of sheet material. The plurality of apertures extending through the web of sheet material may be aligned. The plurality of apertures extending through the web of sheet material may be aligned to form an air inlet or an air outlet through the wall of the frame.

[0025] The frame may comprise a frame outer surface. The frame outer surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The frame outer surface may at least partially define or form one or more external surfaces of the aerosol-generating article. For example, the frame outer surface may at least partially define or form one or more external walls of the aerosol-generating article. The frame outer surface may circumscribe or encircle the frame aperture. The frame outer surface may circumscribe or encircle the cavity. The frame may comprise a frame inner surface. The frame inner surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The frame inner surface may define or form a frame aperture outer wall. The frame inner surface may define or form a cavity outer wall. The frame inner surface may circumscribe or encircle the frame aperture extending through the height of the frame. The frame inner surface may circumscribe or encircle the cavity.

[0026] The frame outer surface may circumscribe or encircle the frame inner surface. The frame inner surface and the frame outer surface may be concentric with one another.

[0027] The aerosol-generating article may comprise one or more external walls extending between the first planar external surface and the second planar external surface. The one or more external walls may collectively define an entire transverse external area of the aerosol-generating article. The frame may at least partially define each of the one or more external walls. The one or more external walls may circumscribe or encircle the cavity. The frame may define at least 60 percent, at least 70 percent, at least 80 percent, or at least 90 percent of the entire transverse external area of the aerosol-generating article.

[0028] The frame comprises at least one wall. The frame may comprise any suitable number of walls. The frame may comprise a single wall. The frame may comprise a plurality of walls.

[0029] The frame comprises at least one wall comprising the web of sheet material.

[0030] In some embodiments, the at least one wall of the frame comprises the web of sheet material extending substantially perpendicular to the longitudinal axis of the frame. Where the at least one wall comprises a single layer of the web of sheet material extending substantially perpendicular to the longitudinal axis of the frame, the thickness of the web of sheet material may form or define the thickness of the at least one wall. In these embodiments, the thickness of the web of sheet material may extend in the x / y plane of the frame.

[0031] In some embodiments, the at least one wall of the frame comprises the web of sheet material arranged in a laminar structure comprising a plurality of layers of the web of sheet material. In some of these embodiments the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame, and the thickness of the at least one wall may be formed or defined by the sum of the thicknesses of the plurality of layers of the web of sheet material.

[0032] The frame may comprise a peripheral wall. The peripheral wall may circumscribe or encircle at least a portion of the frame aperture. The peripheral wall may circumscribe or encircle at least a portion of the cavity. The peripheral wall may circumscribe or encircle the frame aperture extending through the height of the frame. The peripheral wall may circumscribe or encircle the cavity. The at least one wall comprising the web of sheet material may be or may comprise a peripheral wall of the frame. The peripheral wall may be defined or formed by the at least one wall comprising the web of sheet material. The peripheral wall by be defined or formed by the at least one wall comprising the web of sheet material, wherein the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame. The peripheral wall may be defined or formed by the at least one wall comprising the web of sheet material arranged in a laminar structure.

[0033] The peripheral wall may be defined or formed by the frame outer surface and the frame inner surface. The peripheral wall may at least partially define or form one or more external surfaces or walls of the aerosol-generating article. The peripheral wall may define or form a frame aperture outer wall. The peripheral wall may define or form a cavity outer wall.

[0034] The peripheral wall may have a radial thickness. The radial thickness may be defined as the minimum distance between the frame outer surface and the frame inner surface, such as in the x / y plane.

[0035] The peripheral wall may have a radial thickness greater than or equal to 0.5 millimetres. The peripheral wall may have a radial thickness greater than or equal to 1.5 millimetres. The peripheral wall may have a radial thickness greater than or equal to 2.5 millimetres.

[0036] The peripheral wall may have a radial thickness less than or equal to 3.5 millimetres. The peripheral wall may have a radial thickness less than or equal to 2.5 millimetres.

[0037] The peripheral wall may have a radial thickness between 0.5 millimetres and 3.5 millimetres. The peripheral wall may have a radial thickness between 0.5 millimetres and 2.5 millimetres.

[0038] Advantageously, the peripheral wall having a radial thickness between 0.5 millimetres and 3.5 millimetres has been found to provide good structural strength for the aerosol-generating article whilst not using excess amounts of material which may increase manufacturing costs, and may limit the amount of heat that is undesirably transferred to the frame rather than the aerosol-generating substrate.

[0039] The frame may comprise a front wall. The frame may comprise a back wall. The front wall and the back wall may be separated along the x-direction of the frame. The frame may comprise one or more side walls. The one or more side walls of the frame may extend between the front wall and the back wall of the frame. The frame may comprise a first side wall, and a second side wall, opposite the first side wall. The first side wall and the second side wall may be separated along the y-direction of the frame. The front wall, the back wall, and the one or more side walls may be peripheral walls of the frame. The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material. The web of sheet material may be made from or comprise a biodegradable material. The web of sheet material may be made entirely from a biodegradable material.

[0040] The frame may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The web of sheet material may be made from or 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. The web of sheet material may be made from or comprise a plant material, such as tobacco. The web of sheet material may be made entirely from a cellulosic material.

[0041] The aerosol-generating article may comprise one or more susceptor materials. The frame may comprise one or more susceptor materials. The one more susceptor materials may be in thermal contact with the aerosol-generating substrate. The one more susceptor materials may be in thermal contact with the cavity. The one or more susceptor materials may be incorporated within the material of the frame. For example, the one or more susceptor material may be incorporated within the peripheral wall of the frame.

[0042] The one or more susceptor materials may be one or more particles, strips, threads, or wires of susceptor material. The one or more susceptor materials may be one or more sheets or layers of susceptor material. The one of more sheets or layers of susceptor material may be in the form of a mesh of susceptor material.

[0043] The susceptor material, in whatever form, may comprise one or more materials selected from the list consisting of: aluminium, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0044] The frame may have a height greater than or equal to 50 percent of the height of the aerosol-generating article. The frame may have a height greater than or equal to 70 percent of the height of the aerosol-generating article. The frame may have a height greater than or equal to 90 percent of the height of the aerosol-generating article. The frame may have a height greater than or equal to 95 percent of the height of the aerosol-generating article.

[0045] The frame may have a height less than or equal to 95 percent of the height of the aerosolgenerating article. The frame may have a height less than or equal to 90 percent of the height of the aerosol-generating article. The frame may have a height less than or equal to 70 percent of the height of the aerosol-generating article.

[0046] The frame may have a height between 50 percent of the height of the aerosol-generating article and 95 percent of the height of the aerosol-generating article. The frame may have a height of between 70 percent of the height of the aerosol-generating article and 95 percent of the height of the aerosol-generating article.

[0047] The frame may have a height greater than or equal to 1 millimetre, greater than or equal to 2 millimetres, greater than or equal to 3 millimetres, or greater than or equal to 4 millimetres. The frame may have a height less than or equal to 5.5 millimetres, less than or equal to 4.5 millimetres, less than or equal to 3.5 millimetres, less than or equal to 2.5 millimetres, or less than or equal to 1 .5 millimetres. The frame may have a height between 1 millimetre and 5.5 millimetres. Preferably, the frame may have a height between 1.5 millimetres and 5.5 millimetres.

[0048] The frame may have a length that is equal to the length of the aerosol-generating article. The frame may have a length that is at least 90 percent of the length of the aerosol-generating article. The frame may have a length that is at least 95 percent of the length of the aerosolgenerating article.

[0049] The frame may have a width that is equal to the width of the aerosol-generating article. The frame may have a width that is at least 90 percent of the width of the aerosol-generating article.

[0050] 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 comprising layers having different compositions. Advantageously, the properties of each layer may be individually optimised depending on the relative distance between the layer and aerosol-generating substrate or heater of the aerosol-generating device.

[0051] The frame may comprise a first frame layer and a second frame layer. The first frame layer and the second frame layer may be the only layers of the frame. That is, the frame may comprise no more than two layers or may comprise exactly two layers. The frame aperture may be defined through both the first frame layer and the second frame layer.

[0052] The frame may comprise a first frame layer, a second frame layer and a third frame layer. The second frame layer may be positioned between the first frame layer and the third frame layer. The first frame layer, the second frame layer and the third frame layer may be the only layers of the frame. That is, the frame may comprise no more than three layers or may comprise exactly three layers.

[0053] According to the present disclosure, there is provided a method of manufacturing a frame for an aerosol-generating article. The method comprises providing a web of sheet material. The method further comprises overlapping the web of sheet material on itself to form a frame comprising at least one wall, the at least one wall having a laminar structure comprising a plurality of layers of the web of sheet material.

[0054] Advantageously, forming at least one wall of a frame of an aerosol-generating article by overlapping a sheet of web material onto itself to form a laminar structure comprising a plurality of layers of the web of sheet material may facilitate inexpensive and straightforward manufacture of a frame of an aerosol-generating article, on a production line, the frame having at least one wall with increased thickness and structural rigidity due to the laminar structure comprising a plurality of layers of the web of sheet material.

[0055] The formed frame may have longitudinal axis, wherein the web of sheet material has a length and a width, and wherein the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame. The formed frame may be elongate, having a length in the direction of the longitudinal axis that is greater than the other dimensions of the formed frame.

[0056] The at least one wall having a laminar structure may comprise any suitable number of layers. For example, the at least one wall may have at least two layers of the web of sheet material, or at least three layers of the web of sheet material. The formed frame may comprise one or more peripheral walls, the one or more peripheral walls being formed from the sheet of web material and having a laminar structure comprising at least two layers of the web of sheet material, or at least three layers of the web of sheet material.

[0057] In some embodiments, the overlapping of the web of sheet material may comprise winding the web of sheet material around a spindle. In some of these embodiments, the method further comprises removing the frame from the spindle. The method may comprise removing the frame from the spindle such that the formed frame comprises a frame aperture about which the web of sheet material is wound.

[0058] Advantageously, winding the web of sheet material around a spindle to form a frame, and removing the spindle to form a frame comprising a frame aperture in the space occupied by the spindle before the spindle was removed from the frame may further facilitate inexpensive and straightforward manufacture of a frame of an aerosol-generating article, on a production line, the frame having at least one wall with increased thickness and structural rigidity due to the laminar structure comprising a plurality of layers of the web of sheet material.

[0059] The spindle may have a longitudinal axis about which the web of sheet material is wound. The spindle may have a transverse cross-sectional shape, perpendicular to the longitudinal axis of the spindle. The transverse cross-sectional shape of the spindle may be at least one of: circular, non-circular, elliptical, stadium shaped, polygonal, triangular, rectangular, trapezoidal, pentagonal, or hexagonal. The transverse cross-sectional shape of the spindle may form the longitudinal cross- sectional shape of the frame aperture of the frame in the x / y plane of the frame. The transverse cross-sectional shape of the spindle may form the longitudinal cross-sectional shape of the cavity of the aerosol-generating article in the x / y plane of the aerosol-generating article. The spindle may have any suitable dimensions as described below for the cavity. In some embodiments, the overlapping the web of sheet material on itself to form a frame comprises compressing two or more of the overlapping layers of the web of sheet material together. Advantageously, compressing two or more of the overlapping layers of the web of sheet material together may further increase the structural rigidity of the at least one wall of the frame.

[0060] In some embodiments, the method comprises crimping a section of the web of sheet material to form a crimped section having corrugations. In some of these embodiments, the crimped portion of the web of sheet material is compressed to compress the corrugations of the crimped portion together. Advantageously, crimping a section of the web of sheet material to form a crimped sections, and particularly compressing the corrugations of the crimped portion together, may further increase the structural rigidity of the at least one wall of the frame.

[0061] In some embodiments, the method comprises applying adhesive to a surface the web of sheet material before the overlapping the web of sheet material on itself. The overlapping the web of sheet material on itself may comprise bringing the adhesive on a surface of the web of sheet material into contact with another surface of the web material.

[0062] Where the method comprises crimping a section of the web of sheet material to form a crimped sections, the applying the adhesive may comprise applying the adhesive to one or more of the corrugations of the crimped portion.

[0063] Where the method comprises compressing two or more of the overlapping layers of the web of sheet material together, the method may comprise compressing a surface the web of sheet material having adhesive applied into contact with another surface of the web material. Advantageously, compressing a surface the web of sheet material having adhesive applied to it into contact with another surface of the web material may improve the adhesion of the surface the web of sheet material having adhesive applied to it to the other surface of the web of sheet material.

[0064] The method may further comprise forming one or more apertures in the web of sheet material. The apertures may be formed in the web of sheet material in any suitable manner. For example, the one or more apertures may be punched or cut out of the web of sheet material.

[0065] The forming the one or more apertures may occur at any suitable time in the method. The forming the one or more apertures may comprise forming one or more apertures before the overlapping of the web of sheet material on itself. The forming the one or more apertures may comprise forming one or more apertures during the overlapping of the web of sheet material on itself. The forming the one or more apertures may comprise forming one or more apertures after the overlapping of the web of sheet material on itself.

[0066] Where the method comprises forming one or more apertures before overlapping of the web of sheet material on itself, the overlapping of the web of sheet material on itself may comprise aligning two or more of the apertures. The at least one wall of the frame having a laminar structure of the web of sheet material may comprise two or more aligned apertures. The two or more aligned apertures may form an air inlet of the aerosol-generating article. The two or more aligned apertures may form an air outlet of the aerosol-generating article.

[0067] Where the overlapping of the web of sheet material comprises winding the web of sheet material around a spindle, the winding the web of sheet material around a spindle may comprise aligning two or more of the apertures.

[0068] Where the overlapping of the web of sheet material comprises crimping a section of the web of sheet material to form a crimped sections, the forming one or more apertures in the web of sheet material may comprise forming apertures in two or more of the corrugations of a crimped section. The overlapping of the web of sheet material may further comprise aligning the apertures in the two or more of the corrugations of a crimped section.

[0069] Advantageously, forming one or more apertures before overlapping of the web of sheet material on itself, and aligning two or more of the apertures when overlapping of the web of sheet material on itself, may provide a reliable and inexpensive method of creating an air inlet and an air outlet in a relatively thick wall of the frame.

[0070] In some embodiments, the web of sheet material may be provided with preformed apertures. In these embodiments, the providing the web of sheet material comprises providing a web of sheet material having one or more preformed apertures.

[0071] In some embodiments, the method further comprises arranging one or more elements in or over one or more of the apertures. The one or more elements may comprises one or more of a filter element and a mesh. The filter element may comprise a cellulose acetate. The arranging one or more elements in one or more of the apertures may be performed before the overlapping of the web of sheet material on itself. The arranging one or more elements in one or more of the apertures may be performed after the overlapping of the web of sheet material on itself.

[0072] The formed frame may comprise one or more apertures at an outer surface, such as an air inlet and an air outlet. The method may comprise circumscribing the formed frame with an outer wrapper. The outer wrapper may cover an outer surface of the frame. The outer wrapper may cover one or more apertures at the outer surface of the frame. The outer wrapper may cover the air inlet and the air outlet of the frame. The outer wrapper may be removable from the frame. Advantageously, covering apertures, such as an air inlet and an air outlet, at an outer surface of the frame may help to protect an aerosol-forming substrate in a cavity of the aerosol-generating article.

[0073] In some embodiments, the outer wrapper comprises a section of the web of sheet material. In some embodiments, the formed frame, and the outer wrapper are connected at a weakened region of the web of sheet material. Advantageously, the weakened region of the web of sheet material may enable the outer wrapper to be easily disconnected or removed from the frame by a user when the outer wrapper is removed before use of the aerosol-generating article. The weakened region may be weakened by any suitable means. For example, the weakened region may comprise a region or a line of perforations. For example, the weakened region may comprise a region or a line with a reduced thickness. The weakened region may be weakened by cutting, scoring, or punching, using a blade, or a laser, or a punch, or any other suitable means of forming holes, or perforations, or regions of reduced thickness.

[0074] The method may further comprise applying, forming, or providing an indicia or taggant on a surface of the web of sheet material. The indicia or taggant may be arranged on an outer surface of the frame when the frame is formed. Advantageously, providing an indicia or taggant on a surface of the web of sheet material may be a straightforward way of providing an indicia or taggant on a surface of the aerosol-generating article. An indicia or taggant on a surface of the aerosolgenerating article may, advantageously, provide a reliable means of identifying the aerosolgenerating article. An indicia or taggant on a surface of the aerosol-generating article may provide a reliable means of authenticating an aerosol-generating article, to help identify counterfeit aerosolgenerating articles originating from an unauthorized source. In some embodiments, the applying, forming, or providing the indicia or taggant on a surface of the web of sheet material may comprise applying, forming, or providing the indicia or taggant on a surface of the web of sheet material that forms an outer surface of the frame, and preferably an outer surface of the aerosol-generating article

[0075] In some embodiments, the overlapping the web of sheet material on itself comprises overlapping different numbers of layers of the web of sheet material at different sections of the frame. For example, the frame may comprise a wall having a first section having a laminar structure comprising a first number of layers of the web of sheet material, and a second section having a laminar structure comprising a second number of layers of the web of sheet material, the second number being different from the first number. Advantageously, varying the number of layers of the web of sheet material forming different sections of walls of the frame may enable the structure of the frame to be varied to optimise the frame strength where needed, and to minimise the cost and materials used in the frame. For example, sections of the frame that require additional strength or rigidity may be provided with a greater number of layers of the web of sheet material compared to other sections of the frame.

[0076] In some embodiments, the formed frame comprises a frame aperture configured to receive an aerosol-forming substrate. In some embodiments, the formed frame comprises a plurality of frame apertures. Where the formed frame comprises a plurality of frame apertures, each frame aperture one or more of the frame apertures may be configured to receive an aerosol-forming substrate. In some embodiments, the providing a web of sheet material comprises providing a first web of a first sheet material and providing a second web of a second sheet material. The second sheet material may be different from the first sheet material. The second sheet material may be the same as the first sheet material.

[0077] In some of these embodiments, the overlapping the web of sheet material on itself comprises overlapping the first web of the first sheet material on itself and overlapping the second web of the second sheet material on itself to form a frame comprising at least a first wall having a laminar structure, the laminar structure comprising a plurality of layers of the first web of the first sheet material, and the frame comprising at least a second wall having a laminar structure, the laminar structure comprising a plurality of layers of the second web of the second sheet material.

[0078] In some of these embodiments, the method further comprises overlapping the first web of the first sheet material with the second web of the second sheet material to form a combined web of sheet material, and the overlapping the web of sheet material on itself comprises overlapping the combined web of sheet material on itself.

[0079] Advantageously, providing a first web of a first sheet material and a second web of a second sheet material, and forming the frame from both the first sheet material and the second sheet material may enable the frame to benefit from different properties of the first sheet material and the second sheet material.

[0080] According to the present disclosure, there is provided a frame of an aerosol-generating article formed by a method as described above.

[0081] According to the present disclosure, there is provided a method of manufacturing an aerosol-generating article, the method comprising forming a frame for an aerosol-generating article as described above.

[0082] The method of manufacturing an aerosol-generating article may further comprise: providing a first sheet of external layer material, and a second sheet of external layer material; positioning the formed frame between the first sheet of external layer material, and the second sheet of external layer material; and bonding the first sheet of external layer material, and the second sheet of external layer material to the formed frame.

[0083] The bonding the first sheet of external layer material, and the second sheet of external layer material to the formed frame may be achieved by any suitable bonding means. In some preferred embodiments, an adhesive is applied to one of the frame and the first sheet of external layer material and the second sheet of external layer material.

[0084] The method of manufacturing an aerosol-generating article may further comprise inserting an aerosol-generating material into a cavity of the aerosol-generating article, the cavity being formed at least partially by a frame aperture of the frame. The method of manufacturing an aerosol-generating article may further comprise: providing a first sheet of external layer material, and a second sheet of external layer material; providing a first sheet of aerosol-generating material, and a second sheet of aerosol-generating material; positioning the formed frame between the first sheet of aerosol-generating material, and the second sheet of aerosol-generating material; positioning the formed frame, the first sheet of aerosolgenerating material, and the second sheet of aerosol-generating material between the first sheet of external layer material, and the second sheet of external layer material; and bonding one or more of the sheet material to the formed frame.

[0085] According to the present disclosure, there is provided an aerosol-generating article comprising a frame as described above. According to the present disclosure, there is provided an aerosol-generating article comprising a frame formed by a method as described above. The aerosol-generating article may comprise one or more aerosol-generating substrates. The aerosolgenerating article may comprise one or more aerosol-generating substrates.

[0086] According to the present disclosure, there is provided an aerosol-generating article. The aerosol-generating article is for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article comprises one or more aerosol-generating substrates. The aerosolgenerating article comprises a cavity. The aerosol-generating article comprises an air inlet and an air outlet. The aerosol-generating article comprises an airflow passage extending between the air inlet and the air outlet through the cavity. The aerosol-generating article comprises a first planar external surface. The aerosol-generating article comprises a second planar external surface. The aerosol-generating article comprises a frame as described above. The frame is positioned between the first planar external surface and the second planar external surface. The frame at least partially defines the cavity.

[0087] Advantageously, the frame may allow the aerosol-generating article to be relatively thin while maintaining structural rigidity.

[0088] Advantageously, the first planar external surface and the second planar external surface allow for good contact with an external heater, particularly an external heater, of an aerosolgenerating device, thereby providing optimum heating of the aerosol-generating substrate.

[0089] Advantageously, aerosol-generating articles of the present disclosure may be heated along substantially their entire length and width, thereby allowing the entire aerosol-generating substrate to be sufficiently heated to generate an aerosol.

[0090] Advantageously, aerosol-generating articles of the present disclosure may be manufactured by layering sheet materials which can be achieved through a continuous manufacturing process, thereby resulting in an aerosol-generating article that is relatively easy and cheap to manufacture. The aerosol-generating article may have a length extending in an x-direction. The aerosolgenerating article may have a width extending in a y-direction. The aerosol-generating article may have a height extending in a z-direction.

[0091] The aerosol-generating article may be a substantially flat aerosol-generating article or a substantially planar aerosol-generating article. In particular, a height of the aerosol-generating article may be less than 50 percent of both a length and a width of the aerosol-generating article. Advantageously, a smaller height may provide a small temperature gradient or difference across the height of the aerosol-generating substrate during heating.

[0092] The aerosol-generating article may have any suitable shape. The aerosol-generating article may have a quadrilaterally-faced hexahedron shape. The aerosol-generating article may have a rectangular prism shape. The aerosol-generating article may have a cuboid shape. The aerosolgenerating article may have a cylindrical shape. The aerosol-generating article may have a right- angled cylinder shape.

[0093] The aerosol-generating article may have a laminated structure, for example the aerosolgenerating article may comprise or be formed from at least two layers. In particular, the aerosolgenerating article may comprise a frame and at least one of: a first external layer, a second external layer, a first aerosol-generating substrate layer, and a second aerosol-generating substrate layer, as discussed in more detail below.

[0094] Substantially the entirety of the aerosol-generating article, excluding the one or more aerosol-generating substrates and (if present) adhesive, may be paper or cardboard.

[0095] The aerosol-generating article may have a cellulose acetate content of less than 5 percent. The aerosol-generating article may have a cellulose acetate content of less than 3 percent. The aerosol-generating article may have a cellulose acetate content of less than 1 percent.

[0096] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate layer. Advantageously, the aerosol-generating substrate layer can be made thin and, therefore, quickly heat up and release volatile compounds to form an aerosol. Advantageously, the aerosol-generating substrate layer can be positioned close to a heater of an aerosol-generating device.

[0097] The aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. The aerosol-generating substrate layer may be, and may be made entirely of, a sheet of aerosol-generating material. The aerosol-generating substrate layer may be positioned between the frame and the first planar external surface. The aerosol-generating substrate layer may be positioned between the frame and the second planar external surface. The aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame.

[0098] The aerosol-generating substrate layer may be positioned between the frame and an outer wrapper. The outer wrapper is discussed in more detail below. The aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the outer wrapper.

[0099] The aerosol-generating substrate layer may be positioned between the frame and the first planar external layer. The aerosol-generating substrate layer may be positioned between the frame and the second planar external layer. The first planar external layer and the second planar external layer are discussed in more detail below. The aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the first planar external layer. The aerosolgenerating substrate layer may in physical contact with, and may be bonded to, both the frame and the second planar external layer.

[0100] The aerosol-generating substrate layer may overlie an end of the cavity. The aerosolgenerating substrate layer may define or form a wall of the cavity, such as the first cavity end wall or the second cavity end wall. Advantageously, the aerosol-generating substrate layer may therefore be in, or at least partially define or form, the airflow passage thereby allowing released volatile compounds to quickly form an aerosol.

[0101] The one or more aerosol-generating substrates may comprise a first aerosol-generating substrate layer and a second aerosol-generating substrate layer. Advantageously, a first and a second aerosol-generating substrate layer may allow rapid generation of a satisfactory volume of aerosol compared with using a single aerosol-generating substrate layer.

[0102] The first aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. The first aerosol-generating substrate layer may be, and may be made entirely of, a sheet of aerosol-generating material.

[0103] The second aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. The second aerosol-generating substrate layer may be, and may be made entirely of, a sheet of aerosol-generating material. The first aerosol-generating substrate layer may be positioned between the frame and the first planar external surface. The first aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame.

[0104] The first aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The first aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the outer wrapper.

[0105] The first aerosol-generating substrate layer may be positioned between the frame and the first planar external layer. The first aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the first planar external layer.

[0106] The second aerosol-generating substrate layer may be positioned between the frame and the second planar external surface. The second aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame.

[0107] The second aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The second aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the outer wrapper.

[0108] The second aerosol-generating substrate layer may be positioned between the frame and the second planar external layer. The second aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the second planar external layer.

[0109] The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may overlie opposing ends of the cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may define or form opposing end walls of the cavity. That is, the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may collectively define the cavity.

[0110] One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 100 micrometres, greater than or equal to 200 micrometres, greater than or equal to 300 micrometres, greater than or equal to 400 micrometres, or greater than or equal to 500 micrometres.

[0111] One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness less than or equal to 600 micrometres, less than or equal to 500 micrometres, less than or equal to 400 micrometres, less than or equal to 300 micrometres, or less than or equal to 300 micrometres.

[0112] One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness between 100 micrometres and 600 micrometres, between 200 micrometres and 500 micrometres, between 200 micrometres and 400 micrometres, or between 200 micrometres and 300 micrometres.

[0113] The aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article.

[0114] The first aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The first aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article.

[0115] The second aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The second aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article.

[0116] The aerosol-generating substrate layer may have a width substantially the same as the width of the frame. The aerosol-generating substrate layer may have a width substantially the same as the width of the aerosol-generating article.

[0117] The first aerosol-generating substrate layer may have a width substantially the same as the width of the frame. The first aerosol-generating substrate layer may have a width substantially the same as the width of the aerosol-generating article.

[0118] The second aerosol-generating substrate layer may have a width substantially the same as the width of the frame. The second aerosol-generating substrate layer may have a width substantially the same as the width of the aerosol-generating article.

[0119] The first planar external surface may be a planar upper surface and the second planar external surface may be a planar lower surface. The first planar external surface may be positioned parallel to the second planar external surface. The first planar external surface may extend in the x / y plane. The second planar external surface may extend in the x / y plane. The second planar external surface may be spaced from the first planar external surface in the z- direction or transverse direction. The distance between the first planar external surface and the second planar external surface in the z-direction or transverse direction may define the height of the aerosol-generating article.

[0120] The aerosol-generating article may comprise an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may comprise a hydrophobic material.

[0121] The outer wrapper may define or form the first planar external surface. The outer wrapper may define or form the second planar external surface. The outer wrapper may define or form both the first planar external surface and the second planar external surface.

[0122] The outer wrapper may circumscribe or encircle the frame. The outer wrapper may be in physical contact with, and may be bonded to, the frame. The outer wrapper may overlie opposing ends of the cavity. The outer wrapper may define or form opposing end walls of the cavity, such as the first cavity end wall and the second cavity end wall. That is, the frame and the outer wrapper may collectively define the cavity.

[0123] The outer wrapper may circumscribe or encircle the frame and the aerosol-generating substrate layer. The outer wrapper may be in physical contact with, and may be bonded to, both the frame and the aerosol-generating substrate layer.

[0124] The outer wrapper may circumscribe or encircle the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer. The outer wrapper may be in physical contact with, and may be bonded to, both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer.

[0125] The aerosol-generating article may comprise a first planar external layer and a second planar external layer. The first planar external layer may be an upper layer and the second planar external layer may be a lower layer.

[0126] The first planar external layer may define or form the first planar external surface. The first planar external layer may extend in the x / y plane. The second planar external layer may define or form the second planar external surface. The second planar external layer may extend in the x / y plane.

[0127] The first planar external layer may be in physical contact with, and may be bonded to, the frame. The first planar external layer may overlie an end of the cavity. The first planar external layer may define or form a wall of the cavity, such as the first cavity end wall.

[0128] The second planar external layer may be in physical contact with, and may be bonded to, the frame. The second planar external layer may overlie an end of the cavity. The second planar external layer may define or form a wall of the cavity, such as the second cavity end wall.

[0129] The first planar external layer and the second planar external layer may overlie opposing ends of the cavity. The first planar external layer and the second planar external layer may define or form opposing end walls of the cavity, such as the first cavity end wall and the second cavity end wall. That is, the frame, the first planar external layer and the second planar external layer may collectively define the cavity.

[0130] The first planar external layer may be spaced, such as in a transverse direction, from the frame. For example, the aerosol-generating substrate layer or the first aerosol-generating substrate layer may be positioned between the first planar external layer and the frame. The first planar external layer may be in physical contact with, and may be bonded to, the aerosolgenerating substrate layer or the first aerosol-generating substrate layer.

[0131] The second planar external layer may be spaced, such as in a transverse direction, from the frame. For example, the aerosol-generating substrate layer or the second aerosol-generating substrate layer may be positioned between the second planar external layer and the frame. The second planar external layer may be in physical contact with, and may be bonded to, the aerosolgenerating substrate layer or the second aerosol-generating substrate layer.

[0132] The first planar external layer may be hydrophobic. The first planar external layer may comprise a hydrophobic material. The second planar external layer may be hydrophobic. The second planar external layer may comprise a hydrophobic material.

[0133] One or more of the outer wrapper, the first planar external layer and the second planar external layer may comprise, or be made from, a cellulosic material. The cellulosic material may be paper, cigarette paper, tobacco paper, cardboard, wood, textile, natural fibres, or artificial fibres.

[0134] One or more of the outer wrapper, the first planar external layer and the second planar external layer may be an aerosol-generating substrate comprising an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. In particular, the aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. Alternatively, one or more of the outer wrapper, the first planar external layer and the second planar external layer may not comprise any aerosol-generating material, particularly in embodiments comprising an aerosol-generating substrate layer, a first aerosolgenerating substrate layer, a second aerosol-generating substrate layer or an aerosol-generating substrate positioned within the cavity. One or more of the outer wrapper, the first planar external layer and the second planar external layer may be substantially nicotine-free.

[0135] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness greater than or equal to 25 micrometres, greater than or equal to 30 micrometres, greater than or equal to 35 micrometres, greater than or equal to 40 micrometres, or greater than or equal to 45 micrometres.

[0136] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness less than or equal to 55 micrometres, less than or equal to 50 micrometres, less than or equal to 45 micrometres, less than or equal to 40 micrometres, or less than or equal to 35 micrometres.

[0137] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness between 25 micrometres and 55 micrometres, between 25 micrometres and 45 micrometres, or between 30 micrometres and 45 micrometres.

[0138] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a length substantially the same as the length of the frame. One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a length substantially the same as the length of the aerosol-generating article. One or more of the first planar external layer and the second planar external layer may have a width substantially the same as the width of the frame. One or more of the first planar external layer and the second planar external layer may have a width substantially the same as the width of the aerosol-generating article.

[0139] The cavity may have a height greater than or equal to 0.5 millimetres. The cavity may have a height greater than or equal to 1 .5 millimetres. The cavity may have a height greater than or equal to 2.5 millimetres. The cavity may have a height greater than or equal to 3.5 millimetres.

[0140] The cavity may have a height less than or equal to 4.5 millimetres. The cavity may have a height less than or equal to 3.5 millimetres. The cavity may have a height less than or equal to 2.5 millimetres. The cavity may have a height less than or equal to 1 .5 millimetres.

[0141] The cavity may have a height between 0.5 millimetres and 4.5 millimetres. The cavity may have a height between 1 millimetre and 4.5 millimetres. Preferably, the cavity may have a height between 2.8 millimetres and 3.3 millimetres.

[0142] The cavity may have a length greater than or equal to 14 millimetres. The cavity may have a length equal to a greater than 18 millimetres. The cavity may have a length greater than or equal to 22 millimetres. The cavity may have a length greater than or equal to 30 millimetres. The cavity may have a length greater than or equal to 38 millimetres.

[0143] The cavity may have a length less than or equal to 40 millimetres. The cavity may have a length less than or equal to 34 millimetres. The cavity may have a length less than or equal to 28 millimetres. The cavity may have a length less than or equal to 22 millimetres. The cavity may have a length less than or equal to 18 millimetres.

[0144] The cavity may have a length between 14 millimetres and 40 millimetres. The cavity may have a length between 14 millimetres and 34 millimetres. The cavity may have a length between 24 millimetres and 28 millimetres.

[0145] The cavity may have a width greater than or equal to 4.5 millimetres. The cavity may have a width greater than or equal to 7 millimetres. The cavity may have a width greater than or equal to 11 millimetres.

[0146] The cavity may have a width less than or equal to 13 millimetres. The cavity may have a width less than or equal to 11 millimetres. The cavity may have a width less than or equal to 7 millimetres. The cavity may have a width less than or equal to 5 millimetres.

[0147] The cavity may have a width between 4.5 millimetres and 13 millimetres. The cavity may have a width between 7 millimetres and 10 millimetres. The cavity may have a width between 7.5 millimetres and 8.5 millimetres.

[0148] The cavity may have a length between 14 millimetres and 40 millimetres, a width between 4.5 millimetres and 13 millimetres, and a height between 0.5 millimetres and 4.5 millimetres. Preferably, the cavity may have a length between 20 millimetres and 30 millimetres, a width between 7 millimetres and 10 millimetres, and a height between 2.5 millimetres and 4 millimetres.

[0149] Most preferably, the cavity may have a length of 26 millimetres, a width of 8 millimetres, and a height of 3.1 millimetres.

[0150] The cavity may have a volume of greater than or equal to 30 cubic millimetres, greater than or equal to 100 cubic millimetres, greater than or equal to 300 cubic millimetres, greater than or equal to 500 cubic millimetres, greater than or equal to 700 cubic millimetres, greater than or equal to 900 cubic millimetres, greater than or equal to 1000 cubic millimetres, greater than or equal to 2000 cubic millimetres, or greater than or equal to 30 cubic millimetres.

[0151] The cavity may have a volume of less than or equal to 3500 cubic millimetres, less than or equal to 2500 cubic millimetres, less than or equal to 1500 cubic millimetres, less than or equal to 1000 cubic millimetres, less than or equal to 800 cubic millimetres, less than or equal to 600 cubic millimetres, less than or equal to 500 cubic millimetres, less than or equal to 400 cubic millimetres, or less than or equal to 300 cubic millimetres.

[0152] The cavity may have a volume between 30 cubic millimetres and 3500 cubic millimetres. The cavity may have a volume between 30 cubic millimetres and 2500 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 1500 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 1000 cubic millimetres.

[0153] The cavity may be substantially empty.

[0154] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate positioned within the cavity. The aerosol-generating substrate positioned within the cavity may fill the cavity.

[0155] The aerosol-generating substrate positioned within the cavity may comprise an aerosolgenerating material. The aerosol-generating material may be any aerosol-generating material described herein. For example, the aerosol-generating material may be in the form of shredded aerosol-generating material.

[0156] The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. For example, the sheet of aerosol-generating material may be a sheet of homogenised tobacco material.

[0157] The sheet of aerosol-generating material may extend the entire length of the cavity. The sheet of aerosol-generating material may extend the entire width of the cavity.

[0158] The sheet of aerosol-generating material may be a gathered sheet of aerosol-generating material. That is, the sheet of aerosol-generating material may be convoluted, folded, or otherwise compressed or constricted substantially perpendicular to the transverse direction of the aerosolgenerating article.

[0159] The sheet of aerosol-generating material may be a crimped sheet of aerosol-generating material. The sheet of aerosol-generating material may be a corrugated sheet of aerosolgenerating material. The crimped sheet of aerosol-generating material or the corrugated sheet of aerosol-generating material may comprise a plurality of parallel corrugations. For example, the crimped sheet of aerosol-generating material may comprise a plurality of substantially parallel peaks and troughs.

[0160] The plurality of parallel corrugations may be defined by a corrugation profile, in which the corrugation profile is sinusoidal, or triangular, or rectangular, or trapezoidal, or toroidal, or parabolic.

[0161] The plurality of parallel corrugations may define, or form, a plurality of channels between the sheet of aerosol-generating material and one or more walls of the cavity. The plurality of channels may be a plurality of longitudinally extending channels. The plurality of channels may be a plurality of laterally extending channels. The plurality of channels may defined, or form, at least a portion of the airflow passage extending between the air inlet and air outlet of the aerosol-generating article.

[0162] The aerosol-generating material may comprise one or more organic materials such as tobacco, mint, tea, and cloves. The aerosol-generating material 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.

[0163] The aerosol-generating material 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 aerosol-generating 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.

[0164] The aerosol-generating material may be cut filler. The aerosol-generating material may be tobacco cut filler. As used herein, the term “cut filler” is used to describe to 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.

[0165] The aerosol-generating material 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. The aerosol-generating material may comprise one or more aerosol-formers. Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosolformers 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 aerosolformer 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.

[0166] The aerosol-generating material 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-generating material may have an aerosol-former 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.

[0167] The aerosol-generating material 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.

[0168] The aerosol-generating material may have an aerosol-former content between 5 percent and 30 percent by weight on a dry weight basis, between 5 percent and 25 percent by weight on a dry weight basis, or between 5 percent and 20 percent by weight on a dry weight basis.

[0169] The aerosol-generating material may have an aerosol-former content between 10 percent and 30 percent by weight on a dry weight basis, between 10 percent and 25 percent by weight on a dry weight basis, or between 10 percent and 20 percent by weight on a dry weight basis. The aerosol-generating material may comprise nicotine. The aerosol-generating material may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0170] 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.

[0171] 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.

[0172] 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. The aerosol-generating material 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. That is, the aerosol-generating material may have a nicotine content of at least 0.5 percent by weight, at least 1 percent by weight, at least 1 .5 percent by weight, or at least 2 percent by weight.

[0173] The aerosol-generating material may be in the form of a plurality of beads. The plurality of beads may have an average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm.

[0174] The term “bead” refers to a discrete, solid particle formed of the aerosol-generating substrate. A bead may have a rounded, typically spherical, form. Other terms may be used to define the substrate such as, for example, “granule”.

[0175] Providing the aerosol-generating material as a plurality of beads may provide certain advantages. Beads can be easily handled compared to other aerosol-forming substrates such as fine powders or cut filler. The beads flow easily, and so can reliably and consistently fill the cavity of the aerosol-generating article during manufacture. This may allow a consistent and reproducible amount of aerosol-forming substrate to be loaded into each article during manufacture. Beads may also be cleaner to handle than powders and cut fillers, which may cause dust in factories, and may leak from aerosol-generating articles in transit or in use. By selecting beads with appropriate bead sizes and appropriate particle size distributions, air flow through the cavity of the aerosol-generating article may be controlled more reproducibly than would be the case for, say, a cut filler substrate. Where a particle is not perfectly spherical, but a diameter of the particle is referred to, the term “diameter” may refer to a largest dimension of the particle. Alternatively, the term “diameter” may refer to the diameter of a perfectly spherical particle having the same volume as the not perfectly spherical particle.

[0176] The term “average particle diameter”, as used herein, may refer to a number average particle diameter. Other methods of determining average particle diameter are known. Thus, the average particle diameter may be, for example, a volume average particle diameter.

[0177] The aerosol-generating material may be in form of a wrapped body of aerosol-generating material, the wrapped body comprising a wrapper at least partially enclosing aerosol-generating material.

[0178] The wrapped body of aerosol-generating material may occupy between 15% and 100% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 30% and 100% of the interior volume of the cavity. The wrapped body of aerosolgenerating material may occupy between 50% and 100% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 50% and 80% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 50% and 70% of the interior volume of the cavity.

[0179] The air inlet may be defined by a peripheral wall of the aerosol-generating article. The air inlet may be defined by a front wall of the aerosol-generating article. The air inlet may be defined by the frame. The air inlet may extend through frame. The air inlet may be defined by a wall of the frame. The air inlet may extend through a wall of the frame. The air outlet may extend through a peripheral wall of the frame. The air inlet may be defined by a peripheral wall of the frame. The air inlet may extend through the peripheral wall of the frame. The air inlet may be defined by the at least one wall of the frame comprising the web of sheet material, wherein the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame. The air inlet may be defined by the at least one wall of the frame comprising the web of sheet material arranged in a laminar structure. The web of sheet material may comprise a plurality of apertures, and the air inlet may be defined by a plurality of the plurality of apertures in the web of sheet material. The web of sheet material may comprise a plurality of apertures, and the air inlet may be formed by a plurality of the plurality of apertures in the web of sheet material.

[0180] The air outlet may be defined by a peripheral wall of the aerosol-generating article. The air outlet may be defined by a back wall of the aerosol-generating article. The air outlet may be defined by the frame. The air outlet may extend through the frame. The air outlet may be defined by a wall of the frame. The air outlet may extend through a wall of the frame. The air outlet may be defined by a peripheral wall of the frame. The air outlet may extend though a peripheral wall of the frame. The air outlet may be defined by the at least one wall of the frame comprising the web of sheet material, wherein the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame. The air outlet may be defined by the at least one wall of the frame comprising the web of sheet material arranged in a laminar structure. The web of sheet material may comprise a plurality of apertures, and the air outlet may be defined by a plurality of the plurality of apertures in the web of sheet material. The web of sheet material may comprise a plurality of apertures, and the air outlet may be formed by a plurality of the plurality of apertures in the web of sheet material.

[0181] The air inlet may have a round cross-section, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section. The air outlet may have a round crosssection, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section.

[0182] The air inlet may be defined by, and may extend through, the first planar external surface. The air inlet may be defined by, and may extend through, the outer wrapper. The air inlet may be defined by, and may extend through, the outer wrapper and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the outer wrapper and the first aerosolgenerating substrate layer. The air inlet may be defined by, and may extend through, the first planar external layer and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the first planar external layer and the first aerosol-generating substrate layer.

[0183] The air inlet may be defined by, and may extend through, the second planar external surface. The air inlet may be defined by, and may extend through, the outer wrapper and the second aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the second planar external layer and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the second planar external layer and the second aerosol-generating substrate layer.

[0184] The air outlet may be defined by, and may extend through, the first planar external surface. The air outlet may be defined by, and may extend through, the outer wrapper. The air outlet may be defined by, and may extend through, the outer wrapper and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the outer wrapper and the first aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the first planar external layer and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the first planar external layer and the first aerosol-generating substrate layer.

[0185] The air outlet may be defined by, and may extend through, the second planar external surface. The air outlet may be defined by, and may extend through, the outer wrapper and the second aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the second planar external layer and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the second planar external layer and the second aerosol-generating substrate layer.

[0186] One or both of the air inlet and the air outlet may have an equivalent diameter greater than or equal to 0.1 millimetres, greater than or equal to 0.4 millimetres, greater than or equal to 0.7 millimetres, or greater than or equal to 1 .0 millimetres.

[0187] One or both of the air inlet and the air outlet may have an equivalent diameter less than or equal to 3 millimetres, less than or equal to 2.7 millimetres, less than or equal to 2.4 millimetres, less than or equal to 2.1 millimetres. The air inlet may have an equivalent diameter less than or equal to 2.7 millimetres, less than or equal to 1 .8 millimetres, or less than or equal to 1 .5 millimetres.

[0188] One or both of the air inlet and the air outlet may have an equivalent diameter between 0.1 millimetres and 3 millimetres, between 0.1 millimetres and 2.4 millimetres, between 0.4 millimetres and 2.1 millimetres, between 0.4 millimetres and 1.8 millimetres, between 0.7 millimetres and 1.5 millimetres, or between 1.0 millimetres and 1.5 millimetres.

[0189] The air inlet may have a width less than a width of the cavity. The air outlet may have a width less than a width of the cavity. The air inlet may have a height less than a height of the cavity. The air outlet may have a height less than a height of the cavity.

[0190] One or both of the air inlet and the air outlet may a width of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres.

[0191] One or both of the air inlet and the air outlet may have a height of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres.

[0192] Preferably, the air inlet may have a width of between 0.3 millimetres and 3 millimetres, and a height of between 0.3 millimetres and 3 millimetres.

[0193] Preferably, the air outlet may have a width of between 0.3 millimetres and 3 millimetres, and a height of between 0.3 millimetres and 3 millimetres.

[0194] Advantageously, an aerosol-generating article having an air outlet or air inlet with a width of between 0.3 millimetres and 3 millimetres, and a height of between 0.3 millimetres and 3 millimetres may provide for a relatively large inlet or outlet opening while allowing for improved retention of the aerosol-generating substrate within the aerosol-generating article. Improved retention of the aerosol-generating substrate within the aerosol-generating article may reduce the risk of aerosol-generating substrate falling out of the aerosol-generating article.

[0195] A ratio of the width of the air inlet to the height of the air inlet may be between 0.33 and 3. A ratio of the width of the air inlet to the height of the air inlet may be between 0.5 and 1 .5. A ratio of the width of the air inlet to the height of the air inlet may be between 0.75 and 1 .25.

[0196] A ratio of the width of the air outlet to the height of the air outlet may be between 0.33 and 3. A ratio of the width of the air outlet to the height of the air outlet may be between 0.5 and 1 .5. A ratio of the width of the air outlet to the height of the air outlet may be between 0.75 and 1 .25.

[0197] The aerosol-generating article may comprise a plurality of air inlets. One or each of the air inlets may have one or more of the features of the air inlet described herein.

[0198] The aerosol-generating article may comprise a plurality of air outlets. One or each of the air outlets may have one or more of the features of the air outlet described herein.

[0199] The aerosol-generating article may comprise a filter element positioned downstream of the aerosol-forming substrate. The aerosol-generating article may comprise a filter element positioned downstream of the cavity. The aerosol-generating article may comprise a filter element at least partially positioned within the air outlet. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at a downstream end of, the cavity. The aerosol-generating article may comprise a filter element positioned upstream of the aerosol-forming substrate. The aerosol-generating article may comprise a filter element positioned upstream of the cavity. The aerosol-generating article may comprise a filter element at least partially positioned within the air inlet. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at an upstream end of, the cavity.

[0200] The filter element may comprise one or more segments of a fibrous filtration material. Suitable fibrous filtration materials would be known to the skilled person. The filter element may comprise a cellulose acetate.

[0201] A ratio between the length and the height of the aerosol-generating article, and between the width and the height of the aerosol-generating article may be greater than 2:1 , greater than 5:1 , greater than 10:1 , greater than 12:1 , or greater than 15:1 .

[0202] A ratio between the length and the height of the aerosol-generating article, and between the width and the height of the aerosol-generating article may be less than 15:1 , less than 12:1 , less than 10:1 , less than 5:1 , or less than 2.5:1 .

[0203] A ratio between the length and the height of the aerosol-generating article, and between the width and the height of the aerosol-generating article may be between 2:1 and 15:1 , between 2:1 and 12:1 , between 2:1 and 10:1 , or between 5:1 and 10:1.

[0204] A ratio between the length and the width of the aerosol-generating article may be greater than 1 :1 , greater than 2:1 , greater than 3:1 , greater than 4:1 , or greater than 5:1 .

[0205] A ratio between the length and the width of the aerosol-generating article may be less than 10:1 , less than 8:1 , less than 5:1 , less than 4:1 , less than 3:1 , or less than 2:1 .

[0206] A ratio between the length and the width of the aerosol-generating article may be between 1 :1 and 10:1 , between 1 :1 and 5:1 , between 1 :1 and 4:1 , between 1 :1 and 3:1 , between 2:1 and 4:1 , or between 2:1 and 3:1 .

[0207] The aerosol-generating article may have a length greater than or equal to 15 millimetres, greater than or equal to 20 millimetres, greater than or equal to 25 millimetres, greater than or equal to 30 millimetres, greater than or equal to 35 millimetres, or greater than or equal to 40 millimetres.

[0208] The aerosol-generating article may have a length less than or equal to 45 millimetres, less than or equal to 40 millimetres, less than or equal to 35 millimetres, or less than or equal to 30 millimetres.

[0209] The aerosol-generating article may have a length between 15 millimetres and 45 millimetres, between 20 millimetres and 40 millimetres, between 20 millimetres and 35 millimetres, or between 25 millimetres and 30 millimetres. The aerosol-generating article may have a width equal to greater than 3 millimetres, greater than 5 millimetres, greater than 7.5 millimetres, greater than 9 millimetres, greater than 11 millimetres, or greater than 13 millimetres.

[0210] The aerosol-generating article may have a width less than or equal to 17 millimetres, less than or equal to 15 millimetres, less than or equal to 12.5 millimetres, less than or equal to 11 millimetres, or less than or equal to 9 millimetres.

[0211] The aerosol-generating article may have a width between 3 millimetres and 17 millimetres, between 5 millimetres and 15 millimetres, between 7.5 millimetres and 12.5 millimetres, or between 9 millimetres and 11 millimetres.

[0212] The aerosol-generating article may have a height equal to greater than 1 millimetre, greater than or equal to 1.5 millimetres, greater than or equal to 2 millimetres, greater than or equal to 2.5 millimetres, greater than or equal to 3 millimetres, greater than or equal to 3.5 millimetres, greater than or equal to 4 millimetres, or greater than or equal to 4.5 millimetres.

[0213] The aerosol-generating article may have a height less than or equal to 5.5 millimetres, less than or equal to 5 millimetres, less than or equal to 4.5 millimetres, less than or equal to 4 millimetres, less than or equal to 3.5 millimetres, less than or equal to 3 millimetres, less than or equal to 2.5 millimetres, or less than or equal to 2 millimetres.

[0214] The aerosol-generating article may have a height between 1 millimetres and 5 millimetres, between 1.5 millimetres and 5 millimetres, between 2 millimetres and 4.5 millimetres, between 2.5 millimetres and 4 millimetres, or between 3 millimetres and 3.5 millimetres.

[0215] According to the present disclosure, there is provided an aerosol-generating device for receiving an aerosol-generating article as disclosed herein. The aerosol-generating device comprises a cavity dimensioned to receive at least a portion of the aerosol-generating article. The aerosol-generating device comprises a heater or heating means, a power source for supplying power to the heater or heating means, and a controller to control a supply of power to the heater or heating means. The aerosol-generating device is configured to heat at least one of the one or more aerosol-generating substrates to form an aerosol, for example an inhalable aerosol. The aerosol-generating device may be configured to heat each of the one or more aerosol-generating substrates to form an aerosol, for example an inhalable aerosol.

[0216] According to the present disclosure, an aerosol-generating system comprises an aerosolgenerating device as disclosed herein and an aerosol-generating article as disclosed herein. The system may comprise a plurality of such articles for use with the aerosol-generating device.

[0217] As used herein, the term “aerosol-generating article” refers to an article comprising an aerosol-generating substrate. The article may be heated in use to produce and deliver an inhalable aerosol to a consumer. As used herein, the term “aerosol-generating substrate” refers to a substrate capable of releasing volatile compounds upon heating, for example compounds which, in use, cool and condense to generate an aerosol.

[0218] As used herein, the term “aerosol-generating device” refers to a device that, in use, interacts with, for example heats, an aerosol-generating substrate of an aerosol-generating article to generate an aerosol.

[0219] As used herein, the term “planar” refers to a feature generally formed in a single Euclidean plane and not wrapped around or otherwise conformed to fit a curved or other non-planar shape. A planar surface may extend in two dimensions in a single Euclidean plane. A planar object may extend in two dimensions in a single Euclidean plane substantially more than in a third dimension perpendicular to the plane. More specifically, a planar object may extend in a first dimension and a second dimension perpendicular to the first dimension at least two, five or ten times further than the object extends in a third dimension perpendicular to the first and second dimensions.

[0220] As used herein, the term “transverse” refers to a direction extending between the first planar external surface and the second planar external surface. The transverse direction may also be referred to as the “z-direction”.

[0221] As used herein, the term “longitudinal” refers to a direction that is perpendicular to the transverse direction. For example, a direction between a front wall and a back wall of the aerosolgenerating article. The lateral direction may also be referred to as the “x-direction”.

[0222] As used herein, the term “lateral” refers to a direction that is perpendicular to the transverse direction and the longitudinal direction. For example, a direction from a first side wall to a second side wall of the aerosol-generating article. The lateral direction may also be referred to as the “y- direction”.

[0223] As used herein, the term “height” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the transverse direction.

[0224] As used herein, the term “length” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the longitudinal direction.

[0225] As used herein, the term “width” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the lateral direction.

[0226] As used herein, the terms “upstream” and “downstream” refer to the relative positions of components, or portions of components, of the aerosol-generating article in relation to the direction in which the air or aerosol is transported through the aerosol-generating article during use.

[0227] As used herein, the term “bulk density” may refer to the total weight of the aerosol-generating substrate divided by the bulk volume of the aerosol-generating substrate. 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-generating substrate or aerosol-generating article.

[0228] As used herein, the term “aerosol former content” may refer to aerosol former content in percent on a dry weight basis, unless otherwise specified.

[0229] As used herein, a "susceptor" refers to a conductive element that heats up when subjected to a changing magnetic field. This may be the result of eddy currents induced in the susceptor element and / or hysteresis losses.

[0230] As used herein, the term “hydrophobic” refers to a surface exhibiting water repelling properties. One useful way to determine this is to measure the water contact angle. The “water contact angle” is the angle, conventionally measured through the liquid, where a liquid / vapour interface meets a solid surface. It quantifies the wettability of a solid surface by a liquid via the Young equation.

[0231] As used herein, the term “equivalent diameter” of an opening or an aperture is used herein to denote the diameter of a circular opening The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting 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.

[0232] EX1 . A frame for an aerosol-generating article, wherein the frame has a longitudinal axis, and wherein the frame comprises at least one wall, the at least one wall comprising a web of sheet material having a length and a width, the width of the web of sheet material extending substantially perpendicular to the longitudinal axis.

[0233] EX2. A frame for an aerosol-generating article comprising at least one wall, the at least one wall comprising a web of sheet material arranged in a laminar structure, the laminar structure comprising a plurality of layers of the web of sheet material.

[0234] EX3. A frame according to example EX2, wherein the plurality of layers comprises at least two layers or at least three layers.

[0235] EX4. A frame according to example EX2 or EX3, wherein the frame has a longitudinal axis, wherein the web of sheet material has a length and a width, and wherein the width of the web of sheet material extends substantially perpendicular to the longitudinal axis.

[0236] EX5. A frame according to example EX1 or EX4, wherein the frame is elongate, having a length in the direction of the longitudinal axis that is greater than the other dimensions of the frame.

[0237] EX6. An aerosol-generating article comprising a frame according to any one of examples

[0238] EX1 to EX5. EX7. A method of manufacturing a frame for an aerosol-generating article, the method comprising: providing a web of sheet material; and overlapping the web of sheet material on itself to form a frame comprising at least one wall, the at least one wall having a laminar structure comprising a plurality of layers of the web of sheet material.

[0239] EX8. A method according to example EX7, wherein the formed frame has a longitudinal axis, wherein the web of sheet material has a length and a width, and wherein the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame, and optionally wherein the formed frame is elongate, having a length in the direction of the longitudinal axis that is greater than the other dimensions of the formed frame.

[0240] EX9. A method according to example EX7 or EX8, wherein the at least one wall having a laminar structure comprises at least two layers of the web of sheet material, or at least three layers of the web of sheet material, and optionally wherein the formed frame comprises one or more peripheral walls, the one or more peripheral walls having a laminar structure comprising at least two layers of the web of sheet material, or at least three layers of the web of sheet material.

[0241] EX10. A method according to any one of examples EX7 to EX9, wherein the overlapping of the web of sheet material comprises winding the web of sheet material around a spindle, and optionally the method further comprises removing the frame from the spindle such that the formed frame comprises a frame aperture about which the web of sheet material is wound.

[0242] EX11. Method according to example EX10, wherein the spindle has a longitudinal axis about which the web of sheet material is wound, and wherein the spindle has a transverse cross- sectional shape perpendicular to the longitudinal axis, the transverse cross-sectional shape being at least one of: circular, non-circular, elliptical, stadium shaped, polygonal, triangular, rectangular, trapezoidal, pentagonal, or hexagonal.

[0243] EX12. A method according to any one of examples EX7 to EX11 , wherein the overlapping the web of sheet material on itself to form a frame comprises compressing two or more of the overlapping layers of the web of sheet material together.

[0244] EX13. A method according to any one of examples EX7 to EX12, wherein the method further comprises crimping a section of the web of sheet material to form a crimped section having corrugations, and optionally wherein the crimped portion of the web of sheet material is compressed to compress the corrugations of the crimped portion together.

[0245] EX14. A method according to any one of examples EX7 to EX13, wherein the method further comprises applying adhesive to a surface the web of sheet material before the overlapping the web of sheet material on itself, and optionally wherein the overlapping the web of sheet material on itself comprises bringing the adhesive on a surface of the web of sheet material into contact with another surface of the web material.

[0246] EX15. A method according to any one of examples EX7 to EX14, wherein the method further comprises forming one or more apertures in the web of sheet material.

[0247] EX16. A method according to example EX15, wherein the forming the one or more apertures comprises at least one of: forming one or more apertures before the overlapping of the web of sheet material on itself; forming one or more apertures during the overlapping of the web of sheet material on itself; and forming one or more apertures after the overlapping of the web of sheet material on itself.

[0248] EX17. A method according to any one of examples EX7 to EX16, wherein the providing the web of sheet material comprises providing a web of sheet material having one or more preformed apertures.

[0249] EX18. A method according to any one of examples EX15 to EX17, wherein the method further comprises arranging one or more elements in or over one or more of the apertures, and optionally wherein the one or more elements comprises one or more of a filter and a mesh.

[0250] EX19. A method according to any one of examples EX7 to EX18, wherein the web of sheet material comprises one of: a web of cellulosic material, optionally wherein the cellulosic material is one of paper or cardboard; and a web of polymeric material.

[0251] EX20. A method according to any one of examples EX7 to EX19, wherein the formed frame comprises one or more apertures at an outer surface, and wherein the method comprises circumscribing the formed frame with a wrapper that covers an outer surface of the frame and the frame and covers the one or more apertures at the outer surface of the frame, and optionally wherein the wrapper comprises a section of the web of sheet material, and optionally wherein the formed frame and the wrapper are connected at a weakened region of the web of sheet material.

[0252] EX21 . A method according to any one of examples EX7 to EX20, wherein the method further comprises applying, forming, or providing an indicia or taggant on a surface of the web of sheet material, and optionally wherein the indicia or taggant is arranged on an outer surface of the frame when the frame is formed.

[0253] EX22. A method according to any one of examples EX7 to EX21 , wherein the overlapping the web of sheet material on itself comprises overlapping different numbers of layers of the web of sheet material at different sections of the frame, and optionally wherein the formed frame comprises a first section comprising a first number of layers of the web of sheet material and a second section comprising a second number of layers of the web of sheet material, the second number being different from the first number. EX23. A method according to any one of examples EX7 to EX22, wherein the formed frame comprises a frame aperture configured to receive an aerosol-forming substrate, and optionally wherein the formed frame comprises a plurality of frame apertures, each frame aperture being configured to receive an aerosol-forming substrate.

[0254] EX24. A method according to any one of examples EX7 to EX23, wherein the providing a web of sheet material comprises providing a first web of a first sheet material and providing a second web of a second sheet material, and optionally wherein the method further comprises overlapping the first web of the first sheet material on itself and overlapping the second web of the second sheet material on itself to form a frame comprising at least a first wall having a laminar structure, the laminar structure comprising a plurality of layers of the first web of the first sheet material, and the frame comprising at least a second wall having a laminar structure, the laminar structure comprising a plurality of layers of the second web of the second sheet material.

[0255] EX25. A method according to any one of examples EX7 to EX24, wherein the providing a web of sheet material comprises providing a first web of a first sheet material and providing a second web of a second sheet material, and optionally wherein the method further comprises overlapping the first web of the first sheet material with the second web of the second sheet material to form a combined web of sheet material, and the overlapping the web of sheet material on itself comprises overlapping the combined web of sheet material on itself.

[0256] EX26. A method of manufacturing an aerosol-generating article, the method comprising forming a frame for an aerosol-generating article according to the method of any one of examples EX7 to EX25.

[0257] EX27. A method according to examples EX26, wherein the method further comprises: providing a first sheet of external layer material, and a second sheet of external layer material; positioning the formed frame between the first sheet of external layer material, and the second sheet of external layer material; and bonding the first sheet of external layer material, and the second sheet of external layer material to the formed frame.

[0258] EX28. A method according to example EX26, wherein the method further comprises: providing a first sheet of external layer material, and a second sheet of external layer material; providing a first sheet of aerosol-generating material, and a second sheet of aerosolgenerating material; positioning the formed frame between the first sheet of aerosol-generating material, and the second sheet of aerosol-generating material; positioning the formed frame, the first sheet of aerosol-generating material, and the second sheet of aerosol-generating material between the first sheet of external layer material, and the second sheet of external layer material; and bonding one or more of the sheet material to the formed frame.

[0259] EX29. A frame of an aerosol-generating article formed by a method according to any one of examples EX7 to EX25.

[0260] Examples will now be further described with reference to the figures in which:

[0261] Figure 1 shows a perspective view of an exemplary aerosol-generating article suitable to comprise a frame according to the present disclosure;

[0262] Figure 2 shows an exploded perspective view of the aerosol-generating article of Figure 1 ;

[0263] Figure 3 shows an exploded perspective view of another exemplary aerosol-generating article suitable to comprise a frame according to the present disclosure;

[0264] Figure 4 shows a perspective view of another exemplary aerosol-generating article; suitable to comprise a frame according to the present disclosure;

[0265] Figure 5 shows a perspective view of another exemplary aerosol-generating article suitable to comprise a frame according to the present disclosure;

[0266] Figure 6 shows an exploded perspective view of another exemplary aerosol-generating article suitable to comprise a frame according to the present disclosure;

[0267] Figure 7 shows a perspective view of another exemplary aerosol-generating article suitable to comprise a frame according to the present disclosure;

[0268] Figure 8 shows a frame of an aerosol-generating article according to an embodiment of the present disclosure;

[0269] Figure 9 shows the frame of Figure 8 including an aerosol-generating material arranged in the frame aperture of the frame;

[0270] Figure 10 shows an aerosol-generating article according to an embodiment of the disclosure, the aerosol-generating article comprising the frame of Figures 8 and 9;

[0271] Figure 11 shows the frame of Figure 8, the frame comprising an outer wrapper;

[0272] Figure 12 shows the frame of Figure 11 , the frame having the outer wrapper removed;

[0273] Figure 13 shows another exemplary frame of an aerosol-generating article according to an embodiment of the present disclosure;

[0274] Figure 14 shows the frame of Figure 13 including an aerosol-generating material arranged in the frame aperture of the frame;

[0275] Figure 15 shows a method of manufacturing a frame of an aerosol-generating article according to an embodiment of the disclosure; Figure 16 shows a frame of an aerosol-generating article according to an embodiment of the present disclosure;

[0276] Figure 17 shows the frame of Figure 16 including an aerosol-generating material arranged in the frame aperture of the frame;

[0277] Figure 18 shows a method of manufacturing a frame of an aerosol-generating article according to an embodiment of the disclosure;

[0278] Figure 19 shows a method of manufacturing an aerosol-generating article according to an embodiment of the present disclosure, the aerosol-generating article comprising a frame according to an embodiment of the present disclosure;

[0279] Figure 20 shows a plan view of the method of Figure 19;

[0280] Figure 21 shows a schematic cross-sectional view of an aerosol-generating device according to the present disclosure;

[0281] Figure 22 shows a schematic cross-sectional view of the aerosol-generating device of Figure 21 in engagement with an aerosol-generating article of the present disclosure.

[0282] Figure 1 shows an aerosol-generating article 10 comprising a first planar external layer 24 forming a first planar external surface 21 , a second planar external layer 25 forming a second planar external surface 22, and a frame 50 positioned between the first planar external layer 24 and the second planar external layer 25. The first planar external layer 24 and the second planar external layer 25 both comprise an aerosol-generating substrate comprising an aerosol-generating material, namely tobacco. However, it will be understood that in some embodiments only one of the first planar external layer 24 and the second planar external layer 25 may comprise an aerosolgenerating substrate. Alternatively, or additionally, the aerosol-generating substrate may be positioned elsewhere within the aerosol-generating article 10.

[0283] The aerosol-generating article 10 has a length extending in the x-direction, a width extending in the y-direction and a height extending in the z-direction. The aerosol-generating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a height of 3.1 millimetres.

[0284] The aerosol-generating article 10 is substantially flat aerosol-generating article or substantially planar aerosol-generating article. In particular, the thickness of the aerosol-generating article 10 is less than 50 percent of both the length and the width of the aerosol-generating article 10. The aerosol-generating article 10 has a generally rectangular cuboid shape and a laminated structure formed by the first planar external layer 24, the frame 50 and the second planar external layer 25. The first planar external layer 24, the frame 50 and the second planar external layer 25 are bonded together with an adhesive, in particular guar gum, as discussed in more detail below in relation to Figure 2.

[0285] Figure 2 shows an exploded view of the aerosol-generating article 10 of Figure 1 . The frame 50 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 2.7 millimetres. The frame 50 is made from cardboard and defines a frame aperture extending through the thickness of the frame 50. The frame aperture at least partially forms a cavity 30. The cavity 30 has length of 26 millimetres, a width of 6 millimetres, and a thickness of 2.7 millimetres.

[0286] Therefore, the cavity 30 has a volume of about 421 .2 cubic millimetres. In this embodiment, the cavity 30 is substantially empty.

[0287] The frame 50 has a frame inner surface 52 extending in the z-direction or the transverse direction between the first planar external surface 21 and the second planar external surface 22. The frame inner surface 52 defines a cavity outer wall. The frame 50 has a frame outer surface 53 extending in the z-direction or the transverse direction between the first planar external surface 21 and the second planar external surface 22. The frame outer surface 53 at least partially defines one or more external surfaces of the aerosol-generating article, such as the front wall 13 and the back wall 14.

[0288] The frame 50 comprises a peripheral wall 51 that circumscribes the cavity 30. In more detail, the peripheral wall 51 is defined by the frame inner surface 52 and the frame outer surface 52. The peripheral wall 51 has a radial thickness, as measured between the frame inner surface 52 and the frame outer surface 53 in the x / y plane, of about 2 millimetres.

[0289] The first planar external layer 24 and the second planar external layer 25 have a thickness of 200 micrometres and are in physical contact with the frame 50. The first planar external layer 24 and the second planar external layer 25 are bonded to the frame with an adhesive 15. The first planar external layer 24 defines at least a portion of the cavity 30. The second planar external layer 25 defines at least a portion of the cavity 30.

[0290] The aerosol-generating article 10 comprises an air inlet 11 and an air outlet 12. The air inlet 11 and the air outlet 12 are defined by, and extend through, the peripheral wall 51 of the frame 50. The air inlet 11 and the air outlet 12 each have a rectangular cross-section, a width of 2 millimetres, and a thickness of 0.9 millimetres. An airflow passage extends between the air inlet 11 and the air outlet 12 through the cavity 30.

[0291] Figure 3 shows an exploded view of an aerosol-generating article that is similar to the aerosol-generating article 10 of Figure 1 except that the first planar external layer 24 and the second planar external layer 25 do not comprise an aerosol-generating substrate. Instead, an aerosol-generating substrate 40 is positioned within the cavity 30. The aerosol-generating substrate 40 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. As shown, the aerosolgenerating substrate 40 fills the entire volume of the cavity 30. In the example of Figure 3, the aerosol-generating substrate 40 has a packing density of about 0.87, a density of about 0.3 grams per cubic centimetre, and a mass of about 110 milligrams. In another example, the aerosolgenerating substrate 40 may have a different packing density, a different density, and a different mass. For example, aerosol-generating substrate may have a packing density of 0.64, a density of 0.35 grams per cubic centimetre, and a mass of about 95 milligrams.

[0292] Figure 4 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figures 1 and 3 except that the aerosol-generating article 10 of Figure 4 comprises an outer wrapper 23 defining the first planar external surface 21 and the second planar external surface 22 instead of the first planar external layer 24 and the second planar external layer 25.

[0293] Figure 5 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1 except that the aerosol-generating article 10 of Figure 5 further comprises a first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are formed from a sheet of aerosol-generating material. In particular, a sheet of homogenised tobacco material having an aerosol-former content of 5 percent by weight on a dry weight basis. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 each have a length equal to the length of the aerosol-generating article 10, a width equal to the width of the aerosol-generating article 10 and a thickness of 200 micrometres. That is, the aerosolgenerating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.5 millimetres.

[0294] The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are in physical contact with the frame 50 and are bonded to the frame with an adhesive 15. The first aerosol-generating substrate layer 41 defines at least a portion of the cavity 30. The second aerosol-generating layer 42 defines at least a portion of the cavity 30.

[0295] The first planar external layer 24 is in physical contact with the first aerosol-generating substrate layer 41 and are bonded together with an adhesive 15. The second planar external layer 25 is in physical contact with the second aerosol-generating substrate layer 42 and are bonded together with an adhesive 15.

[0296] Figure 6 shows an exploded view of an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 5 except that an aerosol-generating substrate 40 is positioned within the cavity 30 as described in relation to Figure 3. The aerosol-generating substrate 40 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. As shown, the aerosolgenerating substrate 40 fills the entire volume of the cavity 30. Figure 7 shows an aerosolgenerating article 10 similar to the aerosol-generating article 10 of Figure 5 except that the aerosolgenerating article 10 of Figure 7 comprises an outer wrapper 23 defining the first planar external surface 21 and the second planar external surface 22 instead of the first planar external layer 24 and the second planar external layer 25.

[0297] Figure 8 shows a frame 50 according to an embodiment of the present disclosure. The frame is suitable for use as a frame of an aerosol-generating article, such as the aerosol-generating articles described above with reference to Figures 1 to 7.

[0298] The frame 50 of Figure 8 has a similar form to the frame 50 of Figures 1 to 7, having a generally rectangular cuboid shape, and a length of 30 millimetres, a width of 10 millimetres, and a height of 2.7 millimetres. The frame 50 of Figure 8 differs from the frame 50 of Figures 1 to 7 in that it is formed from a single sheet of web material, which in this embodiment is a single sheet of cardboard. The frame 50 of Figure 8 has a longitudinal axis 54, the single sheet of web material has a length and a width, and the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame. In other words, the width of the web of sheet material extends substantially in the z-direction. Accordingly, the width of the web of sheet material defines the height of the frame 50. The width of the web of sheet material is 2.7 millimetres, and the thickness of the web of sheet material is 0.5 millimetres.

[0299] The web of sheet material is arranged in a laminar structure, the laminar structure comprising a plurality of layers of the web of sheet material. The laminar structure provides additional rigidity to the walls of the frame 50, with sections of the walls having a larger number of layers of the web of sheet material having greater rigidity.

[0300] The frame 50 comprises a front portion 55, and a back portion 56. Each of the front portion 55 and the back portion 56 have a laminar structure formed from eight layers of the web of sheet material, the layers being folded back onto each other in a zig-zag formation, and compressed together. The front portion 55 and the back portion 56 are wrapped by a peripheral portion of the web of sheet material to form the final frame 50 defining a frame aperture 33 between the front portion 55 and the back portion 56. Peripheral sidewalls 57 at opposite sides of the frame aperture 33, between the front portion 55 and the back portion 56 , also have a laminar structure, the laminar structure of the peripheral sidewalls 57 being formed from two layers of the web of sheet material.

[0301] The layers of the front portion 55 and the back portion 56 each comprise an aperture 58 punched through the web of sheet material. The apertures 58 of the layers of the front portion 56 are aligned to form the air outlet 12 of the frame 50, extending from the frame aperture 33 to the front wall 13 of the frame 50. The apertures 58 of the layers of the back portion 56 are also aligned to form the air inlet 11 of the frame 50, extending from the frame aperture 33 to the back wall 14 of the frame 50.

[0302] The relatively thick front portion 55 and back portion 56 of the frame 50, being comprised of a relatively large number of layers of the web of sheet material compared to other sections of the aerosol-generating article, provide increased rigidity to the frame at the front and back, which helps the aerosol-generating article to retain its shape when being inserted into an aerosol-generating device and removed from an aerosol-generating device. The relatively thick front portion 55 and back portion 56 of the frame 50, with the aligned apertures 58 forming a long air inlet 11 , and a long air outlet 12, enable the resistance to draw (RTD) through the aerosol-generating article to be precisely controlled.

[0303] Figure 9 shows the frame 50 of Figure 8 with the frame aperture 33 filled with aerosolgenerating substrate 40.

[0304] Figure 10 shows an aerosol-generating article 10 comprising the frame 50 of Figures 8 and 9. The aerosol-generating article 10 comprises a first planar external layer 24 forming a first planar external surface 21 , a second planar external layer 25 forming a second planar external surface 22, and the frame 50 positioned between the first planar external layer 24 and the second planar external layer 25. In this embodiment, the first planar external layer 24 and the second planar external layer 25 are formed from paper, such as cigarette paper.

[0305] Figures 11 and 12 show the frame 50 of Figures 8 and 9, wherein the frame 50 further comprises an outer wrapper 23. The outer wrapper 23 circumscribes the outer surfaces of the frame 50, including the front wall 12, the back wall 11 , and the peripheral sidewalls 57, and covers the air outlet 12 and air inlet 11 , such that ambient air is unable to reach the aerosol-generating material 40 in the frame aperture 33. In this embodiment, the outer wrapper 23 is formed from the same, single web of sheet material as the rest of the frame 50, and is separable from the rest of the web of sheet material forming the frame at a weakened region 27. The weakened region 27 comprises a row of perforations extending along the width of the web of sheet material, which makes the outer wrapper 23 straightforward to tear away from the rest of the web of sheet material at the weakened region 27. The outer wrapper 23 is bonded to itself using an adhesive (not shown) towards a free end 28, with the free end 28 being configured to be grasped by a user for peeling the outer wrapper 23 away from the frame 50, and tearing the outer wrapper 23 away from the rest of the web of sheet material forming the rest of the frame 50 at the weakened region 27.

[0306] It is envisaged that in some embodiments, the outer wrapper 23 may be formed from a different material to the web of sheet material, such as paper, and the outer wrapper 23 may be removably bonded to the frame 50, or to itself once wrapped tightly around the walls of the frame 50, over the air outlet 12 and air inlet 11 .

[0307] Figure 13 shows a schematic illustration of a method 100 of manufacturing a frame 50 according to an embodiment of the disclosure, such as the frame 50 of Figures 8 and 9. In general, the method 100 comprises providing a web of sheet material, punching, and crimping a portion of the web of sheet material, compressing corrugations of the crimped portion together, and winding the web of sheet material around a spindle to form a frame.

[0308] More specifically, the method 100 comprises feeding a web of sheet material 101 , which in this embodiment is cardboard, from a bobbin 102 between a first pair of rollers 103, and punching apertures 58 in the web of sheet material 101 using a punch 104. The method further comprises crimping portions of the web of sheet material comprising the apertures 58, using crimping rollers 105, and applying adhesive to surfaces of the corrugations of the crimped portions using an adhesive applicator 106, which may be in the form of a spray or a brush. The web of sheet material 101 is fed over a spindle 108, via a roller 107, and crimped portions of the web 101 are compressed together against the spindle 108 by pushers 109, with overlapping layers of the crimped portions being bonded together by the adhesive. The spindle 108 is rotated, to wrap a subsequent portion of the web 101 around the spindle and the compressed crimped portions of the web 101 , and the web 101 is cut by an air blade 110 after the desired number of rotations of the spindle 108, to form the frame 50. The frame 50 is pushed off of the spindle 108, with the space previously occupied by the spindle 108 forming the frame aperture 33. The frame aperture 33 has the same cross-sectional shape and size as the spindle 108, and the apertures 58 punched in the web 101 are aligned to form an air passage through the frame 50, along the longitudinal axis.

[0309] In some embodiments, it is envisaged that the adhesive applicator 106 may be arranged in or around the crimping rollers 105, or other crimping means, such that the adhesive may be applied to the web of sheet material. It is also envisaged that the cardboard punched out of the web of sheet material 101 may be collected and recycled.

[0310] Figure 14 shows a frame 50 according to an embodiment of the present disclosure. The frame 50 is suitable for use as a frame of an aerosol-generating article, such as the aerosolgenerating articles described above with reference to Figures 1 to 7. The frame 50 of Figure 14 is similar to the frame 50 of Figures 8 and 9, except that the frame 50 defines three frame apertures, a central frame apertures 33, a front frame aperture 34, and a back frame aperture 35.

[0311] The frame 50 of Figure 14 does not comprise the thick front and back portions of the frame 50 of Figures 8 and 9, but rather the frame 50 of Figure 14 comprises a front dividing wall 55, separating the central frame aperture 33 from the front frame aperture 34, and a back dividing wall 56, separating the central frame aperture 33 from the back frame aperture 35.

[0312] In this embodiment, the peripheral walls of the frame 50, including the front wall 13, the back wall 14, the peripheral side walls 57, and the front dividing wall 55, and the read dividing wall 56 are all formed from two layers of a single web of sheet material, which in this embodiment is cardboard. The layers of the single web of sheet material which form the front wall 13, the back wall 14, the front dividing wall 55, and the back dividing wall 56 each comprise an aperture 58 punched through the web of sheet material. The apertures 58 of the layers forming the front wall 13 are aligned to form the air outlet 12 of the frame 50, the apertures of the layers forming the back wall 14 are aligned to form the air inlet 11 of the frame 50, the apertures 58 forming the front dividing wall 56 are aligned to form an air passage from the central frame aperture 33 to the front frame aperture 34, and the apertures 58 forming the back dividing wall 35 are aligned to form an air passage from the back frame aperture 35 to the central frame aperture 33. All of the apertures 58 in the web of sheet material are aligned on the longitudinal axis 54 of the frame 50. An airflow passage is provided through the frame 50 from the air inlet 11 to the air outlet 12, through each of the back frame aperture 35, the central frame aperture 33, and the front frame aperture 34, via the apertures 58 in the web of sheet material.

[0313] Figure 15 shows the frame 50 of Figure 14 with the central frame aperture 33 filled with aerosol-generating substrate 40. The front frame aperture 34, and the back frame aperture 35 in this embodiment are not filled with aerosol-generating substrate, but rather are empty. The front frame aperture 34 and the back frame aperture 35 help to control resistance to draw (RTD) through the aerosol-generating article, and the front frame aperture 34 in particular helps to cool vapour released from the aerosol-generating material when it is heated, so that it forms an aerosol with the desired properties. It is envisaged that in some embodiments, at least one of the front frame aperture 34 and the back frame aperture 35 may contain an element, such as a filter or a flavourant.

[0314] Figure 16 shows a frame 50 according to an embodiment of the present disclosure. The frame 50 is suitable for use as a frame of an aerosol-generating article, such as the aerosolgenerating articles described above with reference to Figures 1 to 7. The frame 50 of Figure 16 is similar to the frame 50 of Figures 8 and 9, except that the frame 50 does not comprise the thick front and back portions 55, 56 of the frame 50 of Figures 8 and 9. The frame 50 of Figure 16 comprises a single web of sheet material circumscribing a single frame aperture 33 in a laminar structure having two layers of the web of sheet material. Accordingly, each of the front wall 12, back wall 13, and peripheral sidewalls 57 have a laminar structure comprising two layers of the web of sheet material. The web of sheet material is oriented such that the width of the web extends in the z-direction of the frame 50, and the thickness of the web extends in the x-y plane of the frame 50. Accordingly, the height of the frame 50 equates to the width of the web, and the wall thickness of the walls of the frame 50 equate to double the thickness of the web.

[0315] The frame 50 of Figure 16 comprises an air inlet 11 , and an air outlet 12, formed from aligned apertures 58 in the web of sheet material forming the frame 50. In this embodiment, the apertures 58 forming the air outlet 12 have a filter element applied over them, such that the frame 50, and ultimately the aerosol-generating article comprising the frame 50, has a filter at the air outlet 12.

[0316] Figure 17 shows the frame 50 of Figure 15 with an aerosol-generating material 40 arranged in the frame aperture 33. In this embodiment, the frame aperture 33 is not filled with the aerosolgenerating material 40, but rather the frame aperture 33 is partially filled with the aerosolgenerating material, in a central region of the frame aperture 33.

[0317] Figure 18 shows a schematic illustration of a method 100 of manufacturing a frame 50 according to an embodiment of the disclosure, such as the frame 50 of Figures 16 and 17. In general, the method 100 comprises providing a web of sheet material, punching apertures in a portion of the web of sheet material and applying a filter element over some of the apertures, and winding the web of sheet material around a spindle to form a frame.

[0318] More specifically, the method 100 comprises feeding a web of sheet material 101 , which in this embodiment is cardboard, from a bobbin 102 between a first pair of rollers 103, and punching apertures 58 in the web of sheet material 101 using a punch 104. The method further comprises applying adhesive to a lower surface of the web of sheet material using an adhesive applicator 106, and applying a filter element, in the form of a sheet of cellulose acetate tow, using a filter element applicator 111 , over apertures 58 in the web 101 that are going to form the air outlet 12 of the frame 50. An initial portion of the web of sheet material 101 is fed over a spindle 108, via a roller 107, and the spindle 108 is rotated to wrap a subsequent portion of the web 101 around the spindle and the initial portion of the web 101 . The web 101 is cut by an air blade 110 after the desired number of rotations of the spindle 108, to form the frame 50. The frame 50 is pushed off of the spindle 108, with the space previously occupied by the spindle 108 forming the frame aperture 33. The frame aperture 33 has the same cross-sectional shape and size as the spindle 108, and the apertures 58 punched in the web 101 are aligned to form an air passage through the frame 50, along the longitudinal axis.

[0319] Figure 19 shows a schematic illustration of a method 200 of manufacturing an aerosolgenerating article 10, such as the aerosol-generating article 10 of Figure 10. Figure 20 shows a schematic plan view of the method of Figure 19, but with the manufacturing equipment not depicted. In general, the method comprises bonding a first sheet of external layer material 201 to a frame 50, filling the frame aperture 33 with aerosol-generating material, bonding a second sheet of external layer material to the frame 50, and punching the sheets of external layer material to form the aerosol-generating article 10.

[0320] More specifically, the method 200 comprises feeding a first sheet of external layer material 201 , which in this embodiment is cigarette paper, from a bobbin 202 between a first pair of rollers 203 and a second pair of rollers 204. The method further comprises applying an adhesive 205 to an upper surface of the first sheet of external layer material 201 , using a first adhesive applicator 206, and introducing a frame 50, from a frame dispenser 207, onto the adhesive 205 on the upper surface of the first sheet of external layer material 201 to bond the frame 50 to the upper surface of the first sheet of external layer material 201 . The frame 50 is introduced onto the upper surface of the first sheet of external layer material 201 with the x-y plane of the frame 50 parallel to the x-y plane of the upper surface of the first sheet of external layer material 201 , such that the first sheet of external layer material covers an open end of the frame aperture 33. The method further comprises filling the frame aperture 33 with an aerosol-generating substrate 40 using an aerosolgenerating material dispenser 208, and applying an adhesive 209 to an upper surface of the frame 50 using a second adhesive applicator 210. The method further comprises feeding a second sheet of external layer material 211 , which in this embodiment is also cigarette paper, from a bobbin 212, between a third roller 213 and the second pair of rollers 204, onto the adhesive applied to the upper surface of the frame 50 to bond the second sheet of external layer material 209 to the upper surface of the frame 50. The method finally comprises punching around the frame 50, through the first sheet of external layer material 201 and the second sheet of external layer material 211 , using a punch 214, to produce a formed aerosol-generating article 10, leaving an aperture 215 in the remaining first and second sheets of external layer material 201 , 211.

[0321] It is envisaged that in some embodiments, pre-sized sheets of external layer material may be bonded to the frame 50 to form the aerosol-generating article 10, rather than continuous webs of the external layer material being bonded to the frame 50 and the aerosol-generating article 10 being formed by punching through the sheets of external layer material.

[0322] Figure 21 shows a schematic cross-sectional view of an aerosol-generating device 90 configured for use with an aerosol-generating article 10 described herein. The aerosol-generating device 90 is an elongate aerosol-generating device extending between a proximal end 91 and a distal end 92. The aerosol-generating device 90 comprises a battery 93, a controller 94, a first heater 95 and a second heater 96 located within a housing 97. The controller 94 controls supply of power from the battery 93 to the first heater 95 and the second heater 96. A cavity 1000 is defined in the device 90, the cavity 1000 having an opening 1010 defined in the proximal end 91 of the device 90. The opening 1010 is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosol-generating article 10. The cavity 1000 comprises an upper planar surface 1020 and a lower planar surface 1030. The first heater 95 is located in the upper planar surface 1020 to heat the first planar external surface 21 of an aerosol-generating article 10 inserted into the cavity 1000, and the second heater 96 is located in the lower planar surface 1030 to heat the second planar external surface 22 of an aerosol-generating article 10 inserted into the cavity 1000. The device 90 comprises an air inlet 98 defining an air-flow path configured to allow air to flow into the cavity 1000 from outside the device.

[0323] Figure 22 shows a schematic cross-sectional view of the aerosol-generating device 90 of Figure 21 in engagement with the aerosol-generating article 10 of Figure 1 . There is little tolerance between the first planar external surface 21 and the second planar external surface 22 of the aerosol-generating article 10 and the internal surfaces 1020, 1030 of the cavity 1000. Thus, there is a snug fit between the aerosol-generating article 10 and the aerosol-generating device 90. When a consumer has inserted the aerosol-generating article 10 into the cavity 1000, the device can be operated. The first heater 95 heats the first planar external surface 21 of the aerosol-generating article 10 and the second heater 96 heats the second planar external surface 22 of the aerosolgenerating article, and as a result the aerosol-generating substrate is heated. Volatile components of the aerosol-generating substrate are evaporated and condense in the cavity 30 of the aerosolgenerating article 10 to form an aerosol. The consumer inhales the aerosol by drawing on the end of the aerosol-generating article 10 comprising the air outlet 12. Once the aerosol-generating substrate has been depleted of volatile components, the aerosol-generating article 10 is removed from the cavity 1000.

[0324] 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.

Claims

CLAIMS1 . A frame for an aerosol-generating article, wherein the frame has a longitudinal axis, and wherein the frame comprises at least one wall, the at least one wall comprising a web of sheet material having a length and a width, the width of the web of sheet material extending substantially perpendicular to the longitudinal axis of the frame.

2. A frame for an aerosol-generating article comprising at least one wall, the at least one wall comprising a web of sheet material arranged in a laminar structure, the laminar structure comprising a plurality of layers of the web of sheet material.

3. A frame according to claim 2, wherein the plurality of layers comprises at least two layers or at least three layers.

4. A frame according to claim 2 or claim 3, wherein the frame has a longitudinal axis, wherein the web of sheet material has a length and a width, the width of the web of sheet material extending substantially perpendicular to the longitudinal axis of the frame.

5. A frame according to claim 1 or claim 4, wherein the frame is elongate, having a length in the direction of the longitudinal axis that is greater than the other dimensions of the frame.

6. An aerosol-generating article comprising a frame according to any one of claims 1 to 5.

7. A method of manufacturing a frame for an aerosol-generating article, the method comprising: providing a web of sheet material; and overlapping the web of sheet material on itself to form a frame comprising at least one wall, the at least one wall having a laminar structure comprising a plurality of layers of the web of sheet material.

8. A method according to claim 7, wherein the formed frame has a longitudinal axis, wherein the web of sheet material has a length and a width, and wherein the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame, and optionally wherein the formed frame is elongate, having a length in the direction of the longitudinal axis that is greater than the other dimensions of the formed frame.

9. A method according to claim 7 or claim 8, wherein the at least one wall having a laminar structure comprises at least two layers of the web of sheet material, or at least three layers of the web of sheet material, and optionally wherein the formed frame comprises one or more peripheral walls, the one or more peripheral walls having a laminar structure comprising at least two layers of the web of sheet material, or at least three layers of the web of sheet material.

10. A method according to any one of claims 7 to 9, wherein the overlapping of the web of sheet material comprises winding the web of sheet material around a spindle, and optionally the method further comprises removing the frame from the spindle such that the formed frame comprises a frame aperture about which the web of sheet material is wound.

11. A method according to claim 10, wherein the spindle has a longitudinal axis about which the web of sheet material is wound, and wherein the spindle has a transverse cross-sectional shape perpendicular to the longitudinal axis, the transverse cross-sectional shape being at least one of: circular, non-circular, elliptical, stadium shaped, polygonal, triangular, rectangular, trapezoidal, pentagonal, or hexagonal.

12. A method according to any one of claims 7 to 11 , wherein the overlapping the web of sheet material on itself to form a frame comprises compressing two or more of the overlapping layers of the web of sheet material together.

13. A method according to any one of claims 7 to 12, wherein the method further comprises crimping a section of the web of sheet material to form a crimped section having corrugations, and optionally wherein the crimped portion of the web of sheet material is compressed to compress the corrugations of the crimped portion together.

14. A method according to any one of claims 7 to 13, wherein the method further comprises applying adhesive to a surface the web of sheet material before the overlapping the web of sheet material on itself, and optionally wherein the overlapping the web of sheet material on itself comprises bringing the adhesive on a surface of the web of sheet material into contact with another surface of the web material.

15. A method according to any one of claims 7 to 14, wherein the method further comprises forming one or more apertures in the web of sheet material, and optionally wherein the forming theone or more apertures comprises at least one of: forming one or more apertures before the overlapping of the web of sheet material on itself; forming one or more apertures during the overlapping of the web of sheet material on itself; and forming one or more apertures after the overlapping of the web of sheet material on itself.

Images