Aerosol-generating article

Abstract

There is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article comprises a first elongate sheet debossed or embossed to form a tray. The tray is defined by a peripheral region of the first elongate sheet surrounding a plurality of cavities formed in the first elongate sheet. When viewing the first elongate sheet from above, the plurality of cavities form an intruded or depressed region of the sheet relative to the peripheral region. When viewing the first elongate sheet from below, the part of the first elongate sheet in which the plurality of cavities is formed is raised relative to the peripheral region. A portion of sensorial media is disposed within at least one of the plurality of cavities. 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 height is less than each of the width and the length. The height is less than 4 millimetres.

Description

[0001] FTR3921 / PCT - P / 90513.W001

[0002] 1 / 39

[0003] AEROSOL-GENERATING ARTICLE

[0004] The present disclosure relates to an aerosol-generating article comprising an aerosol-forming substrate.

[0005] 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 aerosolgenerating articles are often similar to the dimensions of conventional cigarettes.

[0006] However, a significant portion of the aerosol-forming substrate in these cylindrical aerosolgenerating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-forming substrate contributes to the cost of manufacture and transport of the aerosol-generating article, but does not contribute to the aerosol delivered to an end user. This may be the case regardless of the way in which the aerosol-forming substrate is heated, for example regardless of whether a resistive or inductive heater is used and regardless of whether the aerosol-forming substrate is heated from the inside or the outside. Moreover, the components of these cylindrical aerosol-generating articles normally need to have the same or very similar outer diameters so that they can be brought together, accurately positioned in co-axial alignment and wrapped in a cigarette paper. This can lead to increased cost and complexity of manufacture.

[0007] 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.

[0008] According to a first aspect of the present disclosure, there may be provided an aerosolgenerating article for use with an aerosol-generating device to generate an aerosol. The aerosolgenerating article may comprise a first elongate sheet. The first elongate sheet may be debossed or embossed to form a tray, the tray defining a plurality of cavities. A portion of sensorial media may be disposed within at least one of the plurality of cavities. 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 height may be less than each of the width and the length. Preferably, the height may be less than 4 millimetres.

[0009] The tray may be defined by a peripheral region of the first elongate sheet surrounding a plurality of cavities formed in the first elongate sheet. When viewing the first elongate sheet from above, the plurality of cavities form an intruded or depressed region of the sheet relative to the peripheral region. When viewing the first elongate sheet from below, the part of the first elongate sheet in which the plurality of cavities is formed is raised relative to the peripheral region.

[0010] Debossing or embossing of the first elongate sheet creates an intruded area in the first elongate sheet suitable for containing sensorial media. The intruded area may be referred to as an debossed or embossed area. The intruded area may define the plurality of cavities. Defining the cavities by debossing or embossing of the first elongate sheet to form a tray structure may allow the aerosol-generating article to have a lower overall mass than if the cavities were instead defined by cutting into a surface of a slab or block to remove material from the slab or block.

[0011] Minimising the height of the aerosol-generating article provides the article with a geometric profile which is more compact, and also facilitates homogenous through-thickness heating of the article and the sensorial media.

[0012] Preferably, a portion of sensorial media may be positioned within each one of the plurality of cavities.

[0013] The provision of the plurality of cavities in the tray may facilitate effective dosing and segmented consumption of sensorial media.

[0014] Preferably, the first elongate sheet may define a majority of the flexural rigidity of the aerosolgenerating article. So, the first elongate sheet may thereby form the primary structural element of the aerosol-generating article.

[0015] The height of the aerosol-generating article may be less than 3.5 millimetres, for example less than 3 millimetres, for example less than 2.5 millimetres, for example less than 2 millimetres. These values may define an upper bound value of the height of the aerosol-generating article.

[0016] The height of the aerosol-generating article may be greater than 0.2 millimetres, for example greater than 0.25 millimetres, for example greater than 0.5 millimetres. These values may define a lower bound value of the height of the aerosol-generating article.

[0017] The height of the aerosol-generating article may be between the upper and lower bound values indicated in the preceding paragraphs.

[0018] Each cavity of the plurality of cavities may have a depth of between 75 and 500 microns, for example between 75 and 250 microns, for example between 75 and 125 microns, for example about 100 microns.

[0019] Each cavity of the plurality of cavities may define a volume of between 150 mm3and 300 mm3, for example between 175 mm3and 275 mm3, for example between 200 mm3and 250 mm3.

[0020] The plurality of cavities may define a cumulative volume of between 300 mm3and 600 mm3, for example between 350 mm3and 550 mm3, for example between 400 mm3and 500 mm3, for example about 400 mm3or about 500 mm3.

[0021] Each cavity of the plurality of cavities may hold a mass of sensorial media in a range of between 15 mg and 40 mg, for example between 20 mg and 35 mg, for example about 25 mg.

[0022] The plurality of cavities may hold a cumulative mass of sensorial media in a range of between 30 mg and 80 mg, for example between 40 mg and 70 mg, for example about 50 mg.

[0023] The plurality of cavities may be two in number. However, it will be appreciated that the plurality of cavities may be greater in number than two.

[0024] Preferably, the first elongate sheet may be configured to be substantially impermeable. Impermeability of the first elongate sheet may prevent or inhibit unwanted loss of moisture content from the sensorial media, whether through absorption by the first elongate sheet or by escape to outside of the confines of the aerosol-generating article. More generally, impermeability of the first elongate sheet may be beneficial in preventing or inhibiting absorption by the first elongate sheet of moisture from inside or outside of the aerosol-generating article and any consequential reduction in flexural stiffness of the article.

[0025] Advantageously, the first elongate sheet may be configured to be impermeable to water or air. Where the portion of sensorial media is formed of a liquid, a gel, a slurry or a paste, having the first elongate sheet being impermeable may help to avoid or inhibit loss of liquid content of the sensorial media to outside of the aerosol-generating article.

[0026] The first elongate sheet may preferably be paper-based. In such an embodiment, the paper would define the primary structural element of the first elongate sheet, providing the majority or all of the flexural stiffness of the first elongate sheet. The use of paper for the first elongate sheet is favoured due to paper having characteristics of being lightweight and flexible. The paper of the first elongate sheet may act as a suitable base or foundation for one or more coatings or layers of other material(s), such as a coating or layer having material properties designed to impart or increase impermeability of the first elongate sheet. A paper-based first elongate sheet may have a thickness of about 1 .1 to about 4.5 microns. A paper-based first elongate sheet may have a basis weight of between about 45 to 140 g / m, preferably of between about 50 to 110 g / m. A paper-based first elongate sheet may preferably have a permeability of between about 1 to 5 Coresta Units (CU). Impermeability of the paper-based first elongate sheet may be enhanced through the first elongate sheet comprising a coating or layer less permeable than the paper content of the first elongate sheet. The coating or layer may be substantially impermeable; for example, being water-impermeable or air-impermeable. The coating or layer may preferably have a thickness of between about 0.75 and 1 .5 microns. Preferably, the coating or layer may be formed of a material having an FDA food & beverage industry grade composition, such as a composition complying with FDA Regulation 21 CFR. Examples of such FDA-compliant compositions include dispersions based on copolymers consisting of acrylic ester and styrene, or based on styrene-butadiene copolymers, applied during paper processing as aqueous dispersions of copolymers of styrene-butadiene with a solids content of approximately 50 %. Advantageously, the coating or layer may be formed of a bio-polymeric compound. The bio-polymeric compound may be derived from botanic-based cellulosic material, preferably being pulp-based. The bio-polymeric compound may be derived from recycled waste tobacco materials, thereby providing a more sustainable, environmentally friendly design for the aerosol-generating article. The recycled waste tobacco materials may comprise tobacco dust, fragments, stems and tobacco leaves.

[0027] The first elongate sheet may be based on paperboard or cardboard, rather than paper. In such a scenario, the paperboard or cardboard would provide the majority or all of the flexural stiffness of the first elongate sheet. Paperboard and cardboard differ from paper in having a higher basis weight. In common with paper, both paperboard and cardboard also have characteristics of being lightweight and flexible. Where the first elongate sheet is based on paperboard or cardboard, it will be understood that one or more coatings or layers may be overlaid onto the base of paperboard or cardboard to reduce or minimise the permeability of the first elongate sheet in the same manner as described above for a paper-based first elongate sheet. Preferably, the first elongate sheet may comprise a layer of paper, paperboard or cardboard overlaid by a layer or coating of a polymeric compound, for example a bio-polymeric compound as described above. In such a scenario, the layer of paper, paperboard or cardboard may provide the majority or all of the flexural stiffness of the first elongate sheet. The layer or coating of the polymeric compound may be less permeable than the layer of paper, paperboard or cardboard.

[0028] The first elongate sheet may comprise a layer of paper, paperboard or cardboard, with a dispersion of a polymeric compound (for example, a bio-polymeric compound as described above) provided within the layer. In this manner, the polymeric compound may be integrated into the structure of the layer of paper, paperboard or cardboard. The layer of paper, paperboard or cardboard may provide the majority or all of the flexural stiffness of the first elongate sheet.

[0029] Advantageously, the aerosol-generating article may comprise a second elongate sheet, the second elongate sheet positioned above the first elongate sheet, for example in the z-direction.

[0030] The second elongate sheet may be arranged to overlie and close the plurality of cavities and retain the portion of sensorial media within the respective cavity of the plurality of cavities. So, the second elongate sheet may provide a degree of physical protection to portion(s) of sensorial media disposed within the various cavities.

[0031] Preferably, opposing surfaces of the first and second elongate sheets may be configured to be substantially impermeable. The opposing surfaces of the first and second elongate sheets may be configured to be impermeable to water or air.

[0032] Impermeability of the first and second elongate sheets may provide the same or similar advantages as described above for impermeability of the first elongate sheet.

[0033] Advantageously, the level of impermeability of the first and second elongate sheets may be sufficient to assist in hermetically sealing the plurality of cavities. In this manner, portions of sensorial media positioned within the cavities between the first and second elongate sheets are able to retain freshness and moisture content for longer, for example during storage and transportation of unused aerosol-generating articles.

[0034] The second elongate sheet may be partially or wholly transparent, thereby allowing a consumer to have sight of any portions of sensorial media disposed within the cavities. Alternatively however, the second elongate sheet may be opaque. The second elongate sheet may be formed from a polymeric compound certified by the FDA for food & beverage use. The polymeric compound may include those described for the first elongate sheet. The polymeric compound may be a bio-polymeric compound, and include those described for the first elongate sheet. The second elongate sheet may be formed from polymeric compound compositions incorporating vinyl-based polymers and copolymers, polyurethane, acrylic, cellulose and its derivatives, and compounds of the same.

[0035] It is envisaged that the second elongate sheet may contribute very little to the flexural stiffness of the aerosol-generating article. For example, preferably the first elongate sheet may provide a majority of the flexural stiffness of the aerosol-generating article. Preferably, the second elongate sheet may comprise a foil.

[0036] The second elongate sheet may be bonded to the first elongate sheet, for example by an adhesive. Preferably, a surface of the second elongate sheet positioned above and corresponding in size to the plurality of cavities may be free of adhesive. In this manner, contamination of the sensorial media with adhesive may be avoided or inhibited, with the adhesive being confined to that part of the second elongate sheet intended to be bonded to the first elongate sheet. Suitable adhesives for use in bonding the first and second elongate sheets together include a polyethylene adhesive, being waterbased or solvent-based (preferably water-based), as well as acrylic-based adhesives. Advantageously, an adhesive used to bond the first and second elongate sheets to each other may be FDA certified for food & beverage use, such as under FDA 21 CFR 175.105 (Adhesives) and FDA 21 CFR 175.125 (Pressure-sensitive adhesives). Advantageously, the adhesive selected for bonding the first and second elongate sheets to each other assists in hermetically sealing the plurality of cavities.

[0037] Preferably, the first and second elongate sheets may be bonded to each other along a peelable interface between the first and second elongate sheets. The peelable interface is to be understood as providing a non-permanent bond between the first and second elongate sheets along the peelable interface. A non-permanent adhesive may be used for the peelable interface, thereby allowing the first and second elongate sheets to be separated from each other along the peelable interface. Conveniently, laterally opposed edges of the second elongate sheet are bonded to laterally opposed edges of the first elongate sheet to define a non-peelable interface, the non-peelable interface located outward of the peelable interface. In this manner, when force is applied to detach the second elongate sheet from the aerosol-generating article, the second elongate sheet fractures or tears inwards of the non-peelable interface to leave part of the second elongate sheet still bonded to the first elongate sheet along the non-peelable interface. Further, the bond between the second and first elongate sheets is then broken along the peelable interface to allow peelable removal of the remainder of the second elongate sheet from the article. A permanent adhesive may be used for the non-peelable interface.

[0038] The second elongate sheet may comprise or be coupled to a pull tab. A user may grip the pull tab to apply a force to separate the second elongate sheet from the aerosol-generating article.

[0039] It is envisaged that in a preferred embodiment, the second elongate sheet may be detached from the aerosol-generating article prior to inserting the aerosol-generating article into an aerosolgenerating device. Such an aerosol-generating device may have a cavity for receiving the aerosolgenerating article. A heating element may be arranged within the aerosol-generating device (for example within the cavity) to overlie the portion(s) of sensorial media of the aerosol-generating article. Conveniently, the heating element may be planar in form, with the aerosol-generating article also being generally planar.

[0040] Preferably, the first and second elongate sheets may be aligned parallel to each other.

[0041] Preferably, the first and second elongate sheets may be generally planar.

[0042] Preferably, the height of the aerosol-generating article may be defined by a separation distance (for example, along the z-direction) between an outward-facing surface of the first elongate sheet and an outward-facing surface of the second elongate sheet. An outward-facing surface of the second elongate sheet and an outward-facing surface of the first elongate sheet may define at least part of an exterior of the aerosol-generating article. As a general comment, the provision of impermeability to the first and (where provided) second elongate sheets may be particularly beneficial for storage of sensorial media in the form of a liquid, a gel, a slurry or a paste. Such sensorial media are inherently “wet”. Therefore, providing a level of impermeability to the first and / or second elongate sheets may help to prevent or inhibit leakage of the sensoria media (or liquid content of the sensorial media) out from the aerosol-generating article. Further, providing a level of impermeability to the first and / or second elongate sheets may facilitate inhibiting moisture absorption by the first and / or second elongate sheets, thereby helping to maintain a desired level of flexural stiffness for the article. Providing a level of impermeability to the first and / or second elongate sheets may also facilitate hermetically sealing the cavities of the article and ensure that freshness of sensorial media stored in those cavities is maintained.

[0043] The use of “wet” sensorial media may assist the sensorial media to adhere to the surface of the first elongate sheet within the respective cavity. The inherent stickiness of “wet” sensorial media may help to ensure that a given portion of sensorial media positioned in one of the cavities during manufacture of the article remains in a static, stable position throughout subsequent manufacturing operations and / or transportation of the completed aerosol-generating article.

[0044] Conveniently, the aerosol-generating article may further comprise a porous sheet arranged to overlie and close the plurality of cavities and retain the portion of sensorial media within the respective cavity of the plurality of cavities. Such a porous sheet may thereby perform dual functions of helping to physically retain sensorial media within the plurality of cavities, whilst also permitting the passage of vapour evolved from the sensorial media, for example when heat is applied to the sensorial media to vaporise components of the sensorial media. The porous sheet may be beneficial in facilitating aerosolisation of the sensorial media. Further, the use of a porous sheet may provide a fluid retention capability, for example through the porous sheet retaining fluid derived from the sensorial media.

[0045] The porous sheet may resemble in form and porosity a tea-bag material.

[0046] The porous sheet may be bonded to the first elongate sheet along a continuous seal line, the continuous seal line surrounding the plurality of cavities. An adhesive may be used to bond the porous sheet to the first elongate sheet. The bond between the porous sheet and the first elongate sheet may preferably be a permanent, non-peelable bond.

[0047] The porous sheet may be bonded to the first elongate sheet along a plurality of continuous seal lines. Each continuous seal line may surround a different cavity or a different subset of cavities of the plurality of cavities.

[0048] No second elongate sheet may be present for the aerosol-generating article. In such a scenario, the height of the aerosol-generating article may be defined by a separation distance between an outward-facing surface of the porous sheet and an outward-facing surface of the first elongate sheet. In this manner, the outward-facing surface of the porous sheet and the outward-facing surface of the first elongate sheet may define at least part of an exterior of the aerosol-generating article.

[0049] Conveniently, the porous sheet may be disposed between the first and (where provided) the second elongate sheets. So, the porous sheet may be sandwiched between the first and second elongate sheets. Where the second elongate sheet is present, it is envisaged that the second elongate sheet would be removed prior to use of the aerosol-generating article, with the porous sheet allowing escape of vapours arising from heating of the sensorial media. Preferably, the second elongate sheet may be bonded to the first elongate sheet along an outer bond interface and the porous sheet bonded to the first elongate sheet along an inner bond interface, wherein the outer bond interface surrounds the inner bond interface.

[0050] The plurality of cavities may consist of or comprise a first cavity and a second cavity arranged in side-by-side relationship with each other. Each of the first cavity and the second cavity may have a length extending along the x-direction. Each of the first cavity and the second cavity may have a length extending along the y-direction.

[0051] Preferably, each of the plurality of cavities may contain a respective portion of sensorial media. Advantageously, a composition of at least one of the portions of sensorial media may be different from the composition of the other portion or portions of sensorial media. The use of different compositions of substrate in different ones of the cavities may allow for aerosols or vapours of different compositions to be generated at different points in a usage session; for example, an aerosol or vapour of a first composition may be generated from a first portion of sensorial media disposed in a first cavity of the first elongate sheet at a first point in time and an aerosol or vapour of a different, second composition may be generated from a second portion of sensorial media disposed in a second cavity of the first elongate sheet at a later, second point in time. This provides a dynamic element to the consumption experience of a user, enabling the user to experience different flavours and / or intensities at different stages of a usage session.

[0052] According to a second aspect of the present disclosure, there may be provided an aerosolgenerating article for use with an aerosol-generating device to generate an aerosol. The aerosolgenerating article may comprise a plurality of micro-cavities containing sensorial media. At least 50% of the entirety of the mass of sensorial media of the aerosol-generating article may be disposed within the plurality of micro-cavities.

[0053] Preferably, each of the plurality of micro-cavities may define a volume of less than 5 mm3, for example less than 2.5 mm3, for example less than 1 mm3. These values may define an upper bound value of the volume of each of the micro-cavities.

[0054] Preferably, each of the plurality of micro-cavities may define a volume of more than 0.01 mm3, for example more than 0.05 mm3, for example more than 0.1 mm3. These values may define a lower bound value of the volume of each of the micro-cavities.

[0055] The volume of each of the plurality of micro-cavities may be between the upper and lower bound values indicated in the preceding paragraphs.

[0056] The plurality of microcavities may be greater than 25 in number, for example greater than 50 in number, for example greater than 100 in number, for example greater than 250 in number.

[0057] Advantageously, at least some of the plurality of micro-cavities may be defined in a porous wall or layer of the aerosol-generating article. For example, micro-cavities may be defined in a porous wrapper of the aerosol-generating article.

[0058] According to a third aspect of the present disclosure, there may be provided an aerosolgenerating article for use with an aerosol-generating device to generate an aerosol. 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 height may be less than each of the width and the length. The height may be less than 4 millimetres. The aerosol-generating article may further comprise first and second elongate sheets, wherein the second elongate sheet is positioned above the first elongate sheet (for example in the z-direction). One or more cavities may be defined between the first elongate sheet and the second elongate sheet. A portion of sensorial media may be disposed within the cavity. The aerosol-generating article may be configured to hermetically isolate the portion of sensorial media and / or the cavity from an environment outside of the aerosol-generating article.

[0059] Hermetic isolation may facilitate maintaining freshness of the sensorial media during transportation and storage of the article(s), as well as preventing or inhibiting loss of moisture content from the sensorial media during such transportation and storage.

[0060] In common with the first aspect of the present disclosure, minimising the height of the aerosolgenerating article provides the article with a geometric profile which is more compact, and also facilitates homogenous through-thickness heating of the article and the sensorial media.

[0061] The first elongate sheet may define a majority of the flexural rigidity of the aerosol-generating article. In this manner, the first elongate sheet may thereby form the primary structural element of the aerosol-generating article.

[0062] In common with the first aspect of the present disclosure, the height of the aerosol-generating article may be less than 3.5 millimetres, for example less than 3 millimetres, for example less than 2.5 millimetres, for example less than 2 millimetres. These values may define an upper bound value of the height of the aerosol-generating article.

[0063] In common with the first aspect of the present disclosure, the height of the aerosol-generating article may be greater than 0.2 millimetres, for example greater than 0.25 millimetres, for example greater than 0.5 millimetres. These values may define a lower bound value of the height of the aerosolgenerating article.

[0064] The height of the aerosol-generating article may be between the upper and lower bound values indicated in the preceding paragraphs.

[0065] Preferably, opposed surfaces of the first and second elongate sheets may be bonded to each other to close and isolate the cavity from the environment outside of the aerosol-generating article. For example, the opposed surfaces of the first and second elongate sheets may be bonded to each other about a continuous seal line, the cavity surrounded by the continuous seal line. So, the sensorial media and any adhesive (if present) used to bond the opposing surfaces of the first and second elongate sheets to each other may be the only features of the aerosol-generating article disposed between the first and second elongate sheets.

[0066] A frame may be disposed between the first and second elongate sheets, the frame at least partially defining the cavity. The cavity may extend through a thickness of the frame (for example along the z-direction), with the first and second elongate sheets bonded to respective opposed surfaces of the frame to thereby close the cavity. In this manner, the cavity may be defined by the frame and opposing surfaces of the first and second elongate sheets.

[0067] If a frame is present, the frame may be formed of paper, paperboard or cardboard. The frame may be formed as a single layer. Alternatively, the frame may be formed from two or more layers successively overlaid over each other, for example in the z-direction. The frame may have a thickness extending in the z direction of less than 3 millimetres, for example less than 2 millimetres, for example less than 1 .5 millimetres, for example less than 1 millimetre.

[0068] More generally, the cavity may be at least partially defined by opposing surface regions of the first and second elongate sheets, the opposing surface regions being free of adhesive. The lack of adhesive on those surfaces of the first and second elongate sheets which overlie and / or define the cavity facilitates inhibiting contamination of the sensorial media with adhesive.

[0069] The first and second elongate sheet may be formed of the same materials and / or have the same level of impermeability as described above for the first aspect of the present disclosure. As described for the first aspect of the present disclosure, it is preferred that any polymeric materials used to form the first and second elongate sheets are bio-polymeric compounds and / or are certified by the FDA for food and beverage use. Where bio-polymeric compounds are employed, it is preferred that they be derived from botanic-based cellulosic material, preferably being pulp-based. The bio-polymeric compounds may be derived from recycled waste tobacco materials, thereby providing a more sustainable, environmentally friendly design for the aerosol-generating article. The recycled waste tobacco materials may comprise tobacco dust, fragments, stems and tobacco leaves.

[0070] Opposing surfaces of the first and second elongate sheets may be configured to be substantially impermeable. The opposing surfaces of the first and second elongate sheets may be configured to be impermeable to water or air.

[0071] The first elongate sheet may comprise a layer of paper, paperboard or cardboard overlaid by a layer or coating of a polymeric compound, the layer or coating of the polymeric compound being less permeable than the layer of paper, paperboard or cardboard.

[0072] The first elongate sheet may comprise a layer of paper, paperboard or cardboard, with a dispersion of a polymeric compound provided within the layer.

[0073] As discussed in earlier paragraphs of the present disclosure, the polymeric compound may be a bio-polymeric compound.

[0074] Where the first elongate sheet comprises a layer of paper, paperboard or cardboard, this layer may preferably provide a majority or all of the flexural stiffness of the first elongate sheet.

[0075] As described for the first aspect of the present disclosure, the second elongate sheet may be formed from a bio-polymeric compound.

[0076] The first and second elongate sheets may preferably be aligned parallel to each other.

[0077] The first and second elongate sheets may each be generally planar.

[0078] The height of the aerosol-generating article may be defined by a separation distance (for example, along the z-direction) between an outward-facing surface of the first elongate sheet and an outward-facing surface of the second elongate sheet.

[0079] Preferably, a first pre-rupture region may be defined in one of the first and second elongate sheets and a second pre-rupture region defined in one of the first and second elongate sheets. The first and second pre-rupture regions may be arranged such that on breaching of the first and second pre-rupture regions of the respective elongate sheet, an air inlet is defined through the first pre-rupture region and an air outlet is defined through the second pre-rupture region, with the air inlet and the air outlet both in fluid communication with the cavity.

[0080] The first and second pre-rupture regions may be defined areas of the respective elongate sheet which are intended to be breached to permit the passage of airflow into or out from the article. The elongate sheet of which the first and second pre-rupture regions form part may include features or characteristics to assist breaching of the first and second pre-rupture regions. Such features may include score lines or localised thinning of the respective elongate sheet.

[0081] Preferably, the first and second pre-rupture regions may be defined in the same elongate sheet. For example, the first and second pre-rupture regions may each be defined in the second elongate sheet. Alternatively, the first and second pre-rupture regions may instead be defined in different ones of the first and second elongate sheets.

[0082] An intermediate sheet may be disposed between the first and second elongate sheets, the intermediate sheet bonded to the first elongate sheet and arranged to cover and seal the cavity. Preferably, first and second pre-rupture regions may be defined in the intermediate sheet, the second elongate sheet bonded to the first and second pre-rupture regions of the intermediate sheet such that on removal of the second elongate sheet from the article the intermediate sheet is breached to define an air inlet through the first pre-rupture region and an air outlet through the second pre-rupture region, wherein the air inlet and the air outlet are both in fluid communication with the cavity.

[0083] The first and second pre-rupture regions may be defined areas of the intermediate sheet which are intended to be breached to permit the passage of airflow into or out from the article. The intermediate sheet may include features or characteristics to assist in breaching of the first and second pre-rupture regions. Such features may include score lines or localised thinning of the intermediate sheet.

[0084] The intermediate sheet may be formed of the same materials as used for either one of the first or second elongate sheets. The intermediate sheet may contribute very little to the flexural stiffness of the aerosol-generating article; for example, preferably the first elongate sheet may provide a majority of the flexural stiffness of the aerosol-generating article. Preferably, the intermediate sheet may comprise a foil.

[0085] The first and second pre-rupture regions may be disposed at opposite ends of the aerosolgenerating article. In one example, the first and second pre-rupture regions may be disposed at opposite longitudinal ends of the aerosol-generating article. In this manner, on breaching of the first and second pre-rupture regions, an airflow path may be defined extending substantially along a length direction of the aerosol-generating article via the cavity. In another example, the first and second prerupture regions may be disposed at opposite lateral ends of the aerosol-generating article. In this manner, on breaching of the first and second pre-rupture regions, an airflow path may be defined extending substantially along a width direction of the aerosol-generating article via the cavity.

[0086] As indicated in the preceding paragraphs, the first and second pre-rupture regions may comprise one or more score lines.

[0087] The one or more cavities may preferably be a plurality of cavities. As described for the first aspect of the present disclosure, the plurality of cavities may consist of or comprise a first cavity and a second cavity arranged in side-by-side relationship with each other. Each of the first cavity and the second cavity may have a length extending along the x-direction. Each of the first cavity and the second cavity may have a length extending along the y-direction.

[0088] Where the one or more cavities are a plurality of cavities, preferably each of the plurality of cavities may contain a respective portion of sensorial media. Advantageously, a composition of at least one of the portions of sensorial media may be different from the composition of the other portion or portions of sensorial media. In a similar manner to as described for the first aspect of the present disclosure, the use of different compositions of substrate in different ones of the cavities may allow for aerosols or vapours of different compositions to be generated at different points in a usage session. For example, an aerosol or vapour of a first composition may be generated from a first portion of sensorial media disposed in a first cavity of the article at a first point in time and an aerosol or vapour of a different, second composition may be generated from a second portion of sensorial media disposed in a second cavity of the article at a later, second point in time. This provides a dynamic element to the consumption experience of a user, enabling the user to experience different flavours and / or intensities at different stages of a usage session.

[0089] According to a fourth aspect of the present disclosure, there may be provided an aerosolgenerating article for use with an aerosol-generating device to generate an aerosol. The aerosolgenerating article may comprise first and second elongate sheets, an intermediate sheet disposed between the first and second elongate sheets, and a portion of sensorial media disposed within a cavity between the first elongate sheet and the intermediate sheet. First and second pre-rupture regions may be defined in the intermediate sheet. The second elongate sheet may be bonded to the first and second pre-rupture regions of the intermediate sheet such that on removal of the second elongate sheet from the article the intermediate sheet is breached to define an air inlet through the first pre-rupture region and an air outlet through the second pre-rupture region, wherein an airflow passage through an interior of the aerosol-generating article is thereby defined through the aerosolgenerating article between the air inlet and the air outlet.

[0090] The first and second pre-rupture regions may be defined areas of the intermediate sheet which are intended to be breached to permit the passage of airflow into or out from the article. The intermediate sheet may include features or characteristics to assist in breaching of the first and second pre-rupture regions. Such features may include score lines or localised thinning of the intermediate sheet.

[0091] Preferably, the airflow passage defined by breaching of the first and second pre-rupture regions of the intermediate sheet extends through the cavity.

[0092] The following paragraphs discuss suitable forms of the sensorial media and are applicable to any of the aspects of the present disclosure described herein.

[0093] As indicated in previous paragraphs, the sensorial media may consist of or comprise a liquid or gel. The sensorial media may be in the form of a slurry or a paste.

[0094] However, it will be appreciated that the sensorial media may be formed wholly or in part of solid matter. Preferably, the sensorial media may comprise or consist of aerosol-forming substrate or a flavouring agent.

[0095] The sensorial media may comprise nicotine. It is preferred that the sensorial media is physically and chemically stable over a broad range of environmental conditions. In this manner, the sensorial media may be better capable of retaining freshness during storage and transportation. Where the sensorial media is in the form of a gel composition comprising nicotine, it is preferred that on the application of heat to the sensorial media, the sensorial media vaporises nicotine, but does not release or absorb liquid phase matter (for example, water). It is preferred that the sensorial media does not release or absorb water over a range of humidity levels, for example from about 5% to about 70% relative humidity.

[0096] The sensorial media preferably may have a composition adapted to facilitate the generation of an aerosol upon application of a heating profile to the sensorial media. The heating profile may be adapted to cause volatile compounds to be vaporise from the sensorial media through heating rather than burning of the sensorial media. Heat may be imparted to the sensorial media by a heating element of an aerosol-generating device; for example, the aerosol-generating device may be configured to receive the aerosol-generating article and apply the heating profile to the sensorial media of the aerosol-generating article. The vaporised volatile compounds may become entrained with an airflow flowing over the sensorial media (for example, an airflow flowing along an airflow path through the aerosol-generating device), with the entrained airflow progressively cooling to form an aerosol for subsequent inhalation by a user.

[0097] The sensorial media may be a gel composition incorporating a gelling agent forming a solid medium, with glycerol dispersed in the solid medium, and nicotine dispersed in the glycerol. The sensorial media may be formed of about 80% to about 90% wt. glycerol, with a water content of less than about 20% wt., with a total combined weight of water and glycerol in a range from of about 85 to 95% wt. The gelling agent may be incorporated in the gel composition in a range from about 2% to about 7% by weight. Suitable gelling agents include xanthan gum, as well as low acyl gellan, and agar, or a mix of those in approximately equal amounts.

[0098] Advantageously, the sensorial media may remain stable when exposed to a relative humidity in a range from about 10% to about 60% at 24 degrees Celsius and one atmosphere. Preferably, the sensorial media may keep its volumetric and geometrical shape (not changing by more than about 2%), and the overall mass of the sensorial media not changing by more than about 1 %, under such environmental conditions.

[0099] The sensorial media may be a gel composition containing nicotine, in which the content of nicotine in the sensorial media may vary within a range of about 1 to about 3% wt. of nicotine. The gel composition may incorporate about 85% to about 95% wt. glycerol; about 1 % to about 5% wt. agar, xanthan gum and low acyl gellan ; levulinic acid. The gel composition may be substantially free of water content.

[0100] Reference to “nicotine content” refers to nicotine and nicotine derivatives, including free-base nicotine, and nicotine salts. Alternatively or in addition, the sensorial media may have a composition containing flavouring agents, preferably natural flavouring agents. The flavouring agent may be of a single type, or a blend of flavouring agents may be used. The sensorial media may be formed of about 1% to about 4% wt. flavouring agent, preferably of about 1% to about 2% wt. Such flavouring agents may be obtained by a physical process such as roasting, heating, or chemical processes such as extraction, distillation, enzymatic, or microbiological processes from plant parts, including from tobacco stems. The flavouring agents may be in the form of essential oil, oleoresin, and essences, as alcoholic or hydroalcoholic solutions of volatile substances, or extractive, distillate, or any product of roasting, heating, or enzymolysis. Examples of flavouring agents that may be successfully used in the composition of sensorial media are complex volatile oil I anise oil, aldehyde I vanillin, ginger oil, peppermint oil, lemongrass oil, tobacco extract oil, and menthol oil.

[0101] As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol. For example, an aerosol-generating article may be an article comprising an aerosol-forming substrate that is capable of releasing volatile compounds that can form an aerosol. The aerosol-generating article may be disposable.

[0102] As used herein, the term “sensorial media” relates to a substrate capable of releasing one or more volatile compounds that can form an aerosol or a vapor or that can be brought into the gaseous phase. The sensorial media may serve as one or more of a nicotine provider, a flavour enhancer, and a volume enhancer. The sensorial media may be an aerosol-forming substrate. The aerosol-forming substrate may include an aerosol former.

[0103] As used herein, the term “aerosol-forming substrate” may refer to a substrate capable of releasing an aerosol or volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. An aerosol-forming substrate may comprise an aerosol-forming material. An aerosol-forming substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. An aerosol-forming substrate may conveniently be part of an aerosol-generating article or smoking article.

[0104] As used herein, the term “aerosol former” may refer to any suitable known compound or mixture of compounds that, in use, facilitates formation of an aerosol. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-forming substrate or aerosol-generating article.

[0105] As used herein, the term “aerosol-generating device” may refer to a device for use with an aerosol-generating article to enable the generation, or release, of an aerosol.

[0106] As used herein, the term “aerosol generating system” may refer to a combination of an aerosolgenerating device and one or more aerosol-forming articles for use with the device. An aerosolgenerating system may include additional components, such as a charging unit for recharging an onboard electric power supply in an electrically operated or electric aerosol-generating device.

[0107] As used herein with reference to the invention, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt. As used herein with reference to the invention, the terms “proximal”, “distal”, “upstream” and “downstream” are used to describe the relative positions of components, or portions of components, of the aerosol-generating article.

[0108] The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0109] Example Ex1 : An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: a first elongate sheet debossed or embossed to form a tray, the tray defining a plurality of cavities; a portion of sensorial media disposed within at least one of the plurality of cavities; wherein the aerosol generating article is defined by a length extending in an x-direction, a width extending in a y-direction, and a height extending in a z-direction, wherein the height is less than each of the width and the length, the height being less than 4 millimetres.

[0110] Example Ex1 a: An aerosol-generating article according to Ex1 , wherein the first elongate sheet defines a majority of the flexural rigidity of the aerosol-generating article.

[0111] Example Ex2: An aerosol-generating article according to either one of Ex1 or Ex1 a, wherein the height of the aerosol-generating article is less than 3.5 millimetres, for example less than 3 millimetres, for example less than 2.5 millimetres, for example less than 2 millimetres.

[0112] Example Ex3: An aerosol-generating article according to any one of Ex1 to Ex2, wherein the height of the aerosol-generating article is greater than 0.2 millimetres, for example greater than 0.25 millimetres, for example greater than 0.5 millimetres.

[0113] Example Ex4: An aerosol-generating article according to any one of Ex1 to Ex3, wherein each cavity of the plurality of cavities has a depth of between 75 and 500 microns, for example between 75 and 250 microns, for example between 75 and 125 microns, for example about 100 microns.

[0114] Example Ex5: An aerosol-generating article according to any one of Ex1 to Ex4, wherein each cavity of the plurality of cavities define a volume of between 150 mm3and 300 mm3, for example between 175 mm3and 275 mm3, for example between 200 mm3and 250 mm3.

[0115] Example Ex6: An aerosol-generating article according to any one of Ex1 to Ex5, wherein the plurality of cavities define a cumulative volume of between 300 mm3and 600 mm3, for example between 350 mm3and 550 mm3, for example between 400 mm3and 500 mm3, for example about 400 mm3or about 500 mm3.

[0116] Example Ex7: An aerosol-generating article according to any one of Ex1 to Ex6, wherein each cavity of the plurality of cavities holds a mass of sensorial media in a range of between 15 mg and 40 mg, for example between 20 mg and 35 mg, for example about 25 mg.

[0117] Example Ex8: An aerosol-generating article according to any one of Ex1 to Ex7, wherein the plurality of cavities hold a cumulative mass of sensorial media in a range of between 30 mg and 80 mg, for example between 40 mg and 70 mg, for example about 50 mg.

[0118] Example Ex9: An aerosol-generating article according to any one of Ex1 to Ex8, wherein the first elongate sheet is configured to be substantially impermeable. Example Ex10: An aerosol-generating article according to any one of Ex1 to Ex9, wherein the first elongate sheet is configured to be impermeable to water or air.

[0119] Example Ex11 : An aerosol-generating article according to any one of Ex1 to Ex10, wherein the first elongate sheet comprises a layer of paper, paperboard or cardboard overlaid by a layer or coating of a polymeric compound, the layer or coating of the polymeric compound being less permeable than the layer of paper, paperboard or cardboard.

[0120] Example Ex12: An aerosol-generating article according to any one of Ex1 to Ex11 , wherein the first elongate sheet comprises a layer of paper, paperboard or cardboard, wherein a dispersion of a polymeric compound is provided within the layer.

[0121] Example Ex13: An aerosol-generating article according to either one of Ex11 or Ex12, wherein the polymeric compound is a bio-polymeric compound.

[0122] Example Ex13a: An aerosol-generating article according to any one of Ex11 to Ex13, wherein the layer of paper, paperboard or cardboard provides a majority or all of the flexural stiffness of the first elongate sheet.

[0123] Example Ex14: An aerosol-generating article according to any one of Ex1 to Ex13, further comprising a second elongate sheet, wherein the second elongate sheet is positioned above the first elongate sheet, for example in the z-direction.

[0124] Example Ex15: An aerosol-generating article according to Ex14, wherein the second elongate sheet is arranged to overlie and close the plurality of cavities and retain the portion of sensorial media within the respective cavity of the plurality of cavities.

[0125] Example Ex16: An aerosol-generating article according to either one of Ex14 or Ex15, wherein opposing surfaces of the first and second elongate sheets are configured to be substantially impermeable.

[0126] Example Ex17: An aerosol-generating article according to Ex16, wherein the opposing surfaces of the first and second elongate sheets are configured to be impermeable to water or air.

[0127] Example Ex18: An aerosol-generating article according to any one of Ex14 to Ex17, wherein the second elongate sheet is at least partially transparent.

[0128] Example Ex19: An aerosol-generating article according to any one of Ex14 to Ex18, wherein the second elongate sheet is formed from a bio-polymeric compound.

[0129] Example Ex20: An aerosol-generating article according to any one of Ex14 to Ex19, wherein the second elongate sheet is bonded to the first elongate sheet, for example by an adhesive.

[0130] Example Ex21 : An aerosol-generating article according to Ex20, wherein a surface of the second elongate sheet positioned above and corresponding in size to the plurality of cavities is free of adhesive.

[0131] Example Ex22: An aerosol-generating article according to any one of Ex14 to Ex21 , wherein the second elongate sheet is bonded to the first elongate sheet along a peelable interface between the first and second elongate sheets.

[0132] Example Ex23: An aerosol-generating article according to Ex22, wherein the peelable interface comprises a non-permanent adhesive. Example Ex23a: An aerosol-generating article according to either one of Ex22 or Ex23, wherein laterally opposed edges of the second elongate sheet are bonded to laterally opposed edges of the first elongate sheet to define a non-peelable interface, the non-peelable interface located outward of the peelable interface.

[0133] Example Ex23b: An aerosol-generating article according to Ex23a, wherein the non-peelable interface comprises a permanent adhesive.

[0134] Example Ex23c: An aerosol-generating article according to any one of Ex14 to Ex23b, wherein the second elongate sheet comprises or is coupled to a pull tab.

[0135] Example Ex24: An aerosol-generating article according to any one of Ex14 to Ex23c, wherein the first and second elongate sheets are aligned parallel to each other.

[0136] Example Ex25: An aerosol-generating article according to any one of Ex14 to Ex24, wherein the first and second elongate sheets are each generally planar.

[0137] Example Ex26: An aerosol-generating article according to any one of Ex14 to Ex25, wherein the height of the aerosol-generating article is defined by a separation distance (for example, along the z- direction) between an outward-facing surface of the first elongate sheet and an outward-facing surface of the second elongate sheet.

[0138] Example Ex27: An aerosol-generating article according to any one of Ex1 to Ex26, further comprising a porous sheet arranged to overlie and close the plurality of cavities and retain the portion of sensorial media within the respective cavity of the plurality of cavities.

[0139] Example Ex28: An aerosol-generating article according to Ex27, wherein the porous sheet is bonded to the first elongate sheet along a continuous seal line, the continuous seal line surrounding the plurality of cavities.

[0140] Example Ex29: An aerosol-generating article according to either one of Ex27 or Ex28, wherein the porous sheet is bonded to the first elongate sheet along a plurality of continuous seal lines, each continuous seal line surrounding a different cavity or a different subset of cavities of the plurality of cavities.

[0141] Example Ex30: An aerosol-generating article according to any one of Ex27 to Ex29, wherein the height of the aerosol-generating article is defined by a separation distance between an outward-facing surface of the porous sheet and an outward-facing surface of the first elongate sheet.

[0142] Example Ex31 : An aerosol-generating article according to any one of Ex27 to Ex30, wherein the porous sheet is disposed between the first and a or the second elongate sheet.

[0143] Example Ex32: An aerosol-generating article according to Ex31 , wherein the second elongate sheet is bonded to the first elongate sheet along an outer bond interface and the porous sheet is bonded to the first elongate sheet along an inner bond interface, the outer bond interface surrounding the inner bond interface.

[0144] Example Ex33: An aerosol-generating article according to any one of Ex1 to Ex32, wherein the plurality of cavities consist of or comprise a first cavity and a second cavity arranged in side-by-side relationship with each other.

[0145] Example Ex34: An aerosol-generating article according to Ex33, wherein each of the first cavity and the second cavity have a length extending along the x-direction. Example Ex35: An aerosol-generating article according to Ex33, wherein each of the first cavity and the second cavity have a length extending along the y-direction.

[0146] Example Ex36: An aerosol-generating article according to any one of Ex1 to Ex35, wherein each of the plurality of cavities contains a respective portion of sensorial media.

[0147] Example Ex37: An aerosol-generating article according to Ex36, wherein a composition of at least one of the portions of sensorial media is different from the composition of the other portion or portions of sensorial media.

[0148] Example Ex38: An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: a plurality of micro-cavities containing sensorial media, wherein at least 50% of the entirety of the mass of sensorial media of the aerosol-generating article is disposed within the plurality of microcavities.

[0149] Example Ex39: An aerosol-generating article according to Ex38, wherein each of the plurality of micro-cavities defines a volume of less than 5 mm3, for example less than 2.5 mm3, for example less than 1 mm3.

[0150] Example Ex40: An aerosol-generating article according to either one of Ex38 or Ex39, wherein each of the plurality of micro-cavities defines of volume of more than 0.01 mm3, for example more than 0.05 mm3, for example more than 0.1 mm3.

[0151] Example Ex41 : An aerosol-generating article according to any one of Ex38 to Ex40, wherein the plurality of micro-cavities are greater than 25 in number, for example greater than 50 in number, for example greater than 100 in number, for example greater than 250 in number.

[0152] Example Ex42: An aerosol-generating article according to any one of Ex38 to Ex41 , wherein at least some of the plurality of micro-cavities are defined in a porous wall or layer of the aerosolgenerating article, for example a porous wrapper of the aerosol-generating article.

[0153] Example Ex43: An aerosol-generating article according to any one of Ex1 to Ex42, wherein the sensorial media consists of or comprises a liquid or gel.

[0154] Example Ex44: An aerosol-generating article according to Ex43, wherein the sensorial media is an aerosol-generating substrate or a flavouring agent.

[0155] Example Ex45: An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, for example an aerosol-generating article according to any one of Ex1 to Ex44, the aerosol-generating article defined by a length extending in an x-direction, a width extending in a y-direction, and a height extending in a z-direction, wherein the height is less than each of the width and the length, the height being less than 4 millimetres, the aerosol-generating article comprising: first and second elongate sheets, wherein the second elongate sheet is positioned above the first elongate sheet, for example in the z-direction; one or more cavities defined between the first elongate sheet and the second elongate sheet; a portion of sensorial media disposed within the cavity; the aerosol-generating article configured to hermetically isolate the portion of sensorial media and / or the cavity from an environment outside of the aerosol-generating article. Example Ex46: An aerosol-generating article according to Ex45, wherein the height of the aerosol-generating article is less than 3.5 millimetres, for example less than 3 millimetres, for example less than 2.5 millimetres, for example less than 2 millimetres.

[0156] Example Ex47: An aerosol-generating article according to either one of Ex45 or Ex46, wherein the height of the aerosol-generating article is greater than 0.2 millimetres, for example greater than 0.25 millimetres, for example greater than 0.5 millimetres.

[0157] Example Ex48: An aerosol-generating article according to any one of Ex45 to Ex47, wherein opposed surfaces of the first and second elongate sheets are bonded to each other to close and isolate the cavity from the environment outside of the aerosol-generating article.

[0158] Example Ex49: An aerosol-generating article according to any one of Ex45 to Ex48, comprising a frame disposed between the first and second elongate sheets, the frame at least partially defining the cavity.

[0159] Example Ex50: An aerosol-generating article according to Ex49, wherein the cavity extends through a thickness of the frame (for example along the z-direction), the first and second elongate sheets bonded to respective opposed surfaces of the frame to thereby close the cavity.

[0160] Example Ex51 : An aerosol-generating article according to any one of Ex48 to Ex50, wherein the cavity is at least partially defined by opposing surface regions of the first and second elongate sheets, the opposing surface regions being free of adhesive.

[0161] Example Ex52: An aerosol-generating article according to any one of Ex45 to Ex51 , wherein opposing surfaces of the first and second elongate sheets are configured to be substantially impermeable.

[0162] Example Ex53: An aerosol-generating article according to Ex52, wherein the opposing surfaces of the first and second elongate sheets are configured to be impermeable to water or air.

[0163] Example Ex54: An aerosol-generating article according to any one of Ex45 to Ex53, wherein the first elongate sheet comprises a layer of paper, paperboard or cardboard overlaid by a layer or coating of a polymeric compound, the layer or coating of the polymeric compound being less permeable than the layer of paper, paperboard or cardboard.

[0164] Example Ex55: An aerosol-generating article according to any one of Ex45 to Ex54, wherein the first elongate sheet comprises a layer of paper, paperboard or cardboard, wherein a dispersion of a polymeric compound is provided within the layer.

[0165] Example Ex56: An aerosol-generating article according to either one of Ex54 or Ex55, wherein the polymeric compound is a bio-polymeric compound.

[0166] Example Ex57: An aerosol-generating article according to any one of Ex54 to Ex56, wherein the layer of paper, paperboard or cardboard provides a majority or all of the flexural stiffness of the first elongate sheet.

[0167] Example Ex58: An aerosol-generating article according to any one of Ex45 to Ex57, wherein the second elongate sheet is formed from a bio-polymeric compound.

[0168] Example Ex59: An aerosol-generating article according to any one of Ex45 to Ex58, wherein the first and second elongate sheets are aligned parallel to each other. Example Ex60: An aerosol-generating article according to any one of Ex45 to Ex59, wherein the first and second elongate sheets are each generally planar.

[0169] Example Ex61 : An aerosol-generating article according to any one of Ex45 to Ex60, wherein the height of the aerosol-generating article is defined by a separation distance (for example, along the z- direction) between an outward-facing surface of the first elongate sheet and an outward-facing surface of the second elongate sheet.

[0170] Example Ex62: An aerosol-generating article according to any one of Ex45 to Ex61 , wherein a first pre-rupture region is defined in one of the first and second elongate sheets and a second prerupture region is defined in one of the first and second elongate sheets, the first and second prerupture regions arranged such that on breaching of the first and second pre-rupture regions of the respective elongate sheet an air inlet is defined through the first pre-rupture region and an air outlet is defined through the second pre-rupture region, wherein the air inlet and the air outlet are both in fluid communication with the cavity.

[0171] Example Ex63: An aerosol-generating article according to any one of Ex45 to Ex61 , further comprising an intermediate sheet disposed between the first and second elongate sheets, the intermediate sheet bonded to the first elongate sheet and arranged to cover and seal the cavity.

[0172] Example Ex64: An aerosol-generating article according to Ex63, wherein first and second prerupture regions are defined in the intermediate sheet, the second elongate sheet bonded to the first and second pre-rupture regions of the intermediate sheet such that on removal of the second elongate sheet from the article the intermediate sheet is breached to define an air inlet through the first prerupture region and an air outlet through the second pre-rupture region, wherein the air inlet and the air outlet are both in fluid communication with the cavity.

[0173] Example Ex65: An aerosol-generating article according to either one of Ex63 or Ex64, wherein the cavity is at least partially defined by a surface region of the intermediate sheet, the surface region of the intermediate sheet being free of adhesive.

[0174] Example Ex66: An aerosol-generating article according to any one of Ex62 to Ex65, wherein the first and second pre-rupture regions are disposed at opposite ends of the aerosol-generating article.

[0175] Example Ex67: An aerosol-generating article according to Ex66, wherein the first and second pre-rupture regions are disposed at opposite longitudinal ends of the aerosol-generating article.

[0176] Example Ex68: An aerosol-generating article according to Ex66, wherein the first and second pre-rupture regions are disposed at opposite lateral ends of the aerosol-generating article.

[0177] Example Ex69: An aerosol-generating article according to any one of Ex62 to Ex68, wherein the first and second pre-rupture regions comprise one or more score lines.

[0178] Example Ex70: An aerosol-generating article according to any one of Ex45 to Ex69, wherein the one or more cavities are a plurality of cavities, the plurality of cavities consisting of or comprising a first cavity and a second cavity arranged in side-by-side relationship with each other.

[0179] Example Ex71 : An aerosol-generating article according to Ex70, wherein each of the first cavity and the second cavity have a length extending along the x-direction.

[0180] Example Ex72: An aerosol-generating article according to Ex70, wherein each of the first cavity and the second cavity have a length extending along the y-direction. Example Ex73: An aerosol-generating article according to any one of Ex45 to Ex72, wherein the one or more cavities are a plurality of cavities, each of the plurality of cavities containing a respective portion of sensorial media.

[0181] Example Ex74: An aerosol-generating article according to Ex73, wherein a composition of at least one of the portions of sensorial media is different from the composition of the other portion or portions of sensorial media.

[0182] Example Ex75: An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: first and second elongate sheets; an intermediate sheet disposed between the first and second elongate sheets; a portion of sensorial media disposed within a cavity between the first elongate sheet and the intermediate sheet; wherein first and second pre-rupture regions are defined in the intermediate sheet, the second elongate sheet bonded to the first and second pre-rupture regions of the intermediate sheet such that on removal of the second elongate sheet from the article the intermediate sheet is breached to define an air inlet through the first pre-rupture region and an air outlet through the second pre-rupture region, wherein an airflow passage through an interior of the aerosol-generating article is thereby defined through the aerosol-generating article between the air inlet and the air outlet.

[0183] Example Ex76: An aerosol-generating article according to Ex75, wherein the airflow passage defined by breaching of the first and second pre-rupture regions of the intermediate sheet extends through the cavity.

[0184] Example Ex77. An aerosol-generating article according to any one of Ex45 to Ex76, wherein the sensorial media consists of or comprises a liquid or gel.

[0185] Example Ex78: An aerosol-generating article according to Ex77, wherein the sensorial media is an aerosol-generating substrate or a flavouring agent.

[0186] Examples will now be further described with reference to the figures in which:

[0187] Figure 1 is a disassembled perspective view from above of component parts of a first embodiment of aerosol-generating article;

[0188] Figure 2 is an assembled perspective view from above of the aerosol-generating article of figure 1 ;

[0189] Figure 3 is a perspective view from above illustrating removal of a cover sheet from the aerosolgenerating article of figure 2;

[0190] Figure 4 is a longitudinal cross-section view through section A-A of the aerosol-generating article of figure 3 after removal of the cover sheet;

[0191] Figure 5 is a transverse cross-section view through section B-B of the aerosol-generating article of figure 3 after removal of the cover sheet;

[0192] Figure 6 is a disassembled perspective view from above of component parts of a second embodiment of aerosol-generating article;

[0193] Figure 7 is an assembled perspective view from above of the aerosol-generating article of figure 6; Figure 8 is a perspective view from above illustrating removal of a cover sheet from the aerosolgenerating article of figure 7;

[0194] Figure 9 is a longitudinal cross-section view through section C-C of the aerosol-generating article figure 8 after removal of the cover sheet;

[0195] Figure 10 is a transverse cross-section view through section D-D of the aerosol-generating article of figure 8 after removal of the cover sheet;

[0196] Figure 11 indicates reference signs applicable to various different dimensions of component parts of the aerosol-generating article of figures 1 to 5;

[0197] Figures 12 and 13 illustrate an exemplary process for forming one or more cavities within a planar sheet to thereby form a component part of the aerosol-generating articles of figures 1 to 5 and figures 6 to 10;

[0198] Figure 14 is a disassembled perspective view from above of component parts of a third embodiment of aerosol-generating article;

[0199] Figure 15 is an assembled perspective view from above of the aerosol-generating article of figure 14 in a hermetically sealed state;

[0200] Figure 16 is a longitudinal cross-section view through section E-E of the aerosol-generating article of figure 15;

[0201] Figure 17 is a transverse cross-section view through section F-F of the aerosol-generating article of figure 15;

[0202] Figure 18 is a perspective view from above of the aerosol-generating article of figure 15 after breaching of a cover sheet of the article;

[0203] Figure 19 is a longitudinal cross-section view through section G-G of the aerosol-generating article of figure 18 illustrating a flow of air into, through and out from the aerosol-generating article;

[0204] Figures 20(a-c) are cross-sectional views of component parts of part of an aerosol-generating device for breaching the cover sheet of the aerosol-generating article of figures 14 to 19;

[0205] Figure 21 is a disassembled perspective view from above of component parts of a fourth embodiment of aerosol-generating article;

[0206] Figure 22 is an assembled perspective view from above of the aerosol-generating article of figure 21 in a hermetically sealed state;

[0207] Figure 23 is a perspective view from above illustrating removal of a cover sheet from the aerosolgenerating article of figure 22;

[0208] Figure 24 is a longitudinal cross-section view through section H-H of the aerosol-generating article of figure 23 after removal of the cover sheet, illustrating a flow of air into, through and out from the aerosol-generating article;

[0209] Figure 25 is a disassembled perspective view from above of component parts of a fifth embodiment of aerosol-generating article;

[0210] Figure 26 is an assembled perspective view from above of the aerosol-generating article of figure 25 in a hermetically sealed state;

[0211] Figure 27 is a perspective view from above of the aerosol-generating article of figure 26 after removal of a cover sheet from the article; Figure 28 shows a schematic view of an aerosol-generating device according to an embodiment of the present disclosure, the device configured to engage with an aerosol-generating article;

[0212] Figure 29 shows a schematic end view of the aerosol-generating device of figure 28;

[0213] Figure 30 is a schematic view showing an aerosol-generating article in engagement with the aerosol-generating device of figure 28 to form an aerosol-generating system.

[0214] Figure 1 illustrates a perspective disassembled view of component parts of a first embodiment of aerosol-generating article 100. The aerosol-generating article 100 has a bottom sheet 110, two portions 121 , 122 of aerosol-forming substrate 120, a porous sheet 130 and a cover sheet 140.

[0215] The bottom sheet 110 is rectangular in shape, having a length extending in an x-direction and a width extending in a y-direction. The bottom sheet 110 is predominantly formed of a paper substrate. The paper substrate of the bottom sheet 110 has a thickness of about 3 microns and a basis weight of about 100 g / m. A polymer film is applied to the paper substrate, with the polymer film defining an upper surface 111 of the bottom sheet 110. The polymer film has a thickness of about 1 micron. The polymer film is a bio-polymeric compound formed from waste tobacco materials, such as dust, fragments, stems and / or leaves of tobacco. The composition of the bio-polymeric compound used for the polymer film complies with FDA Regulation 21 CFR. The polymer film and paper substrate may be thought of as distinct layers of the bottom sheet 110. The polymer film is substantially impermeable to water or air, thereby making the upper surface 111 of the bottom sheet 110 essentially impermeable. A portion of material is cut-out from one corner of the bottom sheet 110 to define a cut-out region 112 in the bottom sheet. The bottom sheet 110 has a single cavity 113 defining an intruded area in the bottom sheet. The cavity 113 is surrounded by a peripheral region 114 of the sheet. As shown in figures 1 , 4 and 5, the bottom sheet 110 defines a tray-shaped profile.

[0216] In an alternative embodiment, paperboard or cardboard may be used as a substrate material for the bottom sheet 110 instead of paper.

[0217] In an alternative embodiment, the polymer film may comprise dispersions based on copolymers consisting of acrylic ester and styrene, or based on styrene-butadiene copolymers, applied during paper processing as aqueous dispersions of copolymers of styrene-butadiene with a solids content of approximately 50 %.

[0218] In an alternative embodiment, the bottom sheet 110 may include a dispersion of a polymer compound within the paper substrate of the bottom sheet.

[0219] The portions 121 , 122 of aerosol-forming substrate 120 are in the form of rectangular strips of a gel composition. The gel composition contains about 2% wt of nicotine and about 90% wt of glycerol. The cavity 113 defined in the bottom sheet 110 is large enough to accommodate both portions 121 , 122 of aerosol-forming substrate 120 in side-by-side relationship. Each portion 121 , 122 of aerosolforming substrate 120 is positioned within the cavity 113 to sit upon the polymer film of the bottom sheet 110 and is arranged to extend along a length of the cavity 113 in the x-direction. The portions 121 , 122 of aerosol-forming substrate 120 are identical to each other in terms of their chemical composition. As shown in figures 4 and 5, the portions 121 , 122 of aerosol-forming substrate 120 extend to below the height of the peripheral region 114 of the sheet 110 surrounding the cavity 113. The inherently “wet” nature of the gel composition used for the portions 121 , 122 of aerosol-forming substrate 120 means that each portion 121 , 122 naturally adheres to the surface of the bottom sheet 110.

[0220] In an alternative embodiment, the portions 121 , 122 of aerosol-forming substrate 120 may differ from each other in their chemical composition. For example, portion 121 may contain a different type and / or concentration of flavourant to a type and / or concentration of flavourant of portion 122.

[0221] As shown in figure 1 , the porous sheet 130 is rectangular in shape, being dimensioned to have a length and a width generally corresponding to those of the cavity 113. The porous sheet 130 has a structure resembling that found in a tea-bag material. An adhesive track 131 (shown in broken outline) is applied to the surface 111 of the bottom sheet 110. The adhesive track 131 defines a continuous loop extending around the cavity 113. During assembly of the article 100, the porous sheet 130 is positioned over the cavity 113 and pressed against the adhesive track 131 . The adhesive track 131 bonds the porous sheet 130 and the bottom sheet 110 together along a continuous path extending around the cavity 113. The adhesive used for the adhesive track 131 is chosen to provide a permanent, non-peelable bond between the porous sheet 130 and the bottom sheet 110. The bond between the porous sheet 130 and the bottom sheet 110 helps to retain the portions 121 , 122 of aerosol-forming substrate 120 within the cavity 113. The inherent porosity of the porous sheet 130 permits the passage of vapour evolved from the portions 121 , 122 of aerosol-forming substrate on the application of heat during subsequent use of the aerosol-generating article 100.

[0222] The cover sheet 140 is rectangular in shape, with a length and a width corresponding to those of the bottom sheet 110. The cover sheet 140 is a foil formed of a bio-polymeric compound certified for food and beverage applications by the FDA. For aerosol-generating article 100, the bio-polymeric compound selected for the cover sheet 140 is the same as that used for the polymer film described above for bottom sheet 110. However, it will be appreciated that other polymers and materials may be used for the cover sheet 140. An adhesive annulus 141 (shown cross-hatched in figures 1 to 3) is provided on the underside of the cover sheet 140. Two linear adhesive tracks 142, 143 (shown in broken outline in figure 1 ) are also provided on the underside of the cover sheet 140. The linear adhesive tracks 142, 143 extend along laterally opposed edges of the underside of the cover sheet 140. The adhesive tracks 142, 143 are located outward of the adhesive annulus 141 . During assembly of the article 100, the cover sheet 140 is positioned over the bottom sheet 110, with pressure then applied to the cover sheet along the adhesive annulus 141 and the linear adhesive tracks 142, 143. The adhesive annulus 141 bonds the cover sheet 140 to the bottom sheet 110 along a continuous path extending around the cavity 113, the continuous path located outward of the bond between the porous sheet 130 and the bottom sheet 110. The adhesive tracks 142, 143 bond laterally-opposed edges of the cover sheet 140 to the bottom sheet 110. The adhesive used for the adhesive annulus 141 is chosen to provide a non-permanent, peelable bond between the cover sheet 140 and the bottom sheet 110. The adhesive used for the adhesive tracks 142, 143 is chosen to provide a permanent, non-peelable bond between the cover sheet 140 and the bottom sheet 110. An area 144 of the underside of the cover sheet 140 enclosed by the adhesive annulus 141 is free of any adhesive. The adhesive-free area 144 directly overlies and corresponds in size to the cavity 113. A tab 145 is located at one end of the cover sheet 140. The tab 145 is not bonded to the bottom sheet 110. Figure 2 shows the aerosol-generating article 100 after assembly of the bottom sheet 110, the portions 121 , 122 of aerosol-forming substrate 120, the porous sheet 130 and the cover sheet 140. The aerosol-generating article 100 is generally planar and flat in an X-Y plane on both upper and lower surfaces of the article. A separation between an outward-facing surface of the bottom sheet 110 and an outward-facing surface of the cover sheet 140 defines a height of the aerosol-generating article 100. The height extends in a z-direction. The article 100 has a length and a width extending along a x-direction and a y-direction respectively. The generally planar, flat construction of the aerosolgenerating article 100 of figure 2 provides for space efficient packaging of multiple ones of the aerosolgenerating article 100, which is especially helpful for storage and transportation of the articles 100. The adhesive bond between the cover sheet 140 and bottom sheet 110, along with the polymer foil cover sheet 140 and the polymer film of the bottom sheet 110, help to provide a hermetic seal between the cavity 113 and the environment outside of the aerosol-generating article 100.

[0223] Prior to commencing a usage session to deplete the portions 121 , 122 of aerosol-forming substrate 120, a user would remove the cover sheet 140 from the assembled aerosol-generating article 110. To initiate removal of the cover sheet 140, the user would grip the tab 145 and pull the tab in the direction of the arrow shown in figure 3. Application of sufficient force on the tab 145 would result in i) tearing of the cover sheet 140 inwards of the non-peelable bond between the cover sheet 140 and the bottom sheet 110 defined by the linear adhesive tracks 142, 143, simultaneously with ii) peeling separation of the cover sheet 140 from the bottom sheet 110 along the path of the adhesive annulus 141 . Removal of the cover sheet 140 would expose the porous sheet 130, as shown in figures 4 and 5 which show a longitudinal section view (through section A-A of figure 3) and a transverse section view (through section B-B of figure 3) for the aerosol-generating article 100. Thin strips 146, 147 of the cover sheet 140 remain adhered to the bottom sheet 110 on either side of the cavity 113. The strips 146, 147 are those portions of the cover sheet 140 permanently bonded to the bottom sheet 110 by the linear adhesive tracks 142, 143.

[0224] The aerosol-generating article 100 of figures 4 and 5 (with cover sheet 140 removed) would be coupled with an aerosol-generating device, the device having a heating arrangement for applying heat to one or both portions 121 , 122 of aerosol-forming substrate 120. An exemplary aerosol-generating system formed of such an aerosol-generating device and an aerosol-generating article within the scope of the present disclosure is described in subsequent paragraphs.

[0225] Figure 6 is a disassembled perspective view of component parts of a second embodiment of aerosol-generating article 200. In common with aerosol-generating article 100, the aerosol-generating article 200 has a bottom sheet 200, two portions 221 , 222 of aerosol-forming substrate 220, a porous sheet 230 and a cover sheet 240. The aerosol-generating article 200 of figure 2 differs from aerosolgenerating article 100 in that two distinct cavities 213, 213’ are defined in the bottom sheet 210. Portion 221 of aerosol-forming substrate 220 is positioned within cavity 213 and portion 222 of aerosol-forming substrate is positioned within cavity 213’.

[0226] The bottom sheet 210 is rectangular in shape, having a length extending in an x-direction and a width extending in a y-direction. The materials used for the bottom sheet 210 are the same as those described for the bottom sheet 110 of aerosol-generating article 100. Again, a portion of material is cut-out from one corner of the bottom sheet 210 to define a cut-out region 212 in the bottom sheet. The two cavities 213, 213’ each define an intruded area in the bottom sheet 210. The two cavities 213, 213’ are together surrounded by a peripheral region 214 of the bottom sheet 210. The cavities 213, 213’ are separated from each other by a linear elongate surface 248 of the bottom sheet 210. As shown in figures 6, 9 and 10, the bottom sheet 210 defines a tray-shaped profile.

[0227] The portions 221 , 222 of aerosol-forming substrate 220 have the same size and composition as the portions 121 , 122 of aerosol-forming substrate 120 described in relation to aerosol-generating article 100.

[0228] The porous sheet 230 is rectangular in shape, being dimensioned to have a length and a width sufficient to cover both cavities 213, 213’. Two distinct adhesive tracks 231 , 231 ’ (shown in broken outline in figure 6) are applied to the surface 211 of the bottom sheet 210. Adhesive track 231 defines a continuous loop extending around cavity 213. Adhesive track 231 ’ defines a continuous loop extending around cavity 213’. During assembly of the aerosol-generating article 200, the porous sheet 230 is positioned to cover both cavities 213, 213’ and is pressed against the adhesive tracks 231 , 231 ’. Adhesive track 231 bonds the porous sheet 230 and the bottom sheet 210 together along a continuous path extending around cavity 213. Adhesive track 231 ’ bonds the porous sheet 230 and the bottom sheet 210 together along a continuous path extending around cavity 213’. The same adhesive may be used to bond the porous sheet 230 in place as used for the porous sheet 130 of aerosol-generating article 100.

[0229] The cover sheet 240 has the same shape and construction as the cover sheet 140 of aerosolgenerating article 100. In a similar manner to aerosol-generating article 100, an adhesive annulus 241 (shown cross-hatched in figures 6 to 8) and two linear adhesive tracks 242, 243 (shown in broken outline in figures 6 to 8) are provided on the underside of the cover sheet 240. The adhesive annulus 241 and adhesive tracks 242, 243 each bond the cover sheet 240 to the bottom sheet 210 in the same manner described for aerosol-generating article 100. The adhesive used for adhesive annulus 241 is chosen to provide a non-permanent, peelable bond between the cover sheet 240 and the bottom sheet 210. The adhesive used for the adhesive tracks 242, 243 is chosen to provide a permanent, non- peelable bond between the cover sheet 240 and the bottom sheet 210. An area 244 of the underside of the cover sheet 240 overlying the cavities 213, 213’ is free of adhesive. Tab 245 is located at one end of the cover sheet 240. The tab 245 is not bonded to the bottom sheet 210.

[0230] Figure 7 shows the aerosol-generating article 200 after assembly of the bottom sheet 210, the portions 221 , 222 of aerosol-forming substrate 220, the porous sheet 230 and the cover sheet 240. When viewed from above (as in figure 7), aerosol-generating article 200 is identical in appearance to aerosol-generating article 100. However, when viewed from below, the aerosol-generating article 200 would be seen to differ from aerosol-generating article 100 in having two cavities 213, 213’ instead of a single cavity 113.

[0231] The user would remove the cover sheet 240 from the assembled aerosol-generating article 200 in the same manner described for aerosol-generating article 100 - by gripping and pulling on tab 245 (see figure 8). Removal of the cover sheet 240 from the article 200 would expose the porous sheet 230, as illustrated in figures 9 and 10. Figures 9 and 10 show a longitudinal cross-section view (through section C-C of figure 8) and a transverse cross-section view (through section D-D of figure 8) of the article 200. Thin strips 246, 247 of the cover sheet 240 remain adhered to the bottom sheet 210. The strips 246, 247 are those portions of the cover sheet 240 permanently bonded to the bottom sheet 210 by the linear adhesive tracks 242, 243. The aerosol-generating article 100 of figures 9 and 10 (with cover sheet 240 removed) would be coupled with an aerosol-generating device, the device having a heating arrangement for applying heat to one or both portions 221 , 222 of aerosol-forming substrate 220. An exemplary aerosolgenerating system formed of such an aerosol-generating device and an aerosol-generating article within the scope of the present disclosure is described in subsequent paragraphs. In an alternative embodiment, a linear adhesive track may also be provided to bond the cover sheet 240 to the linear elongate surface 248 of the bottom sheet 210. This linear adhesive track may be formed from the same adhesive as used for adhesive annulus 241 (to provide a non-permanent, peelable bond), with opposite ends of the linear adhesive track merging with the adhesive annulus 241 . Figure 11 is a schematic perspective view of components of the aerosol-generating article 100 of figures 1 to 5, but is also applicable to the aerosol-generating article 200 of figures 6 to 10. In figure 11 , different reference signs have been assigned to the different dimensions of the components of the aerosol-generating article 100. Table 1 below shows some exemplary ranges for the various dimensions of the component parts of aerosol-generating article 100:

[0232] Table 1

[0233] Figures 12 and 13 illustrate an exemplary process for forming the cavities 113, 213, 213’ within the bottom sheets 110, 210 of aerosol-generating articles 100, 200. The process described in relation to figures 12 and 13 is also applicable to other embodiments of aerosol-generating article discussed in subsequent paragraphs (such as aerosol-generating articles 300, 400).

[0234] Figure 12 shows a wholly planar sheet 810 of material, with a peripheral region of the planar sheet clamped by clamping assemblies 821 , 822. A die 830 is initially positioned above the planar sheet 810 (see figure 12). The die 830 is moved down in the direction of the arrow shown in figure 12 to deform the sheet 810. As shown in figure 13, continued downward motion of the die 830 progressively deforms the sheet 810 to define a cavity 813 within the sheet, the cavity 813 surrounded by a peripheral region or lip 814 of the sheet. The deformation process illustrated in figures 12 and 13 can be understood to be one of debossing or embossing of the planar sheet 810. When viewing the sheet 810 from above, the deformation process may be described as debossing due to the cavity 813 being formed by an indented or depressed region of the sheet 810 relative to peripheral region 814. However, when viewing the sheet 810 from below, the deformation process may be described as embossing due to the cavity 813 then appearing to be raised relative to peripheral region 814.

[0235] As can be understood from comparison of figures 12 and 13, the clamping assemblies 821 , 822 allow for limited slippage between the sheet 810 and the clamping assemblies, thereby reducing the risk of the downward motion of the die 830 causing rupture of the sheet. The dimensions of the die 830 determine the shape, as well as the length and width of the resulting cavity 813. The extent to which the die 830 is moved downwardly into the upper surface of the sheet 810 determines the depth of the resulting cavity 813.

[0236] Figure 14 is a disassembled perspective view of component parts of a third embodiment of aerosol-generating article 300. The aerosol-generating article 300 has a bottom sheet 310, two portions 321 , 322 of aerosol-forming substrate 320 and a cover sheet 340.

[0237] The bottom sheet 310 has the same shape and is formed of the same materials as the bottom sheet 110 of aerosol-generating article 100. So, the bottom sheet 310 is predominantly formed of a paper substrate having a thickness of about 3 microns and a basis weight of about 100 g / m. A polymer film is applied to the paper substrate, with the polymer film having a thickness of about 1 micron and defining an upper surface 311 of the bottom sheet 310. The polymer film is a bio-polymeric compound formed from waste tobacco materials, such as dust, fragments, stems and / or leaves of tobacco. The composition of the bio-polymeric compound used for the polymer film complies with FDA Regulation 21 CFR. The polymer film makes the upper surface 311 of the bottom sheet 310 essentially impermeable. A portion of material is cut-out from one corner of the bottom sheet 310 to define a cut- out region 312 in the bottom sheet. In common with the bottom sheet 210 of aerosol-generating article 200, the bottom sheet 310 has two distinct cavities 313, 313’ defining separate intruded areas in the bottom sheet. The cavities 313, 313’ are surrounded by a peripheral region 314 of the bottom sheet 310 and separated from each other by a linear elongate surface 348 of the bottom sheet 310. As shown in figures 14, 16, 17 and 19, the bottom sheet 310 defines a tray-shaped profile.

[0238] In an alternative embodiment, paperboard or cardboard may be used as a substrate material for the bottom sheet 310 instead of paper.

[0239] In an alternative embodiment, the polymer film may comprise dispersions based on copolymers consisting of acrylic ester and styrene, or based on styrene-butadiene copolymers, applied during paper processing as aqueous dispersions of copolymers of styrene-butadiene with a solids content of approximately 50 %.

[0240] In an alternative embodiment, the bottom sheet 310 may include a dispersion of a polymer compound within the paper substrate of the bottom sheet.

[0241] The portions 321 , 322 of aerosol-forming substrate 320 are in the form of rectangular strips of a gel composition. The gel composition contains about 2% wt of nicotine and about 90% wt of glycerol. Cavity 313 is sized to accommodate portion 321 and cavity 313’ is sized to accommodate portion 322. The portions 321 , 322 of aerosol-forming substrate 320 are positioned within their respective cavity 313, 313’ to sit upon the surface 311 of the bottom sheet 310 and extend along a length of the respective cavity 313, 313’ in the x-direction. The portions 321 , 322 of aerosol-forming substrate 320 are identical to each other in terms of their chemical composition. As shown in figures 16, 17 and 19, the portions 321 , 322 of aerosol-forming substrate 320 extend to below the height of the peripheral region 314 surrounding the cavities 313, 313’. As discussed for aerosol-generating article 100, in an alternative embodiment the portions 321 , 322 of aerosol-forming substrate 320 may differ from each other in their chemical composition. For example, portion 321 may contain a different type and / or concentration of flavourant to a type and / or concentration of flavourant of portion 322.

[0242] The cover sheet 340 is rectangular in shape, with a width corresponding to that of the bottom sheet 310. However, the cover sheet 340 is shorter in length than the bottom sheet 310. The cover sheet 340 is a foil formed of a bio-polymeric compound certified for food and beverage applications by the FDA. For aerosol-generating article 300, the bio-polymeric compound selected for the cover sheet 340 is the same as that used for the polymer film described above for bottom sheet 310. However, it will be appreciated that other polymers and materials may be used for the cover sheet 340. An adhesive annulus 341 (shown cross-hatched in figures 14, 15 and 18) is provided on the underside of the cover sheet 340. During assembly of the aerosol-generating article 300, the cover sheet 340 is positioned over the bottom sheet 310, with pressure applied to the cover sheet along the adhesive annulus 341 . The adhesive annulus 341 bonds the cover sheet 340 to the bottom sheet 310 along a continuous path extending around the cavities 313, 313’. The adhesive used for the adhesive annulus 341 is chosen to provide a permanent, non-peelable bond between the cover sheet 340 and the bottom sheet 310. The cover sheet 340 is not intended to be removed from the aerosol-generating article 300 prior to use and consumption of the article in a usage session. An area 344 of the underside of the cover sheet 340 overlying the cavities 313, 313’ is free of adhesive. The foil cover sheet 340 is provided with first and second score lines 351 , 352 - shown in broken outline in figures 14 and 15. Each score line 351 , 352 extends along a continuous path to enclose and define respective first and second pre-rupture areas of the cover sheet 340. The score lines 351 , 352 are positioned at opposite longitudinal ends of the cover sheet 340. The score lines 351 , 352 extend only partially through the thickness of the foil cover sheet 340. For the described embodiment, the score lines 351 , 352 are uniformly thinned along their respective continuous paths. However, in an alternative embodiment the score lines 351 , 352 may be discontinuous, for example consisting of alternating thinned and non-thinned regions of the cover sheet 340. Each score line 351 , 352 extends over both cavities 313, 313’.

[0243] Figure 15 shows the aerosol-generating article 300 after assembly of the bottom sheet 310, the portions 321 , 322 of aerosol-forming substrate 320 and the cover sheet 340. The aerosol-generating article 300 is generally planar and flat in an X-Y plane on its upper and lower surfaces. A separation between an outward-facing surface of the bottom sheet 310 and an outward-facing surface of the cover sheet 340 defines a height of the aerosol-generating article 300. The height extends in a z- direction. The article 300 has a length and a width extending along a x-direction and a y-direction respectively. In common with aerosol-generating articles 100, 200, the generally planar, flat construction of aerosol-generating article 300 provides for space efficient packaging of multiple ones of the aerosol-generating article 300. The adhesive bond between the cover sheet 340 and the bottom sheet 310 (due to adhesive annulus 341 ) and the score lines 351 , 352 extending only partially through the thickness of the foil cover sheet 340 both help to maintain a hermetic seal between the cavities 313, 313’ and the environment outside of the aerosol-generating article 300. Figures 16 and 17 show longitudinal and transverse cross-section views of the aerosol-generating article 300 of figure 15 (through sections E-E and F-F respectively) prior to rupturing of the score lines 351 , 352. In this preruptured state, the portions 321 , 322 of aerosol-forming substrate 320 are hermetically sealed within respective cavities 313, 313’.

[0244] Prior to commencing a usage session to deplete the portions 321 , 322 of aerosol-forming substrate 320, a user would breach the cover sheet 330 at the locations of the score lines 351 , 352 to define first and second openings 361 , 362 through the cover sheet (see figure 18). Both of the first and second openings 361 , 362 extend over both cavities 313, 313’. The breaching of the cover sheet 340 may be performed manually by the user, for example by the user pressing down on the cover sheet 340 around the score lines 351 , 352 using their fingers or a separate tool. Alternatively, as described below with reference to figure 20, the cover sheet 340 may instead be breached at the locations of the score lines 351 , 352 by cutting elements of component parts of an aerosol-generating device on or soon after coupling the article 300 with the device.

[0245] Figure 19 shows a longitudinal cross-section view of the aerosol-generating article 300 of figure 18 (through section G-G). As shown in figures 18 and 19, the first opening 361 defines an air inlet permitting a flow of air into the cavity 313, with the second opening 362 defining an air outlet permitting a flow of air out from the cavity 313. As the first and second openings 361 , 362 each extend over both cavities 313, 313’, it will be appreciated that the first opening 361 also defines an air inlet into cavity 313’ and that the second opening 362 also defines an air outlet out of cavity 313’. The air inlet 361 and air outlet 362 define part of an airflow passage 363 extending through the cavity 313 above the aerosol-forming substrate 320. Again, it will be appreciated that a similar distinct airflow path extends through cavity 313’. Arrows in figures 18 and 19 show the path taken by airflow into and out from an interior of the aerosol-generating article 300 during a usage session, for example during use of the article 300 with an aerosol-generating device.

[0246] The aerosol-generating article 300 of figures 18 and 19 would be coupled with an aerosolgenerating device, the device having a heating arrangement for applying heat to one or both portions 321 , 322 of aerosol-forming substrate 320. An exemplary aerosol-generating system formed of such an aerosol-generating device and an aerosol-generating article within the scope of the present disclosure is described in subsequent paragraphs.

[0247] In an alternative embodiment, a linear adhesive track may also be provided to bond the cover sheet 340 to the linear elongate surface 348 of the bottom sheet 310. This linear adhesive track may be formed from the same adhesive as used for adhesive annulus 341 (to provide a permanent, non- peelable bond), with opposite ends of the linear adhesive track merging with the adhesive annulus 341 .

[0248] In a variation to the embodiment of figures 14 to 19, a porous sheet may also be provided between the cover sheet 340 and the bottom sheet 310 to cover the cavities 313, 313’ in a similar manner to the porous sheet 230 of aerosol-generating article 200 described above, with the cover sheet 340 being removably bonded to the bottom sheet 310. In such an embodiment, the porous sheet would remain bonded to the bottom sheet 310 after removal of the cover sheet 340. The porosity of the porous sheet would permit the flow of air into and out from the cavities 313, 313’ via the first and second openings 361 , 362.

[0249] Figure 20 illustrates an example of component parts of an aerosol-generating device 900 configured to breach the cover sheet 340 of aerosol-generating article 300 at the locations of score lines 351 , 352. The aerosol-generating device 900 has a lower part 910 and an upper part 920. The lower part 910 contains a recess 911 dimensioned to receive the aerosol-generating article 300. Prior to commencing a usage session, a user places the article 300 in the recess 911 with the cover sheet 340 facing upwards - see figures 20(a) and 20(b). Cutting elements 921 , 922 are defined on a lower surface of the upper part 920 and are spaced apart from each other by a distance corresponding to the separation between the first and second score lines 351 , 352. The cutting elements 921 , 922 are able to trigger the rupture of the score lines 351 , 352 defined in the cover layer 340. More specifically, with the aerosol-generating article 300 located in the recess 911 , the upper part 920 is moved down towards the lower part 910 to cause the cutting elements 921 , 922 to engage with the cover sheet 340 at the location of the score lines 351 , 352 (see figures 20(b) and 20(c)). Continued downward motion of the upper part 920 causes the cutting elements 921 , 922 to breach the cover sheet 340 at the score lines 351 , 352 to establish the air inlet 361 and the air outlet 362. For convenience, the aerosol-forming substrate 320 is not shown in figure 20.

[0250] Figure 21 illustrates a perspective disassembled view of component parts of a fourth embodiment of aerosol-generating article 400. The aerosol-generating article 400 has a bottom sheet 410, two portions 421 , 422 of aerosol-forming substrate 420, a porous sheet 430, an intermediate sheet 450 and a cover sheet 440.

[0251] The bottom sheet 410 has the same shape and is formed of the same materials as the bottom sheet 110 of aerosol-generating article 100. So, the bottom sheet 410 is predominantly formed of a paper substrate having a thickness of about 3 microns and a basis weight of about 100 g / m. A polymer film is applied to the paper substrate, with the polymer film having a thickness of about 1 micron and defining an upper surface 411 of the bottom sheet 410. The polymer film is a bio-polymeric compound formed from waste tobacco materials, such as dust, fragments, stems and / or leaves of tobacco. The composition of the bio-polymeric compound used for the polymer film complies with FDA Regulation 21 CFR. The polymer film makes the upper surface 411 of the bottom sheet 410 essentially impermeable. A portion of material is cut-out from one corner of the bottom sheet 410 to define a cutout region 412 in the bottom sheet. The bottom sheet 410 has two distinct cavities 413, 413’ defining separate intruded areas in the bottom sheet. The cavity 413, 413’ are surrounded by a peripheral region 414 of the bottom sheet 410. As shown in figures 21 and 24, the bottom sheet 410 defines a tray-shaped profile.

[0252] In an alternative embodiment, paperboard or cardboard may be used as a substrate material for the bottom sheet 410 instead of paper.

[0253] In an alternative embodiment, the polymer film may comprise dispersions based on copolymers consisting of acrylic ester and styrene, or based on styrene-butadiene copolymers, applied during paper processing as aqueous dispersions of copolymers of styrene-butadiene with a solids content of approximately 50 %.

[0254] In an alternative embodiment, the bottom sheet 410 may include a dispersion of a polymer compound within the paper substrate of the bottom sheet.

[0255] The portions 421 , 422 of aerosol-forming substrate 420 are in the form of rectangular strips of a gel composition. The gel composition contains about 2% wt of nicotine and about 90% wt of glycerol. Cavity 413 is sized to accommodate portion 421 and cavity 413’ is sized to accommodate portion 422. The portions 421 , 422 of aerosol-forming substrate 420 are positioned within their respective cavity 413, 413’ to sit upon the surface 411 of the bottom sheet 410 and extend along a length of the respective cavity 413, 413’ in the x-direction. The portions 421 , 422 of aerosol-forming substrate 420 are identical to each other in terms of their chemical composition. As shown in figure 24, the portions 421 , 422 of aerosol-forming substrate 420 extend to below the height of the peripheral region 414 of the bottom sheet 410 surrounding the cavities 413, 413’. As discussed for aerosol-generating article 100, in an alternative embodiment the portions 421 , 422 of aerosol-forming substrate 420 may differ from each other in their chemical composition. For example, portion 421 may contain a different type and / or concentration of flavourant to a type and / or concentration of flavourant of portion 422.

[0256] The porous sheet 430 has the same shape and is formed of the same materials as the porous sheet 130 of aerosol-generating article 100, being dimensioned to have a length and a width sufficient to cover both cavities 413, 413’. Two distinct adhesive tracks 431 , 431 ’ (shown in broken outline in figure 21 ) are applied to the surface 411 of the bottom sheet 410. Adhesive track 431 defines a continuous loop extending around cavity 413. Adhesive track 431 ’ defines a continuous loop extending around cavity 413’. During assembly of the aerosol-generating article 400, the porous sheet 430 is positioned over the cavities 413, 413’ and pressed against the adhesive tracks 431 , 431 ’. Adhesive track 431 bonds the porous sheet 430 and the bottom sheet 410 together along a continuous path extending around cavity 413. Adhesive track 431 ’ bonds the porous sheet 430 and the bottom sheet 410 together along a continuous path extending around cavity 413’. The adhesive used for the adhesive tracks 431 , 431 ’ is chosen to provide a permanent, non-peelable bond between the porous sheet 430 and the bottom sheet 410. The bond between the porous sheet 430 and the bottom sheet 410 helps to retain the portions 421 , 422 of aerosol-forming substrate 420 within their respective cavities 413, 413’. The inherent porosity of the porous sheet 430 permits passage through the porous sheet of vapour evolved from the portions 421 , 422 of aerosol-forming substrate 420 on the application of heat.

[0257] The intermediate sheet 450 and the cover sheet 440 are each rectangular in shape. The cover sheet 440 has a length and a width corresponding to those of the bottom sheet 410. The intermediate sheet 450 is shorter in length than the cover sheet 440. The intermediate sheet 450 and cover sheet 440 are in the form of a foil formed of a bio-polymeric compound certified for food and beverage applications by the FDA. The bio-polymeric compound selected for the intermediate sheet 450 and cover sheet 440 is the same as that used for the polymer film described above for bottom sheet 410. However, it will be appreciated that other polymers and materials may be used for the intermediate and cover sheets 450, 440.

[0258] An adhesive annulus 451 (shown cross-hatched in figures 21 and 23) is provided on the underside of the intermediate sheet 450. During assembly of the aerosol-generating article, the intermediate sheet 450 is positioned over the bottom sheet 410, with pressure applied to the intermediate sheet along the adhesive annulus 451 . The adhesive annulus 451 bonds the intermediate sheet 450 to the bottom sheet 410 along a continuous path extending around both cavities 413, 413’. The continuous path is located outward of the bond between the porous sheet 430 and the bottom sheet 410 represented by adhesive tracks 431 , 431 ’. The adhesive used for the adhesive annulus 451 is chosen to provide a permanent, non-peelable bond between the intermediate sheet 450 and the bottom sheet 410. The intermediate sheet 450 (in common with porous sheet 430) is intended to be a non-removable component part of aerosol-generating article 400. An area 452 of the underside of the intermediate sheet 450 enclosed by the adhesive annulus 451 is free of any adhesive. The adhesive- free area 452 directly overlies and corresponds in size to the porous sheet 430. The foil intermediate sheet 450 is provided with first and second score lines 453, 454 (see figure 21 ). Each score line 453, 454 extends along a linear path to define respective first and second pre-rupture areas of the intermediate sheet 450. The score lines 453, 454 are positioned at opposite longitudinal ends of the intermediate sheet 450. For the described embodiment, the score lines 453, 454 are uniformly thinned along their respective continuous paths. However, in an alternative embodiment the score lines 453, 454 may be discontinuous, for example consisting of alternating thinned and non-thinned regions of the intermediate sheet 450. Each score line 453, 454 extends over both cavities 413, 413’.

[0259] The cover sheet 440 is rectangular in shape, with a length and a width corresponding to those of bottom sheet 410. An adhesive annulus 441 (shown cross-hatched in figures 21 to 23) is provided on the underside of the cover sheet 440. Two linear adhesive tracks 442, 443 are provided on the underside of the cover sheet 440. The linear adhesive tracks 442, 443 are located at opposite longitudinal ends of the cover sheet 440. The distance between the two adhesive tracks 442, 443 corresponds to the spatial separation between the score lines 453, 454 defined in the intermediate sheet 450. During assembly of the aerosol-generating article 400, the cover sheet 440 is positioned over the intermediate sheet 450, with pressure applied to the cover sheet along the adhesive annulus 441 and the linear adhesive tracks 442, 443. The adhesive annulus 441 bonds the cover sheet 440 to the intermediate sheet 450 along a continuous path. The linear adhesive tracks 442, 443 bond the cover sheet 440 to the intermediate sheet 450 over the score lines 453, 454. The adhesive used for the adhesive annulus 441 is chosen to provide a non-permanent, peelable bond between the cover sheet 440 and the intermediate sheet 450. In contrast, the adhesive used for the linear adhesive tracks 442, 443 is chosen to provide a permanent, non-peelable bond between the cover sheet 440 and the intermediate sheet 450. A tab 445 is located at one end of the cover sheet 440. The tab 445 overlies but is not bonded to the bottom sheet 410.

[0260] Figure 22 shows the aerosol-generating article 400 after assembly of the bottom sheet 410, the portions 421 , 422 of aerosol-forming substrate 420, the porous sheet 430, the intermediate sheet 450 and the cover sheet 440. The intermediate sheet 450 and porous sheet 430 are not visible in figure

[0261] 22 as they are sandwiched between the cover sheet 440 and the bottom sheet 410. The assembled aerosol-generating article 400 is generally planar and flat in an X-Y plane on both upper and lower surfaces of the article. A separation between an outward-facing surface of the bottom sheet 410 and an outward-facing surface of the cover sheet 440 defines a height of the aerosol-generating article 400. The height extends in a z-direction. The article 400 has a length and a width extending along a x-direction and a y-direction respectively. The adhesive bond between the cover sheet 440 and the intermediate sheet 450, plus the adhesive bond between the intermediate sheet 450 and the bottom sheet 410 help to provide and maintain a hermetic seal between the cavities 413, 413’ and the environment outside of the aerosol-generating article 400.

[0262] Prior to commencing a usage session to deplete the portions 421 , 422 of aerosol-forming substrate 420, a user would remove the cover sheet 440 from the aerosol-generating article 410. To initiate removal of the cover sheet 440, the user would grip the tab 445 and pull the tab in the direction of the arrow shown in figure 23. Application of sufficient force on the tab 445 would result in the cover sheet 440 separating from the intermediate sheet 450 along the peelable interface defined by adhesive annulus 441 . The permanent bond between the cover sheet 440 and the intermediate sheet 450 along the linear adhesive tracks 442, 443 results in the intermediate sheet 450 being ruptured along and around the score lines 453, 454 as the user pulls on the tab 445 to detach the cover sheet from the article 400. Rupture of the score lines 453, 454 thereby forms a first opening 461 and a second opening 462 through the intermediate sheet 450 (see figure 24 discussed below).

[0263] Figure 24 shows a longitudinal cross-section view of the aerosol-generating article 400 of figure

[0264] 23 (through section H-H) after removal of the cover sheet 440. The first opening 461 defines an air inlet permitting a flow of air into the cavity 413 (via porous sheet 430), with the second opening 462 defining an air outlet permitting a flow of air out from the cavity (again, via porous sheet 430). The air inlet 461 and air outlet 462 define part of an airflow passage 463 extending through the cavity 413 above the aerosol-forming substrate 420. Arrows in figure 24 show the path taken by airflow into and out from the cavity 413 during a usage session. The flow of air along the airflow passage 463 illustrated in figure 24 would occur during a usage session during use of the aerosol-generating article 400 with an aerosol-generating device. The first and second openings 461 , 462 extend over both cavities 413, 413’. Consequently, it will be appreciated that the first opening 461 also defines an air inlet into cavity 413’ and that the second opening 462 also defines an air outlet out from cavity 413’. In this manner, an airflow path may be provided into, through and out from cavity 413’ in the same manner as for cavity 413.

[0265] The aerosol-generating article 400 of figure 24 would be coupled with an aerosol-generating device, the device having a heating arrangement for applying heat to one or both portions 421 , 422 of aerosol-forming substrate 420. An exemplary aerosol-generating system formed of such an aerosolgenerating device and an aerosol-generating article within the scope of the present disclosure is described in subsequent paragraphs.

[0266] Figure 25 illustrates a perspective disassembled view of component parts of a fifth embodiment of aerosol-generating article 500. The aerosol-generating article 500 has a bottom sheet 510 and a cover sheet 540.

[0267] The bottom sheet 510 is rectangular in shape, having a length extending in an x-direction and a width extending in a y-direction. The bottom sheet 510 may be formed of the same materials and have the same dimensions as the bottom sheet 110 of aerosol-generating article 100. A plurality of micro-cavities 511 are defined in the upper surface of the bottom sheet 510. The plurality of microcavities 511 are surrounded by a peripheral region 512 of the bottom sheet 510. The micro-cavities 511 open out onto the upper surface of the bottom sheet 510 but do not extend through to the lower surface of the bottom sheet. The micro-cavities 511 each occupy a volume of about 2.5 mm3. The micro-cavities 511 are between 250 and 300 in number. Each of the micro-cavities 511 contains aerosol-forming substrate (not shown) in the form of a gel composition containing about 1 .5% wt of nicotine and about 90% wt of glycerol.

[0268] As shown in figure 25, the cover sheet 540 is rectangular in shape, being dimensioned to have a length and a width generally corresponding to the bottom sheet 510. The cover sheet 540 may be formed of the same materials as the cover sheet 140 of aerosol-generating article 100. An adhesive track 541 is applied to the underside of the cover sheet 540. During assembly of the article 500, the cover sheet 540 is positioned over the bottom sheet 510 and pressure applied to cause the cover sheet 540 to bond to the bottom sheet 510 along the adhesive track 541. The adhesive track 541 defines a continuous path extending around the plurality of micro-cavities 511 . The adhesive used for the adhesive track 541 is chosen to provide a non-permanent, peelable bond between the cover sheet 540 and the bottom sheet 510.

[0269] An area 542 of the underside of the cover sheet 540 enclosed by the adhesive annulus 541 is free of any adhesive. The adhesive-free area 542 directly overlies and corresponds in size to the area of the bottom sheet 510 occupied by the micro-cavities 511. A tab 543 is located at one end of the cover sheet 540. The tab 543 is not bonded to the bottom sheet 510. Figure 26 shows the aerosol-generating article 500 after assembly of the bottom sheet 510 and the cover sheet 540. The aerosol-generating article 500 is generally planar and flat in an X-Y plane on both upper and lower surfaces of the article. A separation between an outward-facing surface of the bottom sheet 510 and an outward-facing surface of the cover sheet 540 defines a height of the aerosol-generating article 500. The height extends in a z-direction. The article 500 has a length and a width extending along a x-direction and a y-direction respectively. The bond between the cover sheet 540 and the bottom sheet 510 helps to hermetically seal the aerosol-forming substrate contained in the micro-cavities 511 from the environment outside of the aerosol-generating article 500.

[0270] Prior to commencing a usage session to deplete the aerosol-forming substrate contained within the micro-cavities 511 , a user would remove the cover sheet 540 from the assembled aerosolgenerating article 500. To initiate removal of the cover sheet 540, the user would grip the tab 543 and pull the tab in the direction of the arrow shown in figure 26. Application of sufficient force on the tab 543 would result in separation of the cover sheet 540 from the bottom sheet 510 along the path of the adhesive annulus 541 . Removal of the cover sheet 540 would expose the plurality of micro-cavities 511 (as shown in figure 27).

[0271] The aerosol-generating article 500 of figure 27 (with cover sheet 540 removed) would then be coupled with an aerosol-generating device, the device having a heating arrangement for applying heat to the aerosol-forming substrate contained in the exposed micro-cavities 511 . An exemplary aerosolgenerating system formed of such an aerosol-generating device and an aerosol-generating article within the scope of the present disclosure is described in subsequent paragraphs.

[0272] Figures 28 and 29 illustrate an aerosol-generating device 1000 configured for use with the aerosol-generating article 100 after the cover sheet 140 has been removed. More specifically, the device 100 is intended for use with the aerosol-generating article 100 when the article is in the state shown in figures 4 and 5. The device 1000 is an elongate aerosol-generating device extending between a proximal end 1001 and a distal end 1002. The device 1000 comprises a battery 1010, a controller 1020 and a heater 1030 located within a housing 1040. The controller 1020 controls supply of power from the battery 1010 to the heater 1030. A cavity 1050 is defined in the device 1000, the cavity having an opening 1051 defined in the proximal end 1001 of the device. The opening 1051 is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosolgenerating article 100. The cavity 1050 comprises an upper planar surface 1052 and a lower planar surface 1053. The heater 1030 is located in the upper planar surface 1052. An air-flow path is configured to allow air to flow into the cavity 1050 from outside the device 1000.

[0273] Figure 30 illustrates the device 1000 of figure 28 in engagement with the aerosol-generating article 100 to form an aerosol-generating system. When a user has inserted the aerosol-generating article 100 into the cavity 1050, the device 1000 can be operated. The heater 1030 radiates heat onto aerosol-forming substrate 120 contained in the cavity 113 of the aerosol-generating article 100. The airflow path referred to above extends over the upper surface of the aerosol-generating article 100. The heating action of the heater 1030 causes volatile components to be evaporated from the aerosolforming substrate 120. These volatile components flow through the porous sheet 130 of the article 100 and become entrained in airflow passing along the airflow path. The entrained airflow cools and condenses to form an aerosol as it flows downstream towards the proximal end 1001 of the aerosolgenerating device 1000. The user inhales the aerosol by drawing on the proximal end 1001 of the aerosol-generating device 1000. Once the aerosol-forming substrate of the aerosol-generating article 100 has been depleted of volatile components, the aerosol-generating article is removed from the cavity 1050 of the device 1000 and disposed of.

[0274] The aerosol-generating articles 200, 300, 400, 500 or any other aerosol-generating article of the present disclosure may be used with aerosol-generating device 1000 in place of aerosol-generating article 100.

[0275] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term “about”. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number “A” is understood as “A” ± 10% of “A”. Within this context, a number “A” may be considered to include numerical values that are within general standard error for the measurement of the property that the number “A” modifies. The number “A”, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which “A” deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. The terms “in which” and “wherein” are used synonymously through this specification.

Claims

37 / 39CLAIMS1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: a first elongate sheet debossed or embossed to form a tray, the tray defined by a peripheral region of the first elongate sheet surrounding a plurality of cavities formed in the first elongate sheet, wherein when viewing the first elongate sheet from above, the plurality of cavities form an intruded or depressed region of the sheet relative to the peripheral region, and when viewing the first elongate sheet from below, the part of the first elongate sheet in which the plurality of cavities is formed is raised relative to the peripheral region; a portion of sensorial media disposed within at least one of the plurality of cavities; wherein the aerosol generating article is defined by a length extending in an x-direction, a width extending in a y-direction, and a height extending in a z-direction, wherein the height is less than each of the width and the length, the height being less than 4 millimetres.

2. An aerosol-generating article according to claim 1 , wherein the first elongate sheet defines a majority of the flexural rigidity of the aerosol-generating article.

3. An aerosol-generating article according to either one of claim 1 or claim 2, wherein each cavity of the plurality of cavities has a depth of between 75 and 500 microns, for example between 75 and 250 microns, for example between 75 and 125 microns, for example about 100 microns.

4. An aerosol-generating article according to any one of claims 1 to 3, wherein the plurality of cavities define a cumulative volume of between 300 mm3and 600 mm3, for example between 350 mm3and 550 mm3, for example between 400 mm3and 500 mm3, for example about 200 mm3or about 250 mm3.

5. An aerosol-generating article according to any one of claims 1 to 4, wherein the plurality of cavities hold a cumulative mass of sensorial media in a range of between 30 mg and 80 mg, for example between 40 mg and 70 mg, for example about 50 mg.

6. An aerosol-generating article according to any one of claims 1 to 5, wherein the first elongate sheet is configured to be substantially impermeable.

7. An aerosol-generating article according to any one of claims 1 to 6, wherein the first elongate sheet comprises a layer of paper, paperboard or cardboard overlaid by a layer or coating of a polymeric compound, the layer or coating of the polymeric compound being less permeable than the layer of paper, paperboard or cardboard.

8. An aerosol-generating article according to claim 7, wherein the layer of paper, paperboard or cardboard provides a majority or all of the flexural stiffness of the first elongate sheet.

9. An aerosol-generating article according to any one of claims 1 to 8, further comprising a second elongate sheet, wherein the second elongate sheet is positioned above the first elongate sheet, for example in the z-direction.

10. An aerosol-generating article according to claim 9, wherein opposing surfaces of the first and second elongate sheets are configured to be substantially impermeable.

11. An aerosol-generating article according to either one of claim 9 or claim 10, wherein the second elongate sheet is bonded to the first elongate sheet, for example by an adhesive, preferably,38 / 39 wherein a surface of the second elongate sheet positioned above and corresponding in size to the plurality of cavities is free of adhesive.

12. An aerosol-generating article according to any one of claims 1 to 11 , further comprising a porous sheet arranged to overlie and close the plurality of cavities and retain the portion of sensorial media within the respective cavity of the plurality of cavities.

13. An aerosol-generating article according to claim 12, wherein the porous sheet is disposed between the first and a or the second elongate sheet.

14. An aerosol-generating article according to claim 13, wherein the second elongate sheet is bonded to the first elongate sheet along an outer bond interface and the porous sheet is bonded to the first elongate sheet along an inner bond interface, the outer bond interface surrounding the inner bond interface.

15. An aerosol-generating article according to any one of claims 1 to 14, wherein the sensorial media consists of or comprises a liquid or gel.

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