Aerosol-generating article comprising multiple cavities

Abstract

There is provided an aerosol-generating article (10) for use with an aerosol-generating device. The aerosol-generating article (10) is a planar aerosol-generating article defined by a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction. The aerosol-generating article (10) comprises one or more aerosol-generating substrates (41, 42, 45, 46). The aerosol-generating article (10) comprises a first cavity (33) and a second cavity (34) spaced from the first cavity (33) in the z-direction. The aerosol-generating article (10) comprises a first airflow path extending through the first cavity (33). The aerosol-generating article comprises a second airflow path extending through the second cavity (34). At least one of the one or more aerosol-generating substrates (41, 42, 45, 46) is positioned within or adjacent to the first airflow path, and at least one of the one or more aerosol-generating substrates (41, 42, 45, 46) is positioned within or adjacent to the second airflow path. The first cavity (33) and the second cavity (34) may each have a width greater than or equal to 50 percent of a width of the aerosol-generating article.

Description

[0001] AEROSOL-GENERATING ARTICLE COMPRISING MULTIPLE CAVITIES

[0002] The present disclosure relates to an aerosol-generating article. The present disclosure also relates to an aerosol-generating device for use with the aerosol-generating article. The present disclosure also relates to an aerosol-generating system comprising the aerosol-generating device and the aerosol-generating article. The present disclosure also relates to a method of manufacturing the aerosol-generating article.

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

[0007] There is provided an aerosol-generating article for use with an aerosol-generating device. The aerosol-generating article may be a planar aerosol-generating article. The aerosol-generating article may be defined by a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction. The aerosol-generating article may comprise one or more aerosol-generating substrates. The aerosol-generating article may comprise a first cavity and a second cavity. The second cavity may be spaced from the first cavity in the z-direction. The aerosol-generating article may comprise a first airflow path extending through the first cavity. The aerosol-generating article may comprise a second airflow path extending through the second cavity. At least one of the one or more aerosol-generating substrates may be positioned within or adjacent to the first airflow path. At least one of the one or more aerosol-generating substrates may be positioned within or adjacent to the second airflow path. The first cavity and the second cavity may each have a width greater than or equal to 50 percent of a width of the aerosolgenerating article.

[0008] According to an aspect of the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device. The aerosol-generating article is a planar aerosolgenerating article defined by a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction. The aerosol-generating article comprises one or more aerosol-generating substrates. The aerosol-generating article comprises a first cavity and a second cavity spaced from the first cavity in the z-direction. The aerosol-generating article comprises a first airflow path extending through the first cavity. The aerosol-generating article comprises a second airflow path extending through the second cavity. At least one of the one or more aerosolgenerating substrates is positioned within or adjacent to the first airflow path, and at least one of the one or more aerosol-generating substrates is positioned within or adjacent to the second airflow path. The first cavity and the second cavity each have a width greater than or equal to 50 percent of a width of the aerosol-generating article.

[0009] Advantageously, the provision of a first cavity and a second cavity that are spaced in the z-direction may improve aerosolization by positioning the one or more aerosol-generating substrates, that may be located in or around the cavities, in addition to the first air flow path and the second air flow path, closer to an external heater and thereby ensuring a greater proportion of the one or more aerosol-generating substrates are heated to a temperature sufficient to generate an aerosol.

[0010] Advantageously, the aerosol-generating article is planar and, therefore, generally flat and thin thereby allowing for heating of a greater proportion of the one or more aerosol-generating substrates to a temperature at which an aerosol is released whilst minimising the risk of burning the hottest portion of the one or more aerosol-generating substrates closest to the heating element. Additionally, a smaller thickness may provide a small temperature gradient or difference across the thickness of the aerosol-generating article during heating.

[0011] 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.

[0012] 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 efficient and cheap to manufacture. The aerosol-generating substrate(s) being positioned within or adjacent to the first airflow path means that, in use, the air flowing through the first airflow path may flow through or past the aerosol-generating substrate(s). Thus, volatile compounds from the aerosol-generating substrate(s) may be entrained within the air flowing through the first air flow path.

[0013] The aerosol-generating substrate(s) being positioned within or adjacent to the second airflow path means that, in use, the air flowing through the second airflow path may flow through or past the aerosol-generating substrate(s). Thus, volatile compounds from the aerosol-generating substrate(s) may be entrained within the air flowing through the second air flow path.

[0014] When positioned within the first airflow path, the at least one of the one or more aerosolgenerating substrates may be positioned within the first cavity. When positioned within the second airflow path, the at least one of the one or more aerosol-generating substrates may be positioned within the second cavity.

[0015] When positioned adjacent to the first airflow path, the at least one of the one or more aerosol-generating substrates may form a boundary of the first airflow path, at least partially delimit the first air flow path, or may be on a periphery of the first airflow path. For example, an aerosolgenerating substrate may form a wall of the first cavity. Thus, the at least one of the one or more aerosol-generating substrates may be positioned adjacent to the first cavity

[0016] When positioned adjacent to the second airflow path, the at least one of the one or more aerosol-generating substrates may form a boundary of the second airflow path, at least partially delimit the second air flow path, or may be on a periphery of the second airflow path. For example, an aerosol-generating substrate may form a wall of the second cavity. Thus, the at least one of the one or more aerosol-generating substrates may be positioned adjacent to the second cavity.

[0017] The one or more aerosol-generating substrates may be a single aerosol-generating substrate. That is, the aerosol-generating article may only comprise one aerosol-generating substrate. A single aerosol-generating substrate may form a divider or cavity separating wall between the first cavity and second cavity, as discussed in more detail below. Thus, in use, air within both the first airflow path and the second airflow path may flow past the single aerosolgenerating substrate.

[0018] The first airflow path and the second airflow path may be parallel to one another along at least 75 percent of a length of the aerosol-generating article. The first airflow path and the second airflow path may be parallel to one another along at least 80 percent of a length of the aerosolgenerating article. The first airflow path and the second airflow path may be parallel to one another along at least 90 percent of a length of the aerosol-generating article. The first airflow path and the second airflow path may be parallel to one another along at least 95 percent of a length of the aerosol-generating article. The parallel portions of the first airflow path and the second airflow path are distinct airflow paths that are neither upstream nor downstream of each other. In some embodiments, the first airflow path and the second airflow path may be parallel to one another along the entire length of the aerosol-generating article. The first airflow path may comprise a first airflow path portion defined by, and positioned within, the first cavity. The second airflow path may comprise a second airflow path portion defined by, and positioned within, the second cavity. The first airflow path portion may be parallel to the second airflow path portion. The first airflow path portion may have a length at least 75 percent of the length of the first cavity and the second airflow path portion may have a length of at least 75 percent of a length of the second cavity. The first airflow path portion may have a length of at least 80 percent of the length of the first cavity and the second airflow path portion may have a length of at least 80 percent of a length of the second cavity. In some embodiments, the first airflow path portion may have a length substantially the same as a length of the first cavity and the second airflow path portion may have a length substantially the same as a length of the second cavity.

[0019] The first airflow path and the second airflow path may diverge, or split, at or towards an upstream end of one or both of the first cavity and the second cavity. The first airflow path and the second airflow path may diverge, or split, upstream of one or both of the first cavity and the second cavity. Advantageously, this may allow the aerosol-generating article to comprise a single inlet.

[0020] The first airflow path and the second airflow path may merge at or towards a downstream end of one or both of the first cavity and the second cavity. The first airflow path and the second airflow path may merge downstream of one or both of the first cavity and the second cavity. Advantageously, this may allow the aerosol-generating article to comprise a single outlet.

[0021] The aerosol-generating article may comprise at least one air inlet and at least one air outlet. The first airflow path may extend from the at least one air inlet to the at least one air outlet. The second airflow path may extend from the at least one air inlet to the at least one air outlet.

[0022] The first airflow path and the second airflow path may diverge, or split, downstream of the at least one air inlet. The first airflow path and the second airflow path may diverge, or split, immediately downstream of the at least one air inlet. The first airflow path and the second airflow path may merge upstream of the at least one air outlet. The first airflow path and the second airflow path may merge immediately upstream of the at least one air outlet.

[0023] The at least one air inlet may comprise a first air inlet. The aerosol-generating article may comprise a single air inlet. Therefore, the at least one air inlet or the first air inlet may be the single air inlet. The first airflow path may extend from the first air inlet to the at least one air outlet and the second airflow path may extend from the first air inlet to the at least one air outlet. Advantageously, such a configuration allows simultaneous airflow through the first cavity and second cavity whilst allowing the aerosol-generating article to have a single air inlet, thereby simplifying the manufacturing process. Additionally, it may be simpler to align a single air inlet with an airflow conduit of an aerosol-generating device compared to aligning multiple air inlets with one or more airflow conduits in an aerosol-generating device.

[0024] The at least one air outlet may comprise a first air outlet. The aerosol-generating article may comprise a single air outlet. Therefore, the at least one air outlet or the first air outlet may be the single air outlet. The first airflow path may extend from the at least one air inlet to the first air outlet and the second airflow path may extend from the at least one air inlet to the first air outlet. Advantageously, such a configuration allows simultaneous airflow through the first cavity and second cavity whilst allowing the aerosol-generating article to have a single air outlet, thereby simplifying the manufacturing process. Additionally, the use of a single air outlet for both the first airflow path and the second airflow path may allow aerosol in the first airflow path and the second airflow path to mix and homogenise before being delivered to a consumer.

[0025] The at least one air inlet may comprise a first air inlet and the at least one air outlet may comprise a first air outlet. The first airflow path may extend from the first air inlet to the first air outlet and the second airflow path may extend from the first air inlet to the first air outlet. Advantageously, such a configuration allows simultaneous airflow through the first cavity and second cavity whilst allowing the aerosol-generating article to have a single air inlet and a single air outlet, thereby simplifying the manufacturing process.

[0026] The at least one air inlet may comprise a first air inlet and a second air inlet, and the at least one air outlet may comprise of a first air outlet and a second air outlet. The first airflow path may extend from the first air inlet to the first air outlet and the second airflow path may extend from the second air inlet to the second air outlet. The aerosol-generating article may be configured such that air may not flow from the first airflow path to the second airflow path, or vice versa. Advantageously, this may prevent cross-contamination between the first air flow path and the second airflow path, and may also allow the first airflow path to be used in a first smoking session and the second airflow path to be used in a second smoking session, thereby providing a multiuse aerosol-generating article.

[0027] The first airflow path may be convoluted. The first airflow path may have a length greater than a length of the aerosol-generating article. The first airflow path may have a length greater than or equal to 110 percent a length of the aerosol-generating article. The first airflow path may have a length greater than or equal to 130 percent a length of the aerosol-generating article. The first airflow path may have a length greater than or equal to 150 percent a length of the aerosolgenerating article. The first airflow path may have a length greater than or equal to 200 percent a length of the aerosol-generating article.

[0028] Similarly, the second airflow path may be convoluted. The second airflow path may have a length greater than a length of the aerosol-generating article. The second airflow path may have a length greater than or equal to 110 percent a length of the aerosol-generating article. The second airflow path may have a length greater than or equal to 130 percent a length of the aerosolgenerating article. The second airflow path may have a length greater than or equal to 150 percent a length of the aerosol-generating article. The second airflow path may have a length greater than or equal to 200 percent a length of the aerosol-generating article.

[0029] Advantageously, this may increase the contact time between the one or more aerosolgenerating substrates and the airflow with the first or second airflow path. At least one of the one or more aerosol-generating substrates may extend along greater than or equal to 50 percent of a length of the first airflow path or first airflow path portion. At least one of the one or more aerosol-generating substrates may extend along greater than or equal to 60 percent of a length of the first airflow path or first airflow path portion. At least one of the one or more aerosol-generating substrates may extend along greater than or equal to 70 percent of a length of the first airflow path or first airflow path portion. At least one of the one or more aerosolgenerating substrates may extend along greater than or equal to 80 percent of a length of the first airflow path or first airflow path portion.

[0030] At least one of the one or more aerosol-generating substrates may extend along greater than or equal to 50 percent of a length of the second airflow path or second airflow path portion. At least one of the one or more aerosol-generating substrates may extend along greater than or equal to 60 percent of a length of the second airflow path or second airflow path portion. At least one of the one or more aerosol-generating substrates may extend along greater than or equal to 70 percent of a length of the second airflow path or second airflow path portion. At least one of the one or more aerosol-generating substrates may extend along greater than or equal to 80 percent of a length of the second airflow path or second airflow path portion.

[0031] An upstream end of the first cavity may be in fluid communication with an upstream end of the second cavity. A downstream end of the first cavity may be in fluid communication with a downstream end of the second cavity.

[0032] At least one of the one or more aerosol-generating substrates may be positioned in or adjacent to the first cavity. At least one of the one or more aerosol-generating substrates may form a wall, such as an upper or a lower wall, of the first cavity. At least one of the one or more aerosolgenerating substrates may be positioned in or adjacent to the second cavity. At least one of the one or more aerosol-generating substrates may form a wall, such as an upper wall or a lower wall, of the second cavity.

[0033] The first cavity and the second cavity may be stacked in the z-direction. Any cross-section of the aerosol-generating article in the y / z plane extending through the first cavity may also extend through the second cavity. Any cross-section of the aerosol-generating article in the y / z plane extending through the second cavity may also extend through the first cavity. The first cavity and the second cavity may not both extend through the same x / y plane.

[0034] The first cavity and the second cavity may be spaced in the z-direction by less than or equal to 1 millimetre. The first cavity and the second cavity may be spaced in the z-direction by greater than or equal to 100 micrometres.

[0035] The first cavity and the second cavity may be spaced in the z-direction by greater than or equal to 0.5 millimetres, greater than or equal to 1 millimetre, or greater than or equal to 1.5 millimetres.

[0036] The first cavity and the second cavity may be spaced in the z-direction by less than or equal to 5 millimetres, less than or equal to 4 millimetres, or less than or equal to 3 millimetres. The separation in the z-direction of the first cavity and the second cavity may correspond to a width of a cavity separating wall.

[0037] The first cavity and the second cavity may be substantially parallel to one another.

[0038] One or both of the first cavity and the second cavity may have thickness greater than or equal to 25 percent of a thickness of the aerosol-generating article, greater than or equal to 30 percent of a thickness of the aerosol-generating article, greater than or equal to 40 percent of a thickness of the aerosol-generating article, or greater than or equal to 45 percent of a thickness of the aerosol-generating article.

[0039] One or both of the first cavity and the second cavity may have a thickness greater than or equal to 0.25 millimetres, greater than or equal to 0.75 millimetres, greater than or equal to 1.25 millimetres, or greater than or equal to 1 .75 millimetres.

[0040] One or both of the first cavity and the second cavity may have a thickness less than or equal to 2.25 millimetres, less than or equal to 1.75 millimetre, less than or equal to 1.25 millimetres, or less than or equal to 0.75 millimetres.

[0041] One or both of the first cavity and the second cavity may have a thickness between 0.25 millimetres and 2.25 millimetres. One or both of the first cavity and the second cavity may have a thickness between 0.5 millimetre and 2.25 millimetres. Preferably, one or both of the first cavity and the second cavity may have a thickness between 0.8 millimetres and 1.5 millimetres.

[0042] Advantageously, the cavities of the aerosol-generating article are thin thereby improving contact between the one or more aerosol-generating substrates and the airflow through the cavities.

[0043] One or both of the first cavity and the second cavity may have length greater than or equal to 70 percent of a length of the aerosol-generating article, greater than or equal to 80 percent of a length of the aerosol-generating article, greater than or equal to 90 percent of a length of the aerosol-generating article, or greater than or equal to 95 percent of a length of the aerosolgenerating article.

[0044] One or both of the first cavity and the second cavity may have a length greater than or equal to 14 millimetres. One or both of the first cavity and the second cavity may have a length greater than or equal to 18 millimetres. One or both of the first cavity and the second cavity may have a length greater than or equal to 22 millimetres. One or both of the first cavity and the second cavity may have a length greater than or equal to 30 millimetres. One or both of the first cavity and the second cavity may have a length greater than or equal to 38 millimetres.

[0045] One or both of the first cavity and the second cavity may have a length less than or equal to 40 millimetres. One or both of the first cavity and the second cavity may have a length less than or equal to 34 millimetres. One or both of the first cavity and the second cavity may have a length less than or equal to 28 millimetres. One or both of the first cavity and the second cavity may have a length less than or equal to 22 millimetres. One or both of the first cavity and the second cavity may have a length less than or equal to 18 millimetres. One or both of the first cavity and the second cavity may have a length between 14 millimetres and 40 millimetres. One or both of the first cavity and the second cavity may have a length between 14 millimetres and 34 millimetres. One or both of the first cavity and the second cavity may have a length between 24 millimetres and 28 millimetres.

[0046] A ratio between a length of the first cavity and a length of the second cavity may be between 0.8 and 1 .2 or between about 0.9 and 1.1. Preferably, a length of the first cavity and a length of the second cavity are substantially the same.

[0047] One or both of the first cavity and the second cavity may have width greater than or equal to 60 percent of a width of the aerosol-generating article, greater than or equal to 70 percent of a width of the aerosol-generating article, greater than or equal to 80 percent of a width of the aerosolgenerating article, greater than or equal to 90 percent of a width of the aerosol-generating article, or greater than or equal to 95 percent of a width of the aerosol-generating article.

[0048] One or both of the first cavity and the second cavity may have a width greater than or equal to 4.5 millimetres. One or both of the first cavity and the second cavity may have a width greater than or equal to 7 millimetres. One or both of the first cavity and the second cavity may have a width greater than or equal to 11 millimetres.

[0049] One or both of the first cavity and the second cavity may have a width less than or equal to 13 millimetres. One or both of the first cavity and the second cavity may have a width less than or equal to 11 millimetres. One or both of the first cavity and the second cavity may have a width less than or equal to 7 millimetres. One or both of the first cavity and the second cavity may have a width less than or equal to 5 millimetres.

[0050] One or both of the first cavity and the second cavity may have a width between 4.5 millimetres and 13 millimetres. One or both of the first cavity and the second cavity may have a width between 7 millimetres and 10 millimetres. One or both of the first cavity and the second cavity may have a width between 7.5 millimetres and 8.5 millimetres.

[0051] Preferably, a width of the first cavity and a width of the second cavity are substantially the same.

[0052] One or both of the first cavity and the second cavity may have a length between 14 millimetres and 40 millimetres, a width between 4.5 millimetres and 13 millimetres, and a thickness between 0.25 millimetres and 2.25 millimetres.

[0053] Preferably, one or both of the first cavity and the second cavity may have a length between 20 millimetres and 30 millimetres, a width between 7 millimetres and 10 millimetres, and a thickness between 1.25 millimetres and 2 millimetres.

[0054] Most preferably, one or both of the first cavity and the second cavity may have a length of 26 millimetres, a width of 8 millimetres, and a thickness of 1 .5 millimetres.

[0055] One or both of the first cavity and the second cavity may have a volume of greater than or equal to 15 cubic millimetres, greater than or equal to 50 cubic millimetres, greater than or equal to 150 cubic millimetres, greater than or equal to 250 cubic millimetres, greater than or equal to 350 cubic millimetres, greater than or equal to 450 cubic millimetres, greater than or equal to 500 cubic millimetres, greater than or equal to 1000 cubic millimetres, or greater than or equal to 1500 cubic millimetres.

[0056] One or both of the first cavity and the second cavity may have a volume of less than or equal to 1750 cubic millimetres, less than or equal to 1250 cubic millimetres, less than or equal to 750 cubic millimetres, less than or equal to 500 cubic millimetres, less than or equal to 400 cubic millimetres, less than or equal to 300 cubic millimetres, less than or equal to 250 cubic millimetres, less than or equal to 200 cubic millimetres, or less than or equal to 150 cubic millimetres.

[0057] One or both of the first cavity and the second cavity may have a volume between 15 cubic millimetres and 1500 cubic millimetres, between 15 cubic millimetres and 1750 cubic millimetres, between 50 cubic millimetres and 750 cubic millimetres, or between 50 cubic millimetres and 500 cubic millimetres.

[0058] The first cavity may be substantially empty. The second cavity may be substantially empty. Preferably, both the first cavity and the second cavity may be substantially empty. However, in some embodiments, only one of the first cavity and the second cavity may be substantially empty.

[0059] An aerosol-generating substrate may be positioned within the first cavity. The aerosolgenerating substrate positioned within the first cavity may extend across the entire width and thickness of the first cavity.

[0060] The aerosol-generating substrate positioned within the first cavity may extend along at least 80 percent, or at least 90 percent, of a length of the first cavity. The aerosol-generating substrate positioned within the first cavity may extend along the entire length of the first cavity. The aerosol-generating substrate positioned within the first cavity may fill the first cavity.

[0061] The aerosol-generating substrate positioned within the first cavity may have a length equal to or less than 80 percent, equal to or less than 70 percent, equal to or less than 60 percent, or equal to or less than 50 percent of a length of the first cavity.

[0062] The aerosol-generating substrate positioned within the first cavity may be spaced from the downstream end of the first cavity. The aerosol-generating substrate positioned within the first cavity may positioned at, or towards, an upstream end of the cavity.

[0063] The aerosol-generating substrate positioned within the first cavity may be spaced from the upstream end of the first cavity. The aerosol-generating substrate positioned within the first cavity may positioned at, or towards, a downstream end of the first cavity.

[0064] An aerosol-generating substrate may be positioned within the second cavity. The aerosolgenerating substrate positioned within the second cavity may extend across the entire width and thickness of the second cavity. The aerosol-generating substrate positioned within the second cavity may extend along at least 80 percent, or at least 90 percent, of a length of the second cavity. The aerosol-generating substrate positioned within the second cavity may extend along the entire length of the second cavity. The aerosol-generating substrate positioned within the second cavity may fill the second cavity. The aerosol-generating substrate positioned within the second cavity may have a length equal to or less than 80 percent, equal to or less than 70 percent, equal to or less than 60 percent, or equal to or less than 50 percent of a length of the second cavity.

[0065] The aerosol-generating substrate positioned within the second cavity may be spaced from the downstream end of the second cavity. The aerosol-generating substrate positioned within the second cavity may positioned at, or towards, an upstream end of the second cavity.

[0066] The aerosol-generating substrate positioned within the second cavity may be spaced from the upstream end of the second cavity. The aerosol-generating substrate positioned within the second cavity may positioned at, or towards, a downstream end of the second cavity.

[0067] One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity may comprise one or more organic materials such as tobacco, mint, tea and cloves.

[0068] One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity 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.

[0069] One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity may comprise a sheet of aerosolgenerating material.

[0070] 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. The sheet of aerosol-generating material may be a crimped sheet of aerosolgenerating material. The sheet of aerosol-generating material may be a corrugated sheet of aerosol-generating material. The crimped sheet of aerosol-generating material or the corrugated sheet of aerosol-generating material may comprise a plurality of parallel corrugations. For example, the crimped sheet of aerosol-generating material may comprise a plurality of substantially parallel peaks and troughs.

[0071] 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. 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 within which the sheet of aerosol-generating material is positioned. The plurality of channels may be a plurality of longitudinally extending channels. The plurality of channels may be a plurality of laterally extending channels.

[0072] One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity may comprise 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.

[0073] One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity may comprise cut filler, such as 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.

[0074] One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity may comprise one or more aerosol-formers. Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosol-formers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosol-former to be or comprise one or both of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0075] One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity 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. One or both of the aerosol-generating substrate positioned within the first cavity and the aerosolgenerating substrate positioned within the second cavity 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.

[0076] One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity 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.

[0077] One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity 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. One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity 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.

[0078] One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity may comprise nicotine. For example, natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0079] One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity 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, one or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity 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.

[0080] One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity 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.

[0081] The term “bead” refers to a discrete, solid particle formed of the aerosol-generating substrate. A bead may have a rounded, typically spherical, form. Otherterms may be used to define the substrate such as, for example, “granule”.

[0082] Providing the aerosol-generating substrate 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 one or both cavities of the aerosol-generating article during manufacture. This may allow a consistent and reproducible amount of aerosol-generating 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.

[0083] 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. 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.

[0084] One or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity may be in form of a wrapped body of aerosol-generating material, the wrapped body comprising a wrapper at least partially enclosing aerosol-generating substrate.

[0085] The wrapped body of aerosol-generating material may occupy between 15% and 100% of the interior volume of the respective cavity. The wrapped body of aerosol-generating material may occupy between 30% and 100% of the interior volume of the respective cavity. The wrapped body of aerosol-generating material may occupy between 50% and 100% of the interior volume of the respective cavity. The wrapped body of aerosol-generating material may occupy between 50% and 80% of the interior volume of the respective cavity. The wrapped body of aerosol-generating material may occupy between 50% and 70% of the interior volume of the respective cavity.

[0086] The aerosol-generating article may comprise a chamber or region downstream of both the first cavity and the second cavity, and upstream of the at least one air outlet, through which both the first airflow path and the second airflow path extend. Advantageously, the downstream chamber or region may allow for mixing and homogenisation of aerosol from the first cavity and the second cavity.

[0087] The aerosol-generating article may comprise a cavity separating wall positioned between the first cavity and the second cavity. The cavity separating wall may be planar and extend in the x-direction and the y-direction. The cavity separating wall may form a wall of the first cavity and a wall of the second cavity. For example, the cavity separating wall may form a lower wall of the first cavity and the cavity separating wall may form an upper wall of the second cavity. Advantageously, the cavity separating wall may provide structural support for one or more aerosol-generating substrates positioned in or adjacent to the first cavity or the second cavity.

[0088] The cavity separating wall may span the entire width of both the first cavity and the second cavity, and span the entire length of both the first cavity and the second cavity. Advantageously, this may prevent air flow from the first cavity to the second cavity, or vice versa.

[0089] The cavity separating wall may span the entire width of both the first cavity and the second cavity, and span at least 75 percent of a length of the first cavity and the second cavity. The cavity separating wall may span at least 85 percent of a length of the first cavity and the second cavity. The cavity separating wall may span at least 90 percent of a length of the first cavity and the second cavity. The cavity separating wall may span less than or equal to 90 percent of a length of the first cavity and the second cavity. The cavity separating wall may span less than or equal to 80 percent of a length of the first cavity and the second cavity. Advantageously, this may only allow air to flow from the first cavity to second cavity at an upstream end of the first cavity and second cavity, a downstream end of the first cavity and the second cavity, or both the upstream end and the downstream end of the first cavity and the second cavity.

[0090] The cavity separating wall may comprise at least one aperture extending through the thickness of the cavity separating wall for fluid communication between the first cavity and the second cavity. Advantageously, the at least one aperture may allow distribution of air flow between the first cavity and the second cavity. Additionally, the at least one aperture may allow for the first airflow path and the second airflow path to converge or diverge.

[0091] The at least one aperture may be in fluid communication with the at least one inlet. The at least one aperture may be in fluid communication with the at least one outlet.

[0092] The at least one aperture extending through the thickness of the cavity separating wall may comprise an upstream aperture located at or towards an upstream end of the first cavity and an upstream end of the second cavity. The upstream aperture may be located downstream of the at least one inlet of the aerosol-generating article. Preferably, the upstream aperture may be located immediately downstream of the at least one inlet of the aerosol-generating article. More preferably, an upstream end of the upstream aperture may coincide with a downstream end of the at least one air inlet. Advantageously, the upstream aperture may allow air entering the aerosol-generating article to distribute itself between the first cavity and the second cavity, thereby ensuring good airflow within both the first cavity and the second cavity. Additionally, the upstream aperture may promote turbulent airflow within the first cavity and the second cavity, thereby improving aerosolization.

[0093] The upstream aperture may have a width less than a width of the first cavity, and a width less than a width of the second cavity. The upstream aperture may have a width less than or equal to 75 percent a width of the first cavity, and a width less than or equal to 75 percent a width of the second cavity. The upstream aperture may have a width greater than or equal to 25 percent a width of the first cavity, and a width greater than or equal to 25 percent a width of the second cavity. Preferably, the upstream aperture may have a width between 25 percent and 75 percent a width of the first cavity, and a width between 25 percent and 75 percent a width of the second cavity. Advantageously, this may ensure a good volume of air can be distributed between the first cavity and the second cavity whilst ensuring that the cavity separating wall can provide good structural support for the one or more aerosol-generating substrates.

[0094] The upstream aperture may have a length less than or equal to 25 percent of a length of the first cavity, and a length less than 25 percent of a length of the second cavity. The upstream aperture may have a length less than or equal to 10 percent of a length of the first cavity, and a length less than 10 percent of a length of the second cavity. The upstream aperture may have a length less than or equal to 5 percent of a length of the first cavity, and a length less than 5 percent of a length of the second cavity. Advantageously, this may ensure separation of the airflow in the first cavity and the second cavity along a majority of the length of the first cavity and the second cavity. The at least one aperture extending through the thickness of the cavity separating wall may comprise a downstream aperture located at or towards a downstream end of the first cavity and a downstream end of the second cavity. The downstream aperture may be located upstream of the at least one outlet of the aerosol-generating article. Preferably, the downstream aperture may be located immediately upstream of the at least one outlet of the aerosol-generating article. More preferably, a downstream end of the downstream aperture may coincide with an upstream end of the at least one air outlet. Advantageously, the downstream aperture may allow aerosol that has been generated in the first cavity and aerosol the has been generated in the second cavity to merge and homogenise before being inhaled by a consumer.

[0095] The downstream aperture may have a width less than a width of the first cavity, and a width less than a width of the second cavity. The downstream aperture may have a width less than or equal to 75 percent a width of the first cavity, and a width less than or equal to 75 percent a width of the second cavity. The downstream aperture may have a width greater than or equal to 25 percent a width of the first cavity, and a width greater than or equal to 25 percent a width of the second cavity. Preferably, the downstream aperture has a width between 25 percent and 75 percent a width of the first cavity, and a width between 25 percent and 75 percent a width of the second cavity. Advantageously, this may provide a suitably sized region for homogenisation of aerosol whilst ensuring that the cavity separating wall can provide good structural support for the aerosol-generating article.

[0096] The downstream aperture may have a length less than or equal to 25 percent of a length of the first cavity, and a length less than 15 percent of a length of the second cavity. The downstream aperture may have a length less than or equal to 10 percent of a length of the first cavity, and a length less than 5 percent of a length of the second cavity. Advantageously, this may ensure separation of the airflow in the first cavity and the second cavity along a majority of the length of the first cavity and the second cavity.

[0097] The upstream aperture may be the only aperture extending through the thickness of the cavity separating wall. The downstream aperture may be the only aperture extending through the thickness of the cavity separating wall. The upstream aperture and the downstream aperture may be the only apertures extending through the thickness of the cavity separating wall.

[0098] The material of the cavity separating wall may be substantially air impermeable. Thus, the air and aerosol may only flow through the cavity separating wall via the at least one aperture extending through the thickness of the cavity separating wall, if any.

[0099] The cavity separating wall may comprise, or consist of, a sheet of material.

[0100] The sheet of material may have a grammage greater than or equal to 150 grams per square metre, greater than or equal to 200 grams per square metre, greater than or equal to 250 grams per square metre, greater than or equal to 300 grams per square metre, greater than or equal to 400 grams per square metre, or greater than or equal to 500 grams per square metre. The sheet of material may have a grammage less than or equal to 900 grams per square metre, less than or equal to 700 grams per square metre, less than or equal to 500 grams per square metre, less than or equal to 400 grams per square metre, or less than or equal to 350 grams per square metre.

[0101] The sheet of material may have a grammage between 150 grams per square metre and 900 grams per square metre, between 200 grams per square metre and 700 grams per square metre, or between 200 grams per square metre and 500 grams per square metre. Preferably, The sheet of material may have a grammage between 200 grams per square metre and 400 grams per square metre. Advantageously, the cavity separating wall having a grammage between 200 grams per square metre and 400 grams per square meter may allow the cavity separating wall to provide good structural support to the aerosol-generating article whilst having sufficient flexibility for the aerosol-generating article to be manufactured in a continuous manufacturing process.

[0102] The cavity separating wall may comprise, or consist of, a sheet of cellulosic material such as paper, paperboard or cardboard. Advantageously, the use of a sheet of cellulosic material for the cavity separating wall may lead to an aerosol-generating article that is relatively cheap and simple to manufacture. Moreover, it may result in an aerosol-generating article that is easier or more environmentally-friendly to dispose of. The sheet of cellulosic material may comprise a hydrophobic surface, for example the sheet of cellulosic material may have a hydrophobic coating. In particular, the surfaces forming a lower wall of the first cavity and the upper wall of the second cavity may be hydrophobic. Advantageously, the hydroscopic surface may prevent or limit degradation of the cavity separating wall in regions where the cavity separating wall is regularly in contact with aerosol or liquids.

[0103] The cavity separating wall may comprise, or consist of, a sheet of aerosol-generating substrate, such as a sheet of tobacco material. Preferably, the cavity separating wall may comprise, or consist of, a sheet of homogenised tobacco material, such as cast leaf. Advantageously, the use a sheet of aerosol-generating substrate as the cavity separating wall may allow air flow in the first cavity to contact the upper surface of the sheet of aerosol-generating substrate, and air flow in the second cavity to contact the lower surface of the sheet of aerosol-generating substrate, thereby increasing the amount of aerosol that is generated from the sheet of aerosol-generating substrate.

[0104] The cavity separating wall, preferably the sheet of aerosol-generating substrate, may comprise one or more flavourants. The one or more flavourants may comprise one or more of: one or more essential oils such as eugenol, peppermint oil and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and a herbaceous material. Suitable herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, thyme, and caraway.

[0105] The cavity separating wall, preferably the sheet of aerosol-generating substrate, comprise one or more aerosol-formers. Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosol-formers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosol-former to be or comprise one or both of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0106] The cavity separating wall, preferably the sheet of aerosol-generating substrate, may have an aerosol-former content greater than or equal to 1 , 2, 5, 10, or 15 percent by weight on a dry weight basis. The cavity separating wall, preferably the sheet of aerosol-generating substrate, 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.

[0107] The cavity separating wall, preferably the sheet of aerosol-generating substrate, may have an aerosol-former content less than or equal to 30 percent by weight on a dry weight basis, less than or equal to 25 percent by weight on a dry weight basis, or less than or equal to 20 percent by weight on a dry weight basis.

[0108] The cavity separating wall, preferably the sheet of aerosol-generating substrate, 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.

[0109] The cavity separating wall, preferably the sheet of aerosol-generating substrate, 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.

[0110] The cavity separating wall, preferably the sheet of aerosol-generating substrate, may comprise nicotine. For example, natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0111] The cavity separating wall, preferably the sheet of aerosol-generating substrate, may comprise at least 0.5 percent by weight of nicotine, at least 1 percent by weight of nicotine, at least 1 .5 percent by weight of nicotine, or at least 2 percent by weight of nicotine. That is, one or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity 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.

[0112] The cavity separating wall, preferably the sheet of aerosol-generating substrate, may comprise one or more flavourants. The one or more flavourants may comprise one or more of: one or more essential oils such as eugenol, peppermint oil and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and a herbaceous material. Suitable herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavourants may comprise a tobacco material.

[0113] The cavity separating wall, preferably the sheet of aerosol-generating substrate, may comprise one or more botanicals. For example, the cavity separating wall, preferably the sheet of aerosol-generating substrate, may comprise about 15 to 55 %, preferably of about 20 to 35 %, of botanicals such as Clove, Echinacea sp., Fennel, Ginger, Hawthorn berry, Elderberry, Monarda, Mullein leaves, Nettle, Plantain, Turmeric, Yarrow, and compounds of those.

[0114] The aerosol-generating article may comprise a first external surface and a second external surface. The first external surface may be spaced from the second external surface in the z- direction. The distance between the first external surface and the second external surface in the z-direction or transverse direction may define the thickness of the aerosol-generating article.

[0115] The first external surface may be referred to as an upper external surface and the second external surface may be referred to as a lower external surface. The first external surface may be a first planar external surface. The second external surface may be a second planar external surface. Advantageously, the first planar external surface and the second planar external surface may allow for good contact with an external heater, particularly a planar external heater, of an aerosol-generating device, thereby providing optimum heating of the aerosol-generating substrate.

[0116] The first external surface may be positioned parallel to the second external surface. The first external surface may extend in the x / y plane. The second external surface may extend in the x / y plane.

[0117] The aerosol-generating article may comprise one or more external walls extending between the first external surface of the aerosol-generating article and the second external surface of the aerosol-generating article. The one or more external walls may collectively define an entire transverse external area of the aerosol-generating article.

[0118] The aerosol-generating article may comprise a frame. The frame may at least partially define or form the first cavity and the second cavity. The frame may comprise the cavity separating wall. Advantageously, the frame may provide the aerosol-generating article with structural support. In particular, the frame may allow the aerosol-generating article to be relatively thin whilst maintaining structural rigidity.

[0119] The frame may be a planar frame.

[0120] The frame may comprise a frame outer surface. The frame outer surface may extend in a transverse direction, for example between the first external surface of the aerosol-generating article and the second external surface of the aerosol-generating article. 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.

[0121] The frame may comprise a frame inner surface. The frame inner surface may extend in a transverse direction, for example between the first external surface of the aerosol-generating article and the second external surface of the aerosol-generating device. The frame inner surface may define or form one or both of an outer wall of the first cavity and an outer wall of the second cavity. The frame outer surface may circumscribe or encircle the first cavity and the second cavity.

[0122] 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.

[0123] The frame may at least partially define each of the one or more external walls of the aerosol-generating article. The one or more external walls of the aerosol-generating article may circumscribe or encircle the first cavity and the second 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.

[0124] The frame may comprise a peripheral wall. The peripheral wall may circumscribe or encircle at least a portion of the first cavity and the second cavity.

[0125] 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 one or both of an outer wall of the first cavity and an outer wall of the second cavity.

[0126] 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.

[0127] 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.

[0128] 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.

[0129] 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.

[0130] 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 aerosolgenerating substrate.

[0131] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material. The frame may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may comprise cellulose fibres. The cellulosic material may be paper, paperboard, or cardboard. The frame may be made from or comprise a plant material, such as tobacco. The frame may be made entirely from a cellulosic material.

[0132] 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 one or more aerosol-generating substrates. The one more susceptor materials may be in thermal contact with one or both the first cavity and the second cavity. The one or more susceptor materials may be incorporated within the material of the frame.

[0133] 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.

[0134] 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.

[0135] The frame may have a thickness greater than or equal to 50 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 70 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 90 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 95 percent of the thickness of the aerosol-generating article.

[0136] The frame may have a thickness less than or equal to 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 90 percent of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 70 percent of the thickness of the aerosol-generating article.

[0137] The frame may have a thickness between 50 percent of the thickness of the aerosolgenerating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 70 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article.

[0138] The frame may have a thickness 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 thickness 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 thickness between 1 millimetre and 5.5 millimetres. Preferably, the frame may have a thickness between 1.5 millimetres and 5.5 millimetres. 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.

[0139] 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.

[0140] 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. 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.

[0141] The frame may comprise a first frame layer, a second frame layer and a 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.

[0142] The first frame layer may be planar.

[0143] The first frame layer may at least partially define or form the first cavity. The first frame layer may define a first frame layer aperture extending through the thickness of the first frame layer. The first frame layer aperture may at least partially define or form the first cavity of the aerosol-generating article.

[0144] The first frame layer may comprise a first frame layer peripheral wall. The first frame layer peripheral wall may at least partially circumscribe or encircle the first cavity. Preferably, the first frame layer peripheral wall circumscribes or encircles the entire perimeter of the first cavity. The first frame layer peripheral wall may have any radial thickness described above in relation to peripheral wall of the frame.

[0145] The first frame layer may be in physical contact with the second frame layer. The first frame layer may be may be bonded to the second frame layer, such as with an adhesive.

[0146] The first frame layer may comprise a biodegradable material. The first frame layer may be made entirely from biodegradable material. The first frame layer may be made from or comprise a cellulosic material, such as a sheet of cellulosic material. The first frame layer may be made entirely from a cellulosic material. The first frame layer may be made from or comprise paper, paperboard, or cardboard. The first frame layer may be made from or comprise a plant material, such as tobacco. The first frame layer may be made from or comprise a sheet of metal foil, such as aluminium foil. The first frame layer may be made from or comprise a sheet of susceptor material.

[0147] The second frame layer may comprise or form the cavity separating wall and may be positioned between the first frame layer and the third frame layer. Thus, the second frame layer may have any features described in relation to the cavity separating wall.

[0148] The second frame layer may comprise a notch extending through the thickness of the second frame layer and defining the at least one inlet of the aerosol-generating article. The notch may define both the upstream aperture and the at least one air inlet of the aerosol-generating article. Advantageously, this may allow the aerosol-generating article to be manufactured more efficiently and cost-effectively by reducing the number of manufacturing steps. Additionally, this may ensure that the upstream aperture is positioned immediately downstream of, and is aligned with, the at least one inlet such that air flowing into the aerosol-generating article through the at least one inlet may distribute between the first cavity and the second cavity at the upstream end of the first and second cavity.

[0149] The second frame layer may comprise a notch extending through the thickness of the second frame layer and defining the at least one outlet of the aerosol-generating article. The notch may define both the downstream aperture and the at least one air outlet of the aerosol-generating article. Advantageously, this may allow the aerosol-generating article to be manufactured more efficiently and cost-effectively by reducing the number of manufacturing steps. Additionally, this may ensure that the downstream aperture is positioned immediately upstream of, and is aligned with, the at least one air outlet such that aerosol that is been generated may homogenised immediately upstream of the at least one air outlet of the aerosol-generating article and be rapidly delivered to the consumer.

[0150] The third frame layer may be planar.

[0151] The third frame layer may at least partially define or form the second cavity. The second frame layer may define a third frame layer aperture extending through the thickness of the third frame layer. The third frame layer aperture may at least partially define or form the second cavity of the aerosol-generating article.

[0152] The third frame layer may comprise a third frame layer peripheral wall. The third frame layer peripheral wall may at least partially circumscribe or encircle the second cavity. Preferably, the third frame layer peripheral wall circumscribes or encircles the entire perimeter of the second cavity. The third frame layer peripheral wall may have any radial thickness described above in relation to peripheral wall of the frame.

[0153] The third frame layer may be in physical contact with the second frame layer. The third frame layer may be may be bonded to the second frame layer, such as with an adhesive.

[0154] The third frame layer may comprise a biodegradable material. The third frame layer may be made entirely from biodegradable material. The third frame layer may be made from or comprise a cellulosic material, such as a sheet of cellulosic material. The third frame layer may be made entirely from a cellulosic material. The third frame layer may be made from or comprise paper, paperboard, or cardboard. The third frame layer may be made from or comprise a plant material, such as tobacco. The third frame layer may be made from or comprise a sheet of metal foil, such as aluminium foil. The third frame layer may be made from or comprise a sheet of susceptor material.

[0155] The aerosol-generating article may comprise at least one aerosol-generating substrate layer. Advantageously, the at least one aerosol-generating substrate layer can be made thin and, therefore, quickly heat up and release volatile compounds to form an aerosol. Advantageously, the at least one aerosol-generating substrate layer can be positioned close to a heater of an aerosolgenerating substrate.

[0156] The at least one aerosol-generating substrate layer may comprise an aerosol-generating substrate layer positioned between the frame and the first external surface of the aerosolgenerating article or an aerosol-generating substrate layer positioned between the frame and the second external surface. The aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame.

[0157] The aerosol-generating substrate layer may overlie the first cavity or the second cavity. The aerosol-generating substrate layer may define or form a wall of the first cavity or a wall of the second cavity. The aerosol-generating substrate layer may extend the entire length and width of the first cavity. The aerosol-generating substrate layer may extend the entire length and width of the second cavity. Advantageously, the aerosol-generating substrate layer may therefore be in, or at least partially define or form, the first airflow path or second airflow path, thereby allowing released volatile compounds to quickly form an aerosol within the first cavity or second cavity.

[0158] The at least one aerosol-generating substrate layer may comprise a first aerosolgenerating substrate layer and a second aerosol-generating substrate layer. The first cavity and the second cavity may be positioned between the first aerosol-generating substrate layer and the second aerosol-generating substrate layer. The frame may be positioned between the first aerosolgenerating substrate layer and the 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.

[0159] The first aerosol-generating substrate layer may be positioned between the frame and the first external surface of the aerosol-generating article. The first aerosol-generating substrate layer may overlie the first cavity. The first aerosol-generating substrate layer may define or form a wall, such as an upper wall, of the first cavity. The first aerosol-generating substrate layer may extend the entire length and width of the first cavity. The first aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame.

[0160] The second aerosol-generating substrate layer may be positioned between the frame and the second external surface of the aerosol-generating article. The second aerosol-generating substrate layer may overlie the second cavity. The second aerosol-generating substrate layer may define or form a wall, such as a lower wall, of the second cavity. The second aerosol-generating substrate layer may extend the entire length and width of the second cavity. The second aerosolgenerating substrate layer may be in physical contact with, and may be bonded to, the frame.

[0161] The, each of the, or any of the, at least one aerosol-generating substrate layer may comprise a sheet of aerosol-generating material. 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 sheet of aerosol-generating material may comprise one or more organic materials such as tobacco, mint, tea and cloves.

[0162] The, each of the, or any of the, at least one aerosol-generating substrate layer may comprise one or more aerosol-formers. Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosol-formers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono- , di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosol-former to be or comprise one or both of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0163] The, each of the, or any of the, at least one aerosol-generating substrate layer may have an aerosol-former content greater than or equal 1 , 2, 5, 10, or 15 percent by weight on a dry weight basis. The, each of the, or any of the, at least one aerosol-generating substrate layer 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.

[0164] The, each of the, or any of the, at least one aerosol-generating substrate layer 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.

[0165] The, each of the, or any of the, at least one aerosol-generating substrate layer 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.

[0166] The, each of the, or any of the, at least one aerosol-generating substrate layer 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.

[0167] The, each of the, or any of the, at least one aerosol-generating substrate layer may comprise nicotine. For example, natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0168] The, each of the, or any of the, at least one aerosol-generating substrate layer 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, one or both of the aerosol-generating substrate positioned within the first cavity and the aerosol-generating substrate positioned within the second cavity 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.

[0169] The, each of the, or any of the, at least one aerosol-generating substrate layer may comprise one or more flavourants. The one or more flavourants may comprise one or more of: one or more essential oils such as eugenol, peppermint oil and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and a herbaceous material. Suitable herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavourants may comprise a tobacco material.

[0170] The, each of the, or any of the, at least one aerosol-generating substrate layer comprise one or more botanicals. For example, the, or each of the, at least one aerosol-generating substrate layer may comprise about 15 to 55 %, preferably of about 20 to 35 %, of botanicals such as Clove, Echinacea sp., Fennel, Ginger, Hawthorn berry, Elderberry, Monarda, Mullein leaves, Nettle, Plantain, Turmeric, Yarrow, and compounds of those.

[0171] The, each of the, or any of the, at least one aerosol-generating substrate layers 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.

[0172] The, each of the, or any of the, at least one aerosol-generating substrate layers 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.

[0173] The, each of the, or any of the, at least one aerosol-generating substrate layers 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.

[0174] The, each of the, or any of the, at least one aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The, each of the, or any of the, at least one aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article.

[0175] The, each of the, or any of the, at least one aerosol-generating substrate layers may have a width substantially the same as the width of the frame. The, each of the, or any of the, at least one aerosol-generating substrate layer may have a width substantially the same as the width of the aerosol-generating article.

[0176] The aerosol-generating article may comprise at least one outer wrapper.

[0177] The at least one outer wrapper may define or form one or both of the first external surface of the aerosol-generating article and the second external surface of the aerosol-generating article. The at least one outer wrapper may define or form one or both of a wall of the first cavity and a wall of the second cavity.

[0178] The at least one outer wrapper may fully circumscribe or encircle the aerosol-generating article. The at least one outer wrapper may fully circumscribe or encircle the aerosol-generating article along greater than or equal to 90 percent of a length of the aerosol-generating article. Preferably, the at least one outer wrapper may fully circumscribe or encircle the aerosol-generating article along 100 percent of a length of the aerosol-generating article.

[0179] The at least one outer wrapper may circumscribe or encircle the frame. The at least one outer wrapper may be in physical contact with, and may be bonded to, the frame. The frame and the at least one outer wrapper may collectively define the first cavity and the second cavity.

[0180] The at least one outer wrapper may circumscribe or encircle the at least one aerosolgenerating substrate layer, such as the first aerosol-generating substrate layer and the second aerosol-generating substrate layer. The at least one outer wrapper may be in physical contact with, and may be bonded to, the at least aerosol-generating substrate layer, such as the first aerosolgenerating substrate layer and the second aerosol-generating substrate layer.

[0181] The at least one outer wrapper may circumscribe or encircle the frame, the first aerosolgenerating substrate layer and the second aerosol-generating substrate layer. The at least one outer wrapper may be in physical contact with, and may be bonded to, both the first aerosolgenerating substrate layer and the second aerosol-generating substrate layer.

[0182] The at least one outer wrapper may comprise a first outer wrapper and a second outer wrapper. The first outer wrapper may form a first external layer of the aerosol-generating article and the second outer wrapper may form a second external layer of the aerosol-generating article. The first external layer may be a first planar external layer. The second external layer may be a second planar external layer. The first outer wrapper may define or form a wall of the first cavity and the second outer wrapper may define or form a wall of the second cavity. The first cavity and the second cavity may be positioned between the first outer wrapper and the second outer wrapper. The frame may be positioned between the first outer wrapper and the second outer wrapper. The at least one aerosol-generating substrate layer, such as the first aerosol-generating substrate layer and the second aerosol-generating substrate layer, may be positioned between the first outer wrapper and the second outer wrapper.

[0183] The first planar external layer may be an upper layer and the second planar external layer may be a lower layer.

[0184] 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. 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 first cavity. The first planar external layer may define or form a wall of the first cavity.

[0185] 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 second cavity. The second planar external layer may define or form a wall of the second cavity.

[0186] The first planar external layer may be spaced, such as in a transverse direction, from the frame. For example, the at least one aerosol-generating substrate layer, such as the first aerosolgenerating 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 at least one aerosol-generating substrate layer, such as the first aerosol-generating substrate layer.

[0187] The second planar external layer may be spaced, such as in a transverse direction, from the frame. For example, the at least one aerosol-generating substrate layer, such as 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 at least one aerosol-generating substrate layer, such as the second aerosolgenerating substrate layer.

[0188] 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.

[0189] The, each of the, or any of the, at least one outer wrapper may be hydrophobic. The, or any of the, at least one outer wrapper may comprise a hydrophobic material.

[0190] The, each of the, or any of the, at least one outer wrapper 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.

[0191] The, each of the, or any of the, at least one outer wrapper comprise an aerosol-generating substrate. Alternatively, the, each of the, or any of the, at least one outer wrapper may not comprise any aerosol-generating substrate. The, each of the, or any of the, at least one outer wrapper may be substantially nicotine-free or substantially tobacco-free.

[0192] The, each of the, or any of the, at least one outer wrapper 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.

[0193] The, each of the, or any of the, at least one outer wrapper 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. The, each of the, or any of the, at least one outer wrapper may have a thickness between 25 micrometres and 55 micrometres, between 25 micrometres and 45 micrometres, or between 30 micrometres and 45 micrometres.

[0194] The, each of the, or any of the, at least one outer wrapper may have a length substantially the same as the length of the frame. The, or any of the, at least one outer wrapper may have a length substantially the same as the length of the aerosol-generating article.

[0195] The, each of the, or any of the, at least one outer wrapper may have a width substantially the same as the width of the frame. The, or any of the, at least one outer wrapper may have a width substantially the same as the width of the aerosol-generating article.

[0196] The aerosol-generating article may comprise at least one air inlet. In some embodiments, the aerosol-generating article has a single air inlet. Therefore, the at least one air inlet may be a single air inlet. In other embodiments, the aerosol-generating article may have a plurality of air inlets. Therefore, the at least one air inlet may be a plurality of air inlets.

[0197] The at least one air inlet may be defined by the front wall of the aerosol-generating article. The at least one air inlet may be defined by, and may extend through, the frame. The at least one air inlet may be defined by, and may extend through, the peripheral wall of the frame. The at least one air inlet may be defined by, and may extend through, one or more of: the least one outer wrapper and the at least one aerosol-generating substrate layer.

[0198] The, or each of the, at least one air inlet may have a round cross-section, a circular crosssection, an oval cross-section, a square cross-section, or a rectangular cross-section.

[0199] The aerosol-generating article may comprise at least one air outlet. In some embodiments, the aerosol-generating article has a single air outlet. Therefore, the at least one air outlet may be a single air inlet. In other embodiments, the aerosol-generating article may have a plurality of air outlets. Therefore, the at least one air outlet may be a plurality of air outlets.

[0200] The at least one air outlet may be defined by the back wall of the aerosol-generating article. The at least one air outlet may be defined by, and may extend through, the frame. The at least one air outlet may be defined by, and may extend through, the peripheral wall of the frame. The at least one air outlet may be defined by, and may extend through, one or more of: the least one outer wrapper and the at least one aerosol-generating substrate layer.

[0201] The, or each of the, at least one air outlet may have a round cross-section, a circular crosssection, an oval cross-section, a square cross-section, or a rectangular cross-section.

[0202] The, or each of the, at least one air inlet 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. The, or each of the, at least one 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.

[0203] The, or each of the, at least one air inlet 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, less than or equal to 1 .8 millimetres, or less than or equal to 1 .5 millimetres. The, or each of the, at least one 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, less than or equal to 1 .8 millimetres, or less than or equal to 1 .5 millimetres.

[0204] The, or each of the, at least one air inlet 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. The, or each of the, at least one 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.

[0205] The, or each of the, at least one air inlet may have a width less than a width of one or both the first cavity and the second cavity. The, or each of the, at least one air outlet may have a width less than a width of one or both the first cavity and the second cavity. The, or each of the, at least one air inlet may have a thickness less than a thickness of one or both the first cavity and the second cavity. The, or each of the, at least one air outlet may have a thickness less than a thickness of one or both the first cavity and the second cavity.

[0206] The, or each of the, at least one air inlet may a width of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres. The, or each of the, at least one air outlet may a width of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres.

[0207] The, or each of the, at least one air inlet may have a thickness of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres. The, or each of the, at least one air outlet may have a thickness of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres.

[0208] Preferably, the, or each of the, at least one air inlet may have a width of between 0.3 millimetres and 3 millimetres, and a thickness of between 0.3 millimetres and 3 millimetres.

[0209] Preferably, the, or each of the, at least one air outlet may have a width of between 0.3 millimetres and 3 millimetres, and a thickness of between 0.3 millimetres and 3 millimetres.

[0210] 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 thickness 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. A ratio of the width to thickness of the, or each of the, at least one air inlet may be between 0.33 and 3. A ratio of the width to thickness of the, or each of the, at least one air inlet may be between 0.5 and 1 .5. A ratio of the width to thickness of the, or each of the, at least one air inlet may be between 0.75 and 1.25.

[0211] A ratio of the width to thickness of the, or each of the, at least one air outlet may be between 0.33 and 3. A ratio of the width to the thickness of the, or each of the, at least one air outlet may be between 0.5 and 1.5. A ratio of the width to thickness of the, or each of the, at least one air outlet may be between 0.75 and 1.25.

[0212] The aerosol-generating article may comprise a filter element positioned downstream of the one or more aerosol-generating substrates. The aerosol-generating article may comprise a filter element positioned downstream of the first cavity and the second cavity. The aerosol-generating article may comprise a filter element at least partially positioned within the, or each of the, at least one air outlet. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at a downstream end of, the first cavity. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at a downstream end of, the second cavity.

[0213] The aerosol-generating article may comprise a filter element positioned upstream of the one or more aerosol-generating substrates. The aerosol-generating article may comprise a filter element positioned upstream of the first cavity and second cavity. The aerosol-generating article may comprise a filter element at least partially positioned within the, or each of the, at least one air inlet. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at an upstream end of, the first cavity. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at an upstream end of, the second cavity.

[0214] 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.

[0215] The aerosol-generating article may be a substantially flat aerosol-generating article or a substantially planar aerosol-generating article. In particular, a thickness of the aerosol-generating article may less than 50 percent of both a length and a width of the aerosol-generating article. Advantageously, a smaller thickness may provide a small temperature gradient or difference across the thickness of the aerosol-generating substrate during heating.

[0216] 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 aerosol-generating article may have a cylindrical shape. The aerosolgenerating article may have a right-angled cylinder shape.

[0217] The aerosol-generating article may have a laminated or layered structure, for example the aerosol-generating article may comprise or be formed from at least two layers. In particular, the aerosol-generating article may comprise at least two of: a first external layer, a second external layer, a frame, a first frame layer, a second frame layer, a third frame layer, a first aerosolgenerating substrate layer, and a second aerosol-generating substrate layer.

[0218] The aerosol-generating article may have a laminated or layered structure comprising the following layers arranged, or stacked, in the z-direction: the first outer wrapper, the frame, and the second outer wrapper. The frame may comprise one or more of: the first frame layer, the second frame layer, and the third frame layer each defining a further layer of the aerosol-generating article.

[0219] The aerosol-generating article may have a laminated or layered structure comprising the following layers arranged, or stacked, in the z-direction: the first aerosol-generating substrate layer, the frame, and the second aerosol-generating substrate layer. The frame may comprise one or more of: the first frame layer, the second frame layer, and the third frame layer each defining a further layer of the aerosol-generating article.

[0220] The aerosol-generating article may have a laminated or layered structure comprising the following layers arranged, or stacked, in the z-direction: the first outer wrapper, the first aerosolgenerating substrate layer, the frame, the second aerosol-generating substrate layer, and the second outer wrapper. The frame may comprise one or more of: the first frame layer, the second frame layer, and the third frame layer each defining a further layer of the aerosol-generating article.

[0221] 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.

[0222] 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.

[0223] The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 20 millimetre H2O. The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 10 millimetre H2O. The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 8 millimetre H2O. The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 6 millimetre H2O. The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 4 millimetre H2O. The aerosolgenerating article may have a resistance to draw (RTD) of less than or equal to 2 millimetre H2O. The aerosol-generating article may have a resistance to draw (RTD) equal to, or close to, zero millimetres H2O.

[0224] A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be greater than 2:1 , greater than 5:1 , greater than 10:1 , greater than 12:1 , or greater than 15:1.

[0225] A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be less than 15:1 , less than 12:1 , less than 10:1 , less than 5:1 , or less than 2.5:1 A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness 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.

[0226] 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.

[0227] 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 .

[0228] 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.

[0229] 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.

[0230] 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.

[0231] 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.

[0232] 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.

[0233] 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.

[0234] 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.

[0235] The aerosol-generating article may have a thickness 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.

[0236] The aerosol-generating article may have a thickness 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. The aerosol-generating article may have a thickness 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.

[0237] 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.

[0238] 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.

[0239] 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.

[0240] 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.

[0241] 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.

[0242] 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.

[0243] As used herein, the term “thickness” refers to a maximum dimension of the aerosolgenerating article or a component of the aerosol-generating article in the z-direction.

[0244] 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 x-direction.

[0245] 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 y-direction. 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.

[0246] 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.

[0247] As used herein, the term “aerosol former content” may refer to aerosol former content in percent on a dry weight basis, unless otherwise specified.

[0248] 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.

[0249] 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.

[0250] As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof.

[0251] As used herein, the term “equivalent diameter” of an opening or an aperture is used herein to denote the diameter of a circular opening or aperture having the same cross-sectional area as the opening or aperture.

[0252] 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.

[0253] Example i . An aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article being a planar aerosol-generating article defined by a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction, the aerosol-generating article comprising: one or more aerosol-generating substrates; a first cavity; a second cavity spaced from the first cavity in the z-direction; a first airflow path extending through the first cavity; and a second airflow path extending through the second cavity; wherein at least one of the one or more aerosol-generating substrates is positioned within or adjacent to the first airflow path, and at least one of the one or more aerosol-generating substrates is positioned within or adjacent to the second airflow path. Example 2. An aerosol-generating article according to Example 1 , wherein the first cavity and the second cavity each have a width greater than or equal to 50 percent of a width of the aerosolgenerating article.

[0254] Example 3. An aerosol-generating article according to Example 1 or 2, wherein the first airflow path and the second airflow path are parallel to one another along at least 75 percent of a length of the aerosol-generating article.

[0255] Example 4. An aerosol-generating article according to any preceding Example, wherein the first airflow path and the second airflow path diverge or split at or towards an upstream end of one or both of the first cavity and the second cavity.

[0256] Example 5. An aerosol-generating article according to any one of Examples 1 to 3, wherein the first airflow path and the second airflow path diverge or split upstream of one or both of the first cavity and the second cavity.

[0257] Example 6. An aerosol-generating article according to any preceding Example, wherein the first airflow path and the second airflow path merge at or towards a downstream end of one or both of the first cavity and the second cavity.

[0258] Example 7. An aerosol-generating article according to any one of Examples 1 to 5, wherein the first airflow path and the second airflow path merge downstream of one or both of the first cavity and the second cavity.

[0259] Example 8. An aerosol-generating article according to any preceding Example comprising at least one air inlet and at least one air outlet, the at least one air inlet comprising a first air inlet and the at least one air outlet comprising a first air outlet, and wherein the first airflow path extends from the first air inlet to the first air outlet and the second airflow path extends from the first air inlet to the first air outlet.

[0260] Example 9. An aerosol-generating article according to any preceding Example, wherein the first airflow path has a length greater than or equal to 150 percent a length of the aerosolgenerating article.

[0261] Example 10. An aerosol-generating article according to any preceding Example, wherein the second airflow path has a length greater than or equal to 150 percent a length of the aerosolgenerating article.

[0262] Example 11. An aerosol-generating article according to any preceding Example, wherein at least one of the one or more aerosol-generating substrates extends along greater than or equal to 70 percent of a length of the first airflow path.

[0263] Example 12. An aerosol-generating article according to any preceding Example, wherein at least one of the one or more aerosol-generating substrates extends along greater than or equal to 70 percent of a length of the second airflow path.

[0264] Example 13. An aerosol-generating article according to any preceding Example, wherein at least one of the one or more aerosol-generating substrates form a wall of the first cavity and at least one of the one or more aerosol-generating substrates form a wall of the second cavity. Example 14. An aerosol-generating article according to any preceding Example, wherein both of the first cavity and the second cavity have a thickness less than or equal to 2.25 millimetres.

[0265] Example 15. An aerosol-generating article according to any preceding Example, wherein both of the first cavity and the second cavity have a length greater than or equal to 80 percent of a length of the aerosol-generating article.

[0266] Example 16. An aerosol-generating article according to any preceding Example, wherein both the first cavity and the second cavity are substantially empty.

[0267] Example 17. An aerosol-generating article according to any one of Examples 1 to 15 wherein an aerosol-generating substrate is positioned within the first cavity.

[0268] Example 18. An aerosol-generating article according to Example 17, wherein the aerosolgenerating substrate positioned within the first cavity comprises shredded aerosol-generating material.

[0269] Example 19. An aerosol-generating article according to Example 17 or 18, wherein the aerosolgenerating substrate positioned within the first cavity comprises tobacco cut filler.

[0270] Example 20. An aerosol-generating article according to any one of Example 1 to 15, or Examples 17 to 19, wherein an aerosol-generating substrate is positioned within the second cavity. Example 21. An aerosol-generating article according to Example 20, wherein the aerosolgenerating substrate positioned within the second cavity comprises shredded aerosol-generating material.

[0271] Example 22. An aerosol-generating article according to Example 20 or 21 , wherein the aerosolgenerating substrate positioned within the second cavity comprises tobacco cut filler.

[0272] Example 23. An aerosol-generating article according to any preceding Example comprising a cavity separating wall positioned between the first cavity and the second cavity and forming a wall of the first cavity and a wall of the second cavity, wherein the cavity separating wall comprises a sheet of cellulosic material or a sheet of homogenised tobacco material.

[0273] Example 24. An aerosol-generating article according to Example 23, wherein the cavity separating wall comprises at least one aperture extending through the thickness of the cavity separating wall for fluid communication between the first cavity and the second cavity.

[0274] Example 25. An aerosol-generating article according to any preceding Example comprising a frame, the frame comprising: a first frame layer, a second frame layer and a third frame layer, and wherein the first frame layer at least partially defines the first cavity, the third frame layer at least partially defines the second cavity, and the second frame layer is positioned between the first frame layer and the third frame layer.

[0275] Example 26. An aerosol-generating article according to Example 25, wherein the second frame layer comprises a notch extending through the thickness of the second frame layer and defining at least one inlet of the aerosol-generating article.

[0276] Example 27. An aerosol-generating article according to any preceding Example comprising at least one aerosol-generating substrate layer, the at least one aerosol-generating substrate layer comprising a first aerosol-generating substrate layer and a second aerosol-generating substrate layer, and wherein the first aerosol-generating substrate layer forms a wall of the first cavity and the second aerosol-generating substrate layer forms a wall of the second cavity.

[0277] Example 28. An aerosol-generating article according to Example 27, wherein each of the at least one aerosol-generating substrate layer comprises a sheet of homogenised tobacco material.

[0278] Example 29. An aerosol-generating article according to any preceding Example comprising at least one outer wrapper, the at least one outer wrapper comprising a first outer wrapper and a second outer wrapper, the first outer wrapper forming a first external layer of the aerosolgenerating article and the second outer wrapper forming a second external layer of the aerosolgenerating article, and wherein the first cavity and the second cavity are positioned between the first outer wrapper and the second outer wrapper.

[0279] Example 30. An aerosol-generating article according to any preceding Example having a laminated or layered structure.

[0280] Examples will now be further described with reference to the figures in which:

[0281] Figure 1 shows a perspective view of an aerosol-generating article according to a first embodiment;

[0282] Figure 2 shows a transverse cross-sectional view of the aerosol-generating article of Figure 1 ;

[0283] Figure 3 shows a longitudinal cross-sectional view of the aerosol-generating article of Figure 1 ;

[0284] Figure 4 shows an exploded view of the aerosol-generating article of Figure 1 ;

[0285] Figure 5 shows a perspective view of an aerosol-generating article according to a second embodiment;

[0286] Figure 6 shows a partially exploded view the aerosol-generating article of Figure 5;

[0287] Figure 7 shows an exploded view of the aerosol-generating article of Figure 5;

[0288] Figure 8 shows a method of manufacturing the aerosol-generating article of Figure 5;

[0289] Figure 9 shows a plan view of a portion of the method of manufacturing of Figure 8;

[0290] Figure 10 shows a plan view of a portion of the method of manufacturing of Figure 8; and Figure 11 shows a plan view of a portion of the method of manufacturing of Figure 8.

[0291] Figures 1 to 4 show an aerosol-generating article 10 according to a first embodiment.

[0292] The aerosol-generating article 10 is a substantially flat aerosol-generating article or a substantially planar aerosol-generating article. In particular, the thickness of the aerosol-generating article 10 is less than 50 percent of both the length and the width of the aerosol-generating article.

[0293] The aerosol-generating article 10 has a length extending in the x-direction, a width extending in the y-direction and a thickness extending in the z-direction. The aerosol-generating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.1 millimetres.

[0294] The aerosol-generating article 10 has a generally rectangular cuboid shape and has a layered structure. The aerosol-generating article 10 comprises a first outer wrapper forming a first planar external layer 24 and defining a first planar external surface 21 ; a frame 50; and a second outer wrapper forming a second planar external layer 25 and defining a second planar external surface 22. The first planar external layer 24, the frame 50 and the second planar external layer 25 are bonded together with an adhesive 15 which is guar gum.

[0295] 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 at least partially defines the first cavity 33 and the second cavity 34. The frame 50 also comprises a cavity separating wall 57. The first cavity 33 and the second cavity 34 are spaced in the z-direction, such that the first cavity 33 is positioned on top of the second cavity 34 and the cavity separating wall 57 is positioned between the first cavity 33 and the second cavity 34. The cavity separating wall 57 forms a lower wall of the first cavity 33 and an upper wall of the second cavity 34. The cavity separating wall 57 extends in the x-direction and the y-direction, so as to span the entire width and length of both the first cavity 33 and the second cavity 34.

[0296] 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 both of an outer wall of the first cavity 33 and an outer wall of the second cavity 34. 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 10, such as the front wall 13 and the back wall 14.

[0297] The frame 50 comprises a peripheral wall 51 that circumscribes the first cavity 33 and the second cavity 34. In more detail, the peripheral wall 51 is defined by the frame inner surface 52 and the frame outer surface 53. 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.

[0298] The first planar external layer 24 and the second planar external layer 25 are each a sheet of paper having a thickness of 200 micrometres and are in physical contact with the frame 50. The first planar external layer 24 forms an upper wall of the first cavity 33 and the second planar external layer 25 forms a lower wall of the second cavity 34. That is, the frame 50, the first planar external layer 24 and the second planar external layer 25 collectively define the first cavity 33 and the second cavity 34.

[0299] Each of the first cavity 33 and the second cavity 34 have a length of 26 millimetres, a width of 6 millimetres, and a thickness of 0.9 millimetres. Therefore, each cavity 33, 34 has a volume of about 140.4 cubic millimetres. An aerosol-generating substrate 45 comprising tobacco cut filler, and having an aerosol-former content of 5 percent by weight on a dry weight basis, is positioned within the first cavity 33. Similarly, an aerosol-generating substrate 46 comprising tobacco cut filler, and having an aerosol-former content of 5 percent by weight on a dry weight basis, is positioned within the second cavity 35. In this embodiment, the aerosol-generating substrates 45, 46 are the same, however, in other embodiments, the aerosol-generating substrates 45, 46 may be different. In some other embodiments, an aerosol-generating substrate may not be positioned within one or both of the first cavity 33 and the second cavity 34.

[0300] The cavity separating wall 57 comprises an upstream aperture 58 extending through the thickness of the cavity separating wall 57 and located towards an upstream end of the first cavity 33 and an upstream end of the second cavity 34. The upstream aperture 58 is located immediately downstream of the air inlet 11 of the aerosol-generating article 10. The upstream aperture 58 allows air entering through the air inlet 11 of the aerosol-generating article 10 to be distributed between the first cavity 33 and the second cavity 34, and to pass through the aerosol-generating substrates 45, 46 positioned in the respective cavities.

[0301] The cavity separating wall 57 comprises a downstream aperture 59 extending through the thickness of the cavity separating wall 57 and located towards a downstream end of the first cavity 33 and a downstream end of the second cavity 34. The downstream aperture 59 is located immediately upstream of the air outlet 12 of the aerosol-generating article 10. The downstream aperture 59 allows aerosol that has been generated in the first cavity 33 and aerosol that has been generated in the second cavity 34 to merge and homogenise before being delivered to a consumer via the air outlet 12.

[0302] Therefore, the aerosol-generating article 10 comprises a first airflow path extending from the air inlet 11 to air outlet 12 and through the first cavity 33, and a second airflow path extending from the air inlet 11 to the air outlet 12 through the second cavity 34. The first airflow path and the second airflow path diverge downstream of the air inlet 11 , at the upstream aperture 58, and converge upstream of the air outlet 12, at the downstream aperture 59. The cavity separating wall 57 is integral with the frame 50 and is also made from cardboard. The cavity separating wall 57 is substantially air impermeable such that air or aerosol cannot flow from the first cavity 33 to the second cavity 34, or vice versa, through the material of the cavity separating wall 57 except through the upstream aperture 58 and the downstream aperture 59.

[0303] 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.

[0304] Figures 5 to 7 show an aerosol-generating article 10 according to a second embodiment.

[0305] The aerosol-generating article 10 is a substantially flat aerosol-generating article or a substantially planar aerosol-generating article. In particular, the thickness of the aerosol-generating article 10 is less than 50 percent of both the length and the width of the aerosol-generating article. The aerosol-generating article 10 has a length extending in the x-direction, a width extending in the y-direction and a thickness extending in the z-direction. The aerosol-generating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.5 millimetres.

[0306] The aerosol-generating article 10 has a laminated or layered structure comprising the following layers arranged, or stacked, in the z-direction: a first outer wrapper forming a first external layer 24, a first aerosol-generating substrate layer 41 , a frame 50, a second aerosol-generating substrate layer 42, and a second outer wrapper forming a second external layer 25. The frame 50 comprises further layers of the aerosol-generating article 10 including a first frame layer 54, a second frame layer 55, and a third frame layer 56. The layers of the aerosol-generating article 10 are bonded together with an adhesive 15 which is guar gum.

[0307] An air inlet 11 and an air outlet 12 are defined by, and extend through, 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.

[0308] The frame 50 at least partially defines a first cavity 33 and a second cavity (not shown). The second frame layer 54 forms a cavity separating wall 57, and the first cavity 33 and the second cavity are spaced in the z-direction, such that the first cavity 33 is positioned on top of the second cavity and the cavity separating wall 57 is positioned between the first cavity 33 and the second cavity. The cavity separating wall 57 forms a lower wall of the first cavity 33 and an upper wall of the second cavity.

[0309] The first frame layer 54 comprises an aperture 81 extending through its thickness which forms the first cavity 33. The first frame layer 54 comprises a first frame layer peripheral wall circumscribing the first cavity 33.

[0310] The second frame layer 55 comprises a first notch 71 extending through the thickness of the second frame layer 55. The first notch 71 defines the air inlet 11 of the aerosol-generating article 10 and also an upstream aperture 58 through the cavity separating wall 57 for fluid communication between an upstream end of the first cavity 33 and an upstream end of the second cavity.

[0311] The second frame layer 55 comprises a second notch 72 extending through the thickness of the second frame layer 55. The second notch 72 defines the air outlet 12 of the aerosolgenerating article 10 and also a downstream aperture 59 through the cavity separating wall 57 for fluid communication between a downstream end of the first cavity 33 and a downstream end of the second cavity.

[0312] The third frame layer 56 comprises an aperture 82 extending through its thickness which forms the second cavity. The third frame layer 56 comprises a third frame layer peripheral wall circumscribing the second cavity.

[0313] The first frame layer 54, the second frame layer 55, and the third frame layer 56 are each made from a sheet of cardboard having a thickness of 900 micrometres.

[0314] The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 each comprise 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. The first aerosol-generating substrate layer 41 forms an upper wall of the first cavity 33 and the second aerosol-generating substrate layer forms a lower wall of the second cavity. Therefore, the first aerosol-generating substrate layer 24, the first frame layer 54, and the second frame layer 55 collectively define the first cavity 33. Also, therefore, the second aerosol-generating substrate layer 42, the third frame layer 56, and the second frame layer 55 collectively define the second cavity.

[0315] The first planar external layer 24 and the second planar external layer 25 are each a sheet of paper having a thickness of 200 micrometres.

[0316] Each of the first cavity 33 and the second cavity are substantially empty. Each of the first cavity 33 and the second cavity have a length of 26 millimetres, a width of 6 millimetres, and a thickness of 0.9 millimetres.

[0317] The aerosol-generating article 10 comprises a first airflow path extending from the air inlet 11 to air outlet 12 and through the first cavity 33, and a second airflow path extending from the air inlet 11 to the air outlet 12 through the second cavity 34. The first airflow path and the second airflow path diverge downstream of the air inlet 11 , at the upstream aperture 58, and converge upstream of the air outlet 12, at the downstream aperture 59. As air flows through the first cavity 33, it flows past the first aerosol-generating substrate layer 41 thereby entraining in it volatile compounds from the first aerosol-generating substrate layer 41 to form an aerosol. Similarly, as air flows through the second cavity, it flows past the second aerosol-generating substrate layer 42 thereby entraining in it volatile compounds from the second aerosol-generating substrate layer 42 to form an aerosol. The aerosol within the first cavity 33 and the aerosol within the second cavity combine and may homogenise at the downstream aperture 59 before being delivered to a consumer through the air outlet 12.

[0318] Figure 8 depicts a schematic illustration of a method of manufacturing 1000 the aerosolgenerating article of the second embodiment. The method comprises punching and bonding a first sheet of frame material 1210, a second sheet of frame material 1220, a third sheet of frame material 1230, a first sheet of aerosol-generating material 1240, a second sheet of aerosolgenerating material 1250, a first sheet of external layer material 1260 and a second sheet of external layer material 1270. Figure 9 depicts a schematic plan view of a portion of the method of Figure 8 between bobbin 1011 and roller 1021 and between bobbin 1013 and roller 1022. Figure 10 depicts a schematic plan view of a portion of the method of Figure 8 between bobbin 1012 and rollers 1023, 1024. Figure 11 depicts a portion of the method of Figure 8 between rollers 1023, 1024 and the end of the manufacturing process. For illustration purposes the manufacturing equipment is not depicted in Figures 9 to 11 . The second sheet of frame material 1220 is fed from a bobbin 1012 and an aperture punching device 1032 punches an air inlet aperture and an air outlet aperture through the second sheet of frame material 1220. An adhesive applying device 1041 applies an adhesive to a lower surface of the second sheet of frame material 1220 and to an upper surface of the second sheet of frame material 1220.

[0319] The first sheet of frame material 1210 is fed from a bobbin 1011 and an aperture punching device 1031 punches an aperture through the first sheet of frame material 1210. The aperture will at least partially form the first cavity 33 of the aerosol-generating article 10. The first sheet of frame material 1210 is fed to rollers 1023, 1024 via roller 1021 and is bonded to the second sheet of frame material 1220 by the adhesive applied to the upper surface of the second sheet of frame material 1220.

[0320] Similarly, the third sheet of frame material 1230 is fed from a bobbin 1013 and an aperture punching device 1033 punches an aperture through the third sheet of frame material 1230. The aperture will at least partially form the second cavity 34 of the aerosol-generating article 10. The third sheet of frame material 1230 is fed to rollers 1023, 1024 via roller 1022 and is bonded to the second sheet of frame material 1220 by the adhesive applied to the lower surface of the second sheet of frame material 1220.

[0321] An adhesive applying device 1042 applies an adhesive to an upper surface of the first sheet of frame material 1210 and to a lower surface of the third sheet of frame material 1230.

[0322] The first sheet of aerosol-generating material 1240 is fed from a bobbin 1014 via a roller 1025 and is bonded to the first sheet of frame material 1210 by the adhesive applied to the upper surface of the first sheet of frame material 1210. The second sheet of aerosol-generating material 1250 is fed from a bobbin 1015 via a roller 1026 and is bonded to the third sheet of frame material 1230 by the adhesive applied to the lower surface of the third sheet of frame material 1230.

[0323] An adhesive applying device 1043 applies an adhesive to an upper surface of the first sheet of aerosol-generating material 1240 and to a lower surface of the second sheet of aerosolgenerating material 1250.

[0324] The first sheet of external layer material 1260 is fed from a bobbin 1016 via a roller 1027 and is bonded to the first sheet aerosol-generating material 1240 by the adhesive applied to the upper surface of the first sheet aerosol-generating material 1240. The second sheet of external layer material 1270 is fed from a bobbin 1017 via a roller 1028 and is bonded to the second sheet of aerosol-generating material 1250 by the adhesive applied to the lower surface of the second sheet of aerosol-generating material 1250.

[0325] An aperture punching device 1034 punches an aperture through the first sheet of external layer material 1260, the first sheet of aerosol-generating material 1240, the first sheet of frame material 1210, the second sheet of frame material 1220, the third sheet of frame material 1230, the second sheet of aerosol-generating material 1250, and the second sheet of external layer material 1270 so as to eject the aerosol-generating article 10. 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. An aerosol-generating article for use with an aerosol-generating device, the aerosolgenerating article being a planar aerosol-generating article defined by a length extending in an x- direction, a width extending in a y-direction, and a thickness extending in a z-direction, the aerosolgenerating article comprising: one or more aerosol-generating substrates; a first cavity; a second cavity spaced from the first cavity in the z-direction; a first airflow path extending through the first cavity; and a second airflow path extending through the second cavity; wherein at least one of the one or more aerosol-generating substrates is positioned within or adjacent to the first airflow path, and at least one of the one or more aerosol-generating substrates is positioned within or adjacent to the second airflow path; and wherein the first cavity and the second cavity each have a width greater than or equal to 50 percent of a width of the aerosol-generating article.

2. An aerosol-generating article according to claim 1 , wherein the first airflow path and the second airflow path are parallel to one another along at least 75 percent of a length of the aerosolgenerating article.

3. An aerosol-generating article according to claim 1 or 2 comprising at least one air inlet and at least one air outlet, the at least one air inlet comprising a first air inlet and the at least one air outlet comprising a first air outlet, and wherein the first airflow path extends from the first air inlet to the first air outlet and the second airflow path extends from the first air inlet to the first air outlet.

4. An aerosol-generating article according to any preceding claim, wherein at least one of the one or more aerosol-generating substrates form a wall of the first cavity and at least one of the one or more aerosol-generating substrates form a wall of the second cavity.

5. An aerosol-generating article according to any preceding claim, wherein both of the first cavity and the second cavity have a thickness less than or equal to 2.25 millimetres.

6. An aerosol-generating article according to any preceding claim, wherein both of the first cavity and the second cavity have a length greater than or equal to 80 percent of a length of the aerosol-generating article.

7. An aerosol-generating article according to any preceding claim, wherein both the first cavity and the second cavity are substantially empty.

8. An aerosol-generating article according to any preceding claim comprising a cavity separating wall positioned between the first cavity and the second cavity and forming a wall of the first cavity and a wall of the second cavity, wherein the cavity separating wall comprises a sheet of cellulosic material or a sheet of homogenised tobacco material.

9. An aerosol-generating article according to claim 8, wherein the cavity separating wall comprises at least one aperture extending through the thickness of the cavity separating wall for fluid communication between the first cavity and the second cavity.

10. An aerosol-generating article according to any preceding claim comprising a frame, the frame comprising: a first frame layer, a second frame layer and a third frame layer, and wherein the first frame layer at least partially defines the first cavity, the third frame layer at least partially defines the second cavity, and the second frame layer is positioned between the first frame layer and the third frame layer.

11. An aerosol-generating article according to claim 10, wherein the second frame layer comprises a notch extending through the thickness of the second frame layer, the notch defining at least one inlet of the aerosol-generating article.

12. An aerosol-generating article according to any preceding claim comprising at least one aerosol-generating substrate layer, the at least one aerosol-generating substrate layer comprising a first aerosol-generating substrate layer and a second aerosol-generating substrate layer, and wherein the first aerosol-generating substrate layer forms a wall of the first cavity and the second aerosol-generating substrate layer forms a wall of the second cavity.

13. An aerosol-generating article according to claim 12, wherein each of the at least one aerosol-generating substrate layer comprises a sheet of homogenised tobacco material.

14. An aerosol-generating article according to any preceding claim comprising at least one outer wrapper, the at least one outer wrapper comprising a first outer wrapper and a second outer wrapper, the first outer wrapper forming a first external layer of the aerosol-generating article and the second outer wrapper forming a second external layer of the aerosol-generating article, and wherein the first cavity and the second cavity are positioned between the first outer wrapper and the second outer wrapper.

15. An aerosol-generating article according to any preceding claim having a laminated or layered structure.

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