Aerosol-generating article comprising a frame

Abstract

There is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article comprises a first planar external surface and a second planar external surface. The aerosol-generating article comprises a first cavity and a second cavity. The aerosol-generating article comprises a frame between the first planar external surface and the second planar external surface, the frame at least partially defining the first cavity and the second cavity. The aerosol-generating article comprises an air inlet and an air outlet, and an airflow passage extending from the air inlet to the air outlet through the first cavity and the second cavity. The first cavity is closer to the air inlet than the second cavity, and the first cavity and the second cavity are arranged in series such that the airflow passage extends from the first cavity to the second cavity. The first cavity has a volume equal to at least 5% of a volume of the second cavity, and the second cavity has a volume equal to at least 5% of a volume of the first cavity.

Description

[0001] AEROSOL-GENERATING ARTICLE COMPRISING A FRAME

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

[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 a mouthpiece filter element and a cooling element, which are arranged in the form of a rod and wrapped in a cigarette paper.

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

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

[0007] According to the present disclosure, there is provided an aerosol-generating article. The aerosol-generating article may be for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article may comprise a first planar external surface. The aerosolgenerating article may comprise a second planar external surface. The aerosol-generating article may comprise a first cavity. The aerosol-generating article may comprise a second cavity. The aerosol-generating article may comprise a frame. The frame may be between the first planar external surface and the second planar external surface. The frame may at least partially define the first cavity. The frame may at least partially define the second cavity. The aerosol-generating article may comprise an air inlet. The aerosol-generating article may comprise an air outlet. The aerosol-generating article may comprise an airflow passage. 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 first cavity and the second cavity. The first cavity may be closer to the air inlet than the second cavity. The first cavity and the second cavity may be arranged in series. The first cavity and the second cavity may be arranged in series along a longitudinal direction of the aerosolgenerating article. The first cavity and the second cavity may be arranged in series such that the airflow passage extends from the first cavity to the second cavity. The first cavity may have a volume equal to at least 5% of a volume of the second cavity. The second cavity may have a volume equal to at least 5% of a volume of the first cavity. The first cavity volume may be a volume of the first cavity which is not dependent on whether there is aerosol-generating substrate present in the first cavity. Equally, the second cavity volume may be a volume of the second cavity which is not dependent on whether there is aerosol-generating substrate present in the second cavity.

[0008] According to the present disclosure, there is provided an aerosol-generating article. The aerosol-generating article is for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article comprises a first planar external surface and a second planar external surface. The aerosol-generating article comprises a first cavity and a second cavity. The aerosolgenerating article comprises a frame between the first planar external surface and the second planar external surface. The frame at least partially defines the first cavity and the second cavity. The aerosol-generating article comprises an air inlet and an air outlet. The aerosol-generating article comprises an airflow passage extending from the air inlet to the air outlet through the first cavity and the second cavity. The first cavity is closer to the air inlet than the second cavity. The first cavity and the second cavity are arranged in series such that the airflow passage extends from the first cavity to the second cavity. The first cavity has a volume equal to at least 5% of a volume of the second cavity. The second cavity has a volume equal to at least 5% of a volume of the first cavity.

[0009] 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 aerosolgenerating device, thereby providing optimum heating of the aerosol-generating substrate.

[0010] Advantageously, the first planar external surface and the second planar external surface may provide a large surface area for heating by an external heater of an aerosol-generating device, thereby allowing the aerosol-generating substrate to be quickly heated to a temperature sufficient for generating an aerosol.

[0011] Advantageously, aerosol-generating articles of the present disclosure may be heated along substantially their entire length and width, thereby allowing the entire aerosol-generating substrate to be sufficiently heated to generate an aerosol.

[0012] Advantageously, aerosol-generating articles of the present disclosure may be manufactured by layering sheet materials which can be achieved through a continuous manufacturing process, thereby resulting in an aerosol-generating article that is relatively easy and cheap to manufacture.

[0013] Advantageously, the frame may allow the aerosol-generating article to be relatively thin whilst maintaining structural rigidity.

[0014] Advantageously, the first cavity and the second cavity may allow for defined compartments for aerosol-generating compartments to be contained.

[0015] Advantageously, a first aerosol-generating substrate in the first cavity and a second aerosol-generating substrate in the second cavity can be heated independently from each other. For example, an aerosol-generating substrate in the first cavity may be heated to a different temperature than an aerosol-generating substrate in the second cavity. An aerosol-generating substrate in the first cavity may be heated at a different time to an aerosol-generating substrate in the second cavity.

[0016] Advantageously, the first cavity and the second cavity provide defined clear regions for aerosol-generating substrate to be located. This improves alignment of the aerosol-generating substrate relative to a heater, improving reliability of heating of the aerosol-generating substrate.

[0017] Advantageously, the relative dimensions of the first cavity and the second cavity may provide a particularly suitable aerosol-generating article, from which a particularly suitable aerosol may be generated.

[0018] Preferably, the first cavity has a volume equal to at least 10% of a volume of the second cavity. Preferably, the second cavity has a volume equal to at least 10% of a volume of the first cavity. Preferably, the first cavity has a volume equal to at least 15% of a volume of the second cavity. Preferably, the second cavity has a volume equal to at least 15% of a volume of the first cavity. Preferably, the first cavity has a volume equal to at least 20% of a volume of the second cavity. Preferably, the second cavity has a volume equal to at least 20% of a volume of the first cavity. Preferably, the first cavity has a volume equal to at least 30% of a volume of the second cavity. Preferably, the second cavity has a volume equal to at least 30% of a volume of the first cavity. Preferably, the first cavity has a volume equal to at least 40% of a volume of the second cavity. Preferably, the second cavity has a volume equal to at least 40% of a volume of the first cavity.

[0019] The aerosol-generating article may have an external volume. The first cavity may have a volume. The volume of the first cavity may be at least 10% of the external volume of the aerosolgenerating article. The second cavity may have a volume. The volume of the second cavity may be at least 10% of the external volume of the aerosol-generating article. This has the advantage of allowing the aerosol-generating article to contain a particularly advantageous amount of aerosolgenerating substrate, while still benefiting from efficient heating of the substrate. Preferably, the volume of the first cavity is at least 20% of the external volume of the aerosol-generating article. Preferably, the volume of the first cavity is at least 30% of the external volume of the aerosolgenerating article. Preferably, the volume of the second cavity is at least 20% of the external volume of the aerosol-generating article. Preferably, the volume of the second cavity is at least 30% of the external volume of the aerosol-generating article.

[0020] The aerosol-generating article may have an internal volume, the first cavity may have a volume, and the volume of the first cavity may be at least20% of the internal volume of the aerosolgenerating article. The aerosol-generating article may have an internal volume, the second cavity may have a volume, and the volume of the second cavity may be at least 20% of the internal volume of the aerosol-generating article. This has the advantage of allowing the aerosol-generating article to benefit from a compact arrangement and contain a suitable amount of aerosol-generating substrate, while still benefiting from efficient heating of the substrate. The internal volume of the aerosol-generating substrate may include: the volume of cavities, the volume of any inlet or outlet passage, and the volume of any internal aperture, such as the primary aperture. The internal volume of the aerosol-generating substrate may include: the volume of the first and second cavities, the volume of the inlet and outlet, and the volume of the primary aperture. Preferably, the volume of the first cavity is at least 30% of the internal volume of the aerosol-generating article. Preferably, the volume of the first cavity is at least 40% of the internal volume of the aerosolgenerating article. Preferably, the volume of the first cavity is at least 50% of the internal volume of the aerosol-generating article. Preferably, the volume of the second cavity is at least 30% of the internal volume of the aerosol-generating article. Preferably, the volume of the second cavity is at least 40% of the internal volume of the aerosol-generating article. Preferably, the volume of the second cavity is at least 50% of the internal volume of the aerosol-generating article.

[0021] The first cavity may be a first distance from the upstream end, the second cavity may be a second distance from the upstream end, and a ratio of the first distance to the second distance may be between 1 : 100 and 1 :1 .5. Preferably, a ratio of the first distance to the second distance is between 1 :10 and 1 :20. A first distance of the first cavity to the upstream end may be a distance from a closest point on the first cavity to the upstream end. A second distance of the second cavity to the upstream end may be a distance from a closest point on the second cavity to the upstream end.

[0022] The first cavity or the second cavity may have a volume of at least 50 mm3. The first cavity or the second cavity may have a volume of at least 100 mm3. The first cavity or the second cavity may have a volume of at least 200 mm3. The first cavity or the second cavity may have a volume of at most 500 mm3. The first cavity or the second cavity may have a volume of at most 400 mm3. The first cavity or the second cavity may have a volume of at most 300 mm3.

[0023] The first cavity may have a width, the second cavity may have a width, and a ratio of the first cavity width to the second cavity width may be between 0.5 and 2. The first cavity may have a thickness, the second cavity may have a thickness, and a ratio of the first cavity thickness to the second cavity thickness may be between 0.5 and 2. The first cavity may have a length, the second cavity may have a length, and a ratio of the first cavity length to the second cavity length may be between 0.1 and 2. Such relative dimensions have the advantage of allowing the aerosolgenerating substrate to contain a suitable amount of aerosol-generating substrate.

[0024] The first cavity and the second cavity may be divided by a primary dividing wall having a primary aperture fluidly connecting the first cavity to the second cavity. This has the advantage of separating the first cavity from the second cavity. The primary aperture may have a volume, the primary aperture volume being less than 10% of a volume of the first or the second cavity.

[0025] The aerosol-generating article may comprise a third cavity. This has the advantage of providing defined compartments for aerosol-generating substrate to be disposed or received.

[0026] Each of the first cavity, the second cavity and the third cavity may have a volume of at least 5% of each other cavity of the first cavity, the second cavity and the third cavity. The second cavity and the third cavity may be divided by a secondary dividing wall. The secondary dividing wall may have a secondary aperture fluidly connecting the second cavity to the third cavity. Advantageously, the relative dimensions of the first cavity, second cavity and the third cavity may provide a particularly suitable aerosol-generating article, in which a particularly suitable aerosol may be generated.

[0027] 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 50 percent of both a length and a width of the aerosol-generating article. Advantageously, a smaller thickness may provide a small temperature gradient or difference across the thickness of the aerosol-generating substrate during heating. Advantageously, this may allow heating of a greater proportion of the aerosol-generating substrate to a temperature at which an aerosol is released whilst minimising the risk of burning the hottest portion of the aerosolgenerating substrate closest to the heater. Advantageously, this may also reduce a time required to heat the aerosol-generating substrate sufficiently to release an aerosol.

[0028] The aerosol-generating article may have a 3-dimensional shape.

[0029] The aerosol-generating article may have a quadrilaterally-faced hexahedron shape. The aerosol-generating article may have a rectangular prism shape. The aerosol-generating article may have a cubic shape. The aerosol-generating article may have a cuboid shape. The aerosolgenerating article may have a rectangular cuboid shape. The aerosol-generating article may have a parallelepiped shape.

[0030] The aerosol-generating article may have an oblong shape.

[0031] The aerosol-generating article may have a laminated structure, for example the aerosolgenerating article may comprise or be formed from at least two layers. In particular, the aerosolgenerating article may comprise at least two of: a first external layer, a second external layer, a frame, a first frame layer, a second frame layer, and a third frame layer.

[0032] At least 50% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 55% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 60% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 65% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 70% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 75% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 80% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 85% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 90% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material.

[0033] At least 50% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 55% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 60% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 65% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 70% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 75% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 80% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 85% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 90% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard.

[0034] Substantially the entirety of the aerosol-generating article, excluding aerosol-generating substrates and (if present) adhesive, may be paper or cardboard.

[0035] 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.

[0036] 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 a planar top surface and the second planar external surface may be a planar bottom surface. The first planar external surface may be a planar ceiling surface and the second planar external surface may be a planar base surface.

[0037] 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-direction and the y-direction. That is, the first planar external surface may extend in the x / y plane. The second planar external surface may extend in the x-direction and the y-direction. That is, the second planar external surface may extend in the x / y plane.

[0038] 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. That is, a thickness of the aerosol-generating article may be defined by the perpendicular distance between the first planar external surface and the second planar external surface.

[0039] The aerosol-generating article may comprise an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may comprise a hydrophobic material.

[0040] 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.

[0041] The aerosol-generating article may comprise a first planar external layer and a second planar external layer. The first planar external layer may be an upper layer and the second planar external layer may be a lower layer. The first planar external layer may be a top layer and the second planar external layer may be a bottom layer. The first planar external layer may be a ceiling layer and the second planar external layer may be a base layer.

[0042] The first planar external layer may define or form the first planar external surface. The first planar external layer may extend in the x direction and the y direction. That is, the first planar external layer may extend in the x / y plane. The second planar external layer may define or form the second planar external surface. The second planar external layer may extend in the x direction and the y direction. That is, the second planar external layer may extend in the x / y plane.

[0043] The first planar external layer may be in physical contact with, and may be bonded to, the frame. The first planar external layer may overlie an end of the first cavity or the second cavity. The first planar external layer may define or form a wall of the first cavity or the second cavity. 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 first cavity or the second cavity. The second planar external layer may define or form a wall of the first cavity or the second cavity.

[0044] The first planar external layer and the second planar external layer may overlie opposing ends of the first cavity and the second cavity. The first planar external layer and the second planar external layer may define or form opposing end walls of the first cavity and the second cavity, such as an upstream end wall and a downstream end wall.

[0045] The aerosol-generating substrate may comprise nicotine. The aerosol-generating substrate may comprise one or more of: aerosol former, tobacco, botanicals, flavouring agents, aerosol volume enhancers. Suitable types of materials for use in the aerosolgenerating substrate include, for example, tobacco cut filler, homogenised tobacco material such as cast leaf, aerosol-generating films and gel compositions. The frame may be fixedly attached to the first planar external surface. The frame may be fixedly attached to the second planar external surface. The frame may be integrally formed with the first planar external surface. The frame may be integrally formed with the second planar external surface.

[0046] The frame may be a planar frame.

[0047] The frame may define a frame aperture extending through the thickness of the frame. The first cavity and the second cavity may be defined within the frame aperture. For example, the frame may have a substantially hollow cuboid shape or a square hollow tube shape.

[0048] 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 first cavity and the second cavity.

[0049] 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 an outer wall of the first cavity and the second cavity. The frame inner surface may define or form a cavity outer wall. The frame inner surface may circumscribe or encircle the frame aperture extending through the thickness of the frame. The frame outer surface may circumscribe or encircle the first cavity and the second cavity.

[0050] 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.

[0051] The frame may define or form at least 75 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame. The frame may define or form at least 80 percent of a perimeter of any cross-section, in an x / y plane, of the aerosolgenerating article that extends through the frame. The frame may define or form at least 85 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame. The frame may define or form at least 90 percent of a perimeter of any crosssection, in an x / y plane, of the aerosol-generating article that extends through the frame. The frame may define or form at least 95 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame. The frame may define or form at least 99 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame.

[0052] Advantageously, providing a frame that forms at least 75 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame means that the frame extends around a significant portion of the aerosol-generating article. Therefore, the frame can provide the aerosol-generating article with good structural support. Advantageously, providing a frame that forms at least 75 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame may mean that any air inlet or air outlet defined through the article is of a size that provides the aerosolgenerating article with a satisfactory resistance to draw.

[0053] Advantageously, in embodiments in which an aerosol-generating substrate is positioned within the first cavity or the second cavity, providing a frame that forms at least 75 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame may allow the frame to act as a barrier that prevents egress of the aerosolgenerating substrate from the aerosol-generating article.

[0054] The aerosol-generating article may comprise a cross-section in a first x / y plane that extends through the frame. The frame may form at least 99 percent of a perimeter of the crosssection in the first x / y plane. The frame may form at least 100 percent of the perimeter of the crosssection in the first x / y plane.

[0055] The aerosol-generating article may comprise a cross-section in a second x / y plane, spaced from the first x / y plane in the z-direction, that extends through the frame. The frame may form at least 99 percent of a perimeter of the cross-section in the second x / y plane. The frame may form 100 percent of the perimeter of the cross-section in the second x / y plane.

[0056] The air inlet may be positioned, in the z-direction, between the first x / y plane and the second x / y plane. The air outlet may be positioned, in the z-direction, between the first x / y plane and the second x / y plane.

[0057] The frame may comprise a first portion that is at least 30 percent of a thickness of the frame. The first portion may be at least 50 percent of the thickness of the frame. The first portion may be at least 70 percent of the thickness of the frame. The first portion may be at least 90 percent of the thickness of the frame. The frame forms 100 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the first portion of the frame.

[0058] The aerosol-generating article may comprise one or more external walls extending between the first planar external surface and the second planar external surface. The one or more external walls may collectively define an entire transverse external area of the aerosol-generating article. The frame may at least partially define each of the one or more external walls.

[0059] The one or more external walls may circumscribe or encircle the first cavity and the second cavity.

[0060] The frame may define at least 60 percent of the entire transverse external area of the aerosol-generating article. The frame may define at least 60 percent of the entire transverse external area of the aerosol-generating article. The frame may define at least 70 percent of the entire transverse external area of the aerosol-generating article. The frame may define at least 80 percent of the entire transverse external area of the aerosol-generating article. The frame may define at least 90 percent of the entire transverse external area of the aerosol-generating article. The frame may comprise a peripheral wall. The peripheral wall may circumscribe or encircle at least a portion of the frame aperture extending through the thickness of the frame. The peripheral wall may circumscribe or encircle at least a portion of the first cavity and the second cavity. The peripheral wall may circumscribe or encircle the frame aperture extending through the thickness of the frame. The peripheral wall may circumscribe or encircle the first cavity and the second cavity. Advantageously, such a peripheral wall allows for a relatively large internal volume for an aerosol-generating substrate or aerosol formation whilst providing the structural strength to maintain the shape of the aerosol-generating article.

[0061] 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.

[0062] 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.

[0063] The peripheral wall may have a radial thickness greater than or equal to 0.5 millimetres. The peripheral wall may have a radial thickness greater than or equal to 1 millimetre. The peripheral wall may have a radial thickness greater than or equal to 1 .5 millimetres. The peripheral wall may have a radial thickness greater than or equal to 2 millimetres. The peripheral wall may have a radial thickness greater than or equal to 2.5 millimetres.

[0064] The peripheral wall may have a radial thickness less than or equal to 4 millimetres. The peripheral wall may have a radial thickness less than or equal to 3.5 millimetres. The peripheral wall may have a radial thickness less than or equal to 3 millimetres. The peripheral wall may have a radial thickness less than or equal to 2.5 millimetres. The peripheral wall may have a radial thickness less than or equal to 2 millimetres.

[0065] The peripheral wall may have a radial thickness between 0.5 millimetres and 3.5 millimetres. The peripheral wall may have a radial thickness between 0.5 millimetres and 3 millimetres. The peripheral wall may have a radial thickness between 0.5 millimetres and 2.5 millimetres. The peripheral wall may have a radial thickness between 1 millimetre and 3 millimetres. The peripheral wall may have a radial thickness between 1 millimetres and 2 millimetres. Advantageously, the peripheral wall having a radial thickness between 0.5 millimetres and 3.5 millimetres has been found to provide good structural strength for the aerosol-generating article whilst not using excess amounts of material which may increase manufacturing costs. Advantageously, a radial thickness between 0.5 millimetres and 3.5 millimetres may limit the amount of heat that is undesirably transferred to the frame rather than the aerosol-generating substrate.

[0066] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material. The frame may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may comprise cellulose fibres. The cellulosic material may be paper, paperboard, or cardboard. The frame may be made from or comprise a plant material, such as tobacco. The frame may be made entirely from a cellulosic material.

[0067] The cellulosic material may have a grammage greater than or equal to 300 grams per square metre. The cellulosic material may have a grammage greater than or equal to 350 grams per square metre. The cellulosic material may have a grammage greater than or equal to 390 grams per square metre. The cellulosic material may have a grammage greater than or equal to 420 grams per square metre. The cellulosic material may have a grammage greater than or equal to 620 grams per square metre. The cellulosic material may have a grammage greater than or equal to 720 grams per square metre. The cellulosic material may have a grammage greater than or equal to 800 grams per square metre.

[0068] The cellulosic material may have a grammage less than or equal to 900 grams per square metre. The cellulosic material may have a grammage less than or equal to 800 grams per square metre. The cellulosic material may have a grammage less than or equal to 720 grams per square metre. The cellulosic material may have a grammage less than or equal to 620 grams per square metre. The cellulosic material may have a grammage less than or equal to 420 grams per square metre. The cellulosic material may have a grammage less than or equal to 390 grams per square metre. The cellulosic material may have a grammage less than or equal to 350 grams per square metre.

[0069] The cellulosic material may have a grammage between 300 grams per square metre and 900 grams per square metre. The cellulosic material may have a grammage between 300 grams per square metre and 800 grams per square metre. The cellulosic material may have a grammage between 350 grams per square metre and 800 grams per square metre. The cellulosic material may have a grammage between 400 grams per square metre and 700 grams per square metre.

[0070] The frame may be made from or comprise a fibrous material. The frame may be made from one or more of: natural fibres, synthetic fibres, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibres, nylon fibres, and ceramic fibres. The frame may comprise cellulosic fibres.

[0071] The frame may comprise a hydrophobic region. The hydrophobic region may comprise hydrophobic groups covalently bonded to the frame. The hydrophobic region may be positioned on, or form, at least a portion of the frame inner surface. Advantageously, a hydrophobic region may prevent or limit degradation of the frame in regions where the frame is regularly in contact with aerosol or liquids from the aerosol-generating substrate.

[0072] The hydrophobic region may be produced by a process comprising the steps of: applying a liquid composition comprising a fatty acid halide to a surface of the frame and maintaining the surface at a temperature of about 120 degrees Celsius to about 180 degrees Celsius. The fatty acid halide reacts in situ with protogenic groups of material in the hydrophobic region resulting in the formation of fatty acid esters.

[0073] The hydrophobic region may have a Cobb water absorption (ISO535:1991) value (at 60 seconds) less than or equal to 40 grams per square metre. The hydrophobic region may have a Cobb water absorption (ISO535:1991) value (at 60 seconds) of less than or equal to 35 grams per square metre. The hydrophobic region may have a Cobb water absorption (ISO535:1991) value (at 60 seconds) less than or equal to 30 grams per square metre. The hydrophobic region may have a Cobb water absorption (ISO535:1991) value (at 60 seconds) less than or equal to about 25 grams per square metre.

[0074] The hydrophobic region may have a water contact angle of greater than or equal to about 90 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 95 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 100 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 110 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 120 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 130 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 140 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 150 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 160 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 170 degrees.

[0075] Hydrophobicity is determined by utilizing the TAPPI T558 om-97 test and the result is presented as an interfacial contact angle and reported in “degrees” and can range from near zero degrees to near 180 degrees. Where no contact angle is specified along with the term hydrophobic, the water contact angle is at least 90 degrees.

[0076] The hydrophobic region may have a water contact angle of greater than or equal to 90 degrees and a Cobb water absorption (ISO535:1991) value (at 60 seconds) less than or equal to 40 grams per square metre.

[0077] The frame may have a thickness greater than or equal to 50 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 60 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 70 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 80 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 90 percent of the thickness of the aerosolgenerating article. The frame may have a thickness greater than or equal to 95 percent of the thickness of the aerosol-generating article.

[0078] The frame may have a thickness less than or equal to 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 90 percent of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 80 percent of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 70 percent of the thickness of the aerosol-generating article.

[0079] The frame may have a thickness between 50 percent of the thickness of the aerosolgenerating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 60 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 70 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 80 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosolgenerating article.

[0080] The frame may have a thickness greater than or equal to 1 millimetre. The frame may have a thickness greater than or equal to 1.5 millimetres. The frame may have a thickness greater than or equal to 2 millimetres. The frame may have a thickness greater than or equal to 2.5 millimetres. The frame may have a thickness greater than or equal to 3 millimetres. The frame may have a thickness greater than or equal to 3.5 millimetres. The frame may have a thickness greater than or equal to 4 millimetres. The frame may have a thickness greater than or equal to 4.5 millimetres.

[0081] The frame may have a thickness less than or equal to 5.5 millimetres. The frame may have a thickness less than or equal to 5 millimetres. The frame may have a thickness less than or equal to 4.5 millimetres. The frame may have a thickness less than or equal to 4 millimetres. The frame may have a thickness less than or equal to 3.5 millimetres. The frame may have a thickness less than or equal to 3 millimetres. The frame may have a thickness less than 2.5 millimetres. The frame may have a thickness less than 2 millimetres. The frame may have a thickness less than 1.5 millimetres.

[0082] The frame may have a thickness between 1 millimetre and 5.5 millimetres. The frame may have a thickness between 1 millimetre and 5 millimetres. Preferably, the frame may have a thickness between 1.5 millimetres and 5 millimetres.

[0083] The frame may have a length that is equal to the length of the aerosol-generating article. The frame may have a length that is at least 90 percent of the length of the aerosol-generating article. The frame may have a length that is at least 95 percent of the length of the aerosolgenerating article.

[0084] The frame may have a width that is equal to the width of the aerosol-generating article. The frame may have a width that is at least 90 percent of the width of the aerosol-generating article. The frame may have a width that is at least 90 percent of the width of the aerosol-generating article.

[0085] The frame may be a unitary component. Alternatively, the frame may comprise two or more layers. That is, the frame may have a laminated structure. Advantageously, the properties of each layer may be individually optimised depending on the relative distance between the layer and aerosol-generating substrate or heater of the aerosol-generating device. Advantageously, the use of two or more layers allows producing, and rapidly adjusting, the desired thickness of the frame by adding or removing layers of sheet material. This may prevent the need to manufacture a single sheet of material having the desired thickness of the frame, which may subsequently need to be changed when the desired thickness of the frame changes.

[0086] The frame may comprise a first frame layer and a second frame layer. The first frame layer and the second frame layer may be the only layers of the frame. That is, the frame may comprise no more than two layers or may comprise exactly two layers. The first frame layer may be an upper frame layer and the second frame layer may be a lower frame layer.

[0087] The frame may have a thickness equal to a sum of a thickness of the first frame layer and a thickness of the second frame layer. The frame aperture may be defined through both the first frame layer and the second frame layer.

[0088] The frame may comprise a first frame layer, a second frame layer and a third frame layer. The second frame layer may be positioned between the first frame layer and the third frame layer. The first frame layer, the second frame layer and the third frame layer may be the only layers of the frame. That is, the frame may comprise no more than three layers or may comprise exactly three layers. The first frame layer may be an upper frame layer, the second frame layer may be an intermediate frame layer, and the third frame layer may be a lower frame layer.

[0089] The first frame layer may be in physical contact with the second frame layer. The first frame layer may be may be bonded to the second frame layer with an adhesive. A lower surface of the first frame layer may be bonded to an upper surface of the second frame layer with an adhesive. The adhesive may extend at least 90% around the periphery of the intersection between the first frame layer and the second frame layer. The adhesive may extend at least 95% around the periphery of the intersection between the first frame layer and the second frame layer. The adhesive may extend at least 99% around the periphery of the intersection between the first frame layer and the second frame layer.

[0090] The second frame layer may be in physical contact with the third frame layer. The second frame layer may be bonded to the third frame layerwith an adhesive. A lower surface of the second frame layer may be bonded to an upper surface of the third frame layer with an adhesive. The adhesive may extend at least 90% around the periphery of the intersection between the second frame layer and the third frame layer. The adhesive may extend at least 95% around the periphery of the intersection between the second frame layer and the third frame layer. The adhesive may extend at least 99% around the periphery of the intersection between the second frame layer and the third frame layer.

[0091] The frame may have a thickness equal to a sum of a thickness of the first frame layer, a thickness of the second frame layer and a thickness of the third frame layer. The frame aperture may be defined through the first planar layer, the second planar layer and the third frame layer.

[0092] The first frame layer may be planar.

[0093] The first frame layer may define a first frame layer aperture extending through the thickness of the first frame layer. The first frame layer aperture may at least partially define or form the first and second cavities of the aerosol-generating article. For example, the first frame layer may have a hollow cuboid shape or a square hollow tube shape. As a further example, the first frame layer may have a cross-section that is annular in shape, preferably the cross-section in x / y plane is annular in shape. The cross-section may have an annulus shape, such as a circular annulus shape, an elliptical annulus shape, a rectangular annulus shape, or a square annulus shape.

[0094] The first frame layer may comprise a first frame layer outer surface. The first frame layer outer surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The first frame layer outer surface may at least partially define or form one or more external surfaces of the aerosol-generating article. For example, the first frame layer outer surface may at least partially define or form one or more external walls of the aerosol-generating article. The first frame layer outer surface may circumscribe or encircle one or both: the first frame layer aperture and the frame aperture. The first frame layer outer surface may circumscribe or encircle the first and second cavities.

[0095] The first frame layer may comprise a first frame layer inner surface. The first frame layer inner surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The first frame layer inner surface may define or form a first frame layer aperture outer wall. The first frame layer inner surface may at least partially define or form a first and second cavity outer wall. The first frame layer inner surface may circumscribe or encircle one or both the first frame layer aperture and the frame aperture.

[0096] The first frame layer outer surface may circumscribe or encircle the first frame layer inner surface. The first frame layer inner surface and the first frame layer outer surface may be concentric with one another.

[0097] The first frame layer may comprise a first frame layer peripheral wall. The first frame layer peripheral wall may circumscribe or encircle one or both of: the frame aperture and the first frame layer aperture. The first frame layer peripheral wall may circumscribe or encircle the first and second cavities.

[0098] The first frame layer peripheral wall may be defined or formed by the first frame layer outer surface and the first frame layer inner surface. The first frame layer peripheral wall may at least partially define or form one or more external surfaces or walls of the aerosol-generating article. The first frame layer peripheral wall may at least partially define or form the first frame layer aperture outer wall. The first frame layer peripheral wall may at least partially define or form the first and second cavity outer wall.

[0099] The first frame layer may be made from or comprise any of the materials described above in relation to the frame. For example, the first frame layer may comprise the one or more susceptor materials.

[0100] The first frame layer may be made from or comprise a biodegradable material. The first frame layer may be entirely made from biodegradable material. The first frame layer may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may comprise cellulosic fibres. The cellulosic material may be paper, paperboard, or cardboard. The first frame layer may be made from or comprise a plant material, such as tobacco. The first frame layer may be made entirely from a cellulosic material.

[0101] The cellulosic material may have any grammage or range of grammages as described above in relation to the frame.

[0102] The first frame layer may be made from a fibrous material. The first frame layer may be made from one or more of: natural fibres, synthetic fibres, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibres, nylon fibres, and ceramic fibres.

[0103] Where the frame comprises exactly two layers, the thickness of the first frame layer may be half (50 percent) the thickness of the frame. The first frame layer may have a thickness substantially the same as the second frame layer. Where the frame comprises exactly three layers, the thickness of the first frame layer may be one third (33.33 percent) the thickness of the frame. The first frame layer may have a thickness substantially the same as each of the second frame layer and the third frame layer.

[0104] The first frame layer may have a thickness greater than or equal to 0.5 millimetres. The frame may have a thickness greater than or equal to 1 millimetre. The first frame layer may have a thickness greater than or equal to 1.5 millimetres. The first frame layer may have a thickness greater than or equal to 2 millimetres. The first frame layer may have a thickness greater than or equal to 2.5 millimetres.

[0105] The first frame layer may have a thickness less than or equal to 3 millimetres. The first frame layer may have a thickness less than or equal to 2.5 millimetres. The first frame layer may have a thickness less than or equal to 2 millimetres. The first frame layer may have a thickness less than or equal to 1 .5 millimetres. The first frame layer may have a thickness less than or equal to 1 millimetres.

[0106] The first frame layer may have a thickness between 0.5 millimetres and 3 millimetres. The first frame layer may have a thickness between 0.5 millimetres and 2.5 millimetres. The first frame layer may have a thickness between 1 millimetres and 2.5 millimetres.

[0107] The second frame layer may be planar.

[0108] The second frame layer may define a second frame layer aperture extending through the thickness of the second frame layer. The second frame layer aperture may at least partially define or form the first and second cavities of the aerosol-generating article. For example, the second frame layer may have a hollow cuboid shape or a square hollow tube shape. As a further example, the second frame layer may have a cross-section that is annular in shape, preferably the crosssection in x / y plane is annular in shape. The cross-section may have an annulus shape, such as a circular annulus shape, an elliptical annulus shape, a rectangular annulus shape, or a square annulus shape. The second frame layer may comprise a second frame layer outer surface. The second frame layer outer surface may extend in a transverse direction, for example between the second planar external surface and the second planar external surface. The second frame layer outer surface may at least partially define or form one or more external surfaces of the aerosolgenerating article. For example, the second frame layer outer surface may at least partially define or form one or more external walls of the aerosol-generating article. The second frame layer outer surface may circumscribe or encircle one or both: the second frame layer aperture and the frame aperture. The second frame layer outer surface may circumscribe or encircle the first and second cavities.

[0109] The second frame layer may comprise a second frame layer inner surface. The second frame layer inner surface may extend in a transverse direction, for example between the second planar external surface and the second planar external surface. The second frame layer inner surface may define or form a second frame layer aperture outer wall. The second frame layer inner surface may at least partially define or form a first and second cavity outer wall. The second frame layer inner surface may circumscribe or encircle one or both the second frame layer aperture and the frame aperture. The second frame layer outer surface may circumscribe or encircle the first and second cavities. The second frame layer outer surface may circumscribe or encircle the second frame layer inner surface. The second frame layer inner surface and the second frame layer outer surface may be concentric with one another.

[0110] The second frame layer may comprise a second frame layer peripheral wall. The second frame layer peripheral wall may circumscribe or encircle one or both of: the frame aperture and the second frame layer aperture. The second frame layer peripheral wall may circumscribe or encircle the first and second cavities.

[0111] The second frame layer peripheral wall may be defined or formed by the second frame layer outer surface and the second frame layer inner surface. The second frame layer peripheral wall may at least partially define or form one or more external surfaces or walls of the aerosolgenerating article. The second frame layer peripheral wall may at least partially define or form the second frame layer aperture outer wall. The second frame layer peripheral wall may at least partially define or form the first and second cavity outer wall.

[0112] The second frame layer may be made from or comprise any of the materials described above in relation to the frame. For example, the second frame layer may comprise the one or more susceptor materials.

[0113] The second frame layer may be made from or comprise a biodegradable material. The second frame layer may be entirely made from biodegradable material.

[0114] The second frame layer may be made from or comprise a cellulosic material, as the cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may be paper, paperboard, or cardboard. The second frame layer may be made from or comprise a plant material, such as tobacco. The second frame layer may be made entirely from a cellulosic material. The cellulosic material may have any grammage or range of grammages as described above in relation to the frame.

[0115] The second frame layer may be made from a fibrous material. The second frame layer may be made from one or more of: natural fibres, synthetic fibres, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibres, nylon fibres, and ceramic fibres.

[0116] Where the frame comprises exactly two layers, the thickness of the second frame layer may be half (50 percent) the thickness of the frame. The second frame layer may have a thickness substantially the same as the first frame layer. Where the frame comprises exactly three layers, the thickness of the second frame layer may be one third (33.33 percent) the thickness of the frame. The second frame layer may have a thickness substantially the same as the first frame layer and the third frame layer.

[0117] The second frame layer may have a thickness greater than or equal to 0.5 millimetres. The frame may have a thickness greater than or equal to 1 millimetre. The second frame layer may have a thickness greater than or equal to 1 .5 millimetres. The second frame layer may have a thickness greater than or equal to 2 millimetres. The second frame layer may have a thickness greater than or equal to 2.5 millimetres.

[0118] The second frame layer may have a thickness less than or equal to 3 millimetres. The second frame layer may have a thickness less than or equal to 2.5 millimetres. The second frame layer may have a thickness less than or equal to 2 millimetres. The second frame layer may have a thickness less than or equal to 1.5 millimetres. The second frame layer may have a thickness less than or equal to 1 millimetres.

[0119] The second frame layer may have a thickness between 0.5 millimetres and 3 millimetres. The second frame layer may have a thickness between 0.5 millimetres and 2.5 millimetres. The second frame layer may have a thickness between 1 millimetres and 2.5 millimetres.

[0120] The third frame layer may be planar.

[0121] The third frame layer may define a third frame layer aperture extending through the thickness of the third frame layer. The third frame layer aperture may at least partially define or form the first and second cavities of the aerosol-generating article. For example, the third frame layer may have a hollow cuboid shape or a square hollow tube shape. As a further example, the third frame layer may have a cross-section that is annular in shape, preferably the cross-section in x / y plane is annular in shape. The cross-section may have an annulus shape, such as a circular annulus shape, an elliptical annulus shape, a rectangular annulus shape, or a square annulus shape.

[0122] The third frame layer may comprise a third frame layer outer surface. The third frame layer outer surface may extend in a transverse direction, for example between the third planar external surface and the third planar external surface. The third frame layer outer surface may at least partially define or form one or more external surfaces of the aerosol-generating article. For example, the third frame layer outer surface may at least partially define or form one or more external walls of the aerosol-generating article. The third frame layer outer surface may circumscribe or encircle one or both: the third frame layer aperture and the frame aperture. The third frame layer outer surface may circumscribe or encircle the first and second cavities.

[0123] The third frame layer may comprise a third frame layer inner surface. The third frame layer inner surface may extend in a transverse direction, for example between the third planar external surface and the third planar external surface. The third frame layer inner surface may define or form a third frame layer aperture outer wall. The third frame layer inner surface may at least partially define or form a first and second cavity outer wall. The third frame layer inner surface may circumscribe or encircle one or both the third frame layer aperture and the frame aperture. The third frame layer outer surface may circumscribe or encircle the first and second cavities.

[0124] The third frame layer outer surface may circumscribe or encircle the third frame layer inner surface. The third frame layer inner surface and the third frame layer outer surface may be concentric with one another.

[0125] The third frame layer may comprise a third frame layer peripheral wall. The third frame layer peripheral wall may circumscribe or encircle one or both of: the frame aperture and the third frame layer aperture. The third frame layer peripheral wall may circumscribe or encircle the first and second cavities.

[0126] The third frame layer peripheral wall may be defined or formed by the third frame layer outer surface and the third frame layer inner surface. The third frame layer peripheral wall may at least partially define or form one or more external surfaces or walls of the aerosol-generating article. The third frame layer peripheral wall may at least partially define or form the third frame layer aperture outer wall. The third frame layer peripheral wall may at least partially define or form the first and second cavity outer wall.

[0127] The third frame layer may be made from or comprise any of the materials described above in relation to the frame. For example, the third frame layer may comprise the one or more susceptor materials.

[0128] The third frame layer may be made from or comprise a biodegradable material. The third frame layer may be entirely made from biodegradable material.

[0129] The third frame layer may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may be paper, paperboard, or cardboard. The third frame layer may be made from or comprise a plant material, such as tobacco. The third frame layer may be made entirely from a cellulosic material.

[0130] The cellulosic material may have any grammage or range of grammages as described above in relation to the frame.

[0131] The third frame layer may be made from a fibrous material. The third frame layer may be made from one or more of: natural fibres, synthetic fibres, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibres, nylon fibres, and ceramic fibres. Where the frame comprises exactly three layers, the thickness of the third frame layer may be one third (33.33 percent) the thickness of the frame. The third frame layer may have a thickness substantially the same as each of the first frame layer and the second frame layer.

[0132] The third frame layer may have a thickness greater than or equal to 0.5 millimetres. The frame may have a thickness greater than or equal to 1 millimetre. The third frame layer may have a thickness greater than or equal to 1.5 millimetres. The third frame layer may have a thickness greater than or equal to 2 millimetres. The third frame layer may have a thickness greater than or equal to 2.5 millimetres.

[0133] The third frame layer may have a thickness less than or equal to 3 millimetres. The third frame layer may have a thickness less than or equal to 2.5 millimetres. The third frame layer may have a thickness less than or equal to 2 millimetres. The third frame layer may have a thickness less than or equal to 1 .5 millimetres. The third frame layer may have a thickness less than or equal to 1 millimetres.

[0134] The third frame layer may have a thickness between 0.5 millimetres and 3 millimetres. The third frame layer may have a thickness between 0.5 millimetres and 2.5 millimetres. The third frame layer may have a thickness between 1 millimetres and 2.5 millimetres.

[0135] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate layer. Advantageously, the aerosol-generating substrate layer can be made thin and, therefore, quickly heat up and release volatile compounds to form an aerosol. Advantageously, the aerosol-generating substrate layer can be positioned close to a heater of an aerosol-generating substrate.

[0136] 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.

[0137] The air inlet may be defined by the upstream end 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, and may extend through, the peripheral wall of the frame. The air outlet may be defined by the downstream end 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, and may extend through, the peripheral wall of the frame.

[0138] 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. The air inlet may be defined by, or through, the first frame layer, the second frame layer or the third frame layer. The air inlet may be defined by, or through, the first frame layer and the second frame layer. The air inlet may be defined by, or through, the second frame layer and the third frame layer. The air inlet may be defined by, or through, the first frame layer, the second frame layer and the third frame layer.

[0139] The air outlet may be defined by, or through, the first frame layer, the second frame layer or the third frame layer. The air outlet may be defined by, or through, the first frame layer and the second frame layer. The air outlet may be defined by, or through, the second frame layer and the third frame layer. The air outlet may be defined by, or through, the first frame layer, the second frame layer and the third frame layer.

[0140] The air inlet may have a width (a dimension in the width or lateral direction of the aerosolgenerating article) of at least 1 mm. The air inlet may have a width of at most 8 mm. The air inlet may have a width of between 1 .5 mm and 5 mm. The air inlet may have a width of 2 mm. The air inlet may have a width of 4 mm.

[0141] The air inlet may have a thickness (a dimension in the thickness or transverse direction of the aerosol-generating article) of at least 1 mm. The air inlet may have a thickness of at most 2 mm. Preferably, the air inlet has a thickness of approximately 1 mm.

[0142] The air outlet may have a width (a dimension in the width or lateral direction of the aerosolgenerating article) of at least 1 mm. The air outlet may have a width of at most 8 mm. The air outlet may have a width of between 1 .5 mm and 5 mm. The air outlet may have a width of 2 mm. The air outlet may have a width of 4 mm.

[0143] The air outlet may have a thickness (a dimension in the thickness or transverse direction of the aerosol-generating article) of at least 1 mm. The air outlet may have a thickness of at most 2 mm. Preferably, the air outlet has a thickness of approximately 1 mm.

[0144] The air inlet may be substantially two-dimensional. The air inlet my comprise an air inlet passage, and may be three-dimensional. The air inlet passage may extend the length of the upstream end wall. The air inlet passage may connect the air inlet to the first cavity.

[0145] The air outlet may be substantially two-dimensional. The air outlet my comprise an air outlet passage, and may be three-dimensional. The air outlet passage may extend the length of the downstream end wall. The air outlet passage may connect the air outlet to a cavity proximate to the air outlet. In an embodiment having two cavities, the air outlet passage may connect the air outlet to the second cavity. In an embodiment having three cavities, the air outlet passage may connect the air outlet to the third cavity.

[0146] The first cavity may be configured to receive a first aerosol-generating substrate. A first aerosol-generating substrate may be disposed in the first cavity.

[0147] The first cavity may be defined between the first planar external surface and the second planar external surface. The first cavity may be sandwiched between the first planar external surface and the second planar external surface. The first cavity may be defined between the upstream end wall and a primary dividing wall. The first cavity may be defined between the first side wall and the second side wall.

[0148] The first cavity may be defined between the first planar external surface, the second planar external surface, the upstream end wall, the primary dividing wall, and the first side wall and the second side wall.

[0149] The first cavity is closer to the air inlet than the second cavity. The first cavity may be disposed next to the air inlet. The first cavity may be disposed closer to an upstream end of the aerosol-generating article than the second cavity.

[0150] The first cavity may be closer to the air inlet than to the air outlet. The first cavity may be disposed closer to an upstream end of the aerosol-generating article than to a downstream end of the aerosol-generating article. The first cavity may be disposed proximate to an upstream end of the aerosol-generating article. The first cavity may be disposed within an upstream half of the aerosol-generating article.

[0151] The first cavity may have a substantially cuboid shape.

[0152] The first cavity may have a length. The first cavity length may be in the same direction as the length of the aerosol-generating article. The first cavity length may be a dimension at the first cavity from the upstream end wall to the primary dividing wall. The first cavity may have a width. The first cavity width may be in the same direction as the width of the aerosol-generating article. The first cavity width may be a dimension at the first cavity from the first side wall to the second side wall. The first cavity may have a depth. The first cavity depth may be in the same direction as the depth of the aerosol-generating article. The first cavity depth may be a dimension at the first cavity from the first planar external surface to the second planar external surface.

[0153] The first cavity length may be larger than the first cavity width. The first cavity width may be larger than the first cavity depth.

[0154] The first cavity may have a width of at least 45% of width of the aerosol-generating article. Preferably, the first cavity has a width of at least 55% of width of the aerosol-generating article. More preferably, the first cavity has a width of at least 65% of width of the aerosol-generating article.

[0155] The first cavity may have a width of at most 95% of width of the aerosol-generating article. Preferably, the first cavity has a width of at most 85% of width of the aerosol-generating article. More preferably, the first cavity has a width of at most 75% of width of the aerosol-generating article.

[0156] The first cavity may have a width of between 45% and 75% of width of the aerosolgenerating article. Preferably, the first cavity has a width between of between 55% and 85% of width of the aerosol-generating article. More preferably, the first cavity has a width of between 65% and 75% of width of the aerosol-generating article.

[0157] The first cavity may have a width of approximately 70% of width of the aerosol-generating article. The first cavity may have a width of at least 4 mm. Preferably, the first cavity has a width of at least 5 mm. More preferably, the first cavity has a width of at least 6 mm.

[0158] The first cavity may have a width of at most 12 mm. Preferably, the first cavity has a width of at most 11 mm. More preferably, the first cavity has a width of at most 10 mm.

[0159] The first cavity may have a width of between 4 mm and 12 mm. Preferably, the first cavity has a width between of between 5 mm and 11 mm. More preferably, the first cavity has a width of between 6 mm and 10 mm. The first cavity may have a width of approximately 7 mm. The first cavity may have a width of approximately 9 mm. In an aerosol-generating article having an external width of 10 mm, the first cavity may have a width of approximately 7 mm. In an aerosol-generating article having an external width of 12 mm, the first cavity may have a width of approximately 9 mm.

[0160] The first cavity may have a length of at least 30% of length of the aerosol-generating article. Preferably, the first cavity has a length of at least 40% of length of the aerosol-generating article. More preferably, the first cavity has a length of at least 45% of length of the aerosol-generating article.

[0161] The first cavity may have a length of at most 80% of length of the aerosol-generating article. Preferably, the first cavity has a length of at most 70% of length of the aerosol-generating article. More preferably, the first cavity has a length of at most 55% of length of the aerosol-generating article.

[0162] The first cavity may have a length of between 30% and 80% of length of the aerosolgenerating article. Preferably, the first cavity has a length between of between 40% and 70% of length of the aerosol-generating article. More preferably, the first cavity has a length of between 45% and 55% of length of the aerosol-generating article.

[0163] The first cavity may have a length of at least 5 mm. Preferably, the first cavity has a length of at least 10 mm. More preferably, the first cavity has a length of at least 11 mm.

[0164] The first cavity may have a length of at most 20 mm. Preferably, the first cavity has a length of at most 15 mm. More preferably, the first cavity has a length of at most 13 mm.

[0165] The first cavity may have a length of between 5 mm and 20 mm. Preferably, the first cavity has a length between of between 10 mm and 15 mm. More preferably, the first cavity has a length of between 11 mm and 13 mm.

[0166] The first cavity may have a depth of at least 50 % of depth of the aerosol-generating article. Preferably, the first cavity has a depth of at least 75 % of depth of the aerosol-generating article. More preferably, the first cavity has a depth of at least 95 % of depth of the aerosol-generating article.

[0167] The first cavity may have a depth of at most 99 % of depth of the aerosol-generating article. Preferably, the first cavity has a depth of at most 95 % of depth of the aerosol-generating article.

[0168] The first cavity may have a depth of between 50 % and 99 % of depth of the aerosolgenerating article. Preferably, the first cavity has a depth between of between 75% and 95% of depth of the aerosol-generating article. The first cavity may have a depth of at least 1 mm. Preferably, the first cavity has a depth of at least 2 mm. More preferably, the first cavity has a depth of at least 2.4 mm.

[0169] The first cavity may have a depth of at most 5 mm. Preferably, the first cavity has a depth of at most 4 mm. More preferably, the first cavity has a depth of at most 3.6 mm.

[0170] The first cavity may have a depth of between 1 mm and 5 mm. Preferably, the first cavity has a depth between of between 2 mm and 4 mm. More preferably, the first cavity has a depth of between 2.4 mm and 3.6 mm. The first cavity may have a depth of approximately 3.1 mm.

[0171] The first cavity may have a volume of at least 10 % of the external volume of the aerosolgenerating article. Preferably, the first cavity has a volume of at least 20% of the external volume of the aerosol-generating article. More preferably, the first cavity has a volume of at least 25% the external of volume of the aerosol-generating article.

[0172] The first cavity may have a volume of at most 50 % of the external volume of the aerosolgenerating article. Preferably, the first cavity has a volume of at most 45 % of the external volume of the aerosol-generating article. More preferably, the first cavity has a volume of at most 30 % of the external volume of the aerosol-generating article.

[0173] The first cavity may have a volume of between 10 % and 50 % of the external volume of the aerosol-generating article. Preferably, the first cavity has a volume between of between 20 % and 45 % of the external volume of the aerosol-generating article. More preferably, the first cavity has a volume of between 25 % and 30 % of the external volume of the aerosol-generating article.

[0174] The first cavity may have a volume of at least 25 mm3. Preferably, the first cavity has a volume of at least 30 mm3. Preferably, the first cavity has a volume of at least 40 mm3. Preferably, the first cavity may has a volume of at least 50 mm3. Preferably, the first cavity may has a volume of at least 60 mm3. Preferably, the first cavity has a volume of at least 100 mm3. Preferably, the first cavity has a volume of at least 200 mm3. More preferably, the first cavity has a volume of at least 250 mm3.

[0175] The first cavity may have a volume of at most 500 mm3. Preferably, the first cavity has a volume of at most 400 mm3. More preferably, the first cavity has a volume of at most 300 mm3. The first cavity may have a volume of at most 100 mm3. The first cavity may have a volume of at most 50 mm3.

[0176] The first cavity may have a volume of between 100 mm3and 500 mm3. Preferably, the first cavity has a volume between of between 200 mm3and 400 mm3. More preferably, the first cavity has a volume of between 250 mm3and 300mm3.

[0177] The first cavity may be between the air inlet and the second cavity. The second cavity may be between the first cavity and the air outlet. The aerosol-generating article may be elongate in a longitudinal direction. The first cavity and the second cavity may be substantially aligned with each other along the longitudinal direction.

[0178] The second cavity may be defined between the first planar external surface and the second planar external surface. The second cavity may be sandwiched between the first planar external surface and the second planar external surface. The second cavity may be defined between the downstream end wall and a primary dividing wall. The second cavity may be defined between the first side wall and the second side wall.

[0179] The second cavity may be defined between the first planar external surface, the second planar external surface, the downstream end wall, the primary dividing wall, and the first side wall and the second side wall.

[0180] The second cavity is closer to the air outlet than the second cavity. The second cavity may be disposed next to the air outlet. The second cavity may be disposed closer to a downstream end of the aerosol-generating article than the second cavity.

[0181] The second cavity may be closer to the air outlet than to the air inlet. The second cavity may be disposed closer to a downstream end of the aerosol-generating article than to an upstream end of the aerosol-generating article. The second cavity may be disposed proximate to a downstream end of the aerosol-generating article. The second cavity may be disposed within a downstream half of the aerosol-generating article.

[0182] The second cavity may have a substantially cuboid shape.

[0183] The second cavity may have a length. The second cavity length may be in the same direction as the length of the aerosol-generating article. The second cavity length may be a dimension at the second cavity from the downstream end wall to the primary dividing wall. The second cavity may have a width. The second cavity width may be in the same direction as the width of the aerosol-generating article. The second cavity width may be a dimension at the second cavity from the first side wall to the second side wall. The second cavity may have a depth. The second cavity depth may be in the same direction as the depth of the aerosol-generating article. The second cavity depth may be a dimension at the second cavity from the first planar external surface to the second planar external surface.

[0184] The second cavity length may be larger than the second cavity width. The second cavity width may be larger than the second cavity depth.

[0185] The second cavity may have a width of at least 45 % of width of the aerosol-generating article. Preferably, the second cavity has a width of at least 55 % of width of the aerosol-generating article. More preferably, the second cavity has a width of at least 65% of width of the aerosolgenerating article.

[0186] The second cavity may have a width of at most 95% of width of the aerosol-generating article. Preferably, the second cavity has a width of at most 85% of width of the aerosol-generating article. More preferably, the second cavity has a width of at most 75% of width of the aerosolgenerating article.

[0187] The second cavity may have a width of between 45 % and 75 % of width of the aerosolgenerating article. Preferably, the second cavity has a width between of between 55 % and 85 % of width of the aerosol-generating article. More preferably, the second cavity has a width of between 65 % and 75 % of width of the aerosol-generating article. The second cavity may have a width of approximately 70 % of width of the aerosolgenerating article.

[0188] The second cavity may have a width of at least 4 mm. Preferably, the second cavity has a width of at least 5 mm. More preferably, the second cavity has a width of at least 6 mm.

[0189] The second cavity may have a width of at most 12 mm. Preferably, the second cavity has a width of at most 11 mm. More preferably, the second cavity has a width of at most 10 mm.

[0190] The second cavity may have a width of between 4 mm and 12 mm. Preferably, the second cavity has a width between of between 5 mm and 11 mm. More preferably, the second cavity has a width of between 6 mm and 10 mm. The second cavity may have a width of approximately 7 mm. The second cavity may have a width of approximately 9 mm. In an aerosol-generating article having an external width of 10 mm, the second cavity may have a width of approximately 7 mm. In an aerosol-generating article having an external width of 12 mm, the second cavity may have a width of approximately 9 mm.

[0191] The second cavity may have a length of at least 30 % of length of the aerosol-generating article. Preferably, the second cavity has a length of at least 40 % of length of the aerosolgenerating article. More preferably, the second cavity has a length of at least 45 % of length of the aerosol-generating article.

[0192] The second cavity may have a length of at most 80 % of length of the aerosol-generating article. Preferably, the second cavity has a length of at most 70 % of length of the aerosolgenerating article. More preferably, the second cavity has a length of at most 55 % of length of the aerosol-generating article.

[0193] The second cavity may have a length of between 30 % and 80 % of length of the aerosolgenerating article. Preferably, the second cavity has a length between of between 70 % and 50 % of length of the aerosol-generating article. More preferably, the second cavity has a length of between 45 % and 55 % of length of the aerosol-generating article.

[0194] The second cavity may have a length of at least 5 mm. Preferably, the second cavity has a length of at least 10 mm. More preferably, the second cavity has a length of at least 11 mm.

[0195] The second cavity may have a length of at most 20 mm. Preferably, the second cavity has a length of at most 15 mm. More preferably, the second cavity has a length of at most 13 mm.

[0196] The second cavity may have a length of between 5 mm and 20 mm. Preferably, the second cavity has a length between of between 10 mm and 15 mm. More preferably, the second cavity has a length of between 11 mm and 13 mm.

[0197] The second cavity may have a depth of at least 50 % of depth of the aerosol-generating article. Preferably, the second cavity has a depth of at least 75 % of depth of the aerosol-generating article. More preferably, the second cavity has a depth of at least 95 % of depth of the aerosolgenerating article. The second cavity may have a depth of at most 99 % of depth of the aerosol-generating article. Preferably, the second cavity has a depth of at most 95 % of depth of the aerosol-generating article.

[0198] The second cavity may have a depth of between 50 % and 99 % of depth of the aerosolgenerating article. Preferably, the second cavity has a depth between of between 75% and 95% of depth of the aerosol-generating article.

[0199] The second cavity may have a depth of at least 1 mm. Preferably, the second cavity has a depth of at least 2 mm. More preferably, the second cavity has a depth of at least 2.4 mm.

[0200] The second cavity may have a depth of at most 5 mm. Preferably, the second cavity has a depth of at most 4 mm. More preferably, the second cavity has a depth of at most 3.6 mm.

[0201] The second cavity may have a depth of between 1 mm and 5 mm. Preferably, the second cavity has a depth between of between 2 mm and 4 mm. More preferably, the second cavity has a depth of between 2.4 mm and 3.6 mm. The second cavity may have a depth of approximately 3.1 mm.

[0202] The second cavity may have a volume of at least 10 % of the external volume of the aerosol-generating article. Preferably, the second cavity has a volume of at least 20% of the external volume of the aerosol-generating article. More preferably, the second cavity has a volume of at least 25% the external of volume of the aerosol-generating article.

[0203] The second cavity may have a volume of at most 50 % of the external volume of the aerosol-generating article. Preferably, the second cavity has a volume of at most 45 % of the external volume of the aerosol-generating article. More preferably, the second cavity has a volume of at most 30 % of the external volume of the aerosol-generating article.

[0204] The second cavity may have a volume of between 10 % and 50 % of the external volume of the aerosol-generating article. Preferably, the second cavity has a volume between of between 20 % and 45 % of the external volume of the aerosol-generating article. More preferably, the second cavity has a volume of between 25 % and 30 % of the external volume of the aerosolgenerating article.

[0205] The second cavity may have a volume of at least 25 mm3. Preferably, the second cavity has a volume of at least 30 mm3. Preferably, the second cavity has a volume of at least 40 mm3. Preferably, the second cavity may has a volume of at least 50 mm3. Preferably, the second cavity may has a volume of at least 60 mm3. Preferably, ,the second cavity has a volume of at least 100 mm3. Preferably, the second cavity has a volume of at least 200 mm3. More preferably, the second cavity has a volume of at least 250 mm3.

[0206] The second cavity may have a volume of at most 500 mm3. Preferably, the second cavity has a volume of at most 400 mm3. More preferably, the second cavity has a volume of at most 300 mm3. The second cavity may have a volume of at most 100 mm3. The second cavity may have a volume of at most 50 mm3. The second cavity may have a volume of between 100 mm3and 500 mm3. Preferably, the second cavity has a volume between of between 200 mm3and 400 mm3. More preferably, the second cavity has a volume of between 250 mm3and 300mm3.

[0207] There may be provided an aerosol-generating article comprising at least three cavities. The at least three cavities may comprise a first cavity, a second cavity and a third cavity. The first cavity may be configured to receive an aerosol-generating substrate. An aerosol-generating substrate may be disposed in the first cavity. The second cavity may be configured to receive an aerosol-generating substrate. An aerosol-generating substrate may be disposed in the second cavity. The third cavity may be configured to receive an aerosol-generating substrate. An aerosolgenerating substrate may be disposed in the third cavity.

[0208] The first cavity may have a substantially cuboid shape. The second cavity may have a substantially cuboid shape. The third cavity may have a substantially cuboid shape.

[0209] The second cavity may be disposed between the first cavity and the third cavity. The first cavity may be defined between the upstream end wall and a primary dividing wall.

[0210] The first cavity may be defined between the first planar external surface, the second planar external surface, the upstream end wall, the primary dividing wall, and the first side wall and the second side wall.

[0211] The first cavity is closer to the air inlet than the second cavity. The first cavity may be closer to the air inlet than the third cavity. The first cavity may be disposed closer to an upstream end of the aerosol-generating article than the second cavity. The first cavity may be disposed closer to an upstream end of the aerosol-generating article than the third cavity.

[0212] The second cavity may be defined between the primary dividing wall and a secondary dividing wall.

[0213] The second cavity may be defined between the first planar external surface, the second planar external surface, the primary dividing wall, the secondary dividing wall, and the first side wall and the second side wall.

[0214] The second cavity may be closer to the air outlet than the first cavity. The second cavity may be closer to the air inlet than the third cavity. The second cavity may be disposed closer to an upstream end of the aerosol-generating article than the third cavity. The second cavity may be disposed closer to an upstream end of the aerosol-generating article than the third cavity.

[0215] The third cavity may be defined between the secondary dividing wall and a downstream end wall.

[0216] The third cavity may be defined between the first planar external surface, the second planar external surface, the secondary dividing wall, the downstream end wall, and the first side wall and the second side wall.

[0217] The third cavity may be closer to the air outlet than the first cavity. The third cavity may be closer to the air outlet than the second cavity. The third cavity may be disposed closer to a downstream end of the aerosol-generating article than the first cavity. The third cavity may be disposed closer to a downstream end of the aerosol-generating article than the second cavity.

[0218] The third cavity may be closer to the air outlet than to the air inlet. The third cavity may be disposed closer to a downstream end of the aerosol-generating article than to an upstream end of the aerosol-generating article. The third cavity may be disposed proximate to a downstream end of the aerosol-generating article. The third cavity may be disposed within a downstream half of the aerosol-generating article.

[0219] The third cavity may have any of the dimensions described herein of the first cavity or the second cavity. The first cavity may have any of the dimensions described herein of the second cavity or the third cavity. The second cavity may have any of the dimensions described herein of the first cavity or the third cavity.

[0220] The first cavity may have a length of at Ieast 5 % of length of the aerosol-generating article. Preferably, the first cavity has a length of at least 10 % of length of the aerosol-generating article. More preferably, the first cavity has a length of at least 15 % of length of the aerosol-generating article.

[0221] The first cavity may have a length of at most 30 % of length of the aerosol-generating article. Preferably, the first cavity has a length of at most 25 % of length of the aerosol-generating article. More preferably, the first cavity has a length of at most 20 % of length of the aerosolgenerating article.

[0222] The first cavity may have a length of between 5 % and 30 % of length of the aerosolgenerating article. Preferably, the first cavity has a length between of between 10 % and 25 % of length of the aerosol-generating article. More preferably, the first cavity has a length of between 15 % and 20 % of length of the aerosol-generating article.

[0223] The first cavity may have a length of at least 2 mm. Preferably, the first cavity has a length of at least 3 mm. More preferably, the first cavity has a length of at least 3.5 mm.

[0224] The first cavity may have a length of at most 7 mm. Preferably, the first cavity has a length of at most 5 mm. More preferably, the first cavity has a length of at most 4.5 mm.

[0225] The first cavity may have a length of between 2 mm and 7 mm. Preferably, the first cavity has a length between of between 3 mm and 5 mm. More preferably, the first cavity has a length of between 3.5 mm and 4.5 mm.

[0226] The first cavity may have a volume of at least 5 % of the external volume of the aerosolgenerating article. Preferably, the first cavity has a volume of at least 7% of the external volume of the aerosol-generating article. More preferably, the first cavity has a volume of at least 9% the external of volume of the aerosol-generating article.

[0227] The first cavity may have a volume of at most 15 % of the external volume of the aerosolgenerating article. Preferably, the first cavity has a volume of at most 13 % of the external volume of the aerosol-generating article. More preferably, the first cavity has a volume of at most 10% of the external volume of the aerosol-generating article. The first cavity may have a volume of between 5 % and 15 % of the external volume of the aerosol-generating article. Preferably, the first cavity has a volume between of between 7 % and 13 % of the external volume of the aerosol-generating article. More preferably, the first cavity has a volume of between 9 % and 10 % of the external volume of the aerosol-generating article.

[0228] The first cavity may have a volume of at least 60 mm3. Preferably, the first cavity has a volume of at least 70 mm3. More preferably, the first cavity has a volume of at least 80 mm3.

[0229] The first cavity may have a volume of at most 150 mm3. Preferably, the first cavity has a volume of at most 120 mm3. More preferably, the first cavity has a volume of at most 100 mm3.

[0230] The first cavity may have a volume of between 60 mm3and 150 mm3. Preferably, the first cavity has a volume between of between 70 mm3and 120 mm3. More preferably, the first cavity has a volume of between 80 mm3and 100 mm3.

[0231] In an embodiment having three cavities, the third cavity may have substantially the same or the same dimensions as the first cavity.

[0232] The primary dividing wall may have a length (a dimension in the longitudinal direction of the aerosol-generating article) of at least 1 mm. The primary dividing wall may have a length of at most 2 mm. The primary dividing wall may have a length of 1 .5 mm.

[0233] The primary dividing wall may extend from a first side wall to a second side wall. The primary dividing wall may separate the first cavity from the second cavity. The primary dividing wall may be configured such that airflow can only flow from the first cavity to the second cavity through the primary aperture. The primary aperture may be disposed substantially centrally on the primary dividing wall. The primary aperture may be disposed substantially centrally along a width of the primary dividing wall. The primary aperture may be disposed substantially centrally along a thickness of the primary dividing wall.

[0234] The secondary dividing wall may have a length (a dimension in the longitudinal direction of the aerosol-generating article) of at least 1 mm. The secondary dividing wall may have a length of at most 2 mm. The secondary dividing wall may have a length of 1 .5 mm.

[0235] The secondary dividing wall may extend from a first side wall to a second side wall. The secondary dividing wall may separate the second cavity from the third cavity. The secondary dividing wall may be configured such that airflow can only flow from the second cavity to the third cavity through the secondary aperture. The secondary aperture may be disposed substantially centrally on the secondary dividing wall. The secondary aperture may be disposed substantially centrally along a width of the secondary dividing wall. The secondary aperture may be disposed substantially centrally along a thickness of the secondary dividing wall.

[0236] The downstream end wall may have a length (a dimension in the longitudinal direction of the aerosol-generating article) of at least 1 mm. The downstream end wall may have a length of at most 4 mm. Preferably, the downstream end wall has a length of at most 3 mm. The downstream end wall may have a length of 2 mm. The upstream end wall may have a length (a dimension in the longitudinal direction of the aerosol-generating article) of at least 1 mm. The upstream end wall may have a length of at most 4 mm. Preferably, the upstream end wall has a length of at most 3 mm. The upstream end wall may have a length of 2 mm.

[0237] The first side wall may have a width (a dimension in the width or lateral direction of the aerosol-generating article) of at least 1 mm. The first side wall may have a width of at most 2 mm. The first side wall may have a width of 1 .5 mm.

[0238] The second side wall may have a width (a dimension in the width or lateral direction of the aerosol-generating article) of at least 1 mm. The second side wall may have a width of at most 2 mm. The second side wall may have a width of 1 .5 mm.

[0239] The primary aperture may have a width (a dimension in the width or lateral direction of the aerosol-generating article) of at least 1 mm. The primary aperture may have a width of at most 7 mm. The primary aperture may have a width of 2 mm.

[0240] The primary aperture may have a thickness (a dimension in the thickness or transverse direction of the aerosol-generating article) of at least 1 mm. The primary aperture may have a thickness of at most 2 mm. Preferably, the primary aperture has a thickness of approximately 1 mm.

[0241] The secondary aperture may have a width (a dimension in the width or lateral direction of the aerosol-generating article) of at least 1 mm. The secondary aperture may have a width of at most 7 mm. The secondary aperture may have a width of 2 mm.

[0242] The secondary aperture may have a thickness (a dimension in the thickness or transverse direction of the aerosol-generating article) of at least 1 mm. The secondary aperture may have a thickness of at most 2 mm. Preferably, the secondary aperture has a thickness of approximately 1 mm.

[0243] The aerosol-generating device may comprise a heating surface comprising a plurality of separately operable heating zones, for example two separately operable heating zones, or three separately operable heating zones, or four separately operable heating zones, or five separately operable heating zones, or six separately operable heating zones. The plurality of separably operable heating zones may be configured to be operated individually, or in any combination of two or more zones at once. In some examples, the plurality of separably operable heating zones may be longitudinally spaced within a cavity of the device. In some example, the plurality of separably operable heating zones may be transversely spaced within the cavity. Different heating zones may be both transversely and longitudinally spaced from one another. Different heating zones may be arranged concentrically relative to one another.

[0244] The aerosol-generating device may comprise one or more resistance heaters, for example one or more resistance heaters integrated into walls of the cavity.

[0245] The device may comprises one or more inductors, for example one or more inductors integrated into walls of the cavity of the aerosol-generating device, or arranged to generate a fluctuating electromagnetic field in walls of the cavity of the aerosol-generating device, or within the cavity of the aerosol-generating device. One or more walls of the cavity of the aerosolgenerating device comprise or consist of susceptor material, such that the one or more walls of the cavity heat up on engagement with a fluctuating electromagnetic field, thereby heating an aerosol-generating article inserted within the cavity.

[0246] The aerosol-generating device may comprise one or more insertable heating elements arranged to project into the cavity of the aerosol-generating device for insertion into an aerosolgenerating article. The insertable heating elements may be resistance heaters. The insertable heating elements may be susceptors.

[0247] The aerosol-generating device may comprise a device body. The device body may comprise the heater. The aerosol-generating device may comprise a mouthpiece element. The device body may comprise a device body housing. The device body housing may define the cavity for receiving at least a portion of the aerosol-generating article. The device body and the mouthpiece element may be releasably connectable. The mouthpiece element may be releasably connectable with the device body, for example the device body housing.

[0248] The mouthpiece element may be releasably connectable with the device body, for example the device body housing, between a connected position and a disconnected position. In the connected position, the cavity of the aerosol-generating device may be at least partially covered, for example by the mouthpiece element. In the disconnected position, the cavity of the aerosolgenerating device may be at least partially exposed, for example so as to allow insertion of the article into the cavity of the aerosol-generating device. The mouthpiece element may be moveable, for example pivotable about a hinge, relative to the device body, for example between a first position and a second position. In the first position, the cavity of the aerosol-generating device may be at least partially covered, for example by the mouthpiece element. In the second position, the cavity may be at least partially exposed, for example so as to allow insertion of the article into the cavity of the aerosol-generating device. Advantageously, covering the cavity of the aerosolgenerating device, or the article in the cavity of the aerosol-generating device, may ensure most aerosol from the article travels along the desired flow path to the user, rather than escaping to the external environment.

[0249] The aerosol-generating device, for example the device body, may comprise a power source such as a battery. In use, the power source may provide power to the heater. The device, for example the device body, may comprise a controller. The controller may be configured to control power from the power supply to the heater.

[0250] The device body may comprise a distal end and a proximal end. The cavity of the aerosolgenerating device may be defined at the proximal end of the device body. The mouthpiece element may comprise a distal end and a proximal end. The distal end of the mouthpiece element may be configured to releasably connect to the proximal end of the device body. The mouthpiece element, or at least a portion of the mouthpiece element, may be configured to be inserted into a mouth of a user. The proximal end of the mouthpiece element may be configured to be inserted into a mouth of a user.

[0251] The aerosol-generating device, for example one or both of the device body and the mouthpiece element, may comprise an air inlet. The device, for example the mouthpiece element, may comprise an air outlet. The device may comprise an air flow path fluidly connecting the air inlet to the air outlet. The air flow path may extend one or both of through and past the cavity of the aerosol-generating device. As such, in use, the device may be configured such that, when a negative pressure is applied to the air outlet, for example by a user drawing on the air outlet, air is drawn in through the air inlet, then past or through an aerosol-generating article received in the cavity, thereby entraining aerosol released from the aerosol-forming substrate of the article, then out through the air outlet.

[0252] According to the present disclosure, an aerosol-generating system comprises an aerosolgenerating device as disclosed herein and an aerosol-generating article as disclosed herein. The system may comprise a plurality of such articles for use with the aerosol-generating device.

[0253] 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.

[0254] 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.

[0255] 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.

[0256] 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.

[0257] As used herein, the term “transverse” refers to a direction extending between the first planar external surface and the second planar external surface.

[0258] As used herein, the term “longitudinal” refers to a direction that is perpendicular to the transverse direction. For example, a direction between the upstream end wall and the downstream end wall of the aerosol-generating article. As used herein, the term “lateral” refers to a direction that is perpendicular to the transverse direction and the longitudinal direction. For example, a direction from a first side wall to a second side wall of the aerosol-generating article.

[0259] As used herein, the term “thickness” or “depth” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the transverse direction.

[0260] As used herein, the term “length” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the longitudinal direction.

[0261] As used herein, the term “width” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the lateral direction.

[0262] 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.

[0263] 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.

[0264] As used herein, the term “aerosol former content” may refer to aerosol former content in percent on a dry weight basis, unless otherwise specified.

[0265] 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.

[0266] Ex1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: a first planar external surface and a second planar external surface; a first cavity and a second cavity; a frame between the first planar external surface and the second planar external surface, the frame at least partially defining the first cavity and the second cavity; and an air inlet and an air outlet, and an airflow passage extending from the air inlet to the air outlet through the first cavity and the second cavity; wherein the first cavity is closer to the air inlet than the second cavity, and the first cavity and the second cavity are arranged in series such that the airflow passage extends from the first cavity to the second cavity; and wherein the first cavity has a volume equal to at least 5% of a volume of the second cavity, and wherein the second cavity has a volume equal to at least 5% of a volume of the first cavity. Ex2. An aerosol-generating article according to Ex1 , wherein the aerosol-generating article has an external volume, the first cavity has a volume, and the volume of the first cavity is at least 10 % of the external volume of the aerosol-generating article.

[0267] Ex3. An aerosol-generating article according to Ex1 or Ex2, wherein the aerosol-generating article has an external volume, the second cavity has a volume, and the volume of the second cavity is at least 10 % of the external volume of the aerosol-generating article.

[0268] Ex4. An aerosol-generating article according to any of Ex1 to Ex3, wherein the aerosolgenerating article has an internal volume, the first cavity has a volume, and the volume of the first cavity is at least 20 % of the internal volume of the aerosol-generating article.

[0269] Ex5. An aerosol-generating article according to any of Ex1 to Ex4, wherein the aerosolgenerating article has an internal volume, the second cavity has a volume, and the volume of the second cavity is at least 20 % of the internal volume of the aerosol-generating article.

[0270] Ex6. An aerosol-generating article according to any of Ex1 to Ex5, wherein the first cavity is a first distance from the upstream end, the second cavity is a second distance from the upstream end, and a ratio of the first distance to the second distance is between 1 :100 and 1 :1 .5

[0271] Ex7. An aerosol-generating article according to any of Ex1 to Ex6, wherein the first cavity is between the air inlet and the second cavity, and the second cavity is between the first cavity and the air outlet.

[0272] Ex8. An aerosol-generating article according to any of Ex1 to Ex7, wherein the aerosolgenerating article is elongate in a longitudinal direction, and the first cavity and the second cavity are substantially aligned with each other along the longitudinal direction.

[0273] Ex9. An aerosol-generating article according to any of Ex1 to Ex8, wherein the first cavity or the second cavity has a volume of at least 50 mm3.

[0274] Ex10. An aerosol-generating article according to any of Ex1 to Ex9, wherein the first cavity or the second cavity has a volume of at most 500 mm3.

[0275] Ex11 . An aerosol-generating article according to any of Ex1 to Ex10, wherein the first cavity has a width, the second cavity has a width, and a ratio of the first cavity width to the second cavity width is between 0.5 and 2. Ex12. An aerosol-generating article according to any of Ex1 to Ex11 , wherein the first cavity has a thickness, the second cavity has a thickness, and a ratio of the first cavity thickness to the second cavity thickness is between 0.5 and 2.

[0276] Ex13. An aerosol-generating article according to any of Ex1 to Ex12, wherein the first cavity has a length, the second cavity has a length, and a ratio of the first cavity length to the second cavity length is between 0.1 and 2.

[0277] Ex14. An aerosol-generating article according to any of Ex1 to Ex13, wherein the first cavity has a volume equal to at least 30% of a volume of the second cavity, and wherein the second cavity has a volume equal to at least 30% of a volume of the first cavity.

[0278] Ex15. An aerosol-generating article according to any of Ex1 to Ex14, wherein the first cavity has a volume equal to at least 40% of a volume of the second cavity, and wherein the second cavity has a volume equal to at least 40% of a volume of the first cavity.

[0279] Ex16. An aerosol-generating article according to any of Ex1 to Ex15, wherein the first cavity has a volume equal to at least 50% of a volume of the second cavity, and wherein the second cavity has a volume equal to at least 50% of a volume of the first cavity.

[0280] Ex17. An aerosol-generating article according to any of Ex1 to Ex16, wherein the first cavity has a volume equal to at least 60% of a volume of the second cavity, and wherein the second cavity has a volume equal to at least 60% of a volume of the first cavity.

[0281] Ex18. An aerosol-generating article according to any of Ex1 to Ex17, wherein the first cavity has a volume equal to at least 70% of a volume of the second cavity, and wherein the second cavity has a volume equal to at least 70% of a volume of the first cavity.

[0282] Ex19. An aerosol-generating article according to any of Ex1 to Ex18, wherein the first cavity has a volume equal to at least 80% of a volume of the second cavity, and wherein the second cavity has a volume equal to at least 80% of a volume of the first cavity.

[0283] Ex20. An aerosol-generating article according to any of Ex1 to Ex19, wherein the first cavity has a volume equal to at least 90% of a volume of the second cavity, and wherein the second cavity has a volume equal to at least 90% of a volume of the first cavity.

[0284] Ex21 . An aerosol-generating article according to any of Ex1 to Ex20, wherein the first cavity volume and the second cavity volume are substantially equal to each other. Ex22. An aerosol-generating article according to any of Ex1 to Ex21 , wherein the first cavity and the second cavity are divided by primary dividing wall having a primary aperture fluidly connecting the first cavity to the second cavity.

[0285] Ex23. An aerosol-generating article according to Ex22, wherein the primary aperture has a volume, the primary aperture volume being less than 10% of a volume of the first or the second cavity.

[0286] Ex24. An aerosol-generating article according to Ex22 or Ex23, wherein the primary aperture has a cross-sectional area, and the first and second cavities each have a cross-sectional area, and the primary aperture cross-sectional area is less than 10% of the cross-sectional area of the first or the second cavity.

[0287] Ex25. An aerosol-generating article according to any of Ex22 to Ex24, wherein the primary aperture has a cross-sectional area of between 1 mm2and 14 mm2.

[0288] Ex26. An aerosol-generating article according to any of Ex1 to Ex25, wherein the aerosolgenerating article comprises a third cavity, wherein each of the first cavity, the second cavity and the third cavity have a volume of at least 5% of each other cavity of the first cavity, the second cavity and the third cavity.

[0289] Ex27. An aerosol-generating article according to Ex26, wherein the second cavity and the third cavity are divided by a secondary dividing wall having a secondary aperture fluidly connecting the second cavity to the third cavity.

[0290] Ex28. An aerosol-generating article according to any of Ex1 to Ex27, wherein the aerosolgenerating article comprises more than three cavities.

[0291] Ex29. An aerosol-generating article according to any of Ex1 to Ex28, wherein a thickness of the aerosol-generating article is less than 50 percent of both a length and a width of the aerosolgenerating article.

[0292] Ex30. An aerosol-generating article according to any of Ex1 to Ex29, wherein the frame is made from paper, paperboard, or cardboard.

[0293] Ex31. An aerosol-generating article according to any of Ex1 to Ex30, having a thickness between 1 millimetres and 5.5 millimetres. Examples will now be further described with reference to the figures in which:

[0294] Figure 1 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0295] Figure 2 shows an exploded perspective view of the aerosol-generating article of Figure 1 ;

[0296] Figure 3 shows a cross-sectional view of an aerosol-generating article according to the present disclosure;

[0297] Figure 4 shows a cross-sectional view of an aerosol-generating article according to the present disclosure;

[0298] Figure 5 shows a cross-sectional view of an aerosol-generating article according to the present disclosure;

[0299] Figure 6 shows a cross-sectional view of an aerosol-generating article according to the present disclosure;

[0300] Figure 7 shows a schematic cross-sectional view of an aerosol-generating device according to the present disclosure; and

[0301] Figure 8 shows a schematic cross-sectional view of the aerosol-generating device of Figure 7 in engagement with an aerosol-generating article of the present disclosure.

[0302] Figure 1 shows an aerosol-generating article 1 comprising a first planar external layer 524 forming a first planar external surface 521 , a second planar external layer 525 forming a second planar external surface 522, and a frame 50 positioned between the first planar external layer 524 and the second planar external layer 525. The first planar external layer 524 and the second planar external layer 525 both comprise an aerosol-generating substrate comprising an aerosolgenerating material, namely tobacco. However, it will be understood that in some embodiments only one of the first planar external layer 524 and the second planar external layer 525 may comprise an aerosol-generating substrate. Alternatively, or additionally, the aerosol-generating substrate may be positioned elsewhere within the aerosol-generating article 1.

[0303] The aerosol-generating article 1 has a length extending in the x-direction along a longitudinal axis 2, a width extending in the y-direction and a thickness extending in the z-direction. The aerosol-generating article 1 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.1 millimetres.

[0304] The first planar external surface 521 and the second planar external surface 522 extend in the x-direction and the y-direction. That is, the first planar external surface 521 and the second planar external surface 522 extend in the x / y plane. The first planar external surface 521 is positioned parallel to the second planar external surface 522 and the first planar external surface 521 is spaced from the second planar external surface 522 in the z-direction or transverse direction. The distance between the first planar external surface 521 and the second planar external surface 522 in the z-direction or transverse direction corresponds to the thickness of the aerosol-generating article 1. The aerosol-generating article 1 is substantially flat aerosol-generating article or substantially planar aerosol-generating article. In particular, the thickness of the aerosol-generating article 1 is less than 50 percent of both the length and the width of the aerosol-generating article. That is, the thickness is less than 15 millimetres (less than 50 percent of the length of the aerosolgenerating article 1) and less than 5 millimetres (less than 50 percent of the width of the width of the aerosol-generating article 1). The aerosol-generating article 1 has a generally rectangular cuboid shape and a laminated structure formed by the first planar external layer 524, the frame 50 and the second planar external layer 525. The first planar external layer 524, the frame 50 and the second planar external layer 525 are bonded together with an adhesive, in particular guar gum, as discussed in more detail below in relation to Figure 2.

[0305] Figure 2 shows an exploded view of the aerosol-generating article 1 of Figure 1.

[0306] 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 first and a second cavity 100, 200.

[0307] The first cavity 100 is substantially empty and the second cavity 200 is substantially empty. The first cavity 100 has length of 12 millimetres, a width of 6 millimetres, and a thickness of 2.7 millimetres. The second cavity 200 has length of 12 millimetres, a width of 6 millimetres, and a thickness of 2.7 millimetres.

[0308] The frame 50 defines a frame first aperture extending through the thickness of the frame 50 and the frame first aperture at least partially forms the first cavity 100. The frame 50 defines a frame second aperture extending through the thickness of the frame 50 and the frame second aperture at least partially forms the second cavity 200.

[0309] The frame 50 comprises primary dividing wall 11 which separates the second cavity 200 and the first cavity 100. The primary dividing wall 11 defines an aperture extending from the second cavity 200 to the first cavity 100. The aperture of the primary dividing wall 11 defines at least a portion of the airflow passage between the air inlet 80 and the air outlet 90. The primary dividing wall 11 extends from a first side wall 5 of the aerosol-generating article to a second side wall 6 of the aerosol-generating article.

[0310] The first planar external layer 524 overlies an end of the first cavity 100 and the second planar external layer 525 overlies an opposite end of the first cavity 100. That is, the frame 50, the first planar external layer 524 and the second planar external layer 525 collectively define the first cavity 100. The first planar external layer 524 overlies an end of the first cavity 100 and the second planar external layer 525 overlies an opposite end of the second cavity 200. That is, the frame 50, the first planar external layer 524 and the second planar external layer 525 collectively define the second cavity 200.

[0311] The frame 50 has a frame inner surface extending in the z-direction or the transverse direction between the first planar external surface 521 and the second planar external surface 522. The frame 50 has a frame outer surface 53 extending in the z-direction or the transverse direction between the first planar external surface 521 and the second planar external surface 522. The frame outer surface 53 at least partially defines one or more external surfaces of the aerosolgenerating article, such as the upstream end wall 13 at an upstream end 3 of the aerosolgenerating article and the downstream end wall 14 at a downstream end 4 of the article. The frame outer surface 53 encircles, and is concentric with, the frame inner surface. Thus, the frame 50 has a cross-section in the x / y plane that is annular in shape, in particular the cross-section is a rectangular annulus shape.

[0312] The frame 50 comprises a peripheral wall 51 that circumscribes the cavities 100, 200. In more detail, the peripheral wall 51 is defined by the frame inner surface and the frame outer surface. The peripheral wall 51 has a radial thickness, as measured between the frame inner surface and the frame outer surface 53 in the x / y plane, of about 2 millimetres.

[0313] The first planar external layer 524 and the second planar external layer 525 have a thickness of 200 micrometres and are in physical contact with the frame 50. The first planar external layer 524 and the second planar external layer 525 are bonded to the frame with an adhesive 515. The first planar external layer 524 overlies an end of the first cavity 100 and second cavity 200 and forms a cavity end wall. The second planar external layer 525 overlies an opposite end of the first cavity 100 and second cavity 200 and forms a cavity end wall. That is, the frame 50, the first planar external layer 524 and the second planar external layer 525 collectively partially define the first cavity 100 and the second cavity 200.

[0314] The air inlet 80 and the air outlet 90 are defined by the peripheral wall 51 of the frame 50. The air inlet 80 and the air outlet 90 each have a rectangular cross-section, a width of 2 millimetres, and a thickness of 0.9 millimetres. An airflow passage extends between the air inlet 80 and the air outlet 90 through the cavities 100, 200. The air inlet comprises an air inlet passage 81 which extends through the upstream end wall 13. The air outlet comprises an air outlet passage 91 which extends through the downstream end wall 14.

[0315] The frame forms at least 95 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame. For example, the frame forms 100 percent of the perimeterof a cross-section, in an x / y plane, of the aerosol-generating article 1 taken between the first planar external layer 524 and the air outlet 90. On the other hand, the frame forms 95 percent of the perimeter of a cross-section, in an x / y plane, of the aerosol-generating article that extends through the air inlet 80 and the air outlet 90. This is because the perimeter of such a cross-section is formed by the frame, a width of the air inlet 80 and a width of the air outlet 90.

[0316] Figure 3 shows a cross-sectional view of an aerosol-generating article having a first cavity 100 and a second cavity 200, as also shown in figure 2. The first cavity 100 and second cavity 200 are separated by a primary dividing wall 11 . The primary dividing wall 11 defines a primary aperture 10. Alternative aerosol-generating articles having first and second cavities 100, 200 are depicted in figures 4 and 5. As will be evident from figures 4 and 5, the length of the first cavity 100 and the second cavity 200 can be varied. Equally, as depicted in figures 4 and 5, the width of the primary aperture 10 can be varied.

[0317] Figure 6 shows a cross-sectional view of an aerosol-generating article having a first cavity 100, a second cavity 200, and a third cavity 300. The first cavity and the second cavity 100, 200, are separated by a primary defining wall 11. The second cavity 200 and the third cavity 300 are separated by a secondary dividing wall 21. The secondary dividing wall 21 defines a secondary aperture 20.

[0318] Figure 7 shows a schematic cross-sectional view of an aerosol-generating device 690 configured for use with an aerosol-generating article 1 described herein. The aerosol-generating device 690 is an elongate aerosol-generating device extending between a proximal end 691 and a distal end 692. The aerosol-generating device 690 comprises a battery 693, a controller 694, a first heater 695 and a second heater 696 located within a housing 697. The controller 694 controls supply of power from the battery 693 to the first heater 695 and the second heater 696. A cavity 1000 is defined in the device 690, the cavity 1000 having an opening 1010 defined in the proximal end 691 of the device 690. The opening 1010 is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosol-generating article 1. The cavity 1000 comprises an upper planar surface 1020 and a lower planar surface 1030. The first heater 695 is located in the upper planar surface 1020 to heat the first planar external surface 21 of an aerosolgenerating article 1 inserted into the cavity 1000, and the second heater 696 is located in the lower planar surface 1030 to heat the second planar external surface 22 of an aerosol-generating article 1 inserted into the cavity 1000. The device 690 comprises an air inlet 698 defining an air-flow path configured to allow air to flow into the cavity 1000 from outside the device.

[0319] Figure 8 shows a schematic cross-sectional view of the aerosol-generating device 690 of Figure 7 in engagement with the aerosol-generating article 1 of Figure 1. Although not shown in the schematic of Figure 8, the aerosol-generating article 1 comprises a first cavity and a second cavity. There is little tolerance between the first planar external surface 21 and the second planar external surface 22 of the aerosol-generating article 1 and the internal surfaces 1020, 1030 of the cavity 1000. Thus, there is a snug fit between the aerosol-generating article 1 and the aerosolgenerating device 690. When a consumer has inserted the aerosol-generating article 1 into the cavity 1000, the device can be operated. The first heater 695 heats the first planar external surface 21 of the aerosol-generating article 1 and the second heater 696 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 a cavity 100, 200, 300 of the aerosol-generating article 1 to form an aerosol. The consumer inhales the aerosol by drawing on the end of the aerosol-generating article 1 comprising the air outlet 12. Once the aerosol-generating substrate has been depleted of volatile components, the aerosolgenerating article 1 is removed from the cavity 1000 and disposed of.

[0320] 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. Where a dimension is provided in mm, this may be manufactured to a tolerance of ± 0.5 mm.

Claims

CLAIMS1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: a first planar external surface and a second planar external surface; a first cavity and a second cavity; a frame between the first planar external surface and the second planar external surface, the frame at least partially defining the first cavity and the second cavity; and an air inlet and an air outlet, and an airflow passage extending from the air inlet to the air outlet through the first cavity and the second cavity; wherein the first cavity is closer to the air inlet than the second cavity, and the first cavity and the second cavity are arranged in series such that the airflow passage extends from the first cavity to the second cavity; and wherein the first cavity has a volume equal to at least 5% of a volume of the second cavity, and wherein the second cavity has a volume equal to at least 5% of a volume of the first cavity.

2. An aerosol-generating article according to claim 1 , wherein the aerosol-generating article has an external volume, the first cavity has a volume, and the volume of the first cavity is at least 10 % of the external volume of the aerosol-generating article.

3. An aerosol-generating article according to claim 1 or claim 2, wherein the aerosolgenerating article has an external volume, the second cavity has a volume, and the volume of the second cavity is at least 10 % of the external volume of the aerosol-generating article.

4. An aerosol-generating article according to any of the preceding claims, wherein the aerosol-generating article has an internal volume, the first cavity has a volume, and the volume of the first cavity is at least 20 % of the internal volume of the aerosol-generating article.

5. An aerosol-generating article according to any of the preceding claims, wherein the aerosol-generating article has an internal volume, the second cavity has a volume, and the volume of the second cavity is at least 20 % of the internal volume of the aerosol-generating article.

6. An aerosol-generating article according to any of the preceding claims, wherein the first cavity is a first distance from the upstream end, the second cavity is a second distance from the upstream end, and a ratio of the first distance to the second distance is between 1 :100 and 1 :1 .

57. An aerosol-generating article according to any of the preceding claims, wherein the first cavity or the second cavity has a volume of at least 50 mm3.

8. An aerosol-generating article according to any of the preceding claims, wherein the first cavity or the second cavity has a volume of at most 500 mm3.

9. An aerosol-generating article according to any of the preceding claims, wherein the first cavity has a width, the second cavity has a width, and a ratio of the first cavity width to the second cavity width is between 0.5 and 2.

10. An aerosol-generating article according to any of the preceding claims, wherein the first cavity has a thickness, the second cavity has a thickness, and a ratio of the first cavity thickness to the second cavity thickness is between 0.5 and 2.

11. An aerosol-generating article according to any of the preceding claims, wherein the first cavity has a length, the second cavity has a length, and a ratio of the first cavity length to the second cavity length is between 0.1 and 2.

12. An aerosol-generating article according to any of the preceding claims, wherein the first cavity and the second cavity are divided by primary dividing wall having a primary aperture fluidly connecting the first cavity to the second cavity.

13. An aerosol-generating article according to claim 12, wherein the primary aperture has a volume, the primary aperture volume being less than 10% of a volume of the first or the second cavity.

14. An aerosol-generating article according to any of the preceding claims, wherein the aerosol-generating article comprises a third cavity, wherein each of the first cavity, the second cavity and the third cavity have a volume of at least 5% of each other cavity of the first cavity, the second cavity and the third cavity.

15. An aerosol-generating article according to claim 14, wherein the second cavity and the third cavity are divided by a secondary dividing wall having a secondary aperture fluidly connecting the second cavity to the third cavity.

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