Aerosol-generating article with narrow portion

Abstract

An aerosol-generating article (600) for use with an aerosol-generating device to generate an aerosol. The aerosol generating article (600) comprises: an upper external surface (610); a lower external surface (620); and an aerosol-forming substrate. The aerosol-generating article (600) is defined by a length extending in an x-direction, a width extending in a y-direction, and a height extending in a z-direction. The upper and lower external surfaces (610, 620) are separated from each other in the z direction. A maximum height of the aerosol-generating article (610) is less than each of a maximum width and a maximum length of the aerosol-generating article (610). The aerosol-enerating article (610) comprises a first end portion (601) and a second end portion (602), the first end portion (601 ) and the second end portion (602) being separated from each other in the x- direction. The aerosol-generating article (600) comprises a narrow portion (603) arranged between the first end portion (601) and the second end portion (602).

Description

[0001] AEROSOL-GENERATING ARTICLE WITH NARROW PORTION

[0002] The present disclosure relates to an aerosol-generating article comprising an aerosol-forming substrate.

[0003] A typical aerosol-generating article may appear similar to a conventional cigarette. For example, such an aerosol-generating article may be substantially cylindrical and comprise an aerosol-forming substrate and other components such as a mouthpiece filter element and a cooling element, all arranged together in the form of a rod and wrapped in a cigarette paper. Dimensions of typical aerosol-generating articles are often similar to the dimensions of conventional cigarettes.

[0004] However, a significant portion of the aerosol-forming substrate in these cylindrical aerosolgenerating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-forming substrate contributes to the cost of manufacture and transport of the aerosol-generating article, but does not contribute to the aerosol delivered to an end user. This may be the case regardless of the way in which the aerosol-forming substrate is heated, for example regardless of whether a resistive or inductive heater is used and regardless of whether the aerosol-forming substrate is heated from the inside or the outside. 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 co-axial alignment and wrapped in a cigarette paper. This can lead to increased cost and complexity of manufacture.

[0005] It is an aim of the present disclosure to provide an aerosol-generating article, in which a greater portion of an aerosol-forming substrate of the aerosol-generating article is sufficiently heated to form an aerosol during use. It is also an aim of the present disclosure to provide an aerosol-generating article that can be manufactured relatively efficiently and cheaply.

[0006] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol generating article may comprise an aerosol-forming substrate. The aerosol-generating article may be defined by a length extending in an x-direction, a width extending in a y-direction, and a height extending in a z-direction. A maximum height of the aerosol-generating article may be less than each of a maximum width and a maximum length of the aerosol-generating article. The aerosol-generating article may comprise a first end portion and a second end portion. The first end portion and the second end portion may be separated from each other in the x-direction. The aerosol-generating article may comprise a narrow portion arranged between the first end portion and the second end portion. According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol generating article comprises an aerosol-forming substrate. The aerosol-generating article is defined by a length extending in an x- direction, a width extending in a y-direction, and a height extending in a z-direction. A maximum height of the aerosol-generating article is less than each of a maximum width and a maximum length of the aerosol-generating article. The aerosol-generating article comprises a first end portion and a second end portion, the first end portion and the second end portion being separated from each other in the x-direction. The aerosol-generating article comprises a narrow portion arranged between the first end portion and the second end portion.

[0007] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol generating article may comprise: an upper external surface; a lower external surface; and an aerosol-forming substrate. The aerosolgenerating article may be defined by a length extending in an x-direction, a width extending in a y- direction, and a height extending in a z-direction. The upper and lower external surfaces may be separated from each other in the z direction. A maximum height of the aerosol-generating article may be less than each of a maximum width and a maximum length of the aerosol-generating article. The aerosol-generating article may comprise a first end portion and a second end portion. The first end portion and the second end portion may be separated from each other in the x-direction. The aerosol-generating article may comprise a narrow portion arranged between the first end portion and the second end portion.

[0008] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol generating article comprises: an upper external surface; a lower external surface; and an aerosol-forming substrate. The aerosolgenerating article is defined by a length extending in an x-direction, a width extending in a y-direction, and a height extending in a z-direction. The upper and lower external surfaces are separated from each other in the z direction. A maximum height of the aerosol-generating article is less than each of a maximum width and a maximum length of the aerosol-generating article. The aerosol-generating article comprises a first end portion and a second end portion, the first end portion and the second end portion being separated from each other in the x-direction. The aerosol-generating article comprises a narrow portion arranged between the first end portion and the second end portion.

[0009] The narrow portion may have a minimum width in the y-direction that is less than a maximum width of the first end portion and less than a maximum width of the second end portion. The narrow portion may have a minimum height in the z-direction that is less than a maximum height of the first end portion and less than a maximum height of the second end portion. The narrow portion may comprise a notch, or a recess, or a channel, or a groove in an external surface of the aerosol- generating article. The narrow portion may comprise a pair of opposing notches, or a pair of opposing recesses, or a pair of opposing channels, or a pair of opposing grooves in opposing external surfaces of the aerosol-generating article.

[0010] Providing a narrow portion of the aerosol-generating article, between the first end portion and the second end portion, may provide several different advantages. For example, a narrow portion may provide a user holding the aerosol-generating article with improved grip on the aerosolgenerating article, enabling a user to remove the aerosol-generating article from a cavity of an aerosol-generating device more easily. For example, a narrow portion may enable the aerosolgenerating article to be held by an aerosol-generating device, within a cavity of the aerosolgenerating device, to prevent the aerosol-generating article from falling out of the cavity, such as under the influence of gravity. For example, where the aerosol-forming substrate is arranged in a cavity of the aerosol-generating article, a narrow portion of the aerosol-generating article may increase the amount of contact between the aerosol-forming substrate and surfaces of the cavity, reducing air gaps between the aerosol-forming substrate and the surface of the cavity, and increasing airflow through the aerosol-forming substrate, rather than around the periphery of the aerosol-forming substrate.

[0011] In some embodiments, the aerosol-generating article comprises a cavity. The cavity may be disposed between the upper external surface and the lower external surface. In some preferred embodiments, the aerosol-forming substrate is arranged in the cavity. In some of these embodiments, the narrow portion is spaced from the aerosol-forming substrate in the x-direction. In some of these embodiments, the narrow portion is arranged at the aerosol-forming substrate in the cavity.

[0012] Arranging the narrow portion at the aerosol-forming substrate may reduce the presence of air gaps or spaces between the aerosol-forming substrate and the surfaces of the cavity. Advantageously, reducing the presence of air gaps or spaces between the aerosol-forming substrate and the surfaces of the cavity may promote the majority of the airflow through the aerosol-generating article to pass through the aerosol-forming substrate. Ensuring that as much of the airflow through the aerosol-generating article as possible passes through the aerosol-forming substrate may improve the entrainment of vapour released from the heated aerosol-forming substrate, and increase the delivery of aerosol from the aerosol-generating article.

[0013] In some preferred embodiments, the aerosol-generating article comprises a frame. The frame may be disposed between the upper external surface and the lower external surface. Preferably, the frame comprises at least one side wall.

[0014] In some of these preferred embodiments in which the aerosol-generating article comprises a frame comprising at least one side wall, the at least one side wall may have a minimum height in the z-direction at the narrow portion. The minimum height of the at least one side wall at the narrow portion may be less than a maximum height of the at least one side wall at the first end portion. The minimum height of the at least one side wall at the narrow portion may be less than a maximum height of the at least one side wall at the second end portion. Where an aerosol-forming substrate is arranged in the cavity, and the narrow portion is arranged at the aerosol-forming substrate, the aerosol-forming substrate may have a maximum height that is greater than the minimum height of the at least one side wall at the narrow portion.

[0015] In some particularly preferred embodiments, the frame comprises a first side wall and a second side wall, wherein the first side wall and the second side wall are separated in the y-direction. The first side wall may have a minimum height in the z-direction at the narrow portion. The minimum height of the first side wall at the narrow portion may be less than a maximum height of the first side wall at the first end portion. The minimum height of the first side wall at the narrow portion may be less than a maximum height of the first side wall at the second end portion. The second side wall may have a minimum height in the z-direction at the narrow portion. The minimum height of the second side wall at the narrow portion may be less than a maximum height of the second side wall at the first end portion. The minimum height of the second side wall at the narrow portion may be less than a maximum height of the second side wall at the second end portion.

[0016] Where the aerosol-generating article comprises a cavity, the frame may at least partially define the cavity. Where the aerosol-generating article has a frame with at least one side wall, the frame at least partially defines a cavity, and the aerosol-forming substrate is arranged in the cavity, the at least one side wall of the frame may have a minimum height at the narrow portion that is less than the maximum height of the aerosol-forming substrate at the narrow portion. In some of these embodiments, the height of the aerosol-forming substrate at the narrow portion is greater than the minimum height of the at least one side wall of the frame at the narrow portion.

[0017] The narrow portion may have any suitable form. The narrow portion may comprises a notch in an external surface of the aerosol-generating article. The narrow portion may comprise a recess in an external surface of the aerosol-generating article. The narrow portion may comprise a channel in an external surface of the aerosol-generating article. The narrow portion may comprise a groove in an external surface of the aerosol-generating article.

[0018] The notch, recess, channel, or groove may extend across a portion of the width of the aerosolgenerating article. The notch, recess, channel, or groove may extend across the width of the aerosolgenerating article. The notch, recess, channel, or groove may extend across the entire width of the aerosol-generating article.

[0019] The notch, recess, channel, or groove may extend across a portion of the height of the aerosolgenerating article. The notch, recess, channel, or groove may extend across the height of the aerosol-generating article. The notch, recess, channel, or groove may extend across the entire height of the aerosol-generating article.

[0020] The notch, recess, channel, or groove may circumscribe the aerosol-generating article.

[0021] The narrow portion may comprise a pair of opposing notches in opposing external surfaces of the aerosol-generating article. The narrow portion may comprise a pair of opposing recesses in opposing external surfaces of the aerosol-generating article. The narrow portion may comprise a pair of opposing channels in opposing external surfaces of the aerosol-generating article. The narrow portion may comprise a pair of opposing grooves in opposing external surfaces of the aerosolgenerating article.

[0022] The narrow portion has a length in the x-direction.

[0023] The ratio of the length of the narrow portion to the length of the aerosol-generating article may be any suitable ratio. In some preferred embodiments, the ratio of the length of the narrow portion to the length of the aerosol-generating article is between about 0.05 to about 0.7, or between about 0.05 and about 0.6, or between about 0.05 and about 0.5, or between about 0.05 and about 0.4, or between about 0.05 and about 0.3, or between about 0.05 and about 0.25, or between about 0.1 and about 0.7, or between about 0.2 and about 0.7, or between about 0.3 and about 0.7, or between about 0.4 and about 0.7.

[0024] The narrow portion may have a reduced width compared to other sections of the aerosolgenerating article. The reduced width of the narrow portion may extend across a portion of the height of the aerosol-generating article. The reduced width of the narrow portion may extend across the entire height of the aerosol-generating article.

[0025] The narrow portion may have a minimum width in the y-direction.

[0026] The ratio of the minimum width of the narrow portion to the width of the aerosol-generating article may be any suitable ratio. In some preferred embodiments, the ratio of the minimum width of the narrow portion to the width of the aerosol-generating article is between about 0.05 and about 0.5, or between about 0.05 and about 0.5, or between about 0.05 and about 0.4, or between about 0.05 and about 0.3, or between about 0.05 and about 0.25.

[0027] The narrow portion may have a reduced height compared to other sections of the aerosolgenerating article. The reduced height of the narrow portion may extend across a portion of the width of the aerosol-generating article. The reduced height of the narrow portion may extend across the entire width of the aerosol-generating article.

[0028] The narrow portion may have a minimum height in the z-direction.

[0029] The ratio of the minimum height of the narrow portion to the height of the aerosol-generating article may be any suitable ratio. The ratio of the minimum height of the narrow portion to the height of the aerosol-generating article is between about 0.05 and about 0.5, or between about 0.05 and about 0.5, or between about 0.05 and about 0.4, or between about 0.05 and about 0.3, or between about 0.05 and about 0.25.

[0030] Where the narrow portion comprises a notch, recess, channel, or groove, the depth of the notch, recess, channel, or groove may be greater than or equal to 0.4 millimetres, or greater than or equal to 0.5 millimetres, or greater than or equal to 0.6 millimetres, or greater than or equal to 0.7 millimetres, or greater than or equal to 0.8 millimetres, or greater than or equal to 0.9 millimetres, or greater than or equal to 1 .0 millimetres.

[0031] Where the narrow portion comprises a notch, recess, channel, or groove, the depth of the notch, recess, channel, or groove may be less than or equal to 3 millimetres, or less than or equal to 2.5 millimetres, or less than or equal to 2 millimetres, or less than or equal to 1 .5 millimetres.

[0032] Where the narrow portion comprises a notch, recess, channel, or groove, the depth of the notch, recess, channel, or groove may be between 0.4 millimetres and 3 millimetres, or between 0.5 millimetres and 2.5 millimetres, or between 0.6 millimetres and 2 millimetres, or between 0.7 millimetres and 1 .5 millimetres.

[0033] Where the narrow portion comprises a notch, recess, channel, or groove, the depth of the notch, recess, channel, or groove may be about 0.7 millimetres, or about 0.8 millimetres, or about 0.9 millimetres, or about 1.0 millimetres, or about 1.1 millimetres, or about 1.2 millimetres, or about 1 .3 millimetres, or about 1 .4 millimetres, or about 1 .5 millimetres.

[0034] The narrow portion may have any suitable length.

[0035] The narrow portion may have a length greater than or equal to 1 millimetres, or greater than or equal to 2 millimetres, or greater than or equal to 3 millimetres, or greater than or equal to 4 millimetres, or greater than or equal to 5 millimetres, or greater than or equal to 6 millimetres, or greater than or equal to 7 millimetres.

[0036] The narrow portion may have a length less than or equal to 60 millimetres, or less than or equal to 50 millimetres, or less than or equal to 40 millimetres, or less than or equal to 30 millimetres, or less than or equal to 20 millimetres, or less than or equal to 10 millimetres.

[0037] The narrow portion may have a length of between 1 millimetres and 60 millimetres, or between

[0038] 2 millimetres and 50 millimetres, or between 2 millimetres and 40 millimetres, or between 2 millimetres and 30 millimetres, or between 2 millimetres and 20 millimetres, or between 2 millimetres and 15 millimetres, or between 2 millimetres and 10 millimetres, or between 2 millimetres and 8 millimetres, or between 2 millimetres and 6 millimetres.

[0039] The narrow portion may have a length of about 1 millimetres, or about 2 millimetres, or about

[0040] 3 millimetres, or about 4 millimetres, or about 5 millimetres, or about 6 millimetres, or about 7 millimetres, or about 8 millimetres, or about 9 millimetres, or about 10 millimetres. The narrow portion may have any suitable height. In some embodiments, the narrow portion is a region of the aerosol-generating article having a reduced width without a reduced height. In these embodiments, the height of the narrow portion is the same as the height of the other portions of the aerosol-generating article. However, in some embodiments, the narrow portion is a region of the aerosol-generating article having a reduced height.

[0041] Where the narrow portion is a region of the aerosol-generating article having a reduced height, the narrow portion may have a height greater than or equal to 0.5 millimetre, or greater than or equal to 0.6 millimetres, or greater than or equal to 0.7 millimetres, or greater than or equal to 0.8 millimetres, or greater than or equal to 0.9 millimetres, or greater than or equal to 1 .0 millimetres, or greater than or equal to 1 .1 millimetres, or greater than or equal to 1 .5 millimetres, or greater than or equal to 2 millimetres, or greater than or equal to 2.5 millimetres, or greater than or equal to 3 millimetres.

[0042] Where the narrow portion is a region of the aerosol-generating article having a reduced height, the narrow portion may have a height less than or equal to 5 millimetres, or less than or equal to 4.5 millimetres, or less than or equal to 4 millimetres, or less than or equal to 3.5 millimetres, or less than or equal to 3 millimetres, or less than or equal to 2.5 millimetres, or less than or equal to 2 millimetres, or less than or equal to 1 .5 millimetres.

[0043] Where the narrow portion is a region of the aerosol-generating article having a reduced height, the narrow portion may have a height of between 0.5 millimetres and 8 millimetres, or between 0.8 millimetres and 7 millimetres, or between 1 millimetres and 6 millimetres, or between 1.2 millimetres and 5 millimetres, or between 1.5 millimetres and 4 millimetres.

[0044] Where the narrow portion is a region of the aerosol-generating article having a reduced height, the narrow portion may have a height of about 1.5 millimetres, or about 2 millimetres, or about 2.5 millimetres, or about 3 millimetres, or about 3.5 millimetres.

[0045] Where the narrow portion is a region of the aerosol-generating article having a reduced width without a reduced height, the narrow portion may have a height greater or equal to 0.3 millimetres, or greater than or equal to 0.4 millimetres, or greater than or equal to 0.5 millimetres, or greater than or equal to 0.7 millimetres, or greater than or equal to 0.8 millimetres, or greater than or equal to 0.9 millimetres, greater than or equal to 1 millimetre, or greater than or equal to 1 .5 millimetres, or greater than or equal to 2 millimetres, or greater than or equal to 2.5 millimetres, or greater than or equal to 3 millimetres, or greater than or equal to 3.5 millimetres, or greater than or equal to 4 millimetres, or greater than or equal to 4.5 millimetres, or greater than or equal to 5 millimetres, or greater than or equal to 6 millimetres, or greater than or equal to 7 millimetres, or greater than or equal to 8 millimetres, or greater than or equal to 9 millimetres, or greater than or equal to 10 millimetres, or greater than or equal to 12 millimetres, or greater than or equal to 14 millimetres, or greater than or equal to 16 millimetres, or greater than or equal to 18 millimetres, or greater than or equal to 20 millimetres, or greater than or equal to 22 millimetres.

[0046] Where the narrow portion is a region of the aerosol-generating article having a reduced width without a reduced height, the narrow portion may have a height less than or equal to 25 millimetres, or less than or equal to 23 millimetres, or less than or equal to 21 millimetres, or less than or equal to 19 millimetres, or less than or equal to 17 millimetres, or less than or equal to 15 millimetres, or less than or equal to 13 millimetres, or less than or equal to 11 millimetres, or less than or equal to 10 millimetres, or less than or equal to 9 millimetres, or less than or equal to 8 millimetres, or less than or equal to 7 millimetres, or less than or equal to 6 millimetres, or less than or equal to 5.5 millimetres, or less than or equal to 5 millimetres, or less than or equal to 4.5 millimetres, or less than or equal to 4 millimetres, or less than or equal to 3.5 millimetres, or less than or equal to 3 millimetres, or less than or equal to 2.5 millimetres, or less than or equal to 2 millimetres, or less than or equal to 1 millimetre, or less than or equal to 0.9 millimetres, or less than or equal to 0.8 millimetres, or less than or equal to 0.7 millimetres, or less than or equal to 0.6 millimetres, or less than or equal to 0.5 millimetres.

[0047] Where the narrow portion is a region of the aerosol-generating article having a reduced width without a reduced height, the narrow portion may have a height of between 0.3 millimetres and 25 millimetres, or between 0.4 millimetres and 23 millimetres, or between 0.5 millimetres and 21 millimetres, or between 0.6 millimetres and 19 millimetres, or between 0.7 millimetres and 17 millimetres, or between 0.8 millimetres and 15 millimetres, or between 0.9 millimetres and 13 millimetres, or between 1 millimetres and 10 millimetres, or between 1 millimetres and 5 millimetres, or between 1 .2 millimetres and 8 millimetres, or between 1 .4 millimetres and 7 millimetres, or between 1.5 millimetres and 5 millimetres, or between 1.5 millimetres and 4 millimetres, or between 1.5 millimetres and 3 millimetres, or between 1 .5 millimetres and 2 millimetres, or between 1 .6 millimetres and 6 millimetres, or between 1.7 millimetres and 5 millimetres, or between 2 millimetres and 4.5 millimetres, or between 2.5 millimetres and 4 millimetres, or between 3 millimetres and 3.5 millimetres.

[0048] Where the narrow portion is a region of the aerosol-generating article having a reduced width without a reduced height, the narrow portion may have a height of about 1 .7 millimetres, or about 4.5 millimetres, or about 2 millimetres, or about 3 millimetres, or about 4 millimetres.

[0049] The narrow portion may have any suitable width. In some embodiments, the narrow portion is a region of the aerosol-generating article having a reduced height without a reduced width. In these embodiments, the width of the narrow portion is the same as the width of the other portions of the aerosol-generating article. However, in some embodiments, the narrow portion is a region of the aerosol-generating article having a reduced width. Where the narrow portion is a region of the aerosol-generating article having a reduced width, the narrow portion may have a width equal to greater than 2 millimetres, or greater than 2.5 millimetres, or greater than 3 millimetres, or greater than 3.5 millimetres, or greater than 4 millimetres, or greater than 4.5 millimetres.

[0050] Where the narrow portion is a region of the aerosol-generating article having a reduced width, the narrow portion may have a width less than or equal to 15 millimetres, or less than or equal to 12 millimetres, or less than or equal to 10 millimetres, or less than or equal to 9 millimetres, or less than or equal to 8 millimetres.

[0051] Where the narrow portion is a region of the aerosol-generating article having a reduced width, the narrow portion may have a width of between 2 millimetres and 18 millimetres, or between 2 millimetres and 16 millimetres, or between 3 millimetres and 15 millimetres, or between 3 millimetres and 12 millimetres, or between 3 millimetres and 10 millimetres.

[0052] Where the narrow portion is a region of the aerosol-generating article having a reduced width, the narrow portion may have a width of about 6 millimetres, or about 7 millimetres, or about 8 millimetres, or about 9 millimetres, or about 10 millimetres, or about 11 millimetres, or about 12 millimetres.

[0053] In some embodiments, the narrow portion may comprise a first narrow portion and a second narrow portion. The first narrow portion may be arranged between the first end portion and the second end portion of the aerosol-generating article. The second narrow portion may be arranged between the first end portion and the second end portion of the aerosol-generating article. The first narrow portion may be arranged between the first end portion and the second narrow portion. The second narrow portion may be arranged between the second end portion and the first narrow portion. The first narrow portion may be arranged adjacent the first end portion of the aerosol-generating article. The second narrow portion may be arranged adjacent the second end portion of the aerosolgenerating article.

[0054] The aerosol-generating article may have any suitable length.

[0055] The aerosol-generating article may have a length greater than or equal to 15 millimetres, or greater than or equal to 20 millimetres, or greater than or equal to 25 millimetres, or greater than or equal to 30 millimetres, or greater than or equal to 35 millimetres, or greater than or equal to 40 millimetres.

[0056] The aerosol-generating article may have a length less than or equal to 45 millimetres, or less than or equal to 40 millimetres, or less than or equal to 35 millimetres, or less than or equal to 30 millimetres.

[0057] The aerosol-generating article may have a length of between 10 millimetres and 100 millimetres, or between 10 millimetres and 50 millimetres, or between 10 millimetres and 40 millimetres, or between 12 millimetres and 30 millimetres, or between 14 millimetres and 26 millimetres, or between 16 millimetres and 24 millimetres, or between 18 millimetres and 22 millimetres, or between 15 millimetres and 45 millimetres, or between 20 millimetres and 40 millimetres, or between 20 millimetres and 35 millimetres, or between 25 millimetres and 30 millimetres.

[0058] The aerosol-generating article may have a length of about 18 millimetres, or about 19 millimetres, or about 20 millimetres, or about 21 millimetres, or about 22 millimetres.

[0059] The separation between the upper external surface and the lower external surface may define the height of the aerosol-generating article.

[0060] The aerosol-generating article may have any suitable height.

[0061] The aerosol-generating article may have a height greater or equal to 0.3 millimetres, or greater than or equal to 0.4 millimetres, or greater than or equal to 0.5 millimetres, or greater than or equal to 0.7 millimetres, or greater than or equal to 0.8 millimetres, or greater than or equal to 0.9 millimetres, greater than or equal to 1 millimetre, or greater than or equal to 1 .5 millimetres, or greater than or equal to 2 millimetres, or greater than or equal to 2.5 millimetres, or greater than or equal to 3 millimetres, or greater than or equal to 3.5 millimetres, or greater than or equal to 4 millimetres, or greater than or equal to 4.5 millimetres, or greater than or equal to 5 millimetres, or greater than or equal to 6 millimetres, or greater than or equal to 7 millimetres, or greater than or equal to 8 millimetres, or greater than or equal to 9 millimetres, or greater than or equal to 10 millimetres, or greater than or equal to 12 millimetres, or greater than or equal to 14 millimetres, or greater than or equal to 16 millimetres, or greater than or equal to 18 millimetres, or greater than or equal to 20 millimetres, or greater than or equal to 22 millimetres.

[0062] The aerosol-generating article may have a height less than or equal to 25 millimetres, or less than or equal to 23 millimetres, or less than or equal to 21 millimetres, or less than or equal to 19 millimetres, or less than or equal to 17 millimetres, or less than or equal to 15 millimetres, or less than or equal to 13 millimetres, or less than or equal to 11 millimetres, or less than or equal to 10 millimetres, or less than or equal to 9 millimetres, or less than or equal to 8 millimetres, or less than or equal to 7 millimetres, or less than or equal to 6 millimetres, or less than or equal to 5.5 millimetres, or less than or equal to 5 millimetres, or less than or equal to 4.5 millimetres, or less than or equal to 4 millimetres, or less than or equal to 3.5 millimetres, or less than or equal to 3 millimetres, or less than or equal to 2.5 millimetres, or less than or equal to 2 millimetres, or less than or equal to 1 millimetre, or less than or equal to 0.9 millimetres, or less than or equal to 0.8 millimetres, or less than or equal to 0.7 millimetres, or less than or equal to 0.6 millimetres, or less than or equal to 0.5 millimetres. The aerosol-generating article may have a height of between 0.3 millimetres and 25 millimetres, or between 0.4 millimetres and 23 millimetres, or between 0.5 millimetres and 21 millimetres, or between 0.6 millimetres and 19 millimetres, or between 0.7 millimetres and 17 millimetres, or between 0.8 millimetres and 15 millimetres, or between 0.9 millimetres and 13 millimetres, or between 1 millimetres and 10 millimetres, or between 1 millimetres and 5 millimetres, or between 1.2 millimetres and 8 millimetres, or between 1 .4 millimetres and 7 millimetres, or between 1 .5 millimetres and 5 millimetres, or between 1.5 millimetres and 4 millimetres, or between 1.5 millimetres and 3 millimetres, or between 1.5 millimetres and 2 millimetres, or between 1.6 millimetres and 6 millimetres, or between 1.7 millimetres and 5 millimetres, or between 2 millimetres and 4.5 millimetres, or between 2.5 millimetres and 4 millimetres, or between 3 millimetres and 3.5 millimetres.

[0063] The aerosol-generating article may have a height of about 1.7 millimetres, or about 4.5 millimetres, or about 2 millimetres, or about 3 millimetres, or about 4 millimetres.

[0064] The aerosol-generating article may have any suitable width.

[0065] The aerosol-generating article may have a width equal to greater than 3 millimetres, or greater than 5 millimetres, or greater than 7.5 millimetres, or greater than 9 millimetres, or greater than 11 millimetres, or greater than 13 millimetres.

[0066] The aerosol-generating article may have a width less than or equal to 17 millimetres, or less than or equal to 15 millimetres, or less than or equal to 12.5 millimetres, or less than or equal to 11 millimetres, or less than or equal to 9 millimetres.

[0067] The aerosol-generating article may have a width of between 3 millimetres and 20 millimetres, or between 3 millimetres and 17 millimetres, or between 5 millimetres and 20 millimetres, or between 5 millimetres and 15 millimetres, or between 7.5 millimetres and 12.5 millimetres, or between 8 millimetres and 18 millimetres, or between 9 millimetres and 11 millimetres, or between 10 millimetres and 16 millimetres, or between 11 millimetres and 15 millimetres, or between 12 millimetres and 14 millimetres.

[0068] The aerosol-generating article may have a width of about 10 millimetres, or about 11 millimetres, or about 12 millimetres, or about 13 millimetres, or about 14 millimetres, or about 15 millimetres, or about 16 millimetres.

[0069] A ratio between the length and the height of the aerosol-generating article, and between the width and the height 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 .

[0070] A ratio between the length and the height of the aerosol-generating article, and between the width and the height 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 . A ratio between the length and the height of the aerosol-generating article, and between the width and the height 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 .

[0071] 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 .

[0072] 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.

[0073] 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 .

[0074] An air flow channel may be defined between the upper external surface and the lower external surface.

[0075] In some preferred embodiments, the upper external surface is substantially planar and the lower external surface is substantially planar. In some particularly preferred embodiments, the planar upper external surface and the planar lower external surface extend substantially in parallel planes. The aerosol-generating article may have a constant height along the length of the aerosol-generating article. The aerosol-generating article may have a constant height along the width of the aerosolgenerating article. Where the narrow portion has a minimum height in the z-direction that is less than a maximum height of the first end portion and less than a maximum height of the second end portion, the planar upper external surface and the planar lower external surface may be non-planar at the narrow portion. Where the narrow portion has a minimum height in the z-direction that is less than a maximum height of the first end portion and less than a maximum height of the second end portion, the aerosol-generating article may have a constant height along the length of the aerosol-generating article except for at the narrow portion. Where the narrow portion has a minimum height in the z- direction that is less than a maximum height of the first end portion and less than a maximum height of the second end portion, the aerosol-generating article may have a constant height along the width of the aerosol-generating article except for at the narrow portion.

[0076] In some preferred embodiments, the aerosol-generating article comprises a first external side surface, and a second external side surface, the second external side surface being spaced from the first external side surface in the y-direction. In some particularly preferred embodiments, the first external side surface is substantially planar, and the second external side surface is substantially planar. The planar first external side surface and the planar second external side surface may extend in parallel planes. The aerosol-generating article may have a constant width along the length of the aerosol-generating article. The aerosol-generating article may have a constant width along the height of the aerosol-generating article. Where the narrow portion has a minimum width in the y-direction that is less than a maximum width of the first end portion and less than a maximum width of the second end portion, the planar first external side surface, and the planar second external side surface may be non-planar at the narrow portion. Where the narrow portion has a minimum width in the y- direction that is less than a maximum width of the first end portion and less than a maximum width of the second end portion, the aerosol-generating article may have a constant width along the length of the aerosol-generating article except for at the narrow portion. Where the narrow portion has a minimum width in the y-direction that is less than a maximum width of the first end portion and less than a maximum width of the second end portion, the aerosol-generating article may have a constant width along the height of the aerosol-generating article except for at the narrow portion.

[0077] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising an aerosol-forming substrate for producing an aerosol, the aerosol-generating article being a planar aerosol-generating article having a base defined by a length extending in an x direction, a width extending in a y direction, and a height extending in a z direction.

[0078] The height of the aerosol-generating article is less than both of the length and width of the aerosol-generating article. For the purpose of the present disclosure, the “height” of the aerosolgenerating article may also be referred to as the “thickness” of the aerosol-generating article.

[0079] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising an aerosol-forming substrate for producing an aerosol, the aerosol-generating article comprising a substantially planar upper surface defined by a length extending in an x direction and a width extending in a y direction, and a substantially planar lower surface defined by a length extending in an x direction and a width extending in a y direction. The substantially planar upper surface and the substantially planar lower surface may be vertically spaced from each other by a height defined in a z direction.

[0080] Aerosol-generating articles according to the present disclosure may preferably be substantially flat articles or substantially planar articles. Such articles have a large base area relative to the volume of the article. In particular, the height of the aerosol-generating article may be less than 50 percent of both the length and width of the aerosol-generating article. Advantageously, a larger base area may provide greater surface area for heating by a planar heater of an aerosol-generating device. Advantageously, a smaller height may allow a smaller temperature gradient or difference across the height of the aerosol-generating article during heating. For example, where the base of the aerosolgenerating article is in contact with, and heated by, a planar heater, there may be a smaller temperature difference between the base and an upper surface opposing the base if the spacing, or height, between the base and the upper surface is smaller. Advantageously, this may allow heating of a greater proportion of the aerosol-forming substrate of the aerosol-generating article to a temperature at which an aerosol is released, whilst minimising the risk of burning the hottest portion of the substrate closest to the heater. Alternatively, or in addition, this may reduce a time required to heat the aerosol-forming substrate sufficiently to release an aerosol.

[0081] The aerosol-generating article according to any of the aspects disclosed herein may have an air flow path extending through the aerosol-generating article. The aerosol-generating article may have an air-flow path defined through the aerosol-generating article in an x / y plane from one side of the aerosol-generating article to the other side of the aerosol-generating article. The aerosolgenerating article preferably has a resistance to draw (RTD) of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in the direction of the airflow path. Preferably, the aerosolgenerating article has a RTD of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in at least one direction in an x / y plane of the aerosol-generating article. An aerosol-generating article with a low resistance air-flow path may allow for superior air-flow management and allow aerosol to be extracted more efficiently from the aerosol-generating article and guided to a user.

[0082] Unless otherwise specified, the resistance to draw (RTD) is measured in accordance with ISO 6565-2015. The RTD refers to the pressure required to force air through the full length of a component, such as the aerosol-generating article. The terms “pressure drop” or “draw resistance” of a component or article may also refer to the “resistance to draw”. Such terms generally refer to the measurements made in accordance with ISO 6565-2015 and are normally carried out at under test at a volumetric flow rate of about 17.5 millilitres per second at the output or downstream end of the measured component at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr) and a relative humidity of about 60%.

[0083] The aerosol-generating article according to any of the aspects disclosed herein may comprise substantially planar upper and lower surfaces. A vertical separation between the substantially planar upper and lower surfaces may define a height (for example, a z dimension) of the aerosol-generating article. An air flow channel may be defined between the substantially planar upper and lower surfaces. The height of the aerosol-generating article may be less than 5 millimetres, for example between 1 .5 millimetres and 5 millimetres, for example between 1 .5 millimetres and 4 millimetres, for example between 1.5 millimetres and 3 millimetres, for example between 1.5 millimetres and 2 millimetres. One or both of the substantially planar upper and lower surfaces may comprise an aerosol-forming substrate. The aerosol-generating article may comprise upper and lower layers, the upper layer forming the substantially planar upper surface and the lower layer forming the substantially planar lower surface. At least one of the upper and lower layers may comprise or consist of aerosol-forming substrate. According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer. At least one of the first planar layer, the second planar layer and the corrugated layer may comprise or consist of an aerosol-forming substrate.

[0084] The use of a corrugated structure in the aerosol-generating article may advantageously allow the production of an aerosol-generating article that has extremely low RTD while still being sufficiently rigid to for a user to handle. Further, use of a corrugated structure may allow a low density, low RTD, aerosol-generating article to be produced using high speed production methods similar to those used for production of corrugated cardboard.

[0085] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article may comprise a first planar external surface, a second planar external surface, a cavity, and a frame. The frame is positioned between the first planar external surface and the second planar external surface. The frame at least partially defines the cavity. The aerosol-generating article comprises an aerosolforming substrate. The aerosol-generating article may comprise an air inlet and an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity.

[0086] Preferably, an aerosol-forming substrate is positioned between the first planar external surface and the second planar external surface.

[0087] The frame may comprise a peripheral wall at least partially circumscribing or encircling the cavity. The frame may comprise a peripheral wall wholly circumscribing or encircling the cavity. Advantageously, the frame may allow the aerosol-generating article to be relatively thin whilst maintaining structural rigidity.

[0088] The aerosol-generating article may comprise a first planar external layer and a second planar external layer, in which the first planar external layer forms the first planar external surface and the second planar external layer forms the second planar external surface. Optionally, at least one of the first planar external layer, the second planar external layer, and the frame may comprise or consist of aerosol-forming substrate.

[0089] The cavity may be substantially empty.

[0090] Aerosol-forming substrate may be positioned within the cavity.

[0091] A corrugated layer may be positioned within the cavity.

[0092] The frame may be a planar frame.

[0093] The frame may have a height between 50 percent and 95 percent of the height of the aerosolgenerating article. The frame may have a height between 60 percent and 95 percent of the height of the aerosol-generating article. The frame may have a height between 70 percent and 95 percent of the height of the aerosol-generating article. The frame may have a height between 80 percent and 95 percent of the height of the aerosol-generating article.

[0094] The frame may have a height between 1 millimetre and 5.5 millimetres. The frame may have a height between 1 millimetre and 5 millimetres. Preferably, the frame may have a height between 1 .5 millimetres and 5 millimetres.

[0095] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0096] 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.

[0097] 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.

[0098] The aerosol-generating article of any of the aspects of the present disclosure when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof. Where the aerosol-generating article comprises substantially planar upper and lower surfaces, one or both of the upper and lower surfaces when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof. A perimeter of the aerosol-generating article when viewed in plan may be formed of a plurality of straight sides, a plurality of curved sides, or a combination of straight and curved sides. Where the aerosol-generating article comprises substantially planar upper and lower surfaces, a perimeter of one or both of the upper and lower surfaces when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof.

[0099] The aerosol-generating article may consist entirely of aerosol-forming substrate. Alternatively, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-generating article.

[0100] The aerosol-forming substrate may comprise nicotine. Nicotine may be present in the form of a tobacco material or may be in the form of a nicotine extract.

[0101] The aerosol-forming substrate may comprise one or more organic materials such as tobacco, mint, tea, and cloves. The aerosol-forming substrate 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. The aerosol-forming substrate may comprise or consist of homogenised tobacco material, for example a reconstituted tobacco material or a cast leaf tobacco material.

[0102] The aerosol-forming substrate 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.

[0103] The aerosol-forming substrate may be cut filler. The aerosol-forming substrate may be tobacco cut filler. The cut filler may comprise one or more of bright tobacco, dark tobacco, aromatic tobacco, and filler tobacco. Examples of bright tobaccos are Flue-Cured Brazil, Indian Flue-Cured, Chinese Flue-Cured, US Flue-Cured such as Virginia tobacco, and Flue-Cured from Tanzania. Examples of aromatic tobaccos are Oriental Turkey, Greek Oriental, semi-oriental tobacco but also Fire Cured, US Burley, such as Perique, and Rustica. Examples of dark tobacco are Dark Cured Brazil Galpao, Burley Malawi, or other African Burley, Sun Cured or Air Cured Indonesian Kasturi. As used herein, the term “cut filler” is used to describe 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.

[0104] The aerosol-forming substrate 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.

[0105] The aerosol-forming substrate may comprise a bound collection of strips, strands, or particles of tobacco material. The aerosol-forming substrate may be in the form of a compressed plug of tobacco material; for example, in which a plug having a substantially circular cross-section in an initial state of the plug is compressed into a flatter cross-sectional profile in a subsequent state of the plug. The tobacco material may be enclosed by a wrapper. The aerosol-forming substrate may be in the form of strips, strands or particles of tobacco material bound together in a binder matrix.

[0106] The aerosol-forming substrate may comprise one or more aerosol-formers. Suitable aerosolformers 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.

[0107] The aerosol-forming substrate 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-forming substrate 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.

[0108] The aerosol-forming substrate 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. That is, the aerosolforming substrate may have an aerosol-former content less than or equal to 30 by weight on a dry weight basis, less than or equal to 25 by weight on a dry weight basis, or less than or equal to 20 by weight on a dry weight basis.

[0109] The aerosol-forming substrate may have an aerosol-former content between 1 percent and 30 percent by weight on a dry weight basis, between 1 percent and 25 percent by weight on a dry weight basis, or between 1 percent and 20 percent by weight on a dry weight basis.

[0110] The aerosol-forming substrate may comprise at least 50 percent by weight of aerosol former, at least 60 percent by weight of aerosol former, or at least 70 percent by weight of aerosol former.

[0111] The aerosol-forming substrate may comprise less than or equal to 85 percent by weight of aerosol former, less than or equal to 80 percent by weight of aerosol former, or less than or equal to 75 percent by weight of aerosol former.

[0112] The aerosol-forming substrate may comprise between 50 percent and 85 percent by weight of aerosol former, between 50 percent and 80 percent by weight of aerosol former, or between 50 percent and 75 percent by weight of aerosol former.

[0113] The aerosol-forming substrate may comprise nicotine. The aerosol-forming substrate may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0114] The aerosol-forming substrate 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.

[0115] The aerosol-forming substrate may comprise one or more flavourants. The one or more flavourants may comprise one or more of: one or more essential oils such as eugenol, peppermint oil and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and an herbaceous material. Suitable herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavourants may comprise a tobacco material.

[0116] The aerosol-forming substrate may comprise one or more botanicals. For example, the aerosol-forming substrate may comprise about 1 to 90 %, for example about 15 to 55 %, preferably of about 20 to 35 %, of botanicals such as Clove, Echinacea sp., Fennel, Ginger, Hawthorn berry, Elderberry, Monarda, Mullein leaves, Nettle, Plantain, Turmeric, Yarrow, Rooibos, Star Anise, Thyme, Anethum, Chamomile and compounds of those.

[0117] The aerosol-forming substrate may have a moisture content of about 5 to 25%, preferably of about 7 to 15%, at final product state. For example, the aerosol-forming substrate may be a homogenised tobacco material with a moisture of about 5 to 25%, preferably of about 7 to 15%, at final product state.

[0118] The aerosol-forming substrate may comprise a binder. For example, the aerosol-forming substrate may comprise about 1 to 10%, preferably of about 1 to 5%, of a binder such as any of common gums or pectins used in food and beverage (F&B) industries. Preferred binders may be natural pectins, such as fruit, for example citrus, or tobacco pectins; guar gums, land locust bean gums, such as hydroxyethyl and / or hydroxypropyl of those; starches, such as modified or derivatized starches; alginate; methyl, ethyl, ethyl hydroxymethyl and carboxymethyl, celluloses; dextran; and xanthan gum. A preferable binder is guar.

[0119] The aerosol-forming substrate may comprise, or consist of, a solid aerosol-forming material. The aerosol-forming substrate may comprise a liquid aerosol-forming material, for example a liquid aerosol-forming material retained within a porous matrix. The aerosol-forming substrate may comprise a gel aerosol-forming material.

[0120] The aerosol-forming substrate 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.

[0121] The term “bead” refers to a discrete, solid particle formed of the aerosol-forming substrate. A bead may have a rounded, typically spherical, form. Other terms may be used to define the substrate such as, for example, “granule”.

[0122] Providing the aerosol-forming substrate 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 aerosolgenerating 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.

[0123] 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.

[0124] 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.

[0125] The aerosol-forming substrate may be in form of a wrapped body of aerosol-forming substrate, the wrapped body comprising a wrapper at least partially enclosing aerosol-forming substrate.

[0126] The wrapped body of aerosol-forming substrate may occupy between 15% and 100% of the interior volume of the cavity. The wrapped body of aerosol-forming substrate may occupy between 30% and 100% of the interior volume of the cavity. The wrapped body of aerosol-forming substrate may occupy between 50% and 100% of the interior volume of the cavity. The wrapped body of aerosol-forming substrate may occupy between 50% and 80% of the interior volume of the cavity. The wrapped body of aerosol-forming substrate may occupy between 50% and 70% of the interior volume of the cavity.

[0127] According to the present disclosure, there is provided an aerosol-generating system. The aerosol-generating system may comprise an aerosol-generating article as described above, and an aerosol-generating device. The aerosol-generating device is configured to be used with the aerosolgenerating article to generate an aerosol.

[0128] The aerosol-generating device may be configured to receive the aerosol-generating article. The aerosol-generating device may be configured to receive a portion of the aerosol-generating article. The aerosol-generating device may be configured to receive a portion of the aerosolgenerating article, such that a portion of the aerosol-generating article is arranged outside of the aerosol-generating device when the aerosol-generating article is received in the aerosol-generating device. The aerosol-generating device may be configured to receive the entirety of the aerosolgenerating article, such that the aerosol-generating article is wholly enclosed within the aerosolgenerating device. The aerosol-generating device may be configured to receive the entirety of the aerosol-generating article.

[0129] The aerosol-generating device may comprise a cavity configured to receive the aerosolgenerating article. The cavity may be dimensioned to receive the aerosol-generating article. The cavity may be configured to receive at least a portion of the aerosol-generating article. The cavity may be configured to receive a portion of the aerosol-generating article. The cavity may be configured to receive the entire aerosol-generating article.

[0130] In some embodiments, a portion of the aerosol-generating article extends out of the cavity of the aerosol-generating device when the aerosol-generating article is received in the cavity of the aerosol-generating device. In some of these embodiments, the narrow portion of the aerosolgenerating article may be arranged at least partially outside of the cavity of the aerosol-generating device. In some of these embodiments, the narrow portion of the aerosol-generating article may be arranged outside of the cavity of the aerosol-generating device. Advantageously, arranging the narrow portion of the aerosol-generating article outside of the cavity of the aerosol-generating device when the aerosol-generating article is received in the cavity of the aerosol-generating device may facilitate a user gripping the aerosol-generating article, at the narrow portion, to help the user remove the aerosol-generating article from the cavity of the aerosol-generating device.

[0131] In some embodiments, the cavity of the aerosol-generating device is configured to receive at least a portion of the aerosol-generating article, the portion of the aerosol-generating article including the narrow portion. A portion of the aerosol-generating article may be configured to be received in the cavity of the aerosol-generating device. A portion of the aerosol-generating article comprising the narrow portion may be configured to be received in the cavity of the aerosol-generating device.

[0132] In some of these embodiments, the aerosol-generating device further comprises a latch or protrusion. The latch or protrusion may be configured to interact with the narrow portion of the aerosol-generating article when the aerosol-generating article is received in the article cavity to releasably retain the aerosol-generating article in the article cavity. The latch or protrusion may be any suitable type of latch or protrusion. For example, the latch or protrusion may comprise a resilient latch arm, a detent, and a spring-loaded pin. The latch or protrusion may comprise a resilient portion of the aerosol-generating device. The latch or protrusion may be configured to be received in the narrow portion when the aerosol-generating article is received in the aerosol-generating device. The latch or protrusion may be configured to be received in the narrow portion when the aerosolgenerating article is received in the cavity of the aerosol-generating device. The latch or protrusion may be configured to be removably received in the narrow portion when the aerosol-generating article is received in the cavity of the aerosol-generating device.

[0133] Advantageously, providing the aerosol-generating device with a latch or protrusion configured to be received in the narrow portion when the aerosol-generating article is received in the aerosolgenerating device may help to retain the aerosol-generating article in the aerosol-generating device. In particular, the latch or protrusion and narrow portion may cooperate to prevent the aerosolgenerating article from moving out of the cavity of the aerosol-generating device under the influence of gravity. The latch or protrusion may be configured to move or deform under a force applied to the aerosol-generating article in the x-direction. In particular, the latch or protrusion may be configured to move or deform under a force applied to the aerosol-generating article in the x-direction that is greater than the weight of the aerosol-generating article. This may help to prevent the aerosolgenerating article from falling out of the cavity of the aerosol-generating device, while enabling a user to pull on the aerosol-generating article to remove the aerosol-generating article from the cavity of the aerosol-generating device.

[0134] The aerosol-generating system comprises an aerosol-generating device.

[0135] The aerosol-generating device may comprise a cavity configured to receive at least a portion of the aerosol-generating article described above. The aerosol-generating device may comprise a heater or heating means. The aerosol-generating device may comprise a power source for supplying power to the heater or heating means. The aerosol-generating device may comprise a controller to control supply of power to the heater or heating means. Preferably, the aerosol-generating device is configured to heat an aerosol-forming substrate, for example an aerosol-forming substrate that is a component part of an aerosol-generating article, to form an aerosol, for example an inhalable aerosol.

[0136] The cavity may comprise an opening into which a distal end of the aerosol-generating article can be inserted. The cavity may have any suitable cross-sectional shape. For example, the cavity may have a rectangular transverse cross-section, for example a rectangular cross-section having opposing top and bottom sides that are greater in length than left and right sides.

[0137] Preferably, at least one internal surface of the cavity is a heating surface configured to heat an aerosol-generating article. The heating surface may comprise a heater, for example a resistance heater, or an infra-red heater, or a susceptor configured to be heated by engagement with an inductor. The heating surface may comprise an inductor, for example the surface may comprise a coil arranged to generate a fluctuating electromagnetic field within a space of the cavity. The heating surface may be a surface that is permeable to a fluctuating electromagnetic field, such that an inductor arranged outside the cavity can project a fluctuating electromagnetic field through the heating surface to engage with a susceptor arranged within the cavity.

[0138] According to the present disclosure, an aerosol-generating device for receiving an aerosolgenerating article as disclosed herein, or an aerosol-forming substrate as disclosed herein, may comprise a cavity dimensioned to receive at least a portion of the aerosol-generating article or aerosol-forming substrate, a heater or heating means, a power source for supplying power to the heater or heating means, and a controller to control supply of power to the heater or heating means. The aerosol-generating device is configured to heat an aerosol-forming substrate, for example an aerosol-forming substrate that is a component part of an aerosol-generating article, to form an aerosol, for example an inhalable aerosol. In some embodiments, the aerosol-generating system may comprise a mouthpiece. The mouthpiece may be configured to be received in an oral cavity of a user. The mouthpiece may be a separate component of the aerosol-generating system to the aerosol-generating device. The mouthpiece may be configured to couple with the aerosol-generating article. The mouthpiece may be removably couplable to the aerosol-generating article. The mouthpiece may be configured to couple with the aerosol-generating device. The mouthpiece may be removably couplable to the aerosol-generating device. The mouthpiece may be configured to couple with the aerosol-generating article and to couple with the aerosol-generating device.

[0139] Advantageously, providing an aerosol-generating system with a mouthpiece that is couplable to the aerosol-generating device and couplable to the aerosol-generating article may enable a user to insert the aerosol-generating article into the cavity of the aerosol-generating device and remove the aerosol-generating article from the cavity of the aerosol-generating device without touching the aerosol-generating article.

[0140] The mouthpiece may comprise an air inlet. The mouthpiece may comprise an air outlet. The mouthpiece may comprise an airflow path. The mouthpiece may comprise an airflow path extending between an air inlet and an air outlet. The mouthpiece may be configured such that when the mouthpiece is coupled with the aerosol-generating article, the air inlet of the mouthpiece is aligned with an air outlet of the aerosol-generating article.

[0141] The mouthpiece may comprise a cavity. The cavity of the mouthpiece may be configured to receive a portion of the aerosol-generating article. The cavity of the mouthpiece may be configured to receive a portion of the aerosol-generating article comprising the narrow portion.

[0142] A portion of the aerosol-generating article may be configured to be received in the cavity of the mouthpiece. A portion of the aerosol-generating article comprising the narrow portion may be configured to be received in the cavity of the mouthpiece.

[0143] In some embodiments, the mouthpiece further comprises a latch or protrusion. The latch or protrusion may be configured to interact with the narrow portion of the aerosol-generating article when the aerosol-generating article is received in the cavity of the mouthpiece. The latch or protrusion may be configured to interact with the narrow portion of the aerosol-generating article to releasably retain the aerosol-generating article in the cavity of the mouthpiece. The latch or protrusion may be any suitable type of latch or protrusion. For example, the latch or protrusion may comprise a resilient latch arm, a detent, and a spring-loaded pin. The latch or protrusion may comprise a resilient portion of the mouthpiece. The latch or protrusion may be configured to be received in the narrow portion when the aerosol-generating article is received in the cavity of the mouthpiece. The latch or protrusion may be configured to be removably received in the narrow portion when the aerosol-generating article is received in the cavity of the mouthpiece. Where the aerosol-generating article comprises a first narrow portion and a second narrow portion, the first narrow portion may be configured to be received in the cavity of the mouthpiece and the second narrow portion may be configured to be received in the cavity of the aerosol-generating device. The mouthpiece may comprise a latch or protrusion in the cavity of the mouthpiece, the latch or protrusion being configured to be received in the first narrow portion of the aerosol-generating article. The aerosol-generating device may comprise a latch or protrusion in the cavity of the aerosolgenerating device, the latch or protrusion being configured to be received in the second narrow portion of the aerosol-generating article.

[0144] The mouthpiece may be formed from any suitable material. The mouthpiece may be formed from a material forming the aerosol-generating article. The mouthpiece may be formed from the same material as a housing of the aerosol-generating device. The mouthpiece may be formed from a plastics material. The mouthpiece may be formed from a polymeric material or a resin. The mouthpiece may be formed from cardboard or paper.

[0145] The mouthpiece may have any suitable size and shape.

[0146] The mouthpiece may have a height that is the same as the height of the aerosol-generating device. The mouthpiece may have a height that is different to the height of the aerosol-generating device.

[0147] The mouthpiece may have a height greater than or equal to 0.5 millimetres, or greater than or equal to 0.7 millimetres, or greater than or equal to 0.8 millimetres, or greater than or equal to 0.9 millimetres, greater than or equal to 1 millimetre, or greater than or equal to 1 .5 millimetres, or greater than or equal to 2 millimetres, or greater than or equal to 2.5 millimetres, or greater than or equal to 3 millimetres, or greater than or equal to 3.5 millimetres, or greater than or equal to 4 millimetres, or greater than or equal to 4.5 millimetres, or greater than or equal to 5 millimetres, or greater than or equal to 6 millimetres, or greater than or equal to 7 millimetres, or greater than or equal to 8 millimetres, or greater than or equal to 9 millimetres, or greater than or equal to 10 millimetres, or greater than or equal to 12 millimetres, or greater than or equal to 14 millimetres, or greater than or equal to 16 millimetres, or greater than or equal to 18 millimetres, or greater than or equal to 20 millimetres, or greater than or equal to 22 millimetres.

[0148] The mouthpiece may have a height less than or equal to 25 millimetres, or less than or equal to 23 millimetres, or less than or equal to 21 millimetres, or less than or equal to 19 millimetres, or less than or equal to 17 millimetres, or less than or equal to 15 millimetres, or less than or equal to 13 millimetres, or less than or equal to 11 millimetres, or less than or equal to 10 millimetres, or less than or equal to 9 millimetres, or less than or equal to 8 millimetres, or less than or equal to 7 millimetres, or less than or equal to 6 millimetres, or less than or equal to 5.5 millimetres, or less than or equal to 5 millimetres, or less than or equal to 4.5 millimetres, or less than or equal to 4 millimetres, or less than or equal to 3.5 millimetres, or less than or equal to 3 millimetres, or less than or equal to 2.5 millimetres, or less than or equal to 2 millimetres, or less than or equal to 1 millimetre, or less than or equal to 0.9 millimetres, or less than or equal to 0.8 millimetres, or less than or equal to 0.7 millimetres, or less than or equal to 0.6 millimetres, or less than or equal to 0.5 millimetres.

[0149] The mouthpiece may have a height of between 0.3 millimetres and 25 millimetres, or between 0.4 millimetres and 23 millimetres, or between 0.5 millimetres and 21 millimetres, or between 0.6 millimetres and 19 millimetres, or between 0.7 millimetres and 17 millimetres, or between 0.8 millimetres and 15 millimetres, or between 0.9 millimetres and 13 millimetres, or between 1 millimetres and 10 millimetres, or between 1 millimetres and 5 millimetres, or between 1 .2 millimetres and 8 millimetres, or between 1.4 millimetres and 7 millimetres, or between 1.5 millimetres and 5 millimetres, or between 1 .5 millimetres and 4 millimetres, or between 1.5 millimetres and 3 millimetres, or between 1.5 millimetres and 2 millimetres, or between 1.6 millimetres and 6 millimetres, or between 1.7 millimetres and 5 millimetres, or between 2 millimetres and 4.5 millimetres, or between 2.5 millimetres and 4 millimetres, or between 3 millimetres and 3.5 millimetres.

[0150] The mouthpiece may have a height of about 1.7 millimetres, or about 4.5 millimetres, or about 2 millimetres, or about 3 millimetres, or about 4 millimetres.

[0151] The mouthpiece may have a height that is the same as the height of the aerosol-generating device. The mouthpiece may have a height that is different to the height of the aerosol-generating device.

[0152] The mouthpiece may have a width greater than or equal to 5 millimetres, or greater than or equal to 6 millimetres, or greater than or equal to 7 millimetres, or greater than or equal to 8 millimetres, or greater than or equal to 9 millimetres, or greater than or equal to 10 millimetres, or greater than or equal to 11 millimetres, or greater than or equal to 12 millimetres, or greater than or equal to 13 millimetres, or greater than or equal to 14 millimetres, or greater than or equal to 15 millimetres, or greater than or equal to 16 millimetres, or greater than or equal to 17 millimetres, or greater than or equal to 18 millimetres, or greater than or equal to 19 millimetres, or greater than or equal to 20 millimetres.

[0153] The mouthpiece may have a width less than or equal to 25 millimetres, or less than or equal to 24 millimetres, or less than or equal to 23 millimetres, or less than or equal to 22 millimetres, or less than or equal to 21 millimetres, or less than or equal to 20 millimetres, or less than or equal to 19 millimetres, or less than or equal to 18 millimetres, or less than or equal to 17 millimetres, or less than or equal to 16 millimetres, or less than or equal to 15 millimetres, or less than or equal to 14 millimetres, or less than or equal to 13 millimetres, or less than or equal to 12 millimetres, or less than or equal to 11 millimetres, or less than or equal to 10 millimetres. The mouthpiece may have a width of between 5 millimetres and 25 millimetres, or between 6 millimetres and 24 millimetres, or between 7 millimetres and 23 millimetres, or between 8 millimetres and 22 millimetres, or between 9 millimetres and 21 millimetres, or between 10 millimetres and 20 millimetres.

[0154] The mouthpiece may have a length greater than or equal to 10 millimetres, or greater than or equal to 11 millimetres, or greater than or equal to 12 millimetres, or greater than or equal to 13 millimetres, or greater than or equal to 14 millimetres, or greater than or equal to 15 millimetres, or greater than or equal to 16 millimetres, or greater than or equal to 17 millimetres, or greater than or equal to 18 millimetres, or greater than or equal to 19 millimetres, or greater than or equal to 20 millimetres.

[0155] The mouthpiece may have a length less than or equal to 25 millimetres, or less than or equal to 24 millimetres, or less than or equal to 23 millimetres, or less than or equal to 22 millimetres, or less than or equal to 21 millimetres, or less than or equal to 20 millimetres, or less than or equal to 19 millimetres, or less than or equal to 18 millimetres, or less than or equal to 17 millimetres, or less than or equal to 16 millimetres, or less than or equal to 15 millimetres.

[0156] The mouthpiece may have a length of between 10 millimetres and 25 millimetres, or between 11 millimetres and 24 millimetres, or between 12 millimetres and 23 millimetres, or between 13 millimetres and 22 millimetres, or between 14 millimetres and 21 millimetres, or between 15 millimetres and 20 millimetres.

[0157] As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol.

[0158] As used herein, the term “aerosol-forming substrate” may refer to a substrate capable of releasing an aerosol or volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. An aerosol-forming substrate may comprise an aerosol-forming material. An aerosol-forming substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. An aerosol-forming substrate may conveniently be part of an aerosol-generating article or smoking article.

[0159] As used herein, the term “aerosol-generating device” may refer to a device for use with an aerosol-generating article to enable the generation, or release, of an aerosol.

[0160] As used herein, the term “aerosol generating system” refers to a combination of an aerosolgenerating device and one or more aerosol-forming articles for use with the device. An aerosolgenerating system may include additional components, such as a charging unit for recharging an onboard electric power supply in an electrically operated or electric aerosol-generating device.

[0161] 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-forming substrate or aerosol-generating article.

[0162] As used herein with reference to the invention, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.

[0163] As used herein, the term “transverse” refers to a direction extending between the upper external surface and the lower external surface. The transverse direction may also be referred to as the “z- direction”.

[0164] 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 aerosolgenerating article. The lateral direction may also be referred to as the “x-direction”.

[0165] 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”.

[0166] As used herein, the term “height” refers to a dimension of the aerosol-generating article or a component of the aerosol-generating article in the transverse direction. The term “height” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the transverse direction, unless otherwise specified.

[0167] As used herein, the term “length” refers to a dimension of the aerosol-generating article or a component of the aerosol-generating article in the longitudinal direction. The term “length” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the longitudinal direction, unless otherwise specified.

[0168] As used herein, the term “width” refers to a dimension of the aerosol-generating article or a component of the aerosol-generating article in the lateral direction. The term “width” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the lateral direction, unless otherwise specified.

[0169] As used herein with reference to the invention, the terms “proximal”, “distal”, “upstream” and “downstream” are used to describe the relative positions of components, or portions of components, of the aerosol-generating article.

[0170] As used herein, the term “longitudinal” refers to the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. During use, air may be drawn through the aerosol-generating article in the longitudinal direction.

[0171] As used herein, the term “sheet” denotes a laminar element having a width and length substantially greater than the thickness thereof. The width of a sheet may be greater than 10 mm, preferably greater than 20 mm or 30 mm. In certain embodiments, sheets of material for use in forming aerosol-forming substrates as described herein may have a thickness of between 10 pm and about 1000 pm, for example between 10 pm and about 300 pm.

[0172] As used herein, the term “homogenised tobacco material” encompasses any tobacco material formed by the agglomeration of particles of tobacco material. Sheets or webs of homogenised tobacco material are formed by agglomerating particulate tobacco obtained by grinding or otherwise powdering of one or both of tobacco leaf lamina and tobacco leaf stems. In addition, homogenised tobacco material may comprise a minor quantity of one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during the treating, handling, and shipping of tobacco. The sheets of homogenised tobacco material may be produced by casting, extrusion, paper making processes or other any other suitable processes known in the art.

[0173] The term “cast leaf” is used herein to refer to a product made by a casting process that is based on casting a slurry comprising plant particles (for example, clove particles or tobacco particles and clove particles in a mixture) and a binder (for example, guar gum) onto a supportive surface, such as a belt conveyor, drying the slurry and removing the dried sheet from the supportive surface. An example of the casting or cast leaf process is described in, for example, US-A-5,724,998 for making cast leaf tobacco. In a cast leaf process, particulate plant materials are produced by pulverizing, grinding, or comminuting parts of the plant. The particles produced from one or more plants are mixed with a liquid component, typically water, to form a slurry. Other components in the slurry may include fibres, a binder, and an aerosol former. The particulate plant materials may be agglomerated in the presence of the binder. The slurry is cast onto a supportive surface and dried into a sheet of homogenized plant material. Preferably, homogenized plant material used in articles according to the present invention may be produced by casting. Such homogenized plant material may comprise agglomerated particulate plant material.

[0174] As used herein, resistance to draw is expressed with the units of pressure “mm H2O” or “mm WG” or “mm of water gauge” and may be measured in accordance with ISO 6565:2002.

[0175] 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.

[0176] EX1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol generating article comprising: an aerosol-forming substrate, wherein the aerosol-generating article is defined by a length extending in an x-direction, a width extending in a y-direction, and a height extending in a z-direction; wherein a maximum height of the aerosol-generating article is less than each of a maximum width and a maximum length of the aerosol-generating article; wherein the aerosol-generating article comprises a first end portion and a second end portion, the first end portion and the second end portion being separated from each other in the x-direction; and wherein the aerosol-generating article comprises a narrow portion arranged between the first end portion and the second end portion, and wherein at least one of: the narrow portion has a minimum width in the y-direction that is less than a maximum width of the first end portion and less than a maximum width of the second end portion the narrow portion has a minimum height in the z-direction that is less than a maximum height of the first end portion and less than a maximum height of the second end portion; and the narrow portion comprises a notch, or a recess, or a channel, or a groove in an external surface of the aerosol-generating article.

[0177] EX2. An aerosol-generating article according to example EX2, wherein the aerosol generating article comprises: an upper external surface; and a lower external surface, and wherein the upper and lower external surfaces are separated from each other in the z direction.

[0178] EX3. An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol generating article comprising: an upper external surface; a lower external surface; and an aerosol-forming substrate, wherein the aerosol-generating article is defined by a length extending in an x-direction, a width extending in a y-direction, and a height extending in a z-direction; wherein the upper and lower external surfaces are separated from each other in the z direction; wherein a maximum height of the aerosol-generating article is less than each of a maximum width and a maximum length of the aerosol-generating article; wherein the aerosol-generating article comprises a first end portion and a second end portion, the first end portion and the second end portion being separated from each other in the x-direction; and wherein the aerosol-generating article comprises a narrow portion arranged between the first end portion and the second end portion, and wherein at least one of: the narrow portion has a minimum width in the y-direction that is less than a maximum width of the first end portion and less than a maximum width of the second end portion the narrow portion has a minimum height in the z-direction that is less than a maximum height of the first end portion and less than a maximum height of the second end portion; and the narrow portion comprises a notch, or a recess, or a channel, or a groove in an external surface of the aerosol-generating article.

[0179] EX4. An aerosol-generating article according to examples EX2 or EX3, wherein the aerosolgenerating article comprises a cavity disposed between the upper external surface and the lower external surface, wherein the aerosol-forming substrate is arranged in the cavity.

[0180] EX5. An aerosol-generating article according to any one of examples EX1 to EX4, wherein the narrow portion is arranged at the aerosol-forming substrate in the cavity.

[0181] EX6. An aerosol-generating article according to any one of examples EX1 to EX5, wherein the narrow portion is spaced from the aerosol-forming substrate in the x-direction.

[0182] EX7. An aerosol-generating article according to any one of examples EX2 to EX4, and examples EX5 or EX6 when dependent on examples EX2 or EX3, wherein the aerosol-generating article comprises a frame disposed between the upper external surface and the lower external surface, the frame comprising at least one side wall, and wherein the at least one side wall has a minimum height in the z-direction at the narrow portion that is less than a maximum height of the at least one side wall at the first end portion and less than a maximum height of the at least one side wall at the second end portion.

[0183] EX8. An aerosol-generating article according to any one of examples EX2 to EX4, wherein: the aerosol-generating article comprises a cavity disposed between the upper external surface and the lower external surface; the aerosol-forming substrate is arranged in the cavity; the narrow portion is arranged at the aerosol-forming substrate in the cavity; the aerosol-generating article comprises a frame disposed between the upper external surface and the lower external surface, the frame comprising at least one side wall, and wherein the at least one side wall has a minimum height in the z-direction at the narrow portion that is less than a maximum height of the at least one side wall at the first end portion and less than a maximum height of the at least one side wall at the second end portion; and the aerosol-forming substrate has a maximum height in the z-direction that is greater than the minimum height of the at least one side wall at the narrow portion.

[0184] EX9. An aerosol-generating article according to example EX7 or EX8, wherein the frame comprises a first side wall and a second side wall, wherein the first side wall and the second side wall are separated in the y-direction, wherein the first side wall has a minimum height in the z-direction at the narrow portion that is less than a maximum height of the first side wall at the first end portion and less than a maximum height of the first side wall at the second end portion; and wherein the second side wall has a minimum height in the z-direction at the narrow portion that is less than a maximum height of the second side wall at the first end portion and less than a maximum height of the second side wall at the second end portion.

[0185] EX10. An aerosol-generating article according to any one of examples EX1 to EX9, wherein the narrow portion has a length in the x-direction, and wherein the ratio of the length of the narrow portion to the length of the aerosol-generating article is between about 0.05 to about 0.7, or between about 0.05 and about 0.6, or between about 0.05 and about 0.5, or between about 0.05 and about 0.4, or between about 0.05 and about 0.3, or between about 0.05 and about 0.25, or between about 0.1 and about 0.7, or between about 0.2 and about 0.7, or between about 0.3 and about 0.7, or between about 0.4 and about 0.7.

[0186] EX11 . An aerosol-generating article according to any one of examples EX1 to EX10, wherein the narrow portion has a minimum width in the y-direction, and wherein the ratio of the minimum width of the narrow portion to the maximum width of the aerosol-generating article is between about 0.05 and about 0.5, or between about 0.05 and about 0.5, or between about 0.05 and about 0.4, or between about 0.05 and about 0.3, or between about 0.05 and about 0.25.

[0187] EX12. An aerosol-generating article according to any one of examples EX1 to EX11 , wherein the narrow portion has a minimum height in the z-direction, and wherein the ratio of the minimum height of the narrow portion to the maximum height of the aerosol-generating article is between about 0.05 and about 0.5, or between about 0.05 and about 0.5, or between about 0.05 and about 0.4, or between about 0.05 and about 0.3, or between about 0.05 and about 0.25.

[0188] EX13. An aerosol-generating article according to any one of examples EX1 to EX12, wherein the narrow portion comprises a pair of opposing notches, or a pair of opposing recesses, or a pair of opposing channels, or a pair of opposing grooves in opposing external surfaces of the aerosolgenerating article.

[0189] EX14. An aerosol-generating article according to any one of examples EX2 to EX4, or any one of examples EX5 to EX13 when dependent on examples EX2 or EX3, wherein at least one of the upper external surface is substantially planar and the lower external surface is substantially planar, and optionally wherein the planar upper external surface and the planar lower external surface extend substantially in parallel planes.

[0190] EX15. An aerosol-generating system comprising: an aerosol-generating article according to any one of examples EX1 to EX14; and an aerosol-generating device configured to be used with the aerosol-generating article to generate an aerosol.

[0191] EX16. An aerosol-generating system according to example EX15, wherein the aerosolgenerating device comprises an article cavity configured to receive at least a portion of the aerosol- generating article, the portion of the aerosol-generating article including the narrow portion, and wherein the aerosol-generating device further comprises a latch or protrusion, the latch or protrusion being configured to interact with the narrow portion of the aerosol-generating article when the aerosol-generating article is received in the article cavity to releasably retain the aerosol-generating article in the article cavity.

[0192] EX17. An aerosol-generating system according to example EX16, wherein the latch or protrusion of the aerosol-generating device comprises at least one of a resilient latch arm, a detent, and a spring-loaded pin.

[0193] EX18. An aerosol-generating system according to examples EX15 to EX17, wherein the aerosol-generating system further comprises a mouthpiece.

[0194] EX19. An aerosol-generating system according to example EX18, wherein the mouthpiece is removably couplable to the aerosol-generating article.

[0195] EX20. An aerosol-generating system according to examples EX18 or EX19, wherein the mouthpiece comprises an air inlet, an air outlet, and an airflow path extending between the air inlet and the air outlet.

[0196] EX21 . An aerosol-generating system according to example EX20, wherein the mouthpiece is configured such that when the mouthpiece is coupled with the aerosol-generating article, the air inlet of the mouthpiece is aligned with an air outlet of the aerosol-generating article.

[0197] EX22. An aerosol-generating system according to any one of examples EX18 to EX21 , wherein the mouthpiece comprises a cavity configured to receive a portion of the aerosol-generating article.

[0198] EX23. An aerosol-generating system according to example EX22, wherein the cavity of the mouthpiece is configured to receive the narrow portion of the aerosol-generating article, and wherein the mouthpiece further comprises a latch or protrusion that is configured to interact with the narrow portion of the aerosol-generating article to releasably retain the aerosol-generating article in the cavity of the mouthpiece.

[0199] EX24. An aerosol-generating system according to example EX23, wherein the latch or protrusion of the aerosol-generating device comprises at least one of a resilient latch arm, a detent, and a spring-loaded pin.

[0200] Examples will now be further described with reference to the figures in which:

[0201] Figure 1 shows a perspective side view of an aerosol-generating article;

[0202] Figure 2 shows a perspective side view of an aerosol-generating article;

[0203] Figure 3 shows a schematic end view of an aerosol-generating article;

[0204] Figure 4 shows a schematic side view of the aerosol-generating article of Figure 3;

[0205] Figure 5 shows a schematic plan view of the aerosol-generating article of Figure 3; Figure 6 shows a schematic illustration of a corrugated element as used in the aerosolgenerating article of Figure 3;

[0206] Figure 7 shows a perspective view of an aerosol-generating article;

[0207] Figure 8 shows an exploded perspective view of the aerosol-generating article of Figure 7;

[0208] Figure 9 shows a further exploded perspective view of the aerosol-generating article of Figure 7;

[0209] Figure 10 shows a schematic transverse cross-sectional view of the aerosol-generating article of Figure 7;

[0210] Figure 11 shows a schematic longitudinal cross-sectional view of the aerosol-generating article of Figure 7;

[0211] Figure 12 shows an exploded perspective view of an aerosol-generating article;

[0212] Figure 13 shows a schematic transverse cross-sectional view of the aerosol-generating article of Figure 12;

[0213] Figure 14 shows a schematic lateral cross-sectional view of the aerosol-generating article of Figure 12;

[0214] Figure 15 shows a schematic illustration of an aerosol-generating article according to an embodiment of the disclosure;

[0215] Figure 16 shows a schematic plan view of an aerosol-generating article according to an embodiment of the disclosure;

[0216] Figure 17 shows a schematic side view of the aerosol-generating article of Figure 16;

[0217] Figure 18 shows a schematic illustration of an aerosol-generating article according to an embodiment of the disclosure;

[0218] Figure 19 shows a schematic plan view of an aerosol-generating article according to an embodiment of the disclosure;

[0219] Figure 20 shows a schematic side view of the aerosol-generating article of Figure 19;

[0220] Figure 21 shows a schematic side cross-sectional view of an aerosol-generating device, the device being configured to engage with an aerosol-generating article, for example the aerosolgenerating article of any of Figures 1 to 20;

[0221] Figure 22 shows a schematic end view of the aerosol-generating device of Figure 21 ;

[0222] Figure 23 shows a schematic view of an aerosol-generating article (for example, the aerosolgenerating article of any of Figures 1 to 20) in engagement with the aerosol-generating device of Figure 21 ;

[0223] Figure 24 shows a schematic view of an alternative embodiment to that of Figures 21 to 23, showing an aerosol-generating article in engagement with an aerosol-generating device; Figure 25 shows a schematic plan view of an aerosol-generating article according to an embodiment of the disclosure;

[0224] Figure 26 shows a schematic plan view of a mouthpiece of an aerosol-generating system including the aerosol-generating article of Figure 25;

[0225] Figure 27 shows a schematic plan view of the aerosol-generating article of Figure 25 coupled with the mouthpiece of Figure 26;

[0226] Figure 28 shows a plan cross-sectional schematic view of the aerosol-generating device of Figures 21 and 22, which is the aerosol-generating device of the aerosol-generating system including the aerosol-generating article of Figure 25 and the mouthpiece of Figure 26; and

[0227] Figure 29 shows a schematic view of the aerosol-generating article of Figure 25 releasably coupled to the mouthpiece of Figure 26, and releasably coupled to the aerosol-generating device of Figure 28.

[0228] Figure 1 illustrates a perspective side view of an aerosol-generating article 100. The aerosolgenerating article 100 has upper and lower surfaces 110, 120 which are flat or planar.

[0229] The aerosol-generating article 100 comprises an aerosol-forming substrate (not shown). In one embodiment, the aerosol-generating article 100 may consist substantially of aerosol-forming substrate. In another embodiment, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-generating article 100. The aerosol-forming substrate may be enclosed within an interior of the aerosol-generating article 100. The aerosol-forming substrate may at least partially define an exterior of the aerosol-generating article 100; for example, one or both of the upper and lower surfaces 110, 120 may comprise or consist of aerosol-forming substrate.

[0230] A suitable aerosol-forming substrate may be homogenised tobacco.

[0231] The aerosol-generating article 100 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (which may also be referred to as a thickness), extending in a z dimension, of 3.6 millimetres.

[0232] Figure 2 illustrates a perspective side view of an aerosol-generating article 200, the aerosolgenerating article 200 of Figure 2 being a variant of aerosol-generating article 100 of Figure 1. Features in common with aerosol-generating article 100 are referred to with like reference signs but commencing with numeral 2 instead of numeral 1 . An air flow path 230 is defined through the aerosolgenerating article 200 between the upper and lower surfaces 210, 220. The air flow path 230 extends between opposed first and second ends 201 , 202 of the aerosol-generating article 200. The first end 201 may define a distal end of the aerosol-generating article 200, and the second end 202 may define a proximal or mouth end of the aerosol-generating article. The air flow path 230 may be directed towards a mouth of a user to allow a user to inhale aerosol generated in consequence of heating of aerosol-forming substrate of the aerosol-generating article 200. Figures 3, 4, and 5 illustrate respectively an end view, a side view, and a plan view of an aerosol-generating article 300. The aerosol-generating article 300 comprises a planar upper layer 310, a planar lower layer 320, and an intermediate or separation layer 340 arranged between the upper layer 310 and lower layer 320.

[0233] The planar upper layer 310 is formed from a sheet of paper having a thickness of 300 microns. The planar lower layer 320 is formed from a sheet of paper having a thickness of 300 microns. The intermediate layer 340 is a corrugated element formed from a corrugated sheet of aerosol-forming substrate 345. A suitable aerosol-forming substrate may be homogenised tobacco. Thus, the intermediate layer 340 may be formed from a corrugated sheet of homogenised tobacco material 345.

[0234] Figure 6 illustrates the corrugated sheet of aerosol-forming substrate 345. The corrugations have an amplitude 346 of 3 millimetres and a wavelength 347 of 3 millimetres. The sheet of aerosolforming substrate 345 forming the intermediate layer 340 has a thickness of 150 microns.

[0235] Points of intersection 351 , 352 between the upper layer 310 and the intermediate layer 340 and between the lower layer 320 and the intermediate layer 340 comprise an adhesive that joins the respective layers.

[0236] The aerosol-generating article 300 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (or thickness), extending in a z dimension, of 3.6 millimetres.

[0237] Corrugations of the intermediate layer 340 form a first set of longitudinally extending channels 361 that are bounded by the upper layer 310 and the intermediate layer 340, and a second set of longitudinally extending channels 362 bounded by the lower layer 320 and the intermediate layer 340. The first and second sets of longitudinally extending channels 361 , 362 extend through the length of the aerosol-forming substrate between a proximal end 371 of the substrate 345 and a distal end 372 of the substrate 345. The longitudinally extending channels 361 , 362 define an air-flow path through the substrate 345. The air-flow path, therefore, passes over both sides of the sheet of aerosol-forming substrate 345. The porosity of the aerosol-generating article along the air-flow path is in the region of 90 %. This provides a very low resistance to draw (RTD) of less than 5 mm H2O. In fact, the RTD is close to zero.

[0238] The aerosol-forming substrate 345 may be a sheet of any suitable aerosol-forming substrate.

[0239] During use of the aerosol-generating article 300, the aerosol-forming substrate 345 is heated up to cause the aerosol-forming substrate 345 to release volatile compounds, which are then entrained in air drawn into the channels 361 , 362 via the distal end 372. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the channels 361 , 362 of the aerosol-generating article 300 via the proximal end 371 . Figure 7 shows an aerosol-generating article 400. The aerosol-generating article 400 comprises a first planar external layer 424 forming a first planar external surface 421 , a second planar external layer 425 forming a second planar external surface 422, and a frame 450 positioned between the first planar external layer 424 and the second planar external layer 425. The second planar external surface 422 is positioned parallel to the first planar external surface 421 .

[0240] Figures 8 and 9 show exploded views of the aerosol-generating article 400 of Figure 7. The frame 450 circumscribes and at least partially defines a cavity 430. Figure 8 shows the cavity 430 in an empty state. Figure 9 shows the cavity 430 filled with aerosol-forming substrate 440. Figures 10 and 11 show respective transverse and longitudinal cross-sectional views of the aerosol-generating article 400 when the cavity 430 is filled with aerosol-forming substrate 440.

[0241] The first planar external layer 424 and the second planar external layer 425 are made from cigarette paper having a thickness of 35 micrometres and are in physical contact, with and bonded to, the frame 450. The first planar external layer 424 overlies a first end of the cavity 430 and forms a first cavity end wall 431 . The second planar external layer 425 overlies a second end of the cavity 430 and forms a second cavity end wall 432, the second cavity end wall 432 being opposite to the first cavity end wall 431 . That is, the frame 450, the first planar external layer 424 and the second planar external layer 425 collectively define the cavity 430.

[0242] The frame 450 has a hollow cuboid shape and is made from cardboard. The frame 450 defines an aperture extending through the height (also referred to as the thickness) of the frame 450 and the aperture at least partially forms the cavity 430 of the aerosol-generating article 400. The frame 450 comprises a peripheral wall 451 that circumscribes the cavity 430. The peripheral wall 451 includes a front wall 413 and a back wall 414. In more detail, the peripheral wall 451 is defined by an inner transverse surface 452 of the frame 450 and an outer transverse surface 453 of the frame 450. The inner transverse surface 452 of the peripheral wall 451 at least partially defines a perimeter of the cavity 430. The outer transverse surface 453 of the peripheral wall 451 at least partially defines a perimeter of the aerosol-generating article 400. The peripheral wall 451 has a radial thickness measured between the inner transverse surface 452 of the frame 450 and the outer transverse surface 453 of the frame 450 of about 5 millimetres.

[0243] An air inlet 411 and an air outlet 412 are defined by, and extend through, the peripheral wall 451 of the frame 450. More specifically, the air inlet 411 extends through the front wall 413 and the air outlet 412 extends through the back wall 414. The air inlet 411 and the air outlet 412 have an equivalent diameter of 5 millimetres. An airflow passage extends between the air inlet 411 and the air outlet 412 through the cavity 430. As shown in Figures 9-11 , an aerosol-forming substrate 440 is positioned within the cavity 430. The aerosol-forming substrate 440 comprises an aerosol-forming substrate in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis. As shown, the aerosol-forming substrate 440 fills the entire volume of the cavity 430.

[0244] The aerosol-generating article 400 has a cuboid shape and has a height (or thickness) extending in a z dimension, as measured between the first planar external surface 421 and the second planar external surface 422, of 8 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The frame 450 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The cavity 430 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 30 millimetres and a length extending in an x dimension of 50 millimetres.

[0245] Figure 12 shows an aerosol-generating article 500. Features in common with aerosolgenerating article 400 are referred to with like reference signs but commencing with numeral 5 instead of numeral 4. Aerosol-generating article 500 differs from aerosol-generating article 400 in that the aerosol-forming substrate is in the form of a sheet of aerosol-forming substrate 540, in particular a corrugated sheet of homogenised tobacco material. Figures 13 and 14 show respective transverse and lateral cross-section views of the aerosol-generating article 500 of Figure 12.

[0246] As with the aerosol-generating article 400, the aerosol-generating article 500 comprises a first planar external layer 524 forming a first planar external surface 521 , a second planar external layer 525 forming a second planar external surface 522, and a frame 550 positioned between the first planar external layer 524 and the second planar external layer 525. The second planar external surface 522 is positioned parallel to the first planar external surface 521 . An air inlet 511 and an air outlet 512 are defined by, and extend through, a peripheral wall 551 of the frame 550. The frame 550 circumscribes and at least partially defines a cavity 530. The cavity 530 contains the aerosolforming substrate 540, in the form of a corrugated sheet of homogenised tobacco material.

[0247] The corrugated sheet of homogenised tobacco material 540 comprises a plurality of parallel corrugations having a plurality of substantially parallel peaks 543 and troughs 544. The plurality of parallel corrugations are defined by a corrugation profile which, as seen in Figure 13, is sinusoidal. The plurality of parallel corrugations have a corrugation wavelength of about 4.6 millimetres. The corrugation amplitude is approximately the same as the height (or thickness) of the cavity 530, as shown by the peaks 543 and troughs 544 coinciding with a first cavity end wall 531 and a second cavity end wall 532, respectively.

[0248] The plurality of parallel corrugations form a plurality of channels 545 between the sheet of aerosol-forming substrate 540 and the first cavity end wall 531 , and a plurality of channels 546 between the sheet of aerosol-forming substrate 540 and the second cavity end wall 532. The plurality of channels 545, 546 extend in a longitudinal direction of the aerosol-generating article 500 and form at least a portion of the airflow passage extending between the air inlet 511 and the air outlet 512.

[0249] During use of each of the aerosol-generating articles 400, 500, the aerosol-forming substrate 440, 540 is heated up to cause the aerosol-forming substrate 440, 540 to release volatile compounds, which are then entrained in air drawn through the air inlet 411 , 511 into the cavity 430, 530. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the aerosol-generating article 400, 500 through the air outlet 412, 512.

[0250] Figure 15 illustrates an aerosol-generating article 600 according to an embodiment of the disclosure. Figure 15 illustrates a perspective side view of an aerosol-generating article 600, the aerosol-generating article 600 of Figure 15 being a variant of aerosol-generating article 100 of Figure 1 . Features in common with aerosol-generating article 100 are referred to with like reference signs but commencing with numeral 6 instead of numeral 1 .

[0251] The aerosol-generating article 600 comprises an aerosol-forming substrate (not shown). In one embodiment, the aerosol-generating article 600 may consist substantially of aerosol-forming substrate. In another embodiment, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-generating article 600. The aerosol-forming substrate may be enclosed within an interior of the aerosol-generating article 600. The aerosol-forming substrate may at least partially define an exterior of the aerosol-generating article 600; for example, one or both of the upper external surface 610 and lower external surfaces 620 may comprise or consist of aerosolforming substrate.

[0252] A suitable aerosol-forming substrate may be homogenised tobacco.

[0253] The aerosol-generating article 600 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (which may also be referred to as a thickness), extending in a z dimension, of 3.6 millimetres.

[0254] The upper external surface 610 and the lower external surface 620 are separated from each other in the z-direction.

[0255] The aerosol-generating article 600 comprises a first end portion 601 and a second end portion

[0256] 602 separated from each other in the x-direction.

[0257] The aerosol-generating article 600 further comprises a narrow portion 603. The narrow portion

[0258] 603 is arranged between the first end portion 601 and the second end portion 602. In this embodiment, the narrow portion comprises a region of the aerosol-generating article having a reduced width compared to the first end portion 601 and the second end portion 602. As such, a notch is taken out of both sides of the aerosol-generating article 600 to form the narrow portion 603.

[0259] The narrow portion 603 has a length, extending in an x dimension, of 10 millimetres, and a width, extending in a y dimension of 9 millimetres, such that each notch taken out of a side of the aerosol-generating article has a width of 3 millimetres. The notch at each side of the aerosolgenerating article extends through the height of the aerosol-generating article 600.

[0260] In this embodiment, the narrow portion 603 is arranged centrally in an x dimension of the aerosol-generating article 600.

[0261] Figures 16 and 17 illustrate an aerosol-generating article 700 according to an embodiment of the disclosure. Figure 16 illustrates a plan view of the aerosol-generating article 700, and Figure 17 illustrates a side view of the aerosol-generating article 700, the aerosol-generating article 700 being a variant of aerosol-generating article 600 of Figure 15. Features in common with aerosol-generating article 600 are referred to with like reference signs but commencing with numeral 7 instead of numeral 6.

[0262] The aerosol-generating article 700 comprises a first end portion 701 and a second end portion

[0263] 702 separated from each other in the x-direction. The aerosol-generating article 700 comprises an aerosol-forming substrate 740 that is enclosed within an interior of the aerosol-generating article 700, and arranged in the second end portion 702.

[0264] The aerosol-generating article 700 further comprises a narrow portion 703. The narrow portion

[0265] 703 is arranged between the first end portion 701 and the second end portion 702. In this embodiment, the narrow portion comprises a region of the aerosol-generating article having a reduced width compared to the first end portion 701 and the second end portion 702. As such, a notch is taken out of both sides of the aerosol-generating article 700 to form the narrow portion 703. In this embodiment, the intersections between the narrow portion 703 and the first end portion 701 and the second end portion 702 is bevelled, or curved, such that a sharp corner is not defined at the intersections.

[0266] The aerosol-generating article 700 has a length, extending in an x dimension, of 85 millimetres, a width, WA, extending in a y dimension, of 30 millimetres, and a height, HA, (which may also be referred to as a thickness), extending in a z dimension, of 11 millimetres.

[0267] The narrow portion 703 has a length, extending in an x dimension, of 4 millimetres, and a minimum width. WN, extending in a y dimension, of 20 millimetres, such that each notch taken out of a side of the aerosol-generating article has a width of 5 millimetres. The notch at each side of the aerosol-generating article 700 extends through the height of the aerosol-generating article 700.

[0268] In this embodiment, the narrow portion 703 is arranged towards a first end of the aerosolgenerating article 700, in the x dimension, such that the first end portion 701 has a length that is smaller than the second end portion 702. The first end portion 701 has a length of 10 millimetres, and the second end portion 702 has a length of 71 millimetres.

[0269] In this embodiment, the aerosol-generating article 700 is configured such that when the aerosol-generating article 700 is received in a cavity of an aerosol-generating device, the second end portion 702 and the narrow portion 703 are received in the cavity of the aerosol-generating device, and the first end portion 701 extends out of the cavity. The first end portion 701 forms a mouthpiece of the aerosol-generating article 700 for a user, and may also be grasped by the fingers of a user to remove the aerosol-generating article 700 from the cavity of an aerosol-generating device. In this embodiment, the narrow portion of the aerosol-generating article 700 is configured to interact with a latch or protrusion of the aerosol-generating device when the aerosol-generating article 700 is received in the cavity of the aerosol-generating device, to help to retain the aerosol-generating article 700 in the cavity of the aerosol-generating device.

[0270] It will also be appreciated that in some embodiments, the aerosol-generating article 700 may be configured such that when the aerosol-generating article 700 is received in a cavity of an aerosolgenerating device, the second end portion 703 of the aerosol-generating article 700 is received in the cavity of the aerosol-generating device, and the narrow portion 703 and the first end portion 701 extend out of the cavity. In these embodiments, the narrow portion may provide a region of the aerosol-generating article 700 that a user can grasp with their fingers to facilitate removal of the aerosol-generating article 700 from the cavity.

[0271] Figure 18 illustrates an aerosol-generating article 800 according to an embodiment of the disclosure. Figure 18 illustrates a perspective side view of an aerosol-generating article 800, the aerosol-generating article 800 of Figure 18 being a variant of aerosol-generating article 600 of Figure 15. Features in common with aerosol-generating article 600 are referred to with like reference signs but commencing with numeral 8 instead of numeral 6.

[0272] The aerosol-generating article 800 comprises an aerosol-forming substrate (not shown). A suitable aerosol-forming substrate may be homogenised tobacco.

[0273] The aerosol-generating article 800 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (which may also be referred to as a thickness), extending in a z dimension, of 3.6 millimetres.

[0274] The upper external surface 610 and the lower external surface 620 are separated from each other in the z-direction.

[0275] The aerosol-generating article 800 comprises a first end portion 801 and a second end portion

[0276] 802 separated from each other in the x-direction.

[0277] The aerosol-generating article 800 further comprises a narrow portion 803. The narrow portion

[0278] 803 is arranged between the first end portion 801 and the second end portion 802. In this embodiment, the narrow portion comprises a region of the aerosol-generating article 800 having a reduced height compared to the first end portion 801 and the second end portion 802. As such, a channel is formed in each of the upper external surface 810 and the lower external surface 820, at the same position in the x dimension, to form the narrow portion 803 with the reduced height. The narrow portion 803 has a length, extending in an x dimension, of 10 millimetres, and a height, extending in a z dimension, of 2.6 millimetres, such that each channel has a height of 0.5 millimetres. The channels in the upper external surface 810 and the lower external surface 820 extend the entire width of the aerosol-generating article 800.

[0279] In this embodiment, the narrow portion 803 is arranged centrally in an x dimension of the aerosol-generating article 800.

[0280] Figures 19 and 20 illustrate an aerosol-generating article 900 according to an embodiment of the disclosure. Figure 19 illustrates a plan view of the aerosol-generating article 900, and Figure 20 illustrates a side view of the aerosol-generating article 900, the aerosol-generating article 900 being a variant of aerosol-generating article 800 of Figure 18. Features in common with aerosol-generating article 800 are referred to with like reference signs but commencing with numeral 9 instead of numeral 8.

[0281] The aerosol-generating article 900 comprises a first end portion 901 and a second end portion 902 separated from each other in the x-direction. The aerosol-generating article 900 further comprises a narrow portion 903. The narrow portion 903 is arranged between the first end portion 901 and the second end portion 902. The aerosol-generating article 900 comprises an aerosolforming substrate 940 that is enclosed within an interior of the aerosol-generating article 900, and arranged in the narrow portion 903.

[0282] In this embodiment, the narrow portion 903 comprises a region of the aerosol-generating article 900 having a reduced height compared to the first end portion 901 and the second end portion 902, and a reduced width compared to the first end portion 901 and the second end portion 902. As such, a channel circumscribes the aerosol-generating article 900, and is formed in the upper external surface 910, the lower external surface 920, and both sides of the aerosol-generating article 900. In this embodiment, the intersections between the narrow portion 903 and the first end portion 901 and the second end portion 902 is bevelled, or curved, such that a sharp corner is not defined at the intersections.

[0283] The aerosol-generating article 900 has a length, extending in an x dimension, of 85 millimetres, a width, WA, extending in a y dimension, of 30 millimetres, and a height, HA, (which may also be referred to as a thickness), extending in a z dimension, of 11 millimetres.

[0284] The narrow portion 903 has a length, extending in an x dimension, of 4 millimetres, a minimum width, extending in a y dimension, of 24 millimetres, such that the channel formed in each side of the aerosol-generating article has a width of 3 millimetres, and a height, HN, extending in a z dimension, of 5 millimetres, such that the channel formed in each of the upper external surface 910, and the lower external surface 920 has a height of 3 millimetres. In this embodiment, the narrow portion 903 is arranged towards a first end of the aerosolgenerating article 900, in the x dimension, such that the first end portion 900 has a length that is smaller than the second end portion 902. The first end portion 901 has a length of 10 millimetres, and the second end portion 902 has a length of 71 millimetres.

[0285] In this embodiment, the aerosol-generating article 900 is configured such that when the aerosol-generating article 900 is received in a cavity of an aerosol-generating device, the entire aerosol-generating article 900 is received in the cavity of the aerosol-generating device. In this embodiment, the narrow portion 903 of the aerosol-generating article 900 is configured to interact with a latch or protrusion of the aerosol-generating device when the aerosol-generating article 900 is received in the cavity of the aerosol-generating device, to help to retain the aerosol-generating article 900 in the cavity of the aerosol-generating device. In addition, the aerosol-forming substrate 940 is arranged at the narrow portion 903 to reduce the presence of air gaps between the aerosol-forming substrate 940 and the inner surfaces of the cavity in the aerosol-generating article 900 in which the aerosol-forming substrate 940 is arranged. This promotes airflow through the aerosol-forming substrate, rather than around the outside of the aerosol-forming substrate, improving aerosol delivery from the aerosol-generating article 900.

[0286] Figures 21 and 22 illustrate an aerosol-generating device 6000 configured for use with an aerosol-generating article 600 comprising or consisting of aerosol-forming substrate 640. The device 6000 is an elongate aerosol-generating device extending between a proximal end 6001 and a distal end 6002. The device 6000 comprises a battery 6010, a controller 6020 and a heater 6030 located within a housing 6040. The controller 6020 controls supply of power from the battery 6010 to the heater 6030. A cavity 6050 is defined in the device 6000, the cavity 6050 having an opening 6051 defined in the proximal end 6001 of the device. The opening 6051 is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosol-generating article 600. The cavity 6050 comprises an upper planar surface 6052 and a lower planar surface 6053. The heater 6030 is located in the lower planar surface 6053 to heat a lower surface of the aerosolgenerating article 600 inserted into the cavity 6050. An air-flow path is configured to allow air to flow into the cavity 6050 from outside the device 6000.

[0287] As shown in Figure 22, the aerosol-generating device 6000 further comprises latches 6054, in the form of rubber protrusions, extending into the cavity 6050. The latches 6054 are configured to engage with a narrow portion of an aerosol-generating article received in the cavity 6050, to help retain the aerosol-generating article in the cavity 6050. The latches 6054 are configured to deform or deflect on insertion of the aerosol-generating article into the cavity 6050, and to be received in the notch or channel of the narrow portion of the aerosol-generating article when the aerosol-generating article is fully received in the cavity 6050. Similarly, the latches 6054 are configured to deform or deflect when a user pulls the aerosol-generating article in the x dimension, out of the cavity 6050. The latches 6054 are configured to prevent the aerosol-generating article from falling out of the cavity 6050 under its own weight, but not to prevent a user from pulling the aerosol-generating article out of the cavity 6050.

[0288] Figure 23 illustrates the device 6000 of Figure 21 in engagement with the aerosol-generating article 600. There is little tolerance between outer surfaces of the aerosol-generating article 600 and the internal surfaces of the cavity 6050. Thus, there is a snug fit between the aerosol-generating article 600 and the device 6000. As the RTD of the aerosol-generating article 600 is negligible, the RTD of the system formed by the combination of aerosol-generating article 600 and aerosolgenerating device 6000 is controlled by the air-flow path defined within the device. When a user has inserted the aerosol-generating article 600 into the cavity 6050, the device 6000 can be operated. The heater 6030 heats a lower surface of the aerosol-generating article 600, and as a result the aerosol-forming substrate 640 of the aerosol-generating article 600 is heated. Volatile components of the aerosol-forming substrate 640 are evaporated and condense in longitudinal air-flow channels defined within the aerosol-generating article 600 to form an aerosol. The user inhales the aerosol by drawing on the proximal end 601 of the aerosol-generating article 600. Once the aerosol-forming substrate 640 of the aerosol-generating article 600 has been depleted of volatile components, the aerosol-generating article is removed from the cavity 6050 of the device 6000 and disposed of. The aerosol-generating article 600 may be any one of the aerosol-generating articles 100, 200, 300, 400, 500 previously described or any other aerosol-generating article of the present disclosure.

[0289] Although Figure 23 shows part of the aerosol-generating article 600 extending outside of the aerosol-generating device 6000, in other embodiments the entirety of an aerosol-generating article may be wholly enclosed within an aerosol-generating device. By way of example, Figure 24 illustrates an alternative embodiment to that of Figure 23, with like features referred to by the same reference numbers but with the addition of a prime symbol ’.

[0290] As with the aerosol-generating article 600, the aerosol-generating article 600’ comprises an aerosol-forming substrate 640’ and a proximal end 601 ’. As with the aerosol-generating device 6000, the aerosol-generating device 6000’ is an elongate aerosol-generating device extending between a proximal end 6001 ’ and a distal end 6002’. The aerosol-generating device 6000’ comprises a battery 601 O’, a controller 6020’ and a heater 6030’ located within a housing 6040’. A cavity 6050’ is defined in the device 6000’, the cavity 6050’ having an opening 605T defined in the proximal end 600T. of the device. The opening 605T is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosol-generating article 600’. The cavity 6050’ comprises an upper planar surface 6052’ and a lower planar surface 6053’. The heater 6030’ is located in the lower planar surface 6053’ to heat a lower surface of the aerosol-generating article 600’ inserted into the cavity 6050’. An air-flow path is configured to allow air to flow into the cavity 6050’ from outside the device 6000’.

[0291] For the alternative embodiment of Figure 24, the entirety of aerosol-generating article 600’ is enclosed within the interior of the cavity 6050’ of aerosol-generating device 6000’. Accordingly, the first end portion 601 ’ is received in the cavity 6050’ when the aerosol-generating article 600’ is received in the cavity 6050’.

[0292] Figures 25, 26, 27, 28, and 29 show an aerosol-generating system according to an embodiment of the disclosure. The aerosol-generating system comprises an aerosol-generating article 1000, a mouthpiece 7000, and an aerosol-generating device 6000.

[0293] Figure 25 illustrates the aerosol-generating article 1000 of the aerosol-generating system. Figure 25 illustrates a plan view of the aerosol-generating article 1000, the aerosol-generating article 1000 being a variant of aerosol-generating article 600 of Figure 15. Features in common with aerosol-generating article 600 are referred to with like reference signs but commencing with numeral 10 instead of numeral 6.

[0294] The aerosol-generating article 1000 comprises a first end portion 1001 and a second end portion 1002 separated from each other in the x-direction. The aerosol-generating article 1000 comprises an aerosol-forming substrate 1040 that is enclosed within an interior of the aerosolgenerating article 1000, and arranged substantially centrally between the first end portion 1001 and the second end portion 1002.

[0295] The aerosol-generating article 1000 further comprises a first narrow portion 1003, and a second narrow portion 1004.

[0296] The first narrow portion 1003 is arranged between the first end portion 1001 and the second narrow portion 1004. In this embodiment, the first narrow portion 1003 comprises a region of the aerosol-generating article 1000 having a reduced width compared to the first end portion 1001 and the second end portion 1002. As such, a notch is taken out of both sides of the aerosol-generating article 1000 to form the first narrow portion 1003. In this embodiment, the first narrow portion 1003 has a similar form to the narrow portion 703 of the aerosol-generating article of Figure 15, with bevelled, or curved corners. The notch at each side of the aerosol-generating article 1000 extends through the height of the aerosol-generating article 1000.

[0297] The second narrow portion 1004 is arranged between the second end portion 1002 and the first narrow portion 1003. In this embodiment, the second narrow portion 1004 comprises a region of the aerosol-generating article 1000 having a reduced width compared to the first end portion 1001 and the second end portion 1002. As such, a notch is taken out of both sides of the aerosolgenerating article 1000 to form the second narrow portion 1004. In this embodiment, the second narrow portion 1004 has a similar form to the first narrow portion 1003. The notch at each side of the aerosol-generating article 1000 extends through the height of the aerosol-generating article 1000.

[0298] Figure 26 illustrates the mouthpiece 7000 of the aerosol-generating system. The mouthpiece 7000 is an attachment configured to fit over an end of the aerosol-generating article 1000 so that a user is not required to touch the aerosol-generating article 1000 to remove the aerosol-generating article 100 from the aerosol-generating device 6000 after use.

[0299] The mouthpiece 7000 is an elongate structure extending between a proximal end 7001 and a distal end 7002. The mouthpiece 7000 comprises a housing 7003, which in this embodiment is formed from a plastics material, such as polyetheretherketone (PEEK). The mouthpiece housing

[0300] 7003 defines a cavity 7004 at the distal end 7002. The cavity 7004 of the mouthpiece 7000 is configured to receive a portion of the aerosol-generating article 1000 comprising the first narrow portion 1003, and not comprising the aerosol-forming substrate 1040. The mouthpiece 7000 further comprises an airflow path 7005 extending between an air inlet 7006 at a proximal end of the cavity

[0301] 7004 and an air outlet 7007 at the proximal end 7001 of the mouthpiece 7000. The air inlet 7006 of the mouthpiece 7000 is arranged to align with an air outlet of the aerosol-generating article 6000 when the portion of the aerosol-generating article 6000 is received in the cavity 7004 of the mouthpiece 7000.

[0302] The mouthpiece 7000 further comprises latches 7008, in the form of protrusions extending into the cavity 7004, formed by the mouthpiece housing 7003. The latches 7008 are configured to engage with the first narrow portion 1003 of the aerosol-generating article 1000 when the portion of the aerosol-generating article 1000 is received in the cavity 7004 of the mouthpiece 7000, to help retain the aerosol-generating article 6000 in the cavity 7004. The latches 7008 are configured to deform or deflect on insertion of the aerosol-generating article 6000 into the cavity 7004, and to be received in the notch or channel of the first narrow portion 1003 of the aerosol-generating article 1000 when the aerosol-generating article 1000 is fully received in the cavity 7004. Similarly, the latches 7008 are configured to deform or deflect when a user pulls the aerosol-generating article 1000 out of the cavity 7004. The latches 7008 are configured to prevent the aerosol-generating article 1000 from falling out of the cavity 7004 under its own weight, but not to prevent a user from pulling the aerosolgenerating article 1000 out of the cavity 7004 of the mouthpiece 7000.

[0303] Figure 27 illustrates the portion of the aerosol-generating article 1000 received in the cavity 7004 of the mouthpiece 7000, with the latches 7008 received in the notches or channels of the first narrow portion 1003 of the aerosol-generating article 1000.

[0304] Figure 28 shows a plan cross-sectional view of the aerosol-generating device 6000 of the aerosol-generating system including the aerosol-generating article 1000 and the mouthpiece 7000. The aerosol-generating device 6000 is the aerosol-generating device of Figures 21 and 22, described above, and as such, comprises all of the features of the aerosol-generating device 6000 of Figures 21 and 22 described above. In particular, Figure 28 shows the latches 6054 of the aerosol-generating device 6000 in the cavity 6050 of the aerosol-generating device 6000.

[0305] Figure 29 shows the aerosol-generating article 1000 received in the cavity 7004 of the mouthpiece 7000 and the aerosol-generating article 1000 received in the cavity 6050 of the aerosolgenerating device 6000. As such, Figure 29 shows the aerosol-generating system in a use configuration. In the use configuration, the latches 7008 of the mouthpiece 7000 are received in the notches or channels of the first narrow portion 1003 of the aerosol-generating article 1000, and the latches 6054 of the aerosol-generating device 6000 are received in the notches or channels of the second narrow portion 1004 of the aerosol-generating article 1000.

[0306] It will be appreciated that although in this embodiment of the aerosol-generating system, the aerosol-generating article 1000 has two narrow portions, a first narrow portion 1003 and a second narrow portion 1004 in other embodiments, the aerosol-generating article may have a different number of narrow portions. In some embodiments, the aerosol-generating article may have more than two narrow portions. In some embodiments, the aerosol-generating article may have one narrow portion. In some embodiments where the aerosol-generating article has one narrow portion, the narrow portion may be configured to be received in the cavity of the aerosol-generating device, and in these embodiments the mouthpiece may not comprise latches or protrusions. In some embodiments where the aerosol-generating article has one narrow portion, the narrow portion may be configured to be received in the cavity of the mouthpiece, and in these embodiments the aerosolgenerating device may not comprise latches or protrusions.

[0307] 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. The terms “in which” and “wherein” are used synonymously through this specification.

Claims

CLAIMS1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol generating article comprising: an upper external surface; a lower external surface; and an aerosol-forming substrate, wherein the aerosol-generating article is defined by a length extending in an x-direction, a width extending in a y-direction, and a height extending in a z-direction; wherein the upper and lower external surfaces are separated from each other in the z direction; wherein a maximum height of the aerosol-generating article is less than each of a maximum width and a maximum length of the aerosol-generating article; wherein the aerosol-generating article comprises a first end portion and a second end portion, the first end portion and the second end portion being separated from each other in the x- direction; and wherein the aerosol-generating article comprises a narrow portion arranged between the first end portion and the second end portion, the narrow portion having at least one of: a minimum width in the y-direction that is less than a maximum width of the first end portion and less than a maximum width of the second end portion; and a minimum height in the z-direction that is less than a maximum height of the first end portion and less than a maximum height of the second end portion.

2. An aerosol-generating article according to claim 1 , wherein the maximum height of the aerosol-generating article at the narrow portion is between 1 millimetres and 10 millimetres.

3. An aerosol-generating article according to claim 1 or claim 2, wherein the aerosolgenerating article comprises a cavity disposed between the upper external surface and the lower external surface, wherein the aerosol-forming substrate is arranged in the cavity4. An aerosol-generating article according to any one of claims 1 to 3, wherein the narrow portion is arranged at the aerosol-forming substrate in the cavity or wherein the narrow portion is spaced from the aerosol-forming substrate in the x-direction.

5. An aerosol-generating article according to any one of claims 1 to 4, wherein the aerosolgenerating article comprises a frame disposed between the upper external surface and the lower external surface, the frame comprising at least one side wall, and wherein the at least one side wall has a minimum height in the z-direction at the narrow portion that is less than a maximum height of the at least one side wall at the first end portion and less than a maximum height of the at least one side wall at the second end portion.

6. An aerosol-generating article according to claim 1 or claim 2, wherein: the aerosol-generating article comprises a cavity disposed between the upper external surface and the lower external surface; the aerosol-forming substrate is arranged in the cavity; the narrow portion is arranged at the aerosol-forming substrate in the cavity; the aerosol-generating article comprises a frame disposed between the upper external surface and the lower external surface, the frame comprising at least one side wall, and wherein the at least one side wall has a minimum height in the z-direction at the narrow portion that is less than a maximum height of the at least one side wall at the first end portion and less than a maximum height of the at least one side wall at the second end portion; and the aerosol-forming substrate has a maximum height in the z-direction that is greater than the minimum height of the at least one side wall at the narrow portion.

7. An aerosol-generating article according to claim 5 or claim 6, wherein the frame comprises a first side wall and a second side wall, wherein the first side wall and the second side wall are separated in the y-direction, wherein the first side wall has a minimum height in the z-direction at the narrow portion that is less than a maximum height of the first side wall at the first end portion and less than a maximum height of the first side wall at the second end portion; and wherein the second side wall has a minimum height in the z-direction at the narrow portion that is less than a maximum height of the second side wall at the first end portion and less than a maximum height of the second side wall at the second end portion.

8. An aerosol-generating article according to any one of claims 1 to 7, wherein the narrow portion has a length in the x-direction, and wherein the ratio of the length of the narrow portion to the length of the aerosol-generating article is between about 0.05 to about 0.7, or between about 0.05 and about 0.6, or between about 0.05 and about 0.5, or between about 0.05 and about 0.4, or between about 0.05 and about 0.3, or between about 0.05 and about 0.25, or between about 0.1and about 0.7, or between about 0.2 and about 0.7, or between about 0.3 and about 0.7, or between about 0.4 and about 0.7.

9. An aerosol-generating article according to any one of claims 1 to 8, wherein the narrow portion has a minimum width in the y-direction, and wherein the ratio of the minimum width of the narrow portion to the maximum width of the aerosol-generating article is between about 0.05 and about 0.5, or between about 0.05 and about 0.5, or between about 0.05 and about 0.4, or between about 0.05 and about 0.3, or between about 0.05 and about 0.25.

10. An aerosol-generating article according to any one of claims 1 to 9, wherein the narrow portion has a minimum height in the z-direction, and wherein the ratio of the minimum height of the narrow portion to the maximum height of the aerosol-generating article is between about 0.05 and about 0.5, or between about 0.05 and about 0.5, or between about 0.05 and about 0.4, or between about 0.05 and about 0.3, or between about 0.05 and about 0.25.11 . An aerosol-generating article according to any one of claims 1 to 10, wherein the narrow portion comprises a notch, or a recess, or a channel, or a groove in an external surface of the aerosol-generating article, and optionally wherein the narrow portion comprises a pair of opposing notches, or a pair of opposing recesses, or a pair of opposing channels, or a pair of opposing grooves in opposing external surfaces of the aerosol-generating article.

12. An aerosol-generating article according to any one of claims 1 to 11 , wherein at least one of the upper external surface is substantially planar and the lower external surface is substantially planar, and optionally wherein the planar upper external surface and the planar lower external surface extend substantially in parallel planes.

13. An aerosol-generating system comprising: an aerosol-generating article as claimed in any one of claims 1 to 12; and an aerosol-generating device configured to be used with the aerosol-generating article to generate an aerosol.

14. An aerosol-generating system according to claim 13, wherein the aerosol-generating device comprises an article cavity configured to receive at least a portion of the aerosol-generating article, the portion of the aerosol-generating article including the narrow portion, and wherein the aerosolgenerating device further comprises a latch or protrusion, the latch or protrusion being configured tointeract with the narrow portion of the aerosol-generating article when the aerosol-generating article is received in the article cavity to releasably retain the aerosol-generating article in the article cavity.

15. An aerosol-generating system according to claim 14, wherein the latch or protrusion of the aerosol-generating device comprises at least one of a resilient latch arm, a detent, and a spring- loaded pin.

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