Aerosol-generating article comprising a subframe

Abstract

There is provided an aerosol-generating article (10). The aerosol-generating article (10) is for use with an aerosol-generating device to generate an aerosol. The aerosol- generating article (10) comprises a first planar external surface (21) and a second planar external surface (22). The aerosol-generating article (10) comprises a cavity (30) and one or more aerosol-generating substrates (40) positioned within the cavity (30). The aerosol- generating article (10) comprises an air inlet (11), an air outlet (12), and a frame (150; 250; 350; 450) at least partially defining the cavity (30), the air inlet (11) and the air outlet (12). The frame (150; 250; 350; 450) comprises a first subframe (152; 252; 352; 452) and a second subframe (154; 254; 354; 454) connected to the first subframe (152; 252; 352; 452).

Description

[0001] AEROSOL-GENERATING ARTICLE COMPRISING A SUBFRAME

[0002] The present disclosure relates to an aerosol-generating article. The present disclosure also relates to an aerosol-generating system comprising the aerosol-generating article and an aerosol-generating device. The present disclosure also relates to methods of manufacturing the aerosol-generating article.

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

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

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

[0006] It is an objective of the present disclosure to provide an aerosol-generating article in which a greater portion of the aerosol-generating substrate is sufficiently heated to form an aerosol during use. It is also an objective of the present disclosure to provide an aerosolgenerating 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 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 cavity and one or more aerosol-generating substrates positioned within the cavity. The aerosol-generating article comprises an air inlet, an air outlet, and a frame at least partially defining the cavity, the air inlet and the air outlet. The frame comprises a first subframe and a second subframe connected to the first subframe.

[0008] Advantageously, the frame may allow the aerosol-generating article to be relatively thin whilst maintaining structural rigidity.

[0009] Advantageously, the first planar external surface and the second planar external surface allow for good contact with an external heater, particularly an external heater, of an aerosol-generating device, thereby providing optimum heating of the aerosol-generating substrate.

[0010] 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.

[0011] 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.

[0012] Advantageously, forming the frame from first and second subframes facilitates the construction of a frame having a complex geometry while maintaining a frame that is relatively easy and cheap to manufacture.

[0013] Advantageously, forming the frame from first and second subframes may facilitate the manufacture of multiple frames or multiple aerosol-generating articles from a series of repeating sub-units that reduces waste material and results in an aerosol-generating article that is relatively easy and cheap to manufacture.

[0014] Preferably, the first subframe is identical to the second subframe. Advantageously, providing identical first and second subframes may reduce waste material and result in an aerosol-generating article that is relatively easy and cheap to manufacture.

[0015] The air inlet may be defined by the first subframe and the air outlet may be defined by the second subframe. The air inlet may comprise one or more inlet apertures extending through a portion of the first subframe. The air outlet may comprise one or more outlet apertures extending through a portion of the second subframe.

[0016] The first subframe may be spaced apart from the second subframe to at least partially define the cavity between the first subframe and the second subframe.

[0017] The frame may comprise a first side portion extending from the first subframe to the second subframe, and a second side portion extending from the first subframe to the second subframe. Advantageously, providing the frame with first and second side portions may facilitate connection of the first subframe to the second subframe in a spaced apart manner to at least partially define the cavity. Advantageously, forming the frame from first and second subframes and first and second side portions may facilitate the manufacture of a frame having a relatively complex shape from individual parts that each have a relatively simple shape.

[0018] The first side portion may be formed separately from the first subframe and the second subframe. The first side portion may be directly connected to the first subframe and the second subframe. The second side portion may be formed separately from the first subframe and the second subframe. The second side portion may be directly connected to the first subframe and the second subframe. The second side portion may be spaced apart from the first side portion to at least partially define the cavity between the first side portion and the second side portion.

[0019] The first subframe may at least partially define a first end of the aerosol-generating article. The air inlet may be positioned at the first end of the aerosol-generating article.

[0020] The second subframe may at least partially define a second end of the aerosolgenerating article. The air outlet may be positioned at the second end of the aerosolgenerating article.

[0021] The first subframe may comprise a body portion defining a chamber and a first opening at a first end of the chamber. The first subframe may comprise a first flap formed integrally with the body portion and a second flap formed integrally with the body portion. Each of the first flap and the second flap may overlie a second end of the chamber, wherein the first flap and the second flap together define a second opening at the second end of the chamber. The first opening may form the air inlet and the second opening may provide fluid communication between the chamber and the cavity. Alternatively, the second opening may form the air inlet and the first opening may provide fluid communication between the chamber and the cavity. Advantageously, the first and second flaps may facilitate the formation of the second opening with a desired cross-sectional shape. Advantageously, this may provide a desired resistance to draw for the aerosol-generating article.

[0022] The second subframe may comprise a body portion defining a chamber and a first opening at a first end of the chamber. The second subframe may comprise a first flap formed integrally with the body portion and a second flap formed integrally with the body portion. Each of the first flap and the second flap may overlie a second end of the chamber, wherein the first flap and the second flap together define a second opening at the second end of the chamber. The first opening may form the air outlet and the second opening may provide fluid communication between the chamber and the cavity. Alternatively, the second opening may form the air outlet and the first opening may provide fluid communication between the chamber and the cavity. Advantageously, the first and second flaps may facilitate the formation of the second opening with a desired cross-sectional shape. Advantageously, this may provide a desired resistance to draw for the aerosol-generating article. The aerosol-generating article may define a longitudinal direction extending from the air inlet to the air outlet. Each of the first subframe, the second subframe, and the cavity may have a length extending in the longitudinal direction. Preferably, the length of the first subframe is the same as the length of the second subframe, and the length of the cavity is an integer multiple of the length of the first subframe.

[0023] Advantageously, providing the cavity with a length that is an integer multiple of the length of the first and second subframes may facilitate the manufacture of multiple aerosolgenerating articles from a series of repeating sub-units that reduces waste material and result in an aerosol-generating article that is relatively easy and cheap to manufacture.

[0024] Each of the first subframe and the second subframe may be in the form of a tube. Each of the first subframe and the second subframe may define a first opening at a first end of the subframe, a second opening at a second end of the subframe, and an airflow passage extending between the first opening and the second opening. The first opening of the first subframe may form the air inlet. The first opening of the second subframe may form the air outlet. Preferably, each first opening, second opening and airflow passage has the same cross-sectional size and shape, optionally wherein the tube has a rectangular cross-sectional shape.

[0025] Each of the first subframe and the second subframe may comprise a first portion and a second portion, wherein the first portion is formed separately from the second portion, and wherein the first portion overlies the second portion. Each of the first portion and the second portion may have an L-shaped cross-sectional shape.

[0026] Each of the first subframe and the second subframe may be formed from a folded sheet material. The folded sheet material may be folded along three fold lines so that each of the first subframe and the second subframe has a rectangular cross-sectional shape.

[0027] The first subframe may partially define the air inlet and the air outlet. The second subframe may partially define the air inlet and the air outlet. The first subframe and the second subframe may together define the air inlet. The first subframe and the second subframe may together define the air outlet. Advantageously, providing a frame in which the first and second subframes together define each of the air inlet and the air outlet, may facilitate forming a frame having a relatively complex configuration from first and second subframes each having a relatively simple configuration.

[0028] The aerosol-generating article may comprise a first end and a second end, wherein each of the first subframe and the second subframe extends between the first end and the second end.

[0029] The first subframe may comprise at least one first protrusion and at least one first recess, and the second subframe may comprise at least one second protrusion and at least one second recess, wherein each first protrusion is received within a second recess, and wherein each second protrusion is received within a first recess. Advantageously, the first and second protrusions and recesses may provide the first and second subframes with an interlocking arrangement. Advantageously, an interlocking arrangement may facilitate correct positioning of the second subframe with respect to the first subframe during manufacture of the aerosol-generating article. Advantageously, an interlocking arrangement may facilitate a secure connection of the second subframe to the first subframe.

[0030] The cavity may have a hexagonal shape. The hexagonal shape may be a rounded hexagonal shape. Each of the first subframe and the second subframe may define half of the hexagonal shape or the rounded hexagonal shape.

[0031] The first subframe and the second subframe may be connected to each other at a first end of the aerosol-generating article and a second end of the aerosol-generating article. Each of the first subframe and the second subframe may define a longitudinally extending half of the hexagonal shape or the rounded hexagonal shape.

[0032] The first subframe and the second subframe may be connected to each other at a first side of the aerosol-generating article and a second side of the aerosol-generating article. Each of the first subframe and the second subframe may define a laterally extending half of the hexagonal shape or the rounded hexagonal shape.

[0033] At least part of each of the first subframe and the second subframe may have an L- shaped cross-sectional shape. The first subframe may comprises a first aperture extending through the first subframe and the second subframe may comprise a second aperture extending through the second subframe. The first subframe may overlie the second subframe so that the first aperture and the second aperture cooperate to at least partially define the cavity.

[0034] Each of the first subframe and the second subframe may be formed from a compressed particulate material. Advantageously, forming each of the first subframe and the second subframe from a compressed particulate material may provide each of the first and second subframes with a desired mechanical strength. Advantageously, forming each of the first subframe and the second subframe from a compressed particulate material may facilitate production of the first and second subframes using a press-moulding process. Advantageously, a press-moulding process may facilitate the formation of first and second subframes having relatively complex shapes. Suitable particulate materials may include those used in the pharmaceutical industry to form compressed tablets. Suitable particulate materials may include at least one of sorbitol, erythritol, and other sugar-like substances. Suitable particulate materials may include at least one cellulosic material, such as wood-based particles.

[0035] The compressed particulate material of at least one of the first subframe and the second subframe may comprises a flavourant. Advantageously, incorporating a flavourant into the compressed particulate material may facilitate delivery of the flavourant to a consumer during use of the aerosol-generating article. Advantageously, incorporating the flavourant into the compressed material may facilitate separation of the flavourant from the one or more aerosol-generating substrates within the cavity. Advantageously, separating the flavourant from the one or more aerosol-generating substrates may reduce or eliminate reactions between the flavourant and one or more components of the aerosol-generating substrate prior to use of the aerosol-generating article.

[0036] According to the present disclosure there is also provided an aerosol-generating system comprising an aerosol-generating article according to any of the examples or embodiments described herein. The aerosol-generating system also comprises an aerosolgenerating device, the aerosol-generating device comprising a chamber for receiving at least a portion of the aerosol-generating article, and an electric heater arranged to heat at least part of the aerosol-generating article when the aerosol-generating article is received within the chamber.

[0037] Preferably, the aerosol-generating device comprises a controller to control a supply of power to the heater. Preferably, the aerosol-generating device is configured to heat at least one of the one or more aerosol-generating substrates to form an aerosol, for example an inhalable aerosol. The aerosol-generating device may be configured to heat each of the one or more aerosol-generating substrates to form an aerosol, for example an inhalable aerosol.

[0038] According to the present disclosure there is also provided a method of forming an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The method comprises providing a plurality of subframes, wherein each subframe has a tubular shape, and wherein each subframe has the same length. The method comprises positioning a first of the subframes and a second of the subframes so that the second subframe is spaced apart from the first subframe by a spacing distance, wherein the spacing distance is an integer multiple of the length of each subframe. The method comprises providing a first side portion and a second side portion, wherein each of the first side portion and the second side portion has a length equal to the sum of the length of the first subframe, the length of the second subframe, and the spacing distance. The method comprises positioning one or more aerosol-generating substrates between the first subframe and the second subframe. The method comprises securing each of the first side portion and the second side portion to both of the first subframe and the second subframe to form a frame, wherein the frame at least partially defines a cavity between the first subframe, the second subframe, the first side portion and the second side portion, wherein the one or more aerosol-generating substrates are positioned within the cavity, and wherein the frame and the one or more aerosol-generating substrates together form an aerosol-generating article. Advantageously, forming the frame from first and second subframes facilitates the construction of a frame having a complex geometry while maintaining a frame that is relatively easy and cheap to manufacture.

[0039] Advantageously, forming the frame from first and second subframes having the same length and spaced apart from each other by an integer multiple of the length of the first and second subframes facilitates the manufacture of multiple aerosol-generating articles from a series of repeating sub-units that reduces waste material and results in an aerosol-generating article that is relatively easy and cheap to manufacture.

[0040] Preferably, the tubular shape of the first subframe defines an air inlet of the aerosolgenerating article, and the tubular shape of the second subframe defines an air outlet of the aerosol-generating article.

[0041] Preferably, the step of providing a plurality of subframes comprises providing a series of subframes, wherein consecutive subframes in the series of subframes abut each other, and wherein the first subframe and the second subframe are non-consecutive subframes. Advantageously, providing a series of subframes abutting each other may facilitate correct spacing of the first and second subframes by the integer multiple of the length of the first and second subframes.

[0042] Preferably, the step of positioning the first and second subframes comprises removing one or more subframes from between the first subframe and the second subframe to form a space between the first subframe and the second subframe. Preferably, the aerosolgenerating article is a first aerosol-generating article, and the method further comprises using the one or more subframes removed from between the first subframe and the second subframe to form a second aerosol-generating article. Advantageously, using the removed subframes to form a second aerosol-generating article may reduce or minimise waster material when forming the aerosol-generating articles.

[0043] Preferably, the step of providing a series of subframes comprises providing a continuous tubular substrate and cutting the continuous tubular substrate to form the series of subframes.

[0044] Preferably, the step of providing a first side portion and a second side portion comprises providing a first continuous side substrate and a second continuous side substrate; securing the first continuous side substrate to the first subframe and the second subframe; securing the second continuous side substrate to the first subframe and the second subframe; and cutting the first continuous side substrate and the second continuous side substrate to form the first side portion and the second side portion.

[0045] The aerosol-generating article formed according to the method may comprise any of the features of aerosol-generating articles according to the present disclosure, according to any of the examples and embodiments described herein. According to the present disclosure, there is also provided a method of forming an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the method comprising providing a first subframe and a second subframe, wherein each of the first subframe and the second subframe is formed from a compressed particulate material. The method comprises securing the first subframe to the second subframe to form a frame, wherein the frame at least partially defines a cavity, an air inlet, and an air outlet. The method comprises positioning one or more aerosol-generating substrates in the cavity, wherein the frame and the one or more aerosol-generating substrates together form an aerosol-generating article.

[0046] Advantageously, forming each of the first subframe and the second subframe from a compressed particulate material may provide each of the first and second subframes with a desired mechanical strength.

[0047] Suitable particulate materials may include those used in the pharmaceutical industry to form compressed tablets. Suitable particulate materials may include at least one of sorbitol, erythritol, and other sugar-like substances. Suitable particulate materials may include at least one cellulosic material, such as wood-based particles.

[0048] Preferably, the step of providing the first subframe and the second subframe comprises press-moulding the first subframe from the particulate material and press-moulding the second subframe from the particulate material.

[0049] Advantageously, press-moulding may facilitate the formation of first and second subframes having relatively complex shapes.

[0050] The compressed particulate material may comprises a flavourant. Advantageously, incorporating a flavourant into the compressed particulate material may facilitate delivery of the flavourant to a consumer during use of the aerosol-generating article. Advantageously, incorporating the flavourant into the compressed material may facilitate separation of the flavourant from the one or more aerosol-generating substrates within the cavity. Advantageously, separating the flavourant from the one or more aerosol-generating substrates may reduce or eliminate reactions between the flavourant and one or more components of the aerosol-generating substrate prior to use of the aerosol-generating article.

[0051] Methods according to the present disclosure for forming an aerosol-generating article may also comprise machining the frame to smooth one or more joints between the first subframe and the second subframe. The machining may comprise at least one of sanding and milling.

[0052] The aerosol-generating article may have a length extending in an x-direction. The aerosol-generating article may have a width extending in a y-direction. The aerosol-generating article may have a thickness extending in a z-direction. 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 aerosolgenerating article may less than 50 percent of both a length and a width of the aerosolgenerating article. Advantageously, a smaller thickness may provide a small temperature gradient or difference across the thickness of the aerosol-generating substrate during heating.

[0053] The aerosol-generating article may have a quadrilaterally-faced hexahedron shape. The aerosol-generating article may have a rectangular prism shape. The aerosol-generating article may have a cuboid shape. The aerosol-generating article may have a cylindrical shape. The aerosol-generating article may have a right-angled cylinder shape.

[0054] The aerosol-generating article may have a laminated structure, for example the aerosol-generating article may comprise or be formed from at least two layers. In particular, the aerosol-generating article may comprise at least two of: a first external layer, a second external layer, a frame, a first frame layer, a second frame layer, a third frame layer, a first aerosol-generating substrate layer, and a second aerosol-generating substrate layer as discussed in more detail below.

[0055] Substantially the entirety of the aerosol-generating article, excluding the one or more aerosol-generating substrates and (if present) adhesive, may be paper or cardboard.

[0056] 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.

[0057] The frame may be a planar frame.

[0058] The frame may define a frame aperture extending through the thickness of the frame. The frame aperture may define or form the airflow passage of the aerosol-generating article. The frame aperture may define or form the cavity of the aerosol-generating article. For example, the frame may have a hollow cuboid shape or a square hollow tube shape. As a further example, the frame may have a cross-section that is annular in shape, preferably the cross-section in an x / y plane is annular in shape.

[0059] The frame may comprise a frame outer surface. The frame outer surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The frame outer surface may at least partially define or form one or more external surfaces of the aerosol-generating article. For example, the frame outer surface may at least partially define or form one or more external walls of the aerosol-generating article. The frame outer surface may circumscribe or encircle the frame aperture. The frame outer surface may circumscribe or encircle the cavity.

[0060] The frame may comprise a frame inner surface. The frame inner surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The frame inner surface may define or form a frame aperture outer wall. The frame inner surface may define or form a cavity outer wall. The frame inner surface may circumscribe or encircle the frame aperture extending through the thickness of the frame. The frame inner surface may circumscribe or encircle the cavity.

[0061] 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.

[0062] The aerosol-generating article may comprise one or more external walls extending between the first planar external surface and the second planar external surface. The one or more external walls may collectively define an entire transverse external area of the aerosolgenerating article. The frame may at least partially define each of the one or more external walls. The one or more external walls may circumscribe or encircle the cavity. The frame may define at least 60 percent, at least 70 percent, at least 80 percent, or at least 90 percent of the entire transverse external area of the aerosol-generating article.

[0063] The frame may comprise a peripheral wall. The peripheral wall may circumscribe or encircle at least a portion of the frame aperture extending through the thickness of the frame. The peripheral wall may circumscribe or encircle at least a portion of the cavity. The peripheral wall may circumscribe or encircle the frame aperture extending through the thickness of the frame. The peripheral wall may circumscribe or encircle the cavity.

[0064] The peripheral wall may be defined or formed by the frame outer surface and the frame inner surface. The peripheral wall may at least partially define or form one or more external surfaces or walls of the aerosol-generating article. The peripheral wall may define or form a frame aperture outer wall. The peripheral wall may define or form a cavity outer wall.

[0065] 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.

[0066] The peripheral wall may have a radial thickness greater than or equal to 0.5 millimetres. The peripheral wall may have a radial thickness greater than or equal to 1.5 millimetres. The peripheral wall may have a radial thickness greater than or equal to 2.5 millimetres.

[0067] The peripheral wall may have a radial thickness less than or equal to 3.5 millimetres. The peripheral wall may have a radial thickness less than or equal to 2.5 millimetres.

[0068] The peripheral wall may have a radial thickness between 0.5 millimetres and 3.5 millimetres. The peripheral wall may have a radial thickness between 0.5 millimetres and 2.5 millimetres.

[0069] Advantageously, the peripheral wall having a radial thickness between 0.5 millimetres and 3.5 millimetres has been found to provide good structural strength for the aerosolgenerating article whilst not using excess amounts of material which may increase manufacturing costs, and may limit the amount of heat that is undesirably transferred to the frame rather than the aerosol-generating substrate.

[0070] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0071] 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.

[0072] The aerosol-generating article may comprise one or more susceptor materials. The frame may comprise one or more susceptor materials. The one more susceptor materials may be in thermal contact with the aerosol-generating substrate. The one more susceptor materials may be in thermal contact with the cavity. The one or more susceptor materials may be incorporated within the material of the frame. For example, the one or more susceptor material may be incorporated within the peripheral wall of the frame.

[0073] The one or more susceptor materials may be one or more particles, strips, threads, or wires of susceptor material. The one or more susceptor materials may be one or more sheets or layers of susceptor material. The one of more sheets or layers of susceptor material may be in the form of a mesh of susceptor material.

[0074] The susceptor material, in whatever form, may comprise one or more materials selected from the list consisting of: aluminium, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0075] The frame may have a thickness greater than or equal to 50 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 70 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 90 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 95 percent of the thickness of the aerosolgenerating article.

[0076] The frame may have a thickness less than or equal to 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 90 percent of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 70 percent of the thickness of the aerosol-generating article.

[0077] The frame may have a thickness between 50 percent of the thickness of the aerosolgenerating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 70 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 1 millimetre, greater than or equal to 2 millimetres, greater than or equal to 3 millimetres, or greater than or equal to 4 millimetres. The frame may have a thickness less than or equal to 5.5 millimetres, less than or equal to 4.5 millimetres, less than or equal to 3.5 millimetres, less than or equal to 2.5 millimetres, or less than or equal to 1 .5 millimetres. The frame may have a thickness between 1 millimetre and 5.5 millimetres. Preferably, the frame may have a thickness between 1.5 millimetres and 5.5 millimetres.

[0078] The frame may have a length that is equal to the length of the aerosol-generating article. The frame may have a length that is at least 90 percent of the length of the aerosolgenerating article. The frame may have a length that is at least 95 percent of the length of the aerosol-generating article.

[0079] 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.

[0080] 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.

[0081] The frame may comprise a first frame layer and a second frame layer. The first frame layer and the second frame layer may be the only layers of the frame. That is, the frame may comprise no more than two layers or may comprise exactly two layers. The frame aperture may be defined through both the first frame layer and the second frame layer.

[0082] 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.

[0083] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate layer. Advantageously, the aerosol-generating substrate layer can be made thin and, therefore, quickly heat up and release volatile compounds to form an aerosol. Advantageously, the aerosol-generating substrate layer can be positioned close to a heater of an aerosolgenerating device.

[0084] 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.

[0085] The aerosol-generating substrate layer may be positioned between the frame and the first planar external surface. The aerosol-generating substrate layer may be positioned between the frame and the second planar external surface. The aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame.

[0086] The aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The outer wrapper is discussed in more detail below. The aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the outer wrapper.

[0087] The aerosol-generating substrate layer may be positioned between the frame and the first planar external layer. The aerosol-generating substrate layer may be positioned between the frame and the second planar external layer. The first planar external layer and the second planar external layer are discussed in more detail below. The aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the first planar external layer. The aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the second planar external layer.

[0088] The aerosol-generating substrate layer may overlie an end of the cavity. The aerosolgenerating substrate layer may define or form a wall of the cavity, such as the first cavity end wall or the second cavity end wall. Advantageously, the aerosol-generating substrate layer may therefore be in, or at least partially define or form, the airflow passage thereby allowing released volatile compounds to quickly form an aerosol.

[0089] The one or more aerosol-generating substrates may comprise a first aerosolgenerating substrate layer and a second aerosol-generating substrate layer. Advantageously, a first and a second aerosol-generating substrate layer may allow rapid generation of a satisfactory volume of aerosol compared with using a single aerosol-generating substrate layer.

[0090] The first aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. The first aerosol-generating substrate layer may be, and may be made entirely of, a sheet of aerosol-generating material.

[0091] The second aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. The second aerosol-generating substrate layer may be, and may be made entirely of, a sheet of aerosol-generating material.

[0092] The first aerosol-generating substrate layer may be positioned between the frame and the first planar external surface. The first aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame.

[0093] The first aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The first aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the outer wrapper.

[0094] The first aerosol-generating substrate layer may be positioned between the frame and the first planar external layer. The first aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the first planar external layer.

[0095] The second aerosol-generating substrate layer may be positioned between the frame and the second planar external surface. The second aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame.

[0096] The second aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The second aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the outer wrapper.

[0097] The second aerosol-generating substrate layer may be positioned between the frame and the second planar external layer. The second aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the second planar external layer.

[0098] The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may overlie opposing ends of the cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may define or form opposing end walls of the cavity. That is, the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may collectively define the cavity.

[0099] One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 100 micrometres, greater than or equal to 200 micrometres, greater than or equal to 300 micrometres, greater than or equal to 400 micrometres, or greater than or equal to 500 micrometres.

[0100] One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness less than or equal to 600 micrometres, less than or equal to 500 micrometres, less than or equal to 400 micrometres, less than or equal to 300 micrometres, or less than or equal to 300 micrometres. One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness between 100 micrometres and 600 micrometres, between 200 micrometres and 500 micrometres, between 200 micrometres and 400 micrometres, or between 200 micrometres and 300 micrometres.

[0101] The aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article.

[0102] The first aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The first aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article.

[0103] The second aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The second aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article.

[0104] The aerosol-generating substrate layer may have a width substantially the same as the width of the frame. The aerosol-generating substrate layer may have a width substantially the same as the width of the aerosol-generating article.

[0105] The first aerosol-generating substrate layer may have a width substantially the same as the width of the frame. The first aerosol-generating substrate layer may have a width substantially the same as the width of the aerosol-generating article.

[0106] The second aerosol-generating substrate layer may have a width substantially the same as the width of the frame. The second aerosol-generating substrate layer may have a width substantially the same as the width of the aerosol-generating article.

[0107] The first planar external surface may be a planar upper surface and the second planar external surface may be a planar lower surface. The first planar external surface may be positioned parallel to the second planar external surface. The first planar external surface may extend in the x / y plane. The second planar external surface may extend in the x / y plane. The second planar external surface may be spaced from the first planar external surface in the z- direction or transverse direction. The distance between the first planar external surface and the second planar external surface in the z-direction or transverse direction may define the thickness of the aerosol-generating article.

[0108] The aerosol-generating article may comprise an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may comprise a hydrophobic material.

[0109] 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. The outer wrapper may circumscribe or encircle the frame. The outer wrapper may be in physical contact with, and may be bonded to, the frame. The outer wrapper may overlie opposing ends of the cavity. The outer wrapper may define or form opposing end walls of the cavity, such as the first cavity end wall and the second cavity end wall. That is, the frame and the outer wrapper may collectively define the cavity.

[0110] The outer wrapper may circumscribe or encircle the frame and the aerosol-generating substrate layer. The outer wrapper may be in physical contact with, and may be bonded to, both the frame and the aerosol-generating substrate layer.

[0111] The outer wrapper may circumscribe or encircle the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer. The outer wrapper may be in physical contact with, and may be bonded to, both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer.

[0112] 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.

[0113] The first planar external layer may define or form the first planar external surface. The first planar external layer may extend in the x / y plane. The second planar external layer may define or form the second planar external surface. The second planar external layer may extend in the x / y plane.

[0114] The first planar external layer may be in physical contact with, and may be bonded to, the frame. The first planar external layer may overlie an end of the cavity. The first planar external layer may define or form a wall of the cavity, such as the first cavity end wall.

[0115] The second planar external layer may be in physical contact with, and may be bonded to, the frame. The second planar external layer may overlie an end of the cavity. The second planar external layer may define or form a wall of the cavity, such as the second cavity end wall.

[0116] The first planar external layer and the second planar external layer may overlie opposing ends of the cavity. The first planar external layer and the second planar external layer may define or form opposing end walls of the cavity, such as the first cavity end wall and the second cavity end wall. That is, the frame, the first planar external layer and the second planar external layer may collectively define the cavity.

[0117] The first planar external layer may be spaced, such as in a transverse direction, from the frame. For example, the aerosol-generating substrate layer or the first aerosol-generating substrate layer may be positioned between the first planar external layer and the frame. The first planar external layer may be in physical contact with, and may be bonded to, the aerosolgenerating substrate layer or the first aerosol-generating substrate layer. The second planar external layer may be spaced, such as in a transverse direction, from the frame. For example, the aerosol-generating substrate layer or the second aerosolgenerating substrate layer may be positioned between the second planar external layer and the frame. The second planar external layer may be in physical contact with, and may be bonded to, the aerosol-generating substrate layer or the second aerosol-generating substrate layer.

[0118] The first planar external layer may be hydrophobic. The first planar external layer may comprise a hydrophobic material. The second planar external layer may be hydrophobic. The second planar external layer may comprise a hydrophobic material.

[0119] One or more of the outer wrapper, the first planar external layer and the second planar external layer may comprise, or be made from, a cellulosic material. The cellulosic material may be paper, cigarette paper, tobacco paper, cardboard, wood, textile, natural fibres or artificial fibres.

[0120] One or more of the outer wrapper, the first planar external layer and the second planar external layer may be an aerosol-generating substrate comprising an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. In particular, the aerosol-generating material may be in the form of a sheet of aerosolgenerating material. The sheet of aerosol-generating material may be any sheet of aerosolgenerating material described herein. Alternatively, one or more of the outer wrapper, the first planar external layer and the second planar external layer may not comprise any aerosolgenerating material, particularly in embodiments comprising an aerosol-generating substrate layer, a first aerosol-generating substrate layer, a second aerosol-generating substrate layer or an aerosol-generating substrate positioned within the cavity. One or more of the outer wrapper, the first planar external layer and the second planar external layer may be substantially nicotine-free.

[0121] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness greater than or equal to 25 micrometres, greater than or equal to 30 micrometres, greater than or equal to 35 micrometres, greater than or equal to 40 micrometres, or greater than or equal to 45 micrometres.

[0122] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness less than or equal to 55 micrometres, less than or equal to 50 micrometres, less than or equal to 45 micrometres, less than or equal to 40 micrometres, or less than or equal to 35 micrometres.

[0123] One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness between 25 micrometres and 55 micrometres, between 25 micrometres and 45 micrometres, or between 30 micrometres and 45 micrometres. One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a length substantially the same as the length of the frame. One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a length substantially the same as the length of the aerosol-generating article.

[0124] One or more of the first planar external layer and the second planar external layer may have a width substantially the same as the width of the frame. One or more of the first planar external layer and the second planar external layer may have a width substantially the same as the width of the aerosol-generating article.

[0125] The cavity may have a thickness greater than or equal to 0.5 millimetres. The cavity may have a thickness greater than or equal to 1.5 millimetres. The cavity may have a thickness greater than or equal to 2.5 millimetres. The cavity may have a thickness greater than or equal to 3.5 millimetres.

[0126] The cavity may have a thickness less than or equal to 4.5 millimetres. The cavity may have a thickness less than or equal to 3.5 millimetres. The cavity may have a thickness less than or equal to 2.5 millimetres. The cavity may have a thickness less than or equal to 1.5 millimetres.

[0127] The cavity may have a thickness between 0.5 millimetres and 4.5 millimetres. The cavity may have a thickness between 1 millimetre and 4.5 millimetres. Preferably, the cavity may have a thickness between 2.8 millimetres and 3.3 millimetres.

[0128] The cavity may have a length greater than or equal to 14 millimetres. The cavity may have a length equal to a greater than 18 millimetres. The cavity may have a length greater than or equal to 22 millimetres. The cavity may have a thickness greater than or equal to 30 millimetres. The cavity may have a thickness greater than or equal to 38 millimetres.

[0129] The cavity may have a length less than or equal to 40 millimetres. The cavity may have a thickness less than or equal to 34 millimetres. The cavity may have a thickness less than or equal to 28 millimetres. The cavity may have a thickness less than or equal to 22 millimetres. The cavity may have a thickness less than or equal to 18 millimetres.

[0130] The cavity may have a length between 14 millimetres and 40 millimetres. The cavity may have a length between 14 millimetres and 34 millimetres. . The cavity may have a length between 24 millimetres and 28 millimetres.

[0131] The cavity may have a width greater than or equal to 4.5 millimetres. The cavity may have a width greater than or equal to 7 millimetres. The cavity may have a width greater than or equal to 11 millimetres.

[0132] The cavity may have a width less than or equal to 13 millimetres. The cavity may have a width less than or equal to 11 millimetres. The cavity may have a width less than or equal to 7 millimetres. The cavity may have a width less than or equal to 5 millimetres. The cavity may have a width between 4.5 millimetres and 13 millimetres. The cavity may have a width between 7 millimetres and 10 millimetres. The cavity may have a width between 7.5 millimetres and 8.5 millimetres.

[0133] The cavity may have a length between 14 millimetres and 40 millimetres, a width between 4.5 millimetres and 13 millimetres, and a thickness between 0.5 millimetres and 4.5 millimetres.

[0134] Preferably, the cavity may have a length between 20 millimetres and 30 millimetres, a width between 7 millimetres and 10 millimetres, and a thickness between 2.5 millimetres and 4 millimetres.

[0135] Most preferably, the cavity may have a length of 26 millimetres, a width of 8 millimetres, and a thickness of 3.1 millimetres.

[0136] The cavity may have a volume of greater than or equal to 30 cubic millimetres, greater than or equal to 100 cubic millimetres, greater than or equal to 300 cubic millimetres, greater than or equal to 500 cubic millimetres, greater than or equal to 700 cubic millimetres, greater than or equal to 900 cubic millimetres, greater than or equal to 1000 cubic millimetres, greater than or equal to 2000 cubic millimetres, or greater than or equal to 30 cubic millimetres.

[0137] The cavity may have a volume of less than or equal to 3500 cubic millimetres, less than or equal to 2500 cubic millimetres, less than or equal to 1500 cubic millimetres, less than or equal to 1000 cubic millimetres, less than or equal to 800 cubic millimetres, less than or equal to 600 cubic millimetres, less than or equal to 500 cubic millimetres, less than or equal to 400 cubic millimetres, or less than or equal to 300 cubic millimetres.

[0138] The cavity may have a volume between 30 cubic millimetres and 3500 cubic millimetres. The cavity may have a volume between 30 cubic millimetres and 2500 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 1500 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 1000 cubic millimetres.

[0139] The cavity may be substantially empty.

[0140] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate positioned within the cavity. The aerosol-generating substrate positioned within the cavity may fill the cavity.

[0141] The aerosol-generating substrate positioned within the cavity may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. For example, the aerosol-generating material may be in the form of shredded aerosol-generating material.

[0142] The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. For example, the sheet of aerosol-generating material may be a sheet of homogenised tobacco material.

[0143] The sheet of aerosol-generating material may extend the entire length of the cavity. The sheet of aerosol-generating material may extend the entire width of the cavity.

[0144] The sheet of aerosol-generating material may be a gathered sheet of aerosolgenerating material. That is, the sheet of aerosol-generating material may be convoluted, folded, or otherwise compressed or constricted substantially perpendicular to the transverse direction of the aerosol-generating article.

[0145] The sheet of aerosol-generating material may be a crimped sheet of aerosolgenerating material. The sheet of aerosol-generating material may be a corrugated sheet of aerosol-generating material. The crimped sheet of aerosol-generating material or the corrugated sheet of aerosol-generating material may comprise a plurality of parallel corrugations. For example, the crimped sheet of aerosol-generating material may comprise a plurality of substantially parallel peaks and troughs.

[0146] The plurality of parallel corrugations may be defined by a corrugation profile, in which the corrugation profile is sinusoidal, or triangular, or rectangular, or trapezoidal, or toroidal, or parabolic.

[0147] The plurality of parallel corrugations may define, or form, a plurality of channels between the sheet of aerosol-generating material and one or more walls of the cavity. The plurality of channels may be a plurality of longitudinally extending channels. The plurality of channels may be a plurality of laterally extending channels. The plurality of channels may defined, or form, at least a portion of the airflow passage extending between the air inlet and air outlet of the aerosol-generating article.

[0148] The aerosol-generating material may comprise one or more organic materials such as tobacco, mint, tea and cloves. The aerosol-generating material may comprise one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenised tobacco such as cast leaf, extruded tobacco, expanded tobacco, aerosol-generating films and gel compositions.

[0149] The aerosol-generating material may be in the form of shredded aerosol-generating material. The shredded aerosol-generating material may comprise one or more of: strips and strands of aerosol-generating material, such as strips and strands of tobacco or homogenised tobacco material. The shredded aerosol-generating material may be in the form of a shredded sheet of homogenised tobacco material.

[0150] The aerosol-generating material may be cut filler. The aerosol-generating material may be tobacco cut filler. As used herein, the term “cut filler” is used to describe to a blend of shredded plant material, such as tobacco plant material, including, in particular, one or more of leaf lamina, processed stems and ribs, homogenised plant material. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenised tobacco material, such as a cast leaf sheet.

[0151] The aerosol-generating material may comprise one or more aerosol-formers. Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosol-formers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosol-former to be or comprise one or both of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0152] The aerosol-generating material may have an aerosol-former content greater than or equal to 1 , 2, 5, 10, or 15 percent by weight on a dry weight basis. The aerosol-generating material may have an aerosol-former content greater than or equal to 15 percent by weight on a dry weight basis, for example greater than 20 by weight on a dry weight basis, or greater than 25 by weight on a dry weight basis, or greater than 30 by weight on a dry weight basis, or greater than 40 by weight on a dry weight basis, or greater than 50 by weight on a dry weight basis.

[0153] The aerosol-generating material may have an aerosol-former content less than or equal to 30 percent by weight on a dry weight basis, less than or equal to 25 percent by weight on a dry weight basis, or less than or equal to 20 percent by weight on a dry weight basis.

[0154] The aerosol-generating material may have an aerosol-former content between 5 percent and 30 percent by weight on a dry weight basis, between 5 percent and 25 percent by weight on a dry weight basis, or between 5 percent and 20 percent by weight on a dry weight basis.

[0155] The aerosol-generating material may have an aerosol-former content between 10 percent and 30 percent by weight on a dry weight basis, between 10 percent and 25 percent by weight on a dry weight basis, or between 10 percent and 20 percent by weight on a dry weight basis.

[0156] The aerosol-generating material may comprise nicotine. The aerosol-generating material may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine. The aerosol-generating material may comprise at least 0.5 percent by weight of nicotine, at least 1 percent by weight of nicotine, at least 1.5 percent by weight of nicotine, or at least 2 percent by weight of nicotine. That is, the aerosol-generating material may have a nicotine content of at least 0.5 percent by weight, at least 1 percent by weight, at least 1.5 percent by weight, or at least 2 percent by weight.

[0157] The aerosol-generating material may be in the form of a plurality of beads. The plurality of beads may have an average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm.

[0158] The term “bead” refers to a discrete, solid particle formed of the aerosol-generating substrate. A bead may have a rounded, typically spherical, form. Other terms may be used to define the substrate such as, for example, “granule”.

[0159] Providing the aerosol-generating material as a plurality of beads may provide certain advantages. Beads can be easily handled compared to other aerosol-forming substrates such as fine powders or cut filler. The beads flow easily, and so can reliably and consistently fill the cavity of the aerosol-generating article during manufacture. This may allow a consistent and reproducible amount of aerosol-forming substrate to be loaded into each article during manufacture. Beads may also be cleaner to handle than powders and cut fillers, which may cause dust in factories, and may leak from aerosol-generating articles in transit or in use. By selecting beads with appropriate bead sizes and appropriate particle size distributions, air flow through the cavity of the aerosol-generating article may be controlled more reproducibly than would be the case for, say, a cut filler substrate.

[0160] Where a particle is not perfectly spherical, but a diameter of the particle is referred to, the term “diameter” may refer to a largest dimension of the particle. Alternatively, the term “diameter” may refer to the diameter of a perfectly spherical particle having the same volume as the not perfectly spherical particle.

[0161] The term “average particle diameter”, as used herein, may refer to a number average particle diameter. Other methods of determining average particle diameter are known. Thus, the average particle diameter may be, for example, a volume average particle diameter.

[0162] The aerosol-generating material may be in form of a wrapped body of aerosolgenerating material, the wrapped body comprising a wrapper at least partially enclosing aerosol-generating material.

[0163] The wrapped body of aerosol-generating material may occupy between 15% and 100% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 30% and 100% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 50% and 100% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 50% and 80% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 50% and 70% of the interior volume of the cavity.

[0164] The air inlet may be defined by a front wall of the aerosol-generating article. The air inlet may be defined by, and may extend through, the frame. The air inlet may be defined by the peripheral wall of the frame. The air inlet may extend through the peripheral wall of the frame. The air outlet may be defined by a back wall of the aerosol-generating article. The air outlet may be defined by, and may extend through, the frame. The air outlet may be defined by the peripheral wall of the frame. The outlet may extend though the peripheral wall of the frame.

[0165] 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.

[0166] The air inlet may be defined by, and may extend through, the first planar external surface. The air inlet may be defined by, and may extend through, the outer wrapper. The air inlet may be defined by, and may extend through, the outer wrapper and the aerosolgenerating substrate layer. The air inlet may be defined by, and may extend through, the outer wrapper and the first aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the first planar external layer and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the first planar external layer and the first aerosol-generating substrate layer.

[0167] The air inlet may be defined by, and may extend through, the second planar external surface. The air inlet may be defined by, and may extend through, the outer wrapper and the second aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the second planar external layer and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the second planar external layer and the second aerosol-generating substrate layer.

[0168] The air outlet may be defined by, and may extend through, the first planar external surface. The air outlet may be defined by, and may extend through, the outer wrapper. The air outlet may be defined by, and may extend through, the outer wrapper and the aerosolgenerating substrate layer. The air outlet may be defined by, and may extend through, the outer wrapper and the first aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the first planar external layer and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the first planar external layer and the first aerosol-generating substrate layer.

[0169] The air outlet may be defined by, and may extend through, the second planar external surface. The air outlet may be defined by, and may extend through, the outer wrapper and the second aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the second planar external layer and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the second planar external layer and the second aerosol-generating substrate layer.

[0170] One or both of the air inlet and the air outlet may have an equivalent diameter greater than or equal to 0.1 millimetres, greater than or equal to 0.4 millimetres, greater than or equal to 0.7 millimetres, or greater than or equal to 1.0 millimetres.

[0171] One or both of the air inlet and the air outlet may have an equivalent diameter less than or equal to 3 millimetres, less than or equal to 2.7 millimetres, less than or equal to 2.4 millimetres, less than or equal to 2.1 millimetres. The air inlet may have an equivalent diameter less than or equal to 2.7 millimetres, less than or equal to 1.8 millimetres, or less than or equal to 1.5 millimetres.

[0172] One or both of the air inlet and the air outlet may have an equivalent diameter between 0.1 millimetres and 3 millimetres, between 0.1 millimetres and 2.4 millimetres, between 0.4 millimetres and 2.1 millimetres, between 0.4 millimetres and 1.8 millimetres, between 0.7 millimetres and 1.5 millimetres, or between 1.0 millimetres and 1.5 millimetres.

[0173] The air inlet may have a width less than a width of the cavity. The air outlet may have a width less than a width of the cavity. The air inlet may have a thickness less than a thickness of the cavity. The air outlet may have a thickness less than a thickness of the cavity.

[0174] One or both of the air inlet and the air outlet may a width of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres.

[0175] One or both of the air inlet and the air outlet may have a thickness of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres.

[0176] Preferably, the air inlet may have a width of between 0.3 millimetres and 3 millimetres, and a thickness of between 0.3 millimetres and 3 millimetres.

[0177] Preferably, the air outlet may have a width of between 0.3 millimetres and 3 millimetres, and a thickness of between 0.3 millimetres and 3 millimetres.

[0178] Advantageously, an aerosol-generating article having an air outlet or air inlet with a width of between 0.3 millimetres and 3 millimetres and a thickness of between 0.3 millimetres and 3 millimetres may provide for a relatively large inlet or outlet opening while allowing for improved retention of the aerosol-generating substrate within the aerosol-generating article. Improved retention of the aerosol-generating substrate within the aerosol-generating article may reduce the risk of aerosol-generating substrate falling out of the aerosol-generating article.

[0179] A ratio of the width of the air inlet to the thickness of the air inlet may be between 0.33 and 3. A ratio of the width of the air inlet to the thickness of the air inlet may be between 0.5 and 1.5. A ratio of the width of the air inlet to the thickness of the air inlet may be between 0.75 and 1.25.

[0180] A ratio of the width of the air outlet to the thickness of the air outlet may be between 0.33 and 3. A ratio of the width of the air outlet to the thickness of the air outlet may be between 0.5 and 1.5. A ratio of the width of the air outlet to the thickness of the air outlet may be between 0.75 and 1.25.

[0181] The aerosol-generating article may comprise a plurality of air inlets. One or each of the air inlets may have one or more of the features of the air inlet described herein.

[0182] The aerosol-generating article may comprise a plurality of air outlets. One or each of the air outlets may have one or more of the features of the air outlet described herein.

[0183] The aerosol-generating article may comprise a filter element positioned downstream of the aerosol-forming substrate. The aerosol-generating article may comprise a filter element positioned downstream of the cavity. The aerosol-generating article may comprise a filter element at least partially positioned within the air outlet. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at a downstream end of, the cavity.

[0184] The aerosol-generating article may comprise a filter element positioned upstream of the aerosol-forming substrate. The aerosol-generating article may comprise a filter element positioned upstream of the cavity. The aerosol-generating article may comprise a filter element at least partially positioned within the air inlet. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at an upstream end of, the cavity.

[0185] The filter element may comprise one or more segments of a fibrous filtration material. Suitable fibrous filtration materials would be known to the skilled person. The filter element may comprise a cellulose acetate.

[0186] A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be greater than 2: 1 , greater than 5:1 , greater than 10:1 , greater than 12:1 , or greater than 15:1.

[0187] A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be less than 15:1 , less than 12:1 , less than 10:1 , less than 5:1 , or less than 2.5:1

[0188] A ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article may be between 2:1 and 15:1 , between 2:1 and 12:1 , between 2:1 and 10:1 , or between 5:1 and 10:1.

[0189] A ratio between the length and the width of the aerosol-generating article may be greater than 1 :1 , greater than 2:1 , greater than 3:1 , greater than 4:1 , or greater than 5:1.

[0190] A ratio between the length and the width of the aerosol-generating article may be less than 10: 1 , less than 8: 1 , less than 5: 1 , less than 4: 1 , less than 3: 1 , or less than 2: 1. A ratio between the length and the width of the aerosol-generating article may be between 1 :1 and 10:1 , between 1 :1 and 5:1 , between 1 :1 and 4:1 , between 1 :1 and 3:1 , between 2:1 and 4:1 , or between 2: 1 and 3: 1.

[0191] The aerosol-generating article may have a length greater than or equal to 15 millimetres, greater than or equal to 20 millimetres, greater than or equal to 25 millimetres, greater than or equal to 30 millimetres, greater than or equal to 35 millimetres, or greater than or equal to 40 millimetres.

[0192] The aerosol-generating article may have a length less than or equal to 45 millimetres, less than or equal to 40 millimetres, less than or equal to 35 millimetres, or less than or equal to 30 millimetres.

[0193] The aerosol-generating article may have a length between 15 millimetres and 45 millimetres, between 20 millimetres and 40 millimetres, between 20 millimetres and 35 millimetres, or between 25 millimetres and 30 millimetres.

[0194] The aerosol-generating article may have a width equal to greater than 3 millimetres, greater than 5 millimetres, greater than 7.5 millimetres, greater than 9 millimetres, greater than 11 millimetres, or greater than 13 millimetres.

[0195] The aerosol-generating article may have a width less than or equal to 17 millimetres, less than or equal to 15 millimetres, less than or equal to 12.5 millimetres, less than or equal to 11 millimetres, or less than or equal to 9 millimetres.

[0196] The aerosol-generating article may have a width between 3 millimetres and 17 millimetres, between 5 millimetres and 15 millimetres, between 7.5 millimetres and 12.5 millimetres, or between 9 millimetres and 11 millimetres.

[0197] The aerosol-generating article may have a thickness equal to greater than 1 millimetre, greater than or equal to 1 .5 millimetres, greater than or equal to 2 millimetres, greater than or equal to 2.5 millimetres, greater than or equal to 3 millimetres, greater than or equal to 3.5 millimetres, greater than or equal to 4 millimetres, or greater than or equal to 4.5 millimetres.

[0198] The aerosol-generating article may have a thickness less than or equal to 5.5 millimetres, less than or equal to 5 millimetres, less than or equal to 4.5 millimetres, less than or equal to 4 millimetres, less than or equal to 3.5 millimetres, less than or equal to 3 millimetres, less than or equal to 2.5 millimetres, or less than or equal to 2 millimetres.

[0199] The aerosol-generating article may have a thickness between 1 millimetres and 5 millimetres, between 1.5 millimetres and 5 millimetres, between 2 millimetres and 4.5 millimetres, between 2.5 millimetres and 4 millimetres, or between 3 millimetres and 3.5 millimetres.

[0200] 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. 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.

[0201] 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.

[0202] 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.

[0203] As used herein, the term “transverse” refers to a direction extending between the first planar external surface and the second planar external surface. The transverse direction may also be referred to as the “z-direction”.

[0204] As used herein, the term “longitudinal” refers to a direction that is perpendicular to the transverse direction. For example, a direction between a front wall and a back wall of the aerosol-generating article. The longitudinal direction may also be referred to as the “x- di recti on”.

[0205] As used herein, the term “lateral” refers to a direction that is perpendicular to the transverse direction and the longitudinal direction. For example, a direction from a first side wall to a second side wall of the aerosol-generating article. The lateral direction may also be referred to as the “y-direction”.

[0206] As used herein, the term “thickness” refers to a maximum dimension of the aerosolgenerating article or a component of the aerosol-generating article in the transverse direction.

[0207] As used herein, the term “length” refers to a maximum dimension of the aerosolgenerating article or a component of the aerosol-generating article in the longitudinal direction.

[0208] As used herein, the term “width” refers to a maximum dimension of the aerosolgenerating article or a component of the aerosol-generating article in the lateral direction.

[0209] 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.

[0210] As used herein, the term “bulk density” may refer to the total weight of the aerosolgenerating substrate divided by the bulk volume of the aerosol-generating substrate. 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.

[0211] As used herein, the term “aerosol former content” may refer to aerosol former content in percent on a dry weight basis, unless otherwise specified.

[0212] As used herein, a "susceptor" refers to a conductive element that heats up when subjected to a changing magnetic field. This may be the result of eddy currents induced in the susceptor element and / or hysteresis losses.

[0213] As used herein, the term “hydrophobic” refers to a surface exhibiting water repelling properties. One useful way to determine this is to measure the water contact angle. The “water contact angle” is the angle, conventionally measured through the liquid, where a liquid / vapour interface meets a solid surface. It quantifies the wettability of a solid surface by a liquid via the Young equation.

[0214] As used herein, the term “equivalent diameter” of an opening or an aperture is used herein to denote the diameter of a circular opening or aperture having the same cross- sectional area as the opening or aperture.

[0215] 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.

[0216] Example 1 : 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; a second planar external surface; a cavity; one or more aerosol-generating substrates positioned within the cavity; an air inlet; an air outlet; and a frame at least partially defining the cavity, the air inlet and the air outlet; wherein the frame comprises a first subframe and a second subframe connected to the first subframe.

[0217] Example 2: An aerosol-generating article according to Example 1 , wherein the first subframe is identical to the second subframe.

[0218] Example 3: An aerosol-generating article according to Example 1 or 2, wherein the air inlet is defined by the first subframe, and wherein the air outlet is defined by the second subframe. Example 4: An aerosol-generating article according to Example 1 , 2 or 3, wherein the first subframe is spaced apart from the second subframe to at least partially define the cavity between the first subframe and the second subframe.

[0219] Example 5: An aerosol-generating article according any preceding Example, wherein the first subframe at least partially defines a first end of the aerosol-generating article, and wherein the second subframe at least partially defines a second end of the aerosolgenerating article.

[0220] Example 6: An aerosol-generating article according to any preceding Example, wherein the frame further comprises: a first side portion extending from the first subframe to the second subframe; and a second side portion extending from the first subframe to the second subframe.

[0221] Example 7: An aerosol-generating article according to Example 6, wherein the second side portion is spaced apart from the first side portion to at least partially define the cavity between the first side portion and the second side portion.

[0222] Example 8: An aerosol-generating article according to Example 6 or 7, wherein each of the first side portion and the second side portion is directly connected to both of the first subframe and the second subframe.

[0223] Example 9: An aerosol-generating article according to any of Examples 6 to 9 in combination with Example 5, wherein each of the first side portion and the second side portion extends between the first end of the aerosol-generating article and the second end of the aerosol-generating article.

[0224] Example 10: An aerosol-generating article according to any preceding Example, wherein the first subframe comprises: a body portion defining a chamber and a first opening at a first end of the chamber; a first flap formed integrally with the body portion; and a second flap formed integrally with the body portion; wherein each of the first flap and the second flap overlies a second end of the chamber, and wherein the first flap and the second flap together define a second opening at the second end of the chamber.

[0225] Example 11 : An aerosol-generating article according to Example 10, wherein the first opening forms the air inlet, and wherein the second opening provides fluid communication between the chamber and the cavity.

[0226] Example 12: An aerosol-generating article according to any preceding Example, wherein the second subframe comprises: a body portion defining a chamber and a first opening at a first end of the chamber; a first flap formed integrally with the body portion; and a second flap formed integrally with the body portion; wherein each of the first flap and the second flap overlies a second end of the chamber, and wherein the first flap and the second flap together define a second opening at the second end of the chamber.

[0227] Example 13: An aerosol-generating article according to Example 12, wherein the first opening forms the air outlet, and wherein the second opening provides fluid communication between the chamber and the cavity.

[0228] Example 14: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating article defines a longitudinal direction extending from the air inlet to the air outlet, wherein each of the first subframe, the second subframe, and the cavity has a length extending in the longitudinal direction, wherein the length of the first subframe is the same as the length of the second subframe, and wherein the length of the cavity is an integer multiple of the length of the first subframe.

[0229] Example 15: An aerosol-generating article according to Example 14 in combination with Example 6, wherein each of the first side portion and the second side portion has a length extending in the longitudinal direction, wherein the length of the first side portion is the same as the length of the second side portion, and wherein the length of the second side portion is an integer multiple of the length of the first subframe.

[0230] Example 16: An aerosol-generating article according to any preceding Example, wherein each of the first subframe and the second subframe is in the form of a tube.

[0231] Example 17: An aerosol-generating article according to Example 16, wherein each of the first subframe and the second subframe defines a first opening at a first end of the subframe, a second opening at a second end of the subframe, and an airflow passage extending between the first opening and the second opening.

[0232] Example 18: An aerosol-generating article according to Example 17, wherein the first opening of the first subframe forms the air inlet, and wherein the first opening of the second subframe forms the air outlet.

[0233] Example 19: An aerosol-generating article according to Example 17 or 18, wherein each first opening, second opening and airflow passage has the same cross-sectional size and shape.

[0234] Example 20: An aerosol-generating article according to any of Examples 16 to 19, wherein the tube has a rectangular cross-sectional shape.

[0235] Example 21 : An aerosol-generating article according to any of Examples 16 to 20, wherein each of the first subframe and the second subframe comprises a first portion and a second portion, wherein the first portion is formed separately from the second portion, and wherein the first portion overlies the second portion.

[0236] Example 22: An aerosol-generating article according to Example 21 , wherein each of the first portion and the second portion has an L-shaped cross-sectional shape. Example 23: An aerosol-generating article according to any of Examples 16 to 20, wherein each of the first subframe and the second subframe is formed from a folded sheet material.

[0237] Example 24: An aerosol-generating article according to Example 1 or 2, wherein the first subframe partially defines the air inlet and the air outlet, and wherein the second subframe partially defines the air inlet and the air outlet.

[0238] Example 25: An aerosol-generating article according to Example 24, wherein the aerosol-generating article comprises a first end and a second end, and wherein each of the first subframe and the second subframe extends between the first end and the second end.

[0239] Example 26: An aerosol-generating article according to Example 24 or 25, wherein the first subframe comprises at least one first protrusion and at least one first recess, wherein the second subframe comprises at least one second protrusion and at least one second recess, wherein each first protrusion is received within a second recess, and wherein each second protrusion is received within a first recess.

[0240] Example 27: An aerosol-generating article according to Example 24, 25 or 26, wherein the cavity has a hexagonal shape or a rounded hexagonal shape.

[0241] Example 28: An aerosol-generating article according to Example 27, wherein each of the first subframe and the second subframe defines half of the hexagonal shape or the rounded hexagonal shape.

[0242] Example 29: An aerosol-generating article according to Example 24, 25 or 26, wherein at least part of each of the first subframe and the second subframe has an L-shaped cross-sectional shape.

[0243] Example 30: An aerosol-generating article according to Example 29, wherein the first subframe comprises a first aperture extending through the first subframe, wherein the second subframe comprises a second aperture extending through the second subframe, and wherein the first subframe overlies the second subframe so that the first aperture and the second aperture cooperate to at least partially define the cavity.

[0244] Example 31 : An aerosol-generating article according to any preceding Example, wherein each of the first subframe and the second subframe is formed from a compressed particulate material.

[0245] Example 32: An aerosol-generating article according to Example 31 , wherein the compressed particulate material of at least one of the first subframe and the second subframe comprises a flavourant.

[0246] Example 33: An aerosol-generating system comprising: an aerosol-generating article according to any preceding claim; and an aerosol-generating device, the aerosol-generating device comprising: a chamber for receiving at least a portion of the aerosol-generating article; and an electric heater arranged to heat at least part of the aerosol-generating article when the aerosol-generating article is received within the chamber.

[0247] Example 34: A method of forming an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the method comprising: providing a plurality of subframes, wherein each subframe has a tubular shape, and wherein each subframe has the same length; positioning a first of the subframes and a second of the subframes so that the second subframe is spaced apart from the first subframe by a spacing distance, wherein the spacing distance is an integer multiple of the length of each subframe; providing a first side portion and a second side portion, wherein each of the first side portion and the second side portion has a length equal to the sum of the length of the first subframe, the length of the second subframe, and the spacing distance; positioning one or more aerosol-generating substrates between the first subframe and the second subframe; and securing each of the first side portion and the second side portion to both of the first subframe and the second subframe to form a frame, wherein the frame at least partially defines a cavity between the first subframe, the second subframe, the first side portion and the second side portion, wherein the one or more aerosol-generating substrates are positioned within the cavity, and wherein the frame and the one or more aerosol-generating substrates together form an aerosol-generating article.

[0248] Example 35: A method according to Example 34, wherein the tubular shape of the first subframe defines an air inlet of the aerosol-generating article, and wherein the tubular shape of the second subframe defines an air outlet of the aerosol-generating article.

[0249] Example 36: A method according to Example 34 or 35, wherein the step of providing a plurality of subframes comprises providing a series of subframes, wherein consecutive subframes in the series of subframes abut each other, and wherein the first subframe and the second subframe are non-consecutive subframes.

[0250] Example 37: A method according to Example 36, wherein the step of positioning the first and second subframes comprises removing one or more subframes from between the first subframe and the second subframe to form a space between the first subframe and the second subframe.

[0251] Example 38: A method according to Example 37, wherein the aerosol-generating article is a first aerosol-generating article, and wherein the method further comprises using the one or more subframes removed from between the first subframe and the second subframe to form a second aerosol-generating article. Example 39: A method according to Example 36, 37 or 38, wherein the step of providing a series of subframes comprises providing a continuous tubular substrate and cutting the continuous tubular substrate to form the series of subframes.

[0252] Example 40: A method according to any of Examples 34 to 39, wherein the step of providing a first side portion and a second side portion comprises: providing a first continuous side substrate and a second continuous side substrate; securing the first continuous side substrate to the first subframe and the second subframe; securing the second continuous side substrate to the first subframe and the second subframe; and cutting the first continuous side substrate and the second continuous side substrate to form the first side portion and the second side portion.

[0253] Example 41 : A method of forming an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the method comprising: providing a first subframe and a second subframe, wherein each of the first subframe and the second subframe is formed from a compressed particulate material; securing the first subframe to the second subframe to form a frame, wherein the frame at least partially defines a cavity, an air inlet, and an air outlet; and positioning one or more aerosol-generating substrates in the cavity, wherein the frame and the one or more aerosol-generating substrates together form an aerosol-generating article.

[0254] Example 42: A method according to Example 41 , wherein the step of providing the first subframe and the second subframe comprises press-moulding the first subframe from the particulate material and press-moulding the second subframe from the particulate material.

[0255] Example 43: A method according to Example 41 or 42, wherein the particulate material comprises a flavourant.

[0256] Examples will now be further described with reference to the figures in which:

[0257] Figure 1 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0258] Figure 2 shows an exploded perspective view of the aerosol-generating article of Figure 1 ;

[0259] Figure 3 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0260] Figure 4 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0261] Figure 5 shows a perspective view of an aerosol-generating article according to the present disclosure; Figure 6 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

[0262] Figure 7 shows a perspective view of an aerosol-generating article according to the present disclosure;

[0263] Figure 8 shows a perspective view of an alternative construction of a frame for an aerosol-generating article according to the present disclosure;

[0264] Figure 9 shows a perspective view of an alternative construction of the subframes of Figure 8;

[0265] Figure 10 shows a perspective view of a further alternative construction of the subframes of Figure 8;

[0266] Figure 11 shows a perspective view of a further alternative construction of the subframes of Figure 8;

[0267] Figure 12 shows a perspective view of a further alternative construction of the subframes of Figure 8;

[0268] Figure 13 illustrates a method of manufacturing the frame of Figure 8;

[0269] Figure 14 shows a top view of a further alternative construction of a frame for an aerosol-generating article according to the present disclosure;

[0270] Figure 15 shows a cross-sectional view of the frame of Figure 14 along line 14-14;

[0271] Figure 16 shows a cross-sectional view of the frame of Figure 14 along line 14-14 and showing an alternative construction of the frame;

[0272] Figure 17 shows an exploded perspective view of a further alternative construction of a frame for an aerosol-generating article according to the present disclosure;

[0273] Figure 18 shows a perspective view of the frame of Figure 17;

[0274] Figure 19 shows a perspective view of a subframe precursor;

[0275] Figure 20 shows a further perspective view of the subframe precursor of Figure 19;

[0276] Figure 21 shows a perspective view of a subframe formed from the subframe precursor of Figures 19 and 20;

[0277] Figure 22 shows a perspective view of a further alternative construction of a frame for an aerosol-generating article according to the present disclosure and comprising two of the subframes of Figure 21 ;

[0278] Figure 23 shows a schematic cross-sectional view of an aerosol-generating device according to the present disclosure; and

[0279] Figure 24 shows a schematic cross-sectional view of the aerosol-generating device of Figure 23 in engagement with an aerosol-generating article of the present disclosure.

[0280] Figure 1 shows an aerosol-generating article 10 comprising a first planar external layer 24 forming a first planar external surface 21 , a second planar external layer 25 forming a second planar external surface 22, and a frame 50 positioned between the first planar external layer 24 and the second planar external layer 25. The first planar external layer 24 and the second planar external layer 25 both comprise an aerosol-generating substrate comprising an aerosol-generating material, namely tobacco. However, it will be understood that in some embodiments only one of the first planar external layer 24 and the second planar external layer 25 may comprise an aerosol-generating substrate. Alternatively, or additionally, the aerosol-generating substrate may be positioned elsewhere within the aerosol-generating article 10.

[0281] The aerosol-generating article 10 has a length extending in the x-direction, a width extending in the y-direction and a thickness extending in the z-direction. The aerosolgenerating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.1 millimetres.

[0282] The aerosol-generating article 10 is substantially flat aerosol-generating article or substantially planar aerosol-generating article. In particular, the thickness of the aerosolgenerating article 10 is less than 50 percent of both the length and the width of the aerosolgenerating article. The aerosol-generating article 10 has a generally rectangular cuboid shape and a laminated structure formed by the first planar external layer 24, the frame 50 and the second planar external layer 25. The first planar external layer 24, the frame 50 and the second planar external layer 25 are bonded together with an adhesive, in particular guar gum, as discussed in more detail below in relation to Figure 2.

[0283] Figure 2 shows an exploded view of the aerosol-generating article 10 of Figure 1.

[0284] The frame 50 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 2.7 millimetres. The frame 50 is made from cardboard and defines a frame aperture extending through the thickness of the frame 50. The frame aperture at least partially forms a cavity 30. The cavity 30 has length of 26 millimetres, a width of 6 millimetres, and a thickness of 2.7 millimetres. Therefore, the cavity 30 has a volume of about 421.2 cubic millimetres. In this embodiment, the cavity 30 is substantially empty.

[0285] The frame 50 has a frame inner surface 52 extending in the z-direction or the transverse direction between the first planar external surface 21 and the second planar external surface 22. The frame inner surface 52 defines a cavity outer wall. The frame 50 has a frame outer surface 53 extending in the z-direction or the transverse direction between the first planar external surface 21 and the second planar external surface 22. The frame outer surface 53 at least partially defines one or more external surfaces of the aerosol-generating article, such as the front wall 13 and the back wall 14.

[0286] The frame 50 comprises a peripheral wall 51 that circumscribes the cavity 30. In more detail, the peripheral wall 51 is defined by the frame inner surface 52 and the frame outer surface 52. The peripheral wall 51 has a radial thickness, as measured between the frame inner surface 52 and the frame outer surface 53 in the x / y plane, of about 2 millimetres.

[0287] The first planar external layer 24 and the second planar external layer 25 have a thickness of 200 micrometres and are in physical contact with the frame 50. The first planar external layer 24 and the second planar external layer 25 are bonded to the frame with an adhesive 15. The first planar external layer 24 defines at least a portion of the cavity 30. The second planar external layer 25 defines at least a portion of the cavity 30.

[0288] The aerosol-generating article 10 comprises an air inlet 11 and an air outlet 12. The air inlet 11 and the air outlet 12 are defined by, and extend through, the peripheral wall 51 of the frame 50. The air inlet 11 and the air outlet 12 each have a rectangular cross-section, a width of 2 millimetres, and a thickness of 0.9 millimetres. An airflow passage extends between the air inlet 11 and the air outlet 12 through the cavity 30.

[0289] Figure 3 shows an exploded view of an aerosol-generating article that is similar to the aerosol-generating article 10 of Figure 1 except that the first planar external layer 24 and the second planar external layer 25 do not comprise an aerosol-generating substrate. Instead, an aerosol-generating substrate 40 is positioned within the cavity 30. The aerosol-generating substrate 40 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. As shown, the aerosolgenerating substrate 40 fills the entire volume of the cavity 30. In the example of Figure 3, the aerosol-generating substrate 40 has a packing density of about 0.87, a density of about 0.3 grams per cubic centimetre, and a mass of about 110 milligrams. In another example, the aerosol-generating substrate 40 may have a different packing density, a different density and a different mass. For example, aerosol-generating substrate may have a packing density of 0.64, a density of 0.35 grams per cubic centimetre, and a mass of about 95 milligrams.

[0290] Figure 4 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figures 1 and 3 except that the aerosol-generating article 10 of Figure 4 comprises an outer wrapper 23 defining the first planar external surface 21 and the second planar external surface 22 instead of the first planar external layer 24 and the second planar external layer 25.

[0291] Figure 5 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1 except that the aerosol-generating article 10 of Figure 5 further comprises a first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are formed from a sheet of aerosol-generating material. In particular, a sheet of homogenised tobacco material having an aerosol-former content of 5 percent by weight on a dry weight basis. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 each have a length equal to the length of the aerosolgenerating article 10, a width equal to the width of the aerosol-generating article 10 and a thickness of 200 micrometres. That is, the aerosol-generating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.5 millimetres.

[0292] The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are in physical contact with the frame 50 and are bonded to the frame with an adhesive 15. The first aerosol-generating substrate layer 41 defines at least a portion of the cavity 30. The second aerosol-generating layer 42 defines at least a portion of the cavity 30.

[0293] The first planar external layer 24 is in physical contact with the first aerosol-generating substrate layer 41 and are bonded together with an adhesive 15. The second planar external layer 25 is in physical contact with the second aerosol-generating substrate layer 42 and are bonded together with an adhesive 15.

[0294] Figure 6 shows an exploded view of an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 5 except that an aerosol-generating substrate 40 is positioned within the cavity 30 as described in relation to Figure 3. The aerosol-generating substrate 40 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. As shown, the aerosolgenerating substrate 40 fills the entire volume of the cavity 30. Figure 7 shows an aerosolgenerating article 10 similar to the aerosol-generating article 10 of Figure 5 except that the aerosol-generating article 10 of Figure 7 comprises an outer wrapper 23 defining the first planar external surface 21 and the second planar external surface 22 instead of the first planar external layer 24 and the second planar external layer 25.

[0295] Figure 8 shows a perspective view of an alternative frame 150 suitable for use with the aerosol-generating articles 10 of Figures 1 to 7. The frame 150 comprises a first subframe 152 and a second subframe 154. The first and second subframes 152, 154 are identical and each have a tubular shape to define the air inlet and the air outlet 12. The first and second subframes 152, 154 may be formed from a compressed particulate material and may be manufactured using a press-moulding process.

[0296] The first and second subframes 152, 154 are spaced apart from each other to define the cavity 30 therebetween. The frame 150 also comprises a first side portion 156 and a second side portion 158, wherein the first and second side portions 156, 158 are attached to the first and second subframes 152, 154 so that the first and second subframes 152, 154 are connected to each other.

[0297] Figure 9 shows an alternative construction for the first and second subframes 152, 154. In Figure 9, each of the first and second subframes 152, 154 has a laminate structure in which a plurality of layers 158 are attached to each other to form the tubular shape of the first and second subframes 152, 154.

[0298] Figure 10 shows a further alternative construction for the first and second subframes 152, 154. In Figure 10, each of the first and second subframes 152, 154 is formed from two L-shaped sections 160, 162 connected to each other at first and second joints 164, 166 extending along side faces and end faces of the first and second subframes 152, 154.

[0299] Figure 11 shows a further alternative construction for the first and second subframes 152, 154. In Figure 10, each of the first and second subframes 152, 154 is formed from two L-shaped sections 168, 170 connected to each other at first and second joints 172, 174 extending along top and bottom faces and end faces of the first and second subframes 152, 154.

[0300] Figure 12 shows a further alternative construction for the first and second subframes 152, 154. In Figure 12, each of the first and second subframes 152, 154 is formed from a sheet 176 of material that is folded along predefined fold lines 178 to form the tubular shape of the first and second subframes 152, 154.

[0301] Figure 13 illustrates a method of forming the frame 150 of Figure 8. In a first step, a continuous tubular subframe 200 precursor is cut into a series of subframes 202. In a second step, first and second continuous side portion precursors 204, 206 are attached to opposite sides of the series of subframes 202. The first and second side portion precursors 204, 206 are only attached to every first and second subframe 202 (denoted by “1” and “2” in Figure 13). As such, every third subframe 202 (denoted by “3” in Figure 13) is not attached to the first and second side portion precursors 204, 206. In a third step, the first and second side portion precursors 204, 206 are cut between each consecutive pair of first and second subframes 202 to form a plurality of frames 150 and the third subframes 202 are removed to form the cavities 30.

[0302] Figure 14 shows a top view of an alternative frame 250 suitable for use with the aerosol-generating articles 10 of Figures 1 to 7. The frame 250 comprises a first subframe 252 and a second subframe 254. The first and second subframes 252, 254 are identical and cooperate to define a cavity 30 having a rounded hexagonal shape.

[0303] Figure 15 shows a cross-sectional view through the frame 250 taken along line 14-14 of Figure 14. Each of the first and second subframes 252, 254 has a laminate structure comprising a plurality of layers 258. The first and second subframes 252, 254 are connected to each other along joints 260 at first and second ends of the cavity 30. The plurality of layers 258 are also sized and shaped to define the air inlet 11 and the air outlet at opposite ends of the frame 250.

[0304] Figure 16 shows an alternative configuration of the laminate structure of the first and second subframes 252, 254. In the alternative configuration, the layers 258 of the laminate structures form an interlocking joint 262 at the first and second ends of the cavity 30.

[0305] Figure 17 shows an exploded perspective view of an alternative frame 350 suitable for use with the aerosol-generating articles 10 of Figures 1 to 7. The frame 350 comprises a first subframe 352 and a second subframe 354. The first and second subframes 352, 354 are identical to each other and each has an L-shaped cross-sectional shape. Each of the first and second subframes 352, 354 comprises a pair of protrusions 356 and a pair of protrusions 358. When the first subframe 352 is connected to the second subframe 354 as shown in Figure 18 to form the frame 350, the pair of protrusions 356 on each of the first and second subframes 352, 354 is received within the corresponding pair of recesses 358 on the other subframe. The protrusions 356 and the recesses 358 provide the first and second subframes 352, 354 with an interlocking arrangement that may facilitate a secure connection of the first subframe 352 to the second subframe 354.

[0306] The first subframe 352 comprises a first aperture 360 extending through the first subframe 352 and the second subframe 354 comprises a second aperture 362 extending through the second subframe 364. The first and second apertures 360, 362 overlie each other to form the cavity 30. The L-shapes of the first and second subframes 352, 354 cooperate to define the air inlet and the air outlet 12.

[0307] Figure 19 shows a perspective view of a subframe precursor 400. The subframe precursor 400 may be used to form both a first subframe and a second subframe. The subframe precursor 400 comprises a body portion 402 defining a chamber 404 and a first opening 406 at a first end of the chamber 404. The subframe precursor 400 also comprises a first flap 408 and a second flap 410 each formed integrally with the body portion 402. Each of the first and second flaps 408, 410 has a U-shape. Figures 20 and 21 illustrate the folding of the first and second flaps 408, 410 so that the flaps overlie a second end of the chamber 404 to form a subframe 414. The U-shapes of the first and second flaps 408, 410 together define a second opening 413 at the second end of the chamber 404.

[0308] Figure 22 shows a perspective view of an alternative frame 450 suitable for use with the aerosol-generating articles 10 of Figures 1 to 7. The frame 450 comprises a first subframe 452 and a second subframe 454. Each of the first and second subframes 452, 454 is identical to the subframe 414 of Figure 21. The first and second subframes 452, 454 are connected to each other by a first side portion 456 and a second side portion 458 to form the frame 450 defining the cavity 30. The frame 450 is illustrated in Figure 22 together with an aerosolgenerating substrate 40 positioned within the cavity 30.

[0309] The first opening 406 of the first subframe 452 forms an air inlet at a first end of the frame 450, and the second opening 413 of the first subframe 452 provides fluid communication between the chamber 404 of the first subframe 452 and the cavity 30. Similarly, the first opening 406 of the second subframe 454 forms an air outlet 412 at a first end of the frame 450, and the second opening 413 of the second subframe 454 provides fluid communication between the chamber 404 of the second subframe 454 and the cavity 30.

[0310] Figure 23 shows a schematic cross-sectional view of an aerosol-generating device 90 configured for use with an aerosol-generating article 10 described herein. The aerosolgenerating device 90 is an elongate aerosol-generating device extending between a proximal end 91 and a distal end 92. The aerosol-generating device 90 comprises a battery 93, a controller 94, a first heater 95 and a second heater 96 located within a housing 97. The controller 94 controls supply of power from the battery 93 to the first heater 95 and the second heater 96. A cavity 1000 is defined in the device 90, the cavity 1000 having an opening 1010 defined in the proximal end 91 of the device 90. The opening 1010 is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosol-generating article 10. The cavity 1000 comprises an upper planar surface 1020 and a lower planar surface 1030. The first heater 95 is located in the upper planar surface 1020 to heat the first planar external surface 21 of an aerosol-generating article 10 inserted into the cavity 1000, and the second heater 96 is located in the lower planar surface 1030 to heat the second planar external surface 22 of an aerosol-generating article 10 inserted into the cavity 1000. The device 90 comprises an air inlet 98 defining an air-flow path configured to allow air to flow into the cavity 1000 from outside the device.

[0311] Figure 24 shows a schematic cross-sectional view of the aerosol-generating device 90 of Figure 23 in engagement with the aerosol-generating article 10 of Figure 1. There is little tolerance between the first planar external surface 21 and the second planar external surface 22 of the aerosol-generating article 10 and the internal surfaces 1020, 1030 of the cavity 1000. Thus, there is a snug fit between the aerosol-generating article 10 and the aerosol-generating device 90. When a consumer has inserted the aerosol-generating article 10 into the cavity 1000, the device can be operated. The first heater 95 heats the first planar external surface 21 of the aerosol-generating article 10 and the second heater 96 heats the second planar external surface 22 of the aerosol-generating article, and as a result the aerosol-generating substrate is heated. Volatile components of the aerosol-generating substrate are evaporated and condense in the cavity 30 of the aerosol-generating article 10 to form an aerosol. The consumer inhales the aerosol by drawing on the end of the aerosol-generating article 10 comprising the air outlet 12. Once the aerosol-generating substrate has been depleted of volatile components, the aerosol-generating article 10 is removed from the cavity 1000 and disposed of.

[0312] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 10% of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

Claims1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: a first planar external surface; a second planar external surface; a cavity; one or more aerosol-generating substrates positioned within the cavity; an air inlet; an air outlet; and a frame at least partially defining the cavity, the air inlet and the air outlet; wherein the frame comprises a first subframe and a second subframe connected to the first subframe.

2. An aerosol-generating article according to claim 1 , wherein the first subframe is identical to the second subframe.

3. An aerosol-generating article according to claim 1 or 2, wherein the air inlet is defined by the first subframe, and wherein the air outlet is defined by the second subframe.

4. An aerosol-generating article according to claim 1 , 2 or 3, wherein the first subframe is spaced apart from the second subframe to at least partially define the cavity between the first subframe and the second subframe.

5. An aerosol-generating article according any preceding claim, wherein the first subframe at least partially defines a first end of the aerosol-generating article, and wherein the second subframe at least partially defines a second end of the aerosol-generating article.

6. An aerosol-generating article according to any preceding claim, wherein the frame further comprises a first side portion extending from the first subframe to the second subframe and a second side portion extending from the first subframe to the second subframe, optionally wherein the second side portion is spaced apart from the first side portion to at least partially define the cavity between the first side portion and the second side portion, optionally wherein each of the first side portion and the second side portion is directly connected to both of the first subframe and the second subframe.

7. An aerosol-generating article according to any preceding claim, wherein the first subframe comprises: a body portion defining a chamber and a first opening at a first end of the chamber; a first flap formed integrally with the body portion; and a second flap formed integrally with the body portion; wherein each of the first flap and the second flap overlies a second end of the chamber, and wherein the first flap and the second flap together define a second opening at the second end of the chamber, optionally wherein the first opening forms the air inlet and the second opening provides fluid communication between the chamber and the cavity.

8. An aerosol-generating article according to any preceding claim, wherein the second subframe comprises: a body portion defining a chamber and a first opening at a first end of the chamber; a first flap formed integrally with the body portion; and a second flap formed integrally with the body portion; wherein each of the first flap and the second flap overlies a second end of the chamber, and wherein the first flap and the second flap together define a second opening at the second end of the chamber, optionally wherein the first opening forms the air outlet and the second opening provides fluid communication between the chamber and the cavity.

9. An aerosol-generating article according to any preceding claim, wherein the aerosolgenerating article defines a longitudinal direction extending from the air inlet to the air outlet, wherein each of the first subframe, the second subframe, and the cavity has a length extending in the longitudinal direction, wherein the length of the first subframe is the same as the length of the second subframe, and wherein the length of the cavity is an integer multiple of the length of the first subframe.

10. An aerosol-generating article according to any preceding claim, wherein each of the first subframe and the second subframe is in the form of a tube, optionally wherein each of the first subframe and the second subframe defines a first opening at a first end of the subframe, a second opening at a second end of the subframe, and an airflow passage extending between the first opening and the second opening, optionally wherein the first opening of the first subframe forms the air inlet, and wherein the first opening of the second subframe forms the air outlet, optionally wherein each first opening, second opening and airflow passage has the same cross-sectional size and shape, optionally wherein the tube has a rectangular cross- sectional shape.

11. An aerosol-generating article according to claim 10, wherein each of the first subframe and the second subframe comprises a first portion and a second portion, wherein the first portion is formed separately from the second portion, and wherein the first portion overlies the second portion, optionally wherein each of the first portion and the second portion has an L- shaped cross-sectional shape.

12. An aerosol-generating article according to claim 10, wherein each of the first subframe and the second subframe is formed from a folded sheet material.

13. An aerosol-generating article according to claim 1 or 2, wherein the first subframe partially defines the air inlet and the air outlet, and wherein the second subframe partially defines the air inlet and the air outlet, optionally wherein the aerosol-generating article comprises a first end and a second end, and each of the first subframe and the second subframe extends between the first end and the second end, optionally wherein the first subframe comprises at least one first protrusion and at least one first recess, wherein the second subframe comprises at least one second protrusion and at least one second recess, wherein each first protrusion is received within a second recess, and wherein each second protrusion is received within a first recess, optionally wherein the cavity has a hexagonal shape or a rounded hexagonal shape, optionally wherein each of the first subframe and the second subframe defines half of the hexagonal shape or the rounded hexagonal shape, optionally wherein at least part of each of the first subframe and the second subframe has an L-shaped cross-sectional shape, optionally wherein the first subframe comprises a first aperture extending through the first subframe, wherein the second subframe comprises a second aperture extending through the second subframe, and wherein the first subframe overlies the second subframe so that the first aperture and the second aperture cooperate to at least partially define the cavity.

14. An aerosol-generating system comprising: an aerosol-generating article according to any preceding claim; and an aerosol-generating device, the aerosol-generating device comprising: a chamber for receiving at least a portion of the aerosol-generating article; and an electric heater arranged to heat at least part of the aerosol-generating article when the aerosol-generating article is received within the chamber.

15. A method of forming an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the method comprising: providing a plurality of subframes, wherein each subframe has a tubular shape, and wherein each subframe has the same length; positioning a first of the subframes and a second of the subframes so that the second subframe is spaced apart from the first subframe by a spacing distance, wherein the spacing distance is an integer multiple of the length of each subframe; providing a first side portion and a second side portion, wherein each of the first side portion and the second side portion has a length equal to the sum of the length of the first subframe, the length of the second subframe, and the spacing distance; positioning one or more aerosol-generating substrates between the first subframe and the second subframe; and securing each of the first side portion and the second side portion to both of the first subframe and the second subframe to form a frame, wherein the frame at least partially defines a cavity between the first subframe, the second subframe, the first side portion and the second side portion, wherein the one or more aerosol-generating substrates are positioned within the cavity, and wherein the frame and the one or more aerosol-generating substrates together form an aerosol-generating article.

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