Aerosol-generating article, device, and system

Abstract

An aerosol-generating system comprises an aerosol-generating article (20AV) and an aerosol-generating device configured to engage with the aerosol-generating article (20AV) to form an inhalable aerosol. The aerosol-generating article (20AV) has an article body, an airflow path being defined through the article body between an article airflow inlet (24AV) and an article airflow outlet (25AV). The aerosol- generating device comprises a cavity dimensioned to receive the aerosol-generating article, the cavity comprising a cavity airflow inlet. The cavity airflow inlet is configured to align with the article airflow inlet (24AV) when the aerosol-generating article (20AV) is received within the cavity, such that air flowing through the cavity inlet flows through the article inlet (24AV) into the aerosol-generating article (20AV).

Description

[0001] AEROSOL-GENERATING ARTICLE, DEVICE, AND SYSTEM

[0002] The present disclosure generally relates to aerosol-generating articles comprising an aerosolforming substrate. The disclosure also relates to methods of manufacturing such articles, aerosolgenerating devices for use with such articles and aerosol-generating systems comprising aerosolgenerating articles and aerosol-generating devices. The disclosure also relates to packaging for aerosolgenerating articles.

[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 aerosol-generating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-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 aerosolgenerating 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 objective of the present disclosure to provide an aerosol-generating article that can be manufactured relatively efficiently and cheaply. It is also an objective of the present disclosure to provide aerosol-generating devices and aerosol-generating systems optimised for use with such aerosolgenerating articles.

[0006] According to the present disclosure, there may be provided an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device configured to engage with the aerosolgenerating article to form an inhalable aerosol, the aerosol-generating article may have an article body, an airflow path being defined through the article body between an article airflow inlet and an article airflow outlet. The aerosol-generating device may comprise a cavity dimensioned to receive the aerosol-generating article, the cavity comprising a cavity airflow inlet. The cavity airflow inlet may be configured to align with the article airflow inlet when the aerosol-generating article is received within the cavity, such that air flowing through the cavity inlet flows through the article inlet into the aerosol-generating article.

[0007] According to the present disclosure, there may be provided an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device configured to engage with the aerosolgenerating article to form an inhalable aerosol. The aerosol-generating article may have an article body defined by a first article dimension, a second article dimension perpendicular to the first article dimension, and an article thickness perpendicular to both the first article dimension and the second article dimension. The aerosol-generating device may comprise a closable cavity having a minimal cavity length extending, when the cavity is closed, between a cavity airflow inlet and a cavity airflow outlet. The cavity may be further defined by a cavity width perpendicular to the minimal cavity length, extending between a left side wall of the cavity and a right side wall of the cavity, and a cavity height perpendicular to both the cavity depth and cavity width, the cavity height extending between a lower wall of the cavity and an upper wall of the cavity. The cavity may be accessible via a closable opening having a width and a height. The aerosol-generating article is preferably configured to be inserted into the cavity in the direction of its first article dimension, preferably in which the cavity width is no more than 30% greater, for example no more than 15% greater, or no more than 10 % greater, or no more than 5% greater, than the second article dimension. Preferably, the minimal cavity length, when the cavity is closed, is no more than 10% greater, for example no more than 5% greater, or nor more than 2% greater, or no greater, than the first article dimension. The cavity width may be at least 5% greater in magnitude than the second article dimension. The minimal cavity length, when the cavity is closed, may be between 1 % greater and 5% lesser in magnitude than the first article dimension.

[0008] According to the present disclosure, there may be provided an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device configured to engage with the aerosolgenerating article to form an inhalable aerosol, in which; the aerosol-generating article has an article body, an airflow path being defined through the article body between an article airflow inlet and an article airflow outlet; in which the aerosol-generating device comprises a cavity dimensioned to receive the aerosolgenerating article, the cavity comprising a cavity airflow inlet; in which the cavity airflow inlet is configured to align with the article airflow inlet when the aerosol-generating article is received within the cavity, such that air flowing through the cavity inlet flows through the article inlet into the aerosol-generating article.

[0009] By providing a close match between the dimensions of the cavity and the dimensions of the article, the article may be located securely in an appropriate position to be heated. Further, the close match in dimensions may allow a good fluidic connection between the device and the article, to optimise aerosoldelivery to a user. A close match in dimensions may also facilitate heat transfer between heaters of the device and the article, particularly if the close tolerance ensures that heaters of the device are brought into physical contact with the article.

[0010] The cavity has a minimum length, a minimum thickness, and a minimum width. The article also has a length, a width, and a thickness. Preferably, each of the minimum length, a minimum thickness, and a minimum width of the cavity is no more than 30% greater than the corresponding length, width, and thickness of the article. Preferably, each of the minimum length, a minimum thickness, and a minimum width of the cavity is no more than 15% greater than the corresponding length, width, and thickness of the article. Preferably, each of the minimum length, a minimum thickness, and a minimum width of the cavity is no more than 10% greater than the corresponding length, width, and thickness of the article. Preferably, each of the minimum length, a minimum thickness, and a minimum width of the cavity is no more than 5% greater than the corresponding length, width, and thickness of the article.

[0011] Preferably, at least one of the minimum length, a minimum thickness, and a minimum width of the cavity is equal to or, lesser in magnitude than the corresponding length, width, and thickness of the article. Preferably, at least one of the minimum length, a minimum thickness, and a minimum width of the cavity is between 1 % and 20% lesser in magnitude than the corresponding length, width, and thickness of the article. Preferably, at least one of the minimum length, a minimum thickness, and a minimum width of the cavity is between 2% and 10% lesser in magnitude than the corresponding length, width, and thickness of the article. Preferably, at least one of the minimum length, a minimum thickness, and a minimum width of the cavity is between 3% and 5% lesser in magnitude than the corresponding length, width, and thickness of the article.

[0012] Preferably, at least two of the minimum length, a minimum thickness, and a minimum width of the cavity is equal to or, lesser in magnitude than the corresponding length, width, and thickness of the article. Preferably, at least two of the minimum length, a minimum thickness, and a minimum width of the cavity is between 1 % and 20% lesser in magnitude than the corresponding length, width, and thickness of the article. Preferably, at least two of the minimum length, a minimum thickness, and a minimum width of the cavity is between 2% and 10% lesser in magnitude than the corresponding length, width, and thickness of the article. Preferably, at least two of the minimum length, a minimum thickness, and a minimum width of the cavity is between 3% and 5% lesser in magnitude than the corresponding length, width, and thickness of the article.

[0013] Advantageously, if one of the minimum width of the cavity or minimum thickness of the cavity is equal to or lesser in magnitude than a corresponding width and thickness of the article, the other of the minimum width of the cavity and minimum thickness of the cavity is greater in magnitude than the corresponding width or thickness of the article. This may facilitate insertion and extraction of the article into the device.

[0014] In some examples, each of the minimum length, a minimum thickness, and a minimum width of the cavity may be equal to or, lesser in magnitude than the corresponding length, width, and thickness of the article. For example, each of the minimum length, a minimum thickness, and a minimum width of the cavity may be between 1 % and 20% lesser in magnitude than the corresponding length, width, and thickness of the article. For example, each of the minimum length, a minimum thickness, and a minimum width of the cavity may be between 2% and 10% lesser in magnitude than the corresponding length, width, and thickness of the article. For example, each of the minimum length, a minimum thickness, and a minimum width of the cavity may be between 3% and 5% lesser in magnitude than the corresponding length, width, and thickness of the article.

[0015] The aerosol-generating device may comprise a main air inlet for receiving an airflow from the outside into an upstream airflow path and a downstream airflow path for delivering the inhalable aerosol to an aerosol outlet. The cavity airflow inlet may be or comprises an upstream fluidic interconnection element configured to fluidically interconnect the upstream airflow path with the aerosol-generating article. The cavity airflow outlet may be or comprise a downstream fluidic interconnection configured to fluidically interconnect the aerosol-generating article with the downstream airflow path. The cavity of the device may be termed a heating chamber.

[0016] Thus, the aerosol-generating system may comprise an aerosol-generating article and an aerosolgenerating device configured to engage with the aerosol-generating article to form an inhalable aerosol, the aerosol-generating device comprising a main air inlet for receiving an airflow from the outside into an upstream airflow path and a downstream airflow path for delivering the inhalable aerosol to an aerosol outlet, in which; the aerosol-generating article has an article body, an airflow path being defined through the article body between an article airflow inlet and an article airflow outlet; in which the aerosol-generating device comprises a heating chamber dimensioned to receive the aerosol-generating article, the heating chamber comprising an upstream fluidic interconnection element configured to fluidically interconnect the upstream airflow path with the aerosol-generating article and a downstream fluidic interconnection configured to fluidically interconnect the aerosol-generating article with the downstream airflow path; in which the upstream fluidic interconnection element is configured to align with the article airflow inlet when the aerosol-generating article is received within the heating chamber, such that air flowing through the upstream fluidic interconnection element flows through the article inlet into the aerosol-generating article.

[0017] The cavity airflow inlet may be configured to engage with the article airflow inlet when the aerosolgenerating article is received within the cavity, such that air flowing through the cavity inlet flows through the article inlet into the aerosol-generating article.

[0018] A protruding portion, for example a rim, of the article airflow inlet may interact or mate with a portion of the cavity airflow inlet, for example a recessed portion or a compressible portion of the cavity airflow inlet, when the aerosol-generating article is received within the cavity. The protruding portion may thus contribute to the formation of a viable seal between the aerosol-generating article and the aerosol-generating device.

[0019] A protruding portion, for example a rim, of the cavity airflow inlet may interact or mate with a portion of the article airflow inlet, for example a recessed portion or a compressible portion of the article airflow inlet, when the aerosol-generating article is received within the cavity.

[0020] Preferably, a sealed airflow path is formed from the cavity inlet into the airflow path of the aerosolgenerating article when the aerosol-generating article is received within the cavity.

[0021] The device preferably comprises an openable cavity closure configured to close the cavity when the aerosol-generating article is received within the cavity.

[0022] The aerosol-generating device may further comprise a cavity airflow outlet, the cavity airflow outlet being configured to align with the article airflow outlet when the aerosol-generating article is received within the cavity, such that air flowing through the aerosol-generating article flows out of the cavity through the article airflow outlet, for example into the downstream airflow path. The cavity airflow outlet may be defined through the cavity closure.

[0023] The cavity airflow outlet is preferably configured to engage with the article airflow outlet when the aerosol-generating article is received within the cavity, such that air flowing through the cavity inlet, for example from the upstream airflow path, flows through the article inlet into the aerosol-generating article.

[0024] A protruding portion, for example a rim, of the article airflow outlet may interact or mate with a portion of the cavity airflow outlet, for example a recessed portion or a compressible portion of the cavity airflow outlet, when the aerosol-generating article is received within the cavity. Conversely, a protruding portion, for example a rim, of the cavity airflow outlet may interact or mate with a portion of the article airflow outlet, for example a recessed portion or a compressible portion of the article airflow outlet, when the aerosolgenerating article is received within the cavity.

[0025] Preferably, a sealed airflow path is formed from the article airflow outlet and through the cavity airflow outlet when the aerosol-generating article is received within the cavity.

[0026] The device further comprise a mouthpiece, the mouthpiece being in fluid communication with a, or the, cavity airflow outlet. Preferably, for example the mouthpiece comprises the aerosol outlet of the device. The mouthpiece may be coupled to, or an integral part of, a cavity closure.

[0027] The aerosol-generating article may have an article body defined by a first article dimension, a second article dimension perpendicular to the first article dimension, and an article thickness perpendicular to both the first article dimension and the second article dimension, in which the aerosol-generating device comprises a closable cavity having a minimal cavity length extending, when the cavity is closed, between a cavity airflow inlet and a cavity airflow outlet, the cavity further defined by a cavity width perpendicular to the minimal cavity length, extending between a left side wall of the cavity and a right side wall of the cavity, and a cavity height perpendicular to both the cavity depth and cavity width, the cavity height extending between a lower wall of the cavity and an upper wall of the cavity, the cavity being accessible via a closable opening having a width and a height. The aerosol-generating article is preferably configured to be inserted into the cavity in the direction of its first article dimension, and in which the cavity width is at least 5% greater in magnitude than the second article dimension and the minimal cavity length, when the cavity is closed, is between 1 % greater and 5% lesser in magnitude than the first article dimension.

[0028] The first article dimension may be an article width and the second article dimension may be an article length. Conversely, the first article dimension may be an article length and the second article dimension may be an article width.

[0029] Preferably, the aerosol-generating device comprises a heating means, for example a heater, configured to heat the aerosol-generating article when the article is received within the cavity. Preferably, at least a portion of the heater is located within the cavity.

[0030] Advantageously, the aerosol-generating article may be removably retained within the cavity by a retaining means or retaining mechanism, for example a retaining means or retaining mechanism located within the cavity, for example a retaining means or retaining mechanism that grips the aerosol-generating article when the article is inserted into the cavity. The aerosol-generating article may be retained within the cavity by interaction between the article and upper and lower walls of the cavity, for example in which at least a portion of upper and lower walls of the cavity are spaced by less than the thickness of the article and deflect when the article is inserted into the cavity, gripping the article. The aerosol-generating article may be retained within the cavity by interaction between at least one heater located in the cavity and the article, for example in which a heater is located on or adjacent to at least one of the upper and lower walls of the cavity, the heater or heaters deflecting when the article is inserted into the cavity, gripping the article. Heaters may be located adjacent both upper and lower walls of the cavity, a minimal cavity thickness being defined by the distance between the heaters. The minimal cavity distance may no more than 30% greater than the thickness of the aerosol-generating article, for example no more than 15% greater, or no more than 5% greater. The minimal cavity distance may be lesser than the thickness of the aerosol-generating article for example between 1 % and 20% less than the thickness of the aerosol-generating article, for example between 5% and 10% less.

[0031] The minimal cavity distance may be less than the thickness of the aerosol-generating article, for example between 5% and 20% less than the thickness of the aerosol-generating article

[0032] The first article dimension may be greater than, or equal to, the second article dimension. The aerosol-generating article may be substantially cuboid, or substantially parallelepiped. The aerosolgenerating article may be substantially rectangular in plan view. In preferred examples, the aerosolgenerating article has a length between 15 millimetres and 45 millimetres, for example between 25 millimetres and 35 millimetres, for example about 30 millimetres. In preferred examples, the aerosolgenerating article has a width between 3 millimetres and 17 millimetres, for example between 9 millimetres and 11 millimetres, for example about 10 millimetres. In preferred examples, the aerosol-generating article has a thickness between 1 millimetres and 5.5 millimetres, for example between 3 millimetres and 3.5 millimetres, for example about 3.1 millimetres.

[0033] Preferably, the aerosol-generating article is an aerosol-generating article according to any aerosolgenerating article disclosed herein. Optionally, an aerosol-generating article used in the system may be a lubricated article in which at least a portion of the external surface of the article is coated with a lubricant, such as a wax, to facilitate interaction with an aerosol-generating device. Aerosol-generating articles according to the present disclosure.

[0034] 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 external surface; and a second planar external surface.

[0035] 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 one or more aerosol-generating substrates, the aerosol-generating article comprising a first planar external surface and a second planar external surface.

[0036] Advantageously, articles and substrates comprising a first planar external surface and a second planar external surface may allow for good contact with an external heater, particularly a planar external heater, of an aerosol-generating device, thereby providing optimum heating of the aerosol-generating substrate.

[0037] Advantageously, articles and substrates comprising a first planar external surface and a second planar external surface may provide a large surface area for heating by an external heater of an aerosolgenerating device, thereby allowing the aerosol-generating substrate to be quickly heated to a temperature sufficient for generating an aerosol.

[0038] Advantageously, aerosol-generating articles of the present disclosure may be heated along substantially their entire length and width, thereby allowing the entire aerosol-generating substrate to be sufficiently heated to generate an aerosol.

[0039] Advantageously, certain examples of aerosol-generating articles of the present disclosure may be manufactured by layering sheet materials which can be achieved through a continuous manufacturing process, thereby resulting in an aerosol-generating article that is relatively easy and cheap to manufacture.

[0040] According to the present disclosure, there may be provided an aerosol-generating article comprising an aerosol-forming substrate, for example an aerosol-forming material, for producing an aerosol, the aerosol-generating article having a base defined by an x dimension extending in an x direction and a y dimension extending in a y direction, and a height defined by a z dimension extending in a z direction.

[0041] According to the present disclosure, there may be provided an aerosol-generating article comprising an aerosol-forming substrate, for example an aerosol-forming material, for producing an aerosol, the aerosol-generating article having a base defined by an x dimension extending in an x direction and a y dimension extending in a y direction, and a height defined by a z dimension extending in a z direction, in which at least a portion of a external surface of the aerosol-generating article comprises a lubricant, such as a wax.

[0042] According to the present disclosure, there may be provided an aerosol-forming substrate comprising an aerosol-forming material for producing an aerosol, the aerosol-forming substrate being a planar aerosolforming substrate 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.

[0043] According to the present disclosure, there may be provided an aerosol-forming substrate comprising an aerosol-forming material for producing an aerosol, the aerosol-forming substrate 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 being vertically spaced from each other by a height defined in a z direction. The aerosol-forming substrate may be an aerosol-generating article. The aerosol-forming substrate may be a component part of an aerosol-generating article.

[0044] According to the present disclosure, there may be provided an aerosol-forming substrate comprising an aerosol-forming material for producing an aerosol, the aerosol-forming substrate having a base defined by an x dimension and a y dimension, and a height defined by a z dimension, in which an air-flow path is defined through the aerosol-forming substrate in an x / y plane from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate. The aerosol-forming substrate may be an aerosolgenerating article. The aerosol-forming substrate may be a component part of an aerosol-generating article.

[0045] 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 aerosolforming 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.

[0046] The height of the aerosol-generating article is preferably less than both of the length and width of the aerosol-generating article. For the purpose of the present disclosure, the “height” of the aerosol-generating article may also be referred to as the “thickness” of the aerosol-generating article.

[0047] 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 aerosolforming substrate, for example an aerosol-forming material, for producing an aerosol, the aerosolgenerating 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.

[0048] According to the present disclosure, there may be provided an aerosol-forming substrate comprising an aerosol-forming material for producing an aerosol, the aerosol-forming substrate having a base defined by an x dimension and a y dimension, and a height defined by a z dimension, in which an air-flow path is defined through the aerosol-forming substrate in an x / y plane from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, in which a resistance to draw (RTD) of the substrate, along the air-flow path, is less than 20 millimetre H2O. The aerosol-forming substrate may be an aerosolgenerating article. The aerosol-forming substrate may be a component part of an aerosol-generating article.

[0049] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first planar layer, and a corrugated layer arranged on a surface of the first planar layer, at least one of the first planar layer and the corrugated layer comprising or consisting of an aerosol-forming material. The aerosol-forming substrate may be an aerosol-generating article. The aerosol-forming substrate may be a component part of an aerosol-generating article.

[0050] 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 material. The use of a corrugated structure in the aerosol-generating substrate or 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.

[0051] According to the present disclosure, there may be provided an aerosol-forming substrate 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 comprising or consisting of an aerosol-forming material. The aerosol-forming substrate may be an aerosol-generating article. The aerosol-forming substrate may be a component part of an aerosolgenerating article.

[0052] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first layer, and a corrugated layer attached to a surface of the first layer by an adhesive, in which an adhesive comprises or consists of an aerosol-forming material. The aerosol-forming substrate may be an aerosol-generating article. The aerosol-forming substrate may be a component part of an aerosolgenerating article.

[0053] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first layer, and a corrugated layer attached to a surface of the first layer, a plurality of longitudinally extending channels being defined between the first layer and the second layer by corrugations, in which a porous element is located in at least one of the longitudinally extending channels. The aerosol-forming substrate may be an aerosol-generating article. The aerosol-forming substrate may be a component part of an aerosol-generating article.

[0054] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first layer, and a corrugated layer attached to a surface of the first layer, a plurality of longitudinally extending channels being defined between the first layer and the corrugated layer by corrugations, in which the longitudinally extending channels are filled with a porous material, for example a porous aerosol forming material. The aerosol-forming substrate may be an aerosol-generating article. The aerosol-forming substrate may be a component part of an aerosol-generating article.

[0055] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first layer, a second layer, and a corrugated layer disposed between the first layer and the second layer, a plurality of longitudinally extending channels being defined by corrugations between the first layer and the corrugated layer, and between the corrugated layer and the second layer, in which a porous element is located in at least one of the longitudinally extending channels. The aerosol-forming substrate may be an aerosol-generating article. The aerosol-forming substrate may be a component part of an aerosolgenerating article.

[0056] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first layer, and a corrugated layer attached to a surface of the first layer, a plurality of longitudinally extending channels being defined between the first layer and the corrugated layer by corrugations, in which one or more flavour releasing component, for example a component such as a thread or capsule that is impregnated with or contains a flavour component, is located within at least one of the longitudinally extending channels. The aerosol-forming substrate may be an aerosol-generating article. The aerosolforming substrate may be a component part of an aerosol-generating article. According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first layer, a second layer, and a corrugated layer disposed between the first layer and the second layer, a plurality of longitudinally extending channels being defined by corrugations between the first layer and the corrugated layer, and between the corrugated layer and the second layer, in which one or more flavour releasing component, for example a component such as a thread or capsule that is impregnated with or contains a flavour component, is located within at least one of the longitudinally extending channels. The aerosol-forming substrate may be an aerosol-generating article. The aerosol-forming substrate may be a component part of an aerosol-generating article.

[0057] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first planar layer, and a corrugated layer arranged on a surface of the first planar layer, at least one of the first planar layer and the corrugated layer comprising perforations or holes to allow air to flow through the first planar layer or the corrugated layer. The aerosol-forming substrate may be an aerosol-generating article. The aerosol-forming substrate may be a component part of an aerosol-generating article.

[0058] According to the present disclosure, there may be provided an aerosol-forming substrate 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 comprising perforations or holes to allow air to flow through the first planar layer, the second planar layer, or the corrugated layer. The aerosol-forming substrate may be an aerosol-generating article. The aerosol-forming substrate may be a component part of an aerosol-generating article.

[0059] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first planar layer, a second planar layer, and a third planar layer arranged between the first planar layer and the second planar layer, the aerosol-forming substrate further comprising a first corrugated layer disposed between the first planar layer and the third planar layer, and a second corrugated layer disposed between the third planar layer and the second planar layer. The aerosol-forming substrate may be an aerosol-generating article. The aerosol-forming substrate may be a component part of an aerosolgenerating article.

[0060] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first layer, a second layer, and an intermediate layer disposed between the first layer and the second layer, in which the intermediate layer is attached to the first layer and / or the second layer by an adhesive, in which an adhesive comprises or consists of an aerosol-forming material. The aerosol-forming substrate may be an aerosol-generating article. The aerosol-forming substrate may be a component part of an aerosol-generating article.

[0061] The separation layer may also be described as an intermediate layer, that is a layer disposed between the upper layer and the lower layer. The terms “separation layer” and “intermediate layer” may be used interchangeably herein.

[0062] As used herein, the terms “upper layer” and “lower layer” describe relative positions of layers of the substrate when the substrate is arranged with its x / y plane disposed horizontally.

[0063] According to the present disclosure, there may be provided a substantially planar aerosol-forming substrate comprising an upper layer, a lower layer, the upper layer and the lower layer being arranged as substantially parallel planes spaced apart by an intermediate layer, or separation layer, located between the upper layer and the lower layer, the intermediate layer or separation layer comprising or consisting of one or more separation members extending between an upper surface of the lower layer and a lower surface of the upper layer. For example, in which the one or more separation members comprise or consist of pillars separating the upper layer from the lower layer.

[0064] According to the present disclosure, there may be provided a substantially planar aerosol-forming substrate, comprising an upper layer, a lower layer, the upper layer and the lower layer being arranged as substantially parallel planes spaced apart by an intermediate or separation layer located between the upper layer and the lower layer, the separation layer comprising or consisting of one or more separation members extending between an upper surface of the lower layer and a lower surface of the upper layer. For example, in which the separation members are ribs or struts separating the upper layer from the lower layer.

[0065] According to the present disclosure, there may be provided an aerosol-forming substrate, the aerosol-forming substrate being a substantially planar aerosol-forming substrate comprising an upper layer, a lower layer, the upper layer and the lower layer being arranged as substantially parallel planes spaced apart by an intermediate or separation layer located between the upper layer and the lower layer, the separation layer comprising or consisting of a corrugated element formed from a corrugated sheet having a triangular corrugation profile.

[0066] According to the present disclosure, there may be provided a substantially planar aerosol-forming substrate comprising an upper layer and a lower layer, the upper layer and the lower layer being arranged as substantially parallel planes spaced apart by a separation layer located between the upper layer and the lower layer, the separation layer comprising or consisting of a corrugated element formed from a corrugated sheet having a triangular corrugation profile.

[0067] The specific aerosol-forming substrates described herein comprise aerosol-forming material, and may be may be substantially entirely formed of aerosol-forming material. Alternatively, some component parts of the aerosol-forming substrates may be formed of aerosol-forming material and some component parts may be formed from non-aerosol-forming material. For the avoidance of doubt, any of the aerosolforming substrates defined herein may be an aerosol-generating article.

[0068] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol, the aerosol-generating article consisting of an aerosol-forming substrate according to any aerosol-forming substrate defined herein.

[0069] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol, the aerosol-generating article comprising an aerosol-forming substrate according to any of examples

[0070] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol, the aerosol-generating article comprising an article upstream end and an article downstream end, wherein an article airflow path and an article length extend from the article upstream end to the article downstream end.

[0071] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol, the aerosol-generating article comprising: an article upstream end and an article downstream end, wherein an article airflow path and an article length extend from the article upstream end to the article downstream end; and a corrugated element, wherein a cross direction of at least a first portion of the corrugated element is non-parallel to one or both of the article length and at least a first portion of the article air flow path.

[0072] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol, the aerosol-generating article comprising: an article upstream end and an article downstream end, an article length extending from the article upstream end to the article downstream end; and one or more corrugated elements, wherein the one or more corrugated elements together extend at least 70% of the article length, wherein a cross direction of at least a first portion of the corrugated element is non-parallel to one or both of the article length and at least a first portion of the article air flow path.

[0073] According to the present disclosure, there may be provided a planar aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol, the aerosol-generating article comprising: an article upstream end and an article downstream end, the article length extending from the article upstream end to the article downstream end; and one or more sheets of aerosol-forming material, each of the one or more sheets of aerosol-forming material having a thickness of less than 1 mm, wherein the one or more sheets of aerosol-forming material together extend along at least 50% of the article length.

[0074] 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 external surface; a second planar external surface; a cavity; a frame positioned between the first planar external surface and the second planar external surface, the frame at least partially defining the cavity; one or more aerosol-generating substrates; and an air inlet and an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity.

[0075] According to the present disclosure, there may be provided an aerosol-generating article comprising an aerosol-forming material for producing an aerosol, the aerosol-forming article comprising a first planar layer extending in a first plane and a second planar layer extending in a second plane, the second plane being parallel to and spaced from the first plane, a thickness of the aerosol-generating article extending in a direction perpendicular to the first plane and the second plane, in which a cavity is defined between the first planar layer and the second planar layer, a height of the cavity being defined by the distance between a lower surface of the first planar layer and an upper surface of the second planar layer, and in which the thickness of the aerosol-generating article is less than 5 millimetres and the height of the cavity is greater than 50 percent of the thickness of the article.

[0076] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article comprising: a substantially planar upper surface and a substantially planar lower surface; an aerosol-forming substrate; the upper surface and the lower surface vertically spaced from each other by a height defined in a z direction; the aerosol-generating article having a length defined in an x direction between a distal end and a proximal end of the aerosolgenerating article, the aerosol-generating article divided over its length into a distal end portion and a proximal end portion, the distal end portion extending from the distal end for 50% of the length of the aerosol-generating article and the proximal end portion extending from the proximal end for 50% of the length of the aerosol-generating article; wherein the ratio of the mass of aerosol-forming substrate in the proximal end portion to the mass of aerosol-forming substrate in the distal end portion is within a range of between 0.77 and 1.30.

[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: a first planar external surface; a second planar external surface; a cavity; a frame positioned between the first planar external surface and the second planar external surface, the frame at least partially defining the cavity; and one or more aerosol-generating substrates, the one or more aerosol-generating substrates comprising an aerosol-generating substrate positioned within the cavity, wherein the aerosol-generating substrate positioned within the cavity has a density of less than or equal to 0.9 grams per cubic centimetre.

[0078] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol, the aerosol-generating article comprising: a planar upper layer and a planar lower layer vertically spaced from each other by a separation height defined in a z direction; and an air inlet, an air outlet, and an airflow passage extending between the air inlet and the air outlet, the airflow passage being defined between the planar upper layer and the planar lower and having a width defined in a y direction, wherein the width of the airflow passage is greater than 1 millimetre and the separation height is less than 5 millimetres.

[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 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 aerosol-forming substrate. The aerosolgenerating 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.

[0080] Preferably, an aerosol-forming substrate is positioned between the first planar external surface and the second planar external surface.

[0081] 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.

[0082] 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.

[0083] The cavity may be substantially empty.

[0084] Aerosol-forming substrate may be positioned within the cavity.

[0085] A corrugated layer may be positioned within the cavity.

[0086] The frame may be a planar frame.

[0087] 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.

[0088] 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.

[0089] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0090] 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.

[0091] 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.

[0092] 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 external surface; a second planar external surface; a cavity; a frame positioned between the first planar external surface and the second planar external surface, the frame at least partially defining the cavity; and one or more aerosol-generating substrates, the one or more aerosol-generating substrates comprising an aerosol-generating substrate positioned within the cavity, wherein the aerosol-generating substrate positioned within the cavity has a packing density greater than or equal to 0.3.

[0093] 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 external layer defining a first planar external surface; a second planar external layer defining a second planar external surface; a cavity; a frame positioned between the first planar external layer and the second planar external layer, the frame at least partially defining the cavity; and one or more aerosolgenerating substrates, wherein one or both of the first planar external layer and the second planar external layer are bonded to the frame with an adhesive.

[0094] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article comprising: a substantially planar upper surface and a substantially planar lower surface; an aerosol-forming substrate; the upper surface and the lower surface vertically spaced from each other by a height defined in a z direction; wherein at least 50% wt of the aerosol-generating article is paper or cardboard.

[0095] 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 length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction; an air inlet, an air outlet and an airflow passage extending between the air inlet and the air outlet; a cavity; one or more aerosol-generating substrates; a first planar external surface and a second planar external surface spaced from the first planar external surface in the z-direction; a frame positioned between the first planar external surface and the second planar external surface, the frame at least partially defining the cavity; and wherein the frame forms at least 75 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame.

[0096] 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 external surface; a second planar external surface; a cavity; a frame positioned between the first planar external surface and the second planar external surface, the frame at least partially defining the cavity; and one or more aerosol-generating substrates, wherein the aerosol-generating article has a length of between 15 millimetres and 45 millimetres, a width of between 5 millimetres and 15 millimetres, and a thickness of between 1 millimetre and 5 millimetres.

[0097] 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 length extending in an x-direction, a width extending in a y-direction and a thickness extending in a z-direction; one or more aerosol-generating substrates; a first planar external surface and a second planar external surface spaced from the first planar external surface in the z-direction; and a first external corner extending from the first planar external surface to the second planar external surface, the first external corner connecting a first end face of the aerosol-generating article and a first side face of the aerosol-generating article; wherein the first external corner is chamfered or rounded.

[0098] 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 external surface; a second planar external surface; a cavity; a frame, the frame at least partially defining the cavity; one or more aerosol-generating substrates; and an air outlet, wherein the air outlet has a width of between 0.3 millimetres and 3 millimetres, and wherein the air outlet has a thickness of between 0.3 millimetres and 3 millimetres.

[0099] 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 external surface; a second planar external surface; a cavity; a frame positioned between the first planar external surface and the second planar external surface, the frame at least partially defining the cavity; and one or more aerosol-generating substrates, wherein at least one of the one or more aerosolgenerating substrates has a mass of less than or equal to 500 milligrams.

[0100] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article comprising a substantially planar upper surface and a substantially planar lower surface, the upper surface and the lower surface vertically spaced from each other by a height defined in a z direction, the aerosol-generating article further comprising a wrapper and an aerosol-forming substrate, the wrapper arranged over the upper surface and the lower surface to at least partially encircle the aerosol-forming substrate and form an exterior surface of the aerosol-generating article.

[0101] 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 aerosolforming substrate or aerosol-forming material comprising thermally conductive particles, each of the thermally conductive particles having a thermal conductivity of at least 1 W / mK in at least one direction at 25 degrees Celsius, wherein the aerosol-generating article is a planar aerosol-generating article having an article length, an article width, and an article thickness, the article thickness being no more than 0.5 times the article length and no more than 0.5 times the article width. For example, the aerosol-forming substrate is a planar aerosol-forming substrate having a substrate length, a substrate width, and a substrate thickness, the substrate thickness being no more than 0.5 times the substrate length and no more than 0.5 times the substrate width.

[0102] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article comprising a substantially planar upper surface and a substantially planar lower surface, the upper surface and the lower surface vertically spaced from each other by a height defined in a z direction, the aerosol-generating article further comprising an aerosol-forming substrate and one or more susceptor materials, the one or more susceptor materials arranged in thermal communication with the aerosol-forming substrate. The aerosol-forming substrate preferably is, or comprises, an aerosol-forming material. According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article comprising a substantially planar upper surface and a substantially planar lower surface, the upper surface and the lower surface vertically spaced from each other by a height defined in a z direction, the aerosol-generating article further comprising an aerosol-forming material and one or more susceptor materials, the one or more susceptor materials arranged in thermal communication with the aerosol-forming material.

[0103] According to the present disclosure, there may be provided an aerosol-generating article comprising a substantially planar aerosol-forming substrate coupled to a mouthpiece. The aerosol-forming substrate in this context may be any aerosol-generating article disclosed herein. Such an aerosol-generating article may be described as a precursor aerosol-generating article. Thus, according to the present disclosure, there may be provided an aerosol-generating article comprising a substantially planar precursor aerosolgenerating article coupled to a mouthpiece.

[0104] According to the present disclosure, there may be provided an aerosol-generating article comprising a substantially planar aerosol-forming substrate, for example a substantially planar precursor aerosolgenerating article, removably-couplable to a mouthpiece, or detachable from a mouthpiece.

[0105] According to the present disclosure, there may be provided an aerosol-generating article comprising a substantially planar aerosol-forming substrate, for example a substantially planar precursor aerosolgenerating article, coupled to a mouthpiece, an airflow path being defined through the aerosol-forming substrate and the mouthpiece.

[0106] According to the present disclosure, there may be provided an aerosol-generating article comprising a substantially planar aerosol-forming substrate, for example a substantially planar precursor aerosolgenerating article, coupled to a mouthpiece, an airflow path being defined through the aerosol-forming substrate and the mouthpiece, in which the airflow path passes through the mouthpiece.

[0107] According to the present disclosure, there may be provided an aerosol-generating article, for example an aerosol-generating article according to any preceding example, comprising an aerosol-forming substrate and a mouthpiece, the mouthpiece comprising a proximal portion for insertion into a user’s mouth, in which the aerosol-forming substrate has a length dimension that is greater than or equal to a width dimension, and a width dimension that is greater than a thickness dimension, and in which the proximal portion of the mouthpiece has a major axis dimension which is greater than the width dimension of the aerosol-forming substrate.

[0108] According to the present disclosure, there may be provided an aerosol-generating article, for example a precursor aerosol-generating article according to any disclosure of an aerosol-generating article herein, comprising an aerosol-forming substrate and a mouthpiece, the mouthpiece comprising a proximal portion for insertion into a user’s mouth, in which the aerosol-forming substrate has a length dimension that is greater than or equal to a width dimension, and a width dimension that is greater than a thickness dimension, and in which the proximal portion of the mouthpiece has a transverse cross-section which has a greater area than a transverse cross-section of the aerosol-forming substrate, the transverse crosssection of the substrate and the mouthpiece being cross-sections taken perpendicular to the length dimension of aerosol-forming substrate.

[0109] According to the present disclosure, there may be provided an aerosol-generating article, for example an aerosol-generating article according to any preceding example, comprising an aerosol-forming substrate and a mouthpiece, in which the mouthpiece comprises a proximal portion for insertion into a user’s mouth and a distal portion comprising a recess dimensioned for engagement with the aerosolforming substrate, in which an airflow path is defined through the mouthpiece between the distal portion and the proximal portion, and in which the aerosol-forming substrate has a length dimension that is greater than or equal to a width dimension, and a width dimension that is greater than a thickness dimension.

[0110] According to the present disclosure, there may be provided an aerosol-generating article, for example an aerosol-generating article according to any preceding example, comprising an aerosol-forming substrate and a mouthpiece, in which the mouthpiece comprises a proximal portion for insertion into a user’s mouth and a distal portion configured for engagement with the aerosol-forming substrate, in which an airflow path is defined by an airflow channel passing through the mouthpiece between the distal portion and the proximal portion.

[0111] According to the present disclosure, there may be provided an aerosol-generating article comprising an aerosol-forming substrate and a mouthpiece, the mouthpiece comprising a proximal portion for insertion into a user’s mouth, in which the aerosol-forming substrate has a length dimension that is greater than or equal to a width dimension, and a width dimension that is greater than a thickness dimension, and in which the proximal portion of the mouthpiece has a major axis dimension which is greater than the width dimension of the aerosol-forming substrate. For example, the proximal portion of the mouthpiece may have a transverse cross-section which has a greater area than a transverse cross-section of the aerosol-forming substrate, the transverse cross-section of the substrate and the mouthpiece being cross-sections taken perpendicular to the length dimension of aerosol-forming substrate.

[0112] Any aerosol-generating article disclosed herein may be coupled to a mouthpiece as described herein.

[0113] According to the present disclosure, there may be provided an aerosol-generating article comprising an aerosol-forming substrate and a mouthpiece, in which the mouthpiece comprises a proximal portion for insertion into a user’s mouth and a distal portion configured for engagement with the aerosol-forming substrate, in which an airflow path is defined by an airflow channel passing through the mouthpiece between the distal portion and the proximal portion, and in which the airflow channel comprises a first constriction portion and a first expansion portion downstream of the first constriction portion.

[0114] According to the present disclosure, there may be provided an aerosol-generating system comprising an aerosol-generating article according to any preceding claim and an aerosol-generating device configured to receive the aerosol-generating article.

[0115] 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 being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: a cavity located within the aerosol-generating article; one or more air inlets; one or more air outlets; one or more airflow passages defined through the aerosolgenerating article between one of the one or more air inlets and one of the one or more air outlets, the one or more airflow passages extending through the cavity; and one or more aerosol-generating substrates, wherein a length of the shortest airflow passage between any one of the one or more air inlets and any one of the one of the more air outlets is greater than the article length.

[0116] 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 being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: opposed discrete upper and lower exterior walls, the upper and lower exterior walls collectively defining all or a majority of a perimeter of the aerosol-generating article; a cavity located within the aerosol-generating article between the upper exterior wall and the lower exterior wall; one or more aerosol-generating substrates; and an air inlet and an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity, wherein the air inlet or the air outlet extends through the upper exterior wall or the lower exterior wall.

[0117] 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 external surface; a second planar external surface; a cavity; a frame positioned between the first planar external surface and the second planar external surface, the frame at least partially defining the cavity; one or more aerosol-generating substrates; and an air inlet and an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity, wherein the air inlet or the air outlet extends through the first planar external surface or the second planar external surface.

[0118] 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 external surface and a second planar external surface; a first cavity and a second cavity; a frame between the first planar external surface and the second planar external surface, the frame at least partially defining the first cavity and the second cavity; and an air inlet and an air outlet, and an airflow passage extending from the air inlet to the air outlet through the first cavity and the second cavity; wherein the first cavity is closer to the air inlet than the second cavity, and the first cavity and the second cavity are arranged in series such that the airflow passage extends from the first cavity to the second cavity; and wherein the first cavity has a volume equal to at least 5% of a volume of the second cavity, and wherein the second cavity has a volume equal to at least 5% of a volume of the first cavity. For example, the aerosol-generating article has an external volume, the first cavity has a volume, and the volume of the first cavity may be at least 10 % of the external volume of the aerosol-generating article. For example, the aerosol-generating article has an external volume, the second cavity has a volume, and the volume of the second cavity may be at least 10 % of the external volume of the aerosol-generating article.

[0119] 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 being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: a first external surface and a second external surface facing in substantially the opposite direction to the first external surface; a cavity located within the aerosolgenerating article between the first external surface and the second external surface; and an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity, wherein an aerosol-generating element is located within the cavity, the aerosol-generating element comprising aerosol-forming substrate and being defined by an element length, an element width, and an element thickness, the element width being greater than the element thickness, in which the aerosol-generating element comprises cut filler dispersed within a solid binder matrix. For example, the aerosol-generating element may be a porous aerosol-generating element. For example, the cut filler may comprise shredded plant material impregnated with an aerosol former.

[0120] According to the present disclosure, there may be provided an 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. The aerosol-generating article may comprise opposed discrete upper and lower exterior walls, the upper and lower exterior walls collectively defining all or a majority of a perimeter of the aerosol-generating article. A cavity may be located within the aerosolgenerating article between the upper exterior wall and the lower exterior wall. A wrapped body of aerosolforming substrate may be disposed within the cavity, the wrapped body comprising a wrapper at least partially enclosing aerosol-forming substrate.

[0121] According to the present disclosure, there may be provided an 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. The upper surface may form at least part of an upper exterior wall of the aerosol-generating article and the lower surface may form at least part of a lower exterior wall of the aerosol-generating article. The upper and lower exterior walls may be discrete and distinct from each other. The upper and lower exterior walls may collectively define all or a majority of a perimeter of the aerosol-generating article. A cavity may be located within the aerosol-generating article between the upper exterior wall and the lower exterior wall. A wrapped body of aerosol-forming substrate may be disposed within the cavity, the wrapped body comprising a wrapper at least partially enclosing aerosol-forming substrate.

[0122] 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 be defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness. The aerosol-generating article may comprise opposed discrete upper and lower exterior walls. The upper and lower exterior walls may collectively define all or a majority of a perimeter of the aerosolgenerating article. A cavity may be located within the aerosol-generating article between the upper exterior wall and the lower exterior wall. An airflow passage may be defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity. A wrapped body of aerosol-forming substrate may be disposed within the cavity, the wrapped body comprising a wrapper at least partially enclosing aerosol-forming substrate.

[0123] According to the present disclosure, there is provided an aerosol-generating article. The aerosolgenerating article may be for use with an aerosol-generating device to generate an aerosol. The aerosolgenerating article may be defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness. The aerosol-generating article may comprise one or more aerosol-generating substrates. The aerosol-generating article comprises a first external surface and a second external surface. The first external surface and the second external surface may be described as opposing first and second surfaces, for example the second external surface may face in substantially the opposite direction to the first external surface.

[0124] The aerosol-generating article may comprise a cavity. The cavity may be located within the aerosolgenerating article between the first external surface and the second external surface. The aerosolgenerating article may comprise a frame positioned between the first external surface and the second external surface. The frame may at least partially define the cavity. The aerosol-generating article may comprise an air inlet. The aerosol-generating article may comprise an air outlet. The aerosol-generating article may comprise an airflow passage extending between the air inlet and the air outlet. The airflow passage may be positioned between the first external surface and the second external surface. The airflow passage may extend between the air inlet and the air outlet through the cavity. A collection of unbound shreds, strips, strands or extrusions of aerosol-forming substrate may be disposed within the cavity.

[0125] The collection of unbound shreds, strips, strands or extrusions of aerosol-forming substrate defines an aerosol-generating element of the aerosol-generating article. So, where the term “aerosol-generating element” is used within this specification, it will be understood that the aerosol-generating element is preferably in the form of a collection of unbound shreds, strips, strands or extrusions of aerosol-forming substrate.

[0126] Thus, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising a first external surface and an opposing second external surface; a cavity located within the aerosol-generating article between the first external surface and the second external surface; a frame positioned between the first external surface and the second external surface, the frame at least partially defining the cavity; and an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity, wherein a collection of unbound shreds, strips, strands or extrusions of aerosol-forming substrate is disposed within the cavity.

[0127] The collection of unbound shreds, strips, strands or extrusions of aerosol-forming substrate comprises, or is, aerosol-forming material. The collection of unbound shreds, strips, strands or extrusions of aerosol-forming substrate may be the only source of aerosol-forming substrate within the article, or there may be other portions of the article that also comprise aerosol-forming substrate.

[0128] The collection of unbound shreds, strips, strands or extrusions of aerosol-forming substrate may be fixed within the cavity, for example fixed by adhesion or fixed by mechanical means such as interference with one or more walls of the cavity. By fixing the collection of unbound shreds, strips, strands or extrusions of aerosol-forming substrate within the cavity, any risk of the aerosol-forming substrate moving within the cavity and blocking or restricting airflow through the cavity is reduced.

[0129] 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 being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: a first external surface and a second external surface facing in substantially the opposite direction to the first external surface; a cavity located within the aerosolgenerating article between the first external surface and the second external surface; and an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity, wherein an aerosol-forming substrate is located within the cavity, the aerosol-forming substrate being in the form of a plurality of beads having an average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm.

[0130] According to the present disclosure, there is provided an aerosol-generating substrate plug for a heated aerosol-generating article. The aerosol-generating substrate plug comprises an aerosol-generating substrate. The aerosol-generating substrate comprises one or more aerosol-formers. The aerosolgenerating substrate comprises an aerosol-former content greater than or equal to 5 percent by weight on a dry weight basis. The aerosol-generating substrate plug comprises a wrapper. The wrapper has a grammage of between 20 grams per square metre and 200 grams per square metre. The wrapper circumscribes the aerosol-generating substrate. A thickness of the aerosol-generating substrate plug is less than 50 percent of a length of the aerosol-generating substrate plug. The thickness of the aerosolgenerating substrate plug is less than 50 percent of a width of the aerosol-generating substrate plug. The thickness of the aerosol-generating substrate plug is constant over at least 90 percent of the width of the aerosol-generating substrate plug.

[0131] According to the present disclosure, there is provided an aerosol-generating article for use with an electrically operated aerosol-generating device. The aerosol-generating article comprises an aerosolgenerating substrate plug. The aerosol-generating substrate plug comprises an aerosol-generating substrate. The aerosol-generating substrate comprises one or more aerosol-formers and has an aerosolformer content greater than or equal to 5 percent by weight on a dry weight basis. The aerosol-generating article comprises a first plug positioned upstream or downstream of the aerosol-generating substrate plug. The aerosol-generating article comprises an outer wrapper circumscribing the aerosol-generating substrate plug and the first plug. A thickness of the aerosol-generating article is less than 50 percent of a length of the aerosol-generating article. The thickness of the aerosol-generating article is less than 50 percent of a width of the aerosol-generating article. The thickness of the aerosol-generating article is constant over at least 90 percent of the width of the aerosol-generating article.

[0132] 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 wrapper encapsulating at least an aerosol-forming substrate to define a wrapped body. The wrapper may be formed of a foldable material. The wrapper may be configured to inhibit or prevent passage of moisture across a thickness of the wrapper.

[0133] An aerosol-generating article as disclosed herein may have at least one wall comprising a web of sheet material.

[0134] According to the present disclosure, there is provided a frame of an aerosol-generating article. The frame has a longitudinal axis. The frame comprises at least one wall comprising a web of sheet material. The web of sheet material has a length and a width, and the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame.

[0135] According to the present disclosure, there is provided an aerosol-generating article comprising a frame. The frame has a longitudinal axis. The frame comprises at least one wall comprising a web of sheet material. The web of sheet material has a length and a width, and the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame.

[0136] According to the present disclosure, there is provided a frame of an aerosol-generating article comprising at least one wall, the at least one wall comprising a web of sheet material arranged in a laminar structure. The laminar structure comprises a plurality of layers of the web of sheet material.

[0137] According to the present disclosure, there is provided an aerosol-generating article comprising a frame, the frame comprising at least one wall, the at least one wall comprising a web of sheet material arranged in a laminar structure. The laminar structure comprises a plurality of layers of the web of sheet material.

[0138] According to the present disclosure, there is provided a frame of an aerosol-generating article. The frame has a longitudinal axis. The frame comprises at least one wall comprising a web of sheet material arranged in a laminar structure. The laminar structure comprises a plurality of layers of the web of sheet material. The web of sheet material has a length and a width, and the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame.

[0139] According to the present disclosure, there is provided an aerosol-generating article comprising a frame. The frame has a longitudinal axis. The frame comprises at least one wall comprising a web of sheet material arranged in a laminar structure. The laminar structure comprises a plurality of layers of the web of sheet material. The web of sheet material has a length and a width, and the width of the web of sheet material extends substantially perpendicular to the longitudinal axis of the frame.

[0140] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device. The aerosol-generating article comprises a first plug, a second plug, and an aerosol-generating substrate plug comprising an aerosol-generating substrate. The first plug is positioned upstream of the aerosol-generating substrate plug and the second plug is positioned downstream of the aerosol-generating substrate plug. A thickness of the aerosol-generating article is less than 50 percent of a length of the aerosol-generating article and the thickness of the aerosol-generating article is less than 50 percent of a width of the aerosol-generating article.

[0141] 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 a first planar external surface. The aerosol-generating article may comprise a second planar external surface. The aerosol-generating article may comprise a frame positioned between the first planar external surface and the second planar external surface. The aerosol-generating article may comprise an air inlet. The aerosol-generating article may comprise an air outlet. The frame may comprise a first side portion. The frame may comprise a second side portion. The first side portion and the second side portion may at least partially define the cavity. The first side portion and the second side portion may extend from the air inlet to the air outlet along the longitudinal axis of the aerosol-generating article. The first side portion may be a support element. The second side portion may be a support element.

[0142] 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 comprising: a first planar external surface; a second planar external surface; a frame positioned between the first planar external surface and the second planar external surface; and an air inlet and an air outlet, wherein the frame comprises a first side portion and a second side portion, the first side portion and the second side portion at least partially defining the cavity and extending from the air inlet to the air outlet along the longitudinal axis of the aerosol-generating article, wherein the first side portion is a support element and the second side portion is a support element.

[0143] According to an aspect of the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device. The aerosol-generating article is a planar aerosol-generating article defined by a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction. The aerosol-generating article comprises one or more aerosol-generating substrates. The aerosol-generating article comprises a first cavity and a second cavity spaced from the first cavity in the z- direction. The aerosol-generating article comprises a first airflow path extending through the first cavity. The aerosol-generating article comprises a second airflow path extending through the second cavity. At least one of the one or more aerosol-generating substrates is positioned within or adjacent to the first airflow path, and at least one of the one or more aerosol-generating substrates is positioned within or adjacent to the second airflow path. The first cavity and the second cavity each have a width greater than or equal to 50 percent of a width of the aerosol-generating article.

[0144] 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 a first external surface. The aerosol-generating article may comprise a second external surface. The aerosolgenerating article may comprise a cavity defined between the first external surface and the second external surface. The aerosol-generating article may comprise one or more air outlets. At least one of the one or more air outlets may have a cross-sectional area of less than or equal to 0.3 square millimetres.

[0145] 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 comprising: a first external surface; a second external surface; a cavity defined between the first external surface and the second external surface; and one or more air outlets, wherein at least one of the one or more air outlets has a cross-sectional area of less than or equal to 0.3 square millimetres.

[0146] 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 a first external surface. The aerosol-generating article may comprise a second external surface. The aerosolgenerating article may comprise a cavity defined between the first external surface and the second external surface. The aerosol-generating article may comprise one or more air inlets. At least one of the one or more air inlets may have a cross-sectional area of less than or equal to 0.3 square millimetres.

[0147] 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 comprising: a first external surface; a second external surface; a cavity defined between the first external surface and the second external surface; and one or more air inlets, wherein at least one of the one or more air inlets has a cross- sectional area of less than or equal to 0.3 square millimetres.

[0148] Aerosol-generating articles according to the present disclosure may comprise an aerosol-forming substrate, for example an aerosol-forming substrate comprising an aerosol-generating article. The aerosolforming substrate may be hermetically isolated from an environment external to the aerosol-generating article.

[0149] 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 aerosolforming 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. The aerosol-forming substrate may be hermetically isolated from an environment external to the aerosol-generating article.

[0150] 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 aerosolforming 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. The aerosol-forming substrate may be hermetically isolated from an environment external to the aerosol-generating article. According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. By way of example, the aerosol-generating article may be as described in any of the preceding paragraphs of the present disclosure. The aerosol generating article may comprise an upper external surface, a lower external surface and an aerosol-forming substrate hermetically isolated from an environment external to the aerosol-generating article. 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 opposed and separated from each other in the z direction, wherein the height is less than each of the width and the length.

[0151] According to the present disclosure, there is provided an aerosol-generating article. The aerosolgenerating article is for use with an aerosol-generating device to generate an aerosol. The aerosolgenerating article comprises a first planar external surface and a second planar external surface. The aerosol-generating article comprises a cavity and one or more aerosol-generating substrates positioned within the cavity. The aerosol-generating article comprises an air inlet, an air outlet, and a frame at least partially defining the cavity, the air inlet and the air outlet. The frame comprises a first subframe and a second subframe connected to the first subframe.

[0152] 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 external surface and a second external surface opposing the first external surface. The aerosol-generating article may comprise a cavity positioned between the first external surface and the second external surface. The aerosol-generating article may comprise an aerosol-forming element positioned within the cavity. The aerosol-forming element may comprise a first plug element comprising an aerosol-forming substrate for producing an aerosol. The aerosol-forming element may comprise a second plug element different to the first plug element. The first plug element and the second plug element may be physically coupled to one another. The aerosol-generating article may have an article length, an article width and an article thickness. The article length and the article width being greater than the article thickness.

[0153] According to the present disclosure, there is provided an aerosol-generating article. The aerosolgenerating article is for use with an aerosol-generating device to generate an aerosol. The aerosolgenerating article comprises a first planar external surface and a second planar external surface. The aerosol-generating article comprises a cavity and a frame, the frame at least partially defining the cavity. The aerosol-generating article comprises one or more aerosol-generating substrates, an air inlet, and an air outlet. At least one of the air inlet and the air outlet has a thickness extending in a direction perpendicular to the first and second planar external surfaces and a width extending perpendicular to the thickness. A ratio of the width to the thickness is at least 4 to 1 .

[0154] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol. The article comprises an aerosol-forming substrate. The substrate is heatable to release an aerosol or volatile compounds capable of forming an aerosol. The article comprises a capsule, optionally able to release capsule contents from within the capsule. The article has an article length, an article width, and an article thickness. The article length and the article width are each at least two times the article thickness. Advantageously, the presence of a capsule may allow the addition of the capsule contents to the air flowing through the article during use. This could allow, for example, the addition of a flavourant to the air flow to enhance user experience. According to the present disclosure there is provided an aerosol-generating article. The aerosolgenerating article may be for use with an aerosol-generating device to generate an aerosol. The aerosolgenerating article may be defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness. The aerosol-generating article may comprise a first external surface. The aerosol-generating article may comprise a second external surface facing in substantially the opposite direction to the first external surface. The aerosol-generating article may comprise a cavity between the first external surface and the second external surface. The aerosol-generating article may comprise an airflow path defined through the aerosol-generating article between an air inlet and an air outlet. The airflow path may extend through the cavity. The aerosol-generating article may comprise an aerosol-generating element located in the cavity. The aerosol-generating element may have at least one longitudinal surface, a first end surface, and a second end surface. The angle between the at least one longitudinal surface and at least one of the first and second end surfaces may be less than 90 degrees.

[0155] According to the present disclosure there is provided an aerosol-generating article. The aerosolgenerating article may be for use with an aerosol-generating device to generate an aerosol. The aerosolgenerating article may extend between a first longitudinal end and a second longitudinal end to define an article length. The aerosol-generating article may further include an article width. The aerosol-generating article may further include an article thickness. The article width may be greater than the article thickness. The aerosol-generating article may comprise a first external surface and a second external surface facing in substantially the opposite direction to the first external surface. The aerosol-generating article may comprise a peripheral wall extending between the first external surface and the second external surface. The aerosol-generating article may comprise at least one cavity located between the first external surface and the second external surface, and at least partially circumscribed by the peripheral wall. The aerosolgenerating article may comprise an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the at least one cavity. The aerosolgenerating article may comprise an aerosol-generating element located in the at least one cavity. The aerosol-generating article may comprise at least one taggant provided on at least one of the first external surface and the peripheral wall.

[0156] According to the present disclosure, there is provided an aerosol-generating article. The aerosolgenerating article is for use with an aerosol-generating device to generate an aerosol. The aerosolgenerating article comprises a first planar external surface and a second planar external surface. The aerosol-generating article comprises a cavity and a frame at least partially defining the cavity. The aerosolgenerating article comprises an air inlet and an air outlet. The aerosol-generating article comprises an aerosol-generating substrate positioned within the cavity between the air inlet and the air outlet. The aerosol-generating article defines an airflow pathway extending through the cavity from the airflow inlet to the airflow outlet. The aerosol-generating article has a length extending between a first end of the aerosolgenerating article and a second end of the generating article, wherein the length is the largest dimension of the aerosol-generating article. A length of the airflow pathway is less than the length of the aerosolgenerating article.

[0157] 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 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. 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.

[0158] 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 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. 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.

[0159] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article having a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction, the aerosolgenerating article comprising: a first planar external surface extending in an x / y plane; a second planar external surface extending in an x / y plane; one or more aerosol-generating substrates; and a cavity extending in the x-direction between a first end of the cavity and a second end of the cavity, wherein the cavity comprises a converging section extending in the x-direction between a first end of the converging section and a second end of the converging section, wherein the width of the converging section decreases along the length of the converging section from the first end to the second end of the converging section, and wherein the length of the converging section is greater than the width of the converging section at the first end of the converging section.

[0160] 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 defined by a first planar dimension, a second planar dimension, and a thickness, in which both the first planar dimension and the second planar dimension are at least three times the magnitude of the thickness, in which an airflow channel is defined through the aerosol-generating article between an airflow inlet and an airflow outlet, and in which a proximal portion of the airflow channel diverges laterally between the airflow inlet and a central portion of the airflow channel, and a distal portion of the airflow channel converges laterally between the central portion of the airflow channel to the airflow outlet.

[0161] According to the present disclosure there is provided an aerosol-generating article. The aerosolgenerating article may be for use with an aerosol-generating device to generate an inhalable aerosol. The article may comprise an aerosol-forming substrate. The substrate may be heatable to release an aerosol or volatile compounds capable of forming an aerosol. The article may further comprise an elongate flavourbearing element. The elongate flavour-bearing element may comprise a carrier material and a flavourant supported on the carrier material. The article may have an article length, an article width, and an article thickness. The article length may be at least two times the article thickness. The article width may be at least two times the article thickness.

[0162] 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 a cavity defined between an upper surface, a lower surface, and at least one side surface. The aerosol-generating article comprises an aerosol-forming substrate arranged in the cavity. The aerosol-generating article is defined by a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction. The upper and lower surfaces are separated from each other in the z direction. The thickness of the aerosol-generating article is less than each of the width and the length of the aerosolgenerating article. At least one of the upper surface, the lower surface, and the at least one side surface is a contact surface. At least a portion of the contact surface is configured to contact the aerosol-forming substrate and to conform to a shape of the aerosol-forming substrate where the surface is in contact with the aerosol-forming substrate.

[0163] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article having a length extending in an x-direction, a width extending in a y-direction, a thickness extending in a z-direction, the aerosolgenerating article comprising: one or more aerosol-generating substrates; a first cavity; a second cavity offset from the first cavity in the y-direction; a first airflow passage extending through the first cavity; and a second airflow passage extending through the second cavity, wherein at least one of the one or more aerosol-generating substates is positioned along the first airflow passage, wherein at least one of the one or more aerosol-generating substrates is positioned along the second airflow passage. The first cavity and the second cavity may each have a mid-point width greater than or equal to 25 percent of a width of the aerosol-generating article, the mid-point width being measured in an x / y plane extending through a midpoint of the thickness of the cavity. The first cavity and the second cavity may each have a width greater than or equal to 35 percent of a width of the aerosol-generating article. The aerosol-generating article may be a planar aerosol-generating article.

[0164] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article having a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction, the aerosolgenerating article comprising: one or more aerosol-generating substrates; a cavity; a first planar external surface; a second planar external surface; a frame positioned between the first planar external surface and the second planar external surface, wherein the frame comprises a peripheral wall circumscribing or defining at least a portion of the cavity, and wherein the cavity has a width less than or equal to 80 percent of the width of the aerosol-generating article.

[0165] 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 substrate sheet comprising an aerosol-forming substrate for producing an aerosol. The substrate sheet may be a rolled substrate sheet. The aerosol-generating article may have an article length, an article width, and an article thickness. The article thickness may be less than the article length. The article thickness may be less than the article width. The article length and the article width may be at least two times the article thickness. According to the present disclosure there is provided an aerosol-generating article. The aerosolgenerating article may be for use with an aerosol-generating device to generate an aerosol. The aerosolgenerating article may be defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness. The aerosol-generating article may comprise a first external surface. The aerosol-generating article may comprise a second external surface facing in substantially the opposite direction to the first external surface. The aerosol-generating article may comprise a cavity between the first external surface and the second external surface. The aerosol-generating article may comprise an airflow path defined through the aerosol-generating article between an air inlet and an air outlet. The airflow path may extend through the cavity. The aerosol-generating article may comprise an aerosol-generating element located in the cavity. The aerosol-generating element may comprise a rope formed from a plurality of twisted or braided fibres of aerosol-generating material.

[0166] According to the present disclosure, there is provided an aerosol-generating article comprising an aerosol-forming substrate and at least one thread, wherein at least a portion of the aerosol-forming substrate may be sewn with the at least one thread. Advantageously, sewing the aerosol-forming substrate with at least one thread may hold the substrate together, or be able to retain the aerosol-forming substrate in a compressed condition. This may advantageously prevent the aerosol-forming substrate from falling apart or restrict expansion of the substrate to take up more space. Alternatively, or in addition, sewing at least a portion of the aerosol-forming substrate with at least one thread may create spaces for airflow or aerosol generation.

[0167] 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 aerosolforming 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. The aerosol-generating article may comprise an upper surface and a lower surface, the upper and lower surfaces opposed to and separated from each other in the z direction. The aerosol-generating article may comprise a first cover, the first cover arranged to overlie one of the upper surface and the lower surface, a flap portion of the first cover folded to overlie or define a side wall of the aerosol-generating article.

[0168] 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 aerosolforming 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. The aerosol-generating article may further comprise a first cover, the first cover arranged to overlie one of the substantially planar upper surface and the substantially planar lower surface, a flap portion of the first cover folded to overlie or define a side wall of the aerosol-generating article.

[0169] 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 upper surface, a lower surface and 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. The upper and lower surfaces may be opposed to and separated from each other in the z direction, wherein the height is less than each of the width and the length. The aerosol-generating article may further comprise a first cover, the first cover arranged to overlie one of the upper surface and the lower surface, a flap portion of the first cover folded to overlie or define a side wall of the aerosol-generating article.

[0170] According to the present disclosure, there is provided an aerosol-generating article. The aerosolgenerating article is for use with an aerosol-generating device to generate an aerosol. The aerosolgenerating article comprises at least one cavity. The aerosol-generating article may comprise a first cavity and a second cavity. The first cavity and the second cavity may be located in series. The aerosol-generating article comprises one or more aerosol-generating substrates. The aerosol-generating article may comprise a first aerosol-generating substrate. The aerosol-generating article may comprise a second aerosolgenerating substrate. The second aerosol-generating substrate may be different to the first aerosol-forming substrate. The first aerosol-generating substrate may be positioned in the first cavity. The second aerosolgenerating substrate may be positioned in the second cavity. The aerosol-generating article comprises an air inlet and an air outlet. The aerosol-generating article comprises an airflow passage extending between the air inlet and the air outlet. The airflow passage may extend through the first cavity and the second cavity. The aerosol-generating article comprises a first planar external surface. The aerosol-generating article comprises a second planar external surface. The aerosol-generating article comprises a frame positioned between the first planar external surface and the second planar external surface. The frame may at least partially define the first cavity and the second cavity.

[0171] According to the present disclosure, there is provided an aerosol-generating article. The aerosolgenerating article is for use with an aerosol-generating device to generate an inhalable aerosol. The aerosol-generating article may comprise a first planar external surface. The aerosol-generating article may comprise a second planar external surface. The aerosol-generating article may comprise a cavity. The aerosol-generating article may comprise a frame positioned between the first planar external surface and the second planar external surface. The frame may at least partially define the cavity. The aerosolgenerating article may comprise an aerosol-generating substrate. The aerosol-generating substrate may comprise at least 15 percent by weight of one or more non-tobacco botanical materials, on a dry weight basis. The aerosol-generating article may comprises an air inlet and an air outlet. The aerosol-generating article may comprise an airflow passage extending between the air inlet and the air outlet through the cavity.

[0172] According to the present disclosure, there is provided an aerosol-generating article. The aerosolgenerating article is for use with an aerosol-generating device to generate an inhalable aerosol. The aerosol-generating article may comprise a first planar external surface. The aerosol-generating article may comprise a second planar external surface. The aerosol-generating article may comprise a cavity. The aerosol-generating article may comprise a frame positioned between the first planar external surface and the second planar external surface. The frame may at least partially define the cavity. The aerosolgenerating article may comprise an aerosol-generating substrate. The aerosol-generating substrate may comprise exogenous nicotine. The aerosol-generating substrate may comprise one or more aerosol formers. The total aerosol former content of the aerosol-generating substrate may be at least 40 percent by weight on a dry weight basis. The aerosol-generating article may comprises an air inlet and an air outlet. The aerosol-generating article may comprise an airflow passage extending between the air inlet and the air outlet through the cavity. Various optional and advantageous features of aerosol-generating articles according to the present disclosure, including preferred dimensions and preferred aerosol-forming material components, are set out in greater detail below.

[0173] Aerosol-generating products comprising aerosol-generating articles and packaging for aerosol-generating articles according to the present disclosure

[0174] According to the present disclosure, there is provided frame assembly for planar aerosol-generating articles. The frame assembly comprises a plurality of planar aerosol-generating articles. The frame assembly comprises a frame defining a plurality of cavities. Each planar aerosol-generating article is disposed in a respective one of the plurality of cavities of the frame.

[0175] According to the present disclosure, there is provided a bundle comprising a plurality of frame assemblies as disclosed herein. The bundle may comprise at least three, at least four or at least five frame assemblies held together by a connecting element. The connecting element may be removable from the bundle to permit or enhance access to at least one frame assembly of the bundle. The connecting element may be a wrapper wrapped around the frame assemblies.

[0176] According to the present disclosure, there is provided a container of planar aerosol-generating articles, the container comprising: a frame assembly as disclosed herein; and an outer housing at least partially enclosing the frame assembly.

[0177] According to the present disclosure, there is provided a bundle comprising a plurality of frame assemblies as disclosed herein. The bundle may comprise at least three, at least four or at least five frame assemblies held together by a connecting element. The connecting element may be removable from the bundle to permit or enhance access to at least one frame assembly of the bundle. The connecting element may be a wrapper wrapped around the frame assemblies.

[0178] According to the present disclosure, there is provided a container of planar aerosol-generating articles, the container comprising: a frame assembly as disclosed herein; and an outer housing at least partially enclosing the frame assembly.

[0179] According to an aspect of the present disclosure, there is provided an aerosol-generating product in the form of a two-dimensional array of aerosol-generating articles, each of the aerosol-generating articles configured to be separable from the aerosol-generating product to be used as a discrete aerosol-generating article to generate an aerosol.

[0180] Various optional and advantageous features of aerosol-generating products and packaging according to the present disclosure are set out in greater detail below.

[0181] Methods of forming aerosol-generating articles according to the present disclosure

[0182] According to the present disclosure, there is provided a method of making a planar corrugated aerosol-forming substrate comprising steps of: providing a first continuous sheet, providing a second continuous sheet, at least one of the first sheet and the second sheet being a sheet comprising or consisting of aerosol-forming material, texturing the second continuous sheet using a fluting roller to form a continuous corrugated sheet, applying adhesive to at least one of the continuous corrugated sheet or the first continuous sheet, applying the continuous corrugated sheet to a surface of the first continuous sheet to form a continuous aerosol-forming substrate, and cutting the continuous aerosol-forming substrate to form the planar corrugated aerosol-forming substrate.

[0183] According to the present disclosure, there is provided a method of making a planar corrugated aerosol-forming substrate comprising steps of: providing a first continuous sheet, providing a second continuous sheet, and providing a third continuous sheet, at least one of the first sheet, the second continuous sheet, and the second sheet being a sheet comprising or consisting of aerosol-forming material, texturing the second continuous sheet using a fluting roller to form a continuous corrugated sheet, applying adhesive to at least one of the continuous corrugated sheet or the first continuous sheet, applying a first side of the continuous corrugated sheet to a surface of the first continuous sheet, applying adhesive to at least one of the continuous corrugated sheet and the third continuous sheet, and applying a second side of the continuous corrugated sheet to a surface of the third continuous sheet, thereby forming a continuous aerosol-forming substrate, and cutting the continuous aerosol-forming substrate to form the planar corrugated aerosol-forming substrate.

[0184] According to the present disclosure, there is provided a method of manufacturing an aerosolgenerating article for use with an aerosol-generating device to generate an aerosol. The method comprises: providing a first continuous sheet of frame material and a further continuous sheet of material; forming a frame aperture through the first continuous sheet of frame material to form a frame core layer; positioning the further continuous sheet of material underneath the first continuous sheet of frame material; and bonding the further continuous sheet of material and the first continuous sheet of frame material to form a laminated structure of the aerosol-generating article comprising the frame core layer.

[0185] Various optional and advantageous features of methods of manufacturing aerosol-generating articles according to the present disclosure are set out in greater detail below.

[0186] Aerosol-generating devices according to the present disclosure

[0187] According to the present disclosure, there is provided an aerosol-generating device for receiving an aerosol-generating article, for example an aerosol-generating article according to any example or embodiment disclosed herein, to form an inhalable aerosol, the aerosol-generating device comprising a cavity dimensioned to receive at least a portion of the aerosol-generating article, 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.

[0188] According to an aspect of the present disclosure, there is provided an aerosol-forming device configured to removably receive an aerosol-forming article, the aerosol-forming article having a substantially rectangular parallelepiped shape defining two opposing main faces or surfaces, which may also be referred to as the large surfaces, two opposing side faces or surfaces, also referred to herein as lateral faces or surfaces, and two opposing end faces or surfaces. The aerosol-forming article includes an aerosol-forming substrate arranged between the opposing main faces. The aerosol-forming device comprises a main air inlet for receiving an airflow from an outside. The outside may refer to an exterior environment or surrounding of the aerosol-forming device. The aerosol-forming device further comprises a downstream element removably or fixedly attachable to a mouthpiece of the aerosol-forming device, wherein the downstream element includes a downstream air channel. The downstream element may also be referred to herein as second housing part or as mouthpiece portion of the aerosol-forming device. The aerosol-forming device further comprises a device body, also referred to herein as body portion or first housing part of the aerosol-forming device, wherein the body part includes a heating chamber, which defines an insertion direction for at least partly inserting an aerosol-forming article into the heating chamber. The aerosol-forming device further comprises a first air path structure with two parallelly arranged first air channels fluidically connected or coupled to the main air inlet, the first air channels running in parallel to the heating chamber on two opposing sides thereof. The aerosol-forming device further comprises a second air path structure arranged and / or configured to redirect the air flow from the two parallelly arranged first air channels to a center axis of the aerosol forming device.

[0189] According to an aspect of the present disclosure, there is provided a fluidic interconnection element for an aerosol-forming device, wherein the fluidic interconnection element may be configured to provide for a fluidic connection between the aerosol-forming device and an aerosol-forming article insertable into and / or removable from the aerosol-forming device. The fluidic interconnection element, as used herein, may refer to an element or component for flu id ically connecting and / or coupling the aerosol-forming device and an aerosol-forming article. The fluidic interconnection element may provide an at least partly fluid-tight sealing between the aerosol-forming device and an aerosol-forming article. The fluidic interconnection element may also be referred to herein as sealing member or element.

[0190] According to an aspect of the present disclosure, there is provided an aerosol-forming device configured to removably receive an aerosol-forming or aerosol-generating article, the aerosol-forming article including an aerosol-forming substrate. The aerosol-forming device comprises a heating chamber for at least partially and removably receiving the aerosol-forming article, an upstream airflow path configured to provide air to the aerosol-forming substrate when received in the heating chamber. For example, the upstream airflow path may be configured to guide or pass air through the aerosol-forming article. The aerosol-forming device further comprises an upstream fluidic interconnection element configured to fluidically interconnect and / or fluidically couple the upstream airflow path with the aerosolforming article, wherein the upstream fluidic interconnection element includes a blade structure configured to cut or press into a wall or frame around an upstream air inlet of the aerosol-forming article, to provide for a fluidic connection and / or fluidic coupling between the upstream airflow path and the substrate of the aerosol-forming article.

[0191] According to an aspect of the present disclosure, there is provided an aerosol-forming device configured to removably receive an aerosol-forming article including an aerosol-forming substrate. The aerosol-forming device comprises a downstream airflow path configured to receive aerosol from the aerosol-forming substrate, and a downstream fluidic interconnection element configured to fluidically interconnect and / or couple to an aerosol outlet of the aerosol-forming article, wherein the downstream fluidic interconnection element includes a blade structure configured to cut or press into a wall or frame around the aerosol outlet of the aerosol-forming article, to provide for a fluidic connection and / or coupling between the downstream airflow path and the substrate of the aerosol-forming article.

[0192] According to an aspect of the present disclosure, there is provided an aerosol-forming device configured to removably receive an aerosol-forming article including an aerosol-forming substrate. The aerosol-forming device comprises a device body or first housing part forming or defining a main axis of extension of the aerosol-forming device. The main axis of extension may refer to or be coaxial with the longitudinal axis and / or center axis of the aerosol-forming device. The device further comprises a heating module arranged at least partially inside the device body, the heating module being configured to at least partially and removably hold the aerosol-forming article. The aerosol-forming device further comprises a downstream element, second housing part or mouthpiece portion movably attached to the device body, and configured to or able to move between an open position and a use position. In the open position, the aerosol-forming device is configured to provide access to a heating chamber of the heating module, and in the use position, the aerosol-forming device is configured to close the heating module. The device further comprises a spring biasing mechanism establishing or configured to establish or exert a compressive force acting onto the inserted aerosol-forming article in a direction along the main axis of extension, when the downstream element is in the use position.

[0193] According to an aspect of the present disclosure, there is provided an aerosol-forming device configured to removably receive an aerosol-forming article including an aerosol-forming substrate, the aerosol-forming article having a substantially rectangular parallelepiped shape defining two opposing main faces, for example opposing each other in normal direction of the aerosol-forming device and / or article. The aerosol-forming device comprises a heating chamber for removably and at least partially receiving the aerosol-forming article, and a convective air heater or convective heater assembly arranged upstream of the heating chamber. Therein, the convective air heater includes a slit-shaped or slot shaped air channel and a resistive heating element, which may be planar or helix- or spiral-shaped, arranged inside the slitshaped or slot-shaped air channel, such that two air flow channels or paths, also referred to herein as narrow air flow channels or simply as gaps, are formed above and below the resistive heating element. The slit-shaped or slot shaped air channel may also be referred to as convective heating chamber. For instance, the air channels or gaps may be formed on two opposite sides, for example two planar sides or surfaces, of the resistive heating element.

[0194] According to an aspect of the present disclosure, there is provided an aerosol-forming device configured to removably receive an aerosol-forming article including an aerosol-forming substrate, the aerosol-forming article having a substantially rectangular parallelepiped shape defining two opposing main faces. The aerosol-forming device comprises a heating chamber for removably and at least partially receiving the aerosol-forming article, the heating chamber defining an insertion direction, for example for inserting the aerosol-forming article into the aerosol-forming device. The insertion direction may extend along or parallel to an insertion axis and / or a longitudinal axis or direction of the aerosol-forming device. The aerosol-forming device further comprises a convective air heater assembly arranged upstream of the heating chamber, the convective air heater assembly including a resistive heater element or resistive heating element extending at least partly into the convective air heater assembly or therein. The space in the convective heater assembly in which the resistive heating element is arranged may also be referred to as convective heating chamber. Therein, the convective air heater assembly includes two air heating channels leading from each side or lateral face of the aerosol-forming device to a central air channel. Alternatively or additionally, the convective air heater assembly may include two air heating channels leading or extending from two opposing sides or lateral faces of the aerosol-forming device, for example opposing in transverse direction and / or normal direction of the aerosol-forming device, to a central air channel. Further, the central air channel may lead or extend fluidically to an air inlet of the aerosol-forming article. Accordingly, the central air channel may be fluidically coupled or couplable to the air inlet of the aerosol-forming article.

[0195] According to an aspect of the present disclosure, there is provided an aerosol-forming device configured to removably receive an aerosol-forming article including an aerosol-forming substrate, the aerosol-forming article having a substantially rectangular parallelepiped shape defining two opposing main faces, and an aerosol-forming substrate arranged between the opposing main faces. The main faces or surfaces may oppose each other in a direction transverse to the longitudinal axis of the aerosol-forming device, for example in transverse direction or normal direction of the aerosol-forming device. The substrate may be arranged therebetween, for example in transverse direction or normal direction of the aerosolforming device. The aerosol-forming device comprises a heating chamber for at least partially and removably receiving the substantially rectangular parallelepiped aerosol-forming article, the heating chamber defining an insertion direction for the aerosol-forming article. The insertion direction may extend along or parallel to an insertion axis and / or a longitudinal axis or direction of the aerosol-forming device. The aerosol-forming device further comprises a heating structure, at least an element thereof made of an electrically conductive material, the heating structure being arranged at least partly inside the heating chamber, such that upon insertion of the aerosol-forming article into the heating chamber, at least a part of the heating structure is configured to move towards an adjacent side face and / or a main face or surface of the heating chamber, so that a heating surface of the heating structure and / or said at least part of the heating structure is pressed against one of the main faces or surfaces of the aerosol-forming article. For example, the heating structure may comprise at least one ortwo heating elements, which may, for example, be resistive heating elements. At least a part of the heating element may be moved by the insertion of the aerosol-forming article into the heating chamber.

[0196] According to an aspect of the present disclosure, there is provided a heating structure for an aerosolforming device, for example for heating an aerosol-forming article having a substantially rectangular parallelepiped shape defining or with two opposing main faces. The heating structure includes a distal end and a proximal end. The heating structure comprises a holding section having two terminals for electrical interconnection arranged at the distal end, for example with an electric circuit of the aerosol-generating device. The heating structure further comprises a central section including a plurality of parallelly-arranged heater branches or resistive branches, and a proximal end section forming one or more plate-like elements. The central section may be arranged between the holding section and the proximal section in direction from the distal to the proximal end of the aerosol-forming device. The central section may be configured to heat at least one main face or surface of the aerosol-forming article. The heating structure may also be referred to herein as a heating element, for example a first and / or second heating element. The holding section may also be referred to herein as a first end. The central section may also be referred to herein as heating section. The proximal end section may also be referred to herein as a second end.

[0197] According to an aspect of the present disclosure, there is provided a heater module for an aerosolforming device, the heater module configured to removably and at least partially receive an aerosol-forming article including an aerosol-forming substrate, the aerosol-forming article having a substantially rectangular parallelepiped shape defining two opposing main faces. The heater module comprises a heating structure including two opposing heating elements forming a substantially rectangular parallelepiped heating volume therebetween for removably and at least partially receiving the aerosol-forming article, the heating volume being arranged at least partially inside a heating chamber of the aerosol-forming device and defining an insertion axis, for example parallel to or coaxial to the longitudinal axis of the aerosol-forming device. The heater elements may oppose each other in a direction transverse to the longitudinal axis, for example along a transverse direction or normal direction of the aerosol-forming device. The heater module further comprises a heater casing made of a non-conductive material forming an outer shell around the two opposing heating elements. Further, two smaller inner side faces or lateral faces of the heater casing form or define the inner small side faces or lateral faces of the heating chamber. The heater module further comprises a backplate forming a distal end wall or end face of the heating chamber, the backplate having an upstream air inlet for fluidic connection with the aerosol-forming article.

[0198] According to an aspect of the present disclosure, there is provided an aerosol-forming device for generating aerosol, for example aerosol inhalable by a user and / or nicotine containing aerosol. The aerosol- forming device comprises a first housing part including a heating chamber configured to receive an aerosolforming article, and a second housing part movably coupled to the first housing part, such that the second housing part is movable relative to the first housing part along a longitudinal direction of the aerosol-forming device between an open position, in which the heating chamber is accessible to receive the aerosol-forming article, and a use position for generating aerosol based on heating at least a part of the aerosol-forming article. Therein, the second housing part includes a fixation means configured to engage with the aerosolforming article, such that the aerosol-forming article is movable along the longitudinal direction based on movement of the second housing part along the longitudinal direction.

[0199] According to an aspect of the present disclosure, there is provided an aerosol-forming device including a device housing and a mouthpiece. The device housing may also be referred to herein as housing of the aerosol-forming device. The device housing includes a storage chamber for storing or accommodating the mouthpiece, wherein the mouthpiece is movable between a storage position, in which the mouthpiece is at least partly arranged inside the storage chamber, and a use or extracted position, in which the mouthpiece is at least partly displaced from the storage position and at least partly protrudes from the device housing, for example at a proximal end of the aerosol-forming device. The aerosol-forming device includes an actuator, also referred to herein as mouthpiece actuator, which is movably arranged on the device housing, the actuator or mouthpiece being movable between a first position and a second position, wherein the movement of the mouthpiece between the storage position and the use position is actuatable by the movement of the actuator between the first position and the second position. Further, a heating chamber of the aerosol-forming device is arranged in the device housing, the heating chamber being configured to heat an aerosol-forming article or substrate, wherein an airflow channel is provided in the device housing, wherein the airflow channel is configured to conduct aerosol from the heating chamber through the mouthpiece for inhalation by a user, and wherein downstream of the heating chamber, the airflow channel includes at least one air inlet channel in the device housing, the at least one air inlet channel being configured to provide a fluid coupling or connection between the airflow channel and an outside environment of the aerosol-forming device. Therein, the at least one air inlet channel is configured to provide an air flow from the outside environment into the airflow channel, wherein the air inlet channel is blocked when the mouthpiece is in the storage position and open when the mouthpiece is in the use position.

[0200] According to an aspect of the present disclosure, there is provided an aerosol-forming device comprising a device housing with a first housing part and a second housing part. The device housing is also referred to herein a housing of the aerosol-forming device. The first housing part is also referred to herein as device body, and the second housing part is also referred to herein as mouthpiece portion or downstream element or part of the aerosol-forming device. The aerosol-forming device further comprises a housing actuator or actuator movably arranged on the first housing part, the housing actuator being movable between a first position and a second position, wherein the first housing part includes a heating chamber, wherein the heating chamber is configured to heat an aerosol-forming article or substrate and includes a loading opening, the loading opening being configured to receive the aerosol-forming article or substrate, for example along an insertion direction or longitudinal direction of the aerosol-forming device. Therein, the second housing part is fixed or hinged to the first housing part via a rotational joint or hinge and rotatably or pivotably movable between a use position, also referred to herein as sealing position, and an open position, also referred to herein as loading position, by movement of the housing actuator between the first position and the second position. Further, the second housing part covers the loading opening of the heating chamber, also referred to herein as opening of the heating chamber, in the use position, and wherein the second housing part is removed from the loading opening or opening of the heating chamber in the open position, for example such that the heating chamber is accessible to receive the aerosol-forming article via the opening or remove it therefrom.

[0201] According to a further aspect of the present disclosure, there is provided a method of loading an aerosol-forming article into an aerosol-forming device or system, for example loading an aerosol-forming article into a heating chamber of an aerosol-forming device. The aerosol-forming device may refer to any aerosol-forming device described herein. In particular, the aerosol-forming device can comprise a first housing part, which includes the heating chamber, and a second housing part movably coupled to the first housing part, such that the second housing part is movable relative to the first housing part along a longitudinal direction of the aerosol-forming device. The method may comprise moving and / or displacing the second and / or first housing part from a use position, in which the heating chamber is covered by the second housing part, towards or into an open position, in which the heating chamber is accessible to receive the aerosol-forming article. The method further comprises inserting the aerosol-forming article at least partly into the heating chamber, and moving the second and / or first housing part from the open position into the use position, thereby at least partly engaging the aerosol-forming article with a fixation means arranged at the second housing part, such that the aerosol-forming article is pushed by the relative movement of the first and second housing parts completely into the heating chamber.

[0202] According to a further aspect of the present disclosure, there is provided a method of loading an aerosol-forming article or substrate into an aerosol-forming device, for example into a heating chamber of an aerosol-forming device. The aerosol-forming device may include a device housing including a first housing part and a second housing part, the second housing part being fixed to the first housing part via a rotational joint. The method comprises moving a housing actuator on the first housing part from a first position into a second position, translating the movement of the housing actuator between the first and second positions into a rotation of the second housing part from a use position, in which the second housing part covers a loading opening or opening of the heating chamber, into an open position, in which the second housing part is removed from the loading opening of the heating chamber.

[0203] According to an aspect, there is provided a method of controlling air flow through an air inlet channel of an airflow channel in an aerosol-forming device, for example an aerosol-forming device as described herein. The air inlet channel may be arranged downstream of a heating chamber of the aerosol-forming device and provide a connection between the airflow channel and an outside environment. The method comprises moving a mouthpiece of the aerosol-forming device between a storage position, in which the mouthpiece is at least partly arranged inside the storage chamber, and a use position, in which the mouthpiece is at least partly displaced from the storage position and at least partly protrudes from the device housing, by moving an actuator or mouthpiece actuator or slider between a first position and a second position. The method further comprises closing the air inlet channel when the mouthpiece is moved into the storage position, and opening the air inlet channel when the mouthpiece is moved into the use position.

[0204] Various optional and advantageous features of aerosol-generating devices, and methods of using aerosol generating devices are set out in greater detail below according to the present disclosure, including preferred dimensions and preferred aerosol-forming material components, are set out in greater detail below.

[0205] Aerosol-generating systems according to the present disclosure

[0206] According to the present disclosure, there is provided an aerosol-generating system comprising an aerosol-generating device and an aerosol-generating article according to any examples or embodiments disclosed herein.

[0207] According to the present disclosure, there is provided an aerosol-generating system. The aerosolgenerating system may comprise an aerosol-generating article as described above, and an aerosolgenerating device. The aerosol-generating device is configured to be used with the aerosol-generating article to generate an aerosol. Optionally, at least a portion of an external surface of the aerosol-generating article may comprise a lubricant, such as a wax, to facilitate interaction with an aerosol-generating device.

[0208] According to the present disclosure, there is provided an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device. The aerosol-generating article comprises an at least one aerosol-forming substrate. The aerosol-generating article is defined by an article length, an article width, and an article thickness, the article length and the article width being at least two times the article thickness. The aerosol-generating device comprises a heating chamber for receiving at least a portion of the aerosol-generating article. The aerosol-generating device comprises at least one heater, the at least one heater defining a heating zone in the heating chamber. When the aerosol-generating article is fully received in the heating chamber of the aerosol-generating device, between 10 and 90 percent, preferably between 20 and 80 percent, of a total mass of the at least one aerosol-forming substrate is located within the heating zone.

[0209] According to the present disclosure, there may be provided an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device configured to engage with the aerosolgenerating article to form an inhalable aerosol, the aerosol-generating article may have an article body, an airflow path being defined through the article body between an article airflow inlet and an article airflow outlet. The aerosol-generating device may comprise a cavity dimensioned to receive the aerosol-generating article, the cavity comprising a cavity airflow inlet. The cavity airflow inlet may be configured to align with the article airflow inlet when the aerosol-generating article is received within the cavity, such that air flowing through the cavity inlet flows through the article inlet into the aerosol-generating article.

[0210] According to the present disclosure, there may be provided an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device configured to engage with the aerosolgenerating article to form an inhalable aerosol. The aerosol-generating article may have an article body defined by a first article dimension, a second article dimension perpendicular to the first article dimension, and an article thickness perpendicular to both the first article dimension and the second article dimension. The aerosol-generating device may comprise a closable cavity having a minimal cavity length extending, when the cavity is closed, between a cavity airflow inlet and a cavity airflow outlet. The cavity may be further defined by a cavity width perpendicular to the minimal cavity length, extending between a left side wall of the cavity and a right side wall of the cavity, and a cavity height perpendicular to both the cavity depth and cavity width, the cavity height extending between a lower wall of the cavity and an upper wall of the cavity. The cavity may be accessible via a closable opening having a width and a height. The aerosol-generating article is preferably configured to be inserted into the cavity in the direction of its first article dimension, preferably in which the cavity width is no more than 30% greater, for example no more than 15% greater, or no more than 10 % greater, or no more than 5% greater, than the second article dimension. Preferably, the minimal cavity length, when the cavity is closed, is no more than 10% greater, for example no more than 5% greater, or nor more than 2% greater, or no greater, than the first article dimension. The cavity width may be at least 5% greater in magnitude than the second article dimension. The minimal cavity length, when the cavity is closed, may be between 1 % greater and 5% lesser in magnitude than the first article dimension.

[0211] According to the present disclosure, there may be provided an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device configured to engage with the aerosolgenerating article to form an inhalable aerosol, in which; the aerosol-generating article has an article body, an airflow path being defined through the article body between an article airflow inlet and an article airflow outlet; in which the aerosol-generating device comprises a cavity dimensioned to receive the aerosolgenerating article, the cavity comprising a cavity airflow inlet; in which the cavity airflow inlet is configured to align with the article airflow inlet when the aerosol-generating article is received within the cavity, such that air flowing through the cavity inlet flows through the article inlet into the aerosol-generating article.

[0212] According to a further aspect of the present disclosure, there is provided an aerosol-forming or aerosol-generating system, the system including at least one aerosol-forming device, for example any of the aerosol-forming device described herein, and a companion device configured to charge and / or at least partly receive the aerosol-forming device, for example in a cavity or compartment arranged in a housing of the companion device.

[0213] According to an aspect of the present disclosure, there is provided an aerosol-forming system including an aerosol-forming device and a removable aerosol forming article, wherein the aerosol-forming article includes an air inlet and an air outlet, wherein one or more walls forming the air inlet and the air outlet are made of a compressible material for engagement with the upstream fluidic interconnection element and / or for engagement with the downstream fluidic interconnection element. The walls forming the air inlet and the air outlet of the aerosol-forming article may be part of or may constitute the frame of the aerosolforming article and may also be referred to as such. The air outlet may also be referred to herein as aerosol outlet of the aerosol-forming article. For instance, in direction of an airflow through the aerosol-forming article, which may correspond to or be parallel to a longitudinal axis of the aerosol-forming device, the aerosol-forming article may be arranged between the upstream fluidic interconnection element and the downstream fluidic interconnection element. The downstream fluidic interconnection element may also be referred to as first or top fluidic interconnection element. The upstream fluidic interconnection element may also be referred to as second or bottom fluidic interconnection element. Therein, the air inlet may be fluidically coupled to the upstream fluidic interconnection element and the air or aerosol outlet may be fluidically coupled to the downstream fluidic interconnection element.

[0214] According to an aspect of the present disclosure, there is provided an aerosol-forming system including an aerosol-forming article and an aerosol-forming device. The aerosol-forming device may be any aerosol-forming device described with reference to any aspect of the present disclosure. In particular, the aerosol-forming device includes a heating chamber for at least partially and removably receiving the aerosol-forming article. The aerosol-forming article includes an aerosol-forming substrate and has a substantially rectangular parallelepiped shape, defining a longitudinal axis. Therein, the aerosol-forming device includes one or more fluidic interconnection elements, for example one or more of the upstream fluidic interconnection element and the downstream fluidic interconnection element. The at least one fluidic interconnection element includes a blade structure surrounding a flow path, wherein the blade structure includes a first end configured to face towards a side face or end face of the aerosol-forming article. The aerosol-forming article includes a cavity or compartment for receiving an aerosol-forming substrate, and a fluidic opening arranged on a side face or end face fluidically connected to the cavity, wherein, upon pressing the aerosol-forming article against the fluidic interconnection element, the blade structure of the fluidic interconnection element is configured to cut or press into a wall or frame around the fluidic opening to provide for a fluidic connection between the aerosol-forming device and the removable aerosol-forming article.

[0215] According to an aspect of the present disclosure, there is provided an aerosol-forming system including an aerosol-forming article and an aerosol-forming device, for example an aerosol-forming device according to one or more aspects of the present disclosure. The aerosol-forming device may include a heating chamber for at least partially and removably receiving the aerosol-forming article, the aerosolforming article including an aerosol-forming substrate and having a substantially rectangular parallelepiped shape. Therein, the heating chamber includes two opposing heater elements forming a substantially rectangular parallelepiped heating volume therebetween for removably and at least partially receiving the aerosol-forming article. The terms heater element and heating element may be interchangeably or synonymously used herein. The heating volume defines an insertion axis for inserting the article therein. The insertion axis may be parallel to or coaxial to the longitudinal axis of the aerosol-forming device. Therein, the aerosol-forming article may have a length, for example as measured along the insertion axis and / or along the longitudinal direction of the aerosol-forming device or article, in a range between 20 mm and 40 mm, preferably between 25 mm and 35 mm, more preferably about 30 mm. The aerosol-forming article may have a width, for example as measured along the transverse direction of the aerosol-forming device or article, in a range between 7 mm and 15 mm, preferably between 9 mm and 13 mm, more preferably about 11 mm. The aerosol-forming article may have a thickness or height, for example as measured along the normal direction of the aerosol-forming device or article, of between 2 mm and 5 mm, preferably between 2.5 mm and 4 mm, more preferably about 3.1 mm. Therein, the length may refer to a minimum, mean or maximum length, the width may refer to a minimum, mean or maximum width and the thickness may referto a minimum, mean or maximum thickness, respectively, height of the aerosol-forming article.

[0216] According to a further aspect of the present disclosure, there is provided an aerosol-forming system, the system including at least one aerosol-forming device as described herein and a companion device configured to charge the aerosol-forming device with electrical energy. The companion device may be configured store and / or at least partly receive the aerosol-forming device, for example in a cavity or compartment thereof.

[0217] According to a further aspect of the present disclosure, there is provided an aerosol-forming system, the system including at least one aerosol-forming device as described herein and a companion device configured to charge the aerosol-forming device with electrical energy. The companion device may be configured store and / or at least partly receive the aerosol-forming device, for example in a cavity or compartment thereof.

[0218] According to a further aspect of the present disclosure, there is provided an aerosol-forming system, the system including at least one aerosol-forming device as described herein and at least one aerosolgenerating article as described herein. Various optional and advantageous features of aerosol-generating systems according to the present disclosure are set out in greater detail below.

[0219] Optional and advantageous features according to the present disclosure

[0220] 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 aerosol-generating 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.

[0221] 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 aerosol-generating 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 aerosol-generating 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 aerosolgenerating 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.

[0222] 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%.

[0223] 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

[0224] The term “aerosol-forming substrate” may conveniently be used to refer to a substantially flat structural component. An aerosol-generating article according to the present disclosure may be formed entirely from such an aerosol-forming substrate, or may include such an aerosol-forming substrate as a component part of the aerosol-generating article. An aerosol-generating article may comprise two or more aerosol-forming substrates as described herein. For avoidance of doubt, where the following paragraphs describe aerosol-forming substrates, those substrates may be equivalent to an aerosol-generating article according to the present disclosure, or may be a component part of an aerosol-generating article according to the present disclosure.

[0225] The aerosol-forming substrate may have a RTD in a direction perpendicular to the z direction, the resistance to draw being less than 20 millimetre H2O, for example less than 10 millimetre H2O. An air-flow path may be defined through the aerosol-forming substrate along the x direction from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, such that the aerosol-forming substrate has a RTD of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in the x direction. An air-flow path may be defined through the aerosol-forming substrate along the y direction from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, such that the aerosol-forming substrate has a RTD of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in the y direction.

[0226] Particularly preferably, the RTD is less than 8 millimetre H2O, for example less than 6 millimetre H2O, for example less than 4 millimetre H2O, for example less than 2 millimetre H2O. Preferably the RTD on an air-flow path through the substrate is close to zero millimetre H2O.

[0227] The RTD may be between 9.9 millimetre H2O and 0 millimetre H2O, for example between 8 millimetre H2O and 1 millimetre H2O, or between 6 millimetre H2O and 2 millimetre H2O, or between 5 millimetre H2O and 3 millimetre H2O.

[0228] 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-forming substrate. The terms “pressure drop” or “draw resistance” of a component or article may also refer to the “resistance to draw”. Such terms generally refer to the measurements in accordance with ISO 6565-2015 are normally carried out at under test at a volumetric flow rate of about 17.5 millilitres per second at the output or downstream end of the measured component at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr) and a relative humidity of about 60%.

[0229] An air-flow path through the substrate may be defined in terms of porosity, for example a percentage of the substrate that is free of aerosol-forming material. The porosity in this case is open porosity, allowing an air-flow path through the substrate. Thus, an aerosol-forming substrate may have an air-flow path defined through the aerosol-forming substrate in an x / y plane from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, and the aerosol-forming substrate may have a porosity of greater than 60 %, for example greater than 80 %, in the direction of the airflow path. The porosity may be greater than 60 %, for example greater than 80 %, in at least one direction in an x / y plane of the aerosolforming substrate. The aerosol-forming substrate may have a porosity in a direction perpendicular to the z direction, the porosity of greater than 60 %, for example greater than 80 %. For example, an air-flow path may be defined through the aerosol-forming substrate along the x direction from one side of the aerosolforming substrate to the other side of the aerosol-forming substrate, such that the aerosol-forming substrate has a porosity of greater than 60 %, for example greater than 80 %, in the x direction. The aerosol-forming substrate may have an air-flow path defined through the aerosol-forming substrate along the y direction from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, such that the aerosol-forming substrate has a porosity of greater than 60 %, for example greater than 80 %, in the y direction. The porosity of the air-flow path may be defined by a ratio of the cross-sectional area of material within the air-flow path and an internal cross-sectional area of the air-flow path.

[0230] Preferably, the porosity is between 81 % and 99%, for example a porosity of between 85% and 95%, for example between 88% and 92%, for example about 90%, in the direction of the air-flow path.

[0231] The substrate may comprise an upper layer defining an upper surface and a lower layer defining a lower surface, in which an air flow path is defined through the aerosol-forming substrate between the upper layer and the lower layer. For example, the substrate may comprise an upper layer defining an upper surface and a lower layer defining a lower surface, in which an air flow path is defined through the aerosolforming substrate from one side to an opposite side between the upper layer and the lower layer. For example, the substrate may comprise an upper layer defining an upper surface and a lower layer defining a lower surface, in which an air flow path is defined in an x / y plane through the aerosol-forming substrate from one side to an opposite side between the upper layer and the lower layer. Preferably, a plurality of channels are defined through the aerosol-forming substrate between the upper surface and the lower surface. The channels preferably provide a low RTD air-flow path through the substrate,

[0232] The aerosol-forming substrate may comprise a separation layer located between the upper layer and the lower layer. For example, a separation layer may comprise one or more ribs or struts separating the upper layer from the lower layer, preferably in which the ribs or struts extend in the direction of an air flow path defined through the aerosol-forming substrate. The separation layer may, therefore, define a distance between the upper layer and the lower layer.

[0233] Preferably, the aerosol-forming substrate comprises a corrugated portion, for example one or more corrugate elements. For example, the separation layer may comprise, or consists of, a corrugated element, for example a corrugated sheet of material. The aerosol-forming substrate may comprise an upper layer, a lower layer, and a separation layer located between the upper layer and the lower layer, in which the separation layer comprises one or more corrugated elements. The one or more corrugated elements preferably define a plurality of air flow channels extending through the aerosol-forming substrate. In some examples a corrugated structure may be combined with a single planar layer.

[0234] The use of a corrugated structure in the aerosol-forming substrate may advantageously allow the production of an aerosol-forming substrate 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, aerosolforming substrate to be produced using high speed production methods similar to those used for production of corrugated cardboard.

[0235] The aerosol-forming substrate may comprise a plurality of corrugated elements. For example, two or more corrugated elements may be arranged in vertical relationship to each, for example between an upper layer and a lower layer. The plurality of corrugated elements may be described as vertically stacked. For example, the aerosol-forming substrate may comprise an upper corrugated element arranged in contact with the upper layer, and a lower corrugated element arranged in contact with the lower layer. There may be more than two corrugated elements. For example, the substrate may comprise at least one additional corrugated element disposed between the upper corrugated element and the lower corrugated element.

[0236] The aerosol-forming substrate may comprise a plurality of corrugated elements, in which two or more of the plurality of corrugated elements are arranged in a lateral side by side relationship to each other between the upper layer and the lower layer. Air following an air-flow path through the substrate may flow through either a first side by side spaced corrugated element or a second side by side spaced corrugated element.

[0237] The aerosol-forming substrate may comprise a plurality of corrugated elements, in which two or more of the plurality of corrugated elements are arranged in a lateral end to end relationship to each other between the upper layer and the lower layer. Air following an air-flow path through the substrate may flow through both a first end to end spaced corrugated element or a second end to end spaced corrugated element.

[0238] The aerosol-forming substrate may be defined as having a proximal end and a distal end. An air-flow path may be defined through the substrate between the proximal end and the distal end. Advantageously, the air flow path may be defined by at least one corrugated element. For example, ridges and troughs of the at least one corrugated element may be aligned substantially parallel to the air flow direction thereby forming an air-flow path in that direction.

[0239] An aerosol-forming substrate may comprise a first corrugated element located at or towards the proximal end of the substrate and a second corrugated element located at or towards the distal end of the substrate. For example, the first corrugated element and the second corrugated element may be arranged in a lateral end to end relationship to each other between an upper layer and a lower layer, each corrugated element being aligned substantially parallel to the air flow direction. In this example, the air-flow path would extend through both the first corrugated element and the second corrugated element.

[0240] The aerosol-forming substrate comprises an aerosol-forming material. Preferably the aerosolforming material forms at least part of a corrugated structure or corrugated element. The aerosol-forming material may be in the form of a sheet used as one or more of the components of a corrugated structure or corrugated element. This may allow great flexibility in selection of different combinations of aerosol-forming materials. This may also allow selection of suitable non-aerosol-forming materials to be used for other purposes, for example to improve the structure of the substrate. In some examples, the entire aerosolforming substrate is formed from aerosol-forming materials.

[0241] Thus, the aerosol-forming substrate may comprise an upper layer, a lower layer, and an intermediate layer disposed between the upper layer and the lower layer, in which the upper layer comprises, or consists of, an aerosol-forming material, for example in which the upper layer comprises, or consists of, an aerosolforming material and the lower layer and the intermediate layer do not comprise an aerosol-forming material.

[0242] Alternatively, the aerosol-forming substrate may comprise an upper layer, a lower layer, and an intermediate layer disposed between the upper layer and the lower layer, in which the lower layer comprises, or consists of, an aerosol-forming material, for example in which the lower layer comprises, or consists of, an aerosol-forming material and the upper layer and the intermediate layer do not comprise an aerosol-forming material.

[0243] Alternatively, the aerosol-forming substrate may comprise an upper layer, a lower layer, and an intermediate layer disposed between the upper layer and the lower layer, in which the intermediate layer comprises, or consists of, an aerosol-forming material, for example in which the intermediate layer comprises, or consists of, an aerosol-forming material and the upper layer and the lower layer do not comprise an aerosol-forming material.

[0244] Alternatively, the aerosol-forming substrate may comprise an upper layer, a lower layer, and an intermediate layer disposed between the upper layer and the lower layer, in which the lower layer comprises, or consists of, a first aerosol-forming material and the upper layer comprises, or consists of, a second aerosol-forming material, and the intermediate layer does not comprise an aerosol-forming material.

[0245] Alternatively, the aerosol-forming substrate may comprise an upper layer, a lower layer, and an intermediate layer disposed between the upper layer and the lower layer, in which the lower layer comprises, or consists of, a first aerosol-forming material and the intermediate layer comprises, or consists of, a second aerosol-forming material, and the lower layer does not comprise an aerosol-forming material.

[0246] Alternatively, the aerosol-forming substrate may comprise an upper layer, a lower layer, and an intermediate layer disposed between the upper layer and the lower layer, in which the upper layer comprises, or consists of, a first aerosol-forming material and the intermediate layer comprises, or consists of, a second aerosol-forming material, and the upper layer does not comprise an aerosol-forming material.

[0247] Alternatively, the aerosol-forming substrate may comprise an upper layer, a lower layer, and an intermediate layer disposed between the upper layer and the lower layer, in which the upper layer comprises, or consists of, a first aerosol-forming material and the intermediate layer comprises, or consists of, a second aerosol-forming material, and the lower layer comprises, or consists of, a third aerosol-forming material.

[0248] The aerosol-forming substrate is preferably formed from sheets of material. For example, each of the upper layer, lower layer, and intermediate layer are preferably formed from sheets of material. The sheets may be sheets of an aerosol-forming material, for example sheets of homogenised tobacco material. The sheets may be sheets of a non-aerosol-forming material, for example sheets of paper. The thickness of any sheet forming part of the aerosol-forming substrate may be between 0.02 mm to 2 mm. For example, any sheet forming part of the aerosol-forming substrate may have a thickness of between 0.05 mm to 1 .5 mm, for example between 0.1 mm and 1 mm, for example between 0.2 mm and 0.8 mm, for example between 0.3 mm and 0.6 mm, for example between 0.4 mm and 0.5 mm.

[0249] In certain embodiments, sheets of homogenised tobacco material for use in aerosol-forming substrates as described herein may have a thickness of between 10 pm and about 300 pm. In certain embodiments, sheets of homogenised tobacco material for use in aerosol-forming substrates as described herein may have a grammage of between 100 g / m2and about 300 g / m2.

[0250] Preferably, the upper layer comprises, or is formed from, a planar sheet of material, the lower layer comprises or is formed from a planar sheet of material, and the intermediate layer comprises or is formed from a corrugated sheet of material. In this case, at least some of the air-flow channels formed by the corrugations are at least partially bounded by aerosol-forming material. This allows for an aerosol generated from the aerosol-forming material to be easily entrained in the air-flow path.

[0251] The aerosol-forming substrate may comprise a first aerosol-forming material and a second aerosolforming material. The aerosol-forming substrate may comprise a third aerosol-forming material.

[0252] The first aerosol-forming material may be the same material as the second aerosol-forming material. The first aerosol-forming material may be the same material as the third aerosol-forming material, for example the first, second, and third aerosol-forming materials may all be the same aerosol-forming material. The first aerosol-forming material may be different to the second aerosol-forming material, for example of different composition to the second aerosol-forming material, for example with different aerosolformer content, or different flavour content, or different nicotine content. The first aerosol-forming material may be different to the third aerosol-forming material, for example of different composition to the third aerosol-forming material, for example with different aerosol-former content, or different flavour content, for example in which first, second, and third aerosol-forming materials are all different materials.

[0253] The aerosol-forming material may be a homogenised tobacco material. For example, any of the first, second, or third aerosol-forming materials may be a homogenised tobacco material.

[0254] The aerosol-forming substrate may comprise an upper layer, a lower layer, and an intermediate layer disposed between the upper layer and the lower layer, in which the intermediate layer is fixed relative to at least one of the upper layer and lower layer by an adhesive, for example an adhesive comprising a gum, for example guar gum. Optionally, the adhesive may be an aerosol forming material. For example, the adhesive may be a homogenised tobacco slurry. The adhesive may be, or may comprise, a flavourant and / or an aerosol-former. It is thus possible to form an aerosol-forming substrate in which all component parts, including the adhesive, are formed from aerosol-forming material.

[0255] In examples in which the substrate comprises an intermediate layer, the intermediate layer may comprise, or consist of, a corrugated element.

[0256] Preferably, an air-flow path is defined through the aerosol-forming substrate by channels formed or defined by longitudinally extending corrugations of a corrugated element. Optionally, a porous material may be located within the channels formed by the longitudinally extending corrugations. The porous material may comprise, or consist of, an aerosol-forming material. The porous material may comprise a flavourant or an aerosol-former. For example, the porous material may be soaked in a liquid flavourant or liquid aerosol-former.

[0257] A flavourant may be located within the channels formed by the longitudinally extending corrugations to release flavour on heating. For example a flavour thread and / or one or more flavour capsules may be located within the channels. A flavour capsule may be a capsule containing a liquid or gel flavourant, for example a capsule configured to release its contents on heating, or a frangible capsule designed to be broken by a user prior to use.

[0258] Preferably an airflow path, or the airflow path, is defined through the aerosol-forming substrate in an x / y plane from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate. The airflow path may pass through a filter or mesh or porous material such as porous paper, for example tea-bag material, incorporated in the aerosol-forming substrate. The filter or mesh or porous material, may be disposed transverse to the airflow path, for example across a proximal ordownstream end of the aerosolforming substrate. Such a filter or mesh or porous material may advantageously act as a filter to prevent solid particulates from being inhaled by a user while not increasing the RTD to a great extent.

[0259] In this context, the term “porous” is used to mean sufficiently porous so as to allow aerosol formed by the aerosol-forming substrate to escape through the porous layer in use. Advantageously, the porous layer may protect the aerosol-forming substrate from one or both of physical damage and chemical contamination. Advantageously, the porous layer may also help to prevent transfer of aerosol-forming material from the aerosol-forming substrate onto a user handling the aerosol-forming substrate. The aerosol-forming substrate may comprise a substantially planar layer and a corrugated layer fixed to a surface of the substantially planar layer such that longitudinal channels formed by longitudinally extending corrugations of the corrugated layer extend in a planar direction of the substantially planar layer.

[0260] Any planar layer described herein, for example any one or more of the first planar layer, the second planar layer, the upper planar layer and the lower planar layer, may be a single, unitary, planar component, for example a planar sheet.

[0261] The aerosol-forming substrate may comprise an upper layer, a lower layer, and an intermediate layer, in which at least one of the upper layer and the lower layer comprises perforations or holes such that at least a portion of air can flow through the upper and / or lower layer. Preferably, the aerosol-forming substrate comprises a proximal or mouth end and a distal end. The perforations or holes may be located in a central portion of the aerosol-forming substrate, for example approximately midway between the proximal or mouth end and the distal end. The intermediate layer may comprise, or consist of, a corrugated element or layer arranged between the upper layer and the lower layer such that longitudinal channels formed by longitudinally extending corrugations of the corrugated element or layer extend in a planar direction of the upper layer and lower layer. The intermediate layer may comprise perforations or holes such that at least a portion of air can flow through the intermediate layer in a direction perpendicular to the longitudinally extending channels. At least one of the upper layer, the lower layer, and the intermediate layer may be, or comprise, a mesh.

[0262] The aerosol-forming substrate may comprise an upper layer, a lower layer, and an intermediate layer, and the intermediate layer may comprise, or consist of, a corrugated element or layer arranged between the upper layer and the lower layer such that longitudinal channels formed by longitudinally extending corrugations of the corrugated element or layer extend in a planar direction of the upper layer and lower layer, and in which the intermediate layer comprises perforations or holes such that at least a portion of air can flow through the intermediate layer in a direction perpendicular to the longitudinally extending channels.

[0263] The aerosol-forming substrate may comprise a proximal end and a distal end. The proximal end may be termed the mouth end. Longitudinal channels formed by longitudinally extending corrugations of the corrugated element or layer may extend in a direction perpendicular to a direction defined between the proximal or mouth end and the distal end. In this case, it may be particularly advantageous for corrugated portion of the corrugated element to comprise perforations or holes such that at least a portion of air can flow through the corrugated element in a direction perpendicular to its longitudinally extending channels.

[0264] The aerosol-generating substrate may comprise one or more sheets of aerosol-forming material, in which a plurality of holes or notches are defined in a surface, for example an upper surface or a lower surface of aerosol-forming material. Where aerosol-forming material is heated, aerosol is generated by gases and vapours which may be released at a surface of the aerosol-forming material. Gases and vapours may also be released between the heated surface of an aerosol-forming material and a heater. Gases released between an aerosol-forming material and a heater may form bubbles which reduce the efficiency of thermal transfer between the heater and the material. A plurality of holes or notches defined in a surface of the aerosol-forming material may advantageously facilitate release of volatilised components of the aerosol-forming material into an air stream passing over a surface of the aerosol-forming material. For example, such holes or notches may provide a low resistance path for gasses and vapours formed by heating the aerosol-forming material to escape from the volume of the material to the surface of the material. By increasing the number of low resistance pathways from the volume of the material to a surface of the material, aerosol deliveries may be improved and substrate utilisation efficiency may be improved.

[0265] The aerosol-forming substrate may comprise a lower layer of aerosol-forming material and a corrugated layer attached to the lower layer, for example a corrugated layer of aerosol-forming material, in which a plurality of holes or notches are defined in at least one of the lower layer of aerosol-forming material and the corrugated layer. A plurality of holes or notches may be defined in an upper surface of the aerosolforming substrate.

[0266] In some examples, at least a portion of the plurality of holes are blind holes that do not extend through the thickness of the aerosol-forming material they are defined in. In some examples, at least a portion of the plurality of holes are through-holes that extend through the thickness of the aerosol-forming material they are defined in.

[0267] The aerosol-forming substrate may comprise a corrugated element or layer, and corrugations of the corrugated element or layer may be defined by a corrugation wavelength and a corrugation peak-to-trough amplitude. The corrugation wavelength may be between 1 mm and 10 mm, for example between 1 .5 mm and 8 mm, for example between 2 mm and 6 mm, for example between 2.5 mm and 5 mm, for example between 3 mm and 4 mm. The corrugation peak-to-trough amplitude may be between 1 mm and 10 mm, for example between 1 .5 mm and 8 mm, for example between 2 mm and 6 mm, for example between 2.5 mm and 5 mm, for example between 3 mm and 4 mm. The corrugation peak-to-trough amplitude is the same as the thickness, for example in the z dimension, of the corrugated element or layer. Thus, for a regular wave-like structure, the peak-to-trough amplitude will be double what would commonly be referred to simply as the amplitude (or the wave amplitude, or the peak-to-midpoint amplitude, or the midpoint-to- trough amplitude).

[0268] Corrugations may be formed in a number of different corrugation profiles. For example, the corrugations may be further defined by a corrugation profile, in which the corrugation profile is sinusoidal, or triangular, or rectangular, or trapezoidal, or toroidal, or parabolic.

[0269] In some examples, the aerosol-forming substrate may be formed as an extrusion of an aerosolforming material, the extrusion having an upper surface, a lower surface, and a plurality of air flow channels defined through the aerosol-forming substrate between the upper surface and the lower surface.

[0270] It may be advantageous for the contact region between the upper and / or lower layer and the intermediate / separation layer to be minimised. The intermediate layer may predominantly provide structure to the substrate, whereas the upper and / or lower layers may predominantly provide aerosol-forming material. Where there is significant contact between the upper / lower layer and the intermediate layer there may be undesirable thermal conduction between the upper / lower layer and the intermediate layer. Thermal conduction may result in portions of the aerosol-forming substrate not reaching an ideal aerosol-generating temperature, or not reaching such a temperature swiftly enough. Cool spots in the aerosol-forming material may result in inefficient delivery of aerosol. Cool spots in the aerosol-forming material may also result in incomplete utilisation of portions of aerosol-forming material. Contact between an upper or lower layer and an intermediate layer may be minimised by selecting appropriate structures for the intermediate layer. For example, where the intermediate layer is corrugated, a triangular profile corrugation may lower the contact area compared with, for example a sinusoidal or trapezoidal profile corrugation.

[0271] As a further example, the intermediate layer may comprise ribs arranged to form walls that extend perpendicularly with respect to the upper and lower layers. Such ribs would form lines of contact between the intermediate layer and upper and lower layers, thereby minimising thermal contact. Ribs may be formed from strips of material arranged such that a width of the strip defines the thickness of the intermediate layer. To facilitate assembly, a plurality of strips may be linked to form an array of ribs that may be positioned to form the intermediate layer. Alternatively, or additionally, strips may be laterally kinked to provide an ability for the strips to stand on their edge and facilitate the assembly process. Advantageously, the strips may be sufficiently kinked to be “self standing” on their edges, which may facilitate assembly.

[0272] As a further example, the intermediate layer may form points of contact with the upper and lower layers. For example, the intermediate layer may comprise a plurality of pillars, each pillar providing a point of contact between the intermediate layer and at least one of the upper layer and the lower layer. The pillars may be separate discrete pillars. Advantageously, such pillars are linked together to facilitate assembly. For example, the intermediate layer may comprise a sheet of material having upwardly and downwardly depending projections that act as pillars to separate the upper and lower layers, while minimizing contact between the intermediate layer and the upper and lower layers. Such a structure also allows for a low RTD airflow path to be defined between the upper layer and the lower layers. Advantageously, such a layer may be provided by forming or embossing a sheet of material such as a sheet of paper. Such a layer may be formed by depositing a pulp onto a shaped surface, for example a shaped mesh surface. The pulp may then be dried and removed from the mesh to form the profiled intermediate layer. In some embodiments the pulp may not be removed from the mesh, in which case the mesh may form part of the profiled intermediate layer. For example, the mesh may form a susceptor of a substrate comprising the profiled intermediate layer.

[0273] The pillars of an intermediate layer may be formed from a plurality of upwardly and downwardly depending structures such as cones formed in the sheet forming the intermediate layer. The profile may resemble and egg box. Such a structure may advantageously provide an overall rigidity to the substrate that allows very thin layers of substrate to be formed. Additionally, airflow through the airflow channels defined between 3-dimensional peaks and troughs of the intermediate layer may undergo sequential accelerations and decelerations on passing through a series of restrictions and expansions, as well as undergoing turbulence. As a result, the airflow may advantageously deliver a highly homogenised mixture of air and aerosol to a user.

[0274] Preferred examples of intermediate layers may have a profile that may be described as egg-box like. The structure of such a layer is one of a regular arrangement of upwardly depending peaks and downwardly depending troughs. The structure of an egg-box like intermediate layer may be described mathematically as a surface or profile obtained by translating perpendicularly a first periodic curve along a second periodic curve, for example by translating perpendicularly a first continuous periodic curve along a second continuous periodic curve, for example by translating perpendicularly a first sinusoid along a second sinusoid. The shape, amplitude, and period of the first periodic curve may be similar or identical to the shape, amplitude and period of the second periodic curve. For example, one or both of the first periodic curve and the second periodic curve may be a sinusoidal curve, for example in which both the first and second periodic curve are sinusoidal curves having the same period and amplitude. The periodic curves may have other profiles, for example one or both of the periodic curves may be a square wave curve, or a triangular wave curve, or a trapezoidal wave curve. The shape of the resulting peaks and troughs will depend on the shape of the curves. The shape of the intermediate layer may be described as a sinusoidal surface. A general equation defining the shape of an egg-box like intermediate layer can be defined. Thus, for a sinusoid function defined by s(x) = Asin(s / b), for a horizontal plan x,y, a vertical axis z, a total vertical height (distance from the top of a peak to the bottom of a valley) of 2A and a periodicity of the peaks and valleys so that there is a peak and a valley every 2nb unit long, the general equation defining the shape may be written as: z = A (sin (x / fe) + sin (y / fe))

[0275] In the resulting intermediate layer structure, each peak (other than peaks at the edges of the structure) are surrounded by four troughs, and each trough (other than troughs at the edge of the structure) are at the centre of four peaks. The precise shape of the peaks and troughs will depend on the shape of the periodic curves forming the x and y profiles of the surface. For example, the peaks and troughs may have a substantially circular profile in plan view, or a substantially rectangular profile on plan view, for example the peaks and troughs may present a square or diamond shaped profile in plan view.

[0276] The configuration of peaks and troughs may influence air flow through the aerosol-forming substrate. For example, the intermediate layer may be arranged and / or oriented to enhance turbulence in an air flow path through the article. Advantageously, an enhanced turbulence may result in more homogeneous mixing of air and vapour within the article, which may result in a more homogeneous aerosol.

[0277] The aerosol-forming substrate may consist entirely of aerosol-forming material.

[0278] The aerosol-forming substrate may further comprise a porous layer covering at least one surface of the aerosol-forming substrate, for example at least an upper surface, or at least a lower surface, or at least upper and lower surfaces. The porous layer may cover at least an end surface of the aerosol-forming substrate, for example at least covering at least one airflow inlet or outlet of the aerosol-forming substrate. The porous layer may completely encapsulate the aerosol-forming substrate. The porous layer may be a porous paper or a porous mesh, for example a layer of tea-bag material. A porous layer may protect a surface of the aerosol-forming substrate, or protect a user handling the aerosol-forming substrate, while allowing passage of gaseous components released from the aerosol-forming substrate.

[0279] 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.

[0280] Preferably, the aerosol-forming substrate comprises, or consists of, homogenised tobacco material, for example a reconstituted tobacco material or a cast leaf tobacco material.

[0281] 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 aerosolforming material retained within a porous matrix. The aerosol-forming substrate may comprise a gel aerosol-forming material.

[0282] A first portion of the aerosol-forming substrate may comprise a first aerosol-forming material, and a second portion of the aerosol-forming substrate may comprise a second aerosol-forming material different to the first aerosol-forming material. For example, the first aerosol-forming material may be a first homogenised tobacco material, and the second aerosol-forming material may be a second homogenised tobacco material having a different composition to the first homogenised tobacco material. The first homogenised tobacco material composition may differ from the second tobacco composition by virtue of having at least one difference selected from the list consisting of: different aerosol-former content, different tobacco content, different flavourant content, different water content, and different nicotine content. The first aerosol-forming material may be a first homogenised tobacco material, and the second aerosol-forming material may be a non- tobacco aerosol forming material comprising an aerosol-former, such as glycerine or propylene glycol, preferably including a flavour component and or an active component such as nicotine or a cannabinol.

[0283] Advantageously, substrates comprising two or more different aerosol-forming materials may allow combinations of aerosol-forming materials which may not otherwise be available. This could allow, for example, combinations of flavours which enhance the user experience. Suitable aerosol-forming material or materials are described in more detail below.

[0284] The aerosol-forming material may comprise particles of a functional material, for example particles of carbon, graphite, activated carbon, or expanded graphite. Such materials may, for example, increase the thermal conductivity of the aerosol-forming material and improve efficiency of aerosol generation.

[0285] The aerosol-forming substrate may further comprise a thermally conductive layer, for example an aluminium layer, covering at least a portion of at least one surface of the aerosol-forming substrate. For example, at least a portion of an upper surface, or at least a portion of a lower surface may comprise such a thermally conductive layer. A thermally conductive layer may facilitate thermal transfer between a heat source and the aerosol-forming material of the aerosol-forming substrate.

[0286] The aerosol-forming substrate may further comprise a paper layer, for example a tipping paper layer, covering at least a portion of at least one surface of the aerosol-forming substrate, for example at least a portion of an upper surface, or at least a portion of a lower surface. A paper layer may protect a user’s hand when handling the substrate. A paper layer may be used to allow a user to insert a portion of the aerosolforming substrate into their mouth.

[0287] The aerosol-forming substrate may comprise conductive materials. For example, the aerosol-forming material may comprising conductive particles. Conductive particles may be, for example, conductive carbon or graphite particles, or conductive metallic particles, for example particles of aluminium, or stainless steel, or nickel.

[0288] The aerosol-forming substrate may comprise one or more susceptor materials. The one or more susceptor materials may be incorporated within an aerosol-forming material of the aerosol-forming substrate, for example as particles of susceptor material distributed within the aerosol-forming material. The presence of susceptor materials may allow the aerosol-forming substrate to he heated by engagement with a fluctuating electromagnetic field formed by an inductor.

[0289] Optionally, one or more susceptor materials may be incorporated within the aerosol-forming substrate as one or more strips, threads, or wires of susceptor material, for example one or more strips, threads, or wires of susceptor material located within an airflow path of the aerosol-forming substrate.

[0290] Optionally, one or more susceptor materials may be incorporated within the aerosol-forming substrate as one or more sheets or layers of susceptor material, for example one or more sheets or layers of susceptor material covering an external portion of the aerosol-forming substrate, or forming a structural component of the aerosol-forming substrate.

[0291] The aerosol-forming substrate may comprise a first planar layer, and a corrugated layer arranged on a surface of the first planar layer, at least one of the first planar layer and the corrugated layer comprising or consisting of a sheet of susceptor material.

[0292] The aerosol-forming substrate may comprise 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 comprising or consisting of a sheet of susceptor material.

[0293] The one of more sheet of susceptor material may be in the form of a mesh of susceptor material.

[0294] The susceptor material, in whatever form, may comprise one or more materials selected from the list consisting of: aluminium, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0295] Aerosol-forming substrates as disclosed herein may be manufactured using any suitable method. For example, sheets of material, including aerosol-forming material may be formed using known methods and assembled together to form the aerosol-forming substrate. In some examples, an extrusion process may be used to form an aerosol-forming substrate.

[0296] Where the substrate comprises a corrugation layer or a corrugated element, it may be advantageous to manufacture the substrate using a process similar to that used to produced corrugated cardboard.

[0297] As disclosed herein, a method of making a planar corrugated aerosol-forming substrate may comprise steps of: providing a first continuous sheet, providing a second continuous sheet, at least one of the first sheet and the second sheet being a sheet comprising or consisting of aerosol-forming material, texturing the second continuous sheet using a fluting roller to form a continuous corrugated sheet, applying adhesive to at least one of the continuous corrugated sheet or the first continuous sheet, applying the continuous corrugated sheet to a surface of the first continuous sheet to form a continuous aerosol-forming substrate, and cutting the continuous aerosol-forming substrate to form the planar corrugated aerosolforming substrate.

[0298] A method of making a planar corrugated aerosol-forming substrate may comprise steps of: providing a first continuous sheet, providing a second continuous sheet, and providing a third continuous sheet, at least one of the first sheet, the second continuous sheet, and the second sheet being a sheet comprising or consisting of aerosol-forming material, texturing the second continuous sheet using a fluting roller to form a continuous corrugated sheet, applying adhesive to at least one of the continuous corrugated sheet or the first continuous sheet, applying a first side of the continuous corrugated sheet to a surface of the first continuous sheet, applying adhesive to at least one of the continuous corrugated sheet and the third continuous sheet, and applying a second side of the continuous corrugated sheet to a surface of the third continuous sheet, thereby forming a continuous aerosol-forming substrate, and cutting the continuous aerosol-forming substrate to form the planar corrugated aerosol-forming substrate.

[0299] At least one of the first second and third continuous sheets may be a sheet of homogenised tobacco.

[0300] The adhesive may comprise guar gum. The adhesive may comprise an aerosol-forming substrate, for example a homogenised tobacco slurry.

[0301] According to the present disclosure, an aerosol-generating article for use with an aerosol-generating article may be provided. The aerosol-generating article may be used to generate an inhalable aerosol. The article comprises an aerosol-forming substrate as disclosed herein. The article may consist entirely of an aerosol forming substrate as disclosed herein. Advantageously, this may provide one or more of the following benefits: a reduction in the cost to manufacture the article, a reduction in the weight and therefore cost to transport the article, and a reduction in waste from manufacturing or using the article.

[0302] The aerosol-generating article may comprise the aerosol-forming substrate located or assembled within an outer wrapper or outer casing. The outer wrapping or outer casing may be a cigarette wrapper. The outer wrapping or outer casing may be a polymeric sheet. Optionally, the outer wrapping or outer casing may comprise a susceptor material, for example a portion of aluminium or stainless steel foil.

[0303] Optionally, one or more perforations may be defined through the outer wrapping or outer casing. Such perforations may allow air flow into or out of the article.

[0304] In some examples, the aerosol-generating article may comprise a plurality of components, and the plurality of components, including the aerosol-forming substrate, may be assembled within the outer wrapping or outer casing.

[0305] Optionally, the aerosol-generating article may comprise two or more aerosol-forming substrates as disclosed herein.

[0306] 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 longitudinal airflow path may be defined through the aerosol-generating article between a distal end of the article and a proximal end of the article.

[0307] The aerosol-generating article may be defined by a length extending in an x direction between a distal end and a proximal end, a width extending in a y direction between a first edge and a second edge, and a height extending in a z direction between an upper surface and a lower surface. A distal portion of the aerosol-generating article may be defined between the distal end of the aerosol-generating article and a longitudinal mid-point of the aerosol-generating article. A proximal portion of the aerosol-generating article may be defined between the proximal end of the aerosol-generating article and the longitudinal mid-point of the aerosol-generating article.

[0308] The aerosol-generating article may comprise a single aerosol-forming substrate that extends between the proximal end and the distal end within the article.

[0309] Optionally, the aerosol-forming substrate may be located within the distal portion of the aerosolgenerating article. In some examples, the aerosol-forming substrate may be located entirely within the distal portion of the aerosol-generating article. The proximal portion may be a portion of the article configured to be inserted into an aerosol-generating device.

[0310] The aerosol-generating article may further comprise a structural element located proximally relative to the aerosol-forming substrate. The structural element may comprise longitudinal channels or porosity allowing an airflow path through the structural element.

[0311] The aerosol-forming substrate may be defined by its transverse cross-section, and the structural element may have a similar or identical transverse cross-section to the aerosol-forming substrate, for example a similar rectangular transverse cross-section. The structural element may be a rectangular tube.

[0312] Optionally, the structural element may comprise a corrugated element, for example such that longitudinal channels within the aerosol-generating article are defined by the corrugated element. The longitudinal channels may be defined by corrugations of the corrugated element.

[0313] The aerosol-generating article may comprise a first aerosol-forming substrate as disclosed herein located at least partially within the distal portion of the aerosol-generating article, and a second aerosolforming substrate as disclosed herein located proximally relative to the first aerosol-forming substrate, for example at least partially within the proximal portion of the aerosol-generating article.

[0314] In some examples, the aerosol-generating article comprises a plurality of components, including at least one aerosol-forming substrate as disclosed herein, a substantially hollow structural element, for example a hollow tube, and a mouthpiece element, for example a mouthpiece filter. The plurality of components may be coaxially aligned and assembled within a wrapper or casing. The aerosol-generating article has a length, a width, and a height. Optionally, the length may be greater in magnitude than the width. Optionally, the width may be greater in magnitude than the height.

[0315] The length of the article may be about 1.5 times the magnitude of the width, or about 2 times the magnitude of the width, or about 2.5 times the magnitude of the width, or about 3 times the magnitude width. The length may be greater than 3 the magnitude of the width, for example greater than 4 times the magnitude of the width, for example greater than 5 times the magnitude of the width.

[0316] Preferably, the aerosol-generating article comprises a substantially planar base. For example the base may be defined by a substantially planar lower surface of the aerosol-forming substrate. In preferred examples, the aerosol-generating article may be in the form of a 3-dimensional shape that may be described as cuboid, or rectangular prismatic.

[0317] The length of the article may have a magnitude equal to or greater than 2 times the magnitude of the height, for example 3 times, or 4 times, or 5 times the height, optionally equal to or greater than 6 times the height, for example 10 times the height, or 15 times the height, or 20 times the height.

[0318] The length of the article may be between 10 mm and 50 mm, for example between 12 mm and 30 mm, for example between 14 mm and 26 mm, for example between 16 mm and 24 mm, for example between 18 mm and 22 mm, for example about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.

[0319] The width of the article may be between 5 mm and 20 mm, for example between 8 mm and 18 mm, for example between 10 mm and 16 mm, for example between 11 mm and 15 mm, for example between 12 mm and 14 mm, for example about 13 mm.

[0320] The height of the article may be between 1 mm and 10 mm, for example between 1 .2 mm and 8 mm, for example between 1 .4 mm and 7 mm, for example between 1 .6 mm and 6 mm, for example between 1 .7 mm and 5 mm, for example about 1 .7 mm, or about 4.5 mm, or about 2 mm, or about 3 mm, or about 4 mm.

[0321] The aerosol-generating article may comprise a first section and a second section removably couplable to the first section. The first section may comprise an aerosol-forming substrate as described herein, and the second section may be, or may comprise, a mouthpiece. The second section may be a reusable mouthpiece designed for use with multiple first sections.

[0322] As mentioned previously, the aerosol-generating article may be an aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol, the aerosol-generating article comprising: an article upstream end and an article downstream end, and an article length extending from the article upstream end to the article downstream end. The aerosol-generating article may comprise or consist of an aerosol-forming substrate, for example any aerosol-forming substrate as described herein.

[0323] The article or substrate may comprise a corrugated element. The corrugated element may comprise one or more perforations or holes for air to flow through the corrugated element. An article air flow path extending from the article upstream end to the article downstream end may extend through the one or more perforations or holes. The one or more perforations or holes may place adjacent channels formed by corrugations of the corrugated element in fluid communication. Advantageously, the perforations or holes may allow adjustment of the RTD of the article.

[0324] The article or substrate may comprise one or more corrugated elements, the one or more corrugated elements together extending at least 50, 60, 70, 80, 90, 95, 98, or 99%, or substantially all, of the article length. Advantageously, this may provide structural support to the article across a large proportion of the article.

[0325] Alternatively, or in addition, the article or substrate may comprise one or more sheets of aerosolforming material. At least one, for example each, of the one or more sheets of aerosol-forming material may have a thickness of less than 1 mm. The one or more sheets of aerosol-forming material may together extend along at least 50, 60, 70, 80, 90, 95, 98, or 99%, or substantially all, of the article length. Advantageously, this may allow the aerosol-generating article to comprise more aerosol-forming material and therefore last longer in use. In addition, advantageously, the use of a long, thin sheet of aerosol-forming material may result in a smaller temperature gradient across the aerosol-forming material compared with a shorter, thicker plug of aerosol-forming material.

[0326] In the context of the above two paragraphs, and in analogous contexts, the term “together extend” and the like should not be interpreted to count overlapping lengths twice. Thus, as an example, for an article having two elements spaced apart in the thickness direction or in the width direction of the article, one element starting at the upstream end and extending along 60% of the article length, and another element starting at the downstream end and extending along 60% of the article length, the elements would together extend along 100% of the article length, not 120% of the article length. In addition, two elements spaced apart in a direction of the length of the article are not considered to together extend along the gap spanning between those two elements in the direction of the length of the article. Thus, as an example, for an article having only two elements spaced apart in the direction of the length of the article, one element starting at the upstream end and extending along 20% of the article length, and the other element starting at the downstream end and extending along 20% of the article length, the elements would together extend along 40% of the article length, not 100% of the article length.

[0327] At least one, for example each, of the one or more sheets of aerosol-forming material may have a thickness of less than 1 , 0.8, or 0.5 mm.

[0328] Optionally, each of the one or more sheets has a thickness less than 1 mm and the one or more sheets together extend along at least 50% of the article length. Optionally, each of the one or more sheets has a thickness less than 1 mm and the one or more sheets together extend along at least 70% of the article length. Optionally, each of the one or more sheets has a thickness less than 1 mm and the one or more sheets together extend along at least 90% of the article length. Optionally, each of the one or more sheets has a thickness less than 1 mm and the one or more sheets together extend along at least 95% of the article length. Optionally, each of the one or more sheets has a thickness less than 1 mm and the one or more sheets together extend along substantially all of the article length.

[0329] Optionally, each of the one or more sheets has a thickness less than 0.8 mm and the one or more sheets together extend along at least 50% of the article length. Optionally, each of the one or more sheets has a thickness less than 0.8 mm and the one or more sheets together extend along at least 70% of the article length. Optionally, each of the one or more sheets has a thickness less than 0.8 mm and the one or more sheets together extend along at least 90% of the article length. Optionally, each of the one or more sheets has a thickness less than 0.8 mm and the one or more sheets together extend along at least 95% of the article length. Optionally, each of the one or more sheets has a thickness less than 0.8 mm and the one or more sheets together extend along substantially all of the article length.

[0330] Optionally, each of the one or more sheets has a thickness less than 0.5 mm and the one or more sheets together extend along at least 50% of the article length. Optionally, each of the one or more sheets has a thickness less than 0.5 mm and the one or more sheets together extend along at least 70% of the article length. Optionally, each of the one or more sheets has a thickness less than 0.5 mm and the one or more sheets together extend along at least 90% of the article length. Optionally, each of the one or more sheets has a thickness less than 0.5 mm and the one or more sheets together extend along at least 95% of the article length. Optionally, each of the one or more sheets has a thickness less than 0.5 mm and the one or more sheets together extend along substantially all of the article length.

[0331] It may be particularly preferable for each of the one or more sheets to have a thickness less than 0.8 mm and the one or more sheets together extend along at least 70% of the article length, and even more preferable for each of the one or more sheets to have a thickness less than 0.5 mm and the one or more sheets together extend along at least 80% of the article length, and most preferable for each of the one or more sheets to have a thickness less than 0.5 mm and the one or more sheets together extend along at least 90% or substantially all of the article length.

[0332] The aerosol-generating article may have an article air flow path extending from the article upstream end to the article downstream end of the article. The article or substrate may comprise a corrugated element. The corrugated element may be one of the one or more corrugated elements discussed above. A cross direction of at least a first portion of the corrugated element may be non-parallel, preferably substantially perpendicular, to one or both of the article length and at least a first portion of the article air flow path. Advantageously, this may allow increasing, or tailoring, the RTD of the article.

[0333] The article air flow path may comprise the air flow path described above in relation to the aerosolforming substrate. Thus, the article air flow path may extend through the aerosol-forming substrate.

[0334] The article may have a substantially planar upper surface defined by a length extending in an x direction and a width extending in a y direction. The article may have 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. The cross direction of at least the first portion of the corrugated element may extend in, or be parallel with, the y direction or the z direction. An angle between the cross direction of at least the first portion of the corrugated element may be at least 15, 30, 45, 60, or 75 degrees to one or both of the article length and at least the first portion of the article air flow path. The cross direction of at least the first portion of the corrugated element is preferably perpendicular to one or both of the article length and at least the first portion of the article air flow path. The first portion of the article air flow path may be defined, at least in part, by the first portion of the corrugated element.

[0335] In technical fields in which corrugation is commonplace, for example in the field of corrugated paper or cardboard, there is standard nomenclature for the three mutually perpendicular directions for a standard corrugated element. A person skilled in the field of this invention would understand this nomenclature but, nonetheless, a brief explanation is set out below.

[0336] A standard corrugated element is formed from a sheet, usually a rectangular sheet, which is bent or folded to have parallel corrugations with constant amplitude and wavelength. A standard corrugated element extends in three mutually perpendicular directions. These directions are the machine direction, the cross direction, and the thickness direction.

[0337] Without wishing to be bound to any particular manufacturing method, the machine direction generally refers to the direction in which material to be corrugated to form the standard corrugated element would be unwound from a roller, or fed into a roller such as the corrugation rollers 511 , 512 of Figure 5, described in more detail later, to form the standard corrugated element. This means that, in the resulting, standard corrugated element, the machine direction refers to the direction extending from a point on a first corrugation peak, to the nearest point on an adjacent corrugation peak. This direction may also be referred to as the wavelength direction, since it is in the same direction as the wavelength of the corrugations would be measured.

[0338] For a standard corrugated element, the cross direction is perpendicular to the machine direction and extends in a direction along a corrugation peak without any change in amplitude. This direction may also be referred to as the longitudinal channel direction herein, since it is the same direction as the longitudinally extending channels formed between adjacent corrugations.

[0339] For a standard corrugated element, the thickness direction is perpendicular to the machine direction and the cross direction and extends in a direction from a midpoint between two adjacent corrugation troughs, to the nearest (i.e., opposing) corrugation peak. This direction may also be referred to as the amplitude direction, since it is in the same direction in which the amplitude of the corrugations would be measured.

[0340] As the skilled person would understand after reading this disclosure, the above directions could also be applied to non-standard corrugated elements. At any point, a non-standard corrugated element may have a local machine direction, a local cross direction, and a local thickness direction.

[0341] Any corrugated element or elements described herein may each be formed from a sheet which is bent or folded to form corrugations. Any corrugated element or elements described herein may each be formed from a sheet forming corrugations through changes in direction of the sheet. The thickness of the sheet forming the corrugated element may differ by no more than 20 or 10 or 5 % along one or both of its length and width. The thickness of the sheet forming the corrugated element may be substantially constant. The thickness of the sheet forming the corrugated element may be less than 1 , 0.8 or 0.5 millimetres. The thickness of the corrugated element may be at least 2, 3, or 5 times a minimum thickness of the sheet. All peaks of corrugations of the corrugated element may have equal amplitude. All troughs of corrugations of the corrugated element may have equal amplitude. All peaks and all troughs of corrugations of the corrugated element may have equal amplitude. All corrugations of the corrugated element may have equal wavelength.

[0342] The aerosol-generating article may be a planar aerosol-generating article. The aerosol-forming substrate may be a planar aerosol-forming substrate. As used herein, the term “planar” may refer to a component having two dimensions, for example a length and a width, each being at least 2, 2.5, 3, 5, or 10 times a third dimension, for example a thickness, each of those three dimensions being perpendicular to one another.

[0343] Thus, the aerosol-generating article may have an article width and an article thickness both perpendicular to the article length. The article width and the article length may each be at least 2, 2.5, 3, 5, or 10 times the article thickness. The aerosol-forming substrate may have a substrate width and a substrate thickness both perpendicular to the substrate length. The substrate width and the substrate length may each be at least 2, 2.5, 3, 5, or 10 times the substrate thickness.

[0344] The article thickness may be the smallest dimension of the article. The article thickness may be less than 7, 6, or 5 millimetres. The substrate thickness may be the smallest dimension of the substrate. The substrate thickness may be less than 7, 6, or 5 millimetres. Advantageously, planar or thin articles or substrates may reduce a maximum distance between a heater and the aerosol-forming material during use. This may advantageously lead to smaller temperature gradients across the aerosol-forming material, thus improving the proportion of aerosol-forming material that can be heated to a high enough temperature to form an aerosol for a given heater temperature, or without a significant risk of burning aerosol-forming material closest to the heater.

[0345] The aerosol-forming substrate may comprise a first planar layer. The corrugated element or the one or more corrugated elements may be arranged on the first planar layer, for example on a first or upper surface of the first planar layer. Troughs of corrugations of the corrugated element or of the one or more corrugated elements may be adjacent to or in contact with the first planar layer, for example the first surface of the first planar layer.

[0346] Optionally in addition to the features of the above paragraph, the aerosol-forming substrate may further comprise a second planar layer. The corrugated element or the one or more corrugated elements may be referred to as a first corrugated layer and may be arranged between the first planar layer and the second planar layer. Peaks of corrugations of the corrugated element or the one or more corrugated elements may be adjacent to or in contact with the second planar layer, for example a second or lower surface of the second planar layer.

[0347] Optionally in addition to the features of the above paragraph, the aerosol-forming substrate may further comprise a second corrugated layer comprising one or both of: at least one corrugated element of the one or more corrugated elements; and one or more additional corrugated elements. The second corrugated layer may be arranged on the second planar layer, for example on a first or upper surface of the second planar layer. Troughs of corrugations of the corrugated element or of the one or more corrugated elements of the second corrugated layer may be adjacent to or in contact with the second planar layer, for example the first or upper surface of the second planar layer.

[0348] Optionally in addition to the features of the above paragraph, the aerosol-forming substrate may further comprise a third planar layer. The second planar layer may be arranged between the first planar layer and the third planar layer. Peaks of corrugations of the corrugated element or of the one or more corrugated elements of the second corrugated layer may be adjacent to or in contact with the second or lower surface of the third planar layer. Such an aerosol-forming substrate is shown in Figure 22 and described later.

[0349] Features described in relation to planar layers herein may be applicable to the first, second and third planar layers of the above four paragraphs.

[0350] The one or more corrugated elements of the article or substrate may comprise at least two, three, four, or five corrugated elements. Advantageously, this may allow the provision of structural support to only the parts of the article or substrate where that support is needed, even where those parts are spaced apart. Also advantageously, the use of two or more corrugated elements may allow the use of different corrugated elements to provide different levels of structural support, or even serve different purposes, such as the provision of structural support and the provision of aerosol-forming material.

[0351] At least one of the at least two corrugated elements may be arranged partially or entirely downstream of another of the at least two corrugated elements. Where there are at least the corrugated element and second and third corrugated elements, the second corrugated element may be partially or entirely upstream of the corrugated element, and the third corrugated element may be partially or entirely downstream of the corrugated element. A cross direction of at least a portion of the second corrugated element may be nonparallel, for example perpendicular, to the cross direction of at least a portion of the corrugated element. A cross direction of at least a portion of the third corrugated element may be non-parallel, for example perpendicular, to the cross direction of at least a portion of the corrugated element. Similarly to before, this may advantageously allow the provision of different levels of structural support to different regions in the article or substrate. Also advantageously, this may allow easy tailoring of the air flow path, and particularly local RTD, in different regions of the article or substrate.

[0352] As an example, the at least two corrugated elements may comprise a first corrugated element, a second corrugated element, and a third corrugated element. A cross direction of at least a portion of the first corrugated element may be substantially parallel to one or both of the article airflow path and the article length. The first corrugated element may advantageously provide structural support at or near an upstream end of the article or substrate. The second corrugated element may be located partially or entirely downstream of the first corrugated element. A cross direction of at least a portion of the second corrugated element may be substantially perpendicular to one or both of the article air flow path and the article length. The second corrugated element may comprise holes or perforations to allow air to flow through the second corrugated element. The second corrugated element may advantageously increase, or allow tailoring of, the RTD of the article or substrate. The third corrugated element may be located partially or entirely downstream of the second corrugated element. A cross direction of at least a portion of the third corrugated element may be substantially parallel to one or both of the article air flow path and the article length. The third corrugated element may advantageously allow cooling of aerosol at or near the downstream end of the article or substrate, and may advantageously provide structural support at or near the downstream end of the article or substrate.

[0353] Alternatively, or in addition, at least one of the at least two corrugated elements may be arranged neither upstream nor downstream of another of the at least two corrugated elements. For example, the two corrugated elements may be in different air flow paths through the article or substrate, or at least one of the two corrugated elements may be not located in an air flow path through the article or substrate.

[0354] The corrugated element, or at least one, for example all, of the one or more corrugated elements, may comprise one or more perforations or holes. Said perforations or holes may be for air to flow through the corrugated element or elements.

[0355] Any corrugated element described herein may comprise corrugations along at least 50, 60, 70, 80 or 90%, or along substantially all of, a dimension in the cross direction of the corrugated element. Any corrugated element described herein may comprise corrugations along at least 50, 60, 70, 80 or 90%, or along substantially all of, a dimension in the machine direction of the corrugated element. Any corrugated element described herein may comprise at least 3, 5 or 10 corrugation peaks. Any corrugated element described herein may comprise at least 3, 5 or 10 corrugation troughs.

[0356] As the skilled person would understand after reading this disclosure, features described earlier in relation to the aerosol-forming substrate may be applicable to the aerosol-generating article. And features described in relation to a particular component of the substrate may be applicable to the same particular component of the article. Thus, merely as examples, features described in relation to corrugated elements or aerosol-forming material of the substrate may be applicable to corrugated elements or aerosol-forming material of the article respectively.

[0357] Some aerosol-generating articles defined above comprise a structure that includes a frame. For example, there may be provided an aerosol-generating article according to any disclosure above.. The aerosol-generating article is for use with an aerosol-generating device to generate an aerosol. The aerosol- generating article may comprise a first external surface and a second external surface, for example a first planar external; surface and a second planar external surface. The aerosol-generating article preferably comprises a cavity. The aerosol-generating article may further comprise a frame positioned between the first external surface and the second external surface. The frame at least partially defines the cavity. The aerosol-generating article comprises one or more aerosol-generating substrates. The aerosol-generating article comprises an air inlet and an air outlet. The aerosol-generating article comprises an airflow passage extending between the air inlet and the air outlet through the cavity.

[0358] Advantageously, the frame may provide the aerosol-generating article with structural support. In particular, the frame may allow the aerosol-generating article to be relatively thin whilst maintaining structural rigidity.

[0359] The aerosol-generating article may have a length, a width and a thickness. The aerosol-generating article may have a length extending in an x-direction. The aerosol-generating article may have a width extending in a y-direction. The aerosol-generating article may have a thickness extending in a z-direction.

[0360] The aerosol-generating article may comprise an x / y plane. The x / y plane may extend through the geometric centre of the aerosol-generating article. The x / y plane may define a plane of symmetry of the aerosol-generating article. The air inlet and air outlet may be symmetric, for example have a symmetric shape or position, about the x / y plane.

[0361] The aerosol-generating article may comprise an x / z plane. The x / z plane may extend through the geometric centre of the aerosol-generating article. The x / z plane may define a plane of symmetry of the aerosol-generating article. The air inlet and air outlet may be symmetric, for example have a symmetric shape or position, about an x / z plane.

[0362] The aerosol-generating article may comprise an y / z plane. The y / z plane may extend through the geometric centre of the aerosol-generating article. The y / z plane may define a plane of symmetry of the aerosol-generating article. The air inlet and air outlet may be symmetric, for example have a symmetric shape or positioned, about the y / z plane.

[0363] Advantageously, a symmetric aerosol-generating article or an article with a symmetrically shaped or positioned air inlet and air outlet may allow the aerosol-generating article to be inserted into an aerosolgenerating device in multiple orientations.

[0364] The aerosol-generating article may be a substantially flat aerosol-generating article or a substantially planar aerosol-generating article. In particular, a thickness of the aerosol-generating article may less than 50 percent of both a length and a width of the aerosol-generating article. Advantageously, a smaller thickness may provide a small temperature gradient or difference across the thickness of the aerosolgenerating substrate during heating. Advantageously, this may allow heating of a greater proportion of the aerosol-generating substrate to a temperature at which an aerosol is released whilst minimising the risk of burning the hottest portion of the aerosol-generating substrate closest to the heater. Advantageously, this may also reduce a time required to heat the aerosol-generating substrate sufficiently to release an aerosol.

[0365] The aerosol-generating article may have a 3-dimensional shape.

[0366] The aerosol-generating article may have a quadrilaterally-faced hexahedron shape. The aerosolgenerating article may have a rectangular prism shape. The aerosol-generating article may have a cubic shape. The aerosol-generating article may have a cuboid shape. The aerosol-generating article may have a rectangular cuboid shape. The aerosol-generating article may have a parallelepiped shape. The aerosol-generating article may have a cylindrical shape. The aerosol-generating article may have a right-angled cylinder shape. The aerosol-generating article may have an elliptical cylinder shape.

[0367] The aerosol-generating article may have an oblong shape.

[0368] The aerosol-generating article may have a laminated structure, for example the aerosol-generating article may comprise or be formed from at least two layers. In particular, the aerosol-generating article may comprise at least two of: a first external layer, a second external layer, a frame, a first frame layer, a second frame layer, a third frame layer, a first aerosol-generating substrate layer, and a second aerosol-generating substrate layer as discussed in more detail below.

[0369] At least 50% of the mass of the aerosol-generating article, excluding the one or more aerosolgenerating substrates, may be paper or cardboard. At least 55% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 60% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 65% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 70% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 75% of the mass of the aerosol-generating article, excluding the one or more aerosolgenerating substrates, may be a cellulosic material. At least 80% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 85% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material. At least 90% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be a cellulosic material.

[0370] At least 50% of the mass of the aerosol-generating article, excluding the one or more aerosolgenerating substrates, may be paper or cardboard. At least 55% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 60% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 65% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 70% of the mass of the aerosolgenerating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 75% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 80% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 85% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard. At least 90% of the mass of the aerosol-generating article, excluding the one or more aerosol-generating substrates, may be paper or cardboard.

[0371] Substantially the entirety of the aerosol-generating article, excluding the one or more aerosolgenerating substrates and (if present) adhesive, may be paper or cardboard.

[0372] The aerosol-generating article may have a cellulose acetate content of less than 5 percent. The aerosol-generating article may have a cellulose acetate content of less than 3 percent. The aerosolgenerating article may have a cellulose acetate content of less than 1 percent.

[0373] The frame may be a planar frame.

[0374] The frame may define a frame aperture extending through the thickness of the frame. The frame aperture may define or form the airflow passage of the aerosol-generating article. The frame aperture may define or form the cavity of the aerosol-generating article. For example, the frame may have a hollow cuboid shape or a square hollow tube shape. As a further example, the frame may have a cross-section that is annular in shape, preferably the cross-section in an x / y plane is annular in shape. The cross-section may have an annulus shape, such as a circular annulus shape, an elliptical annulus shape, a rectangular annulus shape, or a square annulus shape.

[0375] The frame may comprise a frame outer surface. The frame outer surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The frame outer surface may at least partially define or form one or more external surfaces of the aerosolgenerating article. For example, the frame outer surface may at least partially define or form one or more external walls of the aerosol-generating article. The frame outer surface may circumscribe or encircle the frame aperture. The frame outer surface may circumscribe or encircle the cavity.

[0376] The frame may comprise a frame inner surface. The frame inner surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The frame inner surface may define or form a frame aperture outer wall. The frame inner surface may define or form a cavity outer wall. The frame inner surface may circumscribe or encircle the frame aperture extending through the thickness of the frame. The frame outer surface may circumscribe or encircle the cavity.

[0377] The frame outer surface may circumscribe or encircle the frame inner surface. The frame inner surface and the frame outer surface may be concentric with one another.

[0378] The frame may define or form at least 75 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame. The frame may define or form at least 80 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame. The frame may define or form at least 85 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame. The frame may define or form at least 90 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame. The frame may define or form at least 95 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame. The frame may define or form at least 99 percent of a perimeter of any cross-section, in an x / y plane, of the aerosolgenerating article that extends through the frame.

[0379] Advantageously, providing a frame that forms at least 75 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame means that the frame extends around a significant portion of the aerosol-generating article. Therefore, the frame can provide the aerosol-generating article with good structural support.

[0380] Advantageously, providing a frame that forms at least 75 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame may mean that any air inlet or air outlet defined through the article is of a size that provides the aerosol-generating article with a satisfactory resistance to draw.

[0381] Advantageously, in embodiments in which an aerosol-generating substrate is positioned within the cavity, providing a frame that forms at least 75 percent of a perimeter of any cross-section, in an x / y plane, of the aerosol-generating article that extends through the frame may allow the frame to act as a barrier that prevents egress of the aerosol-generating substrate from the aerosol-generating article. The aerosol-generating article may comprise a cross-section in a first x / y plane that extends through the frame. The frame may form at least 99 percent of a perimeter of the cross-section in the first x / y plane. The frame may form at least 100 percent of the perimeter of the cross-section in the first x / y plane.

[0382] The aerosol-generating article may comprise a cross-section in a second x / y plane, spaced from the first x / y plane in the z-direction, that extends through the frame. The frame may form at least 99 percent of a perimeter of the cross-section in the second x / y plane. The frame may form 100 percent of the perimeter of the cross-section in the second x / y plane.

[0383] The air inlet may be positioned, in the z-direction, between the first x / y plane and the second x / y plane. The air outlet may be positioned, in the z-direction, between the first x / y plane and the second x / y plane.

[0384] The frame may comprise a first portion that is at least 30 percent of a thickness of the frame. The first portion may be at least 50 percent of the thickness of the frame. The first portion may be at least 70 percent of the thickness of the frame. The first portion may be at least 90 percent of the thickness of the frame. The frame forms 100 percent of a perimeter of any cross-section, in an x / y plane, of the aerosolgenerating article that extends through the first portion of the frame.

[0385] The aerosol-generating article may comprise one or more external walls extending between the first planar external surface and the second planar external surface. The one or more external walls may collectively define an entire transverse external area of the aerosol-generating article. The frame may at least partially define each of the one or more external walls.

[0386] The one or more external walls may circumscribe or encircle the cavity.

[0387] The frame may define at least 60 percent of the entire transverse external area of the aerosolgenerating article. The frame may define at least 60 percent of the entire transverse external area of the aerosol-generating article. The frame may define at least 70 percent of the entire transverse external area of the aerosol-generating article. The frame may define at least 80 percent of the entire transverse external area of the aerosol-generating article. The frame may define at least 90 percent of the entire transverse external area of the aerosol-generating article.

[0388] The frame may comprise a peripheral wall. The peripheral wall may circumscribe or encircle at least a portion of the frame aperture extending through the thickness of the frame. The peripheral wall may circumscribe or encircle at least a portion of the cavity. The peripheral wall may circumscribe or encircle the frame aperture extending through the thickness of the frame. The peripheral wall may circumscribe or encircle the cavity. Advantageously, such a peripheral wall allows for a relatively large internal volume for an aerosol-generating substrate or aerosol formation whilst providing the structural strength to maintain the shape of the aerosol-generating article.

[0389] The peripheral wall may be defined or formed by the frame outer surface and the frame inner surface. The peripheral wall may at least partially define or form one or more external surfaces or walls of the aerosol-generating article. The peripheral wall may define or form a frame aperture outer wall. The peripheral wall may define or form a cavity outer wall.

[0390] The peripheral wall may have a radial thickness. The radial thickness may be defined as the minimum distance between the frame outer surface and the frame inner surface, such as in the x / y plane.

[0391] The peripheral wall may have a radial thickness greater than or equal to 0.5 millimetres. The peripheral wall may have a radial thickness greater than or equal to 1 millimetre. The peripheral wall may have a radial thickness greater than or equal to 1 .5 millimetres. The peripheral wall may have a radial thickness greater than or equal to 2 millimetres. The peripheral wall may have a radial thickness greater than or equal to 2.5 millimetres.

[0392] The peripheral wall may have a radial thickness less than or equal to 4 millimetres. The peripheral wall may have a radial thickness less than or equal to 3.5 millimetres. The peripheral wall may have a radial thickness less than or equal to 3 millimetres. The peripheral wall may have a radial thickness less than or equal to 2.5 millimetres. The peripheral wall may have a radial thickness less than or equal to 2 millimetres.

[0393] The peripheral wall may have a radial thickness between 0.5 millimetres and 3.5 millimetres. The peripheral wall may have a radial thickness between 0.5 millimetres and 3 millimetres. The peripheral wall may have a radial thickness between 0.5 millimetres and 2.5 millimetres. The peripheral wall may have a radial thickness between 1 millimetre and 3 millimetres. The peripheral wall may have a radial thickness between 1 millimetres and 2 millimetres. Advantageously, the peripheral wall having a radial thickness between 0.5 millimetres and 3.5 millimetres has been found to provide good structural strength for the aerosol-generating article whilst not using excess amounts of material which may increase manufacturing costs. Advantageously, a radial thickness between 0.5 millimetres and 3.5 millimetres may limit the amount of heat that is undesirably transferred to the frame rather than the aerosol-generating substrate.

[0394] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0395] 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.

[0396] The cellulosic material may have a grammage greater than or equal to 300 grams per square metre. The cellulosic material may have a grammage greater than or equal to 350 grams per square metre. The cellulosic material may have a grammage greater than or equal to 390 grams per square metre. The cellulosic material may have a grammage greater than or equal to 420 grams per square metre. The cellulosic material may have a grammage greater than or equal to 620 grams per square metre. The cellulosic material may have a grammage greater than or equal to 720 grams per square metre. The cellulosic material may have a grammage greater than or equal to 800 grams per square metre.

[0397] The cellulosic material may have a grammage less than or equal to 900 grams per square metre. The cellulosic material may have a grammage less than or equal to 800 grams per square metre. The cellulosic material may have a grammage less than or equal to 720 grams per square metre. The cellulosic material may have a grammage less than or equal to 620 grams per square metre. The cellulosic material may have a grammage less than or equal to 420 grams per square metre. The cellulosic material may have a grammage less than or equal to 390 grams per square metre. The cellulosic material may have a grammage less than or equal to 350 grams per square metre.

[0398] The cellulosic material may have a grammage between 300 grams per square metre and 900 grams per square metre. The cellulosic material may have a grammage between 300 grams per square metre and 800 grams per square metre. The cellulosic material may have a grammage between 350 grams per square metre and 800 grams per square metre. The cellulosic material may have a grammage between 400 grams per square metre and 700 grams per square metre. The frame may be made from or comprise a fibrous material. The frame may be made from one or more of: natural fibres, synthetic fibres, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibres, nylon fibres, and ceramic fibres. The frame may comprise cellulosic fibres.

[0399] The frame may comprise a hydrophobic region. The hydrophobic region may comprise hydrophobic groups covalently bonded to the frame. The hydrophobic region may be positioned on, or form, at least a portion of the frame inner surface. Advantageously, a hydrophobic region may prevent or limit degradation of the frame in regions where the frame is regularly in contact with aerosol or liquids from the aerosolgenerating substrate.

[0400] The hydrophobic region may be produced by a process comprising the steps of: applying a liquid composition comprising a fatty acid halide to a surface of the frame and maintaining the surface at a temperature of about 120 degrees Celsius to about 180 degrees Celsius. The fatty acid halide reacts in situ with protogenic groups of material in the hydrophobic region resulting in the formation of fatty acid esters.

[0401] The hydrophobic region may have a Cobb water absorption (ISO535:1991) value (at 60 seconds) less than or equal to 40 grams per square metre. The hydrophobic region may have a Cobb water absorption (ISO535:1991) value (at 60 seconds) of less than or equal to 35 grams per square metre. The hydrophobic region may have a Cobb water absorption (ISO535:1991) value (at 60 seconds) less than or equal to 30 grams per square metre. The hydrophobic region may have a Cobb water absorption (ISO535:1991) value (at 60 seconds) less than or equal to about 25 grams per square metre.

[0402] The hydrophobic region may have a water contact angle of greaterthan or equal to about 90 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 95 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 100 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 110 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 120 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 130 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 140 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 150 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 160 degrees. The hydrophobic region may have a water contact angle of greater than or equal to about 170 degrees.

[0403] Hydrophobicity is determined by utilizing the TAPPI T558 om-97 test and the result is presented as an interfacial contact angle and reported in “degrees” and can range from near zero degrees to near 180 degrees. Where no contact angle is specified along with the term hydrophobic, the water contact angle is at least 90 degrees.

[0404] The hydrophobic region may have a water contact angle of greater than or equal to 90 degrees and a Cobb water absorption (ISO535:1991) value (at 60 seconds) less than or equal to 40 grams per square metre.

[0405] The aerosol-generating article may comprise one or more susceptor materials. The frame may comprise one or more susceptor materials. The one more susceptor materials may be in thermal contact with the aerosol-generating substrate. The one more susceptor materials may be in thermal contact with the airflow passage. The one more susceptor materials may be in thermal contact with the cavity. The one or more susceptor materials may be positioned in or on the frame inner surface. The one or more susceptor materials may be incorporated within the material of the frame. For example, the one or more susceptor material may be incorporated within the peripheral wall of the frame. Advantageously, the presence of one or more susceptor materials may allow the aerosol-generating article, and thus the aerosol-generating substrate, to be heated by engagement with a fluctuating electromagnetic field formed by an inductor.

[0406] The one or more susceptor materials may be one or more particles, strips, threads, or wires of susceptor material. The one or more susceptor materials may be one or more sheets or layers of susceptor material. The one of more sheets or layers of susceptor material may be in the form of a mesh of susceptor material.

[0407] The susceptor material, in whatever form, may comprise one or more materials selected from the list consisting of: aluminium, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0408] The frame may have a thickness greater than or equal to 50 percent of the thickness of the aerosolgenerating article. The frame may have a thickness greater than or equal to 60 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 70 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 80 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 90 percent of the thickness of the aerosol-generating article. The frame may have a thickness greater than or equal to 95 percent of the thickness of the aerosol-generating article.

[0409] The frame may have a thickness less than or equal to 95 percent of the thickness of the aerosolgenerating article. The frame may have a thickness less than or equal to 90 percent of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 80 percent of the thickness of the aerosol-generating article. The frame may have a thickness less than or equal to 70 percent of the thickness of the aerosol-generating article.

[0410] The frame may have a thickness between 50 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 60 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 70 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 80 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article.

[0411] The frame may have a thickness greater than or equal to 1 millimetre. The frame may have a thickness greater than or equal to 1 .5 millimetres. The frame may have a thickness greater than or equal to 2 millimetres. The frame may have a thickness greater than or equal to 2.5 millimetres. The frame may have a thickness greater than or equal to 3 millimetres. The frame may have a thickness greater than or equal to 3.5 millimetres. The frame may have a thickness greater than or equal to 4 millimetres. The frame may have a thickness greater than or equal to 4.5 millimetres.

[0412] The frame may have a thickness less than or equal to 5.5 millimetres. The frame may have a thickness less than or equal to 5 millimetres. The frame may have a thickness less than or equal to 4.5 millimetres. The frame may have a thickness less than or equal to 4 millimetres. The frame may have a thickness less than or equal to 3.5 millimetres. The frame may have a thickness less than or equal to 3 millimetres. The frame may have a thickness less than 2.5 millimetres. The frame may have a thickness less than 2 millimetres. The frame may have a thickness less than 1 .5 millimetres. The frame may have a thickness between 1 millimetre and 5.5 millimetres. The frame may have a thickness between 1 millimetre and 5 millimetres. Preferably, the frame may have a thickness between 1.5 millimetres and 5 millimetres.

[0413] The frame may have a length that is equal to the length of the aerosol-generating article. The frame may have a length that is at least 90 percent of the length of the aerosol-generating article. The frame may have a length that is at least 95 percent of the length of the aerosol-generating article.

[0414] The frame may have a width that is equal to the width of the aerosol-generating article. The frame may have a width that is at least 90 percent of the width of the aerosol-generating article. The frame may have a width that is at least 90 percent of the width of the aerosol-generating article.

[0415] The frame may be a unitary component. Alternatively, the frame may comprise two or more layers. That is, the frame may have a laminated structure. Advantageously, the properties of each layer may be individually optimised depending on the relative distance between the layer and aerosol-generating substrate or heater of the aerosol-generating device. Advantageously, the use of two or more layers allows producing, and rapidly adjusting, the desired thickness of the frame by adding or removing layers of sheet material. This may prevent the need to manufacture a single sheet of material having the desired thickness of the frame, which may subsequently need to be changed when the desired thickness of the frame changes.

[0416] The frame may comprise a first frame layer and a second frame layer. The first frame layer and the second frame layer may be the only layers of the frame. That is, the frame may comprise no more than two layers or may comprise exactly two layers. The first frame layer may be an upper frame layer and the second frame layer may be a lower frame layer.

[0417] The frame may have a thickness equal to a sum of a thickness of the first frame layer and a thickness of the second frame layer. The frame aperture may be defined through both the first frame layer and the second frame layer.

[0418] The frame may comprise a first frame layer, a second frame layer and a third frame layer. The second frame layer may be positioned between the first frame layer and the third frame layer. The first frame layer, the second frame layer and the third frame layer may be the only layers of the frame. That is, the frame may comprise no more than three layers or may comprise exactly three layers. The first frame layer may be an upper frame layer, the second frame layer may be an intermediate frame layer, and the third frame layer may be a lower frame layer.

[0419] The first frame layer may be in physical contact with the second frame layer. The first frame layer may be may be bonded to the second frame layer with an adhesive. A lower surface of the first frame layer may be bonded to an upper surface of the second frame layer with an adhesive. The adhesive may extend at least 90% around the periphery of the intersection between the first frame layer and the second frame layer. The adhesive may extend at least 95% around the periphery of the intersection between the first frame layer and the second frame layer. The adhesive may extend at least 99% around the periphery of the intersection between the first frame layer and the second frame layer.

[0420] The second frame layer may be in physical contact with the third frame layer. The second frame layer may be bonded to the third frame layer with an adhesive. A lower surface of the second frame layer may be bonded to an upper surface of the third frame layer with an adhesive. The adhesive may extend at least 90% around the periphery of the intersection between the second frame layer and the third frame layer. The adhesive may extend at least 95% around the periphery of the intersection between the second frame layer and the third frame layer. The adhesive may extend at least 99% around the periphery of the intersection between the second frame layer and the third frame layer.

[0421] The frame may have a thickness equal to a sum of a thickness of the first frame layer, a thickness of the second frame layer and a thickness of the third frame layer. The frame aperture may be defined through the first planar layer, the second planar layer and the third frame layer.

[0422] The first frame layer may be planar.

[0423] The first frame layer may define a first frame layer aperture extending through the thickness of the first frame layer. The first frame layer aperture may at least partially define or form the cavity of the aerosolgenerating article. For example, the first frame layer may have a hollow cuboid shape or a square hollow tube shape. As a further example, the first frame layer may have a cross-section that is annular in shape, preferably the cross-section in x / y plane is annular in shape. The cross-section may have an annulus shape, such as a circular annulus shape, an elliptical annulus shape, a rectangular annulus shape, or a square annulus shape.

[0424] The first frame layer may comprise a first frame layer outer surface. The first frame layer outer surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The first frame layer outer surface may at least partially define or form one or more external surfaces of the aerosol-generating article. For example, the first frame layer outer surface may at least partially define or form one or more external walls of the aerosol-generating article. The first frame layer outer surface may circumscribe or encircle one or both: the first frame layer aperture and the frame aperture. The first frame layer outer surface may circumscribe or encircle the cavity.

[0425] The first frame layer may comprise a first frame layer inner surface. The first frame layer inner surface may extend in a transverse direction, for example between the first planar external surface and the second planar external surface. The first frame layer inner surface may define or form a first frame layer aperture outer wall. The first frame layer inner surface may at least partially define or form a cavity outer wall. The first frame layer inner surface may circumscribe or encircle one or both the first frame layer aperture and the frame aperture. The first frame layer outer surface may circumscribe or encircle the cavity.

[0426] The first frame layer outer surface may circumscribe or encircle the first frame layer inner surface. The first frame layer inner surface and the first frame layer outer surface may be concentric with one another.

[0427] The first frame layer may comprise a first frame layer peripheral wall. The first frame layer peripheral wall may circumscribe or encircle one or both of: the frame aperture and the first frame layer aperture. The first frame layer peripheral wall may circumscribe or encircle the cavity.

[0428] The first frame layer peripheral wall may be defined or formed by the first frame layer outer surface and the first frame layer inner surface. The first frame layer peripheral wall may at least partially define or form one or more external surfaces or walls of the aerosol-generating article. The first frame layer peripheral wall may at least partially define or form the first frame layer aperture outer wall. The first frame layer peripheral wall may at least partially define or form the cavity outer wall.

[0429] The first frame layer may be made from or comprise any of the materials described above in relation to the frame. For example, the first frame layer may comprise the one or more susceptor materials.

[0430] The first frame layer may be made from or comprise a biodegradable material. The first frame layer may be entirely made from biodegradable material. The first frame layer may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may comprise cellulosic fibres. The cellulosic material may be paper, paperboard, or cardboard. The first frame layer may be made from or comprise a plant material, such as tobacco. The first frame layer may be made entirely from a cellulosic material.

[0431] The cellulosic material may have any grammage or range of grammages as described above in relation to the frame.

[0432] The first frame layer may be made from a fibrous material. The first frame layer may be made from one or more of: natural fibres, synthetic fibres, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibres, nylon fibres, and ceramic fibres.

[0433] Where the frame comprises exactly two layers, the thickness of the first frame layer may be half (50 percent) the thickness of the frame. The first frame layer may have a thickness substantially the same as the second frame layer. Where the frame comprises exactly three layers, the thickness of the first frame layer may be one third (33.33 percent) the thickness of the frame. The first frame layer may have a thickness substantially the same as each of the second frame layer and the third frame layer.

[0434] The first frame layer may have a thickness greater than or equal to 0.5 millimetres. The frame may have a thickness greater than or equal to 1 millimetre. The first frame layer may have a thickness greater than or equal to 1 .5 millimetres. The first frame layer may have a thickness greater than or equal to 2 millimetres. The first frame layer may have a thickness greater than or equal to 2.5 millimetres.

[0435] The first frame layer may have a thickness less than or equal to 3 millimetres. The first frame layer may have a thickness less than or equal to 2.5 millimetres. The first frame layer may have a thickness less than or equal to 2 millimetres. The first frame layer may have a thickness less than or equal to 1.5 millimetres. The first frame layer may have a thickness less than or equal to 1 millimetres.

[0436] The first frame layer may have a thickness between 0.5 millimetres and 3 millimetres. The first frame layer may have a thickness between 0.5 millimetres and 2.5 millimetres. The first frame layer may have a thickness between 1 millimetres and 2.5 millimetres.

[0437] The second frame layer may be planar.

[0438] The second frame layer may define a second frame layer aperture extending through the thickness of the second frame layer. The second frame layer aperture may at least partially define or form the cavity of the aerosol-generating article. For example, the second frame layer may have a hollow cuboid shape or a square hollow tube shape. As a further example, the second frame layer may have a cross-section that is annular in shape, preferably the cross-section in x / y plane is annular in shape. The cross-section may have an annulus shape, such as a circular annulus shape, an elliptical annulus shape, a rectangular annulus shape, or a square annulus shape.

[0439] The second frame layer may comprise a second frame layer outer surface. The second frame layer outer surface may extend in a transverse direction, for example between the second planar external surface and the second planar external surface. The second frame layer outer surface may at least partially define or form one or more external surfaces of the aerosol-generating article. For example, the second frame layer outer surface may at least partially define or form one or more external walls of the aerosol-generating article. The second frame layer outer surface may circumscribe or encircle one or both: the second frame layer aperture and the frame aperture. The second frame layer outer surface may circumscribe or encircle the cavity. The second frame layer may comprise a second frame layer inner surface. The second frame layer inner surface may extend in a transverse direction, for example between the second planar external surface and the second planar external surface. The second frame layer inner surface may define or form a second frame layer aperture outer wall. The second frame layer inner surface may at least partially define or form a cavity outer wall. The second frame layer inner surface may circumscribe or encircle one or both the second frame layer aperture and the frame aperture. The second frame layer outer surface may circumscribe or encircle the cavity.

[0440] The second frame layer outer surface may circumscribe or encircle the second frame layer inner surface. The second frame layer inner surface and the second frame layer outer surface may be concentric with one another.

[0441] The second frame layer may comprise a second frame layer peripheral wall. The second frame layer peripheral wall may circumscribe or encircle one or both of: the frame aperture and the second frame layer aperture. The second frame layer peripheral wall may circumscribe or encircle the cavity.

[0442] The second frame layer peripheral wall may be defined or formed by the second frame layer outer surface and the second frame layer inner surface. The second frame layer peripheral wall may at least partially define or form one or more external surfaces or walls of the aerosol-generating article. The second frame layer peripheral wall may at least partially define or form the second frame layer aperture outer wall. The second frame layer peripheral wall may at least partially define or form the cavity outer wall.

[0443] The second frame layer may be made from or comprise any of the materials described above in relation to the frame. For example, the second frame layer may comprise the one or more susceptor materials.

[0444] The second frame layer may be made from or comprise a biodegradable material. The second frame layer may be entirely made from biodegradable material.

[0445] The second frame layer may be made from or comprise a cellulosic material, as the cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may be paper, paperboard, or cardboard. The second frame layer may be made from or comprise a plant material, such as tobacco. The second frame layer may be made entirely from a cellulosic material.

[0446] The cellulosic material may have any grammage or range of grammages as described above in relation to the frame.

[0447] The second frame layer may be made from a fibrous material. The second frame layer may be made from one or more of: natural fibres, synthetic fibres, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibres, nylon fibres, and ceramic fibres.

[0448] Where the frame comprises exactly two layers, the thickness of the second frame layer may be half (50 percent) the thickness of the frame. The second frame layer may have a thickness substantially the same as the first frame layer. Where the frame comprises exactly three layers, the thickness of the second frame layer may be one third (33.33 percent) the thickness of the frame. The second frame layer may have a thickness substantially the same as the first frame layer and the third frame layer.

[0449] The second frame layer may have a thickness greater than or equal to 0.5 millimetres. The frame may have a thickness greater than or equal to 1 millimetre. The second frame layer may have a thickness greater than or equal to 1 .5 millimetres. The second frame layer may have a thickness greater than or equal to 2 millimetres. The second frame layer may have a thickness greater than or equal to 2.5 millimetres. The second frame layer may have a thickness less than or equal to 3 millimetres. The second frame layer may have a thickness less than or equal to 2.5 millimetres. The second frame layer may have a thickness less than or equal to 2 millimetres. The second frame layer may have a thickness less than or equal to 1 .5 millimetres. The second frame layer may have a thickness less than or equal to 1 millimetres.

[0450] The second frame layer may have a thickness between 0.5 millimetres and 3 millimetres. The second frame layer may have a thickness between 0.5 millimetres and 2.5 millimetres. The second frame layer may have a thickness between 1 millimetres and 2.5 millimetres.

[0451] The third frame layer may be planar.

[0452] The third frame layer may define a third frame layer aperture extending through the thickness of the third frame layer. The third frame layer aperture may at least partially define or form the cavity of the aerosolgenerating article. For example, the third frame layer may have a hollow cuboid shape or a square hollow tube shape. As a further example, the third frame layer may have a cross-section that is annular in shape, preferably the cross-section in x / y plane is annular in shape. The cross-section may have an annulus shape, such as a circular annulus shape, an elliptical annulus shape, a rectangular annulus shape, or a square annulus shape.

[0453] The third frame layer may comprise a third frame layer outer surface. The third frame layer outer surface may extend in a transverse direction, for example between the third planar external surface and the third planar external surface. The third frame layer outer surface may at least partially define or form one or more external surfaces of the aerosol-generating article. For example, the third frame layer outer surface may at least partially define or form one or more external walls of the aerosol-generating article. The third frame layer outer surface may circumscribe or encircle one or both: the third frame layer aperture and the frame aperture. The third frame layer outer surface may circumscribe or encircle the cavity.

[0454] The third frame layer may comprise a third frame layer inner surface. The third frame layer inner surface may extend in a transverse direction, for example between the third planar external surface and the third planar external surface. The third frame layer inner surface may define or form a third frame layer aperture outer wall. The third frame layer inner surface may at least partially define or form a cavity outer wall. The third frame layer inner surface may circumscribe or encircle one or both the third frame layer aperture and the frame aperture. The third frame layer outer surface may circumscribe or encircle the cavity.

[0455] The third frame layer outer surface may circumscribe or encircle the third frame layer inner surface. The third frame layer inner surface and the third frame layer outer surface may be concentric with one another.

[0456] The third frame layer may comprise a third frame layer peripheral wall. The third frame layer peripheral wall may circumscribe or encircle one or both of: the frame aperture and the third frame layer aperture. The third frame layer peripheral wall may circumscribe or encircle the cavity.

[0457] The third frame layer peripheral wall may be defined or formed by the third frame layer outer surface and the third frame layer inner surface. The third frame layer peripheral wall may at least partially define or form one or more external surfaces or walls of the aerosol-generating article. The third frame layer peripheral wall may at least partially define or form the third frame layer aperture outer wall. The third frame layer peripheral wall may at least partially define or form the cavity outer wall.

[0458] The third frame layer may be made from or comprise any of the materials described above in relation to the frame. For example, the third frame layer may comprise the one or more susceptor materials. The third frame layer may be made from or comprise a biodegradable material. The third frame layer may be entirely made from biodegradable material.

[0459] The third frame layer may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may be paper, paperboard, or cardboard. The third frame layer may be made from or comprise a plant material, such as tobacco. The third frame layer may be made entirely from a cellulosic material.

[0460] The cellulosic material may have any grammage or range of grammages as described above in relation to the frame.

[0461] The third frame layer may be made from a fibrous material. The third frame layer may be made from one or more of: natural fibres, synthetic fibres, polyester, bonded polyolefin, polyethylene, terylene, polypropylene, biopolymer fibres, nylon fibres, and ceramic fibres.

[0462] Where the frame comprises exactly three layers, the thickness of the third frame layer may be one third (33.33 percent) the thickness of the frame. The third frame layer may have a thickness substantially the same as each of the first frame layer and the second frame layer.

[0463] The third frame layer may have a thickness greater than or equal to 0.5 millimetres. The frame may have a thickness greater than or equal to 1 millimetre. The third frame layer may have a thickness greater than or equal to 1 .5 millimetres. The third frame layer may have a thickness greater than or equal to 2 millimetres. The third frame layer may have a thickness greater than or equal to 2.5 millimetres.

[0464] The third frame layer may have a thickness less than or equal to 3 millimetres. The third frame layer may have a thickness less than or equal to 2.5 millimetres. The third frame layer may have a thickness less than or equal to 2 millimetres. The third frame layer may have a thickness less than or equal to 1.5 millimetres. The third frame layer may have a thickness less than or equal to 1 millimetres.

[0465] The third frame layer may have a thickness between 0.5 millimetres and 3 millimetres. The third frame layer may have a thickness between 0.5 millimetres and 2.5 millimetres. The third frame layer may have a thickness between 1 millimetres and 2.5 millimetres.

[0466] The one or more aerosol-generating substrates may comprise an aerosol-generating substrate layer. Advantageously, the aerosol-generating substrate layer can be made thin and, therefore, quickly heat up and release volatile compounds to form an aerosol. Advantageously, the aerosol-generating substrate layer can be positioned close to a heater of an aerosol-generating substrate.

[0467] The aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosolgenerating material may be any aerosol-generating material described herein. The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. The aerosol-generating substrate layer may be, and may be made entirely of, a sheet of aerosol-generating material.

[0468] The aerosol-generating substrate layer may be positioned between the frame and the first planar external surface. The aerosol-generating substrate layer may be positioned between the frame and the second planar external surface. The aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame. The aerosol-generating substrate layer may be bonded to the frame with an adhesive.

[0469] The aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The outer wrapper is discussed in more detail below. The aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the outer wrapper. The aerosol-generating substrate layer may be bonded to both the frame and the outer wrapper with an adhesive.

[0470] The aerosol-generating substrate layer may be positioned between the frame and the first planar external layer. The aerosol-generating substrate layer may be positioned between the frame and the second planar external layer. The first planar external layer and the second planar external layer are discussed in more detail below. The aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the first planar external layer. The aerosol-generating substrate layer may be bonded to both the frame and the first planar external layer with an adhesive. The aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the second planar external layer. The aerosol-generating substrate layer may be bonded to both the frame and the second planar external layer with an adhesive.

[0471] The aerosol-generating substrate layer may overlie an end of the cavity. The aerosol-generating substrate layer may define or form a wall of the cavity, such as the first cavity end wall or the second cavity end wall. Advantageously, the aerosol-generating substrate layer may therefore be in, or at least partially define or form, the airflow passage thereby allowing released volatile compounds to quickly form an aerosol.

[0472] The one or more aerosol-generating substrates may comprise a first aerosol-generating substrate layer and a second aerosol-generating substrate layer. Advantageously, a first and a second aerosolgenerating substrate layer may allow rapid generation of a satisfactory volume of aerosol compared with using a single aerosol-generating substrate layer.

[0473] The first aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosolgenerating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosolgenerating material may be any sheet of aerosol-generating material described herein. The first aerosolgenerating substrate layer may be, and may be made entirely of, a sheet of aerosol-generating material.

[0474] The second aerosol-generating substrate layer may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. The aerosolgenerating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosolgenerating material may be any sheet of aerosol-generating material described herein. The second aerosolgenerating substrate layer may be, and may be made entirely of, a sheet of aerosol-generating material.

[0475] The first aerosol-generating substrate layer may be positioned between the frame and the first planar external surface. The first aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame. For example, the first aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the first frame layer. The first aerosol-generating substrate layer may be bonded to the frame with an adhesive. The first aerosol-generating substrate layer may be bonded to the first frame layer with an adhesive. A lower surface of the first aerosol-generating substrate layer may be bonded to an upper surface of the first frame layer with an adhesive.

[0476] The first aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The first aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the outer wrapper. The first aerosol-generating substrate layer may be bonded to the frame and the outer wrapper with an adhesive.

[0477] The first aerosol-generating substrate layer may be positioned between the frame and the first planar external layer. The first aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the first planar external layer. The first aerosol-generating substrate layer may be bonded to the frame and the first planar external layer with an adhesive.

[0478] The second aerosol-generating substrate layer may be positioned between the frame and the second planar external surface. The second aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the frame. For example, the second aerosol-generating substrate layer may be in physical contact with, and may be bonded to, the second frame layer or third frame layer. The second aerosol-generating substrate layer may be bonded to the frame with an adhesive. The second aerosolgenerating substrate layer may be bonded to the second frame layer or third frame layer with an adhesive. An upper surface of the second aerosol-generating substrate layer may be bonded to a lower surface of the second frame layer or third frame layer with an adhesive.

[0479] The second aerosol-generating substrate layer may be positioned between the frame and the outer wrapper. The second aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the outer wrapper. The second aerosol-generating substrate layer may be bonded to the frame and the outer wrapper with an adhesive.

[0480] The second aerosol-generating substrate layer may be positioned between the frame and the second planar external layer. The second aerosol-generating substrate layer may in physical contact with, and may be bonded to, both the frame and the second planar external layer. The second aerosol-generating substrate layer may be bonded to the frame and the second planar external layer with an adhesive.

[0481] The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may overlie opposing ends of the cavity. The first aerosol-generating substrate layer and the second aerosolgenerating substrate layer may define or form opposing end walls of the cavity. That is, the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may collectively define the cavity. In other words, the cavity is defined by the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer.

[0482] The aerosol-generating substrate layer may be a planar aerosol-generating substrate layer. The planar aerosol-generating substrate layer may extend in the x-direction and the y-direction. That is, the planar aerosol-generating substrate layer may extend in the x / y plane.

[0483] The first aerosol-generating substrate layer may be a first planar aerosol-generating substrate layer. The first planar aerosol-generating substrate layer may extend in the x-direction and the y-direction. That is, first the planar aerosol-generating substrate layer may extend in the x / y plane.

[0484] The second aerosol-generating substrate layer may be a second planar aerosol-generating substrate layer. The second planar aerosol-generating substrate layer may extend in the x-direction and the y- direction. That is, the second planar aerosol-generating substrate layer may extend in the x / y plane.

[0485] The aerosol-generating substrate layer may have a thickness greater than or equal to 100 micrometres. The aerosol-generating substrate layer may have a thickness greater than or equal to 200 micrometres. The aerosol-generating substrate layer may have a thickness greater than or equal to 300 micrometres. The aerosol-generating substrate layer may have a thickness greater than or equal to 400 micrometres. The aerosol-generating substrate layer may have a thickness greater than or equal to 500 micrometres.

[0486] The aerosol-generating substrate layer may have a thickness less than or equal to 600 micrometres. The aerosol-generating substrate layer may have a thickness less than or equal to 500 micrometres. The aerosol-generating substrate layer may have a thickness less than or equal to 400 micrometres. The aerosol-generating substrate layer may have a thickness less than or equal to between 300 micrometres. The aerosol-generating substrate layer may have a thickness less than or equal to 200 micrometres.

[0487] The aerosol-generating substrate layer may have a thickness between 100 micrometres and 600 micrometres. The aerosol-generating substrate layer may have a thickness of between 200 micrometres and 500 micrometres. The aerosol-generating substrate layer may have a thickness of between 200 micrometres and 400 micrometres. The aerosol-generating substrate layer may have a thickness of between 200 micrometres and 300 micrometres.

[0488] One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 100 micrometres. One or both the first aerosolgenerating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 200 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 300 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 400 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 500 micrometres.

[0489] One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness less than or equal to 600 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness less than or equal to 500 micrometres. One or both the first aerosol-generating substrate layer and the second aerosolgenerating substrate layer may have a thickness less than or equal to 400 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness less than or equal to between 300 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness less than or equal to 200 micrometres.

[0490] One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness between 100 micrometres and 600 micrometres. One or both the first aerosolgenerating substrate layer and the second aerosol-generating substrate layer may have a thickness of between 200 micrometres and 500 micrometres. One or both the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness of between 200 micrometres and 400 micrometres. One or both the first aerosol-generating substrate layer and the second aerosolgenerating substrate layer may have a thickness of between 200 micrometres and 300 micrometres.

[0491] The aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article.

[0492] The first aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The first aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article.

[0493] The second aerosol-generating substrate layer may have a length substantially the same as the length of the frame. The second aerosol-generating substrate layer may have a length substantially the same as the length of the aerosol-generating article. The aerosol-generating substrate layer may have a width substantially the same as the width of the frame. The aerosol-generating substrate layer may have a width substantially the same as the width of the aerosol-generating article.

[0494] The first aerosol-generating substrate layer may have a width substantially the same as the width of the frame. The first aerosol-generating substrate layer may have a width substantially the same as the width of the aerosol-generating article.

[0495] The second aerosol-generating substrate layer may have a width substantially the same as the width of the frame. The second aerosol-generating substrate layer may have a width substantially the same as the width of the aerosol-generating article.

[0496] The first planar external surface may be a planar upper surface and the second planar external surface may be a planar lower surface. The first planar external surface may be a planar top surface and the second planar external surface may be a planar bottom surface. The first planar external surface may be a planar ceiling surface and the second planar external surface may be a planar base surface.

[0497] The first planar external surface may be positioned parallel to the second planar external surface. The first planar external surface may extend in the x-direction and the y-direction. That is, the first planar external surface may extend in the x / y plane. The second planar external surface may extend in the x- direction and the y-direction. That is, the second planar external surface may extend in the x / y plane.

[0498] The second planar external surface may be spaced from the first planar external surface in the z- direction or transverse direction. The distance between the first planar external surface and the second planar external surface in the z-direction or transverse direction may define the thickness of the aerosolgenerating article. That is, a thickness of the aerosol-generating article may be defined by the perpendicular distance between the first planar external surface and the second planar external surface.

[0499] The aerosol-generating article may comprise an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may comprise a hydrophobic material.

[0500] The outer wrapper may define or form the first planar external surface. The outer wrapper may define or form the second planar external surface. The outer wrapper may define or form both the first planar external surface and the second planar external surface.

[0501] The outer wrapper may circumscribe or encircle the frame. The outer wrapper may be in physical contact with, and may be bonded to, the frame. The outer wrapper may overlie opposing ends of the cavity. The outer wrapper may define or form opposing end walls of the cavity, such as the first cavity end wall and the second cavity end wall. That is, the frame and the outer wrapper may collectively define the cavity. In other words, the cavity is defined by the frame and the outer wrapper.

[0502] The outer wrapper may circumscribe or encircle the frame and the aerosol-generating substrate layer. The outer wrapper may be in physical contact with, and may be bonded to, both the frame and the aerosol-generating substrate layer.

[0503] The outer wrapper may circumscribe or encircle the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer. The outer wrapper may be in physical contact with, and may be bonded to, both the first aerosol-generating substrate layer and the second aerosolgenerating substrate layer.

[0504] The aerosol-generating article may comprise a first planar external layer and a second planar external layer. The first planar external layer may be an upper layer and the second planar external layer may be a lower layer. The first planar external layer may be a top layer and the second planar external layer may be a bottom layer. The first planar external layer may be an ceiling layer and the second planar external layer may be a base layer.

[0505] The first planar external layer may define or form the first planar external surface. The first planar external layer may extend in the x-direction and the y-direction. That is, the first planar external layer may extend in the x / y plane. The second planar external layer may define or form the second planar external surface. The second planar external layer may extend in the x-direction and the y-direction. That is, the second planar external layer may extend in the x / y plane.

[0506] The first planar external layer may be in physical contact with, and may be bonded to, the frame....

Claims

CLAIMS1 . An aerosol-generating system comprising an aerosol-generating article and an aerosolgenerating device configured to engage with the aerosol-generating article to form an inhalable aerosol, in which; the aerosol-generating article has an article body, an airflow path being defined through the article body between an article airflow inlet and an article airflow outlet; in which the aerosol-generating device comprises a cavity dimensioned to receive the aerosol-generating article, the cavity comprising a cavity airflow inlet; in which the cavity airflow inlet is configured to align with the article airflow inlet when the aerosol-generating article is received within the cavity, such that air flowing through the cavity inlet flows through the article inlet into the aerosol-generating article.

2. An aerosol-generating system according to claim 1 in which the aerosol-generating device comprises a main air inlet for receiving an airflow from the outside into an upstream airflow path and a downstream airflow path for delivering the inhalable aerosol to an aerosol outlet, in which the cavity airflow inlet comprises an upstream fluidic interconnection element configured to fluid ically interconnect the upstream airflow path with the aerosol-generating article, and the cavity airflow outlet comprises a downstream fluidic interconnection configured to fluidically interconnect the aerosol-generating article with the downstream airflow path, for example in which the cavity of the device is a heating chamber.

3. An aerosol-generating system according to claim 1 or 2 in which the cavity airflow inlet is configured to engage with the article airflow inlet when the aerosol-generating article is received within the cavity, such that air flowing through the cavity inlet flows through the article inlet into the aerosolgenerating article.

4. An aerosol-generating system according to any preceding claim in which a protruding portion, for example a rim, of the article airflow inlet mates with a portion of the cavity airflow inlet, for example a recessed portion or a compressible portion of the cavity airflow inlet, when the aerosol-generating article is received within the cavity, and / or in which a protruding portion, for example a rim, of the cavity airflow inlet mates with a portion of the article airflow inlet, for example a recessed portion or a compressible portion of the article airflow inlet, when the aerosol-generating article is received within the cavity.

5. An aerosol-generating system according to any preceding claim in which a sealed airflow path is formed from the cavity inlet into the airflow path of the aerosol-generating article when the aerosolgenerating article is received within the cavity.

6. An aerosol-generating system according to any preceding claim in which the device comprises an openable cavity closure configured to close the cavity when the aerosol-generating article is received within the cavity.

7. An aerosol-generating system according to any preceding claim in which the aerosol-generating device further comprises a cavity airflow outlet, the cavity airflow outlet being configured to align with the article airflow outlet when the aerosol-generating article is received within the cavity, such that air flowingthrough the aerosol-generating article flows out of the cavity through the article airflow outlet, for example into the downstream airflow path, for example in which the cavity airflow outlet is defined through the cavity closure.

8. An aerosol-generating system according to any preceding claim in which at least one surface of the aerosol-generating article comprises a lubricant, for example a wax, to facilitate insertion and extraction of the aerosol-generating article into the aerosol-generating device.

9. An aerosol-generating system according to any preceding claim in which the cavity airflow outlet is configured to engage with the article airflow outlet when the aerosol-generating article is received within the cavity, such that air flowing through the cavity inlet, for example from the upstream airflow path, flows through the article inlet into the aerosol-generating article.

10. An aerosol-generating system according to any preceding claim in which a protruding portion, for example a rim, of the article airflow outlet mates with a portion of the cavity airflow outlet, for example a recessed portion or a compressible portion of the cavity airflow outlet, when the aerosol-generating article is received within the cavity, and / or in which a protruding portion, for example a rim, of the cavity airflow outlet mates with a portion of the article airflow outlet, for example a recessed portion or a compressible portion of the article airflow outlet, when the aerosol-generating article is received within the cavity.

11. An aerosol-generating system according to any preceding claim in which a sealed airflow path is formed from the article airflow outlet and through the cavity airflow outlet when the aerosol-generating article is received within the cavity.

12. An aerosol-generating system according to any preceding claim in which the device further comprises a mouthpiece, the mouthpiece being in fluid communication with a, or the, cavity airflow outlet, for example in which the mouthpiece comprises the aerosol outlet of the device, for example in which the mouthpiece is coupled to, or an integral part of, a cavity closure or cover.

13. An aerosol-generating system, for example an aerosol-generating system according to any preceding claim, comprising an aerosol-generating article and an aerosol-generating device configured to engage with the aerosol-generating article to form an inhalable aerosol, in which; the aerosol-generating article has an article body defined by a first article dimension, a second article dimension perpendicular to the first article dimension, and an article thickness perpendicular to both the first article dimension and the second article dimension, in which the aerosol-generating device comprises a closable cavity having a minimal cavity length extending, when the cavity is closed, between a cavity airflow inlet and a cavity airflow outlet, the cavity further defined by a cavity width perpendicular to the minimal cavity length, extending between a left side wall of the cavity and a right side wall of the cavity, and a cavity height perpendicular to both the cavity depth and cavity width, the cavity height extending between a lower wall of the cavity and an upper wall of the cavity, the cavity being accessible via a closable opening having a width and a height; in which the aerosol-generating article is configured to be inserted into the cavity in the direction of its first article dimension, and in which the cavity width is no more than 30% greater, for example no more than 15% greater, or no more than 10 % greater, or no more than 5% greater, than the second article dimensionand the minimal cavity length, when the cavity is closed, no more than 10% greater, for example no more than 5% greater, or nor more than 2% greater, or no greater, than the first article dimension.

14. An aerosol-generating system according to claim 13 in which the first article dimension is an article width and the second article dimension is an article length, or in which the first article dimension is an article length and the second article dimension is an article width.

15. An aerosol-generating system according to any preceding claim in which the aerosol-generating device comprises a heating means, for example a heater, configured to heat the aerosol-generating article when the article is received within the cavity, preferably in which at least a portion of the heater is located within the cavity.

16. An aerosol-generating system according to any preceding claim in which the aerosol-generating article is removably retained within the cavity by a retaining means or retaining mechanism, for example a retaining means or retaining mechanism located within the cavity, for example a retaining means or retaining mechanism that grips the aerosol-generating article when the article is inserted into the cavity.

17. An aerosol-generating system according to claim 16 in which the aerosol-generating article is retained within the cavity by interaction between the article and upper and lower walls of the cavity, for example in which at least a portion of upper and lower walls of the cavity are spaced by less than the thickness of the article and deflect when the article is inserted into the cavity, gripping the article.

18. An aerosol-generating system according to claim 16 in which the aerosol-generating article is retained within the cavity by interaction between at least one heater located in the cavity and the article, for example in which a heater is located on or adjacent to at least one of the upper and lower walls of the cavity, the heater or heaters deflecting when the article is inserted into the cavity, gripping the article, for example in which heaters are located adjacent both upper and lower walls of the cavity and in which a minimal cavity thickness is defined by the distance between the heaters, in which the minimal cavity distance is less than the thickness of the aerosol-generating article, for example between 5% and 20% less than the thickness of the aerosol-generating article19. An aerosol-generating system according to any preceding claim in which the first article dimension is greater than, or equal to, the second article dimension, in which the aerosol-generating article is substantially cuboid, or substantially parallelepiped.

20. An aerosol-generating system according to any preceding claim in which the aerosol-generating article is substantially rectangular in plan view.21 . An aerosol-generating system according to any preceding claim in which the article comprises: a first planar external surface; a second planar external surface; a cavity formed by the airflow channel; a frame positioned between the first planar external surface and the second planar external surface, the frame at least partially defining the cavity; one or more aerosol-generating substrates; andan air inlet and an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity.

22. An aerosol-generating system according to any preceding claim, wherein the aerosolgenerating article has a length between 15 millimetres and 45 millimetres, for example between 25 millimetres and 35 millimetres, for example about 30 millimetres, wherein the aerosol-generating article has a width between 3 millimetres and 17 millimetres, for example between 9 millimetres and 11 millimetres, for example about 10 millimetres, and wherein the aerosol-generating article has a thickness between 1 millimetres and 5.5 millimetres, for example between 3 millimetres and 3.5 millimetres, for example about 3.1 millimetres.

Images