Method of manufacturing an aerosol-generating article comprising a frame

Abstract

There is provided a method of manufacturing an aerosol-generating article (10) for use with an aerosol-generating device to generate an aerosol, the method comprising: providing a first continuous sheet of frame material (1201) and a further continuous sheet of material; forming a frame aperture (1400) through the first continuous sheet of frame material (1201) to form a frame core layer; positioning the further continuous sheet of material underneath the first continuous sheet of frame material (1201); and bonding the further continuous sheet of material and the first continuous sheet of frame material (1201) to form a laminated structure of the aerosol-generating article (10) comprising the frame core layer.

Description

[0001] METHOD OF MANUFACTURING AN AEROSOL-GENERATING ARTICLE COMPRISING A FRAME

[0002] The present disclosure relates to a method of manufacturing an aerosol-generating article of the type intended for use with an aerosol-generating device to generate an aerosol, for example upon heating. The present disclosure also relates to aerosol-generating articles obtainable by the method, as well as to an aerosol-generating system comprising the aerosol-generating article and an aerosol-generating device.

[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 a method of manufacturing an aerosolgenerating article in which a greater portion of the aerosol-generating substrate is sufficiently heated to form an aerosol during use. It is also an objective of the present disclosure to provide a method of manufacturing an aerosol-generating article that can be implemented relatively efficiently and in a cost-effective fashion. It would also be desirable to provide a method of manufacturing an aerosol-generating article that can be implemented on existing apparatus without requiring extensive modifications.

[0007] The present disclosure relates to a method of manufacturing an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The method may comprise a first step of providing a first continuous sheet of frame material and a further continuous sheet of material.

[0008] The method may comprise a second step of forming a frame aperture through the first continuous sheet of frame material to form a frame core layer.

[0009] The method may comprise a third step of positioning the further continuous sheet of material underneath the first continuous sheet of frame material.

[0010] The method may comprise a fourth step of bonding the further continuous sheet of material and the first continuous sheet of frame material to form a laminated structure of the aerosolgenerating article comprising the frame core layer.

[0011] As will be discussed below, the method may comprise one or more additional steps involving the provision of one or more additional continuous sheets of material. The method may also comprise one or more additional steps of bonding the one or more additional continuous sheets of material, the first continuous sheet of frame material and the further continuous sheet of material to form the laminated structure of the aerosol-generating article comprising the frame core layer.

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

[0013] Advantageously, methods in accordance with the present disclosure make it possible for aerosol-generating articles to be manufactured by layering continuous sheets of material through an automated process, thereby resulting in an aerosol-generating article that is relatively easy and cheap to manufacture. Continuous sheets of material can be supplied, layered and bonded (for example by means of an adhesive) at high speed, and so methods in accordance with the present application are suitable for high-volume manufacturing of aerosol-generating articles.

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

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

[0016] In certain preferred embodiments, which will be described in more detail below, the method may comprise providing one or more further continuous sheets of frame material to be combined with the first continuous sheet of frame material to form a laminated frame structure that includes the frame core layer. In turn, the laminated frame structure forms part of a laminate structure of the aerosol-generating article. The one or more further continuous sheets of frame material may advantageously impart increased structural strength and stability to the aerosol-generating article. Further, different sheet materials may be combined to impart desirable properties to the frame.

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

[0018] In certain embodiments, the method may comprise punching an air inlet aperture or an air outlet aperture or both in one or more of the first sheet of frame material and any further sheet of frame material. The air inlet aperture and air outlet aperture formed in one or more sheets of frame material advantageously at least partially define an air inlet and air outlet of the aerosol-generating article. As will be discussed in more detail below, certain preferred embodiments of methods in accordance with the present invention advantageously allow providing an air inlet or an air outlet or both at precisely controlled locations within the aerosol-generating article in ways that are relatively easy and cheap to control.

[0019] The further sheet of material may advantageously provide a surface of the aerosolgenerating article that is exposed to an airflow passage extending through an internal cavity of the aerosol-generating article. The further sheet of material may advantageously provide a surface for supporting an aerosol-generating substrate disposed within the internal cavity of the aerosolgenerating article. In certain embodiments, wherein the further sheet of material comprises an aerosol-generating substrate, the further sheet of material may advantageously provide a source of aerosol species that is exposed to an airflow passage extending through an internal cavity of the aerosol-generating article.

[0020] Advantageously, methods in accordance with the present disclosure may provide aerosolgenerating articles having one or more substantially planar external surfaces, which allows for good contact with an external heater of an aerosol-generating device, thereby providing optimum heating of an aerosol-generating substrate forming part of the aerosol-generating article. For example, aerosol-generating articles obtained by methods in accordance with the present disclosure may be heated along substantially their entire length and width, thereby allowing the entirety of an aerosol-generating substrate forming part of the aerosol-generating article to be sufficiently heated to generate an aerosol.

[0021] Methods in accordance with the present disclosure can be implemented on existing apparatus configured for handling continuous sheet materials, for supplying adhesive, for cutting through continuous sheet materials, and so forth, without requiring extensive modifications.

[0022] 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.

[0023] 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.

[0024] 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.

[0025] 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.

[0026] As used herein, the term “transverse” refers to a direction extending between the first planar external surface and the second planar external surface.

[0027] As used herein, the term “longitudinal” refers to a direction that is perpendicular to the transverse direction. For example, a direction between the front wall and the back wall of the aerosol-generating article.

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

[0029] 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 transverse direction.

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

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

[0032] As used herein, the term “bulk density” may refer to the total weight of the aerosol-generating substrate divided by the bulk volume of the aerosol-generating substrate.

[0033] 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.

[0034] As used herein, the term “aerosol former content” may refer to aerosol former content in percent on a dry weight basis, unless otherwise specified.

[0035] 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.

[0036] 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.

[0037] As used herein, the term “equivalent diameter” of an opening or an aperture is used to denote the diameter of a circular opening or aperture having the same cross-sectional area as the opening or aperture.

[0038] An aerosol-generating article obtained by a method in accordance with the present disclosure may comprise one or more aerosol-generating substrates.

[0039] An aerosol-generating article obtained by a method in accordance with the present disclosure may have a length extending in an x-direction. The aerosol-generating article may have a width extending in a y-direction. The aerosol-generating article may have a thickness extending in a z-direction.

[0040] An aerosol-generating article obtained by a method in accordance with the present disclosure may be a substantially flat aerosol-generating article or a substantially planar aerosolgenerating 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.

[0041] 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. An aerosol-generating article obtained by a method in accordance with the present disclosure may generally have a laminated structure, for example the aerosol-generating article may comprise or be formed from at least two layers.

[0042] In more detail, the aerosol-generating article may comprise at least a frame core layer and a further layer.

[0043] The frame core layer - alone or in combination with one or more additional frame layers, as will be described below - forms a frame of the aerosol-generating article. Features of the frame of the aerosol-generating article will be discussed in more detail below.

[0044] The further layer may be a second frame layer. The frame core layer and the second frame layer may be bonded to form a laminated frame structure. The aerosol-generating article may additionally comprise a third frame layer. The frame core layer, the second frame layer and the third frame layer may be bonded to form a laminated frame structure.

[0045] The further layer may be a first external layer. With reference to an aerosol-generating article having a laminated structure, the term “external layer” is used herein to denote a layer of the aerosol-generating article which is at least partly exposed to an exterior of the aerosolgenerating article. In other words, a face of the external layer defines at least part of an external surface of the aerosol-generating article.

[0046] The further layer may be a first internal layer. With reference to an aerosol-generating article having a laminated structure, the term “internal layer” is generally used herein to denote a layer of material that does not form part of the frame and that is not exposed to an exterior of the aerosol-generating article. In other words, an internal layer is comprised between two other adjacent layers of the laminated structure. It will be understood that, in examples of the method wherein the further layer is a first internal layer, at least an external layer will be provided and bonded to the first internal layer and the frame to complete a laminated structure of the aerosolgenerating article.

[0047] In an example, the aerosol-generating article may comprise a frame core layer and a first external layer.

[0048] In an example, the aerosol-generating article may comprise a frame core layer, a first internal layer and a first external layer, wherein the first internal layer is arranged between the frame core layer and the first external layer.

[0049] In an example, the aerosol-generating article may comprise a frame core layer, a first external layer and a second external layer, wherein the frame core layer is arranged between the first external layer and the second external layer.

[0050] In an example, the aerosol-generating article may comprise: a frame core layer, a first internal layer, a first external layer and a second external layer; wherein the frame core layer is arranged between the first external layer and the second external layer, and the first internal layer is arranged between the frame core layer and the first external layer or between the frame core layer and the second external layer. In an example, the aerosol-generating article may comprise: a frame core layer, a first internal layer, a second internal layer, a first external layer and a second external layer; wherein the frame core layer is arranged between the first external layer and the second external layer; the first internal layer is arranged between the frame core layer and the first external layer; and the second internal layer is arranged between the frame core layer and the second external layer.

[0051] In an example, the aerosol-generating article may comprise a laminated frame structure, a first internal layer and a first external layer, wherein the first internal layer is arranged between the laminated frame structure and the first external layer. The laminated frame structure may comprise the frame core layer and a second frame layer. The laminated frame structure may comprise the frame core layer, a second frame layer and a third frame layer, wherein the core frame layer is comprised between the second frame layer and the third frame layer.

[0052] In an example, the aerosol-generating article may comprise a laminated frame structure, a first external layer and a second external layer, wherein the laminated frame structure is arranged between the first external layer and the second external layer. The laminated frame structure may comprise the frame core layer and a second frame layer. The laminated frame structure may comprise the frame core layer, a second frame layer and a third frame layer, wherein the frame core layer is comprised between the second frame layer and the third frame layer.

[0053] In an example, the aerosol-generating article may comprise: a laminated frame structure, a first internal layer, a first external layer and a second external layer; wherein the laminated frame structure is arranged between the first external layer and the second external layer and the first internal layer is arranged between the laminated frame structure and the first external layer. The laminated frame structure may comprise the frame core layer and a second frame layer. The laminated frame structure may comprise the frame core layer, a second frame layer and a third frame layer, wherein the frame core layer is comprised between the second frame layer and the third frame layer.

[0054] In an example, the aerosol-generating article may comprise: a laminated frame structure, a first internal layer, a second internal layer, a first external layer and a second external layer; wherein the laminated frame structure is arranged between the first external layer and the second external layer; the first internal layer is arranged between the laminated frame structure and the first external layer; and the second internal layer is arranged between the laminated frame structure and the second external layer. The laminated frame structure may comprise the frame core layer and a second frame layer. The laminated frame structure may comprise the frame core layer, a second frame layer and a third frame layer, wherein the frame core layer is comprised between the second frame layer and the third frame layer.

[0055] With reference to the laminated frame structure, any one of the core frame layer, the first frame layer and the second frame layer - if present - may in turn be provided in laminated form.

[0056] In other words, the core frame layer itself may comprise at least two layers of frame material. In an example, the core frame layer itself may comprise three layers of frame material. Similarly, the second frame layer itself may comprise at least two layers of frame material. In an example, the second frame layer may comprise three layers of frame material.

[0057] In similar fashion, the third frame layer itself may comprise at least two layers of frame material. In an example, the third frame layer may comprise three layers of frame material.

[0058] In a preferred example, the laminated frame structure comprises a frame core layer, a second frame layer and a third frame layer, wherein the frame core layer is comprised between the first frame layer and the second frame layer, and each one of the frame core layer, the second frame layer and third frame layer comprises two layers of frame material. In other words, the laminated structure comprises six layers of frame material.

[0059] In another preferred example, the laminated frame structure comprises a frame core layer, a second frame layer and a third frame layer, wherein the frame core layer is comprised between the first frame layer and the second frame layer, and each one of the frame core layer, the second frame layer and third frame layer comprises three layers of frame material. In other words, the laminated structure comprises nine layers of frame material.

[0060] Thus, an overall thickness of the frame or of the laminated frame structure may be adjusted and controlled by selecting sheets or layers of frame material with a certain thickness.

[0061] For example, nine layers of frame material each having a thickness of 0.33 millimetres may be combined to form a laminated frame structure having an (overall) thickness of 3 millimetres.

[0062] Similarly, six layers of frame material each having a thickness of 0.5 millimetres may be combined to form a laminated frame structure having an (overall) thickness of 3 millimetres.

[0063] With reference to a method in accordance with the present disclosure, the term “protective layer” denotes a layer of material that is provided over an external layer of the aerosol-generating article, and which is removable from the aerosol-generating article prior to use of the aerosolgenerating article.

[0064] Thus, in an example, a method in accordance with the present disclosure may provide a product comprising an aerosol-generating article having a laminated structure in line with the foregoing description and a first protective layer removably arranged over a first external layer of the aerosol-generating article. Another example of a method in accordance with the present disclosure may provide a product comprising an aerosol-generating article having a laminated structure in line with the foregoing description, a first protective layer removably arranged over a first external layer of the aerosol-generating article, and a second protective layer removably arranged over a second external layer of the aerosol-generating article.

[0065] As used herein with reference to methods in accordance with the present disclosure, the terms “sheet of frame material” and “frame sheet material” are used to denote a sheet material for forming a frame of an aerosol-generating material or a layer of a laminated frame structure of an aerosol-generating article in line with the foregoing description.

[0066] As used herein with reference to methods in accordance with the present disclosure, the term “continuous” is used to denote a sheet of material that extends continuously in the longitudinal direction, such as for example a sheet of material that is supplied as it is unwound from a bobbin. A continuous sheet of frame material has a longitudinal length, a first side edge and an opposite second side edge defining therebetween a transverse width. The continuous sheet of frame material has a thickness substantially perpendicular to both length and width.

[0067] As used herein with reference to methods in accordance with the present disclosure, the terms “sheet of internal layer material” and “internal layer sheet material” are used to denote a sheet material for forming an internal layer of an aerosol-generating material in line with the foregoing description.

[0068] As used herein with reference to methods in accordance with the present disclosure, the terms “sheet of external layer material” and “external layer sheet material” are used to denote a sheet material for forming an external layer of an aerosol-generating material in line with the foregoing description.

[0069] As used herein with reference to methods in accordance with the present disclosure, the terms “sheet of protective layer material” and “protective layer sheet material” are used to denote a sheet material for providing a protecting layer over an external layer of an aerosol-generating material in line with the foregoing description.

[0070] Substantially the entirety of an aerosol-generating article obtained by a method in accordance with the present disclosure, excluding the one or more aerosol-generating substrates (if present) and (if present) adhesive, may be paper or cardboard.

[0071] 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.

[0072] As described briefly above, an example of a method of manufacturing an aerosolgenerating article in accordance with the present disclosure comprises: providing a first continuous sheet of frame material and a further continuous sheet of material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the further continuous sheet of material underneath the first continuous sheet of frame material; and bonding the further continuous sheet of material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article comprising the frame core layer.

[0073] In the context of the present disclosure, as used with reference to the examples of methods for manufacturing an aerosol-generating article described in the following, the expression “bonding a continuous sheet of material with the first continuous sheet of frame material” is used to describe a step wherein a bond is formed - for example, by means of an adhesive - such that the first continuous sheet of frame material and the continuous sheet of material are laminated together.

[0074] In some examples, the expression “bonding a continuous sheet of material with the first continuous sheet of frame material” means that the continuous sheet of material is bonded directly to the first continuous sheet of frame material. That is, the continuous sheet of material lies adjacent to the first continuous sheet of frame material and a bond is established directly between the continuous sheet of material and the first continuous sheet of frame material. For example, an adhesive may be provided between the continuous sheet of material and the first continuous sheet of frame material.

[0075] More generally, however, the expression “bonding a continuous sheet of material with the first continuous sheet of frame material” means that the continuous sheet of material is bonded directly or indirectly to the first continuous sheet of frame material. That is, the continuous sheet of material may not lie adjacent to the first continuous sheet of frame material, because - as will be described in more detail below with reference to certain examples - the laminated structure comprises one or more intermediate continuous sheets of material comprised between the first continuous sheet of frame material and the further continuous sheet of frame material, wherein the one or more intermediate continuous sheets of material have previously been bonded with the first continuous sheet of frame material. Accordingly, the expression “bonding a continuous sheet of material with the first continuous sheet of frame material” may mean that a direct bond is established between the continuous sheet of material and the one or more intermediate continuous sheets of material. For example, an adhesive may be provided between the continuous sheet of material and the one or more intermediate continuous sheets of material. As a result, an indirect bond is established between the continuous sheet of material and the first sheet of frame material.

[0076] In the aerosol-generating article obtained by the method, the frame core layer provides or forms part of a planar frame. The frame aperture extending through the frame core layer may define or form part of an airflow passage of the aerosol-generating article. The frame aperture extending through the frame core layer may define or form part of an internal cavity of the aerosolgenerating article.

[0077] In general, the planar frame of the aerosol-generating article comprises a first planar surface (for example, a bottom surface) and a second planar surface (for example, a top surface). The planar frame may comprise a frame peripheral outer surface. The frame peripheral outer surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The frame peripheral outer surface may at least partially define or form one or more external surfaces of the aerosol-generating article. For example, the frame peripheral outer surface may at least partially define or form one or more peripheral walls of the aerosol-generating article. The frame peripheral outer surface may circumscribe or encircle the frame aperture. The frame peripheral outer surface may circumscribe or encircle the internal cavity.

[0078] The planar frame may comprise a frame inner surface. The frame inner surface may extend in a transverse direction, for example between the first planar surface and the second planar surface. The frame inner surface may define or at least form part of a frame aperture peripheral wall. The frame inner surface may define or at least form part of a peripheral wall of the internal cavity. The frame peripheral outer surface may circumscribe or encircle the frame inner surface. The frame inner surface and the frame peripheral outer surface may be concentric with one another. In certain examples described above, a first planar surface of the frame core layer may define or at least partially form the first planar surface of the planar frame, whereas a second planar surface of the frame core layer may define or at least partially form the second planar surface of the planar frame.

[0079] In other examples described above, wherein the aerosol-generating article comprises a laminated frame structure, the first planar surface and the second planar surface of the planar frame may be defined by a corresponding planar surface of one of the frame layers forming the laminated frame structure, depending on the specific arrangement of frame layers.

[0080] In more detail, in an aerosol-generating article wherein the laminated frame structure comprises the frame core layer and a second frame layer, a planar surface of the frame core layer may define or at least partially form the first planar surface of the planar frame, whereas a planar surface of the second frame layer may define or at least partially form the second planar surface of the planar frame.

[0081] Similarly, in an aerosol-generating article wherein the laminated frame structure comprises the frame core layer, a second frame layer and a third frame layer, and wherein the frame core layer is comprised between the second frame layer and the third frame layer, a planar surface of the second frame layer may define or at least partially form the first planar surface of the planar frame, whereas a planar surface of the third frame layer may define or at least partially form the second planar surface of the planar frame.

[0082] In some embodiments of the method, the further continuous sheet of material is a second continuous sheet of frame material.

[0083] In other words, the method comprises: providing a first continuous sheet of frame material and a second continuous sheet of material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer, positioning the second continuous sheet of frame material underneath the first continuous sheet of frame material; and bonding the second continuous sheet of frame material and the frame core layer to form a laminated structure of the aerosol-generating article.

[0084] By bonding the second continuous sheet of frame material and the first continuous sheet of frame material a laminated frame structure is formed. The laminated frame structure comprises the frame core layer and a second frame layer.

[0085] The first continuous sheet of frame material and the second continuous sheet of frame material may differ by at least one characteristic, such as for example a sheet thickness or a sheet composition. Accordingly, bonding the first continuous sheet of frame material and the second continuous sheet of frame material may advantageously provide a laminated structure that benefits from a combination of the differing characteristics.

[0086] In embodiments wherein the further continuous sheet of material is a second continuous sheet of frame material, the step of bonding the further continuous sheet of material and the first continuous sheet of frame material may be carried out prior to forming a frame aperture through the first continuous sheet of frame material to form a frame. In other words, the step of forming a frame aperture through the first continuous sheet of frame material may be carried out after a laminated frame structure has been formed. Accordingly, the step of forming a frame aperture through the first continuous sheet of frame material may be carried out such that the frame aperture extends through both the first continuous sheet of frame material and the second continuous sheet of frame material.

[0087] Alternatively, in embodiments wherein the further continuous sheet of material is a second continuous sheet of frame material, the step of bonding the further continuous sheet of material and the first continuous sheet of frame material may be carried out subsequent to forming a frame aperture through the first continuous sheet of frame material. Thus, the second continuous sheet of frame material bonded to the first continuous sheet of frame material may provide a bottom surface for a cavity of the aerosol-generating article that is at least partially delimited by the frame aperture.

[0088] In embodiments wherein the further continuous sheet of material is a second continuous sheet of frame material the method may further comprise a step of providing a third continuous sheet of frame material, a step of positioning the third continuous sheet of frame material above the first continuous sheet of frame material; and a step of bonding the third continuous sheet of frame material and the first sheet of frame material. By bonding the third continuous sheet of frame material and the first sheet of frame material a laminated frame structure may advantageously be formed that comprises three layers of sheet material. In more detail, the laminated frame structure comprises the frame core layer, a second frame layer and a third frame layer.

[0089] In an example, the method comprises a step of positioning the third continuous sheet of frame material above the first continuous sheet of frame material. Consequently, the second continuous sheet of frame material and the third continuous sheet of frame material are bonded to opposite sides of the first continuous sheet of frame material, and so in the laminated frame structure the first continuous sheet of frame material is comprised between the second continuous sheet of frame material and the third continuous sheet of frame material. Thus, a frame of the aerosol-generating article can be obtained wherein the frame core layer is comprised between the second frame layer and the third frame layer.

[0090] In another example, the method comprises a step of positioning the third continuous sheet of frame material underneath the second continuous sheet of frame material. Consequently, the first continuous sheet of frame material, the second continuous sheet of frame material and the third continuous sheet of frame material are bonded together so that the second continuous sheet of frame material and the third continuous sheet of frame material are arranged on the same side of the first continuous sheet of frame material. Thus, in the laminated frame structure, the second continuous sheet of frame material is comprised between the first continuous sheet of frame material and the third continuous sheet of frame material. Thus, a frame of the aerosol-generating article can be obtained, wherein the second frame layer is comprised between the frame core layer and the third frame layer.

[0091] The continuous third sheet of continuous frame material may differ from at least one of the continuous first sheet of frame material and the second continuous sheet of frame material. Accordingly, bonding the first continuous sheet of frame material, the second continuous sheet of frame material and the third continuous sheet of frame material may advantageously provide a laminated frame structure that benefits from a combination of the differing characteristics.

[0092] In embodiments comprising the steps of providing a third continuous sheet of frame material and bonding the third continuous sheet of frame material and the first continuous sheet of frame material, the step of bonding the third continuous sheet of frame material and the first continuous sheet of frame material may be carried out prior to forming a frame aperture through the first continuous sheet of frame material, and subsequent to or simultaneous with bonding the second continuous sheet of frame material and the first continuous sheet of frame material. Accordingly, the step of forming a frame aperture through the first continuous sheet of frame material may be carried out such that the frame aperture extends through the first continuous sheet of frame material and both of the second and third continuous sheets of frame material.

[0093] Alternatively, in embodiments comprising the steps of providing a third continuous sheet of frame material and bonding the third continuous sheet of frame material and the first continuous sheet of frame material, the step of bonding the third continuous sheet of frame material and the first continuous sheet of frame material may be carried out subsequent to forming a frame aperture through the first continuous sheet of frame material to form the frame core layer. Thus, the further continuous sheet of material bonded to the first continuous sheet of frame material may provide a bottom surface for a cavity of the aerosol-generating article that is at least partially delimited by the frame aperture. Thus, where the second continuous sheet of frame material and the third continuous sheet of frame material are bonded to opposite sides of the first continuous sheet of frame material, the second continuous sheet of frame material and the third continuous sheet of frame material bonded to the first continuous sheet of frame material may provide a bottom surface and a top surface, respectively, for a cavity of the aerosol-generating article that is at least partially delimited by the frame aperture.

[0094] With reference to the methods in accordance with the present disclosure described above, in some examples providing a first continuous sheet of frame material comprises: providing a first continuous laminate layer of a first frame material and a second continuous laminate layer of the first frame material; positioning the second continuous laminate layer of the first frame material underneath the first continuous laminate layer of the first frame material; and bonding the first continuous laminate layer of the frame material and the second continuous laminate layer of the first frame material to form the first continuous sheet of frame material.

[0095] In other examples, providing a first continuous laminate layer of a first frame material, a second continuous laminate layer of the first frame material, and a third continuous laminate layer of the first frame material; positioning the first continuous laminate layer of the first frame material between the second continuous laminate layer of the first frame material and the third continuous laminate layer of the first frame material; and bonding the first continuous laminate layer of the first frame material, the second continuous laminate layer of the first frame material and the third continuous laminate layer of the first frame material to form the first continuous sheet of frame material.

[0096] With reference to the methods in accordance with the present disclosure described above, wherein a second continuous sheet of frame sheet material is combined with the first continuous sheet of frame material, in some examples providing a second continuous sheet of frame material comprises: providing a first continuous laminate layer of a second frame material and a second continuous laminate layer of the second frame material; positioning the second continuous laminate layer of the second frame material underneath the first continuous laminate layer of the second frame material; and bonding the first continuous laminate layer of the second frame material and the second continuous laminate layer of the second frame material to form the second continuous sheet of frame material.

[0097] In other examples, providing a first continuous laminate layer of a second frame material, a second continuous laminate layer of the second frame material, and a third continuous laminate layer of the second frame material; positioning the first continuous laminate layer of the second frame material between the second continuous laminate layer of the second frame material and the third continuous laminate layer of the second frame material; and bonding the first continuous laminate layer of the second frame material, the second continuous laminate layer of the second frame material and the third continuous laminate layer of the second frame material to form the second continuous sheet of frame material.

[0098] With reference to the methods in accordance with the present disclosure described above, wherein a second continuous sheet of frame sheet material and a third continuous sheet of frame material are combined with the first continuous sheet of frame material, in some examples providing a third continuous sheet of frame material comprises: providing a first continuous laminate layer of a third frame material and a second continuous laminate layer of the third frame material; positioning the second continuous laminate layer of the third frame material underneath the first continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material and the second continuous laminate layer of the third frame material to form the third continuous sheet of frame material.

[0099] In other examples, providing a third continuous sheet of frame material comprises: providing a first continuous laminate layer of a third frame material, a second continuous laminate layer of the third frame material, and a third continuous laminate layer of the third frame material; positioning the first continuous laminate layer of the third frame material between the second continuous laminate layer of the third frame material and the third continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material, the second continuous laminate layer of the third frame material and the third continuous laminate layer of the third frame material to form the third continuous sheet of frame material.

[0100] Preferably, a method according to present disclosure further comprises a step of forming an air inlet and an air outlet of the aerosol-generating article. More preferably, the step of forming an air inlet and an air outlet of the aerosol-generating article comprises establishing a fluid communication between the air inlet and the air outlet via an internal cavity of the aerosolgenerating article, wherein the internal cavity being is least partially defined by the frame aperture in the frame core layer.

[0101] In an example, the step of forming an air inlet and an air outlet of the aerosol-generating article may be carried out after the frame core layer has been formed. In particular, the step of forming an air inlet and an air outlet of the aerosol-generating article may be carried out after a laminated frame structure comprising the frame core layer has been formed, as described above.

[0102] Alternatively, an air inlet and an air outlet of the aerosol-generating article may be formed along with the frame core layer or more generally along with a laminated frame structure comprising the frame core layer. That is, the method may comprise additional steps by which an air inlet and an air outlet of the aerosol-generating article are formed at the same time as the frame - be it a frame including the frame core layer alone or a frame having a laminated frame structure in line with the foregoing description - is formed.

[0103] To this end, a method according to the present invention may comprise a step of forming an air inlet aperture or an air outlet aperture or both through the first continuous sheet of frame material. Thus, a frame core layer is obtained that comprises not only a frame aperture, but also one or both of an air inlet aperture and an air outlet aperture.

[0104] The frame aperture and one or both of the air inlet aperture and the air outlet aperture may advantageously be formed so that they ultimately define a continuous passage that extends through the frame core layer. For example, in the step of forming an air inlet aperture or an air outlet aperture or both through the first continuous sheet of frame material, the air inlet aperture and the air outlet aperture may be formed so that they define a non-interrupted passage extending through the frame core layer from the air inlet aperture to the air outlet aperture.

[0105] In embodiments wherein the further continuous sheet of material is a second continuous sheet of frame material and a laminated frame structure comprising the frame core layer and a second frame layer is formed, the method may comprise forming an air inlet aperture or an air outlet aperture or both through the first continuous sheet of frame material alone. Thus, in the laminated frame structure, an air inlet or an air outlet or both may be formed so that the air inlet or the air outlet or both extend through the frame core layer but not through the second frame layer.

[0106] Alternatively, in embodiments wherein the further continuous sheet of material is a second continuous sheet of frame material and a laminated frame structure comprising the frame core layer and a second frame layer is formed, the method may comprise forming an air inlet aperture or an air outlet aperture or both through both the first continuous sheet of frame material and the second continuous sheet of frame material. Thus, in the laminated frame structure, an air inlet or an air outlet or both may be formed so that the air inlet or the air outlet or both extend through both layers of the laminated frame structure.

[0107] These alternatives provide a desirable degree of adaptability by which a size of the air inlet or a size of the air outlet or both may be adjusted. For example, in embodiments wherein a frame aperture is formed through both the first continuous sheet of frame material and the second continuous sheet of frame material, the method may conveniently be adapted to form an air inlet or an air outlet or both that have the same height as the frame aperture. Alternatively, the method may equally conveniently be adapted for form an air inlet or an air outlet or both that have a different height compared with the frame aperture. For example, the air inlet or the air outlet or both may extend through a single layer of the laminated frame structure whereas the frame aperture extends through multiple layers of the laminated frame structure, or vice versa.

[0108] In embodiments wherein the further continuous sheet of material is a second continuous sheet of frame material and a third continuous sheet of frame material is provided and bonded with the other sheets of frame material, and a laminated frame structure comprising the frame core layer, a second frame layer and a third frame layer is formed, the method may comprise a step of forming an air inlet aperture or an air outlet aperture or both through the first continuous sheet of frame material alone. Thus, in the laminated frame structure, an air inlet or an air outlet or both may be formed so that the air inlet or the air outlet or both extend through the frame core layer but not through either one of the second frame layer and the third frame layer.

[0109] This may be advantageous in that the second frame layer and the third frame layer may at least partially form planar surfaces delimiting the air inlet or the air outlet or both. In more detail, the first frame layer and the second frame layer may, along with the air inlet (outlet) aperture, define a slit shaped air inlet (outlet).

[0110] Alternatively, in embodiments wherein the further continuous sheet of material is a second continuous sheet of frame material and a third continuous sheet of frame material is provided and bonded with the other sheets of frame material, and a laminated frame structure comprising the frame core layer, a second frame layer and a third frame layer is formed, the method may comprise a step of forming an air inlet aperture or an air outlet aperture or both through the first continuous sheet of frame material, the second continuous sheet of frame material and the third continuous sheet of frame material. Thus, in the laminated frame structure, an air inlet or an air outlet or both may be formed so that the air inlet or the air outlet or both extend through all three layers of the laminated frame structure.

[0111] These alternatives provide a further desirable degree of adaptability by which a size of the air inlet or a size of the air outlet or both may be adjusted.

[0112] The continuous sheets of frame material from which the frame core layer and any additional layers of a frame laminated structure are formed may be made from or comprise a biodegradable material. The continuous sheets of frame material from which the frame core layer and any additional layers of a frame laminated structure are formed may be made entirely from a biodegradable material.

[0113] The continuous sheets of frame material from which the frame core layer and any additional layers of a frame laminated structure are formed may be made from or comprise a cellulosic material. The cellulosic material may comprise cellulose fibres. The cellulosic material may be paper, paperboard, or cardboard. The continuous sheets of frame material from which the frame core layer and any additional layers of a frame laminated structure are formed may be made from or comprise a plant material, such as tobacco. The frame may be made entirely from a cellulosic material.

[0114] Preferably, a method in accordance with the present invention comprises a step of providing a first continuous sheet of external layer material.

[0115] More preferably, the method comprises a step of providing a first continuous sheet of external layer material and a second continuous sheet of external layer material.

[0116] Further, the method preferably comprises a step of positioning the first continuous sheet of frame material and the second continuous sheet of material between the first continuous sheet of external layer material and the second continuous sheet of external layer material.

[0117] Preferably, the method additionally comprises a step of bonding the first continuous sheet of external layer material, the second continuous sheet of external layer material and the frame core layer.

[0118] Advantageously it is thus possible to provide an aerosol-generating article having a laminated structure wherein the frame - be it a frame including the frame core layer alone or a frame having a laminated frame structure in line with the foregoing description - is not exposed to an exterior of the aerosol-generating article. This is because the first continuous sheet of external layer material and the second sheet of external layer material form a first external layer and a second external layer of a laminated structure of the article, respectively.

[0119] Accordingly, the first continuous sheet of external layer material and the second continuous sheet of external layer material advantageously define or at least partially form a first planar surface (for example, a bottom surface) and a second planar surface (for example the top surface) of the aerosol-generating article. By selecting suitable external layer sheet materials, it can therefore be possible to tailor the surface properties of the aerosol-generating article.

[0120] With reference to methods in accordance with the present disclosure involving the provision of continuous sheets of external layer material, the expression “positioning the first continuous sheet of frame material and the second continuous sheet of material between the first continuous sheet of external layer material and the second continuous sheet of external layer material” may denote a step in which the first continuous sheet of external layer material is in fact arranged immediately underneath the second continuous sheet of material and wherein the second continuous sheet of external layer material is in fact arranged immediately above the first continuous sheet of frame material. However, the expression “positioning the first continuous sheet of frame material and the second continuous sheet of material between the first continuous sheet of external layer material and the second continuous sheet of external layer material” is more generally intended to denote a step in which the first continuous sheet of frame material, along with any further continuous layer of frame material provided to form a laminated frame structure comprising the frame core layer, as well as any continuous sheet of internal layer material provided as will be described in detail below, are sandwiched between the first continuous sheet of external layer material and the second continuous sheet of external layer material.

[0121] For example, one or both of the first continuous sheet of external layer material and the second continuous sheet of external layer material may comprise a wrapper material. External layers of the aerosol-generating article comprising a wrapper material may also be denoted as outer wrappers.

[0122] In some example, one or both of the outer wrappers may be hydrophobic. One or both of the first continuous sheet of external layer material and the second continuous sheet of external layer material may comprise a hydrophobic material.

[0123] More generally, one or both of the first continuous sheet of external layer material and the second continuous sheet of external layer material 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.

[0124] In some examples, one or both of the first continuous sheet of external layer material and the second continuous sheet of external layer material may comprise, or be made from, an aerosolgenerating substrate comprising an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material of the type described in more detail below. In particular, the aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein.

[0125] One or both of the first continuous sheet of external layer material and the second continuous sheet of external layer material 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.

[0126] One or both of the first continuous sheet of external layer material and the second continuous sheet of external layer material 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.

[0127] One or both of the first continuous sheet of external layer material and the second continuous sheet of external layer material may have a thickness between 25 micrometres and 55 micrometres, between 25 micrometres and 45 micrometres, or between 30 micrometres and 45 micrometres. In some embodiments of the method, the further continuous sheet of material is a first continuous sheet of internal layer material.

[0128] In other words, the method comprises: providing a first continuous sheet of frame material and a first continuous sheet of internal layer material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer, positioning the first continuous sheet of internal layer material underneath the first continuous sheet of frame material; and bonding the first continuous sheet of internal layer material and the first continuous sheet of frame material to form the laminated structure of the aerosol-generating article.

[0129] Thus, an aerosol-generating article having a laminated structure can advantageously be obtained wherein an internal layer of non-frame material can be provided adjacent to the frame core layer. This may have the benefit that a material having certain desirable properties may be directly exposed to the internal cavity at least partially defined by the frame aperture.

[0130] For example, the first continuous sheet of internal layer material may comprise an aerosolgenerating substrate or the first continuous sheet of internal layer material may be a continuous sheet of aerosol-generating material (such as, for example, a sheet of homogenised tobacco material). As the first continuous sheet of internal layer material directly bonded underneath the frame aperture defines or at least partially forms a bottom surface of the internal cavity of the aerosol-generating article, the aerosol-generating substrate or material contained in the first continuous sheet of internal layer material may be advantageously exposed to the interior of the cavity and to an airflow passage extending between an inlet and an outlet of the aerosol-generating article via the cavity. In another example, the first continuous sheet of internal layer material may comprise a susceptor material. This may be beneficial in that such an internal layer comprising a susceptor material may be used to supply heat to an aerosol-generating substrate that may be provided, as will be described in more detail below, within the internal cavity at least partially defined by the frame aperture.

[0131] In certain embodiments, the method further comprises a step of providing a second continuous sheet of internal layer material, a step of positioning the second continuous sheet of internal layer material above the first continuous sheet of frame material, and a step of bonding the second continuous sheet of internal layer material and the first continuous sheet of frame material.

[0132] Thus, an aerosol-generating article having a laminated structure can advantageously be obtained wherein the frame core layer is comprised between two internal layers of non-frame material.

[0133] The first continuous sheet of internal layer material and the second continuous sheet of internal layer material may differ by at least one characteristic, such as for example the sheet composition. For example, one of the first continuous sheet of internal layer material and the second continuous sheet of internal layer material may comprise an aerosol-generating material whereas the other one of the first continuous sheet of internal layer material and the second continuous sheet of internal layer material is free of aerosol-generating material. One of the first continuous sheet of internal layer material and the second continuous sheet of internal layer material may comprise an aerosol-generating material whereas the other one of the first continuous sheet of internal layer material and the second continuous sheet of internal layer material comprises a susceptor material. Accordingly, bonding the first continuous sheet of internal frame material, the first continuous sheet of internal layer material and the second continuous sheet of internal frame material may advantageously provide a laminated structure that benefits from a combination of the differing characteristics.

[0134] It will be apparent from the foregoing description that methods in accordance with the present disclosure are advantageously adaptable to the provision of aerosol-generating articles comprising a frame and having laminated structures of varying complexity. In fact, certain steps that have been described before with reference to certain embodiments of a method in accordance with the present disclosure may advantageously be combined such that the resulting method is adapted to form an aerosol-generating article having a more complex laminated structure.

[0135] For example, certain steps that have been described before with reference to embodiments of the method adapted to form an aerosol-generating article comprising a laminated frame structure may be combined with steps for that have been described above with reference to embodiments of the method adapted to form an aerosol-generating article comprising internal layers of non-frame material.

[0136] In an example, a method in accordance with the present invention comprises: providing a first continuous sheet of frame material and a second continuous sheet of frame material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer, positioning the second continuous sheet of frame material underneath the first continuous sheet of frame material; bonding the second continuous sheet of frame material and the first continuous sheet of frame material to form a laminated frame structure; and further providing a first continuous sheet of internal layer material; positioning the first continuous sheet of internal layer material underneath the laminated frame structure; bonding the first continuous sheet of internal layer material and the laminated frame structure; optionally providing a second continuous sheet of internal layer material; positioning the second continuous sheet of internal layer material above the laminated frame structure; and bonding the second continuous sheet of internal layer material and the laminated frame structure, to form the laminated structure of the aerosol-generating article.

[0137] This example of a method in accordance with the present disclosure is advantageously adapted to provide an aerosol-generating article having a double-layered laminated frame structure combined with one or two layers of internal sheet material.

[0138] Additionally, certain steps that have been described above with regards to forming external layers of the aerosol-generating article may advantageously be combined into said example of a method in accordance with the present disclosure. Accordingly, the method may further comprise: providing a first continuous sheet of external layer material and a second continuous sheet of external layer material; positioning the laminated frame structure, the first continuous sheet of internal layer material and optionally the second continuous sheet of internal layer material between the first continuous sheet of external layer material and the second continuous sheet of external layer material; and bonding the first continuous sheet of external layer material, the second continuous sheet of external layer material and the laminated frame structure to form a the laminated structure of the aerosol-generating article.

[0139] In another example, a method in accordance with the present invention comprises: providing a first continuous sheet of frame material and a second continuous sheet of material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer, positioning the second continuous sheet of frame material underneath the first continuous sheet of frame material; bonding the second continuous sheet of frame material and the first continuous sheet of frame material; providing a third continuous sheet of frame material; bonding the third continuous sheet of frame material and the first continuous sheet of frame material to form a laminated frame structure; and further: providing a first continuous sheet of internal layer material; positioning the first continuous sheet of internal layer material underneath the laminated frame structure; bonding the first continuous sheet of internal layer material and the laminated frame structure; optionally providing a second continuous sheet of internal layer material, positioning the second continuous sheet of internal layer material above the laminated frame structure, and bonding the second continuous sheet of internal layer material and the laminated frame structure to form the laminated structure of the aerosol-generating article.

[0140] This example of a method in accordance with the present disclosure is advantageously adapted to provide an aerosol-generating article having a triple-layered laminated frame structure combined with one or two layers of internal sheet material.

[0141] Additionally, certain steps that have been described above with regards to forming external layers of the aerosol-generating article may advantageously be combined into said example of a method in accordance with the present disclosure. Accordingly, the method may further comprise: providing a first continuous sheet of external layer material and a second continuous sheet of external layer material; positioning the laminated frame structure, the first continuous sheet of internal layer material and optionally the second continuous sheet of internal layer material between the first continuous sheet of external layer material and the second continuous sheet of external layer material; and bonding the first continuous sheet of external layer material, the triplelayered laminated frame structure and optionally the second continuous sheet of external layer material to form the laminated structure of the aerosol-generating article.

[0142] It will be clear to the skilled reader that methods described above may be further adapted to forming aerosol-generating articles having even more complex structures, such as ones comprising multiple layers of internal sheet materials with different properties or serving different purposes or both. Any one of the methods discussed in the foregoing description may also further comprise a step of providing a first continuous sheet of protective layer material which may be removed from the aerosol-generating article prior to use.

[0143] In more detail, a method in accordance with the present disclosure may further comprise a step of providing a first continuous sheet of protective layer material; a step of positioning the first continuous sheet of protective layer material above the frame core layer and the further continuous sheet of material; and optionally removably bonding the first continuous sheet of protective layer material and the frame core layer.

[0144] With reference to methods in accordance with the present disclosure, the expression “positioning the first continuous sheet of protective layer material above the frame core layer” may denote a step in which the first continuous sheet of protective layer material is in fact arranged immediately above the frame core layer. However, the expression “positioning the first continuous sheet of protective layer material above the frame core layer” is more generally intended to denote a step in which the first continuous sheet of protective layer material is arranged above the frame core layer as well as above any other continuous sheets positioned above the frame core layer to form the laminated structure of the aerosol-generating article. This includes any further continuous sheet of frame material, any continuous sheet of internal layer material and any continuous sheet of external layer material, which may have been combined with the frame core layer in line with embodiments of methods in accordance with the foregoing description.

[0145] Advantageously, positioning a continuous sheet of protective layer material above all the layers of the laminated structure of an aerosol-generating article has the benefit that the aerosolgenerating article may be provided to the consumer in a configuration that helps preserve certain characteristics of the aerosol-generating article, for example during transportation and storage. The protective layer may generally be detached from the aerosol-generating article, for example immediately prior to use.

[0146] Materials suitable for forming a protective layer will be known to the skilled person.

[0147] Once a laminated structure comprising continuous sheets of material that have been provided, positioned and bonded as described above, one or more aerosol-generating articles may be obtained by punching one or more apertures, respectively through the two or more continuous sheets of material. Accordingly, the one or more aerosol-generating articles may be ejected from the remainder of the laminated structure.

[0148] Advantageously, individual aerosol-generating articles may conveniently be provided that the consumer may be able to use as such or following removal of any protective layers, if present. Individual aerosol-generating articles obtained

[0149] As an alternative, one or more weakened lines of severance may be formed through a laminated structure comprising continuous sheets of material that have been provided, positioned and bonded as described above, so as to make one or more aerosol-generating articles, respectively, detachable from the remainder of the laminated structure. In an example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a further continuous sheet of material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the further continuous sheet of material underneath the first continuous sheet of frame material; bonding the further continuous sheet of material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article; and punching an aperture through the first continuous sheet of frame material and the further continuous sheet of material so as to eject the aerosol-generating article.

[0150] In another example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a further continuous sheet of material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the further continuous sheet of material underneath the first continuous sheet of frame material; bonding the further continuous sheet of material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article; and forming a weakened line of severance through the first continuous sheet of frame material and the further continuous sheet of material so as to make the aerosol-generating article detachable from the remainder of the first continuous sheet of frame material and the further continuous sheet of material.

[0151] In an example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a second continuous sheet of frame material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the second continuous sheet of frame material underneath the first continuous sheet of frame material; bonding the second continuous sheet of frame material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article; and punching an aperture through the first continuous sheet of frame material and the second continuous sheet of frame material so as to eject the aerosol-generating article.

[0152] In another example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a second continuous sheet of frame material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the second continuous sheet of frame material underneath the first continuous sheet of frame material; bonding the second continuous sheet of frame material and the first continuous sheet of frame material to form a laminated frame structure of the aerosol-generating article; and forming a weakened line of severance through the first continuous sheet of frame material and the second continuous sheet of frame material so as to make the aerosol-generating article detachable from the remainder of the first continuous sheet of frame material and the second continuous sheet of frame material.

[0153] In an example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a second continuous sheet of frame material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the second continuous sheet of frame material underneath the first continuous sheet of frame material; bonding the second continuous sheet of frame material and the first continuous sheet of frame material; providing a third continuous sheet of frame material; bonding the third continuous sheet of frame material and the first continuous sheet of frame material to form a laminated frame structure of the aerosol-generating article; and punching an aperture through the first continuous sheet of frame material, the second continuous sheet of frame material and the third continuous sheet of frame material so as to eject the aerosol-generating article.

[0154] In another example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a second continuous sheet of frame material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the second continuous sheet of frame material underneath the first continuous sheet of frame material; bonding the second continuous sheet of frame material and the first continuous sheet of frame material; providing a third continuous sheet of frame material; bonding the third continuous sheet of frame material and the first continuous sheet of frame material to form a laminated frame structure of the aerosol-generating article; and forming a weakened line of severance through the first continuous sheet of frame material, the second continuous sheet of frame material and the third continuous sheet of frame material so as to make the aerosolgenerating article detachable from the remainder of the first continuous sheet of frame material and the second continuous sheet of frame material.

[0155] In an example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a first continuous sheet of internal layer material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the first continuous sheet of internal layer material underneath the first continuous sheet of frame material; bonding the first continuous sheet of internal layer material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article; and punching an aperture through the first continuous sheet of frame material and the first continuous sheet of internal layer material so as to eject the aerosol-generating article.

[0156] In another example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a first continuous sheet of internal layer material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the first continuous sheet of internal layer material underneath the first continuous sheet of frame material; bonding the first continuous sheet of internal layer material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article; and forming a weakened line of severance through the first continuous sheet of frame material and the first continuous sheet of internal layer material so as to make the aerosol-generating article detachable from the remainder of the first continuous sheet of frame material and the second continuous sheet of frame material. In an example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a first continuous sheet of internal layer material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the first continuous sheet of internal layer material underneath the first continuous sheet of frame material; bonding the first continuous sheet of internal layer material and the first continuous sheet of frame material; providing a second continuous sheet of internal layer material; positioning the second continuous sheet of internal layer material above the first continuous sheet of frame material; and bonding the second continuous sheet of internal layer material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article; and punching an aperture through the first continuous sheet of frame material, the first continuous sheet of internal layer material and the second continuous sheet of internal layer material so as to eject the aerosol-generating article.

[0157] In another example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a first continuous sheet of internal layer material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the first continuous sheet of internal layer material underneath the first continuous sheet of frame material; bonding the first continuous sheet of internal layer material and the first continuous sheet of frame material; providing a second continuous sheet of internal layer material; positioning the second continuous sheet of internal layer material above the first continuous sheet of frame material; and bonding the second continuous sheet of internal layer material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article; and forming a weakened line of severance through the first continuous sheet of frame material, the first continuous sheet of internal layer material and the second continuous sheet of internal layer material so as to make the aerosol-generating article detachable from the remainder of the first continuous sheet of frame material, the first continuous sheet of internal layer material and the second continuous sheet of internal layer material.

[0158] In an example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a further continuous sheet of material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the further continuous sheet of material underneath the first continuous sheet of frame material; bonding the further continuous sheet of material and the first continuous sheet of frame material; providing a first continuous sheet of external layer material and a second continuous sheet of external layer material; positioning the first continuous sheet of frame material and the further continuous sheet of material between the first continuous sheet of external layer material and the second continuous sheet of external layer material; bonding the first continuous sheet of external layer material, the second continuous sheet of external layer material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article; and punching an aperture through the first continuous sheet of frame material, the further continuous sheet of material, the first continuous sheet of external layer material and the second continuous sheet of external layer material so as to eject the aerosol-generating article.

[0159] In another example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a further continuous sheet of material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the further continuous sheet of material underneath the first continuous sheet of frame material; bonding the further continuous sheet of material and the first continuous sheet of frame material; providing a first continuous sheet of external layer material and a second continuous sheet of external layer material; positioning the first continuous sheet of frame material and the further continuous sheet of material between the first continuous sheet of external layer material and the second continuous sheet of external layer material; bonding the first continuous sheet of external layer material, the second continuous sheet of external layer material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article; and forming a weakened line of severance through the first continuous sheet of frame material, the further continuous sheet of material, the first continuous sheet of external layer material and the second continuous sheet of external layer material so as to make the aerosol-generating article detachable from the remainder of the first continuous sheet of frame material, the further continuous sheet of material, the first continuous sheet of external layer material and the second continuous sheet of external layer material.

[0160] In an example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a second continuous sheet of frame material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the second continuous sheet of frame material underneath the first continuous sheet of frame material; bonding the second continuous sheet of material and the first continuous sheet of frame material; providing a third continuous sheet of frame material; positioning the third continuous sheet of frame material above the first continuous sheet of frame material; bonding the third continuous sheet of frame material to the first continuous sheet of frame material to form a laminated frame structure; providing a first continuous sheet of internal layer material; positioning the first continuous sheet of internal layer material underneath the laminated frame structure; bonding the first continuous sheet of internal layer material and the laminated frame structure; providing a second continuous sheet of internal layer material; positioning the second continuous sheet of internal layer material above the laminated frame structure; bonding the second continuous sheet of internal layer material and the laminated frame structure; providing a first continuous sheet of external layer material and a second continuous sheet of external layer material; positioning the first continuous sheet of internal layer material, the laminated frame structure and the second continuous sheet of internal layer material between the first continuous sheet of external layer material and the second continuous sheet of external layer material; bonding the first continuous sheet of external layer material, the second continuous sheet of external layer material and the laminated frame structure to form the aerosol-generating article; punching an aperture through the first continuous sheet of external layer material, the first continuous sheet of internal layer material, the laminated frame structure, the second continuous sheet of internal layer material and the second continuous sheet of external layer material to eject the aerosol-generating article.

[0161] In another example, a method according to the present invention comprises: providing a first continuous sheet of frame material and a second continuous sheet of frame material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the second continuous sheet of frame material underneath the first continuous sheet of frame material; bonding the second continuous sheet of material and the first continuous sheet of frame material; providing a third continuous sheet of frame material; positioning the third continuous sheet of frame material above the first continuous sheet of frame material; bonding the third continuous sheet of frame material to the first continuous sheet of frame material to form a laminated frame structure; providing a first continuous sheet of internal layer material; positioning the first continuous sheet of internal layer material underneath the laminated frame structure; bonding the first continuous sheet of internal layer material and the laminated frame structure; providing a second continuous sheet of internal layer material; positioning the second continuous sheet of internal layer material above the laminated frame structure; bonding the second continuous sheet of internal layer material and the laminated frame structure; providing a first continuous sheet of external layer material and a second continuous sheet of external layer material; positioning the first continuous sheet of internal layer material, the laminated frame structure and the second continuous sheet of internal layer material between the first continuous sheet of external layer material and the second continuous sheet of external layer material; bonding the first continuous sheet of external layer material, the second continuous sheet of external layer material and the laminated frame structure to form the aerosol-generating article; forming a weakened line of severance through the first continuous sheet of external layer material, the first continuous sheet of internal layer material, the laminated frame structure, the second continuous sheet of internal layer material and the second continuous sheet of external layer material to make the aerosol-generating article detachable from the remainder of the first continuous sheet of external layer material, the first continuous sheet of internal layer material, the laminated frame structure, the second continuous sheet of internal layer material and the second continuous sheet of external layer material.

[0162] Methods in accordance with the present disclosure have been described above with reference to the manufacture of an aerosol-generating article. However, it will be clear that said methods can be implemented to manufacture a plurality of aerosol-generating articles at high speed and high volumes. Sequences of manufacturing steps in line with the foregoing description may for example be replicated in series, so that individual aerosol-generating articles are formed, one after the other. A way of scaling up production further may involve replicating sequences of steps in line with the foregoing description in parallel, so that multiple, substantially identical aerosol-generating articles may be formed at once. For example, in a method according to the present disclosure the step of forming a frame aperture through the first continuous sheet of frame material to form a frame [core layer] may comprise forming an array of frame apertures through the first continuous sheet of frame material to provide a continuous blank for forming a plurality of frame [core layers] of corresponding aerosol-generating articles.

[0163] It will be clear to the skilled person that other manufacturing steps that have been described before can be easily adapted to such a set-up. For example, steps involving forming an aperture through further continuous sheets of frame material may also be modified so that they involve forming an array of apertures in similar fashion. This equally applies to steps involving forming an inlet aperture or an outlet aperture or both in a continuous sheet of frame material. The step of punching an aperture through the layers of a laminated structure to eject an aerosol-generating article and the step of forming a weakened line through the layers of a laminated structure to make an aerosol-generating article detachable from the remainder of the laminated structure may equally be modified so that they involve an array of apertures or an array of weakened lines in similar fashion.

[0164] In methods in accordance with the present disclosure, a thickness of the aerosolgenerating article is preferably less than 50 percent of both a length and a width of the aerosolgenerating article.

[0165] Preferably, the frame has a thickness greater than or equal to 80 percent of the thickness of the aerosol-generating article. The thickness of the frame is substantially given by the combined thickness of the continuous sheets of frame material that have been used to form the frame of the aerosol-generating article. Thus, in certain embodiments the thickness of the frame substantially corresponds to a thickness of the first continuous sheet of frame material - that is, a thickness of the frame core layer. In other embodiments, the thickness of the frame substantially corresponds to the sum of a thickness of the first continuous sheet of frame material and the sum of any further continuous sheet of frame material that has been combined with the first continuous sheet of frame material to form a laminated frame structure.

[0166] In methods in accordance with the present disclosure, the first continuous sheet of frame material preferably comprises paper, paperboard, or cardboard.

[0167] A thickness of the first continuous sheet of frame material may be less than or equal to 0.6 millimetres. In some embodiments, a thickness of the first continuous sheet of frame material may be less than or equal to 0.5 millimetres. For example, a thickness of the first continuous sheet of frame material may be less than or equal to 0.35 millimetres.

[0168] A thickness of the first continuous sheet of frame material may be at least 0.1 millimetres. In some embodiments, a thickness of the first continuous sheet of frame material may be at least 0.2 millimetres, preferably at least 0.25 millimetres. In certain embodiments, a thickness of the first continuous sheet of frame material may be from 0.1 millimetres to 0.5 millimetres, preferably from 0.2 millimetres to 0.5 millimetres, more preferably from 0.25 to 0.5 millimetres.

[0169] In other embodiments, a thickness of the first continuous sheet of frame material may be from 0.1 millimetres to 0.35 millimetres, preferably from 0.2 millimetres to 0.35 millimetres, more preferably from 0.25 to 0.35 millimetres

[0170] In embodiments wherein the first continuous sheet of frame material is combined with at least a further continuous sheet of frame material to form a laminated frame structure, a thickness of any further continuous sheet of frame material may similarly be less than or equal to 0.5 millimetres, and in some embodiments less than or equal to 0.35 millimetres. A thickness of the further continuous sheet of frame material may be at least 0.1 millimetres. In some embodiments, a thickness of the further continuous sheet of frame material may be at least 0.2 millimetres, preferably at least 0.25 millimetres. In certain embodiments, a thickness of the further continuous sheet of frame material may be from 0.1 millimetres to 0.5 millimetres, preferably from 0.2 millimetres to 0.5 millimetres, more preferably from 0.25 to 0.5 millimetres. In other embodiments, a thickness of the further continuous sheet of frame material may be from 0.1 millimetres to 0.35 millimetres, preferably from 0.2 millimetres to 0.35 millimetres, more preferably from 0.25 to 0.35 millimetres

[0171] The laminated frame structure may be formed by combining multiple continuous sheets of frame material all having the same thickness. Alternatively, continuous sheets of frame material having different thicknesses may be combined to form the laminated frame structure.

[0172] For example, a laminated frame structure having a thickness of 3 millimetres may be formed by combining six continuous sheets of frame material, each having a thickness of 0.5 millimetres. In an alternative example, a laminated frame structure having a thickness of 3 millimetres may be formed by combining three continuous sheets of frame material, each having a thickness of 1 millimetre. In a further alternative example, a laminated frame structure having a thickness of 3 millimetres may be formed by combining three continuous sheets of frame material, each having a thickness of 0.33 millimetres, with four continuous sheets of frame material, each having a thickness of 0.5 millimetres.

[0173] In embodiments wherein a first continuous sheet of frame material, a second continuous sheet of frame material and a third continuous sheet of frame material are combined to form a laminated frame structure, and wherein each one of the first continuous sheet of frame material, a second continuous sheet of frame material and a third continuous sheet of frame material is formed from a single layer of frame material, a thickness of each continuous sheet of frame material may for example have a thickness of 1 millimetre and a basis weight from 500 gsm to 700 gsm.

[0174] In embodiments wherein a first continuous sheet of frame material, a second continuous sheet of frame material and a third continuous sheet of frame material are combined to form a laminated frame structure, and wherein each one of the first continuous sheet of frame material, a second continuous sheet of frame material and a third continuous sheet of frame material is formed from two layers of frame material, a thickness of each layer of frame material may for example have a thickness of 0.5 millimetres and a basis weight from 250 gsm to 380 gsm.

[0175] In embodiments wherein a first continuous sheet of frame material, a second continuous sheet of frame material and a third continuous sheet of frame material are combined to form a laminated frame structure, and wherein each one of the first continuous sheet of frame material, a second continuous sheet of frame material and a third continuous sheet of frame material is formed from three layers of frame material, a thickness of each layer of frame material may for example have a thickness of 0.3 millimetres and a basis weight from 170 gsm to 230 gsm.

[0176] A basis weight of the first continuous sheet of frame material may be less than or equal to 700 gsm. In some embodiments, a basis weight of the first continuous sheet of frame material may be less than or equal to 500 gsm. In an example, a basis weight of the first continuous sheet of frame material may be less than or equal to 400 gsm, such as less than or equal to 380 gsm.

[0177] A basis weight of the first continuous sheet of frame material may be at least 100 gsm. Preferably, a basis weight of the first continuous sheet of frame material may be at least 200 gsm. More preferably, a basis weight of the first continuous sheet of frame material may be at least 250 gsm.

[0178] A width of the first continuous sheet of frame material may be at least 10 millimetres, preferably at least 20 millimetres, more preferably at least 25 millimetres. In some embodiments, a width of the first continuous sheet of frame material may be at least 50 millimetres. In an example, a width of the first continuous sheet of frame material may be at least 100 millimetres, such as at least 150 millimetres or at least 200 millimetres.

[0179] In certain embodiments, a width of the continuous sheet of frame material may be up to 1200 millimetres, preferably up to 1000 millimetres, for example up to 960 millimetres, and more preferably up to 720 millimetres.

[0180] Methods in line with the foregoing description allow for a considerable degree of control over the content of the aerosol-generating article. As was discussed in particular with reference to the provision of one or more continuous sheets of internal layer material, methods in accordance with the present disclosure allow for the inclusion of an aerosol-generating material within the laminated structure of the aerosol-generating article. This enables advantageous configurations wherein the aerosol-generating material is exposed to an airflow passage extending through the aerosol-generating article.

[0181] A method in accordance with the present disclosure may further comprise a step of dispensing an aerosol-generating substrate into the frame aperture.

[0182] Advantageously, such a method makes it possible to further control and adjust a content of aerosol-generating substrate in the aerosol-generating article on top of the opportunities already afforded by the laminated structure of the article. In fact, this makes it possible for different types of aerosol-generating species to be combined within a single aerosol-generating article, such that different aerosol release mechanisms may be exploited to provide consistent delivery to the consumer and optionally create novel flavour profiles, etc.

[0183] In certain embodiments comprising a step of dispensing an aerosol-generating substrate into the frame aperture, the method may further comprise a step of compressing the aerosolgenerating substrate within a cavity of the aerosol-generating article, the cavity being at least partially delimited by a peripheral surface of the frame aperture.

[0184] In certain embodiments, the aerosol-generating substrate is in the form of shredded aerosol-generating material. For example, 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.

[0185] In certain embodiments, the aerosol-generating substrate is in the form of a plurality of granules, beads, pellets or flakes of aerosol-generating material.

[0186] In some embodiments, the aerosol-generating material may be in the form of a corrugated sheet of aerosol-generating material.

[0187] Preferably, the aerosol-generating substrate comprises one or more aerosol-formers, such as one or both of glycerine and propylene glycol.

[0188] The aerosol-generating substrate may have a bulk density of less than or equal to 0.5 milligrams per cubic millimetre.

[0189] The aerosol-generating substrate positioned within the cavity may have a packing density of less than or equal to 0.9.

[0190] Features of an aerosol-generating article obtainable by methods in accordance with the present invention are described in more detail below.

[0191] The frame may be a planar frame.

[0192] The frame may define a frame aperture extending through the thickness of the frame. The frame aperture may define or form the airflow passage of the aerosol-generating article. The frame aperture may define or form the cavity of the aerosol-generating article. For example, the frame may have a hollow cuboid shape or a square hollow tube shape. As a further example, the frame may have a cross-section that is annular in shape, preferably the cross-section in an x / y plane is annular in shape.

[0193] The frame may comprise a frame outer surface. The frame outer surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The frame outer surface may at least partially define or form one or more external surfaces of the aerosol-generating article. For example, the frame outer surface may at least partially define or form one or more external walls of the aerosol-generating article. The frame outer surface may circumscribe or encircle the frame aperture. The frame outer surface may circumscribe or encircle the cavity.

[0194] The frame may comprise a frame inner surface. The frame inner surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The frame inner surface may define or form a frame aperture outer wall. The frame inner surface may define or form a cavity outer wall. The frame inner surface may circumscribe or encircle the frame aperture extending through the thickness of the frame. The frame outer surface may circumscribe or encircle the cavity.

[0195] 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.

[0196] The aerosol-generating article may comprise one or more external walls extending between the first planar external surface and the second planar external surface. The one or more external walls may collectively define an entire transverse external area of the aerosol-generating article. The frame may at least partially define each of the one or more external walls. The one or more external walls may circumscribe or encircle the cavity. The frame may define at least 60 percent, at least 70 percent, at least 80 percent, or at least 90 percent of the entire transverse external area of the aerosol-generating article.

[0197] The frame may comprise a peripheral wall. The peripheral wall may circumscribe or encircle at least a portion of the frame aperture extending through the thickness of the frame. The peripheral wall may circumscribe or encircle at least a portion of the cavity. The peripheral wall may circumscribe or encircle the frame aperture extending through the thickness of the frame. The peripheral wall may circumscribe or encircle the cavity.

[0198] The peripheral wall may be defined or formed by the frame outer surface and the frame inner surface. The peripheral wall may at least partially define or form one or more external surfaces or walls of the aerosol-generating article. The peripheral wall may define or form a frame aperture outer wall. The peripheral wall may define or form a cavity outer wall.

[0199] 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.

[0200] 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.

[0201] 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.

[0202] 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.

[0203] 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. The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0204] 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.

[0205] The aerosol-generating article may comprise one or more susceptor materials. The frame may comprise one or more susceptor materials. The one more susceptor materials may be in thermal contact with the aerosol-generating substrate. The one more susceptor materials may be in thermal contact with the cavity. The one or more susceptor materials may be incorporated within the material of the frame. For example, the one or more susceptor material may be incorporated within the peripheral wall of the frame.

[0206] 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.

[0207] 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.

[0208] 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.

[0209] 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.

[0210] 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.

[0211] 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.

[0212] 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.

[0213] 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.

[0214] 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.

[0215] The frame may comprise a first frame layer and a second frame layer. The first frame layer and the second frame layer may be the only layers of the frame. That is, the frame may comprise no more than two layers or may comprise exactly two layers. The frame aperture may be defined through both the first frame layer and the second frame layer.

[0216] The frame may comprise a first frame layer, a second frame layer and a third frame layer. The second frame layer may be positioned between the first frame layer and the third frame layer. The first frame layer, the second frame layer and the third frame layer may be the only layers of the frame. That is, the frame may comprise no more than three layers or may comprise exactly three layers.

[0217] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate layer. Advantageously, the aerosol-generating substrate layer can be made thin and, therefore, quickly heat up and release volatile compounds to form an aerosol. Advantageously, the aerosol-generating substrate layer can be positioned close to a heater of an aerosol-generating substrate.

[0218] The aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. The aerosol-generating substrate layer may be, and may be made entirely of, a sheet of aerosol-generating material.

[0219] The aerosol-generating substrate layer may be positioned between the frame and the first planar external surface. The aerosol-generating substrate layer may be positioned between the frame and the second planar external surface. The aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame. The aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The outer wrapper is discussed in more detail below. The aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the outer wrapper.

[0220] The aerosol-generating substrate layer may be positioned between the frame and the first planar external layer. The aerosol-generating substrate layer may be positioned between the frame and the second planar external layer. The first planar external layer and the second planar external layer are discussed in more detail below. The aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the first planar external layer. The aerosolgenerating substrate layer may in physical contact with, and may be bonded to, both the frame and the second planar external layer.

[0221] The aerosol-generating substrate layer may overlie an end of the cavity. The aerosolgenerating substrate layer may define or form a wall of the cavity, such as the first cavity end wall or the second cavity end wall. Advantageously, the aerosol-generating substrate layer may therefore be in, or at least partially define or form, the airflow passage thereby allowing released volatile compounds to quickly form an aerosol.

[0222] The one or more aerosol-generating substrates may comprise a first aerosol-generating substrate layer and a second aerosol-generating substrate layer. Advantageously, a first and a second aerosol-generating substrate layer may allow rapid generation of a satisfactory volume of aerosol compared with using a single aerosol-generating substrate layer.

[0223] The first aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. The first aerosol-generating substrate layer may be, and may be made entirely of, a sheet of aerosol-generating material.

[0224] The second aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. The second aerosol-generating substrate layer may be, and may be made entirely of, a sheet of aerosol-generating material.

[0225] The first aerosol-generating substrate layer may be positioned between the frame and the first planar external surface. The first aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame.

[0226] The first aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The first aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the outer wrapper. The first aerosol-generating substrate layer may be positioned between the frame and the first planar external layer. The first aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the first planar external layer.

[0227] The second aerosol-generating substrate layer may be positioned between the frame and the second planar external surface. The second aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame.

[0228] The second aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The second aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the outer wrapper.

[0229] The second aerosol-generating substrate layer may be positioned between the frame and the second planar external layer. The second aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the second planar external layer.

[0230] The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may overlie opposing ends of the cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may define or form opposing end walls of the cavity. That is, the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may collectively define the cavity.

[0231] One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 100 micrometres, greater than or equal to 200 micrometres, greater than or equal to 300 micrometres, greater than or equal to 400 micrometres, or greater than or equal to 500 micrometres.

[0232] One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness less than or equal to 600 micrometres, less than or equal to 500 micrometres, less than or equal to 400 micrometres, less than or equal to 300 micrometres, or less than or equal to 300 micrometres.

[0233] One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness between 100 micrometres and 600 micrometres, between 200 micrometres and 500 micrometres, between 200 micrometres and 400 micrometres, or between 200 micrometres and 300 micrometres.

[0234] The aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article.

[0235] The first aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The first aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article. The second aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The second aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article.

[0236] The aerosol-generating substrate layer may have a width substantially the same as the width of the frame. The aerosol-generating substrate layer may have a width substantially the same as the width of the aerosol-generating article.

[0237] The first aerosol-generating substrate layer may have a width substantially the same as the width of the frame. The first aerosol-generating substrate layer may have a width substantially the same as the width of the aerosol-generating article.

[0238] The second aerosol-generating substrate layer may have a width substantially the same as the width of the frame. The second aerosol-generating substrate layer may have a width substantially the same as the width of the aerosol-generating article.

[0239] The first planar external surface may be a planar upper surface and the second planar external surface may be a planar lower surface. The first planar external surface may be positioned parallel to the second planar external surface. The first planar external surface may extend in the x / y plane. The second planar external surface may extend in the x / y plane. The second planar external surface may be spaced from the first planar external surface in the z-direction or transverse direction. The distance between the first planar external surface and the second planar external surface in the z-direction or transverse direction may define the thickness of the aerosolgenerating article.

[0240] The aerosol-generating article may comprise an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may comprise a hydrophobic material.

[0241] The outer wrapper may define or form the first planar external surface. The outer wrapper may define or form the second planar external surface. The outer wrapper may define or form both the first planar external surface and the second planar external surface.

[0242] The outer wrapper may circumscribe or encircle the frame. The outer wrapper may be in physical contact with, and may be bonded to, the frame. The outer wrapper may overlie opposing ends of the cavity. The outer wrapper may define or form opposing end walls of the cavity, such as the first cavity end wall and the second cavity end wall. That is, the frame and the outer wrapper may collectively define the cavity.

[0243] The outer wrapper may circumscribe or encircle the frame and the aerosol-generating substrate layer. The outer wrapper may be in physical contact with, and may be bonded to, both the frame and the aerosol-generating substrate layer.

[0244] The outer wrapper may circumscribe or encircle the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer. The outer wrapper may be in physical contact with, and may be bonded to, both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer. The aerosol-generating article may comprise a first planar external layer and a second planar external layer. The first planar external layer may be an upper layer and the second planar external layer may be a lower layer.

[0245] 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.

[0246] The first planar external layer may be in physical contact with, and may be bonded to, the frame. The first planar external layer may overlie an end of the cavity. The first planar external layer may define or form a wall of the cavity, such as the first cavity end wall.

[0247] The second planar external layer may be in physical contact with, and may be bonded to, the frame. The second planar external layer may overlie an end of the cavity. The second planar external layer may define or form a wall of the cavity, such as the second cavity end wall.

[0248] The first planar external layer and the second planar external layer may overlie opposing ends of the cavity. The first planar external layer and the second planar external layer may define or form opposing end walls of the cavity, such as the first cavity end wall and the second cavity end wall. That is, the frame, the first planar external layer and the second planar external layer may collectively define the cavity.

[0249] The first planar external layer may be spaced, such as in a transverse direction, from the frame. For example, the aerosol-generating substrate layer or the first aerosol-generating substrate layer may be positioned between the first planar external layer and the frame. The first planar external layer may be in physical contact with, and may be bonded to, the aerosolgenerating substrate layer or the first aerosol-generating substrate layer.

[0250] The second planar external layer may be spaced, such as in a transverse direction, from the frame. For example, the aerosol-generating substrate layer or the second aerosol-generating substrate layer may be positioned between the second planar external layer and the frame. The second planar external layer may be in physical contact with, and may be bonded to, the aerosolgenerating substrate layer or the second aerosol-generating substrate layer.

[0251] 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.

[0252] One or more of the outer wrapper, the first planar external layer and the second planar external layer may comprise, or be made from, a cellulosic material. The cellulosic material may be paper, cigarette paper, tobacco paper, cardboard, wood, textile, natural fibres or artificial fibres.

[0253] One or more of the outer wrapper, the first planar external layer and the second planar external layer may be an aerosol-generating substrate comprising an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. In particular, the aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. Alternatively, one or more of the outer wrapper, the first planar external layer and the second planar external layer may not comprise any aerosol-generating material, particularly in embodiments comprising an aerosol-generating substrate layer, a first aerosolgenerating substrate layer, a second aerosol-generating substrate layer or an aerosol-generating substrate positioned within the cavity. One or more of the outer wrapper, the first planar external layer and the second planar external layer may be substantially nicotine-free.

[0254] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness greater than or equal to 25 micrometres, greater than or equal to 30 micrometres, greater than or equal to 35 micrometres, greater than or equal to 40 micrometres, or greater than or equal to 45 micrometres.

[0255] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness less than or equal to 55 micrometres, less than or equal to 50 micrometres, less than or equal to 45 micrometres, less than or equal to 40 micrometres, or less than or equal to 35 micrometres.

[0256] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness between 25 micrometres and 55 micrometres, between 25 micrometres and 45 micrometres, or between 30 micrometres and 45 micrometres.

[0257] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a length substantially the same as the length of the frame. One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a length substantially the same as the length of the aerosol-generating article.

[0258] One or more of the first planar external layer and the second planar external layer may have a width substantially the same as the width of the frame. One or more of the first planar external layer and the second planar external layer may have a width substantially the same as the width of the aerosol-generating article.

[0259] The cavity may have a thickness greater than or equal to 0.5 millimetres. The cavity may have a thickness greater than or equal to 1 .5 millimetres. The cavity may have a thickness greater than or equal to 2.5 millimetres. The cavity may have a thickness greater than or equal to 3.5 millimetres.

[0260] The cavity may have a thickness less than or equal to 4.5 millimetres. The cavity may have a thickness less than or equal to 3.5 millimetres. The cavity may have a thickness less than or equal to 2.5 millimetres. The cavity may have a thickness less than or equal to 1 .5 millimetres.

[0261] The cavity may have a thickness between 0.5 millimetres and 4.5 millimetres. The cavity may have a thickness between 1 millimetre and 4.5 millimetres. Preferably, the cavity may have a thickness between 2.8 millimetres and 3.3 millimetres.

[0262] The cavity may have a length greater than or equal to 14 millimetres. The cavity may have a length equal to a greater than 18 millimetres. The cavity may have a length greater than or equal to 22 millimetres. The cavity may have a thickness greater than or equal to 30 millimetres. The cavity may have a thickness greater than or equal to 38 millimetres.

[0263] The cavity may have a length less than or equal to 40 millimetres. The cavity may have a thickness less than or equal to 34 millimetres. The cavity may have a thickness less than or equal to 28 millimetres. The cavity may have a thickness less than or equal to 22 millimetres. The cavity may have a thickness less than or equal to 18 millimetres.

[0264] The cavity may have a length between 14 millimetres and 40 millimetres. The cavity may have a length between 14 millimetres and 34 millimetres. . The cavity may have a length between 24 millimetres and 28 millimetres.

[0265] The cavity may have a width greater than or equal to 4.5 millimetres. The cavity may have a width greater than or equal to 7 millimetres. The cavity may have a width greater than or equal to 11 millimetres.

[0266] The cavity may have a width less than or equal to 13 millimetres. The cavity may have a width less than or equal to 11 millimetres. The cavity may have a width less than or equal to 7 millimetres. The cavity may have a width less than or equal to 5 millimetres.

[0267] The cavity may have a width between 4.5 millimetres and 13 millimetres. The cavity may have a width between 7 millimetres and 10 millimetres. The cavity may have a width between 7.5 millimetres and 8.5 millimetres.

[0268] The cavity may have a length between 14 millimetres and 40 millimetres, a width between 4.5 millimetres and 13 millimetres, and a thickness between 0.5 millimetres and 4.5 millimetres.

[0269] Preferably, the cavity may have a length between 20 millimetres and 30 millimetres, a width between 7 millimetres and 10 millimetres, and a thickness between 2.5 millimetres and 4 millimetres.

[0270] Most preferably, the cavity may have a length of 26 millimetres, a width of 8 millimetres, and a thickness of 3.1 millimetres.

[0271] The cavity may have a volume of greater than or equal to 30 cubic millimetres, greater than or equal to 100 cubic millimetres, greater than or equal to 300 cubic millimetres, greater than or equal to 500 cubic millimetres, greater than or equal to 700 cubic millimetres, greater than or equal to 900 cubic millimetres, greater than or equal to 1000 cubic millimetres, greater than or equal to 2000 cubic millimetres, or greater than or equal to 30 cubic millimetres.

[0272] The cavity may have a volume of less than or equal to 3500 cubic millimetres, less than or equal to 2500 cubic millimetres, less than or equal to 1500 cubic millimetres, less than or equal to 1000 cubic millimetres, less than or equal to 800 cubic millimetres, less than or equal to 600 cubic millimetres, less than or equal to 500 cubic millimetres, less than or equal to 400 cubic millimetres, or less than or equal to 300 cubic millimetres.

[0273] The cavity may have a volume between 30 cubic millimetres and 3500 cubic millimetres. The cavity may have a volume between 30 cubic millimetres and 2500 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 1500 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 1000 cubic millimetres.

[0274] The cavity may be substantially empty.

[0275] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate positioned within the cavity. The aerosol-generating substrate positioned within the cavity may fill the cavity.

[0276] The aerosol-generating substrate positioned within the cavity may comprise an aerosolgenerating material. The aerosol-generating material may be any aerosol-generating material described herein. For example, the aerosol-generating material may be in the form of shredded aerosol-generating material.

[0277] The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. For example, the sheet of aerosol-generating material may be a sheet of homogenised tobacco material.

[0278] The sheet of aerosol-generating material may extend the entire length of the cavity. The sheet of aerosol-generating material may extend the entire width of the cavity.

[0279] 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.

[0280] The sheet of aerosol-generating material may be a crimped sheet of aerosol-generating material. The sheet of aerosol-generating material may be a corrugated sheet of aerosolgenerating material. The crimped sheet of aerosol-generating material or the corrugated sheet of aerosol-generating material may comprise a plurality of parallel corrugations. For example, the crimped sheet of aerosol-generating material may comprise a plurality of substantially parallel peaks and troughs.

[0281] 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.

[0282] The plurality of parallel corrugations may define, or form, a plurality of channels between the sheet of aerosol-generating material and one or more walls of the cavity. The plurality of channels may be a plurality of longitudinally extending channels. The plurality of channels may be a plurality of laterally extending channels. The plurality of channels may defined, or form, at least a portion of the airflow passage extending between the air inlet and air outlet of the aerosolgenerating article.

[0283] The aerosol-generating material may comprise one or more organic materials such as tobacco, mint, tea and cloves. The aerosol-generating material may comprise one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenised tobacco such as cast leaf, extruded tobacco, expanded tobacco, aerosol-generating films and gel compositions.

[0284] The aerosol-generating material may be in the form of shredded aerosol-generating material. The shredded aerosol-generating material may comprise one or more of: strips and strands of aerosol-generating material, such as strips and strands of tobacco or homogenised tobacco material. The shredded aerosol-generating material may be in the form of a shredded sheet of homogenised tobacco material.

[0285] The aerosol-generating material may be cut filler. The aerosol-generating material may be tobacco cut filler. As used herein, the term “cut filler” is used to describe to a blend of shredded plant material, such as tobacco plant material, including, in particular, one or more of leaf lamina, processed stems and ribs, homogenised plant material.

[0286] The aerosol-generating material may be in the form of a sheet of aerosol-generating material. As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenised tobacco material, such as a cast leaf sheet.

[0287] The aerosol-generating material may comprise one or more aerosol-formers. Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosolformers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosolformer to be or comprise one or both of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0288] The aerosol-generating material may have an aerosol-former content greater than or equal to 1 , 2, 5, 10, or 15 percent by weight on a dry weight basis. The aerosol-generating material may have an aerosol-former content greater than or equal to 15 percent by weight on a dry weight basis, for example greater than 20 by weight on a dry weight basis, or greater than 25 by weight on a dry weight basis, or greater than 30 by weight on a dry weight basis, or greater than 40 by weight on a dry weight basis, or greater than 50 by weight on a dry weight basis.

[0289] The aerosol-generating material may have an aerosol-former content less than or equal to 30 percent by weight on a dry weight basis, less than or equal to 25 percent by weight on a dry weight basis, or less than or equal to 20 percent by weight on a dry weight basis.

[0290] The aerosol-generating material may have an aerosol-former content between 5 percent and 30 percent by weight on a dry weight basis, between 5 percent and 25 percent by weight on a dry weight basis, or between 5 percent and 20 percent by weight on a dry weight basis. The aerosol-generating material may have an aerosol-former content between 10 percent and 30 percent by weight on a dry weight basis, between 10 percent and 25 percent by weight on a dry weight basis, or between 10 percent and 20 percent by weight on a dry weight basis.

[0291] The aerosol-generating material may comprise nicotine. The aerosol-generating material may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0292] The aerosol-generating material may comprise at least 0.5 percent by weight of nicotine, at least 1 percent by weight of nicotine, at least 1.5 percent by weight of nicotine, or at least 2 percent by weight of nicotine. That is, the aerosol-generating material may have a nicotine content of at least 0.5 percent by weight, at least 1 percent by weight, at least 1 .5 percent by weight, or at least 2 percent by weight.

[0293] The aerosol-generating material may be in the form of a plurality of beads. The plurality of beads may have an average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm.

[0294] The term “bead” refers to a discrete, solid particle formed of the aerosol-generating substrate. A bead may have a rounded, typically spherical, form. Other terms may be used to define the substrate such as, for example, “granule”.

[0295] Providing the aerosol-generating material as a plurality of beads may provide certain advantages. Beads can be easily handled compared to other aerosol-forming substrates such as fine powders or cut filler. The beads flow easily, and so can reliably and consistently fill the cavity of the aerosol-generating article during manufacture. This may allow a consistent and reproducible amount of aerosol-forming substrate to be loaded into each article during manufacture. Beads may also be cleaner to handle than powders and cut fillers, which may cause dust in factories, and may leak from aerosol-generating articles in transit or in use. By selecting beads with appropriate bead sizes and appropriate particle size distributions, air flow through the cavity of the aerosolgenerating article may be controlled more reproducibly than would be the case for, say, a cut filler substrate.

[0296] 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.

[0297] 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.

[0298] The aerosol-generating material may be in form of a wrapped body of aerosol-generating material, the wrapped body comprising a wrapper at least partially enclosing aerosol-generating material. The wrapped body of aerosol-generating material may occupy between 15% and 100% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 30% and 100% of the interior volume of the cavity. The wrapped body of aerosolgenerating material may occupy between 50% and 100% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 50% and 80% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 50% and 70% of the interior volume of the cavity.

[0299] The air inlet may be defined by the front wall of the aerosol-generating article. The air inlet may be defined by, and may extend through, the frame. The air inlet may be defined by the peripheral wall of the frame. The air inlet may extend through the peripheral wall of the frame. The air outlet may be defined by the back wall of the aerosol-generating article. The air outlet may be defined by, and may extend through, the frame. The air outlet may be defined by the peripheral wall of the frame. The outlet may extend though the peripheral wall of the frame.

[0300] The air inlet may have a round cross-section, a circular cross-section, an oval crosssection, a square cross-section, or a rectangular cross-section. The air outlet may have a round cross-section, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section.

[0301] The air inlet may be defined by, and may extend through, the first planar external surface. The air inlet may be defined by, and may extend through, the outer wrapper. The air inlet may be defined by, and may extend through, the outer wrapper and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the outer wrapper and the first aerosolgenerating substrate layer. The air inlet may be defined by, and may extend through, the first planar external layer and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the first planar external layer and the first aerosol-generating substrate layer.

[0302] The air inlet may be defined by, and may extend through, the second planar external surface. The air inlet may be defined by, and may extend through, the outer wrapper and the second aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the second planar external layer and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the second planar external layer and the second aerosol-generating substrate layer.

[0303] The air outlet may be defined by, and may extend through, the first planar external surface. The air outlet may be defined by, and may extend through, the outer wrapper. The air outlet may be defined by, and may extend through, the outer wrapper and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the outer wrapper and the first aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the first planar external layer and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the first planar external layer and the first aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the second planar external surface. The air outlet may be defined by, and may extend through, the outer wrapper and the second aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the second planar external layer and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the second planar external layer and the second aerosol-generating substrate layer.

[0304] One or both of the air inlet and the air outlet may have an equivalent diameter greater than or equal to 0.1 millimetres, greater than or equal to 0.4 millimetres, greater than or equal to 0.7 millimetres, or greater than or equal to 1.0 millimetres.

[0305] One or both of the air inlet and the air outlet may have an equivalent diameter less than or equal to 3 millimetres, less than or equal to 2.7 millimetres, less than or equal to 2.4 millimetres, less than or equal to 2.1 millimetres. The air inlet may have an equivalent diameter less than or equal to 2.7 millimetres, less than or equal to 1.8 millimetres, or less than or equal to 1.5 millimetres.

[0306] One or both of the air inlet and the air outlet may have an equivalent diameter between 0.1 millimetres and 3 millimetres, between 0.1 millimetres and 2.4 millimetres, between 0.4 millimetres and 2.1 millimetres, between 0.4 millimetres and 1.8 millimetres, between 0.7 millimetres and 1.5 millimetres, or between 1.0 millimetres and 1.5 millimetres.

[0307] The air inlet may have a width less than a width of the cavity. The air outlet may have a width less than a width of the cavity. The air inlet may have a thickness less than a thickness of the cavity. The air outlet may have a thickness less than a thickness of the cavity.

[0308] One or both of the air inlet and the air outlet may a width of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres.

[0309] One or both of the air inlet and the air outlet may have a thickness of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres.

[0310] Preferably, the 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.

[0311] Preferably, the 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.

[0312] 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.

[0313] A ratio of the width of the air inlet to the thickness of the air inlet may be between 0.33 and 3. A ratio of the width of the air inlet to the thickness of the air inlet may be between 0.5 and 1 .5. A ratio of the width of the air inlet to the thickness of the air inlet may be between 0.75 and 1 .25. A ratio of the width of the air outlet to the thickness of the air outlet may be between 0.33 and 3. A ratio of the width of the air outlet to the thickness of the air outlet may be between 0.5 and 1 .5. A ratio of the width of the air outlet to the thickness of the air outlet may be between 0.75 and 1.25.

[0314] The aerosol-generating article may comprise a plurality of air inlets. One or each of the air inlets may have one or more of the features of the air inlet described herein.

[0315] The aerosol-generating article may comprise a plurality of air outlets. One or each of the air outlets may have one or more of the features of the air outlet described herein.

[0316] The aerosol-generating article may comprise a filter element positioned downstream of the aerosol-forming substrate. The aerosol-generating article may comprise a filter element positioned downstream of the cavity. The aerosol-generating article may comprise a filter element at least partially positioned within the air outlet. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at a downstream end of, the cavity.

[0317] The aerosol-generating article may comprise a filter element positioned upstream of the aerosol-forming substrate. The aerosol-generating article may comprise a filter element positioned upstream of the cavity. The aerosol-generating article may comprise a filter element at least partially positioned within the air inlet. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at an upstream end of, the cavity.

[0318] 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.

[0319] 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.

[0320] 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

[0321] 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.

[0322] 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.

[0323] 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.

[0324] 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. 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.

[0325] 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.

[0326] 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.

[0327] 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.

[0328] 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.

[0329] 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.

[0330] 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.

[0331] 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.

[0332] 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.

[0333] 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.

[0334] 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.

[0335] 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.

[0336] EXAMPLE EX1. A method of manufacturing an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the method comprising: providing a first continuous sheet of frame material and a further continuous sheet of material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the further continuous sheet of material underneath the first continuous sheet of frame material; and bonding the further continuous sheet of material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article comprising the frame core layer.

[0337] EXAMPLE EX2. A method according to example EX1 , wherein the further continuous sheet of material is a second continuous sheet of frame material, the first continuous sheet of frame material and the second continuous sheet of frame material forming a laminated frame structure, and wherein the step of bonding the further continuous sheet of material and the first continuous sheet of frame material is carried out prior to forming a frame aperture through the first continuous sheet of frame material to form the frame core layer.

[0338] EXAMPLE EX 3. A method according to example EX 2, wherein the frame aperture is formed such that it extends through both the first continuous sheet of frame material and the second continuous sheet of frame material.

[0339] EXAMPLE EX 4. A method according to example EX 1 , wherein the further continuous sheet of material is a second continuous sheet of frame material, the first continuous sheet of frame material and the second continuous sheet of frame material forming a laminated frame structure, and wherein the step of bonding the further continuous sheet of material and the first continuous sheet of frame material is carried out subsequent to forming a frame aperture through the first continuous sheet of frame material to form the frame core layer.

[0340] EXAMPLE EX 5. A method according to any one of examples EX 2 to EX 4, the method further comprising: providing a third continuous sheet of frame material; and bonding the third continuous sheet of frame material and the first continuous sheet of frame material to form the laminated structure of the aerosol-generating article, wherein the first continuous sheet of frame material, the second continuous sheet of frame material and the third continuous sheet of frame material form the laminated frame structure. EXAMPLE EX 6. A method according to example EX 5, wherein the step of bonding the third continuous sheet of frame material and the first continuous sheet of frame material is carried out prior to forming a frame aperture through the first continuous sheet of frame material to form the frame core layer, and subsequent to or simultaneous with bonding the second continuous sheet of frame material and the first continuous sheet of frame material.

[0341] EXAMPLE EX 7. A method according to example EX 6, wherein the frame aperture is formed such that it extends through the first continuous sheet of frame material, the second continuous sheet of frame material and the third continuous sheet of frame material.

[0342] EXAMPLE EX 8. A method according to any one of examples EX 1 to EX 7, wherein providing a first continuous sheet of frame material comprises: providing a first continuous laminate layer of a first frame material and a second continuous laminate layer of the first frame material; positioning the second continuous laminate layer of the first frame material underneath the first continuous laminate layer of the first frame material; and bonding the first continuous laminate layer of the frame material and the second continuous laminate layer of the first frame material to form the first continuous sheet of frame material.

[0343] EXAMPLE EX 9. A method according to any one of examples EX 1 to EX 7, wherein providing a first continuous sheet of frame material comprises: providing a first continuous laminate layer of a first frame material, a second continuous laminate layer of the first frame material, and a third continuous laminate layer of the first frame material; positioning the first continuous laminate layer of the first frame material between the second continuous laminate layer of the first frame material and the third continuous laminate layer of the first frame material; and bonding the first continuous laminate layer of the first frame material, the second continuous laminate layer of the first frame material and the third continuous laminate layer of the first frame material to form the first continuous sheet of frame material.

[0344] EXAMPLE EX 10. A method according to any one of examples EX 2 to EX 7, wherein providing a second continuous sheet of frame material comprises: providing a first continuous laminate layer of a second frame material and a second continuous laminate layer of the second frame material; positioning the second continuous laminate layer of the second frame material underneath the first continuous laminate layer of the second frame material; and bonding the first continuous laminate layer of the second frame material and the second continuous laminate layer of the second frame material to form the second continuous sheet of frame material.

[0345] EXAMPLE EX 11 . A method according to any one of examples EX 2 to EX 7, wherein providing a second continuous sheet of frame material comprises: providing a first continuous laminate layer of a second frame material, a second continuous laminate layer of the second frame material, and a third continuous laminate layer of the second frame material; positioning the first continuous laminate layer of the second frame material between the second continuous laminate layer of the second frame material and the third continuous laminate layer of the second frame material; and bonding the first continuous laminate layer of the second frame material, the second continuous laminate layer of the second frame material and the third continuous laminate layer of the second frame material to form the second continuous sheet of frame material.

[0346] EXAMPLE EX 12. A method according to any one of examples EX 5 to EX 7, wherein providing a third continuous sheet of frame material comprises: providing a first continuous laminate layer of a third frame material and a second continuous laminate layer of the third frame material; positioning the second continuous laminate layer of the third frame material underneath the first continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material and the second continuous laminate layer of the third frame material to form the third continuous sheet of frame material.

[0347] EXAMPLE EX 13. A method according to any one of examples EX 5 to EX 7, wherein providing a third continuous sheet of frame material comprises: providing a first continuous laminate layer of a third frame material, a second continuous laminate layer of the third frame material, and a third continuous laminate layer of the third frame material; positioning the first continuous laminate layer of the third frame material between the second continuous laminate layer of the third frame material and the third continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material, the second continuous laminate layer of the third frame material and the third continuous laminate layer of the third frame material to form the third continuous sheet of frame material.

[0348] EXAMPLE EX 14. A method according to any one of the preceding examples further comprising forming an air inlet and an air outlet of the aerosol-generating article.

[0349] EXAMPLE EX 15. A method according to example EX 14, wherein forming an air inlet and an air outlet of the aerosol-generating article comprises establishing a fluid communication between the air inlet and the air outlet via an internal cavity of the aerosol-generating article, the internal cavity being at least partially defined by the frame aperture.

[0350] EXAMPLE EX 16. A method according to any one of examples EX 1 to EX 13 further comprising forming an air inlet aperture or an air outlet aperture or both through the first continuous sheet of frame material.

[0351] EXAMPLE EX 17. A method according to any one of examples EX 2 to EX 7 and EX 11 to EX 13 further comprising forming an air inlet aperture or an air outlet aperture or both through the second continuous sheet of frame material.

[0352] EXAMPLE EX 18. A method according to any one of examples EX 5 to EX 7, EX 12 and EX 13 further comprising forming an air inlet aperture or an air outlet aperture or both through the third continuous sheet of frame material.

[0353] EXAMPLE EX 19. A method according to any one of examples EX 16 to EX 18, wherein forming an air inlet aperture or an air outlet aperture or both through the first continuous sheet of frame material is carried out prior to bonding the second continuous sheet of frame material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article comprising the frame core layer. EXAMPLE EX 20. A method according to example EX 17 or EX 18, wherein forming an air inlet aperture or an air outlet aperture or both through the second continuous sheet of frame material is carried out prior to bonding the second continuous sheet of frame material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article comprising the frame core layer.

[0354] EXAMPLE EX 21. A method according to example EX 18, wherein forming an air inlet aperture or an air outlet aperture or both through the third continuous sheet of frame material is carried out prior to bonding the first continuous sheet of frame material and the third continuous sheet of frame material to form a laminated structure of the aerosol-generating article comprising the frame core layer.

[0355] EXAMPLE EX 22. A method according to any one of the preceding examples further comprising: providing a first continuous sheet of external layer material and a second continuous sheet of external layer material; positioning the first continuous sheet of frame material and the further continuous sheet of material between the first continuous sheet of external layer material and the second continuous sheet of external layer material; and bonding the first continuous sheet of external layer material, the second continuous sheet of external layer material, the first continuous sheet of frame material, and the further continuous sheet of material to form the laminated structure of the aerosol-generating article.

[0356] EXAMPLE EX 23. A method according to example EX1 , wherein the further continuous sheet of material is a first continuous sheet of internal layer material.

[0357] EXAMPLE EX 24. A method according to example EX 23 further comprising: providing a second continuous sheet of internal layer material; positioning the second continuous sheet of internal layer material above the first continuous sheet of frame material; and bonding the second continuous sheet of internal layer material and the frame to form the laminated structure of the aerosol-generating article.

[0358] EXAMPLE EX 25. A method according to example EX 23 or EX 24, wherein the first continuous sheet of internal layer material is a sheet of aerosol-generating material.

[0359] EXAMPLE EX 26. A method according to example EX 23 or EX 24, wherein the first continuous sheet of internal layer material is a sheet comprising a cellulosic material, preferably paper or cardboard.

[0360] EXAMPLE EX 27. A method according to example EX 24, wherein at least one of the first continuous sheet of internal layer material and the second continuous sheet of internal layer material is a sheet of aerosol-generating material.

[0361] EXAMPLE EX 28. A method according to example EX 24, wherein at least one of the first continuous sheet of internal layer material and the second continuous sheet of internal layer material is a sheet comprising a cellulosic material, preferably paper or cardboard.

[0362] EXAMPLE EX 29. A method according to any one of examples EX 1 to EX 28 further comprising: providing a first continuous sheet of protective layer material; positioning the first continuous sheet of protective layer material above the first continuous sheet of frame material and the further continuous sheet of material; and optionally bonding the first continuous sheet of protective layer material and the first continuous sheet of frame material.

[0363] EXAMPLE EX 30. A method according to any one of examples EX 1 to EX 29 further comprising: providing a first continuous sheet of protective layer material and a second continuous sheet of protective layer material; positioning the first continuous sheet of frame material and the further continuous sheet of material between the first continuous sheet of protective layer material and the second continuous sheet of protective layer material; and optionally bonding the first continuous sheet of protective layer material and the second continuous sheet of protective layer material and the first continuous sheet of frame material.

[0364] EXAMPLE EX 31. A method of manufacturing an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the method comprising: providing a first continuous sheet of frame material and a second continuous sheet of frame material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer, positioning the second continuous sheet of frame material underneath the first continuous sheet of frame material; and bonding the second continuous sheet of frame material and the frame core layer to form a laminated frame structure of the aerosol-generating article.

[0365] EXAMPLE EX 32. A method according to example EX 31 further comprising: providing a third continuous sheet of frame material; positioning the third continuous sheet of frame material above the first continuous sheet of frame material; and bonding the third continuous sheet of frame material and the first sheet of frame material to form the laminated frame structure of the aerosol-generating article.

[0366] EXAMPLE EX 33. A method according to example EX 31 or EX 32, wherein providing a first continuous sheet of frame material comprises: providing a first continuous laminate layer of a first frame material and a second continuous laminate layer of the first frame material; positioning the second continuous laminate layer of the first frame material underneath the first continuous laminate layer of the first frame material; and bonding the first continuous laminate layer of the frame material and the second continuous laminate layer of the first frame material to form the first continuous sheet of frame material.

[0367] EXAMPLE EX 34. A method according to example EX 31 or EX 32, wherein providing a first continuous sheet of frame material comprises: providing a first continuous laminate layer of a first frame material, a second continuous laminate layer of the first frame material, and a third continuous laminate layer of the first frame material; positioning the first continuous laminate layer of the first frame material between the second continuous laminate layer of the first frame material and the third continuous laminate layer of the first frame material; and bonding the first continuous laminate layer of the first frame material, the second continuous laminate layer of the first frame material and the third continuous laminate layer of the first frame material to form the first continuous sheet of frame material. EXAMPLE EX 35. A method according to example EX 31 or EX 32, wherein providing a second continuous sheet of frame material comprises: providing a first continuous laminate layer of a second frame material and a second continuous laminate layer of the second frame material; positioning the second continuous laminate layer of the second frame material underneath the first continuous laminate layer of the second frame material; and bonding the first continuous laminate layer of the second frame material and the second continuous laminate layer of the second frame material to form the second continuous sheet of frame material.

[0368] EXAMPLE EX 36. A method according to example EX 31 or EX 32, wherein providing a second continuous sheet of frame material comprises: providing a first continuous laminate layer of a second frame material, a second continuous laminate layer of the second frame material, and a third continuous laminate layer of the second frame material; positioning the first continuous laminate layer of the second frame material between the second continuous laminate layer of the second frame material and the third continuous laminate layer of the second frame material; and bonding the first continuous laminate layer of the second frame material, the second continuous laminate layer of the second frame material and the third continuous laminate layer of the second frame material to form the second continuous sheet of frame material.

[0369] EXAMPLE EX 37. A method according to example EX 32, wherein providing a third continuous sheet of frame material comprises: providing a first continuous laminate layer of a third frame material and a second continuous laminate layer of the third frame material; positioning the second continuous laminate layer of the third frame material underneath the first continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material and the second continuous laminate layer of the third frame material to form the third continuous sheet of frame material.

[0370] EXAMPLE EX 38. A method according to example EX 32, wherein providing a third continuous sheet of frame material comprises: providing a first continuous laminate layer of a third frame material, a second continuous laminate layer of the third frame material, and a third continuous laminate layer of the third frame material; positioning the first continuous laminate layer of the third frame material between the second continuous laminate layer of the third frame material and the third continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material, the second continuous laminate layer of the third frame material and the third continuous laminate layer of the third frame material to form the third continuous sheet of frame material.

[0371] EXAMPLE EX 39. A method according to any one of examples EX 31 to EX 38 further comprising forming an air inlet and an air outlet of the aerosol-generating article.

[0372] EXAMPLE EX 40. A method according to example EX 39, wherein forming an air inlet and an air outlet of the aerosol-generating article comprises establishing a fluid communication between the air inlet and the air outlet via an internal cavity of the aerosol-generating article, the internal cavity being at least partially defined by the frame aperture. EXAMPLE EX 41. A method according to any one of examples EX 31 to EX 40 further comprising: providing a first continuous sheet of internal layer material; positioning the first continuous sheet of internal layer material underneath the laminated frame structure; and bonding the first continuous sheet of internal layer material and the laminated frame structure to form the laminated structure of the aerosol-generating article.

[0373] EXAMPLE EX 42. A method according to any one of examples EX 31 to EX 40 further comprising: providing a first continuous sheet of internal layer material; positioning the first continuous sheet of internal layer material above the laminated frame structure; and bonding the first continuous sheet of internal layer material and the laminated frame structure to form the laminated structure of the aerosol-generating article.

[0374] EXAMPLE EX 43. A method according to any one of examples EX 31 to EX 40 further comprising: providing a first continuous sheet of internal layer material; positioning the first continuous sheet of internal layer material above the laminated frame structure; providing a second continuous sheet of internal layer material; positioning the second continuous sheet of internal layer material underneath the laminated frame structure; and bonding the first continuous sheet of internal layer material, the second continuous sheet of internal layer material and the laminated frame structure to form the laminated structure of the aerosol-generating article.

[0375] EXAMPLE EX 44. A method according to any one of examples EX 31 to EX 40 further comprising providing a first continuous sheet of external layer material and a second continuous sheet of external layer material; positioning the laminated frame structure between the first continuous sheet of external layer material and the second continuous sheet of external layer material; and bonding the laminated frame structure, the first continuous sheet of external layer material and the second continuous sheet of external layer material to form the laminated structure of the aerosol-generating article.

[0376] EXAMPLE EX 45. A method according to example EX 41 or EX 42 further comprising providing a first continuous sheet of external layer material and a second continuous sheet of external layer material; positioning the laminated frame structure and the first continuous sheet of internal layer material between the first continuous sheet of external layer material and the second continuous sheet of external layer material; and bonding the laminated frame structure, the first continuous sheet of internal layer material, the first continuous sheet of external layer material and the second continuous sheet of external layer material to form the laminated structure of the aerosol-generating article.

[0377] EXAMPLE EX 46. A method according to example EX 43 further comprising providing a first continuous sheet of external layer material and a second continuous sheet of external layer material; positioning the laminated frame structure, the first continuous sheet of internal layer material and the second continuous sheet of internal layer material between the first continuous sheet of external layer material and the second continuous sheet of external layer material; and bonding the laminated frame structure, the first continuous sheet of internal layer material, the second continuous sheet of internal layer material the first continuous sheet of external layer material and the second continuous sheet of external layer material to form the laminated structure of the aerosol-generating article.

[0378] EXAMPLE EX 47. A method according to any one of the preceding examples wherein forming a frame aperture through the first continuous sheet of frame material to form a frame core layer comprises forming an array of frame apertures through the first continuous sheet of frame material to provide a continuous blank for forming a plurality of frames of corresponding aerosolgenerating articles.

[0379] EXAMPLE EX48. A method according to any one of the preceding examples, wherein a thickness of the aerosol-generating article is less than 50 percent of both a length and a width of the aerosol-generating article.

[0380] EXAMPLE EX 49. A method according to any one of the preceding examples, wherein a thickness of the frame core layer accounts for greater than or equal to 80 percent of a thickness of the aerosol-generating article.

[0381] EXAMPLE EX 50. A method according to any one of examples EX 2 to EX 5, wherein a thickness of the laminated frame structure accounts for greater than or equal to 80 percent of a thickness of the aerosol-generating article.

[0382] EXAMPLE EX 51 . A method according to any one of the preceding examples, wherein the frame core layer has a thickness between 80 percent and 95 percent of a thickness of the aerosol-generating article.

[0383] EXAMPLE EX 52. A method according to any one of examples EX 2 to EX 5, wherein a thickness of the laminated frame structure accounts for between 80 percent and 95 percent of a thickness of the aerosol-generating article.

[0384] EXAMPLE EX 53. A method according to any one of the preceding examples, wherein the first continuous sheet of frame material comprises paper, paperboard, or cardboard.

[0385] EXAMPLE EX 54. A method according to any one of the preceding examples, wherein a thickness of the first continuous sheet of frame material is less than or equal to 0.6 millimetres.

[0386] EXAMPLE EX 55. A method according to any one of the preceding examples, wherein a basis weight of the first continuous sheet of frame material is less than or equal to 380 gsm.

[0387] EXAMPLE EX 56. A method according to any one of the preceding examples, wherein a basis weight of the first continuous sheet of frame material is at least 100 gsm.

[0388] EXAMPLE EX 57. A method according to any one of the preceding examples, wherein a width of the first continuous sheet of frame material is at least 25 millimetres.

[0389] EXAMPLE EX 58. A method according to any one of the preceding examples, wherein a width of the first continuous sheet of frame material is at least 200 millimetres.

[0390] EXAMPLE EX 59. A method according to any one of the preceding examples further comprising dispensing an aerosol-generating substrate into the frame aperture. EXAMPLE EX 60. A method according to example EX 58 comprising compressing the aerosol-generating substrate within a cavity of the aerosol-generating article, the cavity being at least partially delimited by a peripheral surface of the frame aperture.

[0391] EXAMPLE EX 61. A method according to example EX 58 or EX 59, wherein the aerosol-generating substrate is in the form of shredded aerosol-generating material.

[0392] EXAMPLE EX 62. A method according to example EX 60, wherein the shredded aerosol-generating material comprises one or more of: strips and strands of aerosol-generating material, such as strips and strands of tobacco or homogenised tobacco material.

[0393] EXAMPLE EX 63. A method according to example EX 59 or EX 60, wherein the aerosol-generating substrate is in the form of a corrugated sheet of aerosol-generating material.

[0394] EXAMPLE EX 64 A method according to example EX 59 or EX 60, wherein the aerosol-generating substrate is in the form of plurality of granules, beads, pellets or flakes of aerosol-generating material.

[0395] EXAMPLE EX 65. A method according to any one of examples EX 59 to EX 64, wherein the aerosol-generating substrate comprises one or more aerosol-formers, such as one or both of glycerine and propylene glycol.

[0396] EXAMPLE EX 66. A method according to any one of examples EX 59 to EX 64, wherein the aerosol-generating substrate has a bulk density of less than or equal to 0.5 milligrams per cubic millimetre.

[0397] EXAMPLE EX 67. A method according to any one of examples EX 59 to EX 64, wherein the aerosol-generating substrate positioned within the cavity has a packing density of less than or equal to 0.9.

[0398] Examples will now be further described with reference to the figures in which:

[0399] Figure 1A shows a perspective view of an aerosol-generating article according to the present disclosure;

[0400] Figure 1 B shows an exploded perspective view of the aerosol-generating article of Figure 1A;

[0401] Figure 1 C shows a perspective view of an aerosol-generating article according to the present disclosure;

[0402] Figure 2 shows an exploded perspective view of the aerosol-generating article of Figure 1C;

[0403] Figure 3 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0404] Figure 4 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0405] Figure 5 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0406] Figure 6 shows an exploded perspective view of an aerosol-generating article according to the present disclosure; Figure 7 shows a perspective view of an aerosol-generating article according to the present disclosure; Figure 8 shows a schematic cross-sectional view of an aerosol-generating device according to the present disclosure;

[0407] Figure 9 shows a schematic cross-sectional view of the aerosol-generating device of Figure 8 in engagement with an aerosol-generating article of the present disclosure;

[0408] Figure 10 shows a method of manufacturing an aerosol-generating article according to the present disclosure;

[0409] Figure 11 shows a plan view of the method of manufacturing of Figure 10;

[0410] Figure 12 shows a method of manufacturing an aerosol-generating article according to the present disclosure;

[0411] Figure 13 shows a plan view of the method of manufacturing of Figure 12;

[0412] Figure 14 shows a method of manufacturing an aerosol-generating article according to the present disclosure;

[0413] Figure 15 shows a plan view of the method of manufacturing of Figure 14;

[0414] Figure 16 shows a method of manufacturing an aerosol-generating article according to the present disclosure; and

[0415] Figure 17 shows a plan view of the method of manufacturing of Figure 16.

[0416] Figure 1 A shows an aerosol-generating article 10 obtainable from a method in accordance with the present disclosure. The aerosol-generating article comprises a first planar external layer 22 forming a first planar external surface 25 and a frame 50 positioned above the first planar external layer 22.

[0417] 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 2.9 millimetres.

[0418] The aerosol-generating article 10 is a substantially flat aerosol-generating article or substantially planar aerosol-generating article. In particular, the thickness of the aerosol-generating article 10 is less than 50 percent of both the length and the width of the aerosol-generating article. The aerosol-generating article 10 has a generally rectangular cuboid shape and a laminated structure formed by the first planar external layer 22 and the frame 50. The first planar external layer 22 and the frame 50 are bonded together with an adhesive, in particular guar gum, as discussed in more detail below in relation to Figure 1 B.

[0419] Figure 1 B shows an exploded view of the aerosol-generating article 10 of Figure 1C.

[0420] The frame 50 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 2.7 millimetres. The frame 50 is made from cardboard and defines a frame aperture extending through the thickness of the frame 50. The frame aperture at least partially forms a cavity 30. The cavity 30 has length of 26 millimetres, a width of 6 millimetres, and a thickness of 2.7 millimetres. Therefore, the cavity 30 has a volume of about 421.2 cubic millimetres. In this embodiment, the cavity 30 is substantially empty. The first planar external layer 22 defines a cavity end surface 32 that closes the cavity 30 at one end.

[0421] The frame 50 has a frame inner surface 52 extending in the z-direction or the transverse direction between the first planar external surface 21 and the second planar external surface 22. The frame inner surface 52 defines a cavity outer wall. The frame 50 has a frame outer surface 53 extending in the z-direction or the transverse direction between the first planar external surface 21 and the second planar external surface 22. The frame outer surface 53 at least partially defines one or more external surfaces of the aerosol-generating article, such as the front wall 13 and the back wall 14.

[0422] The frame 50 comprises a peripheral wall 51 that circumscribes the cavity 30. In more detail, the peripheral wall 51 is defined by the frame inner surface 52 and the frame outer surface 52. The peripheral wall 51 has a radial thickness, as measured between the frame inner surface 52 and the frame outer surface 53 in the x / y plane, of about 2 millimetres.

[0423] The first planar external layer 22 has a thickness of 200 micrometres and is in physical contact with the frame 50. The first planar external layer 22 is bonded to the frame 50 with an adhesive 15. The first planar external layer 22 overlies an end of the cavity 30 and forms a first cavity end wall 32. That is, the frame 50 and the first planar external layer 22 collectively delimit the cavity 30.

[0424] An air inlet 11 and an air outlet 12 are defined by, and extend through, the peripheral wall 51 of the frame 50. The air inlet 11 and the air outlet 12 each have a rectangular cross -section, a width of 2 millimetres, and a thickness of 0.9 millimetres. An airflow passage extends between the air inlet 11 and the air outlet 12 through the cavity 30.

[0425] In an example, the first planar external layer 22 comprises a cellulosic material, such as for example cardboard or paper.

[0426] In another example, the first planar external layer 22 comprises an aerosol-generating substrate comprising an aerosol-generating material, namely tobacco.

[0427] In alternative, or in addition to the first planar external later 22 comprising an aerosolgenerating substrate, aerosol-generating material may be positioned elsewhere within the aerosolgenerating article 10. For example, aerosol-generating material may be positioned within the cavity 30. The arrangement of an aerosol-generating material within the cavity of an aerosolgenerating article obtainable from methods in accordance with the present disclosure is described in more detailed below with reference to the examples of Figures 3 to 6.

[0428] The aerosol-generating article 10 of Figure 1C is intended for use with an aerosolgenerating device comprising a device cavity into which the aerosol-generating 10 can be inserted. The device cavity is shaped and sized so as to receive the aerosol-generating 10. An inner wall of the device cavity is configured to overlie the cavity 30 so as to substantially close the cavity 30.

[0429] In other words, when the aerosol-generating article 10 is received within the device cavity, an inner wall of the device cavity defines a second cavity end wall opposite the cavity end wall 32. As a result, during use, the cavity 30 is delimited by the cavity end wall 32, the frame 50 and the inner wall of the device cavity.

[0430] Thus, during use, when a user draws on the air outlet 12, airflow is drawn in through the air inlet 11 , across the cavity 30 and over heated aerosol-generating substrate or material contained in or exposed to the cavity 30, and passes to the air outlet 12 as an airflow containing aerosol.

[0431] Figure 1C shows an aerosol-generating article 10 comprising a first planar external layer 24 forming a first planar external surface 21 , a second planar external layer 25 forming a second planar external surface 22, and a frame 50 positioned between the first planar external layer 24 and the second planar external layer 25. The first planar external layer 24 and the second planar external layer 25 both comprise an aerosol-generating substrate comprising an aerosol-generating material, namely tobacco. However, it will be understood that in some embodiments only one of the first planar external layer 24 and the second planar external layer 25 may comprise an aerosolgenerating substrate. Alternatively, or additionally, the aerosol-generating substrate may be positioned elsewhere within the aerosol-generating article 10.

[0432] 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.

[0433] The aerosol-generating article 10 is substantially flat aerosol-generating article or substantially planar aerosol-generating article. In particular, the thickness of the aerosol-generating article 10 is less than 50 percent of both the length and the width of the aerosol-generating article. The aerosol-generating article 10 has a generally rectangular cuboid shape and a laminated structure formed by the first planar external layer 24, the frame 50 and the second planar external layer 25. The first planar external layer 24, the frame 50 and the second planar external layer 25 are bonded together with an adhesive, in particular guar gum, as discussed in more detail below in relation to Figure 2.

[0434] Figure 2 shows an exploded view of the aerosol-generating article 10 of Figure 1C.

[0435] The frame 50 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 2.7 millimetres. The frame 50 is made from cardboard and defines a frame aperture extending through the thickness of the frame 50. The frame aperture at least partially forms a cavity 30. The cavity 30 has length of 26 millimetres, a width of 6 millimetres, and a thickness of 2.7 millimetres. Therefore, the cavity 30 has a volume of about 421.2 cubic millimetres. In this embodiment, the cavity 30 is substantially empty.

[0436] The frame 50 has a frame inner surface 52 extending in the z-direction or the transverse direction between the first planar external surface 21 and the second planar external surface 22. The frame inner surface 52 defines a cavity outer wall. The frame 50 has a frame outer surface 53 extending in the z-direction or the transverse direction between the first planar external surface 21 and the second planar external surface 22. The frame outer surface 53 at least partially defines one or more external surfaces of the aerosol-generating article, such as the front wall 13 and the back wall 14.

[0437] The frame 50 comprises a peripheral wall 51 that circumscribes the cavity 30. In more detail, the peripheral wall 51 is defined by the frame inner surface 52 and the frame outer surface 52. The peripheral wall 51 has a radial thickness, as measured between the frame inner surface 52 and the frame outer surface 53 in the x / y plane, of about 2 millimetres.

[0438] The first planar external layer 24 and the second planar external layer 25 have a thickness of 200 micrometres and are in physical contact with the frame 50. The first planar external layer 24 and the second planar external layer 25 are bonded to the frame with an adhesive 15. The first planar external layer 24 overlies an end of the cavity 30 and forms a first cavity end wall 31 . The second planar external layer 25 overlies an opposite end of the cavity 30 and forms a second cavity end wall 32. That is, the frame 50, the first planar external layer 24 and the second planar external layer 25 collectively define the cavity 30.

[0439] The air inlet 11 and the air outlet 12 are defined by, and extend through, the peripheral wall 51 of the frame 50. The air inlet 11 and the air outlet 12 each have a rectangular cross-section, a width of 2 millimetres, and a thickness of 0.9 millimetres. An airflow passage extends between the air inlet 11 and the air outlet 12 through the cavity 30.

[0440] Figure 3 shows an exploded view of an aerosol-generating article that is similar to the aerosol-generating article 10 of Figure 1C except that the first planar external layer 24 and the second planar external layer 25 do not comprise an aerosol-generating substrate. Instead, an aerosol-generating substrate 40 is positioned within the cavity 30. The aerosol-generating substrate 40 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. As shown, the aerosolgenerating substrate 40 fills the entire volume of the cavity 30. In the example of Figure 3, the aerosol-generating substrate 40 has a packing density of about 0.87, a density of about 0.3 grams per cubic centimetre, and a mass of about 110 milligrams. In another example, the aerosolgenerating substrate 40 may have a different packing density, a different density and a different mass. For example, aerosol-generating substrate may have a packing density of 0.64, a density of 0.35 grams per cubic centimetre, and a mass of about 95 milligrams.

[0441] Figure 4 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figures 1 and 3 except that the aerosol-generating article 10 of Figure 4 comprises an outer wrapper 23 defining the first planar external surface 21 and the second planar external surface 22 instead of the first planar external layer 24 and the second planar external layer 25.

[0442] Figure 5 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1C except that the aerosol-generating article 10 of Figure 5 further comprises a first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are formed from a sheet of aerosol-generating material. In particular, a sheet of homogenised tobacco material having an aerosol-former content of 5 percent by weight on a dry weight basis. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 each have a length equal to the length of the aerosol-generating article 10, a width equal to the width of the aerosol-generating article 10 and a thickness of 200 micrometres. That is, the aerosolgenerating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.5 millimetres.

[0443] The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are in physical contact with the frame 50 and are bonded to the frame with an adhesive 15. The first aerosol-generating substrate layer 41 overlies an end of the cavity 30 and forms a first cavity end wall 31 . The second aerosol-generating layer 42 overlies an opposite end of the cavity 30 and forms a second cavity end wall 32. That is, the frame 50, the first aerosolgenerating substrate layer 41 and the second aerosol-generating substrate layer 42 collectively define the cavity 30.

[0444] The first planar external layer 24 is in physical contact with the first aerosol-generating substrate Iayer 41 and are bonded togetherwith an adhesive 15. The second planar external layer 25 is in physical contact with the second aerosol-generating substrate layer 42 and are bonded together with an adhesive 15.

[0445] Figure 6 shows an exploded view of an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 5 except that an aerosol-generating substrate 40 is positioned within the cavity 30 as described in relation to Figure 3. The aerosol-generating substrate 40 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. As shown, the aerosolgenerating substrate 40 fills the entire volume of the cavity 30. Figure 7 shows an aerosolgenerating article 10 similar to the aerosol-generating article 10 of Figure 5 except that the aerosolgenerating article 10 of Figure 7 comprises an outer wrapper 23 defining the first planar external surface 21 and the second planar external surface 22 instead of the first planar external layer 24 and the second planar external layer 25.

[0446] Figure 8 shows a schematic cross-sectional view of an aerosol-generating device 90 configured for use with an aerosol-generating article 10 described herein. The aerosol-generating device 90 is an elongate aerosol-generating device extending between a proximal end 91 and a distal end 92. The aerosol-generating device 90 comprises a battery 93, a controller 94, a first heater 95 and a second heater 96 located within a housing 97. The controller 94 controls supply of power from the battery 93 to the first heater 95 and the second heater 96. A cavity 1000 is defined in the device 90, the cavity 1000 having an opening 1010 defined in the proximal end 91 of the device 90. The opening 1010 is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosol-generating article 10. The cavity 1000 comprises an upper planar surface 1020 and a lower planar surface 1030. The first heater 95 is located in the upper planar surface 1020 to heat the first planar external surface 21 of an aerosol-generating article 10 inserted into the cavity 1000, and the second heater 96 is located in the lower planar surface 1030 to heat the second planar external surface 22 of an aerosol-generating article 10 inserted into the cavity 1000. The device 90 comprises an air inlet 98 defining an air-flow path configured to allow air to flow into the cavity 1000 from outside the device.

[0447] Figure 9 shows a schematic cross-sectional view of the aerosol-generating device 90 of Figure 8 in engagement with the aerosol-generating article 10 of Figure 1C. There is little tolerance between the first planar external surface 21 and the second planar external surface 22 of the aerosol-generating article 10 and the internal surfaces 1020, 1030 of the cavity 1000. Thus, there is a snug fit between the aerosol-generating article 10 and the aerosol-generating device 90. When a consumer has inserted the aerosol-generating article 10 into the cavity 1000, the device can be operated. The first heater 95 heats the first planar external surface 21 of the aerosol-generating article 10 and the second heater 96 heats the second planar external surface 22 of the aerosolgenerating article, and as a result the aerosol-generating substrate is heated. Volatile components of the aerosol-generating substrate are evaporated and condense in the cavity 30 of the aerosolgenerating article 10 to form an aerosol. The consumer inhales the aerosol by drawing on the end of the aerosol-generating article 10 comprising the air outlet 12. Once the aerosol-generating substrate has been depleted of volatile components, the aerosol-generating article 10 is removed from the cavity 1000 and disposed of.

[0448] Figure 10 depicts a schematic illustration of a method of manufacturing 1100 an aerosolgenerating article 10 as described herein and, in particular, a method of manufacturing the aerosolgenerating article 10 of Figure 3. The method comprises punching and bonding a first sheet of frame material 1201 , a first sheet of external layer material 1301 and a second sheet of external layer material 1302. Figure 11 depicts a schematic plan view of the method of Figure 10 but for illustration purposes the manufacturing equipment is not depicted. The dotted line 1101 in Figure 11 is for illustration purposes and represents the eventual cross-sectional perimeter of the aerosolgenerating article 10.

[0449] The first sheet of frame material 1201 is fed from a bobbin 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An aperture punching device 1105 punches a frame aperture 1400 through the first sheet of frame material 1201. The frame aperture 1400 will at least partially form the cavity 30 of the aerosol-generating article 10. An adhesive applying device 1106 applies an adhesive to a lower surface of the first sheet of frame material 1201. The first sheet of external layer material 1301 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive applied to the lower surface of the first sheet of frame material 1201. An aerosol-generating substrate dispensing device 1108 dispenses an aerosolgenerating substrate 40 into the frame aperture 1400. An adhesive applying device 1109 applies an adhesive 1110 to an upper surface of the first sheet of frame material 1201. The second sheet of external layer material 1302 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive 1110 applied to the upper surface of the first sheet of frame material 1201. An aperture punching device 1111 punches an aperture 1410 through the first sheet of frame material 1201 , the first sheet of external layer material 1301 and the second sheet of external layer material 1302 so as to eject an aerosol-generating article 10. The air inlet and air outlet may be formed before or after the aerosol-generating article 10 has been ejected.

[0450] In some embodiments, one or more of the first sheet of frame material 1201 , the first sheet of external layer material 1301 and the second sheet of external layer material 1302 comprises an aerosol-generating substrate. Thus, the step of dispensing an aerosol-generating substrate 40 into the frame aperture 1400 may be skipped.

[0451] Figure 12 depicts a schematic illustration of a method of manufacturing 1100 an aerosolgenerating article as described herein and, in particular, a method of manufacturing the aerosolgenerating article that comprises a first internal layer comprising an aerosol-generating substrate and a second internal layer comprising aerosol-generating substrate. The first internal layer and the second internal layer are in contact with a frame of the article and are bonded to the frame with an adhesive. The first internal layer overlies an end of the cavity and forms a first cavity end wall. The second internal layer overlies an opposite end of the cavity and forms a second cavity end wall. That is, the frame, the first internal layer and the second internal layer collectively define the cavity. The frame, the first internal layer and the second internal layer are in turn positioned between a first external layer and a second external layer.

[0452] The method comprises punching and bonding a first sheet of frame material 1201 , a first sheet of aerosol-generating material 1501 , a second sheet of aerosol-generating material 1502, a first sheet of external layer material 1301 and a second sheet of external layer material 1302. Figure 13 depicts a schematic plan view of the method of Figure 12 but for illustration purposes the manufacturing equipment is not depicted. The dotted line 1101 in Figure 13 is for illustration purposes and represents the eventual cross-sectional perimeter of the aerosol-generating article 10.

[0453] The first sheet of frame material 1201 fed from a bobbin 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An aperture punching device 1105 punches a frame aperture 1400 through the first sheet of frame material 1201. The frame aperture 1400 will at least partially form the cavity 30 of the aerosol-generating article 10.

[0454] An adhesive applying device 1106 applies an adhesive 1110 to a lower surface of the first sheet of frame material 1201 and to an upper surface of the first sheet of frame material 1201.

[0455] The first sheet of aerosol-generating material 1501 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive applied to the lower surface of the first sheet of frame material 1201. The second sheet of aerosol-generating material 1502 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive 1110 applied to the upper surface of the first sheet of frame material 1201. An adhesive applying device 1109 applies an adhesive 1110 to a lower surface of the first sheet of aerosol-generating material 1501 and to an upper surface of the second sheet of aerosolgenerating material 1502.

[0456] The first sheet of external layer material 1301 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of aerosol-generating material 1501 by the adhesive applied to the lower surface of the first sheet of aerosol-generating material 1501. The second sheet of external layer material 1302 is fed from a bobbin 1102 via a roller 1107 and is bonded to the second sheet of aerosol-generating material 1502 by the adhesive 1110 applied to the upper surface of the second sheet of aerosol-generating material 1502.

[0457] An aperture punching device 1111 punches an aperture 1410 through the first sheet of frame material 1201 , the first sheet of aerosol-generating material 1501 , the second sheet of aerosol-generating material 1502, the first sheet of external layer material 1301 and the second sheet of external layer material 1302 so as to eject the aerosol-generating article 10. The air inlet and air outlet may be formed before or after the aerosol-generating article 10 has been ejected.

[0458] Figure 14 depicts a schematic illustration of a method of manufacturing 1100 an aerosolgenerating article as described herein and, in particular, a method of manufacturing the aerosolgenerating article comprising an aerosol-generating substrate positioned within the cavity.

[0459] In more detail, the article obtained by the method of manufacturing 1100 of Figure 14 comprises a frame having a laminated frame structure. The laminated frame structure comprises a frame core layer and a second frame layer. Additionally, the aerosol-generating article comprises a first external layer and a second external layer, and the frame is comprised between the first external layer and the second external layer.

[0460] The method comprises punching and bonding a first sheet of frame material 1201 , a second sheet of frame material 1202, a first sheet of external layer material 1301 and a second sheet of external layer material 1302. Figure 15 depicts a schematic plan view of the method of Figure 14 but for illustration purposes the manufacturing equipment is not depicted. The dotted line 1101 in Figure 15 is for illustration purposes and represents the eventual cross-sectional perimeter of the aerosol-generating article 10.

[0461] The first sheet of frame material 1201 is fed from a bobbin 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An adhesive applying device 1106 applies an adhesive 1110 to an upper surface of the first sheet of frame material 1201 . The second sheet of frame material 1202 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive 1110 applied to the upper surface of the first sheet of frame material 1201.

[0462] An aperture punching device 1105 punches a frame aperture 1400 through the first sheet of frame material 1201 and the second sheet of frame material 1202. The frame aperture 1400 will at least partially form the cavity 30 of the aerosol-generating article 10. An adhesive applying device 1106 applies an adhesive to a lower surface of the first sheet of frame material 1201. The first sheet of external layer material 1301 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive applied to the lower surface of the first sheet of frame material 1201.

[0463] An aerosol-generating substrate dispensing device 1108 dispenses an aerosol-generating substrate 40 into the frame aperture 40. An adhesive applying device 1109 applies an adhesive 1110 to an upper surface of the second sheet of frame material 1202. The second sheet of external layer material 1302 is fed from a bobbin 1102 via a roller 1107 and is bonded to the second sheet of frame material 1202 by the adhesive 1110 applied to the upper surface of the second sheet of frame material 1202.

[0464] An aperture punching device 1111 punches an aperture 1410 through the first sheet of frame material 1201 , the second sheet of frame material 1202, the first sheet of external layer material 1301 and the second sheet of external layer material 1302 so as to eject an aerosolgenerating article 10. The air inlet and air outlet may be formed before or after the aerosolgenerating article 10 has been ejected.

[0465] In some embodiments, one or more of the first sheet of frame material 1201 , the second sheet of frame material 1202, the first sheet of external layer material 1301 and the second sheet of external layer material 1302 comprises an aerosol-generating substrate. Thus, the step of dispensing an aerosol-generating substrate 40 into the frame aperture 1400 may be skipped.

[0466] Figure 16 depicts a schematic illustration of a method of manufacturing 1100 an aerosolgenerating article as described herein and, in particular, a method of manufacturing an aerosolgenerating article comprising an aerosol-generating substrate positioned within the cavity.

[0467] In more detail, the article obtained by the method of manufacturing 1100 of Figure 16 comprises a frame having a laminated frame structure. The laminated frame structure comprises a frame core layer, a second frame layer and a third frame layer. The core frame layer is comprised between the second frame layer and the third frame layer. Additionally, the aerosol-generating article comprises a first external layer and a second external layer, and the frame is comprised between the first external layer and the second external layer.

[0468] The method comprises punching and bonding a first sheet of frame material 1201 , a second sheet of frame material 1202, a third sheet of frame material 1203, a first sheet of external layer material 1301 and a second sheet of external layer material 1302. Figure 17 depicts a schematic plan view of the method of Figure 16 but for illustration purposes the manufacturing equipment is not depicted. The dotted line 1101 in Figure 17 is for illustration purposes and represents the eventual cross-sectional perimeter of the aerosol-generating article 10.

[0469] The first sheet of frame material 1201 is fed from a bobbin 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An aperture punching device 1112 punches an air inlet aperture 1610 and an air outlet aperture 1620 through the first sheet of frame material 1201. An adhesive applying device 1106 applies an adhesive 1110 to a lower surface of the first sheet of frame material 1201 and to an upper surface of the first sheet of frame material 1201.

[0470] The second sheet of frame material 1202 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive applied to the lower surface of the first sheet of frame material 1201. The third sheet of frame material 1203 is fed from a bobbin 1102 via a roller 1102 and is bonded to the first sheet of frame material 1201 by the adhesive 1110 applied to the upper surface of the first sheet of frame material 1201.

[0471] An aperture punching device 1105 punches a frame aperture 1400 through the first sheet of frame material 1201 , the second sheet of frame material 1202 and the third sheet of frame material 1203. The frame aperture will at least partially form the cavity 30 of the aerosol-generating article 10.

[0472] An adhesive applying device 1106 applies an adhesive to a lower surface of the second sheet of frame material 1202. The first sheet of external layer material 1301 is fed from a bobbin 1102 via a roller 1107 and is bonded to the second sheet of frame material 1202 by the adhesive applied to the lower surface of the second sheet of frame material 1202.

[0473] An aerosol-generating substrate dispensing device 1108 dispenses an aerosol-generating substrate 40 into the frame aperture 1400. An adhesive applying device 1109 applies an adhesive 1110 to an upper surface of the third sheet of frame material 1203. The second sheet of external layer material 1302 is fed from a bobbin 1102 via a roller 1107 and is bonded to the third sheet of frame material 1203 by the adhesive 1110 applied to the upper surface of the third sheet of frame material 1203.

[0474] An aperture punching machine 1111 punches an aperture 1410 through the first sheet of frame material 1201 , the second sheet of frame material 1202, the third sheet of frame material 1203, the first sheet of external layer material 1301 and the second sheet of external layer material 1302 so as to eject the aerosol-generating article 10.

[0475] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 10% of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

CLAIMS1 . A method of manufacturing an aerosol-generating article for use with an aerosolgenerating device to generate an aerosol, the method comprising: providing a first continuous sheet of frame material and a further continuous sheet of material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the further continuous sheet of material underneath the first continuous sheet of frame material; and bonding the further continuous sheet of material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article comprising the frame core layer.

2. A method according to claim 1 , wherein the further continuous sheet of material is a second continuous sheet of frame material, the first continuous sheet of frame material and the second continuous sheet of frame material forming a laminated frame structure, and wherein the step of bonding the further continuous sheet of material and the first continuous sheet of frame material is carried out prior to forming a frame aperture through the first continuous sheet of frame material to form the frame core layer.

3. A method according to claim 2, wherein the frame aperture is formed such that it extends through both the first continuous sheet of frame material and the second continuous sheet of frame material.

4. A method according to claim 1 , wherein the further continuous sheet of material is a second continuous sheet of frame material, the first continuous sheet of frame material and the second continuous sheet of frame material forming a laminated frame structure, and wherein the step of bonding the further continuous sheet of material and the first continuous sheet of frame material is carried out subsequent to forming a frame aperture through the first continuous sheet of frame material to form the frame core layer.

5. A method according to any one of claims 2 to 4, the method further comprising: providing a third continuous sheet of frame material; and bonding the third continuous sheet of frame material and the first continuous sheet of frame material to form the laminated structure of the aerosol-generating article, wherein the first continuous sheet of frame material, the second continuous sheet of frame material and the third continuous sheet of frame material form the laminated frame structure.

6. A method according to any one of claims 1 to 5, wherein providing a first continuous sheet of frame material comprises: providing a first continuous laminate layer of a first frame material and a second continuous laminate layer of the first frame material; positioning the secondcontinuous laminate layer of the first frame material underneath the first continuous laminate layer of the first frame material; and bonding the first continuous laminate layer of the frame material and the second continuous laminate layer of the first frame material to form the first continuous sheet of frame material.

7. A method according to any one of claims 2 to 5, wherein providing a second continuous sheet of frame material comprises: providing a first continuous laminate layer of a second frame material and a second continuous laminate layer of the second frame material; positioning the second continuous laminate layer of the second frame material underneath the first continuous laminate layer of the second frame material; and bonding the first continuous laminate layer of the second frame material and the second continuous laminate layer of the second frame material to form the second continuous sheet of frame material.

8. A method according to claim 5, wherein providing a third continuous sheet of frame material comprises: providing a first continuous laminate layer of a third frame material and a second continuous laminate layer of the third frame material; positioning the second continuous laminate layer of the third frame material underneath the first continuous laminate layer of the third frame material; and bonding the first continuous laminate layer of the third frame material and the second continuous laminate layer of the third frame material to form the third continuous sheet of frame material.

9. A method according to any one of the preceding claims further comprising forming an air inlet aperture or an air outlet aperture or both through the first continuous sheet of frame material.

10. A method according to claim 9, wherein forming an air inlet aperture or an air outlet aperture or both through the first continuous sheet of frame material is carried out prior to bonding the second continuous sheet of material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article comprising the frame core layer.

11. A method according to any one of the preceding claims further comprising: providing a first continuous sheet of external layer material and a second continuous sheet of external layer material; positioning the first continuous sheet of frame material and the further continuous sheet of material between the first continuous sheet of external layer material and the second continuous sheet of external layer material; and bonding the first continuous sheet of external layer material, the second continuous sheet of external layer material, the first continuous sheet of frame material, and the further continuous sheet of material to form the laminated structure of the aerosol-generating article.

12. A method according to claim 1 , wherein the further continuous sheet of material is a first continuous sheet of internal layer material.

13. A method according to claim 13, wherein the first continuous sheet of internal layer material is a sheet of aerosol-generating material.

14. A method according to any one of the preceding claims further comprising dispensing an aerosol-generating substrate into the frame aperture.15 A method according to claim 14, wherein the aerosol-generating material is in the form of plurality of granules, beads, pellets or flakes of aerosol-generating material.

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