Aerosol-generating article with a converging section

Abstract

An aerosol-generating article (10) for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article (10) having a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction, the aerosol-generating article (10) comprising: a first planar external surface (21); a second planar external surface (22); one or more aerosol-generating substrates; and a cavity (30) extending in the x-direction between a first end of the cavity and a second end of the cavity, wherein the cavity comprises a converging section (32) extending in the x-direction between a first end of the converging section (32) and a second end of the converging section (32), wherein the width of the converging section (32) decreases along the length of the converging section (32) from the first end to the second end of the converging section (32), and wherein the length of the converging section (32) is greater than the width of the converging section (32) at the first end of the converging section (32).

Description

[0001] AEROSOL-GENERATING ARTICLE WITH A CONVERGING SECTION

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

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

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

[0005] However, a significant portion of the aerosol-generating substrate in these cylindrical aerosol-generating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-generating substrate contributes to the cost of manufacture and transport of the aerosol-generating article but does not contribute to the aerosol delivered to the consumer. Moreover, the components of these cylindrical aerosol-generating 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 an objective of the present disclosure to provide an aerosol-generating article in which the quality and quantity of aerosol delivered to a user is optimised. It is an objective of the present disclosure to provide an aerosol-generating article with improved mechanical rigidity. It is 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 for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article has a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction. The aerosol-generating article may comprise a first planar external surface. The first planar external surface may extend in an x / y plane. The aerosol-generating article may comprise a second planar external surface. The second planar external surface may extend in an x / y plane. The aerosol-generating article may comprise one or more aerosolgenerating substrates. The aerosol-generating article may comprise a cavity extending in the x-direction between a first end of the cavity and a second end of the cavity. The cavity may comprise a converging section. The converging section may extend in the x-direction between a first end of the converging section and a second end of the converging section. The width of the converging section may decrease along the length of the converging section. The width of the converging section may decrease along the length of the converging section from the first end to the second end of the converging section. The length of the converging section may be greater than the width of the converging section at the first end of the converging section.

[0008] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article having a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction, the aerosol-generating article comprising: one or more aerosolgenerating substrates; and a cavity extending in the x-direction between a first end of the cavity and a second end of the cavity, wherein the cavity comprises a converging section extending in the x-direction between a first end of the converging section and a second end of the converging section, wherein the width of the converging section decreases along the length of the converging section from the first end to the second end of the converging section, and wherein the length of the converging section is greater than the width of the converging section at the first end of the converging section.

[0009] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article having a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction, the aerosol-generating article comprising: a first planar external surface; a second planar external surface; one or more aerosol-generating substrates; and a cavity extending in the x-direction between a first end of the cavity and a second end of the cavity, wherein the cavity comprises a converging section extending in the x-direction between a first end of the converging section and a second end of the converging section, wherein the width of the converging section decreases along the length of the converging section from the first end to the second end of the converging section, and wherein the length of the converging section is greater than the width of the converging section at the first end of the converging section.

[0010] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article having a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction, the aerosol-generating article comprising: a first planar external surface extending in an x / y plane; a second planar external surface extending in an x / y plane; one or more aerosol-generating substrates; and a cavity extending in the x-direction between a first end of the cavity and a second end of the cavity, wherein the cavity comprises a converging section extending in the x-direction between a first end of the converging section and a second end of the converging section, wherein the width of the converging section decreases along the length of the converging section from the first end to the second end of the converging section, and wherein the length of the converging section is greater than the width of the converging section at the first end of the converging section.

[0011] Accordingly, the width of the converging section at the first end of the converging section is greater than the width of the converging section at the second end of the converging section.

[0012] Advantageously, the first planar external surface and the second planar external surface allow for good contact with an external heater, particularly a planar external heater, of an aerosol-generating device, thereby providing efficient heating of the aerosol-generating substrate.

[0013] 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.

[0014] Advantageously, airflow through the converging section of the cavity of the aerosolgenerating article may be laminar. Accordingly, there may be minimal mixing between airflow through the converging section and adjacent to a wall of the aerosol-generating article and away from the centre or central longitudinal axis of the converging section with airflow located towards the centre of the converging section. Airflow adjacent to a wall of the aerosolgenerating article may be cooled to a greater degree compared to airflow towards the centre of the converging section due to proximity with the walls and the ambient environment. With laminar airflow, airflow towards the centre of the converging section may remain at a desired temperature for better delivery of volatiles, such as nicotine and aerosol formers including glycerine.

[0015] Vapour in an airflow at a lower temperature may be more likely to condense to form large droplets of liquid aerosol-forming substrate compared to vapour in an airflow at a higher temperature. Accordingly, laminar airflow in a converging section of the cavity resulting in less mixing of cooler airflow at the sides and warmer airflow towards the centre may advantageously reduce condensation of vapour, in particular of vapour in an airflow towards the centre of the cavity and undesirable delivery of large droplets of liquid aerosol-forming substrate to a user. Laminar airflow through the cavity may be particularly desirable during the initial puffs of a user experience. During the initial puffs, the walls of the aerosol-generating article may be at ambient temperature. During use of the aerosol-generating article, the walls of the aerosol-generating article may heat up. Vapour during the initial puffs may therefore be more likely to condense than vapour during subsequent puffs. Accordingly, laminar airflow may be particularly advantageous to avoid undesirable delivery of large droplets of liquid aerosolforming substrate to a user and to improve delivery of volatiles.

[0016] The aerosol-generating article may comprise a frame located between the first planar external surface and the second planar external surface. Advantageously, the frame may allow the aerosol-generating article to be relatively thin whilst maintaining structural rigidity.

[0017] Where the aerosol-generating article comprises a frame at least partially defining the converging section of the cavity, the parts or sections of the frame at least partially defining the converging section of the cavity may have increased width and radial thickness compared to other parts of the frame. This may improve the structural rigidity of the frame and of the aerosol-generating article. In particular, the provision of a converging section of the cavity may improve the structural rigidity of the aerosol-generating article without increasing the overall width of the aerosol-generating article.

[0018] Increasing the radial thickness or width of sections of the frame may advantageously reduce the permeability of the frame. Reducing the permeability of the frame may improve sealing of the one or more aerosol-generating substrates of the aerosol-generating article to improve the shelf-life of the aerosol-generating article and improve the quality and quantity of aerosol delivered to a user. Reducing the permeability of the frame may ensure air and aerosol travel along desired airflow pathways through the aerosol-generating article. This may improve the quality and quantity of aerosol delivered to a user.

[0019] 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.

[0020] Increasing the radial thickness or width of sections of the frame may provide an increased area for simpler and better adherence of the frame to other components of the aerosol-generating article, such as a first planar external layer forming the first planar external surface and a second planar external layer forming the second planar external surface, by use of an adhesive. This may help to increase the structural rigidity of the aerosol-generating article and avoid delamination of the aerosol-generating article. Where the frame is formed from multiple layers, increasing the width and area of at least a section of the frame may mean that the layers of the frame may be simply and strongly adhered to one another. This may help to increase the structural rigidity of the frame and avoid delamination of the frame. Avoiding delamination of the frame and of the aerosol-generating article may advantageously reduce air permeability of the frame and reduce unwanted airflow pathways forming through the aerosol-generating article. This may improve the quality and quantity of aerosol delivered to a user.

[0021] The width of the converging section may decrease along the entire length of the converging section. In other words, the width of the converging section may decrease along the length of the converging section from the first end of the converging section to the second end of the converging section.

[0022] The width of the converging section may continuously decrease along the entire length of the converging section.

[0023] The converging section may not comprise a portion having a width that increases in the direction from the first end of the converging section to the second end of the converging section. The converging section may not comprise a portion having a constant width.

[0024] The width of the converging section at the second end of the converging section may be at least 30 percent of the width of the converging section at the first end of the converging section, at least 40 percent of the width of the converging section at the first end of the converging section, or at least 50 percent of the width of the converging section at the first end of the converging section.

[0025] A larger width of the converging section at the second end may avoid sharp and sudden changes in the cross-sectional area of the cavity and thus in the cross-sectional area of an airflow passage through the cavity. This may result in more laminar airflow through the converging section.

[0026] The width of the converging section at the second end of the converging section may be less than or equal to 90 percent of the width of the converging section, less than or equal 80 percent of the width of the converging section, less than or equal to 70 percent of the width of the converging section, or less than or equal to 60 percent of the width of the converging section.

[0027] The ratio of the width of the converging section at the second end to the width of the converging section at the first end of the converging section may be selected based on desired airflow properties through the converging section. The ratio of the width of the converging section at the second end to the width of the converging section at the first end of the converging section may be selected based on the desired shape and size of the cavity and on the desired shape and size of the aerosol-generating article.

[0028] The width of the converging section at the second end of the converging section may be between 30 percent and 90 percent of the width of the converging section at the second end of the converging section, between 30 percent and 80 percent of the width of the converging section at the second end of the converging section, between 30 percent and 70 percent of the width of the converging section at the second end of the converging section, or between 30 percent and 60 percent of the width of the converging section at the second end of the converging section.

[0029] The width of the converging section at the second end of the converging section may be between 40 percent and 90 percent of the width of the converging section at the second end of the converging section, between 40 percent and 80 percent of the width of the converging section at the second end of the converging section, between 40 percent and 70 percent of the width of the converging section at the second end of the converging section, or between 40 percent and 60 percent of the width of the converging section at the second end of the converging section.

[0030] The width of the converging section at the second end of the converging section may be between 50 percent and 90 percent of the width of the converging section at the second end of the converging section, between 50 percent and 80 percent of the width of the converging section at the second end of the converging section, between 50 percent and 70 percent of the width of the converging section at the second end of the converging section, or between 50 percent and 60 percent of the width of the converging section at the second end of the converging section.

[0031] The difference in the width of the converging section at the first end and at the second end of the converging section may be less than or equal to 6 millimetres, less than or equal to 5 millimetres, or less than or equal to 4 millimetres.

[0032] The difference in the width of the converging section at the first end and at the second end of the converging section may be at least 2 millimetres, or at least 2.5 millimetres, or at least 3 millimetres.

[0033] The difference in the width of the converging section at the first end and at the second end of the converging section may be selected based on desired airflow properties through the converging section. The difference in the width of the converging section at the first end and at the second end of the converging section may be selected based on the desired shape and size of the cavity and on the desired shape and size of the aerosol-generating article.

[0034] The difference in the width of the converging section at the first end and at the second end of the converging section may be between 2 millimetres and 6 millimetres, between 2 millimetres and 5 millimetres, or between 2 millimetres and 4 millimetres.

[0035] The difference in the width of the converging section at the first end and at the second end of the converging section may be between 2.5 millimetres and 6 millimetres, between 2.5 millimetres and 5 millimetres, or between 2.5 millimetres and 4 millimetres.

[0036] The difference in the width of the converging section at the first end and at the second end of the converging section may be between 3 millimetres and 6 millimetres, between 3 millimetres and 5 millimetres, or between 3 millimetres and 4 millimetres. The width of the converging section at the first end of the converging section may be equal to the width of the cavity. In other words, the maximum width of the cavity may be at the first end of the converging section of the cavity.

[0037] The converging section may extend along at least 30 percent of the length of the cavity. In other words, the converging section may have a length greater than or equal to 30 percent of the length of the cavity. The converging section may have a length greater than or equal to 40 percent of the length of the cavity, or greater than or equal to 50 percent of the length of the cavity.

[0038] A longer converging section may provide for a slowly converging section and avoid sharp and sudden changes in the cross-sectional area of the cavity and thus in the cross- sectional area of an airflow passage through the cavity. A longer converging section may thus result in more laminar airflow through the converging section.

[0039] The converging section may have a length less than or equal to 80 percent of the length of the cavity, less than or equal to 70 percent of the length of the cavity, or less than or equal to 60 percent of the length of the cavity.

[0040] The length of the converging section may be selected based on a desired balance between the desired airflow properties through the converging section and the desired shape and size of the cavity and on the desired shape and size of the aerosol-generating article.

[0041] The converging section may have a length between 30 percent and 90 percent of the length of the cavity, between 30 percent and 80 percent of the length of the cavity, between 30 percent and 70 percent of the length of the cavity, or between 30 percent and 60 percent of the length of the cavity.

[0042] The converging section may have a length between 40 percent and 90 percent of the length of the cavity, between 40 percent and 80 percent of the length of the cavity, between 40 percent and 70 percent of the length of the cavity, or between 40 percent and 60 percent of the length of the cavity.

[0043] The converging section may have a length between 50 percent and 90 percent of the length of the cavity, between 50 percent and 80 percent of the length of the cavity, between 50 percent and 70 percent of the length of the cavity, or between 50 percent and 60 percent of the length of the cavity.

[0044] For example, the width of the converging section at the second end of the converging section may be between 30 percent and 90 percent of the width of the converging section at the first end of the converging section, and the converging section may have a length between 30 percent and 80 percent of the length of the converging section.

[0045] The length of the converging section is greater than the width of the converging section at the first end of the converging section. The length of the converging section may be at least 1.2 times, at least 1.5 times, at least 2 times the width of the converging section at the first end of the converging section. The length of the converging section may be up to 3 times the width of the converging section at the first end of the converging section.

[0046] The difference in the width of the converging section at the first end of the converging section and the width of the converging section at the second end of the converging section divided by the length of the converging section may be less than or equal to 1 millimetre per millimetre, less than or equal to 0.8 millimetre per millimetre, less than or equal to 0.6 millimetre per millimetre, or less than or equal to 0.4 millimetre per millimetre. For example, where the converging section has a width of 6 millimetres at the first end of the converging section, a width of 3 millimetres at the second end of the converging section, and a length of 10 millimetres, the difference in the width of the converging section at the first end of the converging section and the width of the converging section at the second end of the converging section divided by length of the converging section is 0.3 millimetres per millimetre.

[0047] The difference in the width of the converging section at the first end of the converging section and the width of the converging section at the second end of the converging section divided by length of the converging section may be greater than or equal to 0.1 millimetre per millimetre.

[0048] The difference in the width of the converging section at the first end of the converging section and the width of the converging section at the second end of the converging section divided by length of the converging section may be between 0.1 millimetre per millimetre and 1 millimetre per millimetre, between 0.1 millimetre per millimetre and 0.8 millimetre per millimetre, between 0.1 millimetre per millimetre and 0.6 millimetre per millimetre, or between 0.1 millimetre per millimetre and to 0.4 millimetre per millimetre.

[0049] The difference in the width of the converging section at the first end of the converging section and the width of the converging section at the second end of the converging section divided by length of the converging section captures the rate of change in the width of the converging section along the length of the converging section. Decreasing the rate of change in the width may promote more laminar airflow through the converging section.

[0050] The aerosol-generating article comprises one or more aerosol-generating substrates.

[0051] The converging section of the cavity may be substantially free of aerosol-generating substrate. The converging section of the cavity may not comprise aerosol-generating substrate located within it.

[0052] The converging section of the cavity may be substantially empty.

[0053] The aerosol-generating article has a length extending in an x-direction. The aerosolgenerating article has a width extending in a y-direction. The aerosol-generating article has a thickness extending in a z-direction.

[0054] 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 be less than both a length and a width of the aerosol-generating article. For example, 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 aerosolgenerating substrate during heating.

[0055] The aerosol-generating article may have a quadrilaterally-faced hexahedron shape. The aerosol-generating article may have a rectangular prism shape. The aerosol-generating article may have a cuboid shape. The aerosol-generating article may have a cylindrical shape. The aerosol-generating article may have a right-angled cylinder shape.

[0056] The aerosol-generating article may have a laminated or layered structure, for example the aerosol-generating article may comprise or be formed from at least two layers. In particular, the aerosol-generating article may comprise at least two of: a first external layer, a second external layer, a frame, a first frame layer, a second frame layer, a third frame layer, a first aerosol-generating substrate layer, and a second aerosol-generating substrate layer as discussed in more detail below.

[0057] 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.

[0058] 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.

[0059] The aerosol-generating article may comprise a frame. The frame may be located between the first planar external surface and the second planar external surface.

[0060] The frame may at least partially define the cavity. The frame may at least partially define the converging section of the cavity.

[0061] The frame may be a planar frame.

[0062] The frame may define a frame aperture extending through the thickness of the frame. The frame aperture may define or form an 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.

[0063] 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.

[0064] 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 inner surface may circumscribe or encircle the cavity.

[0065] 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.

[0066] 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 aerosolgenerating article. The frame may at least partially define each of the one or more external walls. The one or more external walls may circumscribe or encircle the cavity. The frame may define at least 60 percent, at least 70 percent, at least 80 percent, or at least 90 percent of the entire transverse external area of the aerosol-generating article.

[0067] The frame may comprise a peripheral wall. The peripheral wall may circumscribe or encircle at least a portion of the cavity. The peripheral wall may circumscribe or encircle the cavity. 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 the frame aperture extending through the thickness of the frame.

[0068] 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 at least a portion of the cavity. The peripheral wall may define the cavity. The peripheral wall may define or form a cavity outer wall.

[0069] The peripheral wall may circumscribe or define at least a portion of the cavity. The peripheral wall may circumscribe or define the cavity.

[0070] 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.

[0071] The peripheral wall may have a radial thickness greater than or equal to 0.5 millimetres. The peripheral wall may have a radial thickness greater than or equal to 1.5 millimetres. The peripheral wall may have a radial thickness greater than or equal to 2.5 millimetres. The peripheral wall may have a radial thickness less than or equal to 3.5 millimetres. The peripheral wall may have a radial thickness less than or equal to 2.5 millimetres.

[0072] The peripheral wall may have a radial thickness between 0.5 millimetres and 3.5 millimetres. The peripheral wall may have a radial thickness between 0.5 millimetres and 2.5 millimetres.

[0073] 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 aerosolgenerating article whilst not using excess amounts of material which may increase manufacturing costs, and may limit the amount of heat that is undesirably transferred to the frame rather than the aerosol-generating substrate.

[0074] The peripheral wall may comprise a front wall and a back wall. The front wall is at the upstream end or first end of the peripheral wall. The back wall is at the downstream end or second end of the peripheral wall.

[0075] The peripheral wall may comprise one or more side walls extending from the front wall to the back wall. The peripheral wall may comprise a first side wall extending from the front wall to the back wall. The first side wall may comprise or consist of a first converging side wall section and a first parallel side wall section, as discussed below. The peripheral wall may comprise a second side wall extending from the front wall to the back wall. The second side wall may comprise or consist of a second converging side wall section and a second parallel side wall section, as discussed below.

[0076] The peripheral wall of the frame may comprise a first converging side wall section and a second converging side wall section.

[0077] The first converging side wall section may have a length. The second converging side wall section may have a length.

[0078] The first converging side wall section and the second converging side wall section may both define at least a portion of the converging section of the cavity. The first converging side wall section and the second converging side wall section may define at least a portion of the length of the converging section of the cavity. The first converging side wall section and the second converging side wall section may define the entire length of the converging section of the cavity.

[0079] The first converging side wall section may extend from the first end of the converging section of the cavity to the second end of the converging section of the cavity. The second converging side wall section may extend from the first end of the converging section of the cavity to the second end of the converging section of the cavity.

[0080] The second converging side wall section may oppose the converging side wall section. This may be such that the separation between the first and the second converging side wall sections define a width of the converging section of the cavity. The first and second converging side wall sections may not be parallel to one another. The first converging side wall section and the second converging side wall section may both not be parallel to the x direction.

[0081] The width of one or both of the first and the second converging side wall sections may increase along the x-direction. The width of one or both of the first and the second converging side wall sections may increase along the x-direction from the first end of the converging section towards the second end of the converging section. The width of one or both of the first and second converging side wall sections may decrease along the x-direction from the second end of the converging section towards the first end of the converging section. The width of one or both of the first and the second converging side wall sections may increase along the x- direction from the first end of the converging section to the second end of the converging section.

[0082] An internal surface of the first converging side wall section may define at least a portion of the converging section of the cavity. An internal surface of the second converging side wall section may define at least a portion of the converging section of the cavity.

[0083] An internal surface of the first converging side wall section and an internal surface of the second converging side wall section may be at an angle relative to one another of less than or equal to 35 degrees, less than or equal to 30 degrees, less than or equal to 25 degrees, or less than or equal to 20 degrees.

[0084] The first converging side wall section and the second converging side wall section having internal surfaces at a smaller angle relative to one another may promote more laminar airflow.

[0085] An internal surface of the first converging side wall section and an internal surface of the second converging side wall section may be at an angle relative to one another of at least 5 degrees ,or at least 10 degrees.

[0086] The angle at which the internal surfaces of the first converging side wall section and the second converging side wall sections are at relative to one another may be selected based on desired airflow properties through the converging section and the overall shape and size of the cavity and the overall shape and size of the aerosol-generating article.

[0087] An internal surface of the first converging side wall section and an internal surface of the second converging side wall section may be at an angle relative to one another of between 5 degrees and 35 degrees, 5 degrees and 30 degrees, 5 degrees and 25 degrees, or 5 degrees and 20 degrees.

[0088] An internal surface of the first converging side wall section and an internal surface of the second converging side wall section may be at an angle relative to one another of between 10 degrees and 35 degrees, 10 degrees and 30 degrees, 10 degrees and 25 degrees, or 10 degrees and 20 degrees. An internal surface of the first converging side wall section may be planar. An internal surface of the second converging side wall section may be planar. An internal surface of the first converging side wall section and an internal surface of the second converging side wall section may both be planar.

[0089] The converging section of the cavity may have a cross-section in the x / y plane substantially in the shape of a trapezium.

[0090] An external surface of the first converging side wall section may be planar. An external surface of the second converging side wall section may be planar. An external surface of the first converging side wall section and an external surface of the second converging side wall section may both be planar.

[0091] An external surface of the first converging side wall section may be substantially parallel to an external surface of the second converging side wall section.

[0092] An external surface of both the first converging side wall section and the second converging side wall section may be parallel to the x-direction.

[0093] The converging section may be located towards the second end or downstream end of the cavity. The converging section may extend to the second end of the cavity.

[0094] The converging section of the cavity may extend to the back wall of the peripheral wall. The first and second converging side wall sections of the peripheral wall may both extend to the back wall of the peripheral wall.

[0095] The converging section may be located towards the second end or downstream end of the aerosol-generating article. The converging section may extend to an air outlet of the aerosol-generating article. In particular, one or more internal surfaces of the converging section may extend to an air outlet of the aerosol-generating article. The width of the converging section at the second end of the converging section may be substantially the same as the width of the air outlet.

[0096] The cavity may not comprise another converging section located immediately downstream of the converging section. Where the cavity comprises another section located immediately downstream of the converging section and extending from the second end of the converging section towards the second end of the cavity, the width of this another section may not immediately decrease along the length of this another section from the second end of the converging section or first end of this another section towards the second end of this another section or second end of the cavity.

[0097] The cavity may comprise a non-converging section. The non-converging section of the cavity may extend from a first or upstream end to a second or downstream end of the nonconverging section. The cavity may comprise a parallel section. The parallel section of the cavity has a constant width along the entire length of the parallel section. The parallel section of the cavity may extend from a first or upstream end to a second or downstream end of the parallel section.

[0098] The peripheral wall of the frame may comprise a first parallel side wall section and a second parallel side wall section. The first parallel side wall section and the second parallel side wall section may oppose one another. The separation between the first and the second parallel side wall sections may define a width of the parallel section of the cavity.

[0099] The first parallel side wall section may have a length. The second parallel side wall section may have a length. The first parallel side wall section may be parallel to the second parallel side wall section. The first parallel side wall section and the second parallel side wall section may both be parallel to the x-direction. The first parallel side wall and the second parallel side wall may both extend in the x / z plane.

[0100] The first parallel side wall section and the second parallel side wall section may both define at least a portion of the parallel section of the cavity. The first parallel side wall section and the second parallel side wall section may define at least a portion of the length of the parallel section of the cavity. The first parallel side wall section and the second parallel side wall section may define the entire length of the parallel section of the cavity.

[0101] The first parallel side wall section may extend from the first end of the parallel section of the cavity to the second end of the parallel section of the cavity. The parallel converging side wall section may extend from the first end of the parallel section of the cavity to the second end of the parallel section of the cavity.

[0102] The width of both of the first and the second parallel side wall sections may be constant along the x-direction.

[0103] An internal surface of the first parallel side wall section may define at least a portion of the parallel section of the cavity. An internal surface of the second parallel side wall section may define at least a portion of the parallel section of the cavity.

[0104] An internal surface of the first parallel side wall section may be planar. An internal surface of the second parallel side wall section may be planar. An internal surface of the first parallel side wall section and an internal surface of the second parallel side wall section may both be planar.

[0105] The parallel section of the cavity may have a cross-section in the x / y plane substantially in the shape of a rectangle or a square.

[0106] The parallel section may be located towards the first end or upstream end of the cavity.

[0107] The parallel section may extend to the first end of the cavity. The parallel section may be located at the upstream or first end of the cavity. In other words, the first end of the parallel section may be at the first end of the cavity. The parallel section of the cavity may extend to the front wall of the peripheral wall. The first and second parallel side wall sections of the peripheral wall may both extend to the back wall of the peripheral wall.

[0108] The parallel section may be located towards the first end or upstream end of the aerosol-generating article. The parallel section may extend to an air inlet of the aerosolgenerating article.

[0109] The parallel section of the cavity may be located adjacent to the converging section of the cavity. The parallel section of the cavity may be immediately adjacent to the converging section of the cavity. The cavity may comprise no sections located between the parallel section and the converging section. The parallel section of the cavity may be located upstream of the converging section of the cavity. For example, the second end of the parallel section of the cavity may coincide with the first end of the converging section of the cavity.

[0110] The first parallel side wall section may extend from the front wall of the peripheral wall to the first converging side wall section. In particular, the first parallel side wall section may extend from the front wall of the peripheral wall to the first end of the first converging side wall section. The first converging side wall section may extend from the first parallel side wall section to the backwall of the peripheral wall. In particular, the first converging side wall section may extend from the second end of the first parallel side wall section to the back wall of the peripheral wall.

[0111] The second parallel side wall section may extend from the front wall of the peripheral wall to the second converging side wall section. In particular, the second parallel side wall section may extend from the front wall of the peripheral wall to the first end of the second converging side wall section. The second converging side wall section may extend from the second parallel side wall section to the backwall of the peripheral wall. In particular, the second converging side wall section may extend from the second end of the second parallel side wall section to the back wall of the peripheral wall.

[0112] The aerosol-generating article may comprise an airflow pathway or passage extending from an air inlet of the aerosol-generating article to an air outlet of the aerosol-generating article through both the parallel section and the converging section of the cavity. During use of the aerosol-generating article, air may be drawn into the aerosol-generating article through an air inlet at the first end of the aerosol-generating article, into the parallel section of the cavity, then into the converging section of the cavity, and then out of the aerosol-generating article through the air outlet.

[0113] The width of the parallel section of the cavity may correspond to the width of the converging section of the cavity at the first end of the converging section. The parallel section may have a length greater than or equal to 20 percent of the length of the cavity, greater than or equal to 30 percent of the length of the cavity, or greater than or equal to 40 percent of the length of the cavity.

[0114] The parallel section may have a length less than or equal to 70 percent, less than or equal to 60 percent, or less than or equal to 50 percent of the length of the cavity.

[0115] The parallel section may have a length between 20 percent and 70 percent, between 20 percent and 60 percent, or between 20 percent and 50 percent of the length of the cavity. The parallel section may have a length between 30 percent and 70 percent, between 30 percent and 60 percent, or between 30 percent and 50 percent of the length of the cavity. The parallel section may have a length between 40 percent and 70 percent, between 40 percent and 60 percent, or between 40 percent and 50 percent of the length of the cavity.

[0116] The length of the cavity may be equal to the sum of the length of the parallel section and the length of the converging section. The cavity may consist of the parallel section and the converging section.

[0117] At least one of the one or more aerosol-generating substrates may be located towards the first or upstream end of the aerosol-generating article. At least one of the one or more aerosol-generating substrates may be located in the parallel section of the cavity.

[0118] At least one of the one or more aerosol-generating substrates may have a length substantially the same as a length of the parallel section of the cavity. At least one or more aerosol-generating substrates may be located in the parallel section of the cavity and extend from the first end of the parallel section to the second end of the parallel section.

[0119] The parallel section of the cavity may be shaped and sized to accommodate at least one of the one or more aerosol-generating substrates. This may be such that the aerosolgenerating substrate is effectively heated during use of the aerosol-generating article.

[0120] At least one of the one or more aerosol-generating substrates may have a length less than a length of the parallel section of the cavity.

[0121] At least one of the one or more aerosol-generating substrates may be spaced apart in the x-direction from the second end of the parallel section. At least one or more aerosolgenerating substrates may be located in the parallel section of the cavity and extend from the first end of the parallel section towards the second end of the parallel section.

[0122] At least one of the one or more aerosol-generating substrates may be spaced apart in the x-direction from the first end of the parallel section. At least one or more aerosol-generating substrates may be located in the parallel section of the cavity and extend from the second end of the parallel section to the first end of the parallel section.

[0123] At least one of the one or more aerosol-generating substrates may be spaced apart in the x-direction from both the first end of the parallel section and the second end of the parallel section. At least one of the one or more aerosol-generating substrates may have a width substantially the same as a width of the parallel section of the cavity.

[0124] The converging section having decreasing width may prevent aerosol-generating substrate being dislodged into the converging section.

[0125] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0126] 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. The frame may not be an aerosol-generating substrate. The frame may comprise less than or equal to 5 percent of aerosol former, less than or equal to 2 percent of aerosol former, or less than or equal to 1 percent of aerosol former, on a dry weight basis.

[0127] The peripheral wall of the frame may be made from or comprise a biodegradable material. The peripheral wall of the frame may be made entirely from a biodegradable material.

[0128] The peripheral wall of 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 peripheral wall of the frame may be made from or comprise a plant material, such as tobacco. The peripheral wall of the frame may be made entirely from a cellulosic material. The peripheral wall of the frame may not be an aerosol-generating substrate. The peripheral wall of the frame may comprise less than or equal to 5 percent of aerosol former, less than or equal to 2 percent of aerosol former, or less than or equal to 1 percent of aerosol former, on a dry weight basis.

[0129] The aerosol-generating article may comprise one or more susceptor materials. The frame may comprise one or more susceptor materials. The one more susceptor materials may be in thermal contact with the aerosol-generating substrate. The one more susceptor materials may be in thermal contact with the cavity. The one or more susceptor materials may be incorporated within the material of the frame. For example, the one or more susceptor material may be incorporated within the peripheral wall of the frame.

[0130] 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.

[0131] 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. The frame may have a thickness greater than or equal to 50 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 70 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 90 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 95 percent of the thickness of the aerosolgenerating article.

[0132] The frame may have a thickness less than or equal to 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 90 percent of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 70 percent of the thickness of the aerosol-generating article.

[0133] The frame may have a thickness between 50 percent of the thickness of the aerosolgenerating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 70 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article.

[0134] The frame may have a thickness greater than or equal to 1 millimetre, greater than or equal to 2 millimetres, greater than or equal to 3 millimetres, or greater than or equal to 4 millimetres. The frame may have a thickness less than or equal to 5.5 millimetres, less than or equal to 4.5 millimetres, less than or equal to 3.5 millimetres, less than or equal to 2.5 millimetres, or less than or equal to 1.5 millimetres. The frame may have a thickness between 1 millimetre and 5.5 millimetres. Preferably, the frame may have a thickness between 1.5 millimetres and 5.5 millimetres.

[0135] 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 aerosolgenerating article. The frame may have a length that is at least 95 percent of the length of the aerosol-generating article.

[0136] 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.

[0137] 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.

[0138] The frame may comprise a first frame layer and a second frame layer. The first frame layer and the second frame layer may be the only layers of the frame. That is, the frame may comprise no more than two layers or may comprise exactly two layers. The frame aperture may be defined through both the first frame layer and the second frame layer. 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.

[0139] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate layer. Advantageously, the aerosol-generating substrate layer can be made thin and, therefore, quickly heat up and release volatile compounds to form an aerosol. Advantageously, the aerosol-generating substrate layer can be positioned close to a heater of an aerosolgenerating device.

[0140] The aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. The aerosol-generating substrate layer may be, and may be made entirely of, a sheet of aerosol-generating material.

[0141] 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.

[0142] 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.

[0143] 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 aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the second planar external layer.

[0144] The aerosol-generating substrate layer may overlie an end of the cavity. The aerosolgenerating substrate layer may define at least a portion of the cavity. The aerosol-generating 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, an airflow passage thereby allowing released volatile compounds to quickly form an aerosol. The one or more aerosol-generating substrates may comprise a first aerosolgenerating 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.

[0145] 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.

[0146] 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.

[0147] 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.

[0148] 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.

[0149] 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.

[0150] 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.

[0151] 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.

[0152] 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 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.

[0153] One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 100 micrometres, greater than or equal to 200 micrometres, greater than or equal to 300 micrometres, greater than or equal to 400 micrometres, or greater than or equal to 500 micrometres.

[0154] One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness less than or equal to 600 micrometres, less than or equal to 500 micrometres, less than or equal to 400 micrometres, less than or equal to 300 micrometres, or less than or equal to 300 micrometres.

[0155] One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness between 100 micrometres and 600 micrometres, between 200 micrometres and 500 micrometres, between 200 micrometres and 400 micrometres, or between 200 micrometres and 300 micrometres.

[0156] 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.

[0157] 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.

[0158] 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.

[0159] 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.

[0160] 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. 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.

[0161] The first planar external surface may be a planar upper surface and the second planar external surface may be a planar lower surface. The first planar external surface may be positioned parallel to the second planar external surface. The first planar external surface may extend in the x / y plane. The second planar external surface may extend in the x / y plane. The second planar external surface may be spaced from the first planar external surface in the z- direction or transverse direction. The distance between the first planar external surface and the second planar external surface in the z-direction or transverse direction may define the thickness of the aerosol-generating article.

[0162] The aerosol-generating article may comprise an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may comprise a hydrophobic material.

[0163] The outer wrapper may define or form the first planar external surface. The outer wrapper may define or form the second planar external surface. The outer wrapper may define or form both the first planar external surface and the second planar external surface.

[0164] 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.

[0165] 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.

[0166] 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.

[0167] 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.

[0168] The first planar external layer may define or form the first planar external surface. The first planar external layer may extend in the x / y plane. The second planar external layer may define or form the second planar external surface. The second planar external layer may extend in the x / y plane. The frame may be positioned between the first planar external layer and the second planar external layer. The cavity may be defined by the frame, the first planar external layer and the second planar external layer.

[0169] The first planar external layer may be in physical contact with, and may be bonded to, the frame. The first planar external layer may overlie an end of the cavity. The first planar external layer may define or form a wall of the cavity, such as the first cavity end wall or top wall.

[0170] The second planar external layer may be in physical contact with, and may be bonded to, the frame. The second planar external layer may overlie an end of the cavity. The second planar external layer may define or form a wall of the cavity, such as the second cavity end wall or bottom wall.

[0171] 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 or top wall and the second cavity end wall or bottom wall. That is, the frame, the first planar external layer and the second planar external layer may collectively define the cavity.

[0172] At least one of the one or more aerosol-generating substates may be located between the first planar external layer and the second planar external layer.

[0173] 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.

[0174] 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 aerosolgenerating 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 aerosol-generating substrate layer or the second aerosol-generating substrate layer.

[0175] 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.

[0176] One or more of the outer wrapper, the first planar external layer and the second planar external layer may comprise, or be made from, a cellulosic material. The cellulosic material may be paper, cigarette paper, tobacco paper, cardboard, wood, textile, natural fibres or artificial fibres. One or more of the outer wrapper, the first planar external layer and the second planar external layer may be an aerosol-generating substrate comprising an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. In particular, the aerosol-generating material may be in the form of a sheet of aerosolgenerating material. The sheet of aerosol-generating material may be any sheet of aerosolgenerating material described herein. Alternatively, one or more of the outer wrapper, the first planar external layer and the second planar external layer may not comprise any aerosolgenerating material, particularly in embodiments comprising an aerosol-generating substrate layer, a first aerosol-generating substrate layer, a second aerosol-generating substrate layer or an aerosol-generating substrate positioned within the cavity. One or more of the outer wrapper, the first planar external layer and the second planar external layer may be substantially nicotine-free.

[0177] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness greater than or equal to 25 micrometres, greater than or equal to 30 micrometres, greater than or equal to 35 micrometres, greater than or equal to 40 micrometres, or greater than or equal to 45 micrometres.

[0178] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness less than or equal to 55 micrometres, less than or equal to 50 micrometres, less than or equal to 45 micrometres, less than or equal to 40 micrometres, or less than or equal to 35 micrometres.

[0179] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness between 25 micrometres and 55 micrometres, between 25 micrometres and 45 micrometres, or between 30 micrometres and 45 micrometres.

[0180] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a length substantially the same as the length of the frame. One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a length substantially the same as the length of the aerosol-generating article.

[0181] One or more of the first planar external layer and the second planar external layer may have a width substantially the same as the width of the frame. One or more of the first planar external layer and the second planar external layer may have a width substantially the same as the width of the aerosol-generating article.

[0182] The cavity may have a thickness greater than or equal to 0.5 millimetres. The cavity may have a thickness greater than or equal to 1 .5 millimetres. The cavity may have a thickness greater than or equal to 2.5 millimetres. The cavity may have a thickness greater than or equal to 3.5 millimetres.

[0183] The cavity may have a thickness less than or equal to 4.5 millimetres. The cavity may have a thickness less than or equal to 3.5 millimetres. The cavity may have a thickness less than or equal to 2.5 millimetres. The cavity may have a thickness less than or equal to 1.5 millimetres.

[0184] The cavity may have a thickness between 0.5 millimetres and 4.5 millimetres. The cavity may have a thickness between 1 millimetre and 4.5 millimetres. Preferably, the cavity may have a thickness between 2.8 millimetres and 3.3 millimetres.

[0185] The cavity may have a length greater than or equal to 14 millimetres. The cavity may have a length equal to a greater than 18 millimetres. The cavity may have a length greater than or equal to 22 millimetres. The cavity may have a length greater than or equal to 30 millimetres. The cavity may have a length greater than or equal to 38 millimetres.

[0186] The cavity may have a length less than or equal to 40 millimetres. The cavity may have a length less than or equal to 34 millimetres. The cavity may have a length less than or equal to 28 millimetres. The cavity may have a length less than or equal to 22 millimetres. The cavity may have a length less than or equal to 18 millimetres.

[0187] The cavity may have a length between 14 millimetres and 40 millimetres. The cavity may have a length between 14 millimetres and 34 millimetres. . The cavity may have a length between 24 millimetres and 28 millimetres.

[0188] The cavity may have a width greater than or equal to 4.5 millimetres. The cavity may have a width greater than or equal to 7 millimetres. The cavity may have a width greater than or equal to 11 millimetres.

[0189] The cavity may have a width less than or equal to 13 millimetres. The cavity may have a width less than or equal to 11 millimetres. The cavity may have a width less than or equal to 7 millimetres. The cavity may have a width less than or equal to 5 millimetres.

[0190] The cavity may have a width between 4.5 millimetres and 13 millimetres. The cavity may have a width between 7 millimetres and 10 millimetres. The cavity may have a width between 7.5 millimetres and 8.5 millimetres.

[0191] 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.

[0192] 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.

[0193] Most preferably, the cavity may have a length of 26 millimetres, a width of 8 millimetres, and a thickness of 3.1 millimetres.

[0194] The cavity may have a volume of greater than or equal to 30 cubic millimetres, greater than or equal to 100 cubic millimetres, greater than or equal to 300 cubic millimetres, greater than or equal to 500 cubic millimetres, greater than or equal to 700 cubic millimetres, greater than or equal to 900 cubic millimetres, greater than or equal to 1000 cubic millimetres, greater than or equal to 2000 cubic millimetres, or greater than or equal to 30 cubic millimetres.

[0195] The cavity may have a volume of less than or equal to 3500 cubic millimetres, less than or equal to 2500 cubic millimetres, less than or equal to 1500 cubic millimetres, less than or equal to 1000 cubic millimetres, less than or equal to 800 cubic millimetres, less than or equal to 600 cubic millimetres, less than or equal to 500 cubic millimetres, less than or equal to 400 cubic millimetres, or less than or equal to 300 cubic millimetres.

[0196] The cavity may have a volume between 30 cubic millimetres and 3500 cubic millimetres. The cavity may have a volume between 30 cubic millimetres and 2500 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 1500 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 1000 cubic millimetres.

[0197] The cavity may be substantially empty.

[0198] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate positioned within the cavity. The aerosol-generating substrate positioned within the cavity may fill the cavity.

[0199] The aerosol-generating substrate positioned within the cavity may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. For example, the aerosol-generating material may be in the form of shredded aerosol-generating material.

[0200] The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. For example, the sheet of aerosol-generating material may be a sheet of homogenised tobacco material.

[0201] The sheet of aerosol-generating material may extend the entire length of the cavity. The sheet of aerosol-generating material may extend the entire width of the cavity.

[0202] The sheet of aerosol-generating material may be a gathered sheet of aerosolgenerating 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 aerosol-generating article.

[0203] The sheet of aerosol-generating material may be a crimped sheet of aerosolgenerating material. The sheet of aerosol-generating material may be a corrugated sheet of aerosol-generating material. The crimped sheet of aerosol-generating material or the corrugated sheet of aerosol-generating material may comprise a plurality of parallel corrugations. For example, the crimped sheet of aerosol-generating material may comprise a plurality of substantially parallel peaks and troughs. 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.

[0204] The plurality of parallel corrugations may define, or form, a plurality of channels between the sheet of aerosol-generating material and one or more walls of the cavity. The plurality of channels may be a plurality of longitudinally extending channels. The plurality of channels may be a plurality of laterally extending channels. The plurality of channels may defined, or form, at least a portion of an airflow passage extending between the air inlet and air outlet of the aerosol-generating article.

[0205] The aerosol-generating material may comprise one or more organic materials such as tobacco, mint, tea and cloves. The aerosol-generating material may comprise one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenised tobacco such as cast leaf, extruded tobacco, expanded tobacco, aerosol-generating films and gel compositions.

[0206] 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.

[0207] The aerosol-generating material may be cut filler. The aerosol-generating material may be tobacco cut filler. As used herein, the term “cut filler” is used to describe to a blend of shredded plant material, such as tobacco plant material, including, in particular, one or more of leaf lamina, processed stems and ribs, homogenised plant material.

[0208] The aerosol-generating material may be in the form of a sheet of aerosol-generating material. As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenised tobacco material, such as a cast leaf sheet.

[0209] The aerosol-generating material may comprise one or more aerosol-formers. Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosol-formers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosol-former to be or comprise one or both of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0210] The aerosol-generating material may have an aerosol-former content greater than or equal to 1 , 2, 5, 10, or 15 percent by weight on a dry weight basis. The aerosol-generating material may have an aerosol-former content greater than or equal to 15 percent by weight on a dry weight basis, for example greater than 20 by weight on a dry weight basis, or greater than 25 by weight on a dry weight basis, or greater than 30 by weight on a dry weight basis, or greater than 40 by weight on a dry weight basis, or greater than 50 by weight on a dry weight basis.

[0211] The aerosol-generating material may have an aerosol-former content less than or equal to 30 percent by weight on a dry weight basis, less than or equal to 25 percent by weight on a dry weight basis, or less than or equal to 20 percent by weight on a dry weight basis.

[0212] The aerosol-generating material may have an aerosol-former content between 5 percent and 30 percent by weight on a dry weight basis, between 5 percent and 25 percent by weight on a dry weight basis, or between 5 percent and 20 percent by weight on a dry weight basis.

[0213] The aerosol-generating material may have an aerosol-former content between 10 percent and 30 percent by weight on a dry weight basis, between 10 percent and 25 percent by weight on a dry weight basis, or between 10 percent and 20 percent by weight on a dry weight basis.

[0214] The aerosol-generating material may comprise nicotine. The aerosol-generating material may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0215] The aerosol-generating material may comprise at least 0.5 percent by weight of nicotine, at least 1 percent by weight of nicotine, at least 1 .5 percent by weight of nicotine, or at least 2 percent by weight of nicotine. That is, the aerosol-generating material may have a nicotine content of at least 0.5 percent by weight, at least 1 percent by weight, at least 1.5 percent by weight, or at least 2 percent by weight.

[0216] The aerosol-generating material may be in the form of a plurality of beads. The plurality of beads may have an average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm.

[0217] The term “bead” refers to a discrete, solid particle formed of the aerosol-generating substrate. A bead may have a rounded, typically spherical, form. Other terms may be used to define the substrate such as, for example, “granule”.

[0218] Providing the aerosol-generating material as a plurality of beads may provide certain advantages. Beads can be easily handled compared to other aerosol-forming substrates such as fine powders or cut filler. The beads flow easily, and so can reliably and consistently fill the cavity of the aerosol-generating article during manufacture. This may allow a consistent and reproducible amount of aerosol-forming substrate to be loaded into each article during manufacture. Beads may also be cleaner to handle than powders and cut fillers, which may cause dust in factories, and may leak from aerosol-generating articles in transit or in use. By selecting beads with appropriate bead sizes and appropriate particle size distributions, air flow through the cavity of the aerosol-generating article may be controlled more reproducibly than would be the case for, say, a cut filler substrate.

[0219] Where a particle is not perfectly spherical, but a diameter of the particle is referred to, the term “diameter” may refer to a largest dimension of the particle. Alternatively, the term “diameter” may refer to the diameter of a perfectly spherical particle having the same volume as the not perfectly spherical particle.

[0220] The term “average particle diameter”, as used herein, may refer to a number average particle diameter. Other methods of determining average particle diameter are known. Thus, the average particle diameter may be, for example, a volume average particle diameter.

[0221] The aerosol-generating material may be in form of a wrapped body of aerosolgenerating material, the wrapped body comprising a wrapper at least partially enclosing aerosol-generating material.

[0222] The wrapped body of aerosol-generating material may occupy between 15% and 100% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 30% and 100% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 50% and 100% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 50% and 80% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 50% and 70% of the interior volume of the cavity.

[0223] The aerosol-generating article may comprise an air inlet and an air outlet. The aerosolgenerating article may comprise an airflow passage extending between the air inlet and the air outlet. The airflow passage may extend between the air inlet and the air outlet through the cavity. The airflow passage may extend from the air inlet to the air outlet. The airflow passage may extend from the air inlet to the air outlet through the cavity. The airflow passage may extend from the air inlet to the air outlet through the converging section of the cavity. The airflow passage may extend from the air inlet to the air outlet through both the parallel section and the converging section of the cavity.

[0224] The air inlet may be defined by a front wall of the aerosol-generating article. The air inlet may be defined by, and may extend through, the frame. The air inlet may be defined by the peripheral wall of the frame. The air inlet may extend through the peripheral wall of the frame. The air inlet may be defined by the front wall of the frame or the front wall of the peripheral wall of the frame. The air inlet may extend through the front wall of the frame or the front wall of the peripheral wall of the frame. The air outlet may be defined by a back wall of the aerosol-generating article. The air outlet may be defined by, and may extend through, the frame. The air outlet may be defined by the peripheral wall of the frame. The outlet may extend though the peripheral wall of the frame. The air outlet may be defined by the back wall of the frame or the back wall of the peripheral wall of the frame.

[0225] 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.

[0226] The air inlet may be defined by, and may extend through, the first planar external surface. The air inlet may be defined by, and may extend through, the outer wrapper. The air inlet may be defined by, and may extend through, the outer wrapper and the aerosolgenerating substrate layer. The air inlet may be defined by, and may extend through, the outer wrapper and the first aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the first planar external layer and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the first planar external layer and the first aerosol-generating substrate layer.

[0227] The air inlet may be defined by, and may extend through, the second planar external surface. The air inlet may be defined by, and may extend through, the outer wrapper and the second aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the second planar external layer and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the second planar external layer and the second aerosol-generating substrate layer.

[0228] The air outlet may be defined by, and may extend through, the first planar external surface. The air outlet may be defined by, and may extend through, the outer wrapper. The air outlet may be defined by, and may extend through, the outer wrapper and the aerosolgenerating substrate layer. The air outlet may be defined by, and may extend through, the outer wrapper and the first aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the first planar external layer and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the first planar external layer and the first aerosol-generating substrate layer.

[0229] The air outlet may be defined by, and may extend through, the second planar external surface. The air outlet may be defined by, and may extend through, the outer wrapper and the second aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the second planar external layer and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the second planar external layer and the second aerosol-generating substrate layer. One or both of the air inlet and the air outlet may have an equivalent diameter greater than or equal to 0.1 millimetres, greater than or equal to 0.4 millimetres, greater than or equal to 0.7 millimetres, or greater than or equal to 1 .0 millimetres.

[0230] One or both of the air inlet and the air outlet may have an equivalent diameter less than or equal to 3 millimetres, less than or equal to 2.7 millimetres, less than or equal to 2.4 millimetres, less than or equal to 2.1 millimetres. The air inlet may have an equivalent diameter less than or equal to 2.7 millimetres, less than or equal to 1.8 millimetres, or less than or equal to 1.5 millimetres.

[0231] One or both of the air inlet and the air outlet may have an equivalent diameter between 0.1 millimetres and 3 millimetres, between 0.1 millimetres and 2.4 millimetres, between 0.4 millimetres and 2.1 millimetres, between 0.4 millimetres and 1.8 millimetres, between 0.7 millimetres and 1.5 millimetres, or between 1.0 millimetres and 1.5 millimetres.

[0232] 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.

[0233] One or both of the air inlet and the air outlet may a width of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres.

[0234] One or both of the air inlet and the air outlet may have a thickness of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres.

[0235] 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.

[0236] 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.

[0237] 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.

[0238] 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.

[0239] 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.

[0240] The aerosol-generating article may comprise a plurality of air inlets. One or each of the air inlets may have one or more of the features of the air inlet described herein.

[0241] The aerosol-generating article may comprise a plurality of air outlets. One or each of the air outlets may have one or more of the features of the air outlet described herein.

[0242] The aerosol-generating article may comprise a filter element positioned downstream of the aerosol-forming substrate. The aerosol-generating article may comprise a filter element positioned downstream of the cavity. The aerosol-generating article may comprise a filter element at least partially positioned within the air outlet. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at a downstream end of, the cavity.

[0243] The aerosol-generating article may comprise a filter element positioned upstream of the aerosol-forming substrate. The aerosol-generating article may comprise a filter element positioned upstream of the cavity. The aerosol-generating article may comprise a filter element at least partially positioned within the air inlet. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at an upstream end of, the cavity.

[0244] 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.

[0245] A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be greater than 2:1 , greater than 5:1 , greater than 10:1 , greater than 12:1 , or greater than 15:1.

[0246] A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be less than 15:1 , less than 12:1 , less than 10:1 , less than 5:1 , or less than 2.5:1

[0247] A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be between 2:1 and 15:1 , between 2:1 and 12:1 , between 2:1 and 10:1 , or between 5:1 and 10:1.

[0248] A ratio between the length and the width of the aerosol-generating article may be greater than 1 :1 , greater than 2:1 , greater than 3: 1 , greater than 4: 1 , or greater than 5:1.

[0249] A ratio between the length and the width of the aerosol-generating article may be less than 10:1 , less than 8:1 , less than 5:1 , less than 4:1 , less than 3:1 , or less than 2:1.

[0250] A ratio between the length and the width of the aerosol-generating article may be between 1 :1 and 10:1 , between 1 :1 and 5:1 , between 1 :1 and 4:1 , between 1 :1 and 3:1 , between 2:1 and 4:1 , or between 2:1 and 3:1. The aerosol-generating article may have a length greater than or equal to 15 millimetres, greater than or equal to 20 millimetres, greater than or equal to 25 millimetres, greater than or equal to 30 millimetres, greater than or equal to 35 millimetres, or greater than or equal to 40 millimetres.

[0251] The aerosol-generating article may have a length less than or equal to 45 millimetres, less than or equal to 40 millimetres, less than or equal to 35 millimetres, or less than or equal to 30 millimetres.

[0252] The aerosol-generating article may have a length between 15 millimetres and 45 millimetres, between 20 millimetres and 40 millimetres, between 20 millimetres and 35 millimetres, or between 25 millimetres and 30 millimetres.

[0253] The aerosol-generating article may have a width greater than or equal to 3 millimetres, greater than or equal to 5 millimetres, greater than or equal to 7.5 millimetres, greater than or equal to 9 millimetres, greater than or equal to 11 millimetres, or greater than or equal to 13 millimetres.

[0254] The aerosol-generating article may have a width less than or equal to 17 millimetres, less than or equal to 15 millimetres, less than or equal to 12.5 millimetres, less than or equal to 11 millimetres, or less than or equal to 9 millimetres.

[0255] The aerosol-generating article may have a width between 3 millimetres and 17 millimetres, between 5 millimetres and 15 millimetres, between 7.5 millimetres and 12.5 millimetres, or between 9 millimetres and 11 millimetres.

[0256] The width of the aerosol-generating article may be constant along at least 80 percent of the length of the aerosol-generating article, along at least 90 percent of the length of the aerosol-generating article, or along at least 95 percent of the length of the aerosol-generating article. The width of the aerosol-generating article may be constant along substantially the entire length of the aerosol-generating article.

[0257] The aerosol-generating article may have a thickness greater than or equal to than 1 millimetre, greater than or equal to 1.5 millimetres, greater than or equal to 2 millimetres, greater than or equal to 2.5 millimetres, greater than or equal to 3 millimetres, greater than or equal to 3.5 millimetres, greater than or equal to 4 millimetres, or greater than or equal to 4.5 millimetres.

[0258] The aerosol-generating article may have a thickness less than or equal to 5.5 millimetres, less than or equal to 5 millimetres, less than or equal to 4.5 millimetres, less than or equal to 4 millimetres, less than or equal to 3.5 millimetres, less than or equal to 3 millimetres, less than or equal to 2.5 millimetres, or less than or equal to 2 millimetres.

[0259] The aerosol-generating article may have a thickness between 1 millimetres and 5 millimetres, between 1.5 millimetres and 5 millimetres, between 2 millimetres and 4.5 millimetres, between 2.5 millimetres and 4 millimetres, or between 3 millimetres and 3.5 millimetres.

[0260] For example, 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 millimetre and 5 millimetres.

[0261] According to the present disclosure, there is provided an aerosol-generating device for receiving an aerosol-generating article as disclosed herein. The aerosol-generating device comprises a cavity dimensioned to receive at least a portion of the aerosol-generating article. The aerosol-generating device comprises a heater or heating means, a power source for supplying power to the heater or heating means, and a controller to control a supply of power to the heater or heating means. The aerosol-generating device is configured to heat at least one of the one or more aerosol-generating substrates to form an aerosol, for example an inhalable aerosol. The aerosol-generating device may be configured to heat each of the one or more aerosol-generating substrates to form an aerosol, for example an inhalable aerosol.

[0262] According to the present disclosure, an aerosol-generating system comprises an aerosol-generating 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 aerosolgenerating device.

[0263] As used herein, the term “aerosol-generating article” refers to an article comprising an aerosol-generating substrate. The article may be heated in use to produce and deliver an inhalable aerosol to a consumer.

[0264] 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.

[0265] 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.

[0266] 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. As used herein, the term “transverse” refers to a direction extending between the first planar external surface and the second planar external surface. The transverse direction may also be referred to as the “z-di recti on”.

[0267] As used herein, the term “longitudinal” refers to a direction that is perpendicular to the transverse direction. For example, a direction between a front wall and a back wall of the aerosol-generating article. The longitudinal direction may also be referred to as the “x- di recti on”.

[0268] As used herein, the term “lateral” refers to a direction that is perpendicular to the transverse direction and the longitudinal direction. For example, a direction from a first side wall to a second side wall of the aerosol-generating article. The lateral direction may also be referred to as the “y-direction”.

[0269] 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.

[0270] As used herein, the term “length” refers to a maximum dimension of the aerosolgenerating article or a component of the aerosol-generating article in the longitudinal direction.

[0271] As used herein, the term “width” refers to a maximum dimension of the aerosolgenerating article or a component of the aerosol-generating article in the lateral direction.

[0272] 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. The “upstream end” of the aerosol-generating article, components of the aerosolgenerating article, or portions of components of the aerosol-generating article may be referred to as the “first end” or “distal end” of the aerosol-generating article, components of the aerosolgenerating article, or portions of components of the aerosol-generating article, respectively. The “downstream end” of the aerosol-generating article, components of the aerosolgenerating article, or portions of components of the aerosol-generating article may be referred to as the “second end” or “proximal end” of the aerosol-generating article, components of the aerosol-generating article, or portions of components of the aerosol-generating article, respectively.

[0273] As used herein, the term “bulk density” may refer to the total weight of the aerosolgenerating substrate divided by the bulk volume of the aerosol-generating substrate.

[0274] 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.

[0275] As used herein, the term “aerosol former content” may refer to aerosol former content in percent on a dry weight basis, unless otherwise specified. 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.

[0276] 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.

[0277] 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.

[0278] 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.

[0279] EX1 : An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article having a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction, the aerosolgenerating article comprising: one or more aerosol-generating substrates, and a cavity extending in the x-direction between a first end of the cavity and a second end of the cavity.

[0280] EX2: An aerosol-generating article according to EX1 comprising a first planar external surface and a second planar external surface.

[0281] EX3: An aerosol-generating article according to EX2 wherein the first planar external surface extends in an x / y plane, and wherein the second planar external surface extends in an x / y plane.

[0282] EX4: An aerosol-generating article according to any one of EX1 to EX3, wherein the cavity comprises a converging section extending in the x-direction between a first end of the converging section and a second end of the converging section.

[0283] EX5: An aerosol-generating article according to EX4, wherein the width of the converging section decreases along the length of the converging section from the first end to the second end of the converging section.

[0284] EX6: An aerosol-generating article according to EX4 or EX5, wherein the width of the converging section continuously decreases along the entire length of the converging section.

[0285] EX7: An aerosol-generating article according to any one of EX4 to EX6, wherein the width of the converging section at the second end of the converging section is at least 30 percent of the width of the converging section at the first end of the converging section. EX8: An aerosol-generating article according to any one of EX4 to EX7, wherein the width of the converging section at the second end of the converging section is less than or equal to 90 percent of the width of the converging section

[0286] EX9: An aerosol-generating article according to any one of EX4 to EX8, wherein the difference in the width of the converging section at the first end and at the second end of the converging section is less than or equal to 6 millimetres.

[0287] EX10: An aerosol-generating article according to any one of EX4 to EX9, wherein the difference in the width of the converging section at the first end and at the second end of the converging section is at least 2 millimetres.

[0288] EX11 : An aerosol-generating article according to any one of EX4 to EX10, wherein the converging section extends along at least 30 percent of the length of the cavity.

[0289] EX12: An aerosol-generating article according to any one of EX4 to EX11 , wherein the converging section has a length less than or equal to 80 percent of the length of the cavity.

[0290] EX13: An aerosol-generating article according to any one of EX4 to EX12, wherein the length of the converging section is greater than the width of the converging section at the first end of the converging section.

[0291] EX14: An aerosol-generating article according to any one of EX4 to EX13, wherein the length of the converging section is at least 1.2 times the width of the converging section at the first end of the converging section

[0292] EX15: An aerosol-generating article according to any one of EX4 to EX14, wherein thee difference in the width of the converging section at the first end of the converging section and the width of the converging section at the second end of the converging section divided by the length of the converging section is less than or equal to 1 millimetre per millimetre.

[0293] EX16: An aerosol-generating article according to any one of EX4 to EX15, wherein the difference in the width of the converging section at the first end of the converging section and the width of the converging section at the second end of the converging section divided by length of the converging section is greater than or equal to 0.1 millimetre per millimetre.

[0294] EX17: An aerosol-generating article according to any one of EX4 to EX15, wherein the converging section of the cavity is substantially empty.

[0295] EX18: An aerosol-generating article according to any one of EX1 to EX17, wherein the aerosol-generating article is a flat or planar aerosol-generating article.

[0296] EX19: An aerosol-generating article according to any one of EX2 to EX18 comprising a frame located between the first planar external surface and the second planar external surface.

[0297] EX20: An aerosol-generating article according to EX19, wherein the frame comprises a peripheral wall circumscribing or defining at least a portion of the cavity. EX21 : An aerosol-generating article according to EX20, wherein the peripheral wall comprises a front wall, a back wall and one or more side walls extending between the front wall and the back wall.

[0298] EX22: An aerosol-generating article according to EX20 or EX21 , wherein the peripheral wall comprises a first converging side wall section and a second converging side wall section defining at least a portion of the length of the converging section of the cavity.

[0299] EX23: An aerosol-generating article according to EX22, wherein the width of one or both of the first and the second converging side wall sections increases along the x-direction.

[0300] EX24: An aerosol-generating article according to EX22 or EX23, wherein an internal surface of the first converging side wall section and an internal surface of the second converging side wall section are at an angle relative to one another of less than or equal to 35 degrees.

[0301] EX25: An aerosol-generating article according to any one of EX22 to EX24, wherein an internal surface of the first converging side wall section and an internal surface of the second converging side wall section are at an angle relative to one another of greater than or equal to 5 degrees.

[0302] EX26: An aerosol-generating article according to any one of EX22 to EX25, wherein an external surface of both the first converging side wall section and the second converging side wall section may be parallel to the x-direction.

[0303] EX27: An aerosol-generating article according to any one of EX4 to EX26, wherein the converging section is located towards or at the second or downstream end of the cavity.

[0304] EX28: An aerosol-generating article according to any one of EX1 to EX27, wherein the cavity comprises a parallel section.

[0305] EX29: An aerosol-generating article according to EX28, wherein the parallel section is located towards or at the first or upstream end of the cavity.

[0306] EX30: An aerosol-generating article according to EX28 or EX29, wherein the parallel section is located upstream of the converging section.

[0307] EX31 : An aerosol-generating article according to any one of EX28 to EX30, wherein the width of the parallel section is equal to the width of the converging section at the first end of the converging section.

[0308] EX32: An aerosol-generating article according to any one of EX28 to EX31 , wherein the parallel section has a length greater than or equal to 20 percent of the length of the cavity.

[0309] EX33: An aerosol-generating article according to any one of EX28 to EX32, wherein the parallel section has a length less than or equal to 70 percent of the length of the cavity.

[0310] EX34: An aerosol-generating article according to any one of EX28 to EX33, wherein at least one of the one or more aerosol-generating substrates is located in the parallel section of the cavity. EX35: An aerosol-generating article according to any one of EX20 to EX34, wherein the peripheral wall is formed from paper, paperboard, or cardboard.

[0311] EX36: An aerosol-generating article according to any one of EX1 to EX35, wherein the aerosol-generating article or the frame has a laminated structure.

[0312] EX37: An aerosol-generating article according to any one of EX1 to EX36, wherein the one or more aerosol-generating substrates comprise a sheet of aerosol-generating material defining at least a portion of the cavity.

[0313] EX38: An aerosol-generating article according to any one of EX2 to EX37 comprising an outer wrapper defining or forming at least one of the first planar external surface and the second external planar surface.

[0314] EX39: An aerosol-generating article according to any one of EX1 to EX38, wherein each of the one or more aerosol-generating substrates comprise at least 5 percent by weight of aerosol-former on a dry weight basis.

[0315] EX40: An aerosol-generating article according to any one of EX1 to EX39, comprising an air inlet and an air outlet.

[0316] EX41 : An aerosol-generating article according to EX40, comprising an airflow passage extending between the air inlet and the air outlet through the cavity.

[0317] EX42: An aerosol-generating article according to EX40 or EX41 , wherein the air inlet is defined by the frame, such as by the peripheral wall of the frame, such as by the front wall.

[0318] EX43: An aerosol-generating article according to any one of EX45 to EX47, wherein the air outlet is defined by the frame, such as by the peripheral wall of the frame, such as by the back wall.

[0319] EX44: An aerosol-generating article according to any one of EX40 to EX43, comprising an airflow pathway or passage extending from the air inlet to the air outlet through the cavity, such as through both the parallel section and the converging section of the cavity.

[0320] EX45: An aerosol-generating system comprising: an aerosol-generating article according to any one of EX1 to EX44 and an aerosol-generating device configured to heat at least one of the one or more aerosol-generating substrates of the aerosol-generating article.

[0321] EX46: An aerosol-generating system according to EX45, wherein the aerosolgenerating device comprises a cavity dimensioned to receive at least a portion of the aerosolgenerating article, a heater, a power source for supplying power to the heater, and a controller to control a supply of power to the heater.

[0322] Examples will now be further described with reference to the figures in which:

[0323] Figure 1 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0324] Figure 2 shows an exploded perspective view of the aerosol-generating article of Figure 1 ; Figure 3 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0325] Figure 4 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0326] Figure 5 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0327] Figure 6 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0328] Figure 7 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0329] Figure 8 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0330] Figure 9 shows a schematic cross-sectional view of an aerosol-generating device according to the present disclosure; and

[0331] Figure 10 shows a schematic cross-sectional view of an aerosol-generating system with the aerosol-generating device of Figure 8 in engagement with an aerosol-generating article of the present disclosure.

[0332] Figure 1 shows an aerosol-generating article 10 comprising a first planar external layer 24 forming a first planar external surface 21 , a second planar external layer 25 forming a second planar external surface 22, and a frame 50 positioned between the first planar external layer 24 and the second planar external layer 25. The first planar external layer 24 and the second planar external layer 25 both comprise an aerosol-generating substrate comprising an aerosol-generating material, namely tobacco. However, it will be understood that in some embodiments only one of the first planar external layer 24 and the second planar external layer 25 may comprise an aerosol-generating substrate. Alternatively, or additionally, the aerosol-generating substrate may be positioned elsewhere within the aerosol-generating article 10.

[0333] 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 aerosolgenerating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.1 millimetres.

[0334] The aerosol-generating article 10 is a substantially flat aerosol-generating article or substantially planar aerosol-generating article. In particular, the thickness of the aerosolgenerating article 10 is less than 50 percent of both the length and the width of the aerosolgenerating article. The aerosol-generating article 10 has a generally rectangular cuboid shape and a laminated structure formed by the first planar external layer 24, the frame 50 and the second planar external layer 25. The first planar external layer 24, the frame 50 and the second planar external layer 25 are bonded together with an adhesive, in particular guar gum, as discussed in more detail below in relation to Figure 2.

[0335] Figure 2 shows an exploded view of the aerosol-generating article 10 of Figure 1.

[0336] 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. The cavity 30 is substantially empty.

[0337] 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.

[0338] 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 53.

[0339] The cavity 30 comprises a parallel section 31 and a converging section 32. The converging section 32 has decreasing width from a first end of the converging section 32 to the second end of the converging section 32.

[0340] The peripheral wall 51 comprises the front wall 13 and the back wall 14. The parallel section 31 extends from the front wall 13 to the converging section 32. The converging section 32 extends from the parallel section 31 to the back wall 14. As such, the converging section 32 is located downstream of the parallel section. During use of the aerosol-generating article 10, air is drawn into the article through an air inlet 11 of the aerosol-generating article 10, then through the parallel section 31 of the cavity 30, then through the converging section 32 of the cavity 30 and then out of the aerosol-generating article 10 through an air outlet 12 of the aerosol-generating article 10.

[0341] The peripheral wall 51 comprises a first side wall and an opposing second side wall 62. The front wall 13, back wall 14, first side wall 61 , and second side wall together define the circumference of the cavity. The first side wall comprises a first parallel side wall portion 61 and a first converging side wall portion 71 . The first parallel side wall portion 61 extends from the front wall 13 to first end of the first converging side wall portion 71. The first converging side wall portion 71 extends from second end of the first parallel side wall portion 61 to the back wall 14. The second side wall comprises a second parallel side wall portion 62 and a second converging side wall portion 72. The second parallel side wall portion 62 extends from the front wall 13 to the first end of the second converging side wall portion 72. The second converging side wall portion 72 extends from the second end of the second parallel side wall portion 71 to the back wall 14.

[0342] Both of the first converging side wall portion 71 and the second converging side wall portion 72 have increasing width from the first end of the converging section 32 to the second end of the converging section 32. This may provide the aerosol-generating article 10 with structural rigidity.

[0343] The external surface of both the first converging side wall portion 71 and the second converging side wall portion 72 are parallel to the x-direction.

[0344] The converging section 32 has a length of 13 millimetres, a width at the first end of the converging section 32 of 6 millimetres, a width at the second end of the converging section 32 of 3 millimetres, and a thickness of 2.7 millimetres. Accordingly, the length of the converging section 32 is greater than the width of the converging section 32 at the first end of the converging section 32.

[0345] The parallel section 32 has a length of 13 millimetres, a constant width along the entire length of the parallel section 32 of 6 millimetres of 2.7 millimetres.

[0346] The first planar external layer 24 and the second planar external layer 25 have a thickness of 200 micrometres and are in physical contact with the frame 50. The first planar external layer 24 and the second planar external layer 25 are bonded to the frame with an adhesive 15. The first planar external layer 24 defines at least a portion of the cavity 30. The second planar external layer 25 defines at least a portion of the cavity 30.

[0347] 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 crosssection, a width of 3 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.

[0348] Figure 3 shows an exploded view of an aerosol-generating article that is similar to the aerosol-generating article 10 of Figure 1 except that the first planar external layer 24 and the second planar external layer 25 do not comprise an aerosol-generating substrate. Instead, an aerosol-generating substrate 40 is positioned within the parallel section 31 of the cavity 30. The aerosol-generating substrate 40 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. The tobacco cut filler may be wrapped in a wrapper. As shown, the aerosol-generating substrate 40 fills the entire volume of the parallel section 31 of the cavity 30. In the example of Figure 3, the aerosol-generating substrate 40 has a packing density of about 0.87, a density of about 0.3 grams per cubic centimetre, and a mass of about 55 milligrams. In another example, the aerosol-generating substrate 40 may have a different packing density, a different density and a different mass. For example, aerosol-generating substrate may have a packing density of 0.64, a density of 0.35 grams per cubic centimetre, and a mass of about 47 milligrams.

[0349] The converging section 32 of the cavity 30 is empty. In particular, the aerosolgenerating substrate 40 does not extend into the converging section 32 of the cavity 30.

[0350] Figure 4 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figures 1 and 3 except that the aerosol-generating article 10 of Figure 4 comprises an outer wrapper 23 defining the first planar external surface 21 and the second planar external surface 22 instead of the first planar external layer 24 and the second planar external layer 25.

[0351] Figure 5 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1 except that the aerosol-generating article 10 of Figure 5 further comprises a first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are formed from a sheet of aerosol-generating material. In particular, a sheet of homogenised tobacco material having an aerosol-former content of 5 percent by weight on a dry weight basis. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 each have a length equal to the length of the aerosolgenerating 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.

[0352] The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are in physical contact with the frame 50 and are bonded to the frame with an adhesive 15. The first aerosol-generating substrate layer 41 defines at least a portion of the cavity 30. The second aerosol-generating layer 42 defines at least a portion of the cavity 30.

[0353] 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.

[0354] Figure 6 shows an exploded view of an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 5 except that an aerosol-generating substrate 40 is positioned within the parallel section 31 of the cavity 30 as described in relation to Figure 3. The aerosol-generating substrate 40 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. As shown, the aerosol-generating substrate 40 fills the entire volume of the parallel section 31 of the cavity 30. Figure 7 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 5 except that the aerosol-generating article 10 of Figure 7 comprises an outer wrapper 23 defining the first planar external surface 21 and the second planar external surface 22 instead of the first planar external layer 24 and the second planar external layer 25.

[0355] Figure 8 shows an aerosol-generating article similar to the aerosol-generating article of Figure 3 except that the aerosol-generating substrate 40 does not fill the entirety of the parallel section 31 of the cavity 30. Instead, the aerosol-generating substrate 40 is spaced away from and not in contact with the front wall 13. The aerosol-generating substrate 40 also does not extend to the second end or downstream end of the parallel section 31 or to the first end or upstream end of the converging section 32. The width of the wrapped aerosolgenerating substrate 40 is less than the width of the parallel section 31 of the cavity 30.

[0356] Figure 9 shows a schematic cross-sectional view of an aerosol-generating device 90 configured for use with an aerosol-generating article 10 described herein. The aerosolgenerating 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.

[0357] Figure 10 shows a schematic cross-sectional view of an aerosol-generating system with the aerosol-generating device 90 of Figure 9 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 aerosolgenerating 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 aerosol-generating article, and as a result the aerosol-generating substrate is heated. Volatile components of the aerosol-generating substrate are evaporated and condense in the cavity 30 of the aerosolgenerating article 10 to form an aerosol. The consumer inhales the aerosol by drawing on the end of the aerosol-generating article 10 comprising the air outlet 12. Once the aerosol- generating substrate has been depleted of volatile components, the aerosol-generating article 10 is removed from the cavity 1000 and disposed of.

[0358] 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 having a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction, the aerosol-generating article comprising: a first planar external surface; a second planar external surface; one or more aerosol-generating substrates; and a cavity extending in the x-direction between a first end of the cavity and a second end of the cavity, wherein the cavity comprises a converging section extending in the x-direction between a first end of the converging section and a second end of the converging section, wherein the width of the converging section decreases along the length of the converging section from the first end to the second end of the converging section, and wherein the length of the converging section is greater than the width of the converging section at the first end of the converging section.

2. An aerosol-generating article according to claim 1 , wherein the width of the converging section continuously decreases along the entire length of the converging section from the first end of the converging section to the second end of the converging section.

3. An aerosol-generating article according to claim 1 or 2, wherein the width of the converging section at the second end of the converging section is between 30 percent and 90 percent of the width of the converging section at the first end of the converging section.

4. An aerosol-generating article according to any preceding claim, wherein the width of the converging section at the second end of the converging section is between 40 percent and 80 percent of the width of the converging section at the first end of the converging section.

5. An aerosol-generating article according to any preceding claim, wherein a difference in the width of the converging section at the first end of the converging section and the width of the converging section at the second end of the converging section divided by the length of the converging section is less than or equal to 1 millimetre per millimetre.

6. An aerosol-generating article according to any preceding claim, wherein a length of the converging section is greater than or equal to 30 percent of a length of the cavity.

7. An aerosol-generating article according to any preceding claim comprising a frame positioned between the first planar external surface and the second planar external surface, wherein the frame comprises a peripheral wall circumscribing or defining at least a portion of the cavity.

8. An aerosol-generating article according to claim 7, wherein the peripheral wall comprises a first converging side wall section and a second converging side wall section opposing the first converging side wall section, and wherein the first converging side wall section and the second converging side wall section both define at least a portion of the length of the converging section of the cavity.

9. An aerosol-generating article according to claim 8, wherein the width of one or both of the first converging side wall section and the second converging side wall section increases along the x-direction.

10. An aerosol-generating article according to claim 8 or 9, wherein an internal surface of the first converging side wall section and an internal surface of the second converging side wall section is at an angle relative to one another, and wherein the angle is less than or equal to 35 degrees.

11. An aerosol-generating article according to any one of claims 8 to 10, wherein an external surface of the first converging side wall section is substantially parallel to an external surface of the second converging side wall section.

12. An aerosol-generating article according to any preceding claim, wherein the converging section is located towards the second end of the cavity.

13. An aerosol-generating article according to any preceding claim, wherein the cavity comprises a non-converging section located towards the first end of the cavity.

14. An aerosol-generating article according to claim 13, wherein one or more aerosolgenerating substrates is located in the non-converging section of the cavity.

15. An aerosol-generating article according to any preceding claim, wherein the converging section of the cavity is empty.

Images