Method of manufacturing discrete batches of aerosol-generating articles

Abstract

There is provided a method of manufacturing an aerosol-generating article (3000) for use with an aerosol-generating device to generate an aerosol, the method comprising: providing a first length of frame sheet material (2100); providing a further length of sheet material (2116; 2124; 2128); forming a plurality of frame apertures (2120) through the first length of frame sheet material (2100) to form a frame core layer blank, such that the frame apertures (2120) are positioned in a predetermined array across the surface of the frame core layer blank; positioning the further length of sheet material (2116; 2124; 2128) underneath and in alignment with the first length of frame sheet material (2100); bonding the further length of sheet material (2116; 2124; 2128) and the first length of frame sheet material (2100) to form a laminated blank structure comprising the frame core layer blank for forming a plurality of aerosol-generating articles (3000).

Description

[0001] METHOD OF MANUFACTURING DISCRETE BATCHES OF AEROSOL-GENERATING ARTICLES

[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.

[0008] The method may comprise a first step of providing a first length of frame sheet material. The method may comprise a second step of providing a further length of sheet material.

[0009] The method may comprise a third step of forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank.

[0010] The method may comprise a fourth step of positioning the further length of sheet material underneath and in alignment with the first length of frame sheet material.

[0011] The method may comprise a fifth step of bonding the further length of sheet material and the first length of frame sheet material to form a laminated blank structure comprising the frame core layer blank for forming a plurality of aerosol-generating articles.

[0012] As will be discussed below, the method may comprise one or more additional steps involving the provision of one or more additional lengths of sheet material. The method may also comprise one or more additional steps of bonding the one or more additional lengths of sheet material, the first length of frame sheet material and the further length of sheet material to form the laminated blank structure.

[0013] 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 length of frame sheet material; providing a further length of sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the further length of sheet material underneath and in alignment with the first length of frame sheet material; bonding the further length of sheet material and the first length of frame sheet material to form a laminated blank structure comprising the frame core layer blank for forming a plurality of aerosol-generating articles.

[0014] Advantageously, methods in accordance with the present disclosure make it possible for aerosol-generating articles to be manufactured by layering discrete, finite lengths of sheet material through an automated process, thereby resulting in batches of aerosol-generating articles that are relatively easy and cheap to manufacture. Finite lengths of sheet material can be supplied, stacked 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.

[0015] In practice, by layering and bonding discrete, finite lengths of sheet material in accordance with the present invention, a laminated blank structure comprising a frame core layer blank is obtained, from which a plurality of aerosol-generating articles can be ejected and subsequently handled independently from one another.

[0016] As an alternative, portions of the laminated blank structure may be weakened, so that a plurality of aerosol-generating articles are independently detachable from the remainder of the laminated blank structure. This arrangement may advantageously provide for alternative ways of packaging the aerosol-generating articles, as a laminated blank structure comprising weakened portions may be packaged as such. At the point of use, a consumer may detach an aerosolgenerating article from the remainder of the laminated blank structure. Further, this arrangement may have the additional benefit that the remainder of the laminated blank structure may advantageously provide structural strength to the package whilst at the same time protecting the aerosol-generating articles.

[0017] Advantageously, a frame of each aerosol-generating article in the batch is formed from the frame core layer blank. In more detail, a frame core layer of a laminated structure of each aerosolgenerating article is formed from frame core layer blank. 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.

[0018] Advantageously, each frame aperture formed in the frame core layer blank may define at least part of an airflow passage through a corresponding aerosol-generating article. Additionally, each frame aperture formed in the frame core layer blank may at least partially define an internal cavity of a corresponding 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 the internal cavities of the aerosol-generating articles.

[0019] In certain preferred embodiments, which will be described in more detail below, the method may comprise providing one or more further finite lengths of frame sheet material to be combined with the first length of frame sheet material to form laminated frame structures of the aerosolgenerating articles. The one or more further lengths of frame sheet material may advantageously impart increased structural strength and stability to the aerosol-generating articles. Further, different frame sheet materials may be combined to impart desirable properties to the frame.

[0020] In preferred embodiments, which will be described in more detail below, the method comprises forming air inlets and air outlets of the aerosol-generating articles. Thus, a predetermined path may be defined for airflow through each of the aerosol-generating articles. A step of forming air inlets and air outlets of the aerosol-generating articles preferably comprises establishing fluid communication between the air inlet and the air outlet via an internal cavity of each one of the aerosol-generating articles. Thus, an aerosol-generating substrate positioned within the cavity of an aerosol-generating article may advantageously be exposed to airflow through the aerosol-generating article during use.

[0021] In certain embodiments, the method may comprise punching air inlet apertures or air outlet apertures or both in one or more of the first length of frame sheet material and any further length of frame sheet material. The air inlet apertures and air outlet apertures formed in one or more length of frame sheet material advantageously at least partially define air inlets and air outlets of the aerosol-generating articles. As will be discussed in more detail below, certain preferred embodiments of methods in accordance with the present invention advantageously allow providing air inlets or air outlets or both at precisely controlled locations within the aerosol-generating articles in ways that are relatively easy and cheap to control.

[0022] The further length of sheet material may advantageously provide each aerosol-generating article with a surface that is exposed to an airflow passage extending through a respective internal cavity of the aerosol-generating article. The further length of sheet material may advantageously provide a surface for supporting an aerosol-generating substrate disposed within respective internal cavities of the aerosol-generating articles. In certain embodiments, wherein the further length of sheet material comprises an aerosol-generating material, the further length of sheet material may advantageously provide in each aerosol-generating article a source of aerosol species that is exposed to an airflow passage extending through an internal cavity of the aerosolgenerating article.

[0023] 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.

[0024] Methods in accordance with the present disclosure can be implemented on existing apparatus configured for handling discrete portions of sheet materials, for supplying adhesive, for cutting through portions of sheet materials, and so forth, without requiring extensive modifications. As will be discussed in more detail below, preferred embodiments involve the use of registration marks provided on one or more of the portions of sheet material as they are layered and bonded to one another, which facilitates precise alignment between the portions of sheet material.

[0025] 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.

[0026] 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.

[0027] 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. 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.

[0028] As used herein, the term “transverse” refers to a direction extending between the first planar external surface and the second planar external surface.

[0029] 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.

[0030] 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.

[0031] 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.

[0032] 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.

[0033] 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.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] As used herein, the term “aerosol former content” may refer to aerosol former content in percent on a dry weight basis, unless otherwise specified.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] An aerosol-generating article obtained by a method in accordance with the present disclosure may comprise one or more aerosol-generating substrates.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] In more detail, the aerosol-generating article may comprise at least a frame core layer and a further layer.

[0047] 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.

[0048] 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.

[0049] 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. 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.

[0050] In an example, the aerosol-generating article may comprise a frame core layer and a first external layer.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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. 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.

[0057] 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.

[0058] 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.

[0059] In other words, the core frame layer itself may comprise more than one layer of frame material. In an example, the core frame layer itself may comprise two or three layers of frame material.

[0060] Similarly, the second frame layer itself may comprise more than one layer of frame material. In an example, the second frame layer may comprise two or three layers of frame material.

[0061] In similar fashion, the third frame layer itself may comprise more than one layer of frame material. In an example, the third frame layer may comprise two three layers of frame material.

[0062] In an 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.

[0063] 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. For example, six layers of frame material each having a thickness of 0.6 millimetres may be combined to form a laminated frame structure having an (overall) thickness of 3.6 millimetres.

[0064] 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.

[0065] 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.

[0066] 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.

[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] As used herein with reference to methods in accordance with the present disclosure, the expression “positioning a length of sheet material in alignment with one or more further lengths of sheet material” is used to denote a step wherein the first length of sheet material and the one or more further lengths of sheet material are placed in a stacked arrangement wherein they occupy predetermined positions relative to each other.

[0071] For example, the lengths of sheet material may be rectangular portions of sheet material all having the same length and width. When positioned in alignment with each other, said rectangular portions of sheet material form a stack having substantially the same length and width of the individual rectangular portions of sheet material and a combined height with is substantially equal to a sum of the heights of the rectangular portions of sheet material taken individually.

[0072] Positioning a given length of sheet material in alignment with or between one or more further lengths of sheet material may involve detecting one or more registration marks provided on the given length of sheet material or on any one of the one or more further lengths of sheet material with which or between which the given length of sheet material is to be aligned with. Positioning a given length of sheet material in alignment with or between one or more further lengths of sheet material may involve detecting one or more registration marks provided on both the given length of sheet material and on any one of the one or more further lengths of sheet material with which or between which the given length of sheet material is to be aligned with.

[0073] 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.

[0074] 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.

[0075] As described briefly above, a method of manufacturing an aerosol-generating article in accordance with the present disclosure comprises: providing a first length of frame sheet material; providing a further length of sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the further length of sheet material underneath and in alignment with the first length of frame sheet material; bonding the further length of sheet material and the first length of frame sheet material to form a laminated blank structure comprising the frame core layer blank for forming a plurality of aerosol-generating articles.

[0076] 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 length of sheet material with the first length of frame sheet material” is used to describe a step wherein a bond is formed - for example, by means of an adhesive - such that the first length of frame sheet material and the length of sheet material are laminated together.

[0077] In some examples, the expression “bonding a length of sheet material with the first length of frame sheet material” means that the length of sheet material is bonded directly to the first length of frame sheet material. That is, length of sheet material lies adjacent to the first length of frame sheet material and a bond is established directly between the length of sheet material and the first length of frame sheet material. For example, an adhesive may be provided between the length of sheet material and the first length of frame sheet material.

[0078] More generally, however, the expression “bonding a length of sheet material with the first length of frame sheet material” means that the length of sheet material is bonded directly or indirectly to the first length of frame sheet material. That is, the length of sheet material may not lie adjacent to the first length of frame sheet material, because - as will be described in more detail below with reference to certain examples - the laminated structure comprises one or more intermediate lengths of sheet material comprised between the length of sheet material and the first length of frame sheet material, wherein the one or more intermediate length of sheet material have previously been bonded with the first length of frame sheet material. Accordingly, the expression “bonding a length of sheet material with the first length of frame sheet material” may mean that a direct bond is established between the length of sheet material and the one or more intermediate lengths of sheet material. For example, an adhesive may be provided between the length of sheet material and the one or more intermediate lengths of sheet material. As a result, an indirect bond is established between the length of sheet material and the first length of frame sheet material.

[0079] In each aerosol-generating article obtained by the method, the frame core layer blank provides or forms part of a planar frame. Each frame aperture extending through the frame core layer blank may define or form part of an airflow passage of a respective aerosol-generating article. Each frame aperture extending through the frame core layer blank may define or form part of an internal cavity of a respective aerosol-generating article.

[0080] 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.

[0081] 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.

[0082] In certain examples described above, a first planar surface of the frame core layer blank 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.

[0083] 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.

[0084] 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 blank may define or at least partially form the first planar surface of the planar frame, whereas a planar surface of the second frame layer blank may define or at least partially form the second planar surface of the planar frame.

[0085] Similarly, in an aerosol-generating article wherein the laminated frame structure comprises the frame core layer blanks, a second frame layer and a third frame layer, and wherein the frame core layer blank 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.

[0086] In some embodiments of the method, the further length of sheet material is a second length of frame sheet material.

[0087] In other words, the method comprises: providing a first length of frame sheet material and a second length of frame sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the second length of frame sheet material underneath and in alignment with the first length of frame sheet material; bonding the second length of frame sheet material and the first length of frame sheet material to form a laminated blank structure comprising the frame core layer blank for forming a plurality of aerosol-generating articles.

[0088] By bonding the second length of frame sheet material and the first length of frame sheet material a laminated frame structure is formed. The laminated frame structure comprises the frame core layer blank and a second frame layer blank.

[0089] The first length of frame sheet material and the second length of frame sheet material may differ by at least one characteristic, such as for example a sheet thickness or a sheet composition. Accordingly, bonding the first length of frame sheet material and the second length of frame sheet material may advantageously provide a laminated frame structure that benefits from a combination of the differing characteristics.

[0090] In embodiments wherein the further length of sheet material is a second length of frame sheet material, the step of bonding the further continuous sheet of material and the first length of frame sheet material may be carried out prior to forming a plurality of frame apertures through the first length of frame sheet material to form the frame core layer blank. In other words, the step of forming the frame apertures through the first length of frame sheet material may be carried out after a laminated frame structure has been formed. Accordingly, the step of forming the frame apertures through the first length of frame sheet material may be carried out such that the frame apertures extend through both the first length of frame sheet material and the second length of frame sheet material.

[0091] Alternatively, in embodiments wherein the further length of sheet material is a second length of frame sheet material, the step of bonding the further length of sheet material and the first length of frame material may be carried out subsequent to forming a plurality of frame apertures through the first length of frame sheet material to form the frame core layer blank. Thus, the second length of frame sheet material bonded to the first length of frame sheet material may provide a bottom surface for cavities of the aerosol-generating articles that are at least partially delimited by the frame apertures.

[0092] In embodiments wherein the further length of sheet material is a second length of frame material the method may further comprise a step of providing a third length of frame sheet material, a step of positioning the third length of frame sheet material in alignment with the first length of frame sheet material; and a step of bonding the third length of frame sheet material and the first length of frame sheet material. By bonding the third length of frame sheet material and the first length of frame sheet 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 blank, a second frame layer blank and a third frame layer blank.

[0093] In an example, the step of positioning the third length of frame sheet material in alignment with the first length of frame sheet material comprises positioning the third length of frame sheet material above the first length of frame sheet material. Consequently, the second length of frame sheet material and the third length of frame sheet material are bonded to opposite sides of the first length of frame sheet material, and so in the laminated frame structure the first length of frame sheet material is comprised between the second length of frame sheet material and the third length of frame sheet material. Thus, frames of the aerosol-generating articles can be obtained, wherein the frame core layer blank is comprised between the second frame layer blank and the third frame layer blank.

[0094] In another example, the step of positioning the third length of frame sheet material in alignment with the first length of frame sheet material comprises positioning the third length of frame sheet material underneath the second length of frame sheet material. Consequently, the first length of frame sheet material, the second length of frame sheet material and the third length of frame sheet material are bonded together so that the second length of frame sheet material and the third length of frame sheet material are arranged on the same side of the first length of frame sheet material. Thus, in the laminated frame structure, the second length of frame sheet material is comprised between the first length of frame sheet material and the third length of frame sheet material. Thus, frames of the aerosol-generating articles can be obtained, wherein the second frame layer blank is comprised between the frame core layer blank and the third frame layer blank.

[0095] The third length of frame sheet material may differ from at least one of the first length of frame sheet material and the second length of frame sheet material. Accordingly, bonding the first length of frame sheet material, the second length of frame sheet material and the third length of frame sheet material may advantageously provide a laminated frame structure that benefits from a combination of the differing characteristics. In embodiments comprising the steps of providing a third length of frame sheet material and bonding the third length of frame sheet material and the first length of frame sheet material, the step of bonding the third length of frame sheet material and the first length of frame sheet material may be carried out prior to forming a plurality of frame apertures through the first length of frame sheet material, and subsequent to or simultaneous with bonding the second length of frame sheet material and the first length of frame sheet material. Accordingly, the step of forming the frame apertures through the first length of frame sheet material may be carried out such that the frame apertures extend through the first length of frame sheet material and both of the second and third lengths of frame sheet material.

[0096] Alternatively, in embodiments comprising the step of providing a third length of frame sheet material and bonding the third length of frame sheet material and the first length of frame sheet material, the step of bonding the third length of frame sheet material and the first length of frame sheet material may be carried out subsequent to forming a plurality of frame apertures through the first length of frame sheet material. Thus, the further length of sheet material bonded to the first length of frame sheet material may provide a bottom surface for cavities of the aerosol-generating articles that are at least partially delimited by the frame apertures. Thus, where the second length of frame sheet material and the third length of frame sheet material are bonded to opposite sides of the first length of frame sheet material, the second length of frame sheet material and the third length of frame sheet material bonded to the first length of frame sheet material may provide a bottom surface and a top surface, respectively, for cavities of the aerosol-generating articles that are at least partially delimited by the frame apertures.

[0097] Preferably, a method according to present disclosure further comprises a step of forming air inlets and air outlets of the aerosol-generating articles. More preferably, the step of forming air inlets and air outlets of the aerosol-generating articles comprises establishing a fluid communication between the air inlet and the air outlet of a given aerosol-generating article via an internal cavity of the given aerosol-generating article, wherein the internal cavity is least partially defined by a respective frame aperture of the plurality of frame apertures of the frame core layer blank.

[0098] In an example, the step of forming air inlets and an air outlets of the aerosol-generating articles may be carried out after the frame core layer blank has been formed. In particular, the step of forming air inlets and air outlets of the aerosol-generating articles may be carried out after a multi-layer laminated frame structure comprising the frame core layer blank has been formed, as described above.

[0099] Alternatively, air inlets and air outlets of the aerosol-generating articles may be formed along with the frame core layer blank or more generally along with a frame laminated structure comprising the frame core layer blank. That is, the method may comprise additional steps by which air inlets and air outlets of the aerosol-generating articles are formed at the same time as the frame structure - be it a frame structure including the frame core layer alone or a laminated frame structure in line with the foregoing description - is formed.

[0100] To this end, a method according to the present invention may comprise a step of forming air inlet apertures or air outlet apertures or both through the first length of frame sheet material. Thus, a frame core layer blank is obtained that comprises not only a plurality of frame apertures, but also one or both of a plurality of air inlet apertures and a plurality of air outlet apertures.

[0101] The plurality of frame apertures and one or both of the plurality of air inlet apertures and the plurality of air outlet apertures may advantageously be formed so that they ultimately define a plurality of continuous passages that extend through the frame core layer blank. For example, in the step of forming air inlet apertures or air outlet apertures or both through the first length of frame sheet material, the air inlet apertures and the air outlet apertures may be formed so that they define a plurality of non-interrupted passages extending through the frame core layer blank, wherein each passage extends from the air inlet aperture of a given aerosol-generating article to the air outlet aperture of the given aerosol-generating article.

[0102] In embodiments wherein the further length of sheet material is a second length of frame sheet material and a laminated frame structure comprising the frame core layer blank and a second frame layer blank is formed, the method may comprise forming air inlet apertures or air outlet apertures or both through the first length of frame sheet material alone. Thus, in the laminated frame structure, air inlets or air outlets or both may be formed so that the air inlets or the air outlets or both extend through the frame core layer blank but not through the second frame layer blank.

[0103] Alternatively, in embodiments wherein the further length of sheet material is a second length of frame sheet material and a laminated frame structure comprising the frame core layer blank and a second frame layer is formed, the method may comprise forming air inlet apertures or air outlet apertures or both through both the first length of sheet frame material and the second length of sheet frame material. Thus, in the laminated frame structure, air inlets or air outlets or both may be formed so that the air inlets or the air outlets or both extend through both layers of the laminated frame structure.

[0104] These alternatives provide a desirable degree of adaptability by which a size of the air inlets or a size of the air outlets or both may be adjusted. For example, in embodiments wherein frame apertures are formed through both the first length of frame sheet material and the second length of frame sheet material, the method may conveniently be adapted to form air inlets or air outlets or both that have the same height as the frame apertures. Alternatively, the method may equally conveniently be adapted for form air inlets or air outlets or both that have a different height compared with the frame apertures. For example, the air inlets or the air outlets or both may extend through a single layer of the laminated frame structure whereas the frame apertures extend through multiple layers of the laminated frame structure, or vice versa.

[0105] In embodiments wherein the further length of sheet material is a second length of frame sheet material and a third length of frame sheet material is provided and bonded with the other sheets of frame material, and a laminated frame structure comprising the frame core layer blank, a second frame layer blank and a third frame layer blank is formed, the method may comprise a step of forming air inlet apertures or air outlet apertures or both through the first length of frame sheet material alone. Thus, in the laminated frame structure, air inlets or air outlets or both may be formed so that the air inlets or the air outlets or both extend through the frame core layer blank but not through either one of the second frame layer blank and the third frame layer blank.

[0106] 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 inlets or the air outlets or both. In more detail, the first frame layer and the second frame layer may, along with the air inlet (outlet) apertures, define slit-shaped air inlets (outlets).

[0107] Alternatively, in embodiments wherein the further length of sheet material is a second length of frame sheet material and a third length of frame sheet material is provided and bonded with the other sheets of frame material, and a laminated frame structure comprising the frame core layer blank, a second frame layer and a third frame layer is formed, the method may comprise a step of forming air inlet apertures or air outlet apertures or both through the first length of frame sheet material, the second length of frame sheet material and the third length of frame sheet material. Thus, in the laminated frame structure, air inlets or air outlets or both may be formed so that the air inlets or the air outlets or both extend through all three layers of the laminated frame structure.

[0108] 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.

[0109] The lengths of frame sheet material from which the frame core layer blank and any additional layers of a frame laminated structure are formed may be made from or comprise a biodegradable material. The lengths of frame sheet material from which the frame core layer blank and any additional layers of a frame laminated structure are formed may be made entirely from a biodegradable material.

[0110] The lengths of frame sheet material from which the frame core layer blank 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 lengths of frame sheet material from which the frame core layer blank 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.

[0111] Preferably, a method in accordance with the present invention comprises a step of providing a first length of external layer sheet material.

[0112] More preferably, the method comprises a step of providing a first length of external layer sheet material and a second length of external layer sheet material. Further, the method preferably comprises a step of positioning the first length of frame sheet material and the second length of sheet material between the first length of external layer sheet material and the second length of external layer sheet material.

[0113] Preferably, the method additionally comprises a step of bonding the first length of external layer sheet material, the second length of external layer sheet material and the length of frame sheet material.

[0114] 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 length of external layer sheet material and the second length of external layer sheet material form a first external layer and a second external layer of a laminated structure of the article, respectively.

[0115] Accordingly, the first length of external layer sheet material and the second length of external layer sheet 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.

[0116] With reference to methods in accordance with the present disclosure involving the provision of lengths of external layer sheet material, the expression “positioning the length of frame sheet material and the second length of sheet material between the first length of external layer sheet material and the second length of external layer sheet material” may denote a step in which the first length of external layer sheet material is in fact arranged immediately underneath the second length of sheet material and the second length of external layer sheet material is in fact arranged immediately above the length of frame sheet material. However, the expression “positioning the length of frame sheet material and the second length of sheet material between the first length of external layer sheet material and the second length of external layer sheet material” is more generally intended to denote a step in which the length of frame sheet material, along with any further length of frame layer material provided to form a laminated frame structure as described above, as well as any length of internal layer sheet material provided as will be described in detail below, are sandwiched between the first length of external layer sheet material and the second length of external layer sheet material.

[0117] For example, one or both of the first length of external layer sheet material and the second length of external layer sheet material may comprise a wrapper material. External layers of the aerosol-generating article comprising a wrapper material may also be denoted as outer wrappers.

[0118] In some example, one or both of the outer wrappers may be hydrophobic. One or both of the first length of external layer sheet material and the second length of external layer sheet material may comprise a hydrophobic material. More generally, one or both of the first length of external layer sheet material and the second length of external layer sheet 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.

[0119] In some examples, one or both of the first length of external layer sheet material and the second length of external layer sheet 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.

[0120] One or both of the first length of external layer sheet material and the second length of external layer sheet 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.

[0121] One or both of the first length of external layer sheet material and the second length of external layer sheet 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.

[0122] One or both of the first length of external layer sheet material and the second length of external layer sheet material may have a thickness between 25 micrometres and 55 micrometres, between 25 micrometres and 45 micrometres, or between 30 micrometres and 45 micrometres.

[0123] In some embodiments of the method, the further length of sheet material is a first length of internal layer sheet material.

[0124] In other words, the method comprises: providing a first length of frame sheet material and a first length of internal layer sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the first length of internal layer sheet material underneath and in alignment with the first length of frame sheet material; bonding the first length of internal layer sheet material and the first length of frame sheet material to form the laminated blank structure comprising the core layer.

[0125] 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.

[0126] For example, the first length of internal layer sheet material may comprise an aerosolgenerating substrate or the first length of internal layer sheet material may be a length of a sheet of aerosol-generating material (such as, for example, a sheet of homogenised tobacco material). As the first length of internal layer sheet material directly bonded underneath the frame aperture defines or at least partially forms a bottom surface of the internal cavities of the aerosol-generating articles, as described above, the aerosol-generating substrate or material contained in the first length of internal layer sheet material may be advantageously exposed to the interior of the cavities and to airflow passages extending between inlets and outlets of each aerosol-generating article via the respective cavity at least partially defined by a frame aperture, as described above. In another example, the first length of internal layer sheet 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 cavities at least partially defined by the frame apertures.

[0127] In certain embodiments, the method further comprises a step of providing a second length of internal layer sheet material, a step of positioning the second length of internal layer sheet material above and in alignment with the first length of frame sheet material, and a step of bonding the second length of internal layer sheet material and the first length of frame sheet material.

[0128] 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.

[0129] The first length of internal layer sheet material and the second length of internal layer sheet material may differ by at least one characteristic, such as for example the sheet composition. For example, one of the first length of internal layer sheet material and the second length of internal layer sheet material may comprise an aerosol-generating material whereas the other one of the first length of internal layer sheet material and the second length of internal layer sheet material is free of aerosol-generating material. One of the first length of internal layer sheet material and the second length of internal layer sheet material may comprise an aerosol-generating material whereas the other one of the first length of internal layer sheet material and the second length of internal layer sheet material comprises a susceptor material. Accordingly, bonding the first length of frame sheet material, the first length of internal layer sheet material and the second length of internal layer sheet material may advantageously provide a laminated structure that benefits from a combination of the differing characteristics.

[0130] 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.

[0131] 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.

[0132] In an example, a method in accordance with the present invention comprises: providing a first length of frame sheet material and a second length of frame sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the second length of frame sheet material underneath and in alignment with first length of frame sheet material; bonding the second length of frame sheet material and the first length of frame sheet material; and further providing a first length of internal layer sheet material; positioning the first length of internal layer sheet material underneath and in alignment with the second length of frame sheet material and the first length of frame sheet material; bonding the first length of internal layer sheet material and the first length of frame sheet material; optionally providing a second length of internal layer sheet material; positioning the second length of internal layer sheet material above and in alignment with the first length of frame sheet material; and bonding the second length of internal layer sheet material and the first length of frame sheet material, to form the aerosol-generating article. This example of a method in accordance with the present disclosure is advantageously adapted to provide an aerosolgenerating article having a double-layered laminated frame structure combined with one or two layers of internal sheet material.

[0133] 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 length of external layer sheet material and a second length of external layer sheet material; positioning the double-layered laminated frame structure, the first length of internal layer sheet material and optionally the second length of internal layer sheet material between the first length of external layer sheet material and the second length of external layer sheet material; and bonding the first length of external layer sheet material and the second length of external layer sheet material and the double-layered laminated frame structure.

[0134] In another example, a method in accordance with the present invention comprises: providing a first length of frame sheet material and a second length of frame sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the second length of frame sheet material underneath and in alignment with the first length of frame sheet material; bonding the second length of frame sheet material and the first length of frame sheet material; providing a third length of frame sheet material; positioning the second length of frame sheet material above and in alignment with the first length of frame sheet material; bonding the third length of frame sheet material and the first length of frame sheet material; and further providing a first length of internal layer sheet material; positioning the first length of internal layer sheet material underneath and in alignment with the second length of frame sheet material and the first length of frame sheet material; bonding the first length of internal layer sheet material and the first length of frame sheet material; optionally providing a second length of internal layer sheet material, positioning the second length of internal layer sheet material above and in alignment with the third length of frame sheet material, and bonding the second length of internal layer sheet material and the first length of frame sheet material. 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.

[0135] 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 length of external layer sheet material and a second length of external layer sheet material; positioning the triple-layered laminated frame structure, the first length of internal layer sheet material and optionally the second length of internal layer sheet material between, and in alignment with, the first length of external layer sheet material and the second length of external layer sheet material; and bonding the first length of external layer sheet material and the second length of external layer sheet material and the triple-layered laminated frame structure.

[0136] 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.

[0137] Any one of the methods discussed in the foregoing description may also further comprise a step of providing a first length of protective layer sheet material which may be removed from the aerosol-generating article prior to use.

[0138] In more detail, a method in accordance with the present disclosure may further comprise a step of providing a first length of protective layer sheet material; a step of positioning the first length of protective layer sheet material above and in alignment the first length of frame sheet material and the further length of sheet material; and optionally removably bonding the first length of protective layer material and the first length of frame sheet material.

[0139] With reference to methods in accordance with the present disclosure, the expression “positioning the first length of protective layer material above and in alignment the first length of frame sheet material” may denote a step in which the first length of protective layer sheet material is in fact arranged immediately above the first length of frame sheet material. However, the expression “positioning the first length of protective layer sheet material above and in alignment with the first length of frame sheet material” is more generally intended to denote a step in which the first length of protective layer sheet material is arranged above the first length of frame sheet material as well as above any other length of sheet material positioned above and in alignment with the first length of frame sheet material to form the laminated structure. In line with the foregoing description, this includes any further length of frame sheet material, any length of internal layer sheet material and any length of external layer sheet material, which may have been combined with the first length of frame sheet material as discussed above with reference to different embodiments of methods in accordance with the present disclosure.

[0140] Advantageously, positioning a length of protective layer sheet 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.

[0141] Materials suitable for forming a protective layer will be known to the skilled person.

[0142] Once a laminated structure comprising discrete, finite lengths of sheet material that have been provided, positioned in alignment with one another 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 lengths of sheet material. Accordingly, the one or more aerosol-generating articles may be ejected from the remainder of the laminated structure.

[0143] 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

[0144] 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.

[0145] In an example, a method according to the present invention comprises: providing a first length of frame sheet material and a further length of sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the second length of sheet material underneath and in alignment with the first length of frame sheet material; bonding the further length of sheet material and the first length of frame sheet material to form the laminated blank structure; and punching a plurality of apertures through the first length of frame sheet material and the further length of sheet material so as to eject the aerosol-generating articles.

[0146] In another example, a method according to the present invention comprises: providing a first length of frame sheet material and a further length of sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the second length of sheet material underneath and in alignment with the first length of frame sheet material; bonding the further length of sheet material and the first length of frame sheet material to form the laminated blank structure; forming a plurality of weakened lines of severance through the first length of frame sheet material and the further length of sheet material so as to make the aerosol-generating articles detachable from the remainder of the first length of frame sheet material and the second length of sheet material.

[0147] In an example, a method according to the present invention comprises: providing a first length of frame sheet material and a second length of frame sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the second length of frame sheet material underneath and in alignment the first length of frame sheet material; bonding the second length of frame sheet material and the first length of frame sheet material to form the laminated blank structure; and punching a plurality of apertures through the first length of frame sheet material and the second length of frame sheet material so as to eject the aerosol-generating articles.

[0148] In another example, a method according to the present invention comprises: providing a first length of frame sheet material and a second length of frame sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the second length of frame sheet material underneath and in alignment the first length of frame sheet material; bonding the second length of frame sheet material and the first length of frame sheet material to form the laminated blank structure; and forming a plurality of weakened lines of severance through the first length of frame sheet material and the second length of frame sheet material so as to make the aerosol-generating articles detachable from the remainder of the first length of frame sheet material and the second length of frame sheet material.

[0149] In an example, a method according to the present invention comprises: providing a first length of frame sheet material and a second length of frame sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the second length of frame sheet material underneath and in alignment with the first length of frame sheet material; bonding the second length of frame material and the first length of frame sheet material; providing a third length of frame sheet material; bonding the third length of frame sheet material and the first length of frame sheet material to form the laminated blank structure; and punching a plurality of apertures through the first length of frame sheet material, the second length of frame sheet material and the third length of frame sheet material so as to eject the aerosol-generating articles. In another example, a method according to the present invention comprises: providing a first length of frame sheet material and a second length of frame sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the second length of frame sheet material underneath and in alignment with the first length of frame sheet material; bonding the second length of frame material and the first length of frame sheet material; providing a third length of frame sheet material; bonding the third length of frame sheet material and the first length of frame sheet material to form the laminated blank structure; and forming a plurality of weakened lines of severance through the first length of frame sheet material, the second length of frame sheet material and the third length of frame sheet material so as to make the aerosol-generating articles detachable from the remainder of the first length of frame sheet material, the second length of frame sheet material and the third length of frame sheet material.

[0150] In an example, a method according to the present invention comprises: providing a first length of frame sheet material and a first length of internal layer sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the first length of internal layer sheet material underneath and in alignment with the first length of frame sheet material to form laminated blank structure; and punching a plurality of apertures through the first length of frame material and the first length of internal layer sheet material so as to eject the aerosol-generating articles.

[0151] In another example, a method according to the present invention comprises: providing a first length of frame sheet material and a first length of internal layer sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the first length of internal layer sheet material underneath and in alignment with the first length of frame sheet material to form laminated blank structure; and forming a plurality of weakened lines of severance through the first length of frame material and the first length of internal layer sheet material so as to make the aerosol-generating articles detachable from the remainder of the first length of frame material and the first length of internal layer sheet material.

[0152] In an example, a method according to the present invention comprises: providing a first length of frame sheet material and a first length of internal layer sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the first length of internal layer sheet material underneath and in alignment with the first length of frame sheet material; bonding the first length of internal layer sheet material and the first length of frame sheet material; providing a second length of internal layer sheet material; positioning the second length of internal layer sheet material above and in alignment with the first length of frame sheet material; and bonding the second length of internal layer sheet material and the first length of frame sheet material to form the laminated blank structure; and punching a plurality of apertures through the first length of frame material, the first length of internal layer sheet material and the second length of internal layer sheet material so as to eject the aerosol-generating articles.

[0153] In another example, a method according to the present invention comprises: providing a first length of frame sheet material and a first length of internal layer sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the first length of internal layer sheet material underneath and in alignment with the first length of frame sheet material; bonding the first length of internal layer sheet material and the first length of frame sheet material; providing a second length of internal layer sheet material; positioning the second length of internal layer sheet material above and in alignment with the first length of frame sheet material; and bonding the second length of internal layer sheet material and the first length of frame sheet material to form the laminated blank structure; and forming a plurality of weakened lines of severance through the first length of frame material, the first length of internal layer sheet material and the second length of internal layer sheet material so as to make the aerosol-generating articles detachable from the remainder of the first length of frame material, the first length of internal layer sheet material and the second length of internal layer sheet material.

[0154] In an example, a method according to the present invention comprises: providing a first length of frame sheet material and a further length of sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the further length of sheet material underneath and in alignment with the first length of frame sheet material; bonding the further length of sheet material and the first length of frame sheet material; providing a first length of external layer material and a second length of external layer material; positioning the first length of frame sheet material and the further length of sheet material between and in alignment with the first length of external layer sheet material and the second length of external layer sheet material; bonding the first length of external layer sheet material, the second length of external layer sheet material and the first length of frame sheet material to form the laminated blank structure; and punching a plurality of apertures through the first length of frame sheet material, the further length of sheet material, the first length of external layer sheet material and the second length of external layer sheet material so as to eject the aerosol-generating articles.

[0155] In another example, a method according to the present invention comprises: providing a first length of frame sheet material and a further length of sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the further length of sheet material underneath and in alignment with the first length of frame sheet material; bonding the further length of sheet material and the first length of frame sheet material; providing a first length of external layer material and a second length of external layer material; positioning the first length of frame sheet material and the further length of sheet material between and in alignment with the first length of external layer sheet material and the second length of external layer sheet material; bonding the first length of external layer sheet material, the second length of external layer sheet material and the first length of frame sheet material to form the laminated blank structure; and forming a plurality of weakened lines of severance through the first length of frame sheet material, the further length of sheet material, the first length of external layer sheet material and the second length of external layer sheet material so as to make the aerosol-generating articles detachable from the remainder of the first length of frame sheet material, the further length of sheet material, the first length of external layer sheet material and the second length of external layer sheet material.

[0156] In an example, a method according to the present invention comprises: providing a first length of frame sheet material and a second length of frame sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the second length of frame sheet material underneath and in alignment with the first length of frame sheet material; bonding the second length of sheet material and the first length of frame sheet material; providing a third length of frame sheet material; positioning the third length of frame sheet material above and in alignment with the first length of frame sheet material; bonding the third length of frame sheet material to the first length of frame sheet material to form a laminated frame structure; providing a first length of internal layer sheet material; positioning the first length of internal layer sheet material underneath and in alignment with the laminated frame structure; bonding the first length of internal layer sheet material and the laminated frame structure; providing a second length of internal layer sheet material; positioning the second length of internal layer sheet material above and in alignment with the laminated frame structure; bonding the second length of internal layer sheet material and the laminated frame structure; providing a first length of external layer sheet material and a second length of external layer sheet material; positioning the first length of internal layer sheet material, the laminated frame structure and the second length of internal layer sheet material between and in alignment with the first length of external layer sheet material and the second length of external sheet layer material; bonding the first length of external layer sheet material, the second length of external layer sheet material and the laminated frame structure to form the laminated blank structure; punching a plurality of apertures through the first length of external layer material, the first length of internal layer sheet material, the laminated frame structure, the second length of internal layer sheet material and the second length of external layer sheet material to eject the aerosol-generating articles.

[0157] In another example, a method according to the present invention comprises: providing a first length of frame sheet material and a second length of frame sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the second length of frame sheet material underneath and in alignment with the first length of frame sheet material; bonding the second length of sheet material and the first length of frame sheet material; providing a third length of frame sheet material; positioning the third length of frame sheet material above and in alignment with the first length of frame sheet material; bonding the third length of frame sheet material to the first length of frame sheet material to form a laminated frame structure; providing a first length of internal layer sheet material; positioning the first length of internal layer sheet material underneath and in alignment with the laminated frame structure; bonding the first length of internal layer sheet material and the laminated frame structure; providing a second length of internal layer sheet material; positioning the second length of internal layer sheet material above and in alignment with the laminated frame structure; bonding the second length of internal layer sheet material and the laminated frame structure; providing a first length of external layer sheet material and a second length of external layer sheet material; positioning the first length of internal layer sheet material, the laminated frame structure and the second length of internal layer sheet material between and in alignment with the first length of external layer sheet material and the second length of external sheet layer material; bonding the first length of external layer sheet material, the second length of external layer sheet material and the laminated frame structure to form the laminated blank structure; forming a plurality of weakened lines of severance through the first length of external layer material, the first length of internal layer sheet material, the laminated frame structure, the second length of internal layer sheet material and the second length of external layer sheet material to make the aerosolgenerating articles detachable from the remainder of the first length of external layer material, the first length of internal layer sheet material, the laminated frame structure, the second length of internal layer sheet material and the second length of external layer sheet material.

[0158] 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.

[0159] 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.

[0160] In methods in accordance with the present disclosure, the first length of frame sheet material preferably comprises paper, paperboard, or cardboard.

[0161] A thickness of the first length of frame sheet material may be at least 0.5 millimetres. Preferably, a thickness of the first length of frame sheet material may be at least 0.6 millimetres. More preferably, a thickness of the first length of frame sheet material may be at least 0.75 millimetres. In an example, a thickness of the first length of frame sheet material may be at least 1 millimetre.

[0162] A basis weight of the first length of frame sheet material may be at least 200 gsm. Preferably, a basis weight of the first length of frame sheet material may be at least 250 gsm. In an example, a basis weight of the first length of frame sheet material may be at least 400 gsm. In another example, a basis weight of the first length of frame sheet material may be at least 500 gsm.

[0163] A basis weight of the first length of frame sheet material may be less than or equal to 750 gsm. Preferably, a basis weight of the first length of frame sheet material may be less than or equal to 700 gsm. In an example, a basis weight of the first length of frame sheet material may be less than or equal to 650 gsm. In another example, a basis weight of the first length of frame sheet material may be less than or equal to 600 gsm.

[0164] 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.

[0165] 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.

[0166] A length of the first length of frame sheet material may be at least 50 millimetres. In some examples, a length of the first length of frame sheet material may be at least 100 millimetres. In other examples, a length of the first length of frame sheet material may be at least 200 millimetres. In further examples, a length of the first length of frame sheet material may be at least 250 millimetres.

[0167] In certain examples, a length of the first length of frame sheet material may be 500 millimetres or 750 millimetres or 1000 millimetres.

[0168] In embodiments wherein the first length of frame sheet material is combined with at least a further length of frame sheet material to form a laminated frame structure, a thickness of any further length of frame sheet material may similarly fall within the ranges described above with reference to the first length of frame sheet material. Similarly, a basis weight of any further length of frame sheet material may similarly fall within the ranges described above with reference to the first length of frame sheet material.

[0169] In embodiments wherein a first length of frame sheet material, a second length of frame sheet material and a third length of frame sheet material are combined to form a laminated frame structure, and wherein each one of the first length of frame sheet material, a second length of frame sheet material and a third length of frame sheet 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.

[0170] In embodiments wherein a first length of frame sheet material, a second length of frame sheet material and a third length of frame sheet material are combined to form a laminated frame structure, and wherein each one of the first length of frame sheet material, a second length of frame sheet material and a third length of frame sheet 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.

[0171] In embodiments wherein a first length of frame sheet material, a second length of frame sheet material and a third length of frame sheet material are combined to form a laminated frame structure, and wherein each one of the first length of frame sheet material, a second length of frame sheet material and a third length of frame sheet 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.

[0172] 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 lengths of internal layer sheet 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 aerosolgenerating article.

[0173] A method in accordance with the present disclosure may further comprise a step of dispensing an aerosol-generating substrate into the frame apertures.

[0174] Advantageously, such a method makes it possible to further control and adjust a content of aerosol-generating substrate in the aerosol-generating articles on top of the opportunities already afforded by the laminated structure of the articles. 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.

[0175] In certain embodiments comprising a step of dispensing an aerosol-generating substrate into the frame apertures, the method may further comprise a step of compressing the aerosol- generating substrate within cavities of the aerosol-generating articles, the cavities being at least partially delimited by peripheral surfaces of the frame apertures.

[0176] 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.

[0177] In certain embodiments, the aerosol-generating substrate is in the form of a plurality of granules, beads, pellets or flakes of aerosol-generating material.

[0178] In some embodiments, the aerosol-generating material may be in the form of a corrugated sheet of aerosol-generating material.

[0179] Preferably, the aerosol-generating substrate comprises one or more aerosol-formers, such as one or both of glycerine and propylene glycol.

[0180] The aerosol-generating substrate may have a bulk density of less than or equal to 0.5 milligrams per cubic millimetre.

[0181] The aerosol-generating substrate positioned within the cavity may have a packing density of less than or equal to 0.9.

[0182] Features of an aerosol-generating article obtainable by methods in accordance with the present invention are described in more detail below.

[0183] The frame may be a planar frame.

[0184] 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.

[0185] 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.

[0186] 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. 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.

[0187] 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.

[0188] 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.

[0189] 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.

[0190] 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.

[0191] 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.

[0192] 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.

[0193] 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.

[0194] 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.

[0195] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0196] 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.

[0197] 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.

[0198] 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.

[0199] 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.

[0200] 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.

[0201] 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.

[0202] 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.

[0203] 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.

[0204] The frame may have a length that is equal to the length of the aerosol-generating article.

[0205] 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.

[0206] 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.

[0207] 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.

[0208] 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.

[0209] 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.

[0210] 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.

[0211] 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.

[0212] 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.

[0213] 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.

[0214] 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.

[0215] 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.

[0216] 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.

[0217] 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.

[0218] 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.

[0219] 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.

[0220] 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.

[0221] 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.

[0222] 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. 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.

[0223] 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.

[0224] 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.

[0225] 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.

[0226] 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.

[0227] 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.

[0228] 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.

[0229] 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.

[0230] 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.

[0231] 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. 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.

[0232] 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.

[0233] 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.

[0234] The aerosol-generating article may comprise an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may comprise a hydrophobic material.

[0235] 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.

[0236] 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.

[0237] 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.

[0238] 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.

[0239] 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.

[0240] The first planar external layer may define or form the first planar external surface. The first planar external layer may extend in the x / y plane. The second planar external layer may define or form the second planar external surface. The second planar external layer may extend in the x / y plane. The first planar external layer may be in physical contact with, and may be bonded to, the frame. The first planar external layer may overlie an end of the cavity. The first planar external layer may define or form a wall of the cavity, such as the first cavity end wall.

[0241] 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.

[0242] 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.

[0243] 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.

[0244] 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.

[0245] 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.

[0246] 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.

[0247] 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. 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.

[0248] 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.

[0249] 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.

[0250] 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.

[0251] 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.

[0252] 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.

[0253] 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.

[0254] 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.

[0255] 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.

[0256] 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. 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.

[0257] 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.

[0258] 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.

[0259] 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.

[0260] 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.

[0261] 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.

[0262] Most preferably, the cavity may have a length of 26 millimetres, a width of 8 millimetres, and a thickness of 3.1 millimetres.

[0263] 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.

[0264] 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.

[0265] 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.

[0266] The cavity may be substantially empty.

[0267] 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. 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.

[0268] 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.

[0269] 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.

[0270] 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.

[0271] 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.

[0272] 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.

[0273] 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.

[0274] 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.

[0275] 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. 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.

[0276] 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.

[0277] 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.

[0278] 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.

[0279] 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.

[0280] 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.

[0281] 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.

[0282] 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.

[0283] 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.

[0284] 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.

[0285] 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”.

[0286] 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.

[0287] 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.

[0288] 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.

[0289] 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.

[0290] 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.

[0291] 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.

[0292] 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.

[0293] 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.

[0294] 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.

[0295] 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.

[0296] 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.

[0297] 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. 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.

[0298] 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.

[0299] 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.

[0300] 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.

[0301] 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.

[0302] 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.

[0303] 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.

[0304] 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.

[0305] 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.

[0306] 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.

[0307] 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.

[0308] 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. 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.

[0309] 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.

[0310] 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.

[0311] 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.

[0312] 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

[0313] 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.

[0314] 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.

[0315] 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.

[0316] 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.

[0317] 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.

[0318] 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. 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.

[0319] 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.

[0320] 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.

[0321] 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.

[0322] 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.

[0323] 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.

[0324] 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.

[0325] 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.

[0326] 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.

[0327] 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. 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 length of frame sheet material; providing a further length of sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the further length of sheet material underneath and in alignment with the first length of frame sheet material; bonding the further length of sheet material and the first length of frame sheet material to form a laminated blank structure comprising the frame core layer blank for forming a plurality of aerosol-generating articles.

[0328] Example EX2: A method according to example EX1 , wherein the further length of sheet of material is a second length of frame sheet material, the first length of frame material and the further length of sheet material forming a laminated frame structure, and wherein the step of bonding the further length of sheet material and the first length of frame sheet material to form the laminated blank structure is carried out prior to forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank.

[0329] Example EX3: A method according to example EX2, wherein the step of bonding the further length of sheet material and the first length of frame sheet material is carried out subsequent to forming the frame apertures through the first length of frame sheet material to form the frame core layer blank.

[0330] Example EX4: A method according to example EX1 , wherein the step of bonding the further length of sheet material and the first length of frame sheet material is carried out subsequent to forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank.

[0331] Example EX5: A method according to any one of examples EX1 , wherein the further length of sheet of material is a second length of frame sheet material, the first length of frame material and the further length of sheet material forming a laminated frame structure, the method further comprising: providing a third length of frame sheet material; and bonding the third length of frame sheet material and the first length of frame sheet material to form the laminated blank structure.

[0332] Example EX6: A method according to example EX5, wherein the step of bonding the third length of frame sheet material and the first length of frame sheet material is carried out prior to forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, and subsequent to or simultaneous with bonding the second length of frame sheet material and the first length of frame sheet material.

[0333] Example EX7: A method according to example EX6, wherein the frame apertures are formed such that they extend through the first length of frame sheet material, the second length of frame sheet material and the third length of frame sheet material.

[0334] Example EX8: A method according to any one of the preceding examples further comprising forming air inlets and an air outlets of the aerosol-generating articles. Example EX9: A method according to example EX8, wherein forming air inlets and an air outlets of the aerosol-generating article comprises establishing a fluid communication between the air inlet of a given aerosol-generating article and the air outlet of the given aerosol-generating article via an internal cavity of the aerosol-generating article, the internal cavity being at least partially defined by a frame aperture in the frame core layer blank.

[0335] Example EX10: A method according to any one of examples EX1 to EX7 further comprising forming air inlet apertures or air outlet apertures or both through the first length of frame sheet material.

[0336] Example EX11 : A method according to any one of examples EX2 to EX7 further comprising forming air inlet apertures or air outlet apertures or both through the second length of frame sheet material.

[0337] Example EX12: A method according to any one of examples EX5 to EX7 further comprising forming air inlet apertures or air outlet apertures or both through the third length of frame sheet material.

[0338] Example EX13: A method according to any one of examples EX10 to EX12, wherein forming an air inlet aperture or an air outlet aperture or both through the first length of frame sheet material is carried out prior to bonding the further length of sheet material and the first length of frame sheet material to form a laminated structure of the aerosol-generating article comprising the frame core layer.

[0339] Example EX14: A method according to any one of examples EX11 to EX12, wherein forming an air inlet aperture or an air outlet aperture or both through the second length of frame sheet material is carried out prior to bonding the second length of sheet material and the first length of frame sheet material to form a laminated structure of the aerosol-generating article comprising the frame core layer.

[0340] Example EX15: A method according to example EX12, wherein forming an air inlet aperture or an air outlet aperture or both through the third length of frame sheet material is carried out prior to bonding the third length of sheet material and the first length of frame sheet material to form a laminated structure of the aerosol-generating article comprising the frame core layer.

[0341] Example EX16: A method according to any one of the preceding examples further comprising: providing a first length of external layer sheet material and a second length of external layer sheet material; positioning the first length of frame sheet material and the further length of sheet material between and in alignment with the first length of external layer sheet material and the second length of external layer sheet material; and bonding the first length of external layer sheet material, the second length of external layer sheet material and the first length of frame sheet material to form the laminated blank structure.

[0342] Example EX17: A method according to any one of the preceding examples, wherein the further length of sheet material is a length of internal layer sheet material. Example EX18: A method according to example EX17 further comprising: providing a second length of internal layer sheet material; positioning the second length of internal layer sheet material above and in alignment with the first length of frame sheet material; and bonding the second length of internal layer sheet material and the first length of frame sheet material to form the laminated blank structure.

[0343] Example EX19: A method according to example EX17 or EX18, wherein the first length of internal layer sheet material is a length of a sheet of aerosol-generating material.

[0344] Example EX20: A method according to example EX17 or EX18, wherein the first length of internal layer sheet material is a length of a sheet comprising a cellulosic material, preferably paper or cardboard.

[0345] Example EX21 : A method according to example EX18, wherein at least one of the first length of internal layer sheet material and the second length of internal layer sheet material is a length of a sheet of aerosol-generating material.

[0346] Example EX22: A method according to example EX18, wherein at least one of the first length of internal layer sheet material and the second length of internal layer sheet material is a length of a sheet comprising a cellulosic material, preferably paper or cardboard.

[0347] Example EX23: A method according to any one of examples EX1 to EX22 further comprising: providing a first length of protective layer sheet material; positioning the first length of protective layer sheet material above and in alignment with the first length of frame sheet material and the further length of sheet material; and optionally removably bonding the length sheet of protective sheet layer material and the length sheet of frame material.

[0348] Example EX24: A method according to any one of examples 1 to EX22 further comprising: providing a first length of protective layer sheet material and a second length of protective layer sheet material; positioning the first length of frame sheet material and the further length of material between the first length of protective layer sheet material and the second length of protective layer sheet material; and optionally removably bonding the first length of protective layer sheet material, the second length of protective layer sheet material and the first length of frame sheet material.

[0349] Example EX25: 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 length of frame sheet material and a second length of frame sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the second length of frame sheet material underneath and in alignment with the first length of frame sheet material; bonding the second length of frame sheet material and the first length of frame sheet material to form a laminated frame structure comprising the frame core layer blank for forming a plurality of aerosol-generating articles.

[0350] Example EX26: A method according to example EX25 further comprising: providing a third length of frame sheet material; positioning the third length of frame sheet material above and in alignment with the first length of frame sheet material; and bonding the third length of frame sheet material and the first length of frame sheet material to form the laminated frame structure.

[0351] Example EX27: A method according to example EX25 or EX26 further comprising forming air inlets and air outlets of the aerosol-generating articles.

[0352] Example EX28: A method according to example EX27, wherein forming air inlets and an air outlets of the aerosol-generating article comprises establishing a fluid communication between the air inlet of a given aerosol-generating article and the air outlet of the given aerosol-generating article via an internal cavity of the aerosol-generating article, the internal cavity being at least partially defined by a frame aperture in the frame core layer blank.

[0353] Example EX29: A method according to any one of examples EX25 to EX28 further comprising: providing a first length of internal layer sheet material; positioning the first length of internal layer sheet material underneath and in alignment with the laminated frame structure; and bonding the first length of internal layer sheet material and the laminated frame structure to form a laminated blank structure for forming the aerosol-generating articles.

[0354] Example EX30: A method according to any one of examples EX25 to EX28 further comprising: providing a first length of internal layer sheet material; positioning the length sheet of internal layer sheet material above and in alignment with the laminated frame structure; and bonding the first length of internal layer sheet material and the laminated frame structure to form a laminated blank structure for forming the aerosol-generating articles.

[0355] Example EX31 : A method according to any one of examples EX25 to EX28 further comprising: providing a first length of internal layer sheet material; positioning the first length of internal layer sheet material underneath and in alignment with the laminated frame structure; providing a second length of internal layer sheet material; positioning the second length of internal layer sheet material above and in alignment with the laminated frame structure; and bonding the first length of internal layer sheet material, the second length of internal layer sheet material and the laminated frame structure to form a laminated blank structure for forming the aerosolgenerating articles.

[0356] Example EX32: A method according to any one of examples EX25 to EX28 further comprising providing a first length of external layer sheet material and a second length of external sheet layer material; positioning the laminated frame structure between the first length of external layer sheet material and the second length of external layer sheet material; and bonding the laminated frame structure, the first length of external layer sheet material and the second length of external layer sheet material to form a laminated blank structure for forming the aerosol-generating articles.

[0357] Example EX33: A method according to example EX29 or EX30 further comprising providing a first length of external layer sheet material and a second length of external layer sheet material; positioning the laminated frame structure and the first length of internal layer sheet material between the first length of external layer sheet material and the second length of external layer sheet material; and bonding the laminated frame structure, the first length of internal layer sheet material, the first length of external layer sheet material and the second length of external layer sheet material to form the laminated blank structure for forming the aerosol-generating articles.

[0358] Example EX34: A method according to example EX31 further comprising providing a first length of external layer material sheet and a second length of external layer sheet material; positioning the laminated frame structure, the first length of internal layer sheet material and the second length of internal layer sheet material between the first length of external layer sheet material and the second length of external layer sheet material; and bonding the laminated frame structure, the first length of internal layer sheet material, the second length of internal layer sheet material, the first length of external layer sheet material and the second length of external layer sheet material to form the laminated blank structure for forming the aerosol-generating articles.

[0359] Example EX35: A method according to any one of the preceding examples, wherein a thickness of each aerosol-generating article of the plurality of aerosol-generating articles is less than 50 percent of both a length and a width of the aerosol-generating article.

[0360] Example EX36: 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 articles.

[0361] Example EX37: A method according to any one of the preceding examples, wherein a thickness of the frame core layer blank accounts for between 80 percent and 95 percent of a thickness of the aerosol-generating articles.

[0362] Example EX38: A method according to any one of examples EX2 to EX5, wherein a thickness of the laminated frame structure accounts for greater than or equal to 80 percent of a thickness of the aerosol-generating articles.

[0363] Example EX39: A method according to any one of examples EX2 to EX5, wherein a thickness of the laminated frame structure accounts for between 80 percent and 95 percent of a thickness of the aerosol-generating articles. Example EX40: A method according to any one of the preceding examples, wherein the first length of frame sheet material comprises paper, paperboard, or cardboard.

[0364] Example EX41 : A method according to any one of the preceding examples, wherein a thickness of the first length of frame sheet material is at least 0.5 millimetres, preferably at least 0.6 millimetres, more preferably at least 0.75 millimetres.

[0365] Example EX42: A method according to any one of the preceding examples, wherein a basis weight of the first length of frame sheet material is at least 200 gsm, preferably at least 250 gsm, more preferably at least 400 gsm, even more preferably at least 500 gsm.

[0366] Example Ex43: A method according to any one of the preceding examples, wherein a width of the first continuous sheet of frame material is at least 50 millimetre, preferably at least 100 millimetres, more preferably at least 200 millimetres, even more preferably at least 250 millimetres. Example EX44: A method according to any one of the preceding examples, wherein a width of the first continuous sheet of frame material is at least 500 millimetres, preferably at least 750 millimetres.

[0367] Example EX45: A method according to any one of the preceding examples further comprising dispensing an aerosol-generating substrate into the frame apertures.

[0368] Example EX46: A method according to Example EX45 comprising compressing the aerosol-generating substrate within cavities of the aerosol-generating articles, the cavities being at least partially delimited by peripheral surfaces of the frame apertures.

[0369] Example EX47: A method according to Example EX45 or EX46, wherein the aerosolgenerating substrate is in the form of shredded aerosol-generating material.

[0370] Example EX48: A method according to example EX47, wherein the shredded aerosolgenerating material comprises one or more of: strips and strands of aerosol-generating material, such as strips and strands of tobacco or homogenised tobacco material.

[0371] Example EX48: A method according to Example EX45 or EX46, wherein the aerosolgenerating material is in the form of a corrugated sheet of aerosol-generating material.

[0372] Example EX49: A method according to Example EX45 or EX46, wherein the aerosolgenerating material is in the form of a plurality of granules, beads, pellets or flakes of aerosolgenerating material.

[0373] Example EX50: A method according to any one of Examples EX45 to EX49, wherein the aerosol-generating substrate comprises one or more aerosol-formers, such as one or both of glycerine and propylene glycol.

[0374] Example EX51 : A method according to any one of Examples EX45 to EX50, wherein the aerosol-generating substrate has a bulk density of less than or equal to 0.5 milligrams per cubic millimetre.

[0375] Example EX52: A method according to any one of Examples EX45 to EX50, wherein the aerosol-generating substrate positioned within the cavity has a packing density of less than or equal to 0.9.

[0376] Examples will now be further described with reference to the figures in which:

[0377] Figure A shows a perspective view of an aerosol-generating article according to the present disclosure;

[0378] Figure B shows an exploded perspective view of the aerosol-generating article of Figure A;

[0379] Figure 1 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0380] Figure 2 shows an exploded perspective view of the aerosol-generating article of Figure 1 ;

[0381] Figure 3 shows an exploded perspective view of an aerosol-generating article according to the present disclosure; Figure 4 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0382] Figure 5 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0383] Figure 6 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0384] 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;

[0385] 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;

[0386] Figure 10 shows a method of manufacturing an aerosol-generating article according to the present disclosure.

[0387] Figure 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.

[0388] 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.

[0389] 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 B.

[0390] Figure B shows an exploded view of the aerosol-generating article 10 of Figure 1.

[0391] 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.

[0392] 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.

[0393] 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.

[0394] 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.

[0395] 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.

[0396] In an example, the first planar external layer 22 comprises a cellulosic material, such as for example cardboard or paper.

[0397] In another example, the first planar external layer 22 comprises an aerosol-generating substrate comprising an aerosol-generating material, namely tobacco.

[0398] 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.

[0399] The aerosol-generating article 10 of Figure 1 is intended for use with an aerosol-generating 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.

[0400] 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, the cavity 30 is delimited by the cavity end wall 32, the frame 50 and the inner wall of the device cavity.

[0401] 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.

[0402] Figure 1 shows an aerosol-generating article 10 comprising a first planar external layer 24 forming a first planar external surface 21 , a second planar external layer 25 forming a second planar external surface 22, and a frame 50 positioned between the first planar external layer 24 and the second planar external layer 25. The first planar external layer 24 and the second planar external layer 25 both comprise an aerosol-generating substrate comprising an aerosol-generating material, namely tobacco. However, it will be understood that in some embodiments only one of the first planar external layer 24 and the second planar external layer 25 may comprise an aerosolgenerating substrate. Alternatively, or additionally, the aerosol-generating substrate may be positioned elsewhere within the aerosol-generating article 10.

[0403] 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.

[0404] 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.

[0405] Figure 2 shows an exploded view of the aerosol-generating article 10 of Figure 1 .

[0406] 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.

[0407] 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. 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.

[0408] 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.

[0409] 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.

[0410] Figure 3 shows an exploded view of an aerosol-generating article that is similar to the aerosol-generating article 10 of Figure 1 except that the first planar external layer 24 and the second planar external layer 25 do not comprise an aerosol-generating substrate. Instead, an aerosol-generating substrate 40 is positioned within the cavity 30. The aerosol-generating substrate 40 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. As shown, the aerosolgenerating substrate 40 fills the entire volume of the cavity 30. In the example of Figure 3, the aerosol-generating substrate 40 has a packing density of about 0.87, a density of about 0.3 grams per cubic centimetre, and a mass of about 110 milligrams. In another example, the aerosolgenerating substrate 40 may have a different packing density, a different density and a different mass. For example, aerosol-generating substrate may have a packing density of 0.64, a density of 0.35 grams per cubic centimetre, and a mass of about 95 milligrams.

[0411] 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.

[0412] Figure 5 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1 except that the aerosol-generating article 10 of Figure 5 further comprises a first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are formed from a sheet of aerosol-generating material. In particular, a sheet of homogenised tobacco material having an aerosol-former content of 5 percent by weight on a dry weight basis. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 each have a length equal to the length of the aerosol-generating article 10, a width equal to the width of the aerosol-generating article 10 and a thickness of 200 micrometres. That is, the aerosolgenerating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.5 millimetres.

[0413] 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.

[0414] The first planar external layer 24 is in physical contact with the first aerosol-generating substrate layer 41 and are bonded together with an adhesive 15. The second planar external layer 25 is in physical contact with the second aerosol-generating substrate layer 42 and are bonded together with an adhesive 15.

[0415] 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.

[0416] 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.

[0417] 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 1. There is little tolerance between the first planar external surface 21 and the second planar external surface 22 of the aerosol-generating article 10 and the internal surfaces 1020, 1030 of the cavity 1000. Thus, there is a snug fit between the aerosol-generating article 10 and the aerosol-generating device 90. When a consumer has inserted the aerosol-generating article 10 into the cavity 1000, the device can be operated. The first heater 95 heats the first planar external surface 21 of the aerosol-generating article 10 and the second heater 96 heats the second planar external surface 22 of the aerosolgenerating article, and as a result the aerosol-generating substrate is heated. Volatile components of the aerosol-generating substrate are evaporated and condense in the cavity 30 of the aerosolgenerating article 10 to form an aerosol. The consumer inhales the aerosol by drawing on the end of the aerosol-generating article 10 comprising the air outlet 12. Once the aerosol-generating substrate has been depleted of volatile components, the aerosol-generating article 10 is removed from the cavity 1000 and disposed of.

[0418] Figures 10, 11 , 12 and 13 depict a schematic illustration of sequences 2000, 2002, 2004, 2006 of steps of a method of manufacturing a plurality of aerosol-generating articles 3000 in line with the foregoing description and, in particular, a method of manufacturing a plurality of aerosolgenerating articles having substantially the same structure of the aerosol-generating article 10 of Figure 6, but not including an aerosol-generating substrate within the internal cavity. For illustration purposes the manufacturing equipment is not depicted.

[0419] The method comprises providing a first length 2100 of frame sheet material. Optionally, as illustrated in Figure 10, the first length 2100 of frame sheet material may be cut off a continuous sheet of frame material 2110 wound in a bobbin 2112.

[0420] Further, the method comprises forming a plurality of air inlet I air outlet apertures 2114 through the first length 2100 of frame sheet material, such that the plurality of air inlet I air outlet apertures 2114 or are arranged according to a predetermined array over the first length 2100 of frame sheet material.

[0421] As shown in Figure 11 , the method further comprises providing a second length 2116 of frame sheet material and a third length 2118 of frame sheet material. The second length 2116 of frame sheet material is positioned underneath and in alignment with the first length 2100 of frame sheet material. The third length 2118 of frame sheet material is positioned above and in alignment with the first length 2100 of frame sheet material.

[0422] The first length 2100 of frame sheet material, the second length 2116 of frame sheet material and the third length 2118 of frame sheet material are bonded together.

[0423] A plurality of frame apertures 2120 are formed through the first length 2100 of frame sheet material, the second length 2116 of frame sheet material and the third length 2118 of frame sheet material. The frame apertures 2120 are disposed in accordance with a predetermined array relative to the first length of frame sheet material 2100. As such, a laminated frame structure 2122 is obtained that comprises a frame core layer blank.

[0424] By forming air inlet apertures or air outlet apertures 2114 and the frame apertures 2120 as described above, a fluid communication is established between the air inlet of a given aerosolgenerating article and the air outlet of the given aerosol-generating article via an internal cavity of the aerosol-generating article. As will become apparent from the description of the remainder of the method, the internal cavities are at least partially defined by the frame apertures 2120.

[0425] As shown in Figure 12, the method further comprises providing a first length 2124 of internal layer sheet material; positioning the first length 2122 of internal layer sheet material underneath and in alignment with the laminated frame structure 2122.

[0426] Further, a second length 2126 of internal layer sheet material is provided and positioned above and in alignment with the laminated frame structure 2122.

[0427] Additionally, a first length 2128 of external layer sheet material is provided and positioned underneath and in alignment with the first length 2124 of internal layer sheet material. A second length 2130 of external layer sheet material is provided and positioned above and in alignment with the second length 2126 of internal layer sheet material.

[0428] The laminated frame structure 2122, the first length 2124 of internal layer sheet material, the second length 2126 of internal layer sheet material, the a first length 2128 of external layer sheet material and the second length 2130 of external layer sheet material are bonded to form a laminated blank structure 2132 from which, as shown in Figure 13, a plurality of aerosol-generating articles are formed.

[0429] As illustrated in Figure 13, a plurality of apertures 2134 are punched through the first length 2128 of external layer material, the first length 2124 of internal layer sheet material, the laminated frame structure 2122, the second length of internal layer sheet material 2126 and the second length 2130 of external layer sheet material to eject the aerosol-generating articles 10.

[0430] 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 length of frame sheet material; providing a further length of sheet material; forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank, such that the frame apertures are positioned in a predetermined array across the surface of the frame core layer blank; positioning the further length of sheet material underneath and in alignment with the first length of frame sheet material; bonding the further length of sheet material and the first length of frame sheet material to form a laminated blank structure comprising the frame core layer blank for forming a plurality of aerosol-generating articles.

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

3. A method according to claim 2, wherein the step of bonding the further length of sheet material and the first length of frame sheet material is carried out subsequent to forming the frame apertures through the first length of frame sheet material to form the frame core layer blank.

4. A method according to claim 1 , wherein the step of bonding the further length of sheet material and the first length of frame sheet material is carried out subsequent to forming a plurality of frame apertures through the first length of frame sheet material to form a frame core layer blank.

5. A method according to any one of claims 1 , wherein the further length of sheet of material is a second length of frame sheet material, the first length of frame material and the further length of sheet material forming a laminated frame structure, the method further comprising: providing a third length of frame sheet material; and bonding the third length of frame sheet material and the first length of frame sheet material to form the laminated blank structure.

6. A method according to claim 5, wherein the step of bonding the third length of frame sheet material and the first length of frame sheet material is carried out prior to forming a plurality of frame apertures through the first length of frame sheet material to form a frame corelayer blank, and subsequent to or simultaneous with bonding the second length of frame sheet material and the first length of frame sheet material.

7. A method according to claim 6, wherein the frame apertures are formed such that they extend through the first length of frame sheet material, the second length of frame sheet material and the third length of frame sheet material.

8. A method according to any one of claims 1 to 7 further comprising forming air inlet apertures or air outlet apertures or both through the first length of frame sheet material.

9. A method according to claim 8, wherein forming an air inlet aperture or an air outlet aperture or both through the first length of frame sheet material is carried out prior to bonding the further length of sheet material and the first length of frame sheet material to form a laminated structure of the aerosol-generating article comprising the frame core layer.

10. A method according to any one of the preceding claims further comprising: providing a first length of external layer sheet material and a second length of external layer sheet material; positioning the first length of frame sheet material and the further length of sheet material between and in alignment with the first length of external layer sheet material and the second length of external layer sheet material; and bonding the first length of external layer sheet material, the second length of external layer sheet material and the first length of frame sheet material to form the laminated blank structure.

11. A method according to any one of the preceding claims, wherein the further length of sheet material is a length of internal layer sheet material.

12. A method according to claim 11 , wherein the first length of internal layer sheet material is a length of a sheet of aerosol-generating material.

13. A method according to any one of the preceding claims, wherein a thickness of the first length of frame sheet material is at least 0.5 millimetres, preferably at least 0.6 millimetres, more preferably at least 0.75 millimetres.

14. A method according to any one of the preceding claims further comprising dispensing an aerosol-generating substrate into the frame apertures.

15. A method according to claim 14, wherein the aerosol-generating material is in the form of a plurality of granules, beads, pellets or flakes of aerosol-generating material.

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