Aerosol-generating article comprising a cavity and an aerosol-generating element

Abstract

There is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article is defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness. The article comprises a first external surface and a second external surface facing in substantially the opposite direction to the first external surface, a cavity located within the aerosol-generating article between the first external surface and the second external surface, and an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity. An aerosol-generating element is located within the cavity, the aerosol-generating element comprising aerosol-forming substrate and being defined by an element length, an element width, and an element thickness. The element width is greater than the element thickness. The aerosol-generating element comprises cut filler dispersed within a solid binder matrix.

Description

[0001] AEROSOL-GENERATING ARTICLE COMPRISING A CAVITY AND AN AEROSOLGENERATING ELEMENT

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

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

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

[0005] However, a significant portion of the aerosol-generating substrate in these cylindrical aerosol-generating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-generating substrate contributes to the cost of manufacture and transport of the aerosol-generating article but does not contribute to the aerosol delivered to the consumer. Moreover, the components of these cylindrical aerosolgenerating articles normally need to have the same or very similar outer diameters so that they can be brought together, accurately positioned in axial alignment and wrapped in a cigarette paper. This can lead to increased cost and complexity of manufacture.

[0006] It is an objective of the present disclosure to provide an aerosol-generating article in which a greater portion of the aerosol-generating substrate is sufficiently heated to form an aerosol during use. It is also an objective of the present disclosure to provide an aerosol-generating article that can be manufactured relatively efficiently and cheaply.

[0007] According to the present disclosure, there is provided an aerosol-generating article. The aerosol-generating article may be for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article may be defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness. The aerosol- generating article may comprise one or more aerosol-generating substrates. The aerosolgenerating article comprises a first external surface and a second external surface. The first external surface and the second external surface may be described as opposing first and second surfaces, for example the second external surface may face in substantially the opposite direction to the first external surface. The aerosol-generating article may comprise a cavity. The cavity may be located within the aerosol-generating article between the first external surface and the second external surface. The aerosol-generating article may comprise an air inlet. The aerosol-generating article may comprise an air outlet. The aerosol-generating article may comprise an airflow passage extending between the air inlet and the air outlet. The airflow passage may be positioned between the first planar external surface and the second planar external surface. The airflow passage may extend between the air inlet and the air outlet through the cavity. An aerosol-generating element may be located within the cavity. The aerosol-generating element comprises aerosol-forming substrate and may be defined by an element length, an element width, and an element thickness, the element width being greater than the element thickness. The aerosol-generating element may comprise cut filler dispersed within a binder matrix, for example cut filler dispersed within a solid binder matrix.

[0008] Thus, there may be provided an aerosol-generating article for use with an aerosolgenerating device to generate an aerosol, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising; a first external surface and a second external surface facing in substantially the opposite direction to the first external surface; a cavity located within the aerosol-generating article between the first external surface and the second external surface; and an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity, wherein an aerosol-generating element is located within the cavity, the aerosol-generating element comprising aerosol-forming substrate and being defined by an element length, an element width, and an element thickness, the element width being greater than the element thickness, in which the aerosol-generating element comprises cut filler dispersed within a solid binder matrix.

[0009] The aerosol-forming substrate of the aerosol-generating element comprises, or is, aerosolforming material. The aerosol-generating element may be the only source of aerosol-forming substrate within the article, or there may be other portions of the article that also comprise aerosolforming substrate.

[0010] Cut filler may be a convenient source of aerosol-forming material, but is difficult to handle cleanly and tends to undergo localised consolidations. When loading an aerosol-generating article, particularly with low doses of cut filler material, there may be significant variation in the dose provided from article to article. The use of an aerosol-generating element comprising cut filler dispersed within a solid binder matrix allows an accurate quantity or dose of aerosol-forming material to be located within the aerosol-generating article, which in turn allows for consistency in dose of aerosol-forming material from article to article. An aerosol-generating element comprising cut filler dispersed within a solid matrix may also be cleaner to handle than loose cut filler. Particles of loose cut filler are likely to contaminate machinery and factories in the form of dust and debris. By binding the cut filler together in the form of an aerosol-generating element, the problems associated with cut filler particles contaminating machinery and factories is reduced or eliminated. As well as cleanliness, there may also be less wastage of cut filler material.

[0011] Furthermore, particles of loose cut filler may easily be removed from an aerosol-generating article during transportation or use. Loose particles of cut filler may, for example, escape from the article via airflow inlets or outlets. The use of an aerosol-generating element comprising cut filler an a binder reduces, or eliminates, the problem of aerosol-generating material escaping from the aerosol-generating article.

[0012] The cut filler may comprise shredded plant material. Advantageously, the use of cut filler comprising shredded plant material may minimise the processing of the plant material that is required during the production of the aerosol-generating element. In particular, the use of cut filler comprising shredded plant material minimises the amount of water required for the production of the aerosol-generating element and also minimises the required drying time compared to processes for producing other aerosol-generating substrates which use plant material in a different form, such as a reconstituted form. The production of such an aerosol-generating element may therefore be carried out in an energy and cost efficient manner.

[0013] The production of a consistent airflow and resistance to draw may be desirable for an aerosol-generating article if the user experience and aerosol-delivery are to remain constant. Loose cut filler inserted into a cavity may have variations in air flow and resistance to draw caused by, for example, settling or conglomeration of the loose cut filler particles. In using an aerosolgenerating element as described herein, the relative dimensions of the aerosol-generating element and the cavity may be controlled to provide desired and consistently reproducible air flow.

[0014] The aerosol-generating element may be fixed within the cavity, for example fixed by adhesion or fixed by mechanical means such as interference with one or more walls of the cavity. By fixing the aerosol-generating article within the cavity, any risk of the aerosol-generating element moving within the cavity and blocking or restricting airflow through the cavity is minimised.

[0015] The cavity is defined by internal dimensions, for example a cavity length, a cavity width, and a cavity height. Cavity height may also be termed cavity thickness. Preferably, the cavity width is greater than the cavity height / thickness.

[0016] Optionally, the aerosol-generating element is a porous aerosol-generating element. Porosity may increase the ability and efficiency of volatile components to be released from the aerosol-generating element on heating. For example, the aerosol-generating elements may have a porous structure, with a plurality of air filled pores within the structure defined by the solid binder matrix and the cut filler.

[0017] Preferably, the aerosol-generating element has a total porosity of at least 0.3, more preferably at least 0.35, more preferably at least 0.4. Preferably, the aerosol-generating element has a total porosity of less than or equal to 0.7, preferably less than or equal to 0.65, preferably less than or equal to 0.6.

[0018] For example, the aerosol-generating element may have a total porosity of between 0.3 and 0.7, or between 0.35 and 0.65, or between 0.4 and 0.6.

[0019] As used herein, the term “total porosity” refers to a ratio of the total void space in a porous body to the overall volume of that porous body. Specifically, the total porosity of the aerosolgenerating element corresponds to the total volume of the pores within the aerosol-generating element, divided by the total volume of the aerosol-generating element. The total pore volume takes into account both open pores and closed pores, which are discussed below.

[0020] The porous structure of the aerosol-generating element includes open pores, which are connected with the external environment of the aerosol-generating element and closed pores, which are not connected with the external environment. Both of these types of pores are taken into account in the measurement of the total porosity as described above. The open pores enable air flow to pass through the aerosol-generating element during use and it is advantageous to maximise the proportion of open pores within the structure.

[0021] Preferably, the open porosity of the aerosol-generating element is at least 0.3, more preferably at least 0.35, more preferably at least 0.4. Preferably, the open porosity of the aerosolgenerating element is less than or equal to 0.6, more preferably less than or equal to 0.55, more preferably less than or equal to 0.5. For example, the open porosity of the aerosol-generating element may be between 0.3 and 0.6, or between 0.35 and 0.55, or between 0.4 and 0.5.

[0022] The “open porosity” refers to a ratio of the total void space of the open pores within a porous body to the overall volume of that porous body. This value of porosity can be measured and calculated as described above in relation to the total porosity, but taking into account only the open pores within the structure.

[0023] The total porosity and open porosity of the aerosol-generating element may be determined using an industrial computed tomography system. For the purposes of the present invention, the total porosity and open porosity of the aerosol-generating element were measured in a Nikon XTH 225 ST industrial computed tomography system from Nikon Metrology NV, which was operated with the following parameters:

[0024] Beam energy: 150kV

[0025] Beam current: 36 microamps

[0026] Power: 5.4W

[0027] Projections: 3141 Exposure time: 708 ms

[0028] The scan obtained from this system was reconstructed in 3D using the “CT Pro 3D” software from Nikon Metrology NV and the 3D data was analysed using the software “VG Studio Max” from Volume Graphics. This software enabled the calculation of the total volume of open pores, the total volume of closed pores and therefore the total overall volume of pores. Using the volume of the aerosol-generating element, the total porosity and open porosity can then be calculated as set out above.

[0029] Preferably, the solid binder matrix comprises at least one binder, for example one specific binder, or a mixture of two or more binders. The binders act as a matrix within which cut filler is distributed. Preferably, the aerosol-generating element comprises at least 1 percent by weight of binder on a dry weight basis. The aerosol-generating element may be formed by a process comprising steps of compressing shreds of cut filler, for example compressing shreds of cut filler tobacco with a binder.

[0030] Preferably, the aerosol-generating element comprises at least 2 percent by weight of the binder, for example at least 5 percent by weight of the binder, on a dry weight basis. The aerosolgenerating element may comprise no more than 30 percent by weight of the binder, for example no more than 20 percent by weight of the binder, for example no more than 15 percent by weight of the binder, on a dry weight basis.

[0031] The weight ratio of the cut filler to the binder may be at least 3, for example at least 4, for example at least 5, on a dry weight basis.

[0032] The binder may comprise polyvinyl alcohol. For example, the aerosol-generating element may comprise between 5 percent and 20 percent by weight of polyvinyl alcohol, for example between 5 percent and 15 percent by weight of polyvinyl alcohol, on a dry weight basis.

[0033] The binder may comprise one or more hydrocolloids. For example, the one or more hydrocolloids may be selected from: starch, modified starch, alginate, pectin, cellulose, cellulose derivatives, agar, carrageenan, gelatin, natural gums and combinations thereof.

[0034] The binder may comprise nanocellulose. For example, the aerosol-generating element may comprise between 1 percent and 15 percent by weight of nanocellulose, for example between 2 percent and 10 percent by weight of nanocellulose, for example between 2 and 8 percent by weight of nanocellulose, on a dry weight basis.

[0035] The binder may comprise micro fibrillated cellulose. For example, the aerosol-generating element may comprise between 1 percent and 10 percent by weight of micro fibrillated cellulose, for example between 2 percent and 8 percent by weight of micro fibrillated cellulose, for example between 2 percent and 6 percent by weight of micro fibrillated cellulose, for example between 2 percent and 4 percent by weight of micro fibrillated cellulose, on a dry weight basis.

[0036] The solid binder matrix may be substantially continuous. The aerosol-generating article may comprise an active agent, for example nicotine. For example, the aerosol-generating element may have a nicotine content of between 1 percent and 5 percent by weight, for example between 1 percent and 3 percent by weight, on a dry weight basis.

[0037] The aerosol-generating element may have an average density of less than 400 mg per cubic centimetre, for example less than 375 mg per cubic centimetre, for example less than 350 mg per cubic centimetre, for example less than 325 mg per cubic centimetre, for example less than 300 mg per cubic centimetre.

[0038] The cut filler may comprise shredded plant material, for example shredded plant material impregnated with an aerosol former. The cut filler may comprise shredded homogenised aerosolforming material. Cut filler may be defined by a cut length, a cut width, and a cut thickness. Preferably, the cut filler has an average cut width of at least 0.75 millimetres.

[0039] Preferably, the aerosol-generating element comprises at least 10 percent by weight (wt %) of aerosol former on a dry weight basis. Suitable aerosol-formers are known in the field of heated aerosol-generating articles, and some examples are set out herein. The aerosol-generating element may comprise an aerosol-former selected from the list consisting of glycerine and propylene glycol. The aerosol-generating element may have an aerosol-former content of greater than 20 wt % on a dry weight basis, for example greater than 25 wt %, or greater than 30 wt %, for example greater than 35 wt %.

[0040] The aerosol-generating element may comprise one or more flavour compounds, for example flavourants, in addition to any aerosol-former. The one or more flavour compounds may comprise one or more of: one or more essential oils such as eugenol, peppermint oil and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool.

[0041] The aerosol-generating element preferably has a total water content of less than or equal to 30 percent by weight, more preferably less than or equal to 20 percent by weight, more preferably less than or equal to 15 percent by weight.

[0042] The aerosol-generating element preferably has a total water content of at least 1 percent by weight, more preferably at least 2 percent by weight, more preferably at least 5 percent by weight.

[0043] For example, the aerosol-generating element may have a total water content of between 1 percent and 30 percent by weight, or between 2 percent and 20 percent by weight, or between 5 percent and 15 percent by weight.

[0044] Preferably, the aerosol-generating element has a moisture content of less than or equal to 30 percent oven volatiles (OV), more preferably less than or equal to 20 percent oven volatiles (OV), more preferably less than or equal to 15 percent oven volatiles (OV). Preferably, the aerosol-generating element has a moisture content of at least 1 percent oven volatiles (OV), more preferably at least 2 percent oven volatiles (OV), more preferably at least 5 percent oven volatiles (OV).

[0045] For example, the aerosol-generating element may have a moisture content of between 1 percent and 30 percent OV, or between 2 percent and 20 percent OV, or between 5 percent and 15 percent OV.

[0046] The term “percent oven volatiles” (percent OV) is used to refer to the moisture content of a material. It is determined by measuring the percentage weight loss from the material being tested upon drying a sample of the material in an oven at 100 plus or minus 1 degree Celsius (°C) for 3 hours plus or minus 0.5 minutes. In practice, it is assumed that a significant majority of the weight loss from plant material results from the evaporation of moisture. It should be noted that, on an absolute basis, the values of moisture content determined by oven drying may be greater than the results of water content analysis when using a specific method such as ISO 6488 (Karl Fischer method). The difference is sample-type dependent and is due to the loss of volatile materials other than water, (for example, aerosol former) from the tested material during oven drying.

[0047] Preferably, the aerosol-generating element has a density of less than 420 mg per cubic centimetre. The cavity of the aerosol-generating article preferably contains between 50 mg and 300 mg of the aerosol-generating element, for example between 100 mg and 200 mg, for example between 125 mg and 175 mg, for example between 140 mg and 160 mg, for example about 140 mg, or about 150 mg or about 160 mg. These weights typically provide sufficient aerosolgenerating material for a single user session.

[0048] In some embodiments, the aerosol-generating element may have a length of between 10 mm and 25 mm, for example between 15 mm and 20 mm, for example about 15 mm or about 17 mm, or about 20 mm.

[0049] In some embodiments, the aerosol-generating element may have a width of between 5 mm and 15 mm, for example between 6 mm and 10 mm, for example between 7 mm and 8 mm, for example about 6 mm or about 7 mm, or about 8 mm.

[0050] In some embodiments, the aerosol-generating element may have a thickness of between 1 mm and 5 mm, for example between 1 .5 mm and 4 mm, for example between 2 mm and 3 mm, for example about 2.5 mm or about 3 mm, or about 3.5 mm.

[0051] Optionally, a surface of the aerosol-generating element may be textured. For example, a surface of the aerosol-generating element may be textured by one or more grooves or channels. For example an upper and / or lower surface of the aerosol-generating element may define one or more grooves or channels. The textured surface may advantageously facilitate air flow over the surface of the aerosol-generating element. For example the one or more grooves or channels may define at least a portion of an air flow path within the aerosol-generating article. For example the one or more grooves or channels may define at least a portion of an air flow path when the aerosolgenerating element is located within the cavity of the aerosol-generating article.

[0052] Preferably, the cavity contains a single unitary portion of the aerosol-generating element. The cavity may, however, contain more than one aerosol-generating element. For example, two or more aerosol-generating elements may be arranged within the cavity in a side-by-side relationship. For example, two or more aerosol-generating elements may be arranged within the cavity in a one on top of the other relationship. If there are more than one aerosol-generating elements within the cavity, they need not have identical composition. That is, the cavity may contain more than one aerosol-generating element of differing compositions, perhaps to facilitate optimisation of aerosoldelivery or flavour profile.

[0053] Either or both of the first external surface and the second external surface may be a curved surface. For example the external surface may present a convex curve, that is the surface may be curved outwardly with respect to the article, Alternatively, the external surface may present a concave curve, that is the surface may be curved inwardly with respect to the article, In preferred examples, however, one or both of the first external surface and the second external surface is substantially planar. Thus, the first external surface may be termed a first planar external surface and the second external surface may be termed the second planar external surface.

[0054] The aerosol-generating article may comprise a frame positioned between the first external surface and the second external surface. The frame may at least partially define the airflow passage. The frame may at least partially define the cavity.

[0055] Advantageously, the first external surface and the second external surface allow for good contact with an external heater, particularly a planar external heater, of an aerosol-generating device, thereby providing optimum heating of the aerosol-generating substrate.

[0056] Advantageously, the first external surface and the second external surface may provide a large surface area for heating by an external heater of an aerosol-generating device, thereby allowing the aerosol-generating substrate to be quickly heated to a temperature sufficient for generating an aerosol.

[0057] Advantageously, aerosol-generating articles of the present disclosure may be heated along substantially their entire length and width, thereby allowing the entire aerosol-generating substrate to be sufficiently heated to generate an aerosol.

[0058] Advantageously, aerosol-generating articles of the present disclosure may be manufactured by layering sheet materials which can be achieved through a continuous manufacturing process, thereby resulting in an aerosol-generating article that is relatively easy and cheap to manufacture. The aerosol-generating element may be located within the cavity during such a layering process.

[0059] In a preferred example, the aerosol-generating article comprises a first planar external surface and a second planar external surface, the aerosol-generating article comprises a cavity, within which one or more aerosol-forming element is located, the aerosol-generating article comprises a frame positioned between the first planar external surface and the second planar external surface, the frame at least partially defining the cavity. The aerosol-generating article further comprises an air inlet and an air outlet. The aerosol-generating article comprises an airflow passage extending between the air inlet and the air outlet through the cavity.

[0060] Advantageously, the frame may provide the aerosol-generating article with structural support. In particular, the frame may allow the aerosol-generating article to be relatively thin whilst maintaining structural rigidity.

[0061] The aerosol-generating article may have a length, a width and a thickness. The aerosolgenerating article may have an article length extending in an x-direction. The aerosol-generating article may have an article width extending in a y-direction. The aerosol-generating article may have an article thickness extending in a z-direction Preferably, the element length, element width, and element thickness of the aerosol-generating element located within the cavity extend in the x- direction, y-direction, and z-direction respectively.

[0062] Preferably, the cavity is defined by internal dimensions, the internal dimensions being a cavity length, a cavity width, and a cavity height. Preferably, the cavity length, cavity width, and cavity height extend in the x-direction, y-direction, and z-direction respectively.

[0063] The aerosol-generating article may comprise an x / y plane. The x / y plane may extend through the geometric centre of the aerosol-generating article. The x / y plane may define a plane of symmetry of the aerosol-generating article. The air inlet and air outlet may be symmetric, for example have a symmetric shape or position, about the x / y plane.

[0064] The aerosol-generating article may comprise an x / z plane. The x / z plane may extend through the geometric centre of the aerosol-generating article. The x / z plane may define a plane of symmetry of the aerosol-generating article. The air inlet and air outlet may be symmetric, for example have a symmetric shape or position, about an x / z plane.

[0065] The aerosol-generating article may comprise an y / z plane. The y / z plane may extend through the geometric centre of the aerosol-generating article. The y / z plane may define a plane of symmetry of the aerosol-generating article. The air inlet and air outlet may be symmetric, for example have a symmetric shape or positioned, about the y / z plane.

[0066] Advantageously, a symmetric aerosol-generating article or an article with a symmetrically shaped or positioned air inlet and air outlet may allow the aerosol-generating article to be inserted into an aerosol-generating device in multiple orientations.

[0067] The aerosol-generating article may be a substantially flat aerosol-generating article or a substantially planar aerosol-generating article. In particular, a thickness of the aerosol-generating article may less than 50 percent of both a length and a width of the aerosol-generating article. Advantageously, a smaller thickness may provide a small temperature gradient or difference across the thickness of the aerosol-generating substrate during heating. Advantageously, this may allow heating of a greater proportion of the aerosol-generating substrate to a temperature at which an aerosol is released whilst minimising the risk of burning the hottest portion of the aerosolgenerating substrate closest to the heater. Advantageously, this may also reduce a time required to heat the aerosol-generating substrate sufficiently to release an aerosol.

[0068] The aerosol-generating article may have a 3-dimensional shape.

[0069] 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 cubic shape. The aerosol-generating article may have a cuboid shape. The aerosolgenerating article may have a rectangular cuboid shape. The aerosol-generating article may have a parallelepiped shape.

[0070] The aerosol-generating article may have a cylindrical shape. The aerosol-generating article may have a right-angled cylinder shape. The aerosol-generating article may have an elliptical cylinder shape.

[0071] The aerosol-generating article may have an oblong shape.

[0072] The aerosol-generating article may have a laminated structure, for example the aerosolgenerating article may comprise or be formed from at least two layers. In particular, the aerosolgenerating article may comprise at least two of: a first external layer, a second external layer, a frame, a first frame layer, a second frame layer, a third frame layer, a first aerosol-generating substrate layer, and a second aerosol-generating substrate layer as discussed in more detail below.

[0073] At least 50% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, for example excluding the aerosol-generating element, may be paper or cardboard. At least 55% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 60% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 65% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 70% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 75% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 80% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 85% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 90% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material.

[0074] At least 50% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 55% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 60% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 65% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 70% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 75% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 80% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 85% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 90% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard.

[0075] Substantially the entirety of the aerosol-generating article, excluding the one or more aerosol-generating substrates and (if present) adhesive, may be paper or cardboard.

[0076] 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.

[0077] Where a frame is present, the frame may be a planar frame.

[0078] 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. The cross-section may have an annulus shape, such as a circular annulus shape, an elliptical annulus shape, a rectangular annulus shape, or a square annulus shape.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] The frame may define or form at least 75 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame. The frame may define or form at least 80 percent of a perimeter of any cross-section, in an x / y plane, of the aerosolgenerating article that extends through the frame. The frame may define or form at least 85 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame. The frame may define or form at least 90 percent of a perimeter of any crosssection, in an x / y plane, of the aerosol-generating article that extends through the frame. The frame may define or form at least 95 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame. The frame may define or form at least

[0083] 99 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame.

[0084] Advantageously, providing a frame that forms at least 75 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame means that the frame extends around a significant portion of the aerosol-generating article. Therefore, the frame can provide the aerosol-generating article with good structural support.

[0085] Advantageously, providing a frame that forms at least 75 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame may mean that any air inlet or air outlet defined through the article is of a size that provides the aerosolgenerating article with a satisfactory resistance to draw.

[0086] Advantageously, providing a frame that forms at least 75 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame may allow the frame to act as a barrier that prevents egress of the aerosol-generating element from the aerosol-generating article.

[0087] The aerosol-generating article may comprise a cross-section in a first x / y plane that extends through the frame. The frame may form at least 99 percent of a perimeter of the crosssection in the first x / y plane. The frame may form at least 100 percent of the perimeter of the crosssection in the first x / y plane.

[0088] The aerosol-generating article may comprise a cross-section in a second x / y plane, spaced from the first x / y plane in the z-direction, that extends through the frame. The frame may form at least 99 percent of a perimeter of the cross-section in the second x / y plane. The frame may form

[0089] 100 percent of the perimeter of the cross-section in the second x / y plane. The air inlet may be positioned, in the z-direction, between the first x / y plane and the second x / y plane. The air outlet may be positioned, in the z-direction, between the first x / y plane and the second x / y plane.

[0090] The frame may comprise a first portion that is at least 30 percent of a thickness of the frame. The first portion may be at least 50 percent of the thickness of the frame. The first portion may be at least 70 percent of the thickness of the frame. The first portion may be at least 90 percent of the thickness of the frame. The frame forms 100 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the first portion of the frame.

[0091] 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.

[0092] The one or more external walls may circumscribe or encircle the cavity.

[0093] The frame may define at least 60 percent of the entire transverse external area of the aerosol-generating article. The frame may define at least 60 percent of the entire transverse external area of the aerosol-generating article. The frame may define at least 70 percent of the entire transverse external area of the aerosol-generating article. The frame may define at least 80 percent of the entire transverse external area of the aerosol-generating article. The frame may define at least 90 percent of the entire transverse external area of the aerosol-generating article.

[0094] 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. Advantageously, such a peripheral wall allows for a relatively large internal volume for an aerosol-generating substrate or aerosol formation whilst providing the structural strength to maintain the shape of the aerosol-generating article.

[0095] 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.

[0096] 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.

[0097] 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 millimetre. 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 millimetres. The peripheral wall may have a radial thickness greater than or equal to 2.5 millimetres.

[0098] The peripheral wall may have a radial thickness less than or equal to 4 millimetres. 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 3 millimetres. The peripheral wall may have a radial thickness less than or equal to 2.5 millimetres. The peripheral wall may have a radial thickness less than or equal to 2 millimetres.

[0099] 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 3 millimetres. The peripheral wall may have a radial thickness between 0.5 millimetres and 2.5 millimetres. The peripheral wall may have a radial thickness between 1 millimetre and 3 millimetres. The peripheral wall may have a radial thickness between 1 millimetres and 2 millimetres. 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. Advantageously, a radial thickness between 0.5 millimetres and 3.5 millimetres may limit the amount of heat that is undesirably transferred to the frame rather than the aerosol-generating substrate.

[0100] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0101] 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.

[0102] The cellulosic material may have a grammage greater than or equal to 300 grams per square metre. The cellulosic material may have a grammage greater than or equal to 350 grams per square metre. The cellulosic material may have a grammage greater than or equal to 390 grams per square metre. The cellulosic material may have a grammage greater than or equal to 420 grams per square metre. The cellulosic material may have a grammage greater than or equal to 620 grams per square metre. The cellulosic material may have a grammage greater than or equal to 720 grams per square metre. The cellulosic material may have a grammage greater than or equal to 800 grams per square metre.

[0103] The cellulosic material may have a grammage less than or equal to 900 grams per square metre. The cellulosic material may have a grammage less than or equal to 800 grams per square metre. The cellulosic material may have a grammage less than or equal to 720 grams per square metre. The cellulosic material may have a grammage less than or equal to 620 grams per square metre. The cellulosic material may have a grammage less than or equal to 420 grams per square metre. The cellulosic material may have a grammage less than or equal to 390 grams per square metre. The cellulosic material may have a grammage less than or equal to 350 grams per square metre.

[0104] The cellulosic material may have a grammage between 300 grams per square metre and 900 grams per square metre. The cellulosic material may have a grammage between 300 grams per square metre and 800 grams per square metre. The cellulosic material may have a grammage between 350 grams per square metre and 800 grams per square metre. The cellulosic material may have a grammage between 400 grams per square metre and 700 grams per square metre.

[0105] The frame may be made from or comprise a fibrous material. The frame may be made from one or more of: natural fibres, synthetic fibres, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibres, nylon fibres, and ceramic fibres. The frame may comprise cellulosic fibres.

[0106] The frame may comprise a hydrophobic region. The hydrophobic region may comprise hydrophobic groups covalently bonded to the frame. The hydrophobic region may be positioned on, or form, at least a portion of the frame inner surface. Advantageously, a hydrophobic region may prevent or limit degradation of the frame in regions where the frame is regularly in contact with aerosol or liquids from the aerosol-generating substrate.

[0107] The hydrophobic region may be produced by a process comprising the steps of: applying a liquid composition comprising a fatty acid halide to a surface of the frame and maintaining the surface at a temperature of about 120 degrees Celsius to about 180 degrees Celsius. The fatty acid halide reacts in situ with protogenic groups of material in the hydrophobic region resulting in the formation of fatty acid esters.

[0108] The hydrophobic region may have a Cobb water absorption (ISO535:1991) value (at 60 seconds) less than or equal to 40 grams per square metre. The hydrophobic region may have a Cobb water absorption (ISO535:1991) value (at 60 seconds) of less than or equal to 35 grams per square metre. The hydrophobic region may have a Cobb water absorption (ISO535:1991) value (at 60 seconds) less than or equal to 30 grams per square metre. The hydrophobic region may have a Cobb water absorption (ISO535:1991) value (at 60 seconds) less than or equal to about 25 grams per square metre.

[0109] The hydrophobic region may have a water contact angle of greater than or equal to about 90 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 95 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 100 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 110 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 120 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 130 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 140 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 150 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 160 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 170 degrees.

[0110] Hydrophobicity is determined by utilizing the TAPPI T558 om-97 test and the result is presented as an interfacial contact angle and reported in “degrees” and can range from near zero degrees to near 180 degrees. Where no contact angle is specified along with the term hydrophobic, the water contact angle is at least 90 degrees.

[0111] The hydrophobic region may have a water contact angle of greater than or equal to 90 degrees and a Cobb water absorption (ISO535:1991) value (at 60 seconds) less than or equal to 40 grams per square metre.

[0112] 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 element. The one more susceptor materials may be in thermal contact with the airflow passage. The one more susceptor materials may be in thermal contact with the cavity. The one or more susceptor materials may be positioned in or on the frame inner surface. 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. Advantageously, the presence of one or more susceptor materials may allow the aerosol-generating article, and thus the aerosol-generating element, to be heated by engagement with a fluctuating electromagnetic field formed by an inductor.

[0113] 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.

[0114] 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.

[0115] 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 60 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 80 percent of the thickness of the aerosol-generating article. The frame may have a thickness greaterthan or equal to 90 percent of the thickness of the aerosolgenerating article. The frame may have a thickness greater 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 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 80 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.

[0116] 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 60 percent of the thickness of the aerosol-generating 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. The frame may have a thickness between 80 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosolgenerating article.

[0117] The frame may have a thickness greater than or equal to 1 millimetre. The frame may have a thickness greater than or equal to 1.5 millimetres. The frame may have a thickness greater than or equal to 2 millimetres. The frame may have a thickness greater than or equal to 2.5 millimetres. The frame may have a thickness greater than or equal to 3 millimetres. The frame may have a thickness greater than or equal to 3.5 millimetres. The frame may have a thickness greater than or equal to 4 millimetres. The frame may have a thickness greater than or equal to 4.5 millimetres.

[0118] The frame may have a thickness less than or equal to 5.5 millimetres. The frame may have a thickness less than or equal to 5 millimetres. The frame may have a thickness less than or equal to 4.5 millimetres. The frame may have a thickness less than or equal to 4 millimetres. The frame may have a thickness less than or equal to 3.5 millimetres. The frame may have a thickness less than or equal to 3 millimetres. The frame may have a thickness less than 2.5 millimetres. The frame may have a thickness less than 2 millimetres. The frame may have a thickness less than 1.5 millimetres.

[0119] The frame may have a thickness between 1 millimetre and 5.5 millimetres. The frame may have a thickness between 1 millimetre and 5 millimetres. Preferably, the frame may have a thickness between 1.5 millimetres and 5 millimetres.

[0120] The frame may have a length that is equal to the length of the aerosol-generating article. The frame may have a length that is at least 90 percent of the length of the aerosol-generating article. The frame may have a length that is at least 95 percent of the length of the aerosolgenerating article.

[0121] 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. The frame may have a width that is at least 90 percent of the width of the aerosol-generating article. 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. Advantageously, the use of two or more layers allows producing, and rapidly adjusting, the desired thickness of the frame by adding or removing layers of sheet material. This may prevent the need to manufacture a single sheet of material having the desired thickness of the frame, which may subsequently need to be changed when the desired thickness of the frame changes.

[0122] 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 first frame layer may be an upper frame layer and the second frame layer may be a lower frame layer.

[0123] The frame may have a thickness equal to a sum of a thickness of the first frame layer and a thickness of the second frame layer. The frame aperture may be defined through both the first frame layer and the second frame layer.

[0124] 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. The first frame layer may be an upper frame layer, the second frame layer may be an intermediate frame layer, and the third frame layer may be a lower frame layer.

[0125] The first frame layer may be in physical contact with the second frame layer. The first frame layer may be may be bonded to the second frame layer with an adhesive. A lower surface of the first frame layer may be bonded to an upper surface of the second frame layer with an adhesive. The adhesive may extend at least 90% around the periphery of the intersection between the first frame layer and the second frame layer. The adhesive may extend at least 95% around the periphery of the intersection between the first frame layer and the second frame layer. The adhesive may extend at least 99% around the periphery of the intersection between the first frame layer and the second frame layer.

[0126] The second frame layer may be in physical contact with the third frame layer. The second frame layer may be bonded to the third frame layer with an adhesive. A lower surface of the second frame layer may be bonded to an upper surface of the third frame layer with an adhesive. The adhesive may extend at least 90% around the periphery of the intersection between the second frame layer and the third frame layer. The adhesive may extend at least 95% around the periphery of the intersection between the second frame layer and the third frame layer. The adhesive may extend at least 99% around the periphery of the intersection between the second frame layer and the third frame layer. The frame may have a thickness equal to a sum of a thickness of the first frame layer, a thickness of the second frame layer and a thickness of the third frame layer. The frame aperture may be defined through the first planar layer, the second planar layer and the third frame layer.

[0127] The first frame layer may be planar.

[0128] The first frame layer may define a first frame layer aperture extending through the thickness of the first frame layer. The first frame layer aperture may at least partially define or form the cavity of the aerosol-generating article. For example, the first frame layer may have a hollow cuboid shape or a square hollow tube shape. As a further example, the first frame layer may have a crosssection that is annular in shape, preferably the cross-section in x / y plane is annular in shape. The cross-section may have an annulus shape, such as a circular annulus shape, an elliptical annulus shape, a rectangular annulus shape, or a square annulus shape.

[0129] The first frame layer may comprise a first frame layer outer surface. The first frame layer outer surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The first frame layer outer surface may at least partially define or form one or more external surfaces of the aerosol-generating article. For example, the first frame layer outer surface may at least partially define or form one or more external walls of the aerosol-generating article. The first frame layer outer surface may circumscribe or encircle one or both: the first frame layer aperture and the frame aperture. The first frame layer outer surface may circumscribe or encircle the cavity.

[0130] The first frame layer may comprise a first frame layer inner surface. The first frame layer inner surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The first frame layer inner surface may define or form a first frame layer aperture outer wall. The first frame layer inner surface may at least partially define or form a cavity outer wall. The first frame layer inner surface may circumscribe or encircle one or both the first frame layer aperture and the frame aperture. The first frame layer outer surface may circumscribe or encircle the cavity.

[0131] The first frame layer outer surface may circumscribe or encircle the first frame layer inner surface. The first frame layer inner surface and the first frame layer outer surface may be concentric with one another.

[0132] The first frame layer may comprise a first frame layer peripheral wall. The first frame layer peripheral wall may circumscribe or encircle one or both of: the frame aperture and the first frame layer aperture. The first frame layer peripheral wall may circumscribe or encircle the cavity.

[0133] The first frame layer peripheral wall may be defined or formed by the first frame layer outer surface and the first frame layer inner surface. The first frame layer peripheral wall may at least partially define or form one or more external surfaces or walls of the aerosol-generating article. The first frame layer peripheral wall may at least partially define or form the first frame layer aperture outer wall. The first frame layer peripheral wall may at least partially define or form the cavity outer wall.

[0134] The first frame layer may be made from or comprise any of the materials described above in relation to the frame. For example, the first frame layer may comprise the one or more susceptor materials.

[0135] The first frame layer may be made from or comprise a biodegradable material. The first frame layer may be entirely made from biodegradable material.

[0136] The first frame layer may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may comprise cellulosic fibres. The cellulosic material may be paper, paperboard, or cardboard. The first frame layer may be made from or comprise a plant material, such as tobacco. The first frame layer may be made entirely from a cellulosic material.

[0137] The cellulosic material may have any grammage or range of grammages as described above in relation to the frame.

[0138] The first frame layer may be made from a fibrous material. The first frame layer may be made from one or more of: natural fibres, synthetic fibres, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibres, nylon fibres, and ceramic fibres.

[0139] Where the frame comprises exactly two layers, the thickness of the first frame layer may be half (50 percent) the thickness of the frame. The first frame layer may have a thickness substantially the same as the second frame layer. Where the frame comprises exactly three layers, the thickness of the first frame layer may be one third (33.33 percent) the thickness of the frame. The first frame layer may have a thickness substantially the same as each of the second frame layer and the third frame layer.

[0140] The first frame layer may have a thickness greater than or equal to 0.5 millimetres. The frame may have a thickness greater than or equal to 1 millimetre. The first frame layer may have a thickness greater than or equal to 1.5 millimetres. The first frame layer may have a thickness greater than or equal to 2 millimetres. The first frame layer may have a thickness greater than or equal to 2.5 millimetres.

[0141] The first frame layer may have a thickness less than or equal to 3 millimetres. The first frame layer may have a thickness less than or equal to 2.5 millimetres. The first frame layer may have a thickness less than or equal to 2 millimetres. The first frame layer may have a thickness less than or equal to 1 .5 millimetres. The first frame layer may have a thickness less than or equal to 1 millimetres.

[0142] The first frame layer may have a thickness between 0.5 millimetres and 3 millimetres. The first frame layer may have a thickness between 0.5 millimetres and 2.5 millimetres. The first frame layer may have a thickness between 1 millimetres and 2.5 millimetres.

[0143] The second frame layer may be planar. The second frame layer may define a second frame layer aperture extending through the thickness of the second frame layer. The second frame layer aperture may at least partially define or form the cavity of the aerosol-generating article. For example, the second frame layer may have a hollow cuboid shape or a square hollow tube shape. As a further example, the second frame layer may have a cross-section that is annular in shape, preferably the cross-section in x / y plane is annular in shape. The cross-section may have an annulus shape, such as a circular annulus shape, an elliptical annulus shape, a rectangular annulus shape, or a square annulus shape.

[0144] The second frame layer may comprise a second frame layer outer surface. The second frame layer outer surface may extend in a transverse direction, for example between the second planar external surface and the second planar external surface. The second frame layer outer surface may at least partially define or form one or more external surfaces of the aerosolgenerating article. For example, the second frame layer outer surface may at least partially define or form one or more external walls of the aerosol-generating article. The second frame layer outer surface may circumscribe or encircle one or both: the second frame layer aperture and the frame aperture. The second frame layer outer surface may circumscribe or encircle the cavity.

[0145] The second frame layer may comprise a second frame layer inner surface. The second frame layer inner surface may extend in a transverse direction, for example between the second planar external surface and the second planar external surface. The second frame layer inner surface may define or form a second frame layer aperture outer wall. The second frame layer inner surface may at least partially define or form a cavity outer wall. The second frame layer inner surface may circumscribe or encircle one or both the second frame layer aperture and the frame aperture. The second frame layer outer surface may circumscribe or encircle the cavity.

[0146] The second frame layer outer surface may circumscribe or encircle the second frame layer inner surface. The second frame layer inner surface and the second frame layer outer surface may be concentric with one another.

[0147] The second frame layer may comprise a second frame layer peripheral wall. The second frame layer peripheral wall may circumscribe or encircle one or both of: the frame aperture and the second frame layer aperture. The second frame layer peripheral wall may circumscribe or encircle the cavity.

[0148] The second frame layer peripheral wall may be defined or formed by the second frame layer outer surface and the second frame layer inner surface. The second frame layer peripheral wall may at least partially define or form one or more external surfaces or walls of the aerosolgenerating article. The second frame layer peripheral wall may at least partially define or form the second frame layer aperture outer wall. The second frame layer peripheral wall may at least partially define or form the cavity outer wall. The second frame layer may be made from or comprise any of the materials described above in relation to the frame. For example, the second frame layer may comprise the one or more susceptor materials.

[0149] The second frame layer may be made from or comprise a biodegradable material. The second frame layer may be entirely made from biodegradable material.

[0150] The second frame layer may be made from or comprise a cellulosic material, as the cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may be paper, paperboard, or cardboard. The second frame layer may be made from or comprise a plant material, such as tobacco. The second frame layer may be made entirely from a cellulosic material.

[0151] The cellulosic material may have any grammage or range of grammages as described above in relation to the frame.

[0152] The second frame layer may be made from a fibrous material. The second frame layer may be made from one or more of: natural fibres, synthetic fibres, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibres, nylon fibres, and ceramic fibres.

[0153] Where the frame comprises exactly two layers, the thickness of the second frame layer may be half (50 percent) the thickness of the frame. The second frame layer may have a thickness substantially the same as the first frame layer. Where the frame comprises exactly three layers, the thickness of the second frame layer may be one third (33.33 percent) the thickness of the frame. The second frame layer may have a thickness substantially the same as the first frame layer and the third frame layer.

[0154] The second frame layer may have a thickness greater than or equal to 0.5 millimetres. The frame may have a thickness greater than or equal to 1 millimetre. The second frame layer may have a thickness greater than or equal to 1.5 millimetres. The second frame layer may have a thickness greater than or equal to 2 millimetres. The second frame layer may have a thickness greater than or equal to 2.5 millimetres.

[0155] The second frame layer may have a thickness less than or equal to 3 millimetres. The second frame layer may have a thickness less than or equal to 2.5 millimetres. The second frame layer may have a thickness less than or equal to 2 millimetres. The second frame layer may have a thickness less than or equal to 1.5 millimetres. The second frame layer may have a thickness less than or equal to 1 millimetres.

[0156] The second frame layer may have a thickness between 0.5 millimetres and 3 millimetres. The second frame layer may have a thickness between 0.5 millimetres and 2.5 millimetres. The second frame layer may have a thickness between 1 millimetres and 2.5 millimetres.

[0157] The third frame layer may be planar.

[0158] The third frame layer may define a third frame layer aperture extending through the thickness of the third frame layer. The third frame layer aperture may at least partially define or form the cavity of the aerosol-generating article. For example, the third frame layer may have a hollow cuboid shape or a square hollow tube shape. As a further example, the third frame layer may have a cross-section that is annular in shape, preferably the cross-section in x / y plane is annular in shape. The cross-section may have an annulus shape, such as a circular annulus shape, an elliptical annulus shape, a rectangular annulus shape, or a square annulus shape.

[0159] The third frame layer may comprise a third frame layer outer surface. The third frame layer outer surface may extend in a transverse direction, for example between the third planar external surface and the third planar external surface. The third frame layer outer surface may at least partially define or form one or more external surfaces of the aerosol-generating article. For example, the third frame layer outer surface may at least partially define or form one or more external walls of the aerosol-generating article. The third frame layer outer surface may circumscribe or encircle one or both: the third frame layer aperture and the frame aperture. The third frame layer outer surface may circumscribe or encircle the cavity.

[0160] The third frame layer may comprise a third frame layer inner surface. The third frame layer inner surface may extend in a transverse direction, for example between the third planar external surface and the third planar external surface. The third frame layer inner surface may define or form a third frame layer aperture outer wall. The third frame layer inner surface may at least partially define or form a cavity outer wall. The third frame layer inner surface may circumscribe or encircle one or both the third frame layer aperture and the frame aperture. The third frame layer outer surface may circumscribe or encircle the cavity.

[0161] The third frame layer outer surface may circumscribe or encircle the third frame layer inner surface. The third frame layer inner surface and the third frame layer outer surface may be concentric with one another.

[0162] The third frame layer may comprise a third frame layer peripheral wall. The third frame layer peripheral wall may circumscribe or encircle one or both of: the frame aperture and the third frame layer aperture. The third frame layer peripheral wall may circumscribe or encircle the cavity.

[0163] The third frame layer peripheral wall may be defined or formed by the third frame layer outer surface and the third frame layer inner surface. The third frame layer peripheral wall may at least partially define or form one or more external surfaces or walls of the aerosol-generating article. The third frame layer peripheral wall may at least partially define or form the third frame layer aperture outer wall. The third frame layer peripheral wall may at least partially define or form the cavity outer wall.

[0164] The third frame layer may be made from or comprise any of the materials described above in relation to the frame. For example, the third frame layer may comprise the one or more susceptor materials.

[0165] The third frame layer may be made from or comprise a biodegradable material. The third frame layer may be entirely made from biodegradable material. The third frame layer may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may be paper, paperboard, or cardboard. The third frame layer may be made from or comprise a plant material, such as tobacco. The third frame layer may be made entirely from a cellulosic material.

[0166] The cellulosic material may have any grammage or range of grammages as described above in relation to the frame.

[0167] The third frame layer may be made from a fibrous material. The third frame layer may be made from one or more of: natural fibres, synthetic fibres, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibres, nylon fibres, and ceramic fibres.

[0168] Where the frame comprises exactly three layers, the thickness of the third frame layer may be one third (33.33 percent) the thickness of the frame. The third frame layer may have a thickness substantially the same as each of the first frame layer and the second frame layer.

[0169] The third frame layer may have a thickness greater than or equal to 0.5 millimetres. The frame may have a thickness greater than or equal to 1 millimetre. The third frame layer may have a thickness greater than or equal to 1.5 millimetres. The third frame layer may have a thickness greater than or equal to 2 millimetres. The third frame layer may have a thickness greater than or equal to 2.5 millimetres.

[0170] The third frame layer may have a thickness less than or equal to 3 millimetres. The third frame layer may have a thickness less than or equal to 2.5 millimetres. The third frame layer may have a thickness less than or equal to 2 millimetres. The third frame layer may have a thickness less than or equal to 1 .5 millimetres. The third frame layer may have a thickness less than or equal to 1 millimetres.

[0171] The third frame layer may have a thickness between 0.5 millimetres and 3 millimetres. The third frame layer may have a thickness between 0.5 millimetres and 2.5 millimetres. The third frame layer may have a thickness between 1 millimetres and 2.5 millimetres.

[0172] The aerosol-generating element located within the cavity is the primary source of aerosolgenerating substrate within the article. In some examples, however, there may be one or more additional aerosol-generating substrates. The one or more additional aerosol-generating substrates may comprise an aerosol-generating substrate layer. Advantageously, an aerosolgenerating substrate layer can be made thin and, therefore, quickly heat up and release volatile compounds to form an aerosol. Advantageously, an aerosol-generating substrate layer can be positioned close to a heater of an aerosol-generating substrate.

[0173] An 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.

[0174] The aerosol-generating substrate layer may be positioned between the frame and the first planar external surface. The aerosol-generating substrate layer may be positioned between the frame and the second planar external surface. The aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame. The aerosol-generating substrate layer may be bonded to the frame with an adhesive.

[0175] 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. The aerosol-generating substrate layer may be bonded to both the frame and the outer wrapper with an adhesive.

[0176] 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 be bonded to both the frame and the first planar external layer with an adhesive. The aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the second planar external layer. The aerosol-generating substrate layer may be bonded to both the frame and the second planar external layer with an adhesive.

[0177] 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.

[0178] 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.

[0179] 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. 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.

[0180] 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. For example, the first aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the first frame layer. The first aerosolgenerating substrate layer may be bonded to the frame with an adhesive. The first aerosolgenerating substrate layer may be bonded to the first frame layer with an adhesive. A lower surface of the first aerosol-generating substrate layer may be bonded to an upper surface of the first frame layer with an adhesive.

[0181] The first aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The first aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the outer wrapper. The first aerosol-generating substrate layer may be bonded to the frame and the outer wrapper with an adhesive.

[0182] 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. The first aerosolgenerating substrate layer may be bonded to the frame and the first planar external layer with an adhesive.

[0183] 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. For example, the second aerosolgenerating substrate layer may be in physical contact with, and may be bonded to, the second frame layer or third frame layer. The second aerosol-generating substrate layer may be bonded to the frame with an adhesive. The second aerosol-generating substrate layer may be bonded to the second frame layer or third frame layer with an adhesive. An upper surface of the second aerosolgenerating substrate layer may be bonded to a lower surface of the second frame layer or third frame layer with an adhesive.

[0184] 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. The second aerosol-generating substrate layer may be bonded to the frame and the outer wrapper with an adhesive. 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. The second aerosol-generating substrate layer may be bonded to the frame and the second planar external layer with an adhesive.

[0185] 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. In other words, the cavity may be defined by the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer.

[0186] The aerosol-generating substrate layer may be a planar aerosol-generating substrate layer. The planar aerosol-generating substrate layer may extend in the x-direction and the y- direction. That is, the planar aerosol-generating substrate layer may extend in the x / y plane.

[0187] The first aerosol-generating substrate layer may be a first planar aerosol-generating substrate layer. The first planar aerosol-generating substrate layer may extend in the x-direction and the y-direction. That is, first the planar aerosol-generating substrate layer may extend in the x / y plane.

[0188] The second aerosol-generating substrate layer may be a second planar aerosol-generating substrate layer. The second planar aerosol-generating substrate layer may extend in the x- direction and the y-direction. That is, the second planar aerosol-generating substrate layer may extend in the x / y plane.

[0189] The aerosol-generating substrate layer may have a thickness greater than or equal to 100 micrometres. The aerosol-generating substrate layer may have a thickness greater than or equal to 200 micrometres. The aerosol-generating substrate layer may have a thickness greater than or equal to 300 micrometres. The aerosol-generating substrate layer may have a thickness greater than or equal to 400 micrometres. The aerosol-generating substrate layer may have a thickness greater than or equal to 500 micrometres.

[0190] The aerosol-generating substrate layer may have a thickness less than or equal to 600 micrometres. The aerosol-generating substrate layer may have a thickness less than or equal to 500 micrometres. The aerosol-generating substrate layer may have a thickness less than or equal to 400 micrometres. The aerosol-generating substrate layer may have a thickness less than or equal to between 300 micrometres. The aerosol-generating substrate layer may have a thickness less than or equal to 200 micrometres.

[0191] The aerosol-generating substrate layer may have a thickness between 100 micrometres and 600 micrometres. The aerosol-generating substrate layer may have a thickness of between 200 micrometres and 500 micrometres. The aerosol-generating substrate layer may have a thickness of between 200 micrometres and 400 micrometres. The aerosol-generating substrate layer may have a thickness of between 200 micrometres and 300 micrometres.

[0192] One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 100 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 200 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 300 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 400 micrometres. One or both the first aerosol-generating substrate layer and the second aerosolgenerating substrate layer may have a thickness greater than or equal to 500 micrometres.

[0193] One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness less than or equal to 600 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness less than or equal to 500 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness less than or equal to 400 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness less than or equal to between 300 micrometres. One or both the first aerosol-generating substrate layer and the second aerosolgenerating substrate layer may have a thickness less than or equal to 200 micrometres.

[0194] One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness between 100 micrometres and 600 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness of between 200 micrometres and 500 micrometres. One or both the first aerosolgenerating substrate layer and the second aerosol-generating substrate layer may have a thickness of between 200 micrometres and 400 micrometres. One or both the first aerosolgenerating substrate layer and the second aerosol-generating substrate layer may have a thickness of between 200 micrometres and 300 micrometres.

[0195] 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.

[0196] The first aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The first aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article. The second aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The second aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article.

[0197] 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.

[0198] 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.

[0199] 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.

[0200] The first external surface may be an upper surface, for example a planar upper surface, and the second planar external surface may be a lower surface, for example a planar lower surface. The first external surface may be a top surface and the second external surface may be a bottom surface. The first external surface may be a ceiling surface and the second external surface may be a base surface.

[0201] The first external surface may be positioned substantially parallel to the second external surface. The first external surface may extend in the x-direction and the y-direction. That is, the first external surface may extend in the x / y plane. The second external surface may extend in the x-direction and the y-direction. That is, the second external surface may extend in the x / y plane.

[0202] The second external surface may be spaced from the first external surface in the z-direction or transverse direction. The distance, or maximum distance, between the first external surface and the second external surface in the z-direction or transverse direction may define the thickness of the aerosol-generating article. That is, a thickness of the aerosol-generating article may be defined by the maximum perpendicular distance between the first external surface and the second external surface.

[0203] The aerosol-generating article may comprise an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may comprise a hydrophobic material.

[0204] The outer wrapper may define or form the first external surface. The outer wrapper may define or form the second external surface. The outer wrapper may define or form both the first external surface and the second external surface.

[0205] 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. In other words, the cavity may be defined by the frame and the outer wrapper.

[0206] 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.

[0207] 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.

[0208] 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. The first planar external layer may be a top layer and the second planar external layer may be a bottom layer. The first planar external layer may be an ceiling layer and the second planar external layer may be a base layer.

[0209] The first planar external layer may define or form the first planar external surface. The first planar external layer may extend in the x-direction and the y-direction. That is, 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-direction and the y-direction. That is, the second planar external layer may extend in the x / y plane.

[0210] The first planar external layer may be in physical contact with, and may be bonded to, a frame. The first planar external layer may be bonded to the frame with an adhesive. The first planar external layer may be bonded to the first frame layer with an adhesive. A lower surface of the first planar external layer may be bonded to an upper surface of the first frame layer with an adhesive. The adhesive may extend at least 90% around the periphery of the intersection between the first planar external layer and the frame. The adhesive may extend at least 95% around the periphery of the intersection between the first planar external layer and the frame. The adhesive may extend at least 99% around the periphery of the intersection between the first planar external layer and the frame.

[0211] 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.

[0212] The second planar external layer may be in physical contact with, and may be bonded to, a frame. The second planar external layer may be bonded to the frame with an adhesive. The second planar external layer may be bonded to the second frame layer with an adhesive. An upper surface of the second planar external layer may be bonded to a lower surface of the second frame layer with an adhesive. The second planar external layer may be bonded to the third frame layer with an adhesive. An upper surface of the second planar external layer may be bonded to a lower surface of the third frame layer with an adhesive. The adhesive may extend at least 90% around the periphery of the intersection between the second planar external layer and the frame. The adhesive may extend at least 95% around the periphery of the intersection between the second planar external layer and the frame. The adhesive may extend at least 99% around the periphery of the intersection between the second planar external layer and the frame.

[0213] 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.

[0214] 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. In other words, the cavity is defined by the frame, the first planar external layer and the second planar external layer.

[0215] 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. The first planar external layer may be bonded to the aerosol-generating substrate layer or the first aerosol-generating substrate layer with an adhesive.

[0216] 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. The second planar external layer may be bonded to the aerosol-generating substrate layer or the second aerosolgenerating substrate layer with an adhesive.

[0217] 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.

[0218] Advantageously, adhesive bonding together components of the aerosol-generating article may provide for a tight seal between layers of the aerosol-generating article. In particular, the adhesive bonding one or both of the first planar external layer and the second planar external layer to the frame may provide for a tight seal between the first planar external layer and the frame or a tight seal between the second planar external layer and the frame.

[0219] Providing a tight seal between layers of the aerosol-generating article may improve airflow through the cavity. Improving air flow through the cavity may improve the user experience. Advantageously, use of an adhesive to bond together components of the aerosolgenerating article may provide for an aerosol-generating article having a high structural integrity.

[0220] The adhesive may comprise a gum. The adhesive may comprise guar gum. The adhesive may comprise polyvinyl alcohol. The adhesive may comprise an aerosol-generating material. The adhesive may consist of an aerosol-generating material. For example, the adhesive may be a homogenised tobacco slurry. The adhesive may be, or may comprise, a flavourant and / or an aerosol-former.

[0221] One or more of the outer wrapper, the first planar external layer and the second planar external layer may be made from a cellulosic material. One or more of the outer wrapper, the first planar external layer and the second planar external layer may comprise a cellulosic material. The cellulosic material may be paper, cardboard, wood, textile, natural fibres or artificial fibres.

[0222] Although the primary source of aerosol-generating material is the aerosol-generating element, one or more of the outer wrapper, the first planar external layer and the second planar external layer may be an additional aerosol-generating substrate comprising an aerosol-generating material. One or more of the outer wrapper, the first external layer and the second external layer may comprise 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 external layer and the second external layer may not comprise any aerosol-generating material.. For example, one or more of the outer wrapper, the first external layer and the second external layer may not comprise tobacco. One or more of the outer wrapper, the first external layer and the second external layer may be substantially nicotine-free.

[0223] One or more of the outer wrapper, the first external layer and the second external layer may comprise a paper material. For example, one or more of the outer wrapper, the first external layer and the second external layer may be paper, cardboard, cigarette paper or tobacco paper.

[0224] The cellulosic material may have a basis weight greater than 10 grams per square metre. The cellulosic material may have a basis weight greater than 20 grams per square metre. The cellulosic material may have a basis weight less than 30 grams per square metre. The cellulosic material may have a basis weight less than 25 grams per square metre. The cellulosic material may have a basis weight between 10 grams per square metre and 30 grams per square metre. The cellulosic material may have a basis weight between 15 grams per square metre and 25 grams per square metre.

[0225] One or more of the outer wrapper, the first external layer and the second external layer may comprise paper and non-paper components.

[0226] One or more of the outer wrapper, the first external layer and the second external layer may exhibit a range of permeabilities including not being permeable. The permeability is determined by utilizing the International Standard test method ISO 2965:2009 and the result is presented as cubic centimetres per minute per square centimetre and referred to as “CORESTA units”. One or more of the outer wrapper, the first external layer and the second external layer may have a permeability between 1 and 10 CORESTA units. T One or more of the outer wrapper, the first external layer and the second external layer may have a permeability between 1 and 5 CORESTA units. One or more of the outer wrapper, the first external layer and the second external layer may have a permeability between 5 and 20 CORESTA units.

[0227] One or more of the outer wrapper, the first external layer and the second external layer may have a thickness greater than or equal to 25 micrometres. One or more of the outer wrapper, the first external layer and the second external layer may have a thickness greater than or equal to 30 micrometres. One or more of the outer wrapper, the first external layer and the second external layer may have a thickness greater than or equal to 35 micrometres. The outer wrapper may have a thickness greater than or equal to 40 micrometres. One or more of the outer wrapper, the first external layer and the second external layer may have a thickness greater than or equal to 45 micrometres.

[0228] One or more of the outer wrapper, the first external layer and the second external layer may have a thickness less than or equal to 55 micrometres. One or more of the outer wrapper, the first external layer and the second external layer may have a thickness greater than or equal to 50 micrometres. One or more of the outer wrapper, the first external layer and the second external layer may have a thickness greater than or equal to 45 micrometres. One or more of the outer wrapper, the first external layer and the second external layer may have a thickness greater than or equal to 40 micrometres. One or more of the outer wrapper, the first external layer and the second external layer may have a thickness greater than or equal to 35 micrometres.

[0229] One or more of the outer wrapper, the first external layer and the second external layer may have a thickness between 25 micrometres and 55 micrometres. One or more of the outer wrapper, the first external layer and the second external layer may have a thickness between 25 micrometres and 45 micrometres. One or more of the outer wrapper, the first external layer and the second external layer may have a thickness between 30 micrometres and 45 micrometres.

[0230] One or more of the outer wrapper, the first external layer and the second external layer may have a length substantially the same as the length of the frame. One or more of the outer wrapper, the first external layer and the second external layer may have a length substantially the same as the length of the aerosol-generating article. One or more of the outer wrapper, the first external layer and the second external layer may have a length of greater than or equal to 90 percent of the length of the frame. One or more of the outer wrapper, the first external layer and the second external layer may have a length of greater than or equal to 95 percent of the length of the frame. One or more of the first external layer and the second external layer may have a width substantially the same as the width of the frame. One or more of the first external layer and the second external layer may have a width substantially the same as the width of the aerosolgenerating article. One or more of the outer wrapper, the first external layer and the second external layer may have a width of greater than or equal to 90 percent of the width of the frame. One or more of the outer wrapper, the first external layer and the second external layer may have a width of greater than or equal to 95 percent of the width of the frame.

[0231] The cavity may comprise a first cavity end wall and a second cavity end wall positioned opposite the first cavity end wall. The first cavity end wall may be defined, or formed, by the outer wrapper, the first external layer or the first aerosol-generating substrate layer. The second cavity end wall may be defined, or formed, by the outer wrapper, the second external layer or the second aerosol-generating substrate layer. The cavity may be enclosed by the first cavity end wall, the second cavity end wall and the frame.

[0232] The cavity may comprise a cavity outer wall. The cavity outer wall may be defined, or formed, by the frame. The cavity outer wall may extend in a transverse direction. The cavity outer wall may extend in a transverse direction between the first cavity end wall and the second cavity end wall. The cavity outer wall may be defined, or formed, by the frame inner surface. The cavity outer wall may be defined, or formed, by the peripheral wall of the frame.

[0233] The cavity may have at least two corners extending between the first planar external surface and the second planar external surface. The at least two corners may be chamfered or rounded or filleted. Preferably, all corners of the cavity extending between the first external surface and the second external surface are chamfered or rounded or filleted.

[0234] Advantageously, a cavity having chamfered, rounded or filleted corners may make the cavity easier to heat. In particular, it may make it easier to heat an aerosol-generating substrate that is positioned within the cavity. Advantageously, a cavity having chamfered, rounded or filleted corners may make the aerosol-generating article stronger and less susceptible to damage. Advantageously, a cavity having chamfered, rounded or filleted corners may make the aerosolgenerating article easier to manufacture.

[0235] The cavity may have a thickness substantially the same as a thickness of the frame.

[0236] The cavity may have a thickness greater than or equal to 30 percent of the thickness of the aerosol-generating article. The cavity may have a thickness greater than or equal to 40 percent of the thickness of the aerosol-generating article. The cavity may have a thickness greater than or equal to 50 percent of the thickness of the aerosol-generating article. The cavity may have a thickness greater than or equal to 60 percent of the thickness of the aerosol-generating article. The cavity may have a thickness greaterthan or equal to 70 percent of the thickness of the aerosolgenerating article. The cavity may have a thickness greater than or equal to 80 percent of the thickness of the aerosol-generating article. The cavity may have a thickness greater than or equal to 90 percent of the thickness of the aerosol-generating article. The cavity may have a thickness greater than or equal to 95 percent of the thickness of the aerosol-generating article.

[0237] The cavity may have a thickness less than or equal to 95 percent of the thickness of the aerosol-generating article. The cavity may have a thickness less than or equal to 90 percent of the thickness of the aerosol-generating article. The cavity may have a thickness less than or equal to 80 percent of the thickness of the aerosol-generating article. The cavity may have a thickness less than or equal to 70 percent of the thickness of the aerosol-generating article.

[0238] The cavity may have a thickness between 30 percent of the thickness of the aerosolgenerating article and 95 percent of the thickness of the aerosol-generating article. The cavity may have a thickness between 40 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article. The cavity may have a thickness between 50 percent of the thickness of the aerosol-generating article and 90 percent of the thickness of the aerosol-generating article. The cavity may have a thickness between 60 percent of the thickness of the aerosol-generating article and 90 percent of the thickness of the aerosolgenerating article. The cavity may have a thickness between 70 percent of the thickness of the aerosol-generating article and 90 percent of the thickness of the aerosol-generating article. The cavity may have a thickness between 80 percent of the thickness of the aerosol-generating article and 90 percent of the thickness of the aerosol-generating article.

[0239] 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 millimetre. 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 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 millimetres. The cavity may have a thickness greater than or equal to 3.5 millimetres. The cavity may have a thickness greater than or equal to 4 millimetres.

[0240] 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 4 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 2 millimetres. The cavity may have a thickness less than or equal to 1 .5 millimetres.

[0241] 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. The cavity may have a thickness between 2 millimetre and 4 millimetres. Preferably, the cavity may have a thickness between 2.8 millimetres and 3.3 millimetres.

[0242] The cavity may have a length greater than or equal to 30 percent of the length of the aerosol-generating article. The cavity may have a length greater than or equal to 40 percent of the length of the aerosol-generating article. The cavity may have a length greater than or equal to 50 percent of the length of the aerosol-generating article. The cavity may have a length greater than or equal to 60 percent of the length of the aerosol-generating article. The cavity may have a length greater than or equal to 70 percent of the length of the aerosol-generating article. The cavity may have a length greater than or equal to 80 percent of the length of the aerosol-generating article. The cavity may have a length greater than or equal to 90 percent of the length of the aerosolgenerating article.

[0243] The cavity may have a length less than or equal to 95 percent of the length of the aerosolgenerating article. The cavity may have a length less than or equal to 90 percent of the length of the aerosol-generating article. The cavity may have a length less than or equal to 80 percent of the length of the aerosol-generating article. The cavity may have a length less than or equal to 70 percent of the length of the aerosol-generating article. The cavity may have a length less than or equal to 60 percent of the length of the aerosol-generating article. The cavity may have a length less than or equal to 55 percent of the length of the aerosol-generating article.

[0244] The cavity may have a length between 30 percent and 95 percent of the length of the aerosol-generating article. The cavity may have a length between 40 percent and 95 percent of the length of the aerosol-generating article. The cavity may have a length between 50 percent and 90 percent of the length of the aerosol-generating article. The cavity may have a length between 55 percent and 90 percent of the length of the aerosol-generating article. The cavity may have a length between 60 percent and 90 percent of the length of the aerosol-generating article. The cavity may have a length between 70 percent and 90 percent of the length of the aerosol-generating article. The cavity may have a length between 80 percent and 90 percent of the length of the aerosol-generating article.

[0245] The cavity may have a length greater than or equal to 14 millimetres. The cavity may have a length equal to a greater than 16 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 26 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 34 millimetres. The cavity may have a thickness greater than or equal to 38 millimetres.

[0246] The cavity may have a length less than or equal to 40 millimetres. The cavity may have a length less than or equal to 38 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 30 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 26 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.

[0247] The cavity may have a length between 14 millimetres and 40 millimetres. The cavity may have a length between 14 millimetres and 38 millimetres. The cavity may have a length between 14 millimetres and 34 millimetres. The cavity may have a length between 14 millimetres and 30 millimetres. The cavity may have a length between 16 millimetres and 30 millimetres. The cavity may have a length between 18 millimetres and 30 millimetres. The cavity may have a length between 20 millimetres and 30 millimetres. The cavity may have a length between 24 millimetres and 28 millimetres.

[0248] The cavity may have a width greater than or equal to 30 percent of the width of the aerosolgenerating article. The cavity may have a width greater than or equal to 40 percent of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 50 percent of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 60 percent of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 70 percent of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 80 percent of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 90 percent of the width of the aerosol-generating article.

[0249] The cavity may have a width less than or equal to 95 percent of the width of the aerosolgenerating article. The cavity may have a width less than or equal to 90 percent of the width of the aerosol-generating article. The cavity may have a width less than or equal to 80 percent of the width of the aerosol-generating article. The cavity may have a width less than or equal to 70 percent of the width of the aerosol-generating article. The cavity may have a width less than or equal to 60 percent of the width of the aerosol-generating article. The cavity may have a width less than or equal to 55 percent of the width of the aerosol-generating article.

[0250] The cavity may have a width between 30 percent and 95 percent of the width of the aerosolgenerating article. The cavity may have a width between 40 percent and 95 percent of the width of the aerosol-generating article. The cavity may have a width between 50 percent and 90 percent of the width of the aerosol-generating article. The cavity may have a width between 50 percent and 95 percent of the width of the aerosol-generating article. The cavity may have a width between 60 percent and 90 percent of the width of the aerosol-generating article. The cavity may have a width between 70 percent and 90 percent of the width of the aerosol-generating article. The cavity may have a width between 80 percent and 90 percent of the width of the aerosol-generating article.

[0251] 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 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 9 millimetres. The cavity may have a width greater than or equal to 11 millimetres.

[0252] The cavity may have a width less than or equal to 13 millimetres. 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 9 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. The cavity may have a width between 4.5 millimetres and 13 millimetres. The cavity may have a width between 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.

[0253] 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.

[0254] 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.

[0255] Most preferably, the cavity may have a length of 26 millimetres, a width of 8 millimetres, and a thickness of 3.1 millimetres.

[0256] The cavity may have a volume of greater than or equal to 30 cubic millimetres. The cavity may have a volume of greater than or equal to 100 cubic millimetres. The cavity may have a volume greater than or equal to 200 cubic millimetres. The cavity may have a volume greater than or equal to 300 cubic millimetres. The cavity may have a volume greater than or equal to 400 cubic millimetres. The cavity may have a volume greater than or equal to 500 cubic millimetres. The cavity may have a volume greater than or equal to 600 cubic millimetres. The cavity may have a volume greater than or equal to 700 cubic millimetres. The cavity may have a volume greater than or equal to 800 cubic millimetres. The cavity may have a volume greater than or equal to 900 cubic millimetres. The cavity may have a volume greater than or equal to 1000 cubic millimetres. The cavity may have a volume greater than or equal to 1500 cubic millimetres. The cavity may have a volume greater than or equal to 2000 cubic millimetres. The cavity may have a volume greater than or equal to 2500 cubic millimetres. The cavity may have a volume greater than or equal to 3000 cubic millimetres.

[0257] The cavity may have a volume of less than or equal to 3500 cubic millimetres. The cavity may have a volume of less than or equal to 3000 cubic millimetres. The cavity may have a volume of less than or equal to 2500 cubic millimetres. The cavity may have a volume of less than or equal to 2000 cubic millimetres. The cavity may have a volume of less than or equal to 1500 cubic millimetres. The cavity may have a volume of less than or equal to 1000 cubic millimetres. The cavity may have a volume of less than or equal to 900 cubic millimetres. The cavity may have a volume less than or equal to 800 cubic millimetres. The cavity may have a volume less than or equal to 700 cubic millimetres. The cavity may have a volume less than or equal to 600 cubic millimetres. The cavity may have a volume less than or equal to 500 cubic millimetres. The cavity may have a volume less than or equal to 400 cubic millimetres. The cavity may have a volume less than or equal to 300 cubic millimetres.

[0258] The cavity may have a volume between 30 cubic millimetres and 3000 cubic millimetres. The cavity may have a volume between 30 cubic millimetres and 3000 cubic millimetres. The cavity may have a volume between 30 cubic millimetres and 2500 cubic millimetres. The cavity may have a volume between 30 cubic millimetres and 2350 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 2000 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 1500 cubic millimetres. The cavity may have a volume between 250 cubic millimetres and 1150 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 1000 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 900 cubic millimetres. The cavity may have a volume between 200 cubic millimetres and 800 cubic millimetres. Preferably, the cavity may have a volume between 300 cubic millimetres and 700 cubic millimetres. The cavity may have a volume between 400 cubic millimetres and 700 cubic millimetres. The cavity may have a volume between 500 cubic millimetres and 700 cubic millimetres.

[0259] The cavity may have a volume greater than or equal to 1 percent of the external volume of the aerosol-generating article. The cavity may have a volume greater than or equal to 5 percent of the external volume of the aerosol-generating article. The cavity may have a volume greater than or equal to 1 percent of the external volume of the aerosol-generating article.

[0260] The cavity may have a volume less than or equal to 90 percent of the external volume of the aerosol-generating article. The cavity may have a volume less than or equal to 80 percent of the external volume of the aerosol-generating article. The cavity may have a volume less than or equal to 70 percent of the external volume of the aerosol-generating article.

[0261] The cavity may have a volume between 1 percent and 90 percent of the external volume of the aerosol-generating article. The cavity may have a volume between 5 percent and 80 percent of the external volume of the aerosol-generating article. The cavity may have a volume between 10 percent and 70 percent of the external volume of the aerosol-generating article.

[0262] The cavity may be a first cavity. The aerosol-generating article may comprise a second cavity. The second cavity may be positioned between the first external surface and the second external surface. The second cavity may have any of the features described in relation to the first cavity.

[0263] A frame may at least partially define or form the second cavity.

[0264] The frame may comprise a frame first aperture extending through the thickness of the frame. The frame first aperture may at least partially define or form the first cavity. The frame may define a frame second aperture extending through the thickness of the frame. The frame second aperture may at least partially define or form the second cavity.

[0265] The peripheral wall of the frame may comprise a frame first inner surface and a frame second inner surface. The frame first inner surface may define or form an outer wall of the first cavity. The frame second inner surface may define or form an outer wall of the second cavity.

[0266] The frame may comprise a dividing wall which separates the first cavity and the second cavity. The dividing wall may define or form an aperture. The aperture may extend from the first cavity to the second cavity. The aperture may define orform at least a portion of the airflow passage between the air inlet and the air outlet.

[0267] The outer wrapper may overlie opposing ends of the first cavity. The outer wrapper may overlie opposing ends of the second cavity. The outer wrapper may define or form opposing end walls of the first cavity. The outer wrapper may define or form opposing end walls of the second cavity. That is, the frame and the outer wrapper may collectively define the first cavity and the second cavity.

[0268] The first external layer and the second external layer may overlie opposing ends of the first cavity. The first external layer and the second external layer may overlie opposing ends of the second cavity. The first external layer and the second external layer may define or form opposing end walls of the first cavity. The first external layer and the second external layer may define or form opposing end walls of the second cavity. That is, the frame, the first external layer and the second external layer may collectively define the first cavity and the second cavity.

[0269] The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may overlie opposing ends of the first cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may overlie opposing ends of the second cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may define or form opposing end walls of the first cavity The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may define or form opposing end walls of the second cavity. That is, the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may collectively define the first cavity and the second cavity.

[0270] The aerosol-generating article comprises an aerosol-generating element, as described herein, positioned within the cavity. The aerosol-generating element may fill the cavity. Advantageously, providing an aerosol-generating element which substantially fills the cavity enables the aerosol-generating element to provide mechanical support to the first external surface and the second external surface. The provision of additional mechanical support to the first external surface and the second external surface may improve the rigidity of the aerosol-generating article.

[0271] The aerosol-generating article may comprise an aerosol-generating element positioned within the first cavity. The aerosol-generating substrate positioned within the cavity may fill the first cavity.

[0272] The aerosol-generating article may comprise an aerosol-generating element positioned within the second cavity.

[0273] The aerosol-generating element positioned within the cavity, the first cavity or the second cavity comprises an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein, providing the aerosol-generating element comprises cut filler dispersed within a solid binder matrix. For example, the aerosol-generating material may comprise shredded aerosol-generating material in a binder matrix. The aerosol-generating article may comprise additional aerosol-generating material as well as the aerosol-generating element. Additional 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.

[0274] The sheet of aerosol-generating material may extend the entire length of the cavity, the first cavity or the second cavity. The sheet of aerosol-generating material may extend the entire width of the cavity, the first cavity or the second cavity.

[0275] 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.

[0276] 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.

[0277] The plurality of parallel corrugations may be defined by a corrugation profile, in which the corrugation profile is sinusoidal, or triangular, or rectangular, or trapezoidal, or toroidal, or parabolic The plurality of parallel corrugations may be defined by a corrugation wavelength and a corrugation amplitude. The corrugation wavelength may be between 0.5 mm and 10 mm, for example between 1 mm and 10 mm, for example between 1 .5 mm and 8 mm, for example between 2 mm and 6 mm, for example between 2.5 mm and 5 mm, for example between 3 mm and 4 mm. The corrugation amplitude may be approximately the same as the thickness of the cavity.

[0278] 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 first cavity and the second cavity. The plurality of channels may be a plurality of longitudinally extending channels. That is, the plurality of channels may extend in a longitudinal direction of the aerosol-generating article. The plurality of channels may be a plurality of laterally extending channels. That is, the plurality of channels may extend in a lateral direction of the aerosol-generating article. The plurality of channels may defined, or form, at least a portion of the airflow passage extending between the air inlet and air outlet of the aerosol-generating article.

[0279] The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of greater than or equal to 0.05 milligrams per cubic millimetre. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of greater than or equal to 0.1 milligrams per cubic millimetre. The aerosol- generating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of greater than or equal to 0.15 milligrams per cubic millimetre. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of greater than or equal to 0.2 milligrams per cubic millimetre. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of greater than or equal to 0.3 milligrams per cubic millimetre. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of greater than or equal to 0.4 milligrams per cubic millimetre.

[0280] The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of less than or equal to 0.5 milligrams per cubic millimetre. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of less than or equal to 0.4 milligrams per cubic millimetre. The aerosolgenerating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of less than or equal to 0.35 milligrams per cubic millimetre. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of less than or equal to 0.3 milligrams per cubic millimetre.

[0281] The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of between 0.05 milligrams per cubic millimetre and 0.5 milligrams per cubic millimetre. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of between 0.1 milligrams per cubic millimetre and 0.4 milligrams per cubic millimetre. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of between 0.1 and 0.3 milligrams per cubic millimetre. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a bulk density of between 0.2 and 0.3 milligrams per cubic millimetre.

[0282] The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have may have a volume greater than or equal to 150 cubic millimetres. The aerosolgenerating element positioned within the cavity, the first cavity or the second cavity may have may have a volume greater than or equal to 200 cubic millimetres. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have may have a volume greater than or equal to 250 cubic millimetres. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have may have a volume greater than or equal to 350 cubic millimetres.

[0283] The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have less than or equal to 1000 cubic millimetres. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have less than or equal to 900 cubic millimetres. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have less than or equal to 800 cubic millimetres. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have less than or equal to 700 cubic millimetres.

[0284] The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a volume between 100 cubic millimetres and 1000 cubic millimetres. The aerosolgenerating element positioned within the cavity, the first cavity or the second cavity may have a volume between 200 cubic millimetres and 1000 cubic millimetres. The aerosol-generating element positioned within the cavity, the first cavity or the second cavity may have a volume between 350 cubic millimetres and 650 cubic millimetres.

[0285] Aerosol-generating substrates in aerosol-generating articles typically have a high density in order to promote heat conduction through the aerosol-generating substrate.

[0286] Advantageously, providing an aerosol-generating article with an aerosol-generating element having a relatively low density of less than or equal to 0.9 grams per cubic centimetre may allow for the aerosol-generating article to contain a reduced mass of the aerosol-generating article. A reduced mass of aerosol-generating substrate may make the aerosol-generating article more convenient to handle and easier to manufacture.

[0287] Advantageously, providing a low density aerosol-generating element in the cavity of an aerosol-generating article comprising a first planar external surface, a second planar external surface and a frame positioned between the first planar external surface and the second planar external surface may allow for efficient heating of the aerosol-generating element while still providing the advantages of a low density aerosol-generating element as described above.

[0288] Advantageously, providing an aerosol-generating article with an aerosol-generating element less than or equal to 500 milligrams may reduce the amount of structural support that needs to be provided to the aerosol-generating article.

[0289] Advantageously, providing an aerosol-generating article with an aerosol-generating element greater than or equal 50 milligrams may allow the aerosol-generating substrate to provide some structural support to the aerosol-generating article.

[0290] Advantageously, providing an aerosol-generating article with a low mass of aerosolgenerating element may result in better heating efficiency because the mass of aerosol-generating element to be heated is relatively low. A relatively low mass of aerosol-generating element is particularly advantageous during the first puff with the aerosol-generating article because the first puff can be achieved much faster than with an aerosol-generating article having a high mass of aerosol-generating element.

[0291] Advantageously, providing an aerosol-generating article with a low mass of aerosolgenerating element may reduce the total water content of the aerosol-generating element. Reducing the total water content of the aerosol-generating element may reduce the temperature of the first puff. The length of the aerosol-generating article may be defined in an x direction between a distal end and a proximal end of the aerosol-generating article. The aerosol-generating article may be divided over its length into a distal end portion and a proximal end portion. The distal end portion may extend from the distal end for 50% of the length of the aerosol-generating article and the proximal end portion may extend from the proximal end for 50% of the length of the aerosolgenerating article.

[0292] A ratio of the mass of the one or more aerosol-generating elements in the proximal end portion to the mass of the one or more aerosol-generating substrates in the distal end portion may be within a range of between 0.77 and 1 .30.

[0293] A ratio of the mass of the one or more aerosol-generating elements in the proximal end portion to the mass of the one or more aerosol-generating elements in the distal end portion may be within a range of between 0.80 and 1 .25, or between 0.83 and 1 .2, or between 0.87 and 1.15; or between 0.91 and 1.10; or between 0.95 and 1.05.

[0294] The mass distribution of the one or more aerosol-generating elements in the proximal end portion in a lengthwise direction of the proximal end portion may be symmetric with the mass distribution of the one or more aerosol-generating elements in the distal end portion in a lengthwise direction of the distal end portion, relative to a midpoint of the length of the aerosol-generating article.

[0295] The one or more aerosol-generating elements in the proximal end portion may be arranged across a width of proximal end portion in first and second halves of the width of the proximal end portion, wherein the ratio of the mass of the one or more aerosol-generating elements in the first half of the width of the proximal end portion to the mass of aerosol-forming element in the second half of the width of the proximal end portion may be within a range of between 0.77 and 1 .30, or between 0.80 and 1.25, or between 0.83 and 1.2, or between 0.87 and 1.15; or between 0.91 and 1.10; or between 0.95 and 1.05.

[0296] The one or more aerosol-generating elements in the distal end portion may be arranged across a width of distal end portion in first and second halves of the width of the distal end portion. The ratio of the mass of the one or more aerosol-generating elements in the first half of the width of the distal end portion to the mass of the one or more aerosol-generating substrates in the second half of the width of the distal end portion may be within a range of between 0.77 and 1.30, or between 0.80 and 1.25, or between 0.83 and 1.2, or between 0.87 and 1.15; or between 0.91 and 1 .10; or between 0.95 and 1.05.

[0297] The one or more aerosol-generating elements in the proximal end portion may be arranged across a height of proximal end portion in first and second halves of the height of the proximal end portion. The ratio of the mass of the one or more aerosol-generating elements in the first half of the height of the proximal end portion to the mass of the one or more aerosol-generating elements in the second half of the height of the proximal end portion may be within a range of between 0.77 and 1.30, or between 0.80 and 1.25, or between 0.83 and 1.2, or between 0.87 and 1.15; or between 0.91 and 1.10; or between 0.95 and 1.05.

[0298] The one or more aerosol-generating elements in the distal end portion may be arranged across a height of distal end portion in first and second halves of the height of the distal end portion. The ratio of the mass of the one or more aerosol-generating elements in the first half of the height of the distal end portion to the mass of the one or more aerosol-generating elements in the second half of the height of the distal end portion may be within a range of between 0.77 and 1.30, or between 0.80 and 1.25, or between 0.83 and 1.2, or between 0.87 and 1.15; or between 0.91 and 1 .10; or between 0.95 and 1.05.

[0299] The structure of the proximal end portion may be symmetric with the structure of the distal end portion, relative to a midpoint of the length of the aerosol-generating article.

[0300] The aerosol-generating article may comprise the outer wrapper and an aerosol-generating element as described herein positioned within the cavity.

[0301] The aerosol-generating article may comprise the outer wrapper, a frame, and an aerosolgenerating element as described herein positioned within the cavity.

[0302] The aerosol-generating article may comprise the outer wrapper and an additional aerosolgenerating substrate layer.

[0303] The aerosol-generating article may comprise the outer wrapper, the frame, and the additional aerosol-generating substrate layer.

[0304] The aerosol-generating article may comprise the outer wrapper, the first cavity, a second cavity and an additional aerosol-generating substrate layer. The first cavity may be empty or an aerosol-generating element as described herein may be positioned within the first cavity. The second cavity may be empty or an aerosol-generating element as described herein may be positioned within the second cavity.

[0305] The aerosol-generating article may comprise the outer wrapper, the frame, a first cavity, a second cavity and the additional aerosol-generating substrate layer. The first cavity may be empty or an aerosol-generating element as described herein may be positioned within the first cavity. The second cavity may be empty or an aerosol-generating element as described herein may be positioned within the second cavity.

[0306] The aerosol-generating article may comprise a first planar external layer, a second planar external layer, a frame, and an additional aerosol-generating substrate layer. An aerosolgenerating element as described herein is positioned within the cavity.

[0307] The aerosol generating element comprises aerosol-generating material. If present, the one or more additional aerosol-generating substrate comprises an aerosol-generating material. The, or each, 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.

[0308] 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.

[0309] The aerosol-generating element comprises aerosol-generating material in the form of cut filler. The cut filler is dispersed within a binder. The cut filler may be tobacco cut filler. The cut filler may comprise one or more of bright tobacco, dark tobacco, aromatic tobacco and filler tobacco. Examples of bright tobaccos are Flue-Cured Brazil, Indian Flue-Cured, Chinese Flue-Cured, US Flue-Cured such as Virginia tobacco, and Flue-Cured from Tanzania. Examples of aromatic tobaccos are Oriental T urkey, Greek Oriental, semi-oriental tobacco but also Fire Cured, US Burley, such as Perique, and Rustica. Examples of dark tobacco are Dark Cured Brazil Galpao, Burley Malawi or other African Burley, Sun Cured or Air Cured Indonesian Kasturi. As used herein, the term “cut filler” is used to describe 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, and homogenised plant material.

[0310] The cut filler suitable to be used with the present invention generally may resemble cut filler used for conventional smoking articles. The cut width of the cut filler preferably may be between 0.3 millimetres and 2.0 millimetres, or between 0.5 millimetres and 1 .2 millimetres, or between 0.6 millimetres and 0.9 millimetres. Preferably, the cut filler is shredded plant material having an average cut width of at least 0.75 millimetres, for example at least 0.85 millimetres. The cut filler may have an average cut width of no more than 2 millimetres, for example no more than 1 .75 millimetres, for example no more than 1.5 millimetres.

[0311] Preferably, the strands of cut filler have a length of between about 5 millimetres and 40 millimetres, for example between 10 millimetres and about 30 millimetres.

[0312] The cut filler may be, or comprise shredded tobacco. Optionally, the shredded tobacco comprises at least 50 percent by weight of shredded tobacco lamina.

[0313] The cut filler may be, or comprise, shredded non-tobacco plant material. For example, the shredded non-tobacco plant material may comprise one or more of: tea, star anise, lavender, clove, peppermint, chamomile, rosemary, eucalyptus, ginger, dill seed, thyme, oregano and cumin.

[0314] Preferably, the cut filler is soaked with an aerosol former. Soaking the cut filler can be done by spraying or by other suitable application methods. Preferably, the aerosol former in the cut filler comprises one or more of glycerol and propylene glycol. The aerosol former may consist of glycerol or propylene glycol or of a combination of glycerol and propylene glycol. The cut filler may comprise at least 15 percent by weight of aerosol former, for example at least 17 percent by weight of aerosol former, on a dry weight basis based on the total weight of the cut filler.

[0315] The aerosol-generating material may comprise homogenised plant material, preferably a homogenised tobacco material. For example, the binder phase of the aerosol-forming element may be, or comprise, homogenised plant material, such as homogenised tobacco material. That is, the aerosol-forming element bay comprise the cut filler bound together in a matrix of homogenised plant material.

[0316] The aerosol-generating element of the present disclosure may comprise one or more cannabinoid compounds selected from the group consisting of: tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannabivarin (CBV), cannabidivarin (CBDV), tetrahydrocannabivarin (THCV), cannabichromene (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), cannabicitran (CBT) and combinations thereof. Preferably, the one or more cannabinoid compounds are selected from CBD, THC and a combination thereof. Particularly preferably, the one or more cannabinoid compounds includes CBD.

[0317] As used herein, the term “homogenised plant material” encompasses any plant material formed by the agglomeration of particles of plant. For example, sheets or webs of homogenised tobacco material for the aerosol-generating substrates of the present invention may be formed by agglomerating particles of tobacco material obtained by pulverising, grinding or comminuting plant material and optionally one or more of tobacco leaf lamina and tobacco leaf stems. The homogenised plant material may be produced by casting, extrusion, paper making processes or other any other suitable processes known in the art.

[0318] The aerosol-generating element may be in the form of a sheet of aerosol-generating material, the sheet having a cut filler phase and a binder phase that holds the cut filler strips together. As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof.

[0319] The aerosol-generating element comprises a binder. For example, the aerosol-generating element may comprise about 1 to 10 wt%, preferably of about 1 to 5 wt%, of a binder such as any of common gums or pectins used in food and beverage (F&B) industries. Preferred binders may be natural pectins, such as fruit, for example citrus, or tobacco pectins; guar gums, land locust bean gums, such as hydroxyethyl and / or hydroxypropyl of those; starches, such as modified or derivatized starches; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl, celluloses; dextran; and xanthan gum. A preferable binder is guar. The binder may be a polyvinyl alcohol (PVOH).

[0320] The aerosol-generating element may additionally comprise one or more botanicals. For example, the aerosol-generating material may comprise botanicals such as Clove, Echinacea sp., Fennel, Ginger, Hawthorn berry, Elderberry, Monarda, Mullein leaves, Nettle, Plantain, Turmeric, Yarrow, and compounds of those.

[0321] The aerosol-generating element may comprise organic botanical extracts. For example, the aerosol-generating material may comprise about 1 to 15 wt%, preferably of about 2 to 7 wt%, of any of the previously referred botanicals, as well as menthol (dl-Menthol, C10H200, 2-lsopropyl- 5-methylcyclohexanol) such as obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related botanic varieties, as well as P-menthan-3-ol, as any secondary alcohol as diastereoisomers of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.

[0322] The aerosol-generating element may comprise botanical essential oils, for example about 0.5 to 5 wt%, preferably of about 1 to 3 wt%, of a botanical essential oil, for example a botanical essential oil such as of palm, coconut, and wooden-based essential oils.

[0323] The aerosol-generating element may comprise particles of a functional material, for example particles of carbon, graphite, activated carbon, or expanded graphite. Such materials may, for example, increase the thermal conductivity of the aerosol-forming material and improve efficiency of aerosol generation.

[0324] 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, if a frame is present. 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, if a frame is present. The air outlet may be defined by the peripheral wall of the frame. The outlet may extend though the peripheral wall of the frame.

[0325] 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.

[0326] The air inlet may be defined by, or through, the first frame layer, the second frame layer or the third frame layer. The air inlet may be defined by, or through, the first frame layer and the second frame layer. The air inlet may be defined by, or through, the second frame layer and the third frame layer. The air inlet may be defined by, or through, the first frame layer, the second frame layer and the third frame layer.

[0327] The air outlet may be defined by, or through, the first frame layer, the second frame layer or the third frame layer. The air outlet may be defined by, or through, the first frame layer and the second frame layer. The air outlet may be defined by, or through, the second frame layer and the third frame layer. The air outlet may be defined by, or through, the first frame layer, the second frame layer and the third frame layer. The air inlet may be defined by, and may extend through, the first 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 external layer and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the first external layer and the first aerosol-generating substrate layer.

[0328] The air inlet may be defined by, and may extend through, the second external surface. The air inlet may be defined by, and may extend through, the outer wrapper and the second aerosolgenerating substrate layer. The air inlet may be defined by, and may extend through, the second external layer and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the second external layer and the second aerosol-generating substrate layer.

[0329] The air outlet may be defined by, and may extend through, the first 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 aerosolgenerating substrate layer. The air outlet may be defined by, and may extend through, the first external layer and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the first external layer and the first aerosol-generating substrate layer.

[0330] The air outlet may be defined by, and may extend through, the second 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 external layer and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the second external layer and the second aerosol-generating substrate layer. The air inlet may have an equivalent diameter greater than or equal to 0.1 millimetres. The air inlet may have an equivalent diameter greater than or equal to 0.4 millimetres. The air inlet may have an equivalent diameter greater than or equal to 0.7 millimetres. The air inlet may have an equivalent diameter greater than or equal to 1 .0 millimetres.

[0331] The air inlet may have an equivalent diameter less than or equal to 3 millimetres. The air inlet may have an equivalent diameter less than or equal to 2.7 millimetres. The air inlet may have an equivalent diameter less than or equal to 2.4 millimetres. The air inlet may have an equivalent diameter less than or equal to 2.1 millimetres. The air inlet may have an equivalent diameter less than or equal to 1 .8 millimetres. The air inlet may have an equivalent diameter less than or equal to 1.5 millimetres.

[0332] The air inlet may have an equivalent diameter between 0.1 millimetres and 3 millimetres. The air inlet may have an equivalent diameter between 0.1 millimetres and 2.4 millimetres. The air inlet may have an equivalent diameter between 0.4 millimetres and 2.1 millimetres. The air inlet may have an equivalent diameter between 0.4 millimetres and 1.8 millimetres. The air inlet may have an equivalent diameter between 0.7 millimetres and 1 .5 millimetres. The air inlet may have an equivalent diameter between 1.0 millimetres and 1.5 millimetres.

[0333] The air outlet may have an equivalent diameter greater than or equal to 0.1 millimetres. The air outlet may have an equivalent diameter greater than or equal to 0.4 millimetres. The air outlet may have an equivalent diameter greater than or equal to 0.7 millimetres. The air outlet may have an equivalent diameter greater than or equal to 1 .0 millimetres.

[0334] The air outlet may have an equivalent diameter less than or equal to 3 millimetres. The air outlet may have an equivalent diameter less than or equal to 2.7 millimetres. The air outlet may have an equivalent diameter less than or equal to 2.4 millimetres. The air outlet may have an equivalent diameter less than or equal to 2.1 millimetres. The air outlet may have an equivalent diameter less than or equal to 1 .8 millimetres. The air outlet may have an equivalent diameter less than or equal to 1 .5 millimetres.

[0335] The air outlet may have an equivalent diameter between 0.1 millimetres and 3 millimetres. The air outlet may have an equivalent diameter between 0.1 millimetres and 2.4 millimetres. The air outlet may have an equivalent diameter between 0.4 millimetres and 2.1 millimetres. The air outlet may have an equivalent diameter between 0.4 millimetres and 1 .8 millimetres. The air outlet may have an equivalent diameter between 0.7 millimetres and 1 .5 millimetres. The air outlet may have an equivalent diameter between 1.0 millimetres and 1.5 millimetres.

[0336] 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.

[0337] The air inlet may a width of between 0.3 millimetres and 3 millimetres. The air inlet may a width of between 0.5 millimetres and 2 millimetres.

[0338] The air inlet may have a thickness of between 0.3 millimetres and 3 millimetres. The air outlet may have a thickness of between 0.5 millimetres and 2 millimetres

[0339] 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.

[0340] The air outlet may a width of between 0.3 millimetres and 3 millimetres. The air outlet may a width of between 0.5 millimetres and 2 millimetres.

[0341] The air outlet may have a thickness of between 0.3 millimetres and 3 millimetres. The air outlet may have a thickness of between 0.5 millimetres and 2 millimetres

[0342] 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.

[0343] Advantageously, an aerosol-generating article having an air inlet or an air outlet 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 good resistance to draw through the aerosol-generating article. 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.

[0344] 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.

[0345] 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.

[0346] The aerosol-generating article may comprise one or more air inlets. The aerosolgenerating 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.

[0347] The aerosol-generating article may comprise one or more air outlets. The aerosolgenerating 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.

[0348] The aerosol-generating article may comprise a filter element positioned downstream of the aerosol-generating element. 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.

[0349] The aerosol-generating article may comprise a filter element positioned upstream of the aerosol-generating element. 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.

[0350] 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.

[0351] The aerosol-generating article may comprise a front wall. The front wall may extend from the first external surface to the second external surface. That is, the front wall may extend in a transverse direction. The front wall may be a downstream wall and may be referred to as the downstream wall. The front wall may be defined by the frame, for example by the peripheral wall of the frame. The aerosol-generating article may comprise a back wall. The back wall may extend from the first external surface to the second external surface. That is, the back wall may extend in a transverse direction. The backwall may be a upstream wall and may be referred to as the upstream wall. The back wall may be defined by the frame, for example by the peripheral wall of the frame.

[0352] The aerosol-generating article may comprise one or more side walls. The one or more side walls may comprise a first side wall and a second side wall, such as a left side wall and a right side wall. The first side wall and the second side wall may oppose one another. The one or more side walls may extend from the front wall to the back wall. The one or more side walls may extend from the first external surface to the second external surface. The one or more side walls, such as the first side wall and the second side wall, may be defined by the frame, for example by the peripheral wall of the frame.

[0353] Any two or more of the front wall, the back wall, the one or more side walls may be integral with one another. Advantageously, this structure may provide a robust article which is easy to manufacture.

[0354] The aerosol-generating article may comprise a first end face. The first end face may extend from the first external surface to the second external surface. The first end face may be defined or formed by an external wall of the aerosol-generating article, such as the front wall or the back wall.

[0355] The aerosol-generating article may comprise a second end face. The second end face may extend from the first external surface to the second external surface. The second end face may be defined or formed by an external wall or surface of the aerosol-generating article, such as the front wall or the back wall. The second end face may be positioned opposite the first end face. The second end face may be parallel to the first end face.

[0356] The aerosol-generating article may comprise a first side face. The first side face may extend from the first external surface to the second external surface. The first side face may be defined or formed by an external wall of the aerosol-generating article, such as the first side wall or the second side wall. The first side face may extend from the first end face to the second end face.

[0357] The aerosol-generating article may comprise a second side face. The second side face may extend from the first external surface to the second external surface. The second side face may be defined or formed by an external wall of the aerosol-generating article, such as the first side wall or the second side wall. The second side face may extend from the first end face to the second end face. The second side face may be positioned opposite the first side face. The second side face may be parallel to the first side face.

[0358] The first end face and the first side face may form an internal angle equal to or less than 90 degrees. The first end face and the second side face may form an internal angle equal to or less than 90 degrees. The aerosol-generating article may comprise a first external corner extending from the first external surface to the second external surface. The first external corner may connect the first end face of the aerosol-generating article and the first side face of the aerosol-generating article.

[0359] The first external corner may be chamfered or rounded.

[0360] In embodiments where the first external corner is rounded, the first external corner may have a radius of curvature. The radius of curvature of the first external corner may be measured in the x / y plane. The radius of curvature of the first external corner may be between 1.25 millimetres and 6.5 millimetres.

[0361] The radius of curvature of the first external corner may be less than or equal to 50 percent of the width of the aerosol-generating article. The radius of curvature of the first external corner may be less than or equal to 30 percent of the width of the aerosol-generating article. The radius of curvature of the first external corner may be less than or equal to 20 percent of the width of the aerosol-generating article. The radius of curvature of the first external corner may be less than or equal to 10 percent of the width of the aerosol-generating article.

[0362] The radius of curvature of the first external corner may be greater than or equal to 1 percent of the width of the aerosol-generating article. The radius of curvature of the first external corner may be greater than or equal to 5 percent of the width of the aerosol-generating article. The radius of curvature of the first external corner may be greater than or equal to 10 percent of the width of the aerosol-generating article.

[0363] The radius of curvature of the first external corner may be between 1 percent and 50 percent of the width of the aerosol-generating article. The radius of curvature of the first external corner may be between 1 percent and 30 percent of the width of the aerosol-generating article. The radius of curvature of the first external corner may be between 5 percent and 30 percent of the width of the aerosol-generating article. The radius of curvature of the first external corner may be between 5 percent and 20 percent of the width of the aerosol-generating article.

[0364] In embodiments where the first external corner is chamfered, the first external corner may be chamfered at an angle between 30 degrees and 60 degrees as measured from the first end face. The first external corner may be chamfered at an angle between 40 degrees and 50 degrees as measured from the first end face. The first external corner may be chamfered at an angle of 45 degrees as measured from the first end face.

[0365] The first external corner may comprise a first corner surface connecting the first end face to the second side face. The first end face may connect to the first corner surface at a first corner transition region and, in any x / y plane, a first corner internal angle formed between a tangent of the first end face at the first corner transition region and a tangent of the first corner surface at the first corner transition region may be between 90 degrees and 180 degrees. The first corner internal angle may be between 120 degrees and 180 degrees. The first corner internal angle may be between 130 degrees and 180 degrees. The aerosol-generating article may comprise a second external corner extending from the first external surface to the second external surface. The second external corner may connect the first end face of the aerosol-generating article and the second side face of the aerosol-generating article.

[0366] The second external corner may be chamfered or rounded.

[0367] In embodiments where the second external corner is rounded, the second external corner may have a radius of curvature. The radius of curvature of the second external corner may be measured in the x / y plane. The radius of curvature of the second external corner may be between 1.25 millimetres and 6.5 millimetres.

[0368] The radius of curvature of the second external corner may be less than or equal to 50 percent of the width of the aerosol-generating article. The radius of curvature of the second external corner may be less than or equal to 30 percent of the width of the aerosol-generating article. The radius of curvature of the second external corner may be less than or equal to 20 percent of the width of the aerosol-generating article. The radius of curvature of the second external corner may be less than or equal to 10 percent of the width of the aerosol-generating article.

[0369] The radius of curvature of the second external corner may be greater than or equal to 1 percent of the width of the aerosol-generating article. The radius of curvature of the second external corner may be greater than or equal to 5 percent of the width of the aerosol-generating article. The radius of curvature of the second external corner may be greater than or equal to 10 percent of the width of the aerosol-generating article.

[0370] The radius of curvature of the second external corner may be between 1 percent and 50 percent of the width of the aerosol-generating article. The radius of curvature of the second external corner may be between 1 percent and 30 percent of the width of the aerosol-generating article. The radius of curvature of the second external corner may be between 5 percent and 30 percent of the width of the aerosol-generating article. The radius of curvature of the second external corner may be between 5 percent and 20 percent of the width of the aerosol-generating article.

[0371] In embodiments where both first external corner and the second external corner are rounded, a radius of curvature of the first external corner may be the same as a radius of curvature of the second external corner.

[0372] In embodiments where the second external corner is chamfered, the second external corner may be chamfered at an angle between 30 degrees and 60 degrees as measured from the first end face. The second external corner may be chamfered at an angle between 40 degrees and 50 degrees as measured from the first end face. The second external corner may be chamfered at an angle of 45 degrees as measured from the first end face.

[0373] The second external corner may comprise a second corner surface connecting the first end face to the second side face. The first end face may connect to the second corner surface at a second corner transition region and, in any x / y plane, a second corner internal angle formed between a tangent of the first end face at the second corner transition region and a tangent of the second corner surface at the second corner transition region may be between 90 degrees and 180 degrees. The second corner internal angle may be between 120 degrees and 180 degrees. The second corner internal angle may be between 130 degrees and 180 degrees.

[0374] The aerosol-generating article may comprise a third external corner extending from the first external surface to the second external surface. The third external corner may connect the second end face of the aerosol-generating article and the first side face of the aerosol-generating article.

[0375] The third external corner may be chamfered or rounded.

[0376] In embodiments where the third external corner is rounded, the third external corner may have a radius of curvature. The radius of curvature of the third external corner may be measured in the x / y plane. The radius of curvature of the third external corner may be between 1.25 millimetres and 6.5 millimetres.

[0377] The radius of curvature of the third external corner may be less than or equal to 50 percent of the width of the aerosol-generating article. The radius of curvature of the third external corner may be less than or equal to 30 percent of the width of the aerosol-generating article. The radius of curvature of the third external corner may be less than or equal to 20 percent of the width of the aerosol-generating article. The radius of curvature of the third external corner may be less than or equal to 10 percent of the width of the aerosol-generating article.

[0378] The radius of curvature of the third external corner may be greater than or equal to 1 percent of the width of the aerosol-generating article. The radius of curvature of the third external corner may be greater than or equal to 5 percent of the width of the aerosol-generating article. The radius of curvature of the third external corner may be greater than or equal to 10 percent of the width of the aerosol-generating article.

[0379] The radius of curvature of the third external corner may be between 1 percent and 50 percent of the width of the aerosol-generating article. The radius of curvature of the third external corner may be between 1 percent and 30 percent of the width of the aerosol-generating article. The radius of curvature of the third external corner may be between 5 percent and 30 percent of the width of the aerosol-generating article. The radius of curvature of the third external corner may be between 5 percent and 20 percent of the width of the aerosol-generating article.

[0380] In embodiments where the third external corner is chamfered, the third external corner may be chamfered at an angle between 30 degrees and 60 degrees as measured from the second end face. The third external corner may be chamfered at an angle between 40 degrees and 50 degrees as measured from the third end face. The third external corner may be chamfered at an angle of 45 degrees as measured from the third end face.

[0381] The aerosol-generating article may comprise a fourth external corner extending from the first external surface to the second external surface. The fourth external corner may connect the second end face of the aerosol-generating article and the second side face of the aerosolgenerating article.

[0382] The fourth external corner may be chamfered or rounded.

[0383] In embodiments where the fourth external corner is rounded, the fourth external corner may have a radius of curvature. The radius of curvature of the fourth external corner may be measured in the x / y plane. The radius of curvature of the fourth external corner may be between 1.25 millimetres and 6.5 millimetres.

[0384] The radius of curvature of the fourth external corner may be less than or equal to 50 percent of the width of the aerosol-generating article. The radius of curvature of the fourth external corner may be less than or equal to 30 percent of the width of the aerosol-generating article. The radius of curvature of the fourth external corner may be less than or equal to 20 percent of the width of the aerosol-generating article. The radius of curvature of the fourth external corner may be less than or equal to 10 percent of the width of the aerosol-generating article.

[0385] The radius of curvature of the fourth external corner may be greater than or equal to 1 percent of the width of the aerosol-generating article. The radius of curvature of the fourth external corner may be greater than or equal to 5 percent of the width of the aerosol-generating article. The radius of curvature of the fourth external corner may be greater than or equal to 10 percent of the width of the aerosol-generating article.

[0386] The radius of curvature of the fourth external corner may be between 1 percent and 50 percent of the width of the aerosol-generating article. The radius of curvature of the fourth external corner may be between 1 percent and 30 percent of the width of the aerosol-generating article. The radius of curvature of the fourth external corner may be between 5 percent and 30 percent of the width of the aerosol-generating article. The radius of curvature of the fourth external corner may be between 5 percent and 20 percent of the width of the aerosol-generating article.

[0387] In embodiments where the fourth external corner is chamfered, the fourth external corner may be chamfered at an angle between 30 degrees and 60 degrees as measured from the second end face. The fourth external corner may be chamfered at an angle between 40 degrees and 50 degrees as measured from the third end face. The fourth external corner may be chamfered at an angle of 45 degrees as measured from the third end face.

[0388] Advantageously, providing an aerosol-generating article having at least one external corner extending from the first external surface to the second external surface that is rounded or chamfered may make the aerosol-generating article easier to insert into an aerosol-generating device.

[0389] Advantageously, providing an aerosol-generating article having at least one external corner extending from the first external surface to the second external surface that is rounded or chamfered may make the aerosol-generating article less susceptible to damage, particularly during insertion of the aerosol-generating article into an aerosol-generating device. Advantageously, providing an aerosol-generating article having at least one external corner extending from the first external surface to the second external surface that is rounded or chamfered may make the aerosol-generating article easier to manufacture.

[0390] 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. 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 3:1. A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be greater than 4:1. A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosolgenerating article may be greater than 5:1. A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be greater than 10:1. A ratio between the length and the thickness of the aerosolgenerating article, and between the width and the thickness of the aerosol-generating article may be greater than 12:1. A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be greater than 15:1.

[0391] 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. 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 12:1. A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be less than 10:1 . A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be less than 5: 1 . A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be less than 4:1. A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be less than 3: 1 . A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article is less than 2.5:1.

[0392] 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. 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 12:1. A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be between 2:1 and 10:1. A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol- generating article may be between 3:1 and 10:1. A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be between 4:1 and 10:1. A ratio between the length and the thickness of the aerosolgenerating article, and between the width and the thickness of the aerosol-generating article may be between 5:1 and 10:1.

[0393] A ratio between the length and the width of the aerosol-generating article may be greater than 1 : 1 . A ratio between the length and the width of the aerosol-generating article may be greater than 1.25:1. A ratio between the length and the width of the aerosol-generating article may be greater than 1.5:1. A ratio between the length and the width of the aerosol-generating article may be greater than 2:1. A ratio between the length and the width of the aerosol-generating article may be greater than 2.5:1 . A ratio between the length and the width of the aerosol-generating article may be greater than 3:1. A ratio between the length and the width of the aerosol-generating article may be greater than 4:1. A ratio between the length and the width of the aerosol-generating article may be greater than 5:1 .

[0394] A ratio between the length and the width of the aerosol-generating article may be less than 10:1. A ratio between the length and the width of the aerosol-generating article may be less than

[0395] 8:1. A ratio between the length and the width of the aerosol-generating article may be less than

[0396] 5:1. A ratio between the length and the width of the aerosol-generating article may be less than

[0397] 4:1. A ratio between the length and the width of the aerosol-generating article may be less than

[0398] 3.5:1. A ratio between the length and the width of the aerosol-generating article may be less than 3:1. A ratio between the length and the width of the aerosol-generating article may be less than 2.5:1. A ratio between the length and the width of the aerosol-generating article may be less than 2:1.

[0399] A ratio between the length and the width of the aerosol-generating article may be between 1 :1 and 10:1. A ratio between the length and the width of the aerosol-generating article may be between 1.5:1 and 5:1. A ratio between the length and the width of the aerosol-generating article may be between 1.5:1 and 4: 1 . A ratio between the length and the width of the aerosol-generating article may be between 1.5:1 and 3:1. A ratio between the length and the width of the aerosolgenerating article may be between 2:1 and 4:1. A ratio between the length and the width of the aerosol-generating article may be between 2:1 and 3:1.

[0400] The aerosol-generating article may have a length greater than or equal to 15 millimetres. The aerosol-generating article may have a length greater than or equal to 20 millimetres. The aerosol-generating article may have a length greater than or equal to 25 millimetres. The aerosolgenerating article may have a length greater than or equal to 30 millimetres. The aerosolgenerating article may have a length greater than or equal to 35 millimetres. The aerosolgenerating article may have a length greater than or equal to 40 millimetres. The aerosol-generating article may have a length less than or equal to 45 millimetres. The aerosol-generating article may have a length less than or equal to 40 millimetres. The aerosolgenerating article may have a length less than or equal to 35 millimetres. The aerosol-generating article may have a length less than or equal to 30 millimetres.

[0401] The aerosol-generating article may have a length between 15 millimetres and 45 millimetres. The aerosol-generating article may have a length between 20 millimetres and 40 millimetres. The aerosol-generating article may have a length between 20 millimetres and 35 millimetres. The aerosol-generating article may have a length between 25 millimetres and 30 millimetres.

[0402] The aerosol-generating article may have a width equal to greater than 3 millimetres. The aerosol-generating article may have a width greater than or equal to 5 millimetres. The aerosolgenerating article may have a width greater than or equal to 7.5 millimetres. The aerosolgenerating article may have a width greater than or equal to 9 millimetres. The aerosol-generating article may have a width greater than or equal to 11 millimetres. The aerosol-generating article may have a width greater than or equal to 13 millimetres.

[0403] The aerosol-generating article may have a width less than or equal to or equal to 17 millimetres. The aerosol-generating article may have a width less than or equal to 15 millimetres. The aerosol-generating article may have a width less than or equal to 12.5 millimetres. The aerosol-generating article may have a width less than or equal to 11 millimetres. The aerosolgenerating article may have a width less than or equal to 9 millimetres.

[0404] The aerosol-generating article may have a width between 3 millimetres and 17 millimetres. The aerosol-generating article may have a width between 5 millimetres and 15 millimetres. The aerosol-generating article may have a width between 7.5 millimetres and 12.5 millimetres. The aerosol-generating article may have a width between 9 millimetres and 11 millimetres.

[0405] The aerosol-generating article may have a thickness equal to greater than 1 millimetre. The aerosol-generating article may have a thickness greater than or equal to 1.5 millimetres. The aerosol-generating article may have a thickness greater than or equal to 2 millimetres. The aerosolgenerating article may have a thickness greater than or equal to 2.5 millimetres. The aerosolgenerating article may have a thickness greater than or equal to 3 millimetres. The aerosolgenerating article may have a thickness greater than or equal to 3.5 millimetres. The aerosolgenerating article may have a thickness greater than or equal to 4 millimetres. The aerosolgenerating article may have a thickness greater than or equal to 4.5 millimetres.

[0406] The aerosol-generating article may have a thickness less than or equal to 5.5 millimetres. The aerosol-generating article may have a thickness less than or equal to 5 millimetres. The aerosol-generating article may have a thickness less than or equal to 4.5 millimetres. The aerosolgenerating article may have a thickness less than or equal to 4 millimetres. The aerosol-generating article may have a thickness less than or equal to 3.5 millimetres. The aerosol-generating article may have a thickness less than or equal to 3 millimetres. The aerosol-generating article may have a thickness less than 2.5 millimetres. The aerosol-generating article may have a thickness less than 2 millimetres.

[0407] The aerosol-generating article may have a thickness between 1 millimetres and 5 millimetres. The aerosol-generating article may have a thickness between 1.5 millimetres and 5 millimetres. The aerosol-generating article may have a thickness between 2 millimetres and 4.5 millimetres. The aerosol-generating article may have a thickness between 2.5 millimetres and 4 millimetres. The aerosol-generating article may have a thickness between 3 millimetres and 3.5 millimetres.

[0408] The aerosol-generating article may have a length between 15 millimetres and 45 millimetres, a width between 5 millimetres and 15 millimetres, and a thickness between 1 millimetres and 5 millimetres.

[0409] Preferably, the aerosol-generating article may have a length between 20 millimetres and 30 millimetres, a width between 7.5 millimetres and 12.5 millimetres, and a thickness between 2.5 millimetres and 4 millimetres.

[0410] More preferably, the aerosol-generating article may have a length of 30 millimetres, a width of 10 millimetres and a thickness of 3.1 millimetres.

[0411] Advantageously, providing an aerosol-generating article having a length of between 15 millimetres and 45 millimetres, a width of between 5 millimetres and 15 millimetres, and a thickness of between 1 millimetre and 5 millimetres may result in an aerosol-generating article that has a high ratio of external surface to volume. An aerosol-generating article having a high ratio of external surface to volume may be more efficiently heated, which may result in better vaporisation of an aerosol-generating substrate stored within the aerosol-generating article. Better vaporisation of an aerosol-generating substrate stored within the aerosol-generating article may lead to an improved user experience.

[0412] Advantageously, providing an aerosol-generating article having a length of between 15 millimetres and 45 millimetres, a width of between 5 millimetres and 15 millimetres, and a thickness of between 1 millimetre and 5 millimetres, with a cavity having a length of between 14 millimetres and 40 millimetres, a width of between 4.5 millimetres and 13 millimetres, and a thickness of between 0.5 millimetres and 4.5 millimetres, may result in the aerosol-generating article containing a large cavity and having a high cavity volume in proportion to external volume of the aerosolgenerating article.

[0413] The aerosol-generating article may have an external volume of between 75 cubic millimetres and 3375 cubic millimetres. The aerosol-generating article may have an external volume of between 375 cubic millimetres and 1750 cubic millimetres.

[0414] The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 20 millimetre H2O. The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 10 millimetre H2O. The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 8 millimetre H2O. The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 6 millimetre H2O. The aerosol-generating article may have a resistance to draw (RTD) of less than or equal to 4 millimetre H2O. The aerosolgenerating article may have a resistance to draw (RTD) of less than or equal to 2 millimetre H2O. The aerosol-generating article may have a resistance to draw (RTD) equal to, or close to, zero millimetres H2O.

[0415] The aerosol-generating article may have a resistance to draw (RTD) between 0 millimetres H2O and 9.9 millimetres H2O. The aerosol-generating article may have a resistance to draw (RTD) between 1 millimetre H2O and 8 millimetres H2O. The aerosol-generating article may have a resistance to draw (RTD) between 2 millimetres H2O and 6 millimetres H2O. The aerosolgenerating article may have a resistance to draw (RTD) between 3 millimetres H2O and 5 millimetres H2O.

[0416] Unless otherwise specified, the resistance to draw (RTD) is measured in accordance with ISO 6565-2015. The RTD refers to the pressure required to force air through the aerosolgenerating article between the air inlet and the air outlet. The terms “pressure drop” or “draw resistance” of a component or article may also refer to the “resistance to draw”. Such terms generally refer to the measurements in accordance with ISO 6565-2015 are normally carried out at under test at a volumetric flow rate of about 17.5 millilitres per second at the output or downstream end of the measured component at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr) and a relative humidity of about 60%.

[0417] According to the present disclosure, there may be provided a method of manufacturing a preferred example of an aerosol-generating article as described herein, the preferred example comprising a frame. The method comprises providing sheet material comprising: a first sheet of frame material, a second sheet of frame material, a third sheet of frame material, a first sheet of external layer material, and a second sheet of external layer material. The method may comprise bonding the first sheet of frame material, the second sheet of frame material and the third sheet of frame material to one another. The method comprises forming an aperture through the first sheet of frame material, the second sheet of frame material and the third sheet of frame material, for example after they have been bonded. The aperture forms a cavity. The method comprises positioning the first, second, and third sheets of frame material, between the first sheet of external layer material and the second sheet of external layer material, with a portion of an aerosolgenerating element as described herein located within the aperture. The method comprises bonding the sheet material to one another. The resulting article includes the aerosol-generating element within a cavity of the article. One or more of the first sheet of frame material, the second sheet of frame material, the third sheet of frame material in the methods of manufacturing described herein may be a sheet of paper or cardboard.

[0418] One or more of the first sheet of external layer material and the second sheet of external layer material in the methods of manufacturing described herein may be a sheet of cigarette paper.

[0419] 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 the aerosol-generating element to form an aerosol, for example an inhalable aerosol.

[0420] The cavity of the aerosol-generating device may comprise an opening into which an end, such as a longitudinal end, of the aerosol-generating article can be inserted. The cavity of the aerosol-generating device may have any suitable cross-sectional shape. For example, the cavity of the aerosol-generating device may have a rectangular transverse cross-section, for example a rectangular cross-section having opposing top and bottom sides that are greater in length than left and right sides.

[0421] Preferably, at least one internal surface of the cavity of the aerosol-generating device is a heating surface configured to heat the aerosol-generating article. The heating surface may comprise a heater, for example a resistance heater, or an infra-red heater, or a susceptor configured to be heated by engagement with an inductor. The heating surface may comprise an inductor, for example the surface may comprise a coil arranged to generate a fluctuating electromagnetic field within a space of the cavity of the aerosol-generating device. The heating surface may be a surface that is permeable to a fluctuating electromagnetic field, such that an inductor arranged outside the cavity can project a fluctuating electromagnetic field through the heating surface to engage with a susceptor arranged within the cavity of the aerosol-generating device.

[0422] Preferably, at least a lower surface of the cavity of the aerosol-generating device is a heating surface configured to heat an aerosol-generating article. Optionally, both the lower and an upper surface of the cavity of the aerosol-generating device are heating surfaces configured to heat an aerosol-generating article.

[0423] Preferably, at least a lower internal surface of the cavity of the aerosol-generating device is a substantially planar surface, preferably in which both lower and upper internal surfaces of the cavity of the aerosol-generating device are substantially planar. Preferably, upper and lower internal surfaces of the cavity of the aerosol-generating device are arranged in parallel relationship to one another. Optionally, upper and lower internal surfaces may converge along a length of the cavity of the aerosol-generating device such that they are slightly closer spaced at a distal end of the cavity than at a proximal end of the cavity. This may allow the cavity of the aerosol-generating device to grip an aerosol-generating article inserted therein. Side internals surfaces may converge in a similar manner to achieve the result of gripping an aerosol-generating article. The upper and lower internal surfaces of the cavity of the aerosol-generating device, and / or opposing side surfaces of the cavity of the aerosol-generating device, may converge by between 1 degree and 10 degrees between the proximal end of the cavity and the distal end of the cavity, for example between 2 and 8 degrees, for example between 3 and 6 degree, for example between 4 and 5 degrees.

[0424] In some example, the lower internal surface and the upper internal surface may be movable relative to each other. For example, the lower internal surface and the upper internal surface may be configured to pivot relative to one another, or to move upward and downward relative to one another. This may allow an aerosol-generating article to be easily inserted into the cavity of the aerosol-generating device, while allowing the cavity walls of the aerosol-generating device to move to retain the substrate or article in position to be heated. For example, relative movement of upper and lower internal surfaces may result in an aerosol-generating article being gripped between the two surfaces to facilitate heating of the article and to help position the article appropriately within the device.

[0425] The cavity of the aerosol-generating device may be defined by a longitudinal dimension or length, a transverse dimension or width, and a depth dimension or height. The length and width are preferably greater in magnitude than the height, for example at least twice the magnitude of the height.

[0426] The aerosol-generating device may comprise a heating surface comprising a plurality of separately operable heating zones, for example two separately operable heating zones, or three separately operable heating zones, or four separately operable heating zones, or five separately operable heating zones, or six separately operable heating zones. The plurality of separably operable heating zones may be configured to be operated individually, or in any combination of two or more zones at once. In some examples, the plurality of separably operable heating zones may be longitudinally spaced within the cavity. In some example, the plurality of separably operable heating zones may be transversely spaced within the cavity. Different heating zones may be both transversely and longitudinally spaced from one another. Different heating zones may be arranged concentrically relative to one another.

[0427] The aerosol-generating device may comprise one or more resistance heaters, for example one or more resistance heaters integrated into walls of the cavity.

[0428] The device may comprises one or more inductors, for example one or more inductors integrated into walls of the cavity of the aerosol-generating device, or arranged to generate a fluctuating electromagnetic field in walls of the cavity of the aerosol-generating device, or within the cavity of the aerosol-generating device. One or more walls of the cavity of the aerosolgenerating device comprise or consist of susceptor material, such that the one or more walls of the cavity heat up on engagement with a fluctuating electromagnetic field, thereby heating an aerosol-generating article inserted within the cavity.

[0429] The aerosol-generating device may comprise one or more insertable heating elements arranged to project into the cavity of the aerosol-generating device for insertion into an aerosolgenerating article. The insertable heating elements may be resistance heaters. The insertable heating elements may be susceptors.

[0430] The aerosol-generating device may comprise a device body. The device body may comprise the heater. The aerosol-generating device may comprise a mouthpiece element. The device body may comprise a device body housing. The device body housing may define the cavity for receiving at least a portion of the aerosol-generating article. The device body and the mouthpiece element may be releasably connectable. The mouthpiece element may be releasably connectable with the device body, for example the device body housing.

[0431] The mouthpiece element may be releasably connectable with the device body, for example the device body housing, between a connected position and a disconnected position. In the connected position, the cavity of the aerosol-generating device may be at least partially covered, for example by the mouthpiece element. In the disconnected position, the cavity of the aerosolgenerating device may be at least partially exposed, for example so as to allow insertion of the article into the cavity of the aerosol-generating device. The mouthpiece element may be moveable, for example pivotable about a hinge, relative to the device body, for example between a first position and a second position. In the first position, the cavity of the aerosol-generating device may be at least partially covered, for example by the mouthpiece element. In the second position, the cavity may be at least partially exposed, for example so as to allow insertion of the article into the cavity of the aerosol-generating device. Advantageously, covering the cavity of the aerosolgenerating device, or the article in the cavity of the aerosol-generating device, may ensure most aerosol from the article travels along the desired flow path to the user, rather than escaping to the external environment.

[0432] The aerosol-generating device, for example the device body, may comprise a power source such as a battery. In use, the power source may provide power to the heater. The device, for example the device body, may comprise a controller. The controller may be configured to control power from the power supply to the heater.

[0433] The device body may comprise a distal end and a proximal end. The cavity of the aerosolgenerating device may be defined at the proximal end of the device body. The mouthpiece element may comprise a distal end and a proximal end. The distal end of the mouthpiece element may be configured to releasably connect to the proximal end of the device body. The mouthpiece element, or at least a portion of the mouthpiece element, may be configured to be inserted into a mouth of a user. The proximal end of the mouthpiece element may be configured to be inserted into a mouth of a user.

[0434] The aerosol-generating device, for example one or both of the device body and the mouthpiece element, may comprise an air inlet. The device, for example the mouthpiece element, may comprise an air outlet. The device may comprise an air flow path fluidly connecting the air inlet to the air outlet. The air flow path may extend one or both of through and past the cavity of the aerosol-generating device. As such, in use, the device may be configured such that, when a negative pressure is applied to the air outlet, for example by a user drawing on the air outlet, air is drawn in through the air inlet, then past or through an aerosol-generating article received in the cavity, thereby entraining aerosol released from the aerosol-forming substrate of the article, then out through the air outlet.

[0435] 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.

[0436] As used herein, the term “aerosol-generating article” refers to an article comprising an aerosol-generating substrate. At least a portion of the aerosol-forming substrate is in the form of an aerosol-generating element located within the article. The article may be heated in use to produce and deliver an inhalable aerosol to a consumer.

[0437] 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.

[0438] 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.

[0439] 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.

[0440] As used herein, the term “transverse” refers to a direction extending between the first planar external surface and the second planar external surface.

[0441] 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. 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.

[0442] 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.

[0443] 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.

[0444] 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.

[0445] 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.

[0446] 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.

[0447] 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.

[0448] As used herein, the term “aerosol former content” may refer to aerosol former content in percent on a dry weight basis, unless otherwise specified.

[0449] 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.

[0450] 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.

[0451] As used herein, the term “equivalent diameter” of an opening or an aperture is used herein to denote the diameter of a circular opening or aperture having the same cross-sectional area as the opening or aperture.

[0452] As used herein, the term “packing density” refers to a ratio of the total volume of the components, such as solid and liquid components, of an aerosol-generating substrate positioned within the cavity, the first cavity or the second cavity to the volume of the cavity that the aerosolgenerating substrate is positioned within. 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.

[0453] Ex1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosolgenerating article comprising: a first external surface and a second external surface facing in substantially the opposite direction to the first external surface; a cavity located within the aerosol-generating article between the first external surface and the second external surface; and an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity, wherein an aerosol-generating element is located within the cavity, the aerosol-generating element being defined by an element length, an element width, and an element thickness, the element width being greater than the element thickness, in which the aerosol-generating element comprises cut filler dispersed within a solid binder matrix.

[0454] Ex2. An aerosol-generating article according to Ex1 in which the cavity is defined by internal dimensions, the internal dimensions being a cavity length, a cavity width, and a cavity height, the cavity width being greater than the cavity height.

[0455] Ex3. An aerosol-generating article according to any preceding example in which the aerosol-generating element is a porous aerosol-generating element.

[0456] Ex4. An aerosol-generating article according to any preceding example in which the solid binder matrix comprises at least one binder.

[0457] Ex5. An aerosol-generating article according to any preceding example in which the aerosol-generating element comprises at least 1 percent by weight of binder on a dry weight basis.

[0458] Ex6. An aerosol-generating article according to any preceding example in which the cut filler comprises shredded plant material impregnated with an aerosol former.

[0459] Ex7. An aerosol-generating article according to any preceding example in which the cut filler an average cut width of at least 0.75 millimetres.

[0460] Ex8. An aerosol-generating article according to any preceding example in which the aerosol-generating element comprises at least 10 percent by weight of aerosol former on a dry weight basis.

[0461] Ex9. An aerosol-generating article according to any preceding example in which the aerosol-generating element has a density of less than 420 mg per cubic centimetre.

[0462] Ex10. An aerosol-generating article according to any preceding example in which the article length extends in an x — direction, the article width extends in a y-direction, and the article thickness extends in a z-direction, in which the element length, element width, and element thickness of the aerosol-generating element located within the cavity extend in the x-direction, y- direction, and z-direction respectively.

[0463] Ex11. An aerosol-generating article according to Ex10 in which the cavity is defined by internal dimensions, the internal dimensions being a cavity length, a cavity width, and a cavity height, the cavity width being greater than the cavity height, in which in which the cavity length, cavity width, and cavity height extend in the x-direction, y-direction, and z-direction respectively.

[0464] Ex12. An aerosol-generating article according to any preceding example in which the aerosol-generating element comprises an aerosol-former, for example an aerosol former selected from the list consisting of glycerine and propylene glycol, for example in which the aerosolgenerating element has an aerosol-former content of greater than 20 wt % on a dry weight basis, for example greater than 25 wt %, or greater than 30 wt %, for example greater than 35 wt %.

[0465] Ex13. An aerosol-generating article according to any preceding example in which the aerosol-generating element comprises one or more flavour compounds.

[0466] Ex14. An aerosol-generating article according to any proceeding example in which the aerosol-generating element is formed by a process comprising steps of compressing shreds of cut filler, for example compressing shreds of cut filler tobacco with a binder.

[0467] Ex15. An aerosol-generating article according to any preceding example in which the cavity comprises between 50 mg and 300 mg of the aerosol-generating element, for example between 100 mg and 200 mg, for example between 125 mg and 175 mg, for example between 140 mg and 160 mg, for example about 140 mg, or about 150 mg or about 160 mg.

[0468] Ex16. An aerosol-generating article according to any preceding example in which the aerosol-generating element has a length of between 10 mm and 25 mm, for example between 15 mm and 20 mm, for example about 15 mm or about 17 mm, or about 20 mm.

[0469] Ex17. An aerosol-generating article according to any preceding example in which the aerosol-generating element has a width of between 5 mm and 15 mm, for example between 6 mm and 10 mm, for example between 7 mm and 8 mm, for example about 6 mm or about 7 mm, or about 8 mm.

[0470] Ex18. An aerosol-generating article according to any preceding example in which the aerosol-generating element has a thickness of between 1 mm and 5 mm, for example between 1 .5 mm and 4 mm, for example between 2 mm and 3 mm, for example about 2.5 mm or about 3 mm, or about 3.5 mm.

[0471] Ex18A. An aerosol-generating article according to any preceding example in which a surface of the aerosol-generating element is textured, for example textured by one or more grooves or channels, for example in which an upper and / or lower surface of the aerosol-generating element defines one or more grooves or channels. Ex18B. An aerosol-generating article according to Ex18A in which the textured surface facilitated air flow over the surface of the aerosol-generating element, for example in which the one or more grooves or channels defines an air flow path within the aerosol-generating article.

[0472] Ex19. An aerosol-generating article according to any preceding example in which the cavity contains a single unitary portion of the aerosol-generating element.

[0473] Ex20. An aerosol-generating article according to any of Ex1 to Ex19 in which the cavity contains more than one aerosol-generating element.

[0474] Ex21. An aerosol-generating article according to any preceding example comprising a frame positioned between the first external surface and the second external surface, the frame at least partially defining the cavity, for example in which side walls of the cavity are at least partially defined by the frame.

[0475] Ex22. An aerosol-generating article according to any preceding example in which at least one of the first external surface and second external surface is a substantially planar surface, for example in which the first external surface is a substantially planar surface, for example in which both the first external surface and the second external surface are substantially planar surfaces.

[0476] Ex23. An aerosol-generating article according to any preceding example, wherein the cavity has a width between 30 percent and 95 percent of the article width.

[0477] Ex24. An aerosol-generating article according to any preceding example, wherein the cavity has a length between 30 percent and 95 percent of the article length.

[0478] Ex25. An aerosol-generating article according to any preceding example, wherein the cavity has a height or thickness of between 30 percent and 95 percent of the article thickness.

[0479] Ex26.An aerosol-generating article according to any preceding example, wherein the cavity has 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.

[0480] Ex27. An aerosol-generating article according to any preceding example, wherein the cavity has 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.

[0481] Ex28. An aerosol-generating article according to any preceding example, wherein the article thickness is less than 50 percent of both article length and article width.

[0482] Ex29. An aerosol-generating article according to any of Ex21 , and any example depending on Ex21 , wherein the frame comprises a peripheral wall circumscribing or encircling the cavity.

[0483] Ex30. An aerosol-generating article according to Ex29, wherein the peripheral wall is formed by a frame inner surface and a frame outer surface, and wherein the frame inner surface defines a cavity outer wall and the frame outer surface at least partially defines one or more external walls of the aerosol-generating article.

[0484] Ex31 . An aerosol-generating article according to Ex29 or Ex30, wherein the peripheral wall has a radial thickness between 1 millimetre and 3 millimetres. Ex32. An aerosol-generating article according to any of Ex29 to Ex31 , wherein the frame has a thickness greater than or equal to 80 percent of the article thickness.

[0485] Ex33. An aerosol-generating article according to any of Ex29 to Ex32, wherein the frame has a thickness between 80 percent and 95 percent of the article thickness.

[0486] Ex34. An aerosol-generating article according to any of Ex29 to Ex33, wherein the frame has a thickness between 1 millimetre and 5.5 millimetres.

[0487] Ex35. An aerosol-generating article according to any of Ex29 to Ex34, wherein the frame comprises a cellulosic material.

[0488] Ex36. An aerosol-generating article according to Ex35, wherein the cellulosic material has a grammage between 300 grams per square metre and 900 grams per square metre.

[0489] Ex37. An aerosol-generating article according to Ex35 or Ex36, wherein the cellulosic material is paper, paperboard, or cardboard.

[0490] Ex38. An aerosol-generating article according to any of Ex29 to Ex37, wherein the frame is a unitary component.

[0491] Ex39. An aerosol-generating article according to any of Ex29 to Ex38, wherein the frame comprises a first frame layer and a second frame layer.

[0492] Ex40. An aerosol-generating article according to Ex39, wherein the first frame layer is bonded to the second frame layer with an adhesive.

[0493] Ex41. An aerosol-generating article according to Ex39 or Ex40, wherein the frame comprises a third frame layer.

[0494] Ex42. An aerosol-generating article according to Ex41 , wherein the second frame layer is positioned between the first frame layer and the third frame layer.

[0495] Ex43. An aerosol-generating article according to Ex41 or Ex42, wherein the second frame layer is bonded to the third frame layer with an adhesive.

[0496] Ex44. An aerosol-generating article according to any of Ex29 to Ex43, comprising one or more aerosol-forming substrates, wherein the one or more aerosol-generating substrates comprise a first aerosol-generating substrate layer positioned between the first planar external surface and the frame, and / or a second aerosol-generating substrate layer positioned between the second planar external surface and the frame.

[0497] Ex45. An aerosol-generating article according to Ex44, wherein one or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer comprises an aerosol-generating material in the form of a sheet of aerosol-generating material.

[0498] Ex46. An aerosol-generating article according to Ex45, wherein the sheet of aerosolgenerating material is a sheet of homogenised tobacco material.

[0499] Ex47. An aerosol-generating article according to Ex45 or Ex46, wherein the sheet of aerosol-generating material comprises one or more aerosol-formers, such as one or both of glycerine and propylene glycol. Ex48. An aerosol-generating article according to any one of Ex45 to Ex47, wherein the first aerosol-generating substrate layer and the second aerosol-generating substrate layer define opposing end walls of the cavity.

[0500] Ex49. An aerosol-generating article according to any one of Ex44 to Ex48, wherein one or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer has a thickness between 100 micrometres and 600 micrometres.

[0501] Ex50. An aerosol-generating article according to any one of Ex44 to Ex49, wherein one or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer has a length substantially the same as the length of the aerosol-generating article.

[0502] Ex51 . An aerosol-generating article according to any one of Ex44 to Ex50, wherein one or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer has a width substantially the same as the width of the aerosol-generating article.

[0503] Ex52. An aerosol-generating article according to any preceding example comprising an outer wrapper defining the first planar external surface and the second planar external surface.

[0504] Ex53. An aerosol-generating article according to any one of Ex1 to Ex52 comprising a first planar external layer and a second planar external layer, wherein the first planar external layer defines the first planar external surface and the second planar external layer defines the second planar external surface.

[0505] Ex54. An aerosol-generating article according to Ex53, wherein the first planar external layer and the second planar external layer overlie opposing ends of the cavity.

[0506] Ex55. An aerosol-generating article according to Ex53 or Ex54, wherein one or both of the first planar external layer and the second planar external layer comprise a cellulosic material.

[0507] Ex56. An aerosol-generating article according to Ex55, wherein the cellulosic material is paper or cardboard.

[0508] Ex57. An aerosol-generating article according to any one of Ex53 to Ex56, wherein one or both of the first planar external layer and the second planar external layer has a length substantially the same as the length of the aerosol-generating article.

[0509] Ex58. An aerosol-generating article according to any one of Ex53 to Ex57, wherein one or both of the first planar external layer and the second planar external layer has a width substantially the same as the width of the aerosol-generating article.

[0510] Ex59. An aerosol-generating article according to any one of Ex29 to Ex58, wherein the air inlet is defined by the frame.

[0511] Ex60. An aerosol-generating article according to any preceding example, wherein the air inlet has an equivalent diameter between 0.1 millimetres and 3 millimetres.

[0512] Ex61. An aerosol-generating article according to any preceding example, wherein the air inlet has a width of between 0.3 millimetres and 3 millimetres. Ex62. An aerosol-generating article according to any preceding example, wherein the air inlet has a thickness of between 0.3 millimetres and 3 millimetres.

[0513] Ex63. An aerosol-generating article according to any one of Ex29 to Ex62, wherein the air outlet is defined by the frame.

[0514] Ex64. An aerosol-generating article according to any preceding example, wherein the air outlet has an equivalent diameter between 0.1 millimetres and 3 millimetres.

[0515] Ex65. An aerosol-generating article according to any preceding example, wherein the air outlet has a width of between 0.3 millimetres and 3 millimetres.

[0516] Ex66. An aerosol-generating article according to any preceding example, wherein the air outlet has a thickness of between 0.3 millimetres and 3 millimetres.

[0517] Ex67. An aerosol-generating article according to any preceding example, wherein a ratio between the article length and the article thickness, and between the article width and the article thickness, is between 2:1 and 15:1.

[0518] Ex68. An aerosol-generating article according to any preceding example, wherein a ratio between the article length and the article width is between 1 :1 and 10:1.

[0519] Ex69. An aerosol-generating article according to any preceding example, wherein the article length is between 15 millimetres and 45 millimetres, for example between 25 millimetres and 30 millimetres.

[0520] Ex70. An aerosol-generating article according to any preceding example, wherein the article width is between 3 millimetres and 17 millimetres, for example between 9 millimetres and 11 millimetres.

[0521] Ex71. An aerosol-generating article according to any preceding example, wherein the article thickness is between 1 millimetres and 5.5 millimetres, for example between 3 millimetres and 3.5 millimetres.

[0522] Ex72. An aerosol-generating article according to any preceding example, wherein the aerosol-generating article has resistance to draw between 0 millimetres H2O and 9.9 millimetres H2O, for example in which the air flow path has a resistance to draw between 0 millimetres H2O and 9.9 millimetres H2O.

[0523] Ex73. An aerosol-generating article according to any preceding example, wherein the total volume of aerosol-generating element within the cavity is between 50% and 95 % of the volume of the cavity, for example between 60% and 90% of the volume of the cavity, for example between 70% and 85% of the volume of the cavity.

[0524] Ex74. An aerosol-generating article according to any preceding example, wherein the cut filler is shredded plant material having an average cut width of at least 0.85 millimetres. Ex75. An aerosol-generating article according to any preceding example, wherein the cut filler is shredded plant material having an average cut width of no more than 2 millimetres, for example no more than 1.75 millimetres, for example no more than 1.5 millimetres.

[0525] Ex76. An aerosol-generating article according to any preceding example, wherein the cut filler comprises, or is, shredded tobacco.

[0526] Ex77. An aerosol-generating article according to Ex76, wherein the shredded tobacco comprises at least 50 percent by weight of shredded tobacco lamina.

[0527] Ex78. An aerosol-generating article according to any preceding example, wherein the cut filler comprises shredded non-tobacco plant material.

[0528] Ex79. An aerosol-generating article according to Ex78, wherein the shredded nontobacco plant material comprises one or more of: tea, star anise, lavender, clove, peppermint, chamomile, rosemary, eucalyptus, ginger, dill seed, thyme, oregano and cumin.

[0529] Ex80. An aerosol-generating article according to any preceding example, wherein the cut filler comprises at least 15 percent by weight of aerosol former, for example at least 17 percent by weight of aerosol former, on a dry weight basis based on the total weight of the cut filler.

[0530] Ex81. An aerosol-generating article according to any preceding example, wherein the aerosol-generating element comprises at least 70 percent by weight of the cut filler, for example at least 80 percent by weight of the cut filler, for example at least 90 percent by weight of the cut filler, on a dry weight basis.

[0531] Ex82. An aerosol-generating article according to any preceding example, wherein the aerosol-generating element comprises at least 15 percent by weight of aerosol former, on a dry weight basis.

[0532] Ex83. An aerosol-generating article according to any preceding example, wherein the porous aerosol-generating element comprises no more than 40 percent by weight of the aerosol former, for example no more than 30 percent by weight of the aerosol former, on a dry weight basis.

[0533] Ex84. An aerosol-generating article according to any preceding example, wherein the aerosol former comprises glycerin, propylene glycol or a combination thereof.

[0534] Ex85. An aerosol-generating article according to any preceding example, wherein the aerosol-generating element comprises at least 2 percent by weight of the binder, for example at least 5 percent by weight of the binder, on a dry weight basis.

[0535] Ex86. An aerosol-generating article according to any preceding example, wherein the aerosol-generating element comprises no more than 30 percent by weight of the binder, for example no more than 20 percent by weight of the binder, for example no more than 15 percent by weight of the binder, on a dry weight basis.

[0536] Ex87. An aerosol-generating article according to any preceding example, wherein the weight ratio of the cut filler to the binder is at least 3, for example at least 4, for example at least 5, on a dry weight basis. Ex88. An aerosol-generating article according to any preceding example, wherein the binder comprises polyvinyl alcohol.

[0537] Ex89. An aerosol-generating article according to example Ex88, wherein the aerosolgenerating element comprises between 5 percent and 20 percent by weight of polyvinyl alcohol, for example between 5 percent and 15 percent by weight of polyvinyl alcohol, on a dry weight basis.

[0538] Ex90. An aerosol-generating article according to any preceding example, wherein the binder comprises one or more hydrocolloids.

[0539] Ex91 . An aerosol-generating article according to example Ex90, wherein the one or more hydrocolloids are selected from: starch, modified starch, alginate, pectin, cellulose, cellulose derivatives, agar, carrageenan, gelatin, natural gums and combinations thereof.

[0540] Ex92. An aerosol-generating article according to any preceding example, wherein the binder comprises nanocellulose.

[0541] Ex93. An aerosol-generating article according to example Ex92, wherein the porous aerosol-generating element comprises between 1 percent and 15 percent by weight of nanocellulose, for example between 2 percent and 10 percent by weight of nanocellulose, for example between 2 and 8 percent by weight of nanocellulose, on a dry weight basis.

[0542] Ex94. An aerosol-generating article according to any preceding example, wherein the binder comprises a polyvinyl alcohol, nanocellulose or a combination thereof.

[0543] Ex95. An aerosol-generating article according to any preceding example, wherein the binder comprises micro fibrillated cellulose.

[0544] Ex96. An aerosol-generating article according to example Ex95, wherein the aerosolgenerating element comprises between 1 percent and 10 percent by weight of micro fibrillated cellulose, for example between 2 percent and 8 percent by weight of micro fibrillated cellulose, for example between 2 percent and 6 percent by weight of micro fibrillated cellulose, for example between 2 percent and 4 percent by weight of micro fibrillated cellulose, on a dry weight basis. Ex97. An aerosol-generating article according to any preceding example, wherein the solid binder matrix is substantially continuous.

[0545] Ex98. An aerosol-generating article according to any preceding example, further comprising an active agent, for example nicotine.

[0546] Ex99. An aerosol-generating article according to any preceding example, wherein the total water content of the aerosol-generating element is no more than 30 percent by weight, for example no more than 20 percent by weight, for example no more than 15 percent by weight, for example no more than 12 percent by weight.

[0547] Ex100. An aerosol-generating article according to any preceding example, wherein the aerosol-generating element has a moisture content of no more than 20 percent oven volatiles, for example no more than 15 percent oven volatiles, for example no more than 12 percent oven volatiles.

[0548] Ex101. An aerosol-generating article according to any preceding example, wherein the aerosol-generating element has a nicotine content of between 1 percent and 5 percent by weight, for example between 1 percent and 3 percent by weight, on a dry weight basis.

[0549] Ex102. An aerosol-generating article according to any preceding example, wherein the aerosol-generating element has an average density of less than 400 mg per cubic centimetre, for example less than 375 mg per cubic centimetre, for example less than 350 mg per cubic centimetre, for example less than 325 mg per cubic centimetre, for example less than 300 mg per cubic centimetre.

[0550] Ex103. An aerosol-generating article according to any preceding example, wherein the aerosol-generating element has an average density of at least 200 mg per cubic centimetre.

[0551] Ex104. A porous aerosol-generating element according to any preceding example, wherein the porous aerosol-generating element has a total porosity of at least 0.3, for example at least 0.35, for example at least 0.4.

[0552] Ex105. A porous aerosol-generating element according to any preceding example, wherein the porous aerosol-generating element has an open porosity of at least 0.3, for example at least 0.35, for example at least 0.4.

[0553] Ex106. An aerosol-generating article according to any preceding example, wherein the aerosol-generating element comprises one or more perforations.

[0554] Ex107. An aerosol-generating article according to any preceding example, wherein the aerosol-generating element comprises a non-homogeneous cross-section.

[0555] Examples will now be further described with reference to the figures in which:

[0556] Figure 1 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0557] Figure 2 shows an exploded perspective view of the aerosol-generating article of Figure 1 ;

[0558] Figure 3 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0559] Figure 4 shows a transverse cross-sectional view of the aerosol-generating article of Figure 3;

[0560] Figure 5 shows a longitudinal cross-sectional view of the aerosol-generating article of Figure 3;

[0561] Figure 6 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0562] Figure 7 shows a transverse cross-sectional view of the aerosol-generating article of Figure

[0563] 6;

[0564] Figure 8 shows a lateral cross-sectional view of the aerosol-generating article of Figure 6; Figure 9 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0565] Figure 10 shows a perspective view of the aerosol-generating article of Figure 9;

[0566] Figure 11 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0567] Figure 12 shows an exploded perspective view of the aerosol-generating article of Figure 11 ;

[0568] Figure 13 shows an exploded perspective view of the aerosol-generating article of Figure 11 ;

[0569] Figure 14 show a perspective view of an aerosol-generating article according to the present disclosure;

[0570] Figure 15 shows an exploded perspective view of the aerosol-generating article of Figure 14;

[0571] Figure 16 shows an exploded perspective view of the aerosol-generating article of Figure 14;

[0572] Figure 17 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0573] Figure 18 shows an exploded perspective view of the aerosol-generating article of Figure 17;

[0574] Figure 19 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0575] Figure 20 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0576] Figure 21 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0577] Figure 22 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0578] Figure 23 shows an exploded perspective view of the aerosol-generating article of Figure 22;

[0579] Figure 24 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0580] Figure 25 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0581] Figure 26 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0582] Figure 27 shows an exploded perspective view of an aerosol-generating article according to the present disclosure; Figure 28 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0583] Figure 29 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0584] Figure 30 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0585] Figure 31 shows a perspective view of the aerosol-generating article of Figure 30;

[0586] Figure 32 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0587] Figure 33 shows a plan view of the aerosol-generating article of Figure 32;

[0588] Figure 34 shows an exploded perspective view of the aerosol-generating article of Figure

[0589] 32;

[0590] Figure 35 shows a cross-sectional view of the aerosol-generating article of Figure 32;

[0591] Figure 36 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0592] Figure 37 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0593] Figure 38 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0594] Figure 39 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0595] Figure 40 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0596] Figure 41 shows a schematic cross-sectional view of an aerosol-generating device according to the present disclosure;

[0597] Figure 42 shows a schematic cross-sectional view of the aerosol-generating device of Figure 41 in engagement with an aerosol-generating article of the present disclosure;

[0598] Figure 43 shows a method of manufacturing an aerosol-generating article according to the present disclosure;

[0599] Figure 44 shows a plan view of the method of manufacturing of Figure 43;

[0600] Figure 45 shows a method of manufacturing an aerosol-generating article according to the present disclosure;

[0601] Figure 46 shows a plan view of the method of manufacturing of Figure 45;

[0602] Figure 47 shows a method of manufacturing an aerosol-generating article according to the present disclosure;

[0603] Figure 48 shows a plan view of the method of manufacturing of Figure 47; Figure 49 shows a method of manufacturing an aerosol-generating article according to the present disclosure; and

[0604] Figure 50 shows a plan view of the method of manufacturing of Figure 49.

[0605] 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 may be formed from a non-aerosol forming material, such as paper or card. Alternatively, either of the first planar external layer 24 and the second planar external layer 25 may comprise an aerosol-generating substrate comprising an aerosol-generating material, for example tobacco.

[0606] 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.

[0607] The first planar external surface 21 and the second planar external surface 22 extend in the x-direction and the y-direction. That is, the first planar external surface 21 and the second planar external surface 22 extend in the x / y plane. The first planar external surface 21 is positioned parallel to the second planar external surface 22 and the first planar external surface 21 is spaced from the second planar external surface 22 in the z-direction or transverse direction. The distance between the first planar external surface 21 and the second planar external surface 22 in the z- direction or transverse direction corresponds to the thickness of the aerosol-generating article 10.

[0608] 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. That is, the thickness is less than 15 millimetres (less than 50 percent of the length of the aerosolgenerating article 10) and less than 5 millimetres (less than 50 percent of the width of the width of the aerosol-generating article 10). The aerosol-generating article 10 has a generally rectangular cuboid shape and a laminated structure formed by the first planar external layer 24, the frame 50 and the second planar external layer 25. The first planar external layer 24, the frame 50 and the second planar external layer 25 are bonded together with an adhesive, in particular guar gum, as discussed in more detail below in relation to Figure 2.

[0609] Figure 2 shows an exploded view of the aerosol-generating article 10 of Figure 1 .

[0610] 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. The cavity 30 serves as a location for an aerosol-forming substrate, for example an aerosol-generating element 40.

[0611] 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 outer surface 53 encircles, and is concentric with, the frame inner surface 52. Thus, the frame 50 has a cross-section in the x / y plane that is annular in shape, in particular the cross-section is a rectangular annulus shape.

[0612] 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.

[0613] 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.

[0614] 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.

[0615] The frame forms at least 95 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame. For example, the frame forms 100 percent of the perimeter of a cross-section, in an x / y plane, of the aerosol-generating article 10 taken between the first planar external layer 24 and the air outlet 12. On the other hand, the frame forms 95 percent of the perimeter of a cross-section, in an x / y plane, of the aerosol-generating article that extends through the air inlet 11 and the air outlet 12. This is because the perimeter of such a cross-section is formed by the frame, a width of the air inlet 11 and a width of the air outlet 12.

[0616] Figure 3 shows an exploded viewofthe aerosol-generating article 10 of Figure 1 illustrating an aerosol-generating element 40 comprising aerosol-generating substrate positioned within the cavity 30. The aerosol-generating element 40 comprises an aerosol-generating material in the form of tobacco cut filler distributed within a solid binder phase.

[0617] The aerosol-generating element 40 is rectangular cuboidal in shape, with a length of about 25 millimetres, a width of about 5.5 millimetres and a thickness of about 2.5 millimetres. The weight of the aerosol-generating element is approximately 120 mg and the density of the aerosolgenerating element is approximately 350 mg per cubic centimetre. Although the aerosolgenerating element 40 is shown to fill the cavity 30, in fact the dimensions of the element 40 are slightly smaller than corresponding dimensions of the cavity 30, providing for an air flow path through the cavity when the aerosol-generating element 40 is present.

[0618] The aerosol-generating element 40 comprises a solid binder matrix and a cut filler dispersed through the solid binder matrix. An example of a suitable composition of the aerosolgenerating element 40 is provided below.

[0619] Example of a suitable aerosol-generating element

[0620] Suitable compositions for forming an aerosol-generating element according to the invention are shown in Table 1 below:

[0621] Table 1

[0622] All amounts are shown as percentages by weight, on a dry weight basis, based on the total weight of the aerosol-generating element.

[0623] In order to make the aerosol-generating element 40, a raw tobacco material is first conditioned in a Direct Conditioning Casing Cylinder (DCCC) through the application of glycerin and steam at approximately 60 degrees. The conditioned tobacco material is cut to an average cut width of 1 millimetre and then dried in a Flash Tower Dryer (FTD) at a temperate of 200 degrees Celsius to provide a moisture content of approximately 9 percent oven volatiles (OV). The dried, conditioned tobacco material is added to an After-Cut cylinder where addbacks including tobacco stems are added to form a cut filler. An aqueous solution of the binder is then applied to the cut filler in the After-Cut cylinder. The binder solution and cut filler are mixed in order to at least partially coat the cut filler in the binder solution. The mixture of the cut filler and binder solution is then compacted by passing the mixture through a series of rollers. The resultant compacted mixture is dried to a moisture content of approximately 10 percent oven volatiles and then cut to form an aerosol-generating element having the desired size and shape. Figures 4 and 5 show transverse and longitudinal cross-sectional views of the aerosolgenerating article 10 of Figure 3, showing the aerosol-generating element 40 located within the cavity 30.

[0624] Figure 6 shows an exploded view of an aerosol-generating 10 that is similar to the aerosolgenerating article 10 of Figure 3 except that the cavity 30 contains an aerosol-generating substrate 47 in the form of a sheet of aerosol-generating material, in particular a corrugated sheet of homogenised tobacco material. Figures 7 and 8 show transverse and lateral cross-sectional views of the aerosol-generating article 10 of Figure 6, respectively. It is noted that the cavity may additionally contain a portion of an aerosol-generating element as described in relation to figures 1 to 5.

[0625] The corrugated sheet of homogenised tobacco material comprises a plurality of parallel corrugations having a plurality of substantially parallel peaks 43 and troughs 44. The plurality of parallel corrugations are defined by a corrugation profile which, as seen in Figure 7, is sinusoidal. The plurality of parallel corrugations have a corrugation wavelength of about 0.92 millimetres. The corrugation amplitude is approximately the same as the thickness of the cavity, as shown by the peaks 43 and troughs 44 coinciding with the first cavity end wall 31 and the second cavity end wall 32, respectively.

[0626] The plurality of parallel corrugations form a plurality of channels 45 between the sheet of aerosol-generating material and the first cavity end wall 31 , and a plurality of channels 46 between the sheet of aerosol-generating material and the second cavity end wall 32. The plurality of channels extend in a longitudinal direction of the aerosol-generating article 10 and form at least a portion of the airflow passage extending between the air inlet 11 and the air outlet 12.

[0627] Figure 9 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figures 1 , 3 and 6 except that the aerosol-generating article 10 of Figure 9 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. Figure 10 shows, for illustration purposes, the aerosol-generating article 10 of Figure 9 in which the outer wrapper 23 has been unwrapped to expose a portion of the peripheral wall 51 of the frame 50. The outer wrapper 23 is cigarette paper.

[0628] Figure 11 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1 except that the frame 50 of the aerosol-generating article 10 of Figure 11 comprises a first frame layer 54 and a second frame layer 55. Figure 12 shows an exploded view of the first planar external layer 24, the frame 50 and the second planar external layer 25 of the aerosolgenerating article 10 of Figure 11 . Figure 13 shows a yet further exploded view of the first planar external layer 24, the first frame layer 54, the second frame layer 55, and the second planar external layer 25 of the aerosol-generating article 10 of Figure 11. An aerosol-generating element 40 may be located in the cavity of the articles of Figures 11 to 13. The first planar external layer 24 is in physical contact with the first frame layer 54 and are bonded together with an adhesive 15. The first frame layer 54 is in physical contact with the second frame layer 55 and are bonded together with an adhesive 15. The second planar external layer 25 is in physical contact with the second frame layer 55 and are bonded together with an adhesive 15.

[0629] The aerosol-generating article 10 has the same dimensions as the aerosol-generating article 10 of Figure 1. The frame 50 has the same dimensions as the frame 50 of Figure 1. The thickness of the frame 50 is equal to the sum of the thickness of the first frame layer 54 and the second frame layer 55, which both have the same thickness. The air inlet 11 and air outlet 12 are formed by both the first frame layer 54 and the second frame layer 55.

[0630] Figure 14 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1 except that the frame 50 of the aerosol-generating article 10 of Figure 14 comprises a first frame layer 54, a second frame layer 55 and a third frame layer 56 positioned between the first frame layer 54 and the second frame layer 55. Figure 15 shows an exploded view of the first planar external layer 24, the frame 50 and the second planar external layer 25 of the aerosolgenerating article 10 of Figure 14. Figure 16 shows a yet further exploded view of the first planar external layer 24, the first frame layer 54, the second frame layer 55, the third frame layer 56 and the second planar external layer 25 of the aerosol-generating article 10 of Figure 14.

[0631] The first planar external layer 24 is in physical contact with the first frame layer 54 and are bonded together with an adhesive 15. The first frame layer 54 is in physical contact with the second frame layer 55 and are bonded together with an adhesive 15. The second frame layer 55 is in physical contact with the third frame layer 56 and are bonded together with an adhesive 15. The second planar external layer 25 is in physical contact with the third frame layer 56 and are bonded together with an adhesive 15.

[0632] The aerosol-generating article 10 has the same dimensions as the aerosol-generating article 10 of Figure 1. The frame 50 has the same dimensions as the frame 50 in Figure 1. The thickness of the frame 50 is equal to the sum of the thickness of the first frame layer 54, the second frame layer 55 and the third frame layer 56. The air inlet 11 and air outlet 12 extend through the second frame layer 55.

[0633] Figure 17 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 17 further comprises a first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42. Figure 18 shows an exploded view of the aerosol-generating article 10 of Figure 17. The first aerosolgenerating 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 aerosolgenerating 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 aerosol-generating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.5 millimetres.

[0634] 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.

[0635] 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.

[0636] The frame 50 is depicted as a unitary component. However, the frame may be a two layer frame as shown in Figure 11 or a three layer frame as shown in Figure 14.

[0637] Figure 19 shows an exploded view of an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 17 except that an aerosol-generating element 40 is positioned within the cavity 30 as described in relation to Figure 3.

[0638] Figure 20 shows an exploded view of an aerosol-generating 10 that is similar to the aerosol-generating article 10 of Figure 19 except that the cavity contains an aerosol-generating substrate 47 is in the form of a sheet of aerosol-generating material, in particular a corrugated sheet of homogenised tobacco material as described in relation to Figure 6.

[0639] Figure 21 shows an exploded view of an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 19 except that the aerosol-generating article 10 further comprises a filter element 60 positioned within the cavity 30.

[0640] The filter element 60 is positioned immediately upstream of the air outlet 12. The filter element 60 is made from cellulose acetate. The filter element 60 has a thickness and a width approximately the same as the thickness and width of the cavity 30, respectively. The filter element 60 has a length of about 6 millimetres. The aerosol-generating element 40 fills the remaining volume of the cavity 30.

[0641] Figure 22 shows an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 1 except that the aerosol-generating article 10 of Figure 22 comprises a first cavity 33 and a second cavity 34. Figure 23 shows an exploded view of the aerosol-generating article 10 of Figure 22. The first cavity 33 is substantially empty and the second cavity 34 is substantially empty. The first cavity 33 has length of 12 millimetres, a width of 6 millimetres, and a thickness of 2.7 millimetres. The second cavity 34 has length of 12 millimetres, a width of 6 millimetres, and a thickness of 2.7 millimetres.

[0642] The frame 50 defines a frame first aperture extending through the thickness of the frame 50 and the frame first aperture at least partially forms the first cavity 33. The frame 50 defines a frame second aperture extending through the thickness of the frame 50 and the frame second aperture at least partially forms the second cavity 34.

[0643] The frame 50 comprises dividing wall 57 which separates the first cavity 33 and the second cavity 34. The dividing wall 59 defines an aperture extending from the first cavity 33 to the second cavity 34. The aperture of the dividing wall 59 defines at least a portion of the airflow passage between the air inlet 11 and the air outlet 12.

[0644] The first planar external layer 24 overlies an end of the first cavity 33 and the second planar external layer 25 overlies an opposite end of the first cavity 33. That is, the frame 50, the first planar external layer 24 and the second planar external layer 25 collectively define the first cavity 33. The first planar external layer 24 overlies an end of the second cavity 34 and the second planar external layer 25 overlies an opposite end of the second cavity 34. That is, the frame 50, the first planar external layer 24 and the second planar external layer 25 collectively define the second cavity 34.

[0645] Figure 24 shows an exploded view of an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 22 except that a first cavity aerosol-generating element 45 is positioned within the first cavity 33 and a second cavity aerosol-generating element 46 is positioned within the second cavity 34.

[0646] Figure 25 shows an exploded view of an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 24 except that the first cavity contains an aerosol-generating substrate 47 is in the form of a sheet of aerosol-generating material, in particular a corrugated sheet of homogenised tobacco material, and the second cavity also contains an aerosol-generating substrate 47 is in the form of a sheet of aerosol-generating material, in particular a corrugated sheet of homogenised tobacco material.

[0647] Figure 26 shows an exploded view of an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 22 except that a first cavity aerosol-generating element 45 is positioned within the first cavity 33, a filter element 60 is positioned within the first cavity 33, and a second cavity aerosol-generating substrate 47 is positioned within the second cavity 34.

[0648] The filter element 60 is positioned immediately upstream of the air outlet 12. The filter element is made from cellulose acetate. The filter element 60 has a thickness and a width approximately the same as the thickness and width of the first cavity 33, respectively. The filter element 60 has a length of about 4 millimetres. Figure 27 shows an exploded view of an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 22 except that a filter element 60 is positioned within the air outlet 12 and a second cavity aerosol-generating element 46 is positioned within the second cavity 34. The filter element 60 is made from cellulose acetate and has the same dimensions as the air outlet 12. The first cavity 33 is empty. The second cavity aerosol-generating element 46 is formed from the same material as the aerosol-generating element of figures 1 to 5.

[0649] Figure 28 shows an exploded view of an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 22 except that the aerosol-generating article 10 further comprises a first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42 as described in relation to Figure 17.

[0650] 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 aerosol-generating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.5 millimetres.

[0651] 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 first cavity 33 and the second aerosol-generating substrate layer 42 overlies an opposite end of the first cavity 33. That is, the frame 50, the first aerosol-generating substrate layer 41 and the second aerosolgenerating substrate layer 42 collectively define the first cavity 33. The first aerosol-generating substrate layer 41 overlies an end of the second cavity 34 and the second aerosol-generating substrate layer 42 overlies an opposite end of the second cavity 34. That is, the frame 50, the first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 collectively define the second cavity 34. An aerosol-generating element 40 may be located in one or both cavities.

[0652] Figure 29 shows an exploded view of an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 28 except that a first cavity aerosol-generating element 45 is positioned within the first cavity 33 and a second cavity aerosol-generating element 46 is positioned within the second cavity 34.

[0653] Figure 30 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figures 17 and 28 except that the aerosol-generating article 10 of Figure 30 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. Figure 31 shows, for illustration purposes, the aerosol-generating article 10 of Figure 30 in which the outer wrapper 23 has been unwrapped to expose a portion of the peripheral wall 51 of the frame 50. The outer wrapper 23 is cigarette paper.

[0654] Figure 32 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 32 comprises a first external corner 71 and a second external corner 72 that are rounded. However, it would be understood that one or both of the first external corner 71 and the second external corner 72 could be chamfered. Figure 33 and 34 show a plan view and an exploded view of the aerosol-generating article 10 of Figure 32, respectively.

[0655] The first external corner 71 extends from the first planar external surface 21 to the second planar external surface 22 and comprises a first corner surface 76 connecting a first end face 73 of the aerosol-generating article 10 and a first side face 74 of the aerosol-generating article 10. In more detail, the first end face 73 connects to the first corner surface 76 at a first corner transition region 82. A first corner internal angle 01 formed between a tangent 81 of the first end face 73 at the first corner transition region 82 and a tangent 83 of the first corner surface 76 at the first corner transition region 82 is between 90 degrees and 180 degrees.

[0656] The second external corner 72 extends from the first planar external surface 21 to the second planar external surface 22 and comprises a second corner surface 77 connecting the first end face 73 of the aerosol-generating article 10 and a second side face 75 of the aerosolgenerating article 10. In more detail, the first end face 73 connects to the second corner surface 77 at a second corner transition region 85. A second corner internal angle 02 formed between a tangent 84 of the first end face 73 at the second corner transition region 85 and a tangent 86 of the second corner surface 77 at the second corner transition region 85 is between 90 degrees and 180 degrees.

[0657] Figure 35 shows a cross-sectional view in the x / y plane of the aerosol-generating article 10 of Figure 32 taken through the intersection between the first planar external layer 24 and the frame 50. The cavity 30 comprises a first corner 35, a second corner 36, a third corner 37 and a fourth corner 38 which each extend in the z-direction and are rounded.

[0658] Figure 36 shows an exploded view of an aerosol-generating article that is similar to the aerosol-generating article 10 of Figure 32 except that an aerosol-generating element 40 is positioned within the cavity 30.

[0659] Figure 37 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 32 and 36 except that the aerosol-generating article 10 of Figure 37 further comprises a first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42 as described in relation to Figure 17. Figure 38 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1 except that the air inlet 11 is defined by the first planar external surface 21 and extends through the first planar external layer 24.

[0660] Figure 39 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 9 except that the air inlet 11 is defined by the first planar external surface 21 and extends through the outer wrapper 23.

[0661] Figure 40 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 17 except that the air inlet 11 is defined by the first planar external surface 21 and extends through the first planar external layer 24 and the first aerosol-generating substrate layer 41.

[0662] Figures 41 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.

[0663] Figure 42 shows a schematic cross-sectional view of the aerosol-generating device 90 of Figure 41 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 element 40 located within the article 10 is heated. Volatile components of the aerosol-generating element are evaporated and condense in the cavity 30 of the aerosol-generating 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 element has been depleted of volatile components, the aerosolgenerating article 10 is removed from the cavity 1000 and disposed of.

[0664] Figure 43 depicts a schematic illustration of a method of manufacturing 1100 an aerosolgenerating article 10 as described herein and, in particular, a method of manufacturing the aerosolgenerating article 10 of Figure 3. The method comprises punching and bonding a first sheet of frame material 1201 , a first sheet of external layer material 1301 and a second sheet of external layer material 1302. Figure 44 depicts a schematic plan view of the method of Figure 43 but for illustration purposes the manufacturing equipment is not depicted. The dotted line 1101 in Figure 44 is for illustration purposes and represents the eventual cross-sectional perimeter of the aerosolgenerating article 10.

[0665] The first sheet of frame material 1201 is fed from a bobbin 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An aperture punching device 1105 punches a frame aperture 1400 through the first sheet of frame material 1201. The frame aperture 1400 will at least partially form the cavity 30 of the aerosol-generating article 10. An adhesive applying device 1106 applies an adhesive to a lower surface of the first sheet of frame material 1201 . The first sheet of external layer material 1301 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive applied to the lower surface of the first sheet of frame material 1201. An aerosol-generating substrate dispensing device 1108 dispenses an aerosolgenerating element 40 into the frame aperture 1400. An adhesive applying device 1109 applies an adhesive 1110 to an upper surface of the first sheet of frame material 1201. The second sheet of external layer material 1302 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive 1110 applied to the upper surface of the first sheet of frame material 1201. An aperture punching device 1111 punches an aperture 1410 through the first sheet of frame material 1201 , the first sheet of external layer material 1301 and the second sheet of external layer material 1302 so as to eject an aerosol-generating article 10. The air inlet and air outlet may be formed before or after the aerosol-generating article 10 has been ejected.

[0666] In some embodiments, one or more of the first sheet of frame material 1201 , the first sheet of external layer material 1301 and the second sheet of external layer material 1302 comprises an aerosol-generating substrate.

[0667] Figure 45 depicts a schematic illustration of a method of manufacturing 1100 an aerosolgenerating article 10 as described herein and, in particular, a method of manufacturing the aerosolgenerating article 10 of Figure 17. The method comprises punching and bonding a first sheet of frame material 1201 , a first sheet of aerosol-generating material 1501 , a second sheet of aerosolgenerating material 1502, a first sheet of external layer material 1301 and a second sheet of external layer material 1302. Figure 46 depicts a schematic plan view of the method of Figure 45 but for illustration purposes the manufacturing equipment is not depicted. The dotted line 1101 in Figure 46 is for illustration purposes and represents the eventual cross-sectional perimeter of the aerosol-generating article 10.

[0668] The first sheet of frame material 1201 fed from a bobbin 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An aperture punching device 1105 punches a frame aperture 1400 through the first sheet of frame material 1201. The frame aperture 1400 will at least partially form the cavity 30 of the aerosol-generating article 10.

[0669] An adhesive applying device 1106 applies an adhesive 1110 to a lower surface of the first sheet of frame material 1201 and to an upper surface of the first sheet of frame material 1201.

[0670] The first sheet of aerosol-generating material 1501 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive applied to the lower surface of the first sheet of frame material 1201. The second sheet of aerosol-generating material 1502 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive 1110 applied to the upper surface of the first sheet of frame material 1201.

[0671] An adhesive applying device 1109 applies an adhesive 1110 to a lower surface of the first sheet of aerosol-generating material 1501 and to an upper surface of the second sheet of aerosolgenerating material 1502.

[0672] The first sheet of external layer material 1301 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of aerosol-generating material 1501 by the adhesive applied to the lower surface of the first sheet of aerosol-generating material 1501 . The second sheet of external layer material 1302 is fed from a bobbin 1102 via a roller 1107 and is bonded to the second sheet of aerosol-generating material 1502 by the adhesive 1110 applied to the upper surface of the second sheet of aerosol-generating material 1502.

[0673] An aperture punching device 1111 punches an aperture 1410 through the first sheet of frame material 1201 , the first sheet of aerosol-generating material 1501 , the second sheet of aerosol-generating material 1502, the first sheet of external layer material 1301 and the second sheet of external layer material 1302 so as to eject the aerosol-generating article 10. The air inlet and air outlet may be formed before or after the aerosol-generating article 10 has been ejected.

[0674] Figure 47 depicts a schematic illustration of a method of manufacturing 1100 an aerosolgenerating article 10 as described herein and, in particular, a method of manufacturing the aerosolgenerating article 10 of Figure 11 comprising an aerosol-generating element 40 positioned within the cavity 30. The method comprises punching and bonding a first sheet of frame material 1201 , a second sheet of frame material 1202, a first sheet of external layer material 1301 and a second sheet of external layer material 1302. Figure 48 depicts a schematic plan view of the method of Figure 47 but for illustration purposes the manufacturing equipment is not depicted. The dotted line 1101 in Figure 48 is for illustration purposes and represents the eventual cross-sectional perimeter of the aerosol-generating article 10. The first sheet of frame material 1201 is fed from a bobbin 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An adhesive applying device 1106 applies an adhesive 1110 to an upper surface of the first sheet of frame material 1201. The second sheet of frame material 1202 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive 1110 applied to the upper surface of the first sheet of frame material 1201.

[0675] An aperture punching device 1105 punches a frame aperture 1400 through the first sheet of frame material 1201 and the second sheet of frame material 1202. The frame aperture 1400 will at least partially form the cavity 30 of the aerosol-generating article 10.

[0676] An adhesive applying device 1106 applies an adhesive to a lower surface of the first sheet of frame material 1201 . The first sheet of external layer material 1301 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive applied to the lower surface of the first sheet of frame material 1201.

[0677] An aerosol-generating element dispensing device 1108 dispenses an aerosol-generating element 40 into the frame aperture 40. An adhesive applying device 1109 applies an adhesive 1110 to an upper surface of the second sheet of frame material 1202. The second sheet of external layer material 1302 is fed from a bobbin 1102 via a roller 1107 and is bonded to the second sheet of frame material 1202 by the adhesive 1110 applied to the upper surface of the second sheet of frame material 1202.

[0678] An aperture punching device 1111 punches an aperture 1410 through the first sheet of frame material 1201 , the second sheet of frame material 1202, the first sheet of external layer material 1301 and the second sheet of external layer material 1302 so as to eject an aerosolgenerating article 10. The air inlet and air outlet may be formed before or after the aerosolgenerating article 10 has been ejected.

[0679] In some embodiments, one or more of the first sheet of frame material 1201 , the second sheet of frame material 1202, the first sheet of external layer material 1301 and the second sheet of external layer material 1302 comprises an aerosol-generating substrate.

[0680] Figure 49 depicts a schematic illustration of a method of manufacturing 1100 an aerosolgenerating article 10 as described herein and, in particular, a method of manufacturing the aerosolgenerating article 10 of Figure 14 comprising an aerosol-generating element 40 positioned within the cavity 30. The method comprises punching and bonding a first sheet of frame material 1201 , a second sheet of frame material 1202, a third sheet of frame material 1203, a first sheet of external layer material 1301 and a second sheet of external layer material 1302.

[0681] Figure 50 depicts a schematic plan view of the method of Figure 49 but for illustration purposes the manufacturing equipment is not depicted. The dotted line 1101 in Figure 50 is for illustration purposes and represents the eventual cross-sectional perimeter of the aerosolgenerating article 10. The first sheet of frame material 1201 is fed from a bobbin 1102 between a first pair of rollers 1103 and a second pair of rollers 1104. An aperture punching device 1112 punches an air inlet aperture 1610 and an air outlet aperture 1620 through the first sheet of frame material 1201.

[0682] An adhesive applying device 1106 applies an adhesive 1110 to a lower surface of the first sheet of frame material 1201 and to an upper surface of the first sheet of frame material 1201.

[0683] The second sheet of frame material 1202 is fed from a bobbin 1102 via a roller 1107 and is bonded to the first sheet of frame material 1201 by the adhesive applied to the lower surface of the first sheet of frame material 1201 . The third sheet of frame material 1203 is fed from a bobbin 1102 via a roller 1102 and is bonded to the first sheet of frame material 1201 by the adhesive 1110 applied to the upper surface of the first sheet of frame material 1201.

[0684] An aperture punching device 1105 punches a frame aperture 1400 through the first sheet of frame material 1201 , the second sheet of frame material 1202 and the third sheet of frame material 1203. The frame aperture will at least partially form the cavity 30 of the aerosol-generating article 10.

[0685] An adhesive applying device 1106 applies an adhesive to a lower surface of the second sheet of frame material 1202. The first sheet of external layer material 1301 is fed from a bobbin 1102 via a roller 1107 and is bonded to the second sheet of frame material 1202 by the adhesive applied to the lower surface of the second sheet of frame material 1202.

[0686] An aerosol-generating element dispensing device 1108 dispenses an aerosol-generating element 40 into the frame aperture 1400. An adhesive applying device 1109 applies an adhesive 1110 to an upper surface of the third sheet of frame material 1203. The second sheet of external layer material 1302 is fed from a bobbin 1102 via a roller 1107 and is bonded to the third sheet of frame material 1203 by the adhesive 1110 applied to the upper surface of the third sheet of frame material 1203.

[0687] An aperture punching machine 1111 punches an aperture 1410 through the first sheet of frame material 1201 , the second sheet of frame material 1202, the third sheet of frame material 1203, the first sheet of external layer material 1301 and the second sheet of external layer material 1302 so as to eject the aerosol-generating article 10.

[0688] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 10% of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

CLAIMS1. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: a first external surface and a second external surface facing in substantially the opposite direction to the first external surface; a cavity located within the aerosol-generating article between the first external surface and the second external surface; and an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity, wherein an aerosol-generating element is located within the cavity, the aerosol-generating element comprising aerosol-forming substrate and being defined by an element length, an element width, and an element thickness, the element width being greater than the element thickness, in which the aerosol-generating element comprises cut filler dispersed within a solid binder matrix.

2. An aerosol-generating article according to claim 1 in which the aerosol-generating element is a porous aerosol-generating element.

3. An aerosol-generating article according to claim 1 or 2 in which the cut filler comprises shredded plant material impregnated with an aerosol former.

4. An aerosol-generating article according to any preceding claim in which the cut filler an average cut width of at least 0.75 millimetres.

5. An aerosol-generating article according to any preceding claim in which the article length extends in an x — direction, the article width extends in a y-direction, and the article thickness extends in a z-direction, in which the element length, element width, and element thickness of the aerosol-generating element located within the cavity extend in the x-direction, y-direction, and z- direction respectively.

6. An aerosol-generating article according to claim 5 in which the cavity is defined by internal dimensions, the internal dimensions being a cavity length, a cavity width, and a cavity height, the cavity width being greater than the cavity height, in which in which the cavity length, cavity width, and cavity height extend in the x-direction, y-direction, and z-direction respectively.

7. An aerosol-generating article according to any preceding claim in which the cavity comprises between 50 mg and 300 mg of the aerosol-generating element, for example between 100 mg and 200 mg, for example between 125 mg and 175 mg, for example between 140 mg and 160 mg, for example about 140 mg, or about 150 mg or about 160 mg.

8. An aerosol-generating article according to any preceding claim in which the aerosolgenerating element has a length of between 10 mm and 25 mm, for example between 15 mm and 20 mm, for example about 15 mm or about 17 mm, or about 20 mm.

9. An aerosol-generating article according to any preceding claim in which the aerosolgenerating element has a width of between 5 mm and 15 mm, for example between 6 mm and 10 mm, for example between 7 mm and 8 mm, for example about 6 mm or about 7 mm, or about 8 mm.

10. An aerosol-generating article according to any preceding claim in which the aerosolgenerating element has a thickness of between 1 mm and 5 mm, for example between 1.5 mm and 4 mm, for example between 2 mm and 3 mm, for example about 2.5 mm or about 3 mm, or about 3.5 mm.

11. An aerosol-generating article according to any preceding claim in which the cavity contains a single unitary portion of the aerosol-generating element.

12. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating article has resistance to draw between 0 millimetres H2O and 9.9 millimetres H2O, for example in which the air flow path has a resistance to draw between 0 millimetres H2O and 9.9 millimetres H2O.

13. An aerosol-generating article according to any preceding claim, wherein the total volume of aerosol-generating element within the cavity is between 50% and 95 % of the volume of the cavity, for example between 60% and 90% of the volume of the cavity, for example between 70% and 85% of the volume of the cavity.

14. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating element has an average density of less than 400 mg per cubic centimetre, for example less than 375 mg per cubic centimetre, for example less than 350 mg per cubic centimetre, for example less than 325 mg per cubic centimetre, for example less than 300 mg per cubic centimetre.

15. A porous aerosol-generating article according to any preceding claim, wherein the porous aerosol-generating element has a total porosity of at least 0.3, for example at least 0.35, for example at least 0.4 and / or in which a surface of the aerosol-generating element is textured, for example by one or more grooves or channels.

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