An aerosol-generating article and a method of forming an aerosol-generating article

Abstract

According to the present disclosure there is provided an aerosol-generating article (110) comprising a disc-shaped support layer (12) defining a plurality of cavities (14), and a plurality of aerosol-generating elements (16). Each aerosol-generating element (16) comprises an aerosol-generating material (122). Each aerosol-generating element (16) is positioned at least partially within one of the cavities (14). According to the present disclosure there is also provided a method of forming an aerosol-generating element (16) for an aerosol-generating article (110), and a method of forming an aerosol-generating article (110).

Description

[0001] AN AEROSOL-GENERATING ARTICLE AND A METHOD OF FORMING AN AEROSOLGENERATING ARTICLE

[0002] The present disclosure relates to an aerosol-generating article comprising a plurality of aerosol-generating elements. The present disclosure also relates to a method of forming an aerosol-generating element for an aerosol-generating article. The present disclosure also relates to a method of forming an aerosol-generating article comprising a plurality of aerosol-generating elements.

[0003] Aerosol-generating articles comprising a plurality of doses of an aerosol-generating substrate have been proposed. Such articles may be used with an aerosol-generating device to heat or otherwise generate an aerosol from each dose of the aerosol-generating substrate.

[0004] In some examples, each dose of the aerosol-generating substrate may be used to generate aerosol over an entire user experience. For example, each dose of aerosol-generating substrate may be used to generate aerosol for multiple puffs. In such examples, the number of user experiences provided by the aerosol-generating article corresponds to the number of doses of aerosol-generating substrate.

[0005] In other examples, the aerosol-generating article may be used for only a single user experience during which the doses of aerosol-generating substrate are used sequentially to generate an aerosol. For example, each dose of aerosol-generating substrate may be used to generate aerosol for a single puff.

[0006] It would be desirable to provide an aerosol-generating article comprising multiple aerosolgenerating substrates or elements that facilitates consistent forming of the aerosol-generating article using low-cost and high-speed manufacturing processes.

[0007] According to the present disclosure there is provided an aerosol-generating article. The aerosol-generating article may comprise a support layer. The support layer may be disc-shaped. The support lay may define a plurality of cavities. The aerosol-generating article may comprise a plurality of aerosol-generating elements. Each aerosol-generating element may comprise an aerosol-generating material. Each aerosol-generating element may be positioned at least partially within one of the cavities.

[0008] According to the present disclosure there is provided an aerosol-generating article comprising a disc-shaped support layer defining a plurality of cavities, and a plurality of aerosolgenerating elements. Each aerosol-generating element comprises an aerosol-generating material. Each aerosol-generating element is positioned at least partially within one of the cavities.

[0009] Advantageously, providing a support layer defining a plurality of cavities facilitates accurate and repeatable positioning of the plurality of aerosol-generating substrates relative to each other. Advantageously, providing a support layer defining the plurality of cavities facilitates using low-cost and high-speed manufacturing processes. For example, the cavities may be formed using a simple punching process.

[0010] Advantageously, the disc shape of the support layer may provide the aerosol-generating article with a disc shape. Advantageously, a disc-shaped aerosol-generating article may facilitate selective and sequential use of the plurality of aerosol-generating elements. For example, a discshaped aerosol-generating article may be used with an aerosol-generating device configured to rotate the disc-shaped aerosol-generating article to selectively align one of the aerosol-generating elements with a heater of the aerosol-generating device.

[0011] Preferably, the cavities are arranged symmetrically about a centre of the support layer. A symmetrical arrangement of the cavities about a centre of the support layer may be particularly advantageous in examples and embodiments in which the aerosol-generating article is used with an aerosol-generating device configured to rotate the aerosol-generating article during a user experience or between user experiences.

[0012] The aerosol-generating article may comprise at least one aperture extending through the support layer.

[0013] Advantageously, the at least one aperture may facilitate correct alignment of the aerosolgenerating article when the aerosol-generating article is inserted into an aerosol-generating device. For example, the aerosol-generating device may comprise one or more projections arranged to engage the at least one aperture of the aerosol-generating article.

[0014] Advantageously, the at least one aperture may facilitate engagement of the aerosolgenerating article with a means for rotating the aerosol-generating article in an aerosol-generating device. For example, an aerosol-generating device may comprise a spindle arranged to engage the at least one aperture for rotating the aerosol-generating article within the aerosol-generating device.

[0015] The at least one aperture may be arranged so that the aerosol-generating article has no rotational symmetry. Advantageously, this may facilitate correct orientation of the aerosolgenerating article when inserted into an aerosol-generating device.

[0016] The at least one aperture may comprise a first aperture and a second aperture spaced apart from the first aperture. Advantageously, the first and second apertures may be arranged to engage first and second projections of an aerosol-generating device. Advantageously, this may facilitate at least one of correct alignment and correct orientation of the aerosol-generating article with respect to an aerosol-generating device. The first and second apertures may be arranged so that neither of the first aperture and the second aperture is positioned at a centre of the support layer.

[0017] The at least one aperture may comprise an aperture positioned at a centre of the support layer. This may be particularly advantageous in examples and embodiments in which the aperture is arranged to engage a spindle or other rotation means of an aerosol-generating device. The at least one aperture may be a single aperture positioned at the centre of the support layer. The single aperture may have a shape with no rotational symmetry. Advantageously, this may facilitate correct orientation of the aerosol-generating article when inserted into an aerosolgenerating device.

[0018] Each of the cavities may extend entirely through a thickness of the support layer. Advantageously, this may facilitate forming the cavities during manufacture of the aerosolgenerating article. For example, the support layer may be formed by punching cavities through the full thickness of a support layer precursor.

[0019] The support layer may be formed of a cellulosic material. The support layer may be formed from at least one of paper, kraft paper, recycled paperboard, and cardboard.

[0020] Each of the cavities may have any suitable cross-sectional shape. Each of the cavities may have a circular shape, a triangular shape, a rounded triangular shape, a trapezoidal shape, or a rounded trapezoidal shape. A trapezoidal shape or a rounded trapezoidal shape may be particularly advantageous in examples and embodiments in which the cavities are arranged symmetrically about a centre of the disc-shaped support layer.

[0021] Each aerosol-generating element may have a laminated structure. Advantageously, a laminated structure may facilitate manufacture of aerosol-generating elements comprising one or more materials in addition to the aerosol-generating material.

[0022] The laminated structure may comprise a layer of the aerosol-generating material and an air permeable layer overlying the layer of the aerosol-generating material.

[0023] Advantageously, the air permeable layer may facilitate handling of the aerosol-generating elements during manufacture of the aerosol-generating, for example during the insertion of each aerosol-generating element into one of the cavities.

[0024] Advantageously, the air permeable layer may facilitate retention of the aerosol-generating material of each aerosol-generating element within the respective cavity of the support layer.

[0025] Advantageously, the air permeable layer may facilitate release of aerosol from the aerosolgenerating material during use of the aerosol-generating article.

[0026] The air permeable layer may be formed from any suitable material. The air permeable layer may be formed from at least one of a cellulosic material and a polymeric material. The air permeable layer may be formed from a paper, such as a food-grade filter paper. The air permeable layer may be formed from at least one of cellulose acetate, polyester, and polypropylene.

[0027] The air permeable layer may be secured to the layer of aerosol-generating material with an adhesive. The air permeable layer may have a thickness of at least 0.035 millimetres, at least 0.04 millimetres, at least 0.045 millimetres, at least 0.05 millimetres, at least 0.055 millimetres, at least 0.06 millimetres, at least 0.065 millimetres, at least 0.07 millimetres, or at least 0.075 millimetres.

[0028] The air permeable layer may have a thickness of no more than 0.12 millimetres, no more than 0.115 millimetres, no more than 0.11 millimetres, no more than 0.105 millimetres, or no more than 0.1 millimetres.

[0029] The air permeable layer may have a thickness of between 0.035 millimetres and 0.12 millimetres, between 0.04 millimetres and 0.12 millimetres, between 0.045 millimetres and 0.12 millimetres, between 0.05 millimetres and 0.115 millimetres, between 0.055 millimetres and 0.115 millimetres, between 0.06 millimetres and 0.11 millimetres, between 0.065 millimetres and 0.11 millimetres, between 0.07 millimetres and 0.105 millimetres, or between 0.075 millimetres and 0.1 millimetres.

[0030] The laminated structure may comprise an air impermeable layer underlying the layer of the aerosol-generating material. In examples and embodiments in which the laminated structure also comprises an air permeable layer, preferably the layer of aerosol-generating material is between the air permeable layer and the air impermeable layer.

[0031] Advantageously, the air impermeable layer may facilitate handling of the aerosolgenerating elements during manufacture of the aerosol-generating, for example during the insertion of each aerosol-generating element into one of the cavities.

[0032] Advantageously, the air impermeable layer may facilitate retention of the aerosolgenerating material of each aerosol-generating element within the respective cavity of the support layer.

[0033] Advantageously, the air impermeable layer may facilitate the transfer of heat from a heater of an aerosol-generating device to the layer of aerosol-generating material.

[0034] The air impermeable layer may be formed from any suitable material. The air impermeable layer may be formed from at least one of a cellulosic material, a polymeric material, and a metallic material. The air impermeable layer may have a laminated structure. The air impermeable layer may be formed from at least one of aluminium foil, and a metallised film, such as at least one of metallised polyester and metallised polypropylene.

[0035] The air impermeable layer may be secured to the layer of aerosol-generating material with an adhesive.

[0036] The air impermeable layer may have a thickness of at least 0.035 millimetres, at least 0.04 millimetres, at least 0.045 millimetres, at least 0.05 millimetres, at least 0.055 millimetres, at least 0.06 millimetres, at least 0.065 millimetres, at least 0.07 millimetres, or at least 0.075 millimetres.

[0037] The air impermeable layer may have a thickness of no more than 0.12 millimetres, no more than 0.115 millimetres, no more than 0.11 millimetres, no more than 0.105 millimetres, or no more than 0.1 millimetres. The air impermeable layer may have a thickness of between 0.035 millimetres and 0.12 millimetres, between 0.04 millimetres and 0.12 millimetres, between 0.045 millimetres and 0.12 millimetres, between 0.05 millimetres and 0.115 millimetres, between 0.055 millimetres and 0.115 millimetres, between 0.06 millimetres and 0.11 millimetres, between 0.065 millimetres and 0.11 millimetres, between 0.07 millimetres and 0.105 millimetres, or between 0.075 millimetres and 0.1 millimetres.

[0038] The aerosol-generating article may comprise a base layer, wherein the support layer overlies the base layer.

[0039] Advantageously, providing a base layer may facilitate correct insertion of the aerosolgenerating elements into the cavities during manufacture of the aerosol-generating article. For example, each aerosol-generating element may be inserted into a cavity until the aerosolgenerating substrate abuts the base layer.

[0040] Advantageously, the base layer may facilitate retention of the aerosol-generating substrates in the cavities.

[0041] The base layer may be formed integrally with the support layer.

[0042] The support layer may be formed separately from and attached to the base layer. Advantageously, forming the support layer separately from the base layer may facilitate forming of the cavities in the support layer. For example, the support layer may be formed by punching the plurality of cavities in a support layer precursor before attaching the support layer to the base layer.

[0043] The base layer may be formed from an air permeable material. Advantageously, forming the base layer from an air permeable material may facilitate an air flow through each aerosolgenerating element during use of the aerosol-generating article.

[0044] The air permeable material may comprise any suitable material. The air permeable material may comprise at least one of a cellulosic material and a polymeric material. The air permeable material may comprise a paper, such as a food-grade filter paper. The air permeable material may comprise at least one of cellulose acetate, polyester, and polypropylene.

[0045] The base layer may be formed from a air impermeable material. Advantageously, forming the base layer from a air impermeable material may facilitate the transfer of heat from a heater of an aerosol-generating device to each aerosol-generating element.

[0046] The air impermeable material may be formed from any suitable material. The air impermeable material may be formed from at least one of a cellulosic material, a polymeric material, and a metallic material. The air impermeable material may have a laminated structure. The air impermeable material may be formed from at least one of aluminium foil, and a metallised film, such as at least one of metallised polyester and metallised polypropylene.

[0047] Preferably, the base layer has the same shape as the support layer. Preferably, the base layer is disc-shaped. The support layer may have a top surface and a bottom surface opposite the top surface, wherein the base layer is secured to the bottom surface of the support layer. The base layer may be secured to the bottom surface of the support layer with an adhesive.

[0048] Each aerosol-generating element may have a top surface and a bottom surface opposite the top surface. Preferably, the bottom surface of each aerosol-generating element abuts the base layer.

[0049] Each aerosol-generating element may protrude from the top surface of the support layer. The top surface of each aerosol-generating element may be flush with the top surface of the support layer.

[0050] The aerosol-generating article may comprise a cover layer overlying the top surface of the support layer.

[0051] Advantageously, the cover layer may facilitate retention of the aerosol-generating substrates in the cavities.

[0052] The cover layer may be secured to the top surface of the support layer with an adhesive. Preferably, the cover layer is formed from an air permeable material. Advantageously, forming the cover layer from an air permeable material may facilitate an air flow through each aerosol-generating element during use of the aerosol-generating article.

[0053] The air permeable material may comprise any suitable material. The air permeable material may comprise at least one of a cellulosic material and a polymeric material. The air permeable material may comprise a paper, such as a food-grade filter paper. The air permeable material may comprise at least one of cellulose acetate, polyester, and polypropylene.

[0054] Preferably, the cover layer has the same shape as the support layer. Preferably, the cover layer is disc-shaped.

[0055] The aerosol-generating article may comprise a protruding tab. Advantageously, the protruding tab may facilitate attachment of the aerosol-generating article to a container containing the aerosol-generating article. Advantageously, the protruding tab may facilitate removal of the aerosol-generating article from a container containing the aerosol-generating article.

[0056] The protruding tab may be connected along a tearable weakened line to an edge of the support layer.

[0057] In embodiments and examples in which the aerosol-generating article comprises a base layer, the protruding tab may be connected along a tearable weakened line to an edge of the base layer. Preferably, the protruding tab is formed continuously with the support layer and the base layer and is connected along a tearable weakened line to an edge of the support layer and an edge of the base layer.

[0058] In embodiments and examples in which the aerosol-generating article comprises a cover layer, the protruding tab may be connected along a tearable weakened line to an edge of the cover layer. Preferably, the protruding tab is formed continuously with the support layer and the cover layer and is connected along a tearable weakened line to an edge of the support layer and an edge of the cover layer.

[0059] In examples and embodiments in which the aerosol-generating article comprises a base layer and a cover layer, preferably, the protruding tab is formed continuously with the support layer, the base layer and the cover layer and is connected along a tearable weakened line to an edge of the support layer, an edge of the base layer, and an edge of the cover layer.

[0060] In examples and embodiments in which the support layer and, where present, the base layer and the cover layer and disc shaped, preferably the protruding tab is connected along the tearable weakened line to an edge of the disc shape.

[0061] The weakened line may be a pre-cut line. The weakened line may be a pre-perforated line. The weakened line may be a curved line matching the disc shape of the support layer and, where present, the base layer and the cover layer.

[0062] The protruding tab may comprise a cut-out. Advantageously, the cut-out may facilitate attachment of the aerosol-generating article to a container, for example by an element of the container extending through the cut-out. The cut-out may be provided at a centre portion of the protruding tab.

[0063] The aerosol-generating material may comprise one or more organic materials such as tobacco, mint, tea and cloves. The aerosol-generating material may comprise one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenised tobacco such as cast leaf, extruded tobacco, expanded tobacco, aerosol-generating films and gel compositions.

[0064] The aerosol-generating material may be in the form of shredded aerosol-generating material. The shredded aerosol-generating material may comprise one or more of: strips and strands of aerosol-generating material, such as strips and strands of tobacco or homogenised tobacco material. The shredded aerosol-generating material may be in the form of a shredded sheet of homogenised tobacco material.

[0065] The aerosol-generating material may be cut filler. The aerosol-generating material may be tobacco cut filler. As used herein, the term “cut filler” is used to describe to a blend of shredded plant material, such as tobacco plant material, including, in particular, one or more of leaf lamina, processed stems and ribs, homogenised plant material.

[0066] The aerosol-generating material may be in the form of a sheet of aerosol-generating material. As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenised tobacco material, such as a cast leaf sheet. The aerosol-generating material may comprise one or more aerosol-formers. Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosolformers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosolformer to be or comprise one or both of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0067] The aerosol-generating material may have an aerosol-former content greater than or equal to 1 , 2, 5, 10, or 15 percent by weight on a dry weight basis. The aerosol-generating material may have an aerosol-former content greater than or equal to 15 percent by weight on a dry weight basis, for example greater than 20 by weight on a dry weight basis, or greater than 25 by weight on a dry weight basis, or greater than 30 by weight on a dry weight basis, or greater than 40 by weight on a dry weight basis, or greater than 50 by weight on a dry weight basis.

[0068] The aerosol-generating material may have an aerosol-former content less than or equal to 30 percent by weight on a dry weight basis, less than or equal to 25 percent by weight on a dry weight basis, or less than or equal to 20 percent by weight on a dry weight basis.

[0069] The aerosol-generating material may have an aerosol-former content between 5 percent and 30 percent by weight on a dry weight basis, between 5 percent and 25 percent by weight on a dry weight basis, or between 5 percent and 20 percent by weight on a dry weight basis.

[0070] The aerosol-generating material may have an aerosol-former content between 10 percent and 30 percent by weight on a dry weight basis, between 10 percent and 25 percent by weight on a dry weight basis, or between 10 percent and 20 percent by weight on a dry weight basis.

[0071] The aerosol-generating material may comprise nicotine. The aerosol-generating material may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0072] The aerosol-generating material may comprise at least 0.5 percent by weight of nicotine, at least 1 percent by weight of nicotine, at least 1.5 percent by weight of nicotine, or at least 2 percent by weight of nicotine. That is, the aerosol-generating material may have a nicotine content of at least 0.5 percent by weight, at least 1 percent by weight, at least 1.5 percent by weight, or at least 2 percent by weight.

[0073] Preferably, each aerosol-generating element comprises a layer of the aerosol-generating material.

[0074] The layer of aerosol-generating material may have a thickness of at least 0.75 millimetres, at least 0.8 millimetres, at least 0.85 millimetres, at least 0.9 millimetres, at least 0.95 millimetres, or at least 1 millimetre. The layer of aerosol-generating material may have a thickness of no more than 5 millimetres, no more than 4.5 millimetres, no more than 4 millimetres, no more than 3.5 millimetres, or no more than 3 millimetres.

[0075] The layer of aerosol-generating material may have a thickness of between 0.75 millimetres and 5 millimetres, between 0.8 millimetres and 4.5 millimetres, between 0.85 millimetres and 4 millimetres, between 0.9 millimetres and 3.5 millimetres, between 0.95 millimetres and 3 millimetres, or between 1 millimetre and 3 millimetres.

[0076] Each aerosol-generating element may have a maximum cross-sectional dimension of at least 5 millimetres, at least 6 millimetres, or at least 7 millimetres.

[0077] Each aerosol-generating element may have a maximum cross-sectional dimension of no more than 20 millimetres, no more than 18 millimetres, no more than 16 millimetres, no more than 14 millimetres, no more than 12 millimetres, no more than 10 millimetres, or no more than 9 millimetres.

[0078] Each aerosol-generating element may have a maximum cross-sectional dimension of between 5 millimetres and 20 millimetres, between 5 millimetres and 18 millimetres, between 5 millimetres and 16 millimetres, between 5 millimetres and 14 millimetres, between 5 millimetres and 12 millimetres, between 6 millimetres and 10 millimetres, or between 7 millimetres and 9 millimetres.

[0079] In examples and embodiments in which each aerosol-generating element has a circular cross-sectional shape, the maximum cross-sectional dimension of each aerosol-generating element is a diameter of the circular cross-sectional shape.

[0080] Each aerosol-generating element may have a trapezoidal or a rounded trapezoidal cross-sectional shape. The trapezoidal or rounded trapezoidal shape may have a maximum length, a maximum width, and a minimum width.

[0081] The maximum length may be at least 7 millimetres, at least 8 millimetres, at least 9 millimetres, at least 10 millimetres, or at least 11 millimetres.

[0082] The maximum length may be no more than 30 millimetres, no more than 29 millimetres, no more than 28 millimetres, no more than 27 millimetres, or no more than 26 millimetres.

[0083] The maximum length may be between 7 millimetres and 30 millimetres, between 8 millimetres and 29 millimetres, between 9 millimetres and 28 millimetres, between 10 millimetres and 27 millimetres, or between 11 millimetres and 26 millimetres.

[0084] The maximum width may be at least 5 millimetres, at least 5.5 millimetres, at least 6 millimetres, at least 6.5 millimetres, or at least 7 millimetres.

[0085] The maximum width may be no more than 19 millimetres, no more than 18.5 millimetres, no more than 18 millimetres, no more than 17.5 millimetres, or no more than 17 millimetres. The maximum width may be between 5 millimetres and 19 millimetres, between 5.5 millimetres and 18.5 millimetres, between 6 millimetres and 18 millimetres, between 6.5 millimetres and 17.5 millimetres, or between 7 millimetres and 17 millimetres.

[0086] The minimum width may be at least 3 millimetres, at least 3.5 millimetres, at least 4 millimetres, at least 4.5 millimetres, or at least 5 millimetres.

[0087] The minimum width may be no more than 14 millimetres, no more than 13 millimetres, no more than 12 millimetres, or no more than 11 millimetres.

[0088] The minimum width may be between 3 millimetres and 14 millimetres, between 3.5 millimetres and 13 millimetres, between 4 millimetres and 12 millimetres, between 4.5 millimetres and 12 millimetres, between 4.5 millimetres and 11 millimetres, or between 5 millimetres and 11 millimetres.

[0089] According to the present disclosure there is also provided a method of forming an aerosolgenerating element for an aerosol-generating article. The method comprises providing a substrate precursor sheet comprising a sheet of aerosol-generating material. The method also comprises cutting a plurality of aerosol-generating elements from the substrate precursor sheet so that each aerosol-generating element comprises a layer of the aerosol-generating material.

[0090] Aerosol-generating elements formed according to the method of the present disclosure may comprise any of the features of the aerosol-generating elements of the aerosol-generating articles described herein.

[0091] The cutting step may comprise punching the plurality of aerosol-generating substrates from the substrate precursor sheet.

[0092] The step of providing the substrate precursor sheet may comprise: providing the sheet of aerosol-generating material, the sheet of aerosol-generating material having a first surface and a second surface opposite the second surface; providing a sheet of air permeable material; and attaching the sheet of air permeable material to the first surface of the sheet of aerosol-generating material; and wherein each aerosol-generating element comprises a layer of the aerosolgenerating material and a layer of the air permeable material overlying the layer of the aerosolgenerating material.

[0093] The air permeable material may comprise any of the air permeable materials described herein.

[0094] The sheet of air permeable material may be attached to the sheet of aerosol-generating material with an adhesive.

[0095] The sheet of air permeable material may be provided as a continuous web of air permeable material.

[0096] The sheet of air permeable material may be a first sheet of air permeable material, wherein the step of providing the substrate precursor sheet comprises providing a second sheet of air permeable material and attaching the second sheet of air permeable material to the second surface of the sheet of aerosol-generating material, and wherein each aerosol-generating element comprises a layer of the aerosol-generating material, a first layer of air permeable material overlying a first side of the layer of the aerosol-generating material, and a second layer of air permeable material overlying a second side of the layer of aerosol-generating material.

[0097] The air permeable material of the second sheet of air permeable material may comprise any of the air permeable materials described herein.

[0098] The second sheet of air permeable material is attached to the sheet of aerosol-generating material with an adhesive.

[0099] The second sheet of air permeable material may be provided as a continuous web of air permeable material.

[0100] The step of providing the substrate precursor sheet may comprise providing a sheet of air impermeable material and attaching the sheet of air impermeable material to the second surface of the sheet of aerosol-generating material, and wherein each aerosol-generating element comprises a layer of the aerosol-generating material, a layer of the air permeable material overlying a first side of the layer of the aerosol-generating material, and a layer of the air impermeable material overlying a second side of the layer of aerosol-generating material.

[0101] The air impermeable material may comprise any of the air impermeable materials described herein.

[0102] The sheet of air impermeable material may be attached to the sheet of aerosol-generating material with an adhesive.

[0103] The sheet of air impermeable material may be provided as a continuous web of air impermeable material.

[0104] The aerosol-generating material may comprise any of the aerosol-generating materials described herein.

[0105] The sheet of aerosol-generating material may be provided as a continuous web of aerosolgenerating material.

[0106] Each of the aerosol-generating elements may have a circular shape, a triangular shape, a rounded triangular shape, a trapezoidal shape, or a rounded trapezoidal shape.

[0107] According to the present disclosure there is also provided a method of forming an aerosolgenerating article. The method comprises providing an article precursor sheet comprising a sheet of support layer material, the sheet of support layer material defining a plurality of cavities. The method also comprises providing a plurality of aerosol-generating elements each comprising an aerosol-generating material. The method also comprises inserting each aerosol-generating element into one of the cavities. The method also comprises cutting at least one aerosolgenerating article from the article precursor sheet so that each aerosol-generating article comprises a disc-shaped support layer comprising the support layer material, wherein the support layer comprises at least two of the cavities and wherein the aerosol-generating article comprises at least two of the aerosol-generating elements.

[0108] Aerosol-generating articles formed using the method according to the present disclosure may comprise any of the features of the aerosol-generating articles described herein.

[0109] The step of providing a plurality of aerosol-generating elements may comprise forming the plurality of aerosol-generating elements using a method according to the present disclosure.

[0110] The cutting step may comprise punching the at least one aerosol-generating article from the article precursor sheet.

[0111] The step of providing the article precursor sheet may comprise providing a support precursor sheet and cutting the plurality of cavities in the support precursor sheet to form the sheet of support layer material.

[0112] The step of cutting the plurality of cavities may comprise punching the support precursor sheet to form the plurality of cavities.

[0113] Cutting each cavity may comprise cutting through an entire thickness of the support precursor sheet.

[0114] The step of cutting the plurality cavities may comprise cutting a plurality of cavities each having a shape selected from a circular shape, a triangular shape, a rounded triangular shape, a trapezoidal shape, or a rounded trapezoidal shape.

[0115] The support precursor sheet may be provided as a continuous web. The sheet of support layer material may be provided as a continuous web. Preferably, each of the support precursor sheet and the sheet of support layer material is provided as a continuous web.

[0116] The article precursor sheet may be provided as a continuous web.

[0117] The cavities of each aerosol-generating article may be arranged symmetrically about a centre of the support layer.

[0118] The method may comprise cutting at least one aperture so that each aerosol-generating article comprises at least one aperture extending through the support layer.

[0119] The at least one aperture may be arranged so that each aerosol-generating article has no rotational symmetry.

[0120] The at least one aperture of each aerosol-generating article may comprise a first aperture and a second aperture spaced apart from the first aperture.

[0121] The at least one aperture of each aerosol-generating article may be a single aperture positioned at a centre of the support layer. Preferably, the single aperture has a shape with no rotational symmetry.

[0122] The step of cutting at least one aperture may be performed on the article precursor sheet before the step of cutting at least one aerosol-generating article from the article precursor sheet.

[0123] The step of cutting at least one aperture may be performed concurrently with the step of cutting at least one aerosol-generating article from the article precursor sheet. The support layer material may comprise any of the support layer materials described herein.

[0124] The aerosol-generating material may comprise any of the aerosol-generating materials described herein.

[0125] The step of providing an article precursor sheet may comprise providing a sheet of base layer material and attaching the sheet of support layer material to the sheet of base layer material to form the article precursor sheet, wherein each aerosol-generating article comprises a base layer comprising the base layer material, and wherein the support layer overlies the base layer.

[0126] The step of providing an article precursor sheet may comprise attaching the sheet of support layer material to the sheet of base layer material with an adhesive.

[0127] The sheet of base layer material may be provided as a continuous web.

[0128] The step of cutting at least one aerosol-generating article from the article precursor sheet may comprise cutting the sheet of base layer material so that the base layer of each aerosolgenerating article is disc-shaped.

[0129] The base layer material may comprise any of the base layer materials described herein. The sheet of support layer material may have a top surface and a bottom surface opposite the top surface, wherein the sheet of base layer material is secured to the bottom surface of the sheet of support layer material.

[0130] Each aerosol-generating element may have a top surface and a bottom surface opposite the top surface.

[0131] The step of inserting each aerosol-generating element into one of the cavities may comprise inserting each aerosol-generating element until the bottom surface of the aerosolgenerating element abuts the sheet of base layer material.

[0132] The step of inserting each aerosol-generating element into one of the cavities may comprise inserting each aerosol-generating element until the top surface of the aerosolgenerating element is flush with the top surface of the support layer.

[0133] The method may comprise providing a sheet of cover layer material, and attaching the sheet of cover layer material to the sheet of support layer material after the step of inserting each aerosol-generating element into one of the cavities and before the step of cutting at least one aerosol-generating article from the article precursor sheet so that each aerosol-generating article further comprises a cover layer overlying the support layer and comprising the cover layer material.

[0134] The sheet of cover layer material may be attached to the sheet of support layer material with an adhesive.

[0135] The cover layer material may comprise any of the cover layer materials described herein. The cover layer of each aerosol-generating article may be disc-shaped. 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. Example 1 : An aerosol-generating article comprising:

[0136] a disc-shaped support layer defining a plurality of cavities; and

[0137] a plurality of aerosol-generating elements, wherein each aerosol-generating element comprises an aerosol-generating material, and wherein each aerosol-generating element is positioned at least partially within one of the cavities.

[0138] Example 2: An aerosol-generating article according to Example 1 or 2, wherein the cavities are arranged symmetrically about a centre of the support layer.

[0139] Example 3: An aerosol-generating article according to any preceding Example, further comprising at least one aperture extending through the support layer.

[0140] Example 4: An aerosol-generating article according to Example 3, wherein the at least one aperture is arranged so that the aerosol-generating article has no rotational symmetry.

[0141] Example 5: An aerosol-generating article according to Example 3 or 4, wherein the at least one aperture comprises a first aperture and a second aperture spaced apart from the first aperture.

[0142] Example 6: An aerosol-generating article according to Example 3 or 4, wherein the at least one aperture is a single aperture positioned at a centre of the support layer, preferably wherein the single aperture has a shape with no rotational symmetry.

[0143] Example 7: An aerosol-generating article according to any preceding Example, wherein each of the cavities extends entirely through a thickness of the support layer.

[0144] Example 8: An aerosol-generating article according to any preceding Example, wherein the support layer is formed from paper or cardboard.

[0145] Example 9: An aerosol-generating article according to any preceding Example, wherein each of the cavities has a circular shape, a triangular shape, a rounded triangular shape, a trapezoidal shape, or a rounded trapezoidal shape.

[0146] Example 10: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating material comprises tobacco.

[0147] Example 11: An aerosol-generating article according to any preceding Example, wherein each aerosol-generating element has a laminated structure.

[0148] Example 12: An aerosol-generating article according to Example 11, wherein the laminated structure comprises a layer of the aerosol-generating material and an air permeable layer overlying the layer of the aerosol-generating material.

[0149] Example 13: An aerosol-generating article according to Example 12, wherein the air permeable layer is formed from paper. Example 14: An aerosol-generating article according to Example 12 or 13, wherein the air permeable layer is secured to the layer of the aerosol-generating material with an adhesive. Example 15: An aerosol-generating article according to any preceding Example, further comprising a base layer, wherein the support layer overlies the base layer.

[0150] Example 16: An aerosol-generating article according to Example 15, wherein the support layer is formed separately from and attached to the base layer, or wherein the support layer is integrally formed with the base layer.

[0151] Example 17: An aerosol-generating article according to Example 15 or 16, wherein the base layer is formed from an air permeable material.

[0152] Example 18: An aerosol-generating article according to Example 17, wherein the air permeable material comprises paper.

[0153] Example 19: An aerosol-generating article according to any of Examples 15 to 18, wherein the base layer is disc-shaped.

[0154] Example 20: An aerosol-generating article according to any of Examples 15 to 19, wherein the support layer has a top surface and a bottom surface opposite the top surface, and wherein the base layer is secured to the bottom surface of the support layer.

[0155] Example 21: An aerosol-generating article according to Example 20, wherein the base layer is secured to the bottom surface of the support layer with an adhesive.

[0156] Example 22: An aerosol-generating article according to Example 20 or 21, wherein each aerosol-generating element has a top surface and a bottom surface opposite the top surface. Example 23: An aerosol-generating article according to Example 22, wherein the bottom surface of each aerosol-generating element abuts the base layer.

[0157] Example 24: An aerosol-generating article according to Example 22 or 23, wherein the top surface of each aerosol-generating element is flush with the top surface of the support layer. Example 25: An aerosol-generating article according to any of Examples 20 to 24, further comprising a cover layer overlying the top surface of the support layer.

[0158] Example 26: An aerosol-generating article according to Example 25, wherein the cover layer is secured to the top surface of the support layer with an adhesive.

[0159] Example 27: An aerosol-generating article according to Example 25 or 26, wherein the cover layer is formed from an air permeable material.

[0160] Example 28: An aerosol-generating article according to Example 27, wherein the air permeable material comprises paper.

[0161] Example 29: An aerosol-generating article according to any of Examples 25 to 28, wherein the cover layer is disc-shaped.

[0162] Example 30: An aerosol-generating article according to Example 20 or 21, wherein each aerosol-generating element protrudes from the top surface of the support layer. Example 31: An aerosol-generating article according to any preceding Example, further comprising a protruding tab connected along a weakened line to an edge of the support layer. Example 32: An aerosol-generating article according to Example 31 , wherein the protruding tab comprises a cut-out extending through the protruding tab.

[0163] Example 33: A method of forming an aerosol-generating element for an aerosol-generating article, the method comprising:

[0164] providing a substrate precursor sheet comprising a sheet of aerosol-generating material; and

[0165] cutting a plurality of aerosol-generating elements from the substrate precursor sheet so that each aerosol-generating element comprises a layer of the aerosol-generating material. Example 34: A method according to Example 33, wherein the cutting step comprises punching the plurality of aerosol-generating substrates from the substrate precursor sheet.

[0166] Example 35: A method according to Example 33 or 34, wherein the step of providing the substrate precursor sheet comprises:

[0167] providing the sheet of aerosol-generating material, the sheet of aerosol-generating material having a first surface and a second surface opposite the second surface;

[0168] providing a sheet of air permeable material; and

[0169] attaching the sheet of air permeable material to the first surface of the sheet of aerosolgenerating material; and

[0170] wherein each aerosol-generating element comprises a layer of the aerosol-generating material and a layer of the air permeable material overlying the layer of the aerosol-generating material.

[0171] Example 36: A method according to Example 35, wherein the air permeable material comprises paper.

[0172] Example 37: A method according to Example 35 or 36, wherein the sheet of air permeable material is attached to the sheet of aerosol-generating material with an adhesive.

[0173] Example 38: A method according to any of Examples 35 to 37, wherein the sheet of air permeable material is provided as a continuous web of air permeable material.

[0174] Example 39: A method according to any of Examples 35 to 38, wherein the sheet of air permeable material is a first sheet of air permeable material, wherein the step of providing the substrate precursor sheet comprises providing a second sheet of air permeable material and attaching the second sheet of air permeable material to the second surface of the sheet of aerosol-generating material, and wherein each aerosol-generating element comprises a layer of the aerosol-generating material, a first layer of air permeable material overlying a first side of the layer of the aerosol-generating material, and a second layer of air permeable material overlying a second side of the layer of aerosol-generating material. Example 40: A method according to Example 39, wherein the air permeable material of the second sheet of air permeable material comprises paper.

[0175] Example 41: A method according to Example 39 or 40, wherein the second sheet of air permeable material is attached to the sheet of aerosol-generating material with an adhesive. Example 42: A method according to any of Examples 39 to 41 , wherein the second sheet of air permeable material is provided as a continuous web of air permeable material.

[0176] Example 43: A method according to any of Examples 35 to 38, wherein the step of providing the substrate precursor sheet comprises providing a sheet of air impermeable material and attaching the sheet of air impermeable material to the second surface of the sheet of aerosolgenerating material, and wherein each aerosol-generating element comprises a layer of the aerosol-generating material, a layer of the air permeable material overlying a first side of the layer of the aerosol-generating material, and a layer of the air impermeable material overlying a second side of the layer of aerosol-generating material.

[0177] Example 44: A method according to Example 43, wherein the air impermeable material comprises a metal foil.

[0178] Example 45: A method according to Example 43 or 44, wherein the sheet of air impermeable material is attached to the sheet of aerosol-generating material with an adhesive.

[0179] Example 46: A method according to any of Examples 43 to 45, wherein the sheet of air impermeable material is provided as a continuous web of air impermeable material.

[0180] Example 47: A method according to any of Examples 33 to 46, wherein the aerosol-generating material comprises tobacco.

[0181] Example 48: A method according to any of Examples 33 to 47, wherein the sheet of aerosolgenerating material is provided as a continuous web of aerosol-generating material.

[0182] Example 49: A method according to any of Examples 33 to 48, wherein each of the aerosolgenerating elements has a circular shape, a triangular shape, a rounded triangular shape, a trapezoidal shape, or a rounded trapezoidal shape.

[0183] Example 50: A method of forming an aerosol-generating article, the method comprising:

[0184] providing an article precursor sheet comprising a sheet of support layer material, the sheet of support layer material defining a plurality of cavities;

[0185] providing a plurality of aerosol-generating elements each comprising an aerosolgenerating material;

[0186] inserting each aerosol-generating element into one of the cavities; and

[0187] cutting at least one aerosol-generating article from the article precursor sheet so that each aerosol-generating article comprises a disc-shaped support layer comprising the support layer material, wherein the support layer comprises at least two of the cavities and wherein the aerosolgenerating article comprises at least two of the aerosol-generating elements. Example 51: A method according to Example 50, wherein the step of providing a plurality of aerosol-generating elements comprises forming the plurality of aerosol-generating elements using a method according to any of Examples 33 to 49.

[0188] Example 52: A method according to Example 50 or 51 , wherein the cutting step comprises punching the at least one aerosol-generating article from the article precursor sheet.

[0189] Example 53: A method according to any of Examples 50 to 52, wherein the step of providing the article precursor sheet comprises:

[0190] providing a support precursor sheet; and

[0191] cutting the plurality of cavities in the support precursor sheet to form the sheet of support layer material.

[0192] Example 54: A method according to Example 53, wherein the step of cutting the plurality of cavities comprises punching the support precursor sheet to form the plurality of cavities.

[0193] Example 55: A method according to Example 53 or 54, wherein cutting each cavity comprises cutting through an entire thickness of the support precursor sheet.

[0194] Example 56: A method according to any of Examples 53 to 55, wherein the step of cutting the plurality cavities comprises cutting a plurality of cavities each having a shape selected from a circular shape, a triangular shape, a rounded triangular shape, a trapezoidal shape, or a rounded trapezoidal shape.

[0195] Example 57: A method according to any of Examples 53 to 56, wherein the support precursor sheet is provided as a continuous web, and wherein the sheet of support layer material is provided as a continuous web.

[0196] Example 58: A method according to any of Examples 50 to 57, wherein the article precursor sheet is provided as a continuous web.

[0197] Example 59: A method according to any of Examples 50 to 58, wherein the cavities of each aerosol-generating article are arranged symmetrically about a centre of the support layer.

[0198] Example 60: A method according to any of Examples 50 to 59, further comprising cutting at least one aperture so that each aerosol-generating article comprises at least one aperture extending through the support layer.

[0199] Example 61 : A method according to Example 60, wherein the at least one aperture is arranged so that each aerosol-generating article has no rotational symmetry.

[0200] Example 62: A method according to Example 60 or 61, wherein the at least one aperture of each aerosol-generating article comprises a first aperture and a second aperture spaced apart from the first aperture.

[0201] Example 63: A method according to Example 60 or 61, wherein the at least one aperture of each aerosol-generating article is a single aperture positioned at a centre of the support layer, preferably wherein the single aperture has a shape with no rotational symmetry. Example 64: A method according to any of Examples 60 to 63, wherein the step of cutting at least one aperture is performed on the article precursor sheet before the step of cutting at least one aerosol-generating article from the article precursor sheet, or wherein the step of cutting at least one aperture is performed concurrently with the step of cutting at least one aerosolgenerating article from the article precursor sheet.

[0202] Example 65: A method according to any of Examples 50 to 64, wherein the support layer material comprises paper or cardboard.

[0203] Example 66: A method according to any of Examples 50 to 65, wherein the aerosol-generating material comprises tobacco.

[0204] Example 67: A method according to any of Examples 50 to 66, wherein the step of providing an article precursor sheet comprises providing a sheet of base layer material and attaching the sheet of support layer material to the sheet of base layer material to form the article precursor sheet, wherein each aerosol-generating article comprises a base layer comprising the base layer material, and wherein the support layer overlies the base layer.

[0205] Example 68: A method according to Example 67, wherein the step of providing an article precursor sheet comprises attaching the sheet of support layer material to the sheet of base layer material with an adhesive.

[0206] Example 69: A method according to Example 67 or 68, wherein the sheet of base layer material is provided as a continuous web.

[0207] Example 70: A method according to any of Examples 67 to 69, wherein the step of cutting at least one aerosol-generating article from the article precursor sheet comprises cutting the sheet of base layer material so that the base layer of each aerosol-generating article is disc-shaped. Example 71: A method according to any of Examples 67 to 70, wherein the base layer material is an air permeable material.

[0208] Example 72: A method according to Example 71 , wherein the air permeable material comprises paper.

[0209] Example 73: A method according to any of Examples 67 to 72, wherein the sheet of support layer material has a top surface and a bottom surface opposite the top surface, and wherein the sheet of base layer material is secured to the bottom surface of the sheet of support layer material. Example 74: A method according to Example 73, wherein each aerosol-generating element has a top surface and a bottom surface opposite the top surface.

[0210] Example 75: A method according to Example 74, wherein the step of inserting each aerosolgenerating element into one of the cavities comprises inserting each aerosol-generating element until the bottom surface of the aerosol-generating element abuts the sheet of base layer material. Example 76: A method according to Examples 74 or 75, wherein the step of inserting each aerosol-generating element into one of the cavities comprises inserting each aerosol-generating element until the top surface of the aerosol-generating element is flush with the top surface of the support layer.

[0211] Example 77: A method according to any of Examples 73 to 76, further comprising providing a sheet of cover layer material, and attaching the sheet of cover layer material to the sheet of support layer material after the step of inserting each aerosol-generating element into one of the cavities and before the step of cutting at least one aerosol-generating article from the article precursor sheet so that each aerosol-generating article further comprises a cover layer overlying the support layer and comprising the cover layer material.

[0212] Example 78: A method according to Example 77, wherein the sheet of cover layer material is attached to the sheet of support layer material with an adhesive.

[0213] Example 79: A method according to Example 77 or 78, wherein the cover layer material is formed from an air permeable material.

[0214] Example 80: A method according to Example 79, wherein the air permeable material comprises paper.

[0215] Example 81 : A method according to any of Examples 77 to 80, wherein the cover layer of each aerosol-generating article is disc-shaped.

[0216] Example 82: A method according to any of Examples 50 to 81, wherein the cutting step comprises cutting at least one aerosol-generating article from the article pre-cursor sheet so that each aerosol-generating article further comprises a protruding tab connected along a weakened line to an edge of the support layer.

[0217] Example 83: A method according to Example 82, wherein the cutting step comprises cutting a cut-out extending through the protruding tab of each aerosol-generating article.

[0218] Examples will now be further described with reference to the figures in which:

[0219] Figure 1 shows a top view of an aerosol-generating article according to a first embodiment of the present disclosure;

[0220] Figure 2 shows a top view of an aerosol-generating article according to a second embodiment of the present disclosure;

[0221] Figure 3 shows a cross-sectional view of the aerosol-generating article of Figure 2 along line 2-2;

[0222] Figure 4 shows a cross-sectional view of an alternative arrangement of the aerosolgenerating article of Figure 2;

[0223] Figure 5 shows a cross-sectional view of a further alternative arrangement of the aerosolgenerating article of Figure 2;

[0224] Figure 6 illustrates a method of forming the aerosol-generating elements of the aerosolgenerating article of Figure 3;

[0225] Figure 7 illustrates a method of forming the aerosol-generating article of Figure 3; and Figure 8 illustrates an aerosol-generating article according to a third embodiment of the present disclosure.

[0226] Figure 1 shows a top view of an aerosol-generating article 10 according to a first embodiment of the present disclosure. The aerosol-generating article 10 comprises a discshaped support layer 12 defining a plurality of cavities 14. Positioned within each cavity 14 is an aerosol-generating element 16 comprising an aerosol-generating material. Each aerosolgenerating element 16 has a circular cross-sectional shape.

[0227] The support layer 12 also comprises an aperture 18 extending through a centre of the support layer 12 for engagement with a spindle of an aerosol-generating device, which enables rotation of the aerosol-generating article 10 by the aerosol-generating device during use.

[0228] In the embodiments described herein, the support layer 12 is formed from paper or cardboard, and the aerosol-generating material comprises tobacco. However, the skilled person will appreciate that other materials may be used to form the support layer 12 and the aerosolgenerating material.

[0229] Advantageously, the plurality of cavities 14 defined by the support layer 12 facilitates correct positioning of the aerosol-generating elements 16 with respect to the support layer 12 during manufacture of the aerosol-generating article 10.

[0230] Advantageously, each cavity 14 engages the respective aerosol-generating element 16 by an interference fit to retain the aerosol-generating element 16 in the support layer 12.

[0231] Figure 2 shows a top view of an aerosol-generating article 110 according to a second embodiment of the present disclosure. The aerosol-generating article 110 is similar to the aerosol-generating article 10 and like reference numerals designate like parts.

[0232] The main difference between the aerosol-generating article 110 and the aerosolgenerating article 10 is the shape of the cavities 14 and the aerosol-generating elements 16. In particular, each of the cavities 14 and the aerosol-generating elements 16 of the aerosolgenerating article 110 has a rounded trapezoidal shape. Advantageously, the rounded trapezoidal shape facilitates tighter packing of the cavities 14 and the aerosol-generating elements 16 on the disc-shaped support layer 12.

[0233] The aerosol-generating article 110 also differs by the shape of the aperture 18, which has a trapezoidal shape. Advantageously, the trapezoidal shape of the aperture 18 has no rotational symmetry, which may allow insertion of the aerosol-generating article 110 into an aerosolgenerating device with only a single orientation.

[0234] Figure 3 shows a cross-sectional view of the aerosol-generating article 110 along line 2-2 of Figure 2. The skilled person will appreciate that the features described with reference to Figure 3 and the subsequent Figures may be applied equally to the aerosol-generating article 10 of Figure 1. Each aerosol-generating element 16 comprises a layer of air impermeable material 120, a layer of the aerosol-generating material 122, and a layer of air permeable material 124. The layers 120, 122, 124 are secured together using an adhesive.

[0235] In this embodiment, the air impermeable material comprises aluminium foil, although the skilled person will appreciate that other air impermeable materials will be suitable. Advantageously, the aluminium foil may facilitate the transfer of heat from a heater of an aerosolgenerating device to the layer of aerosol-generating material 122.

[0236] In this embodiment, the air permeable material comprises paper, although the skilled person will appreciate that other air permeable materials will be suitable. Advantageously, the air permeable material may facilitate the release of aerosol from the layer of aerosol-generating material 122 during use.

[0237] Figure 4 shows an alternative arrangement of the aerosol-generating article 110 of Figure 2. In the embodiment of Figure 4, the layer of air impermeable material has been omitted from each aerosol-generating element 16. Instead, the aerosol-generating article 110 comprises a base layer 220 attached to the bottom surface of the support layer 12. In this embodiment, the base layer 220 is formed from an air impermeable material such as aluminium foil, but the skilled person will appreciate that other materials will be suitable for forming the base layer 220, including air permeable materials.

[0238] Figure 5 shows a further alternative arrangement of the aerosol-generating article 110 of Figure 2. The embodiment of Figure 5 is similar to the embodiment of Figure 4, but differs by the mission of the layer of air permeable material from each aerosol-generating element 16. Instead, the aerosol-generating article 110 comprises a cover layer 324 attached to the top surface of the support layer 12. In this embodiment, the cover layer 324 is formed from an air permeable material such as paper, but the skilled person will appreciate that other materials will be suitable for forming the cover layer 324. In the embodiment of Figure 5, each aerosol-generating element 16 comprises only the layer of aerosol-generating material 122.

[0239] Figure 6 illustrates a method of forming an aerosol-generating element according to the present disclosure. In particular, Figure 6 illustrates a method of forming an aerosol-generating element 16 described with reference to Figure 3.

[0240] In a first step, a continuous web 400 of air permeable material, a continuous web 402 of aerosol-generating material, and a continuous web 404 of air impermeable material are provided. The skilled person will understand that the air permeable material, the aerosol-generating material and the air impermeable material could instead be provided as discrete sheets.

[0241] In a second step, the continuous webs 400, 402, 404 are combined together using an adhesive to form a substrate precursor sheet 406, the substrate precursor sheet 406 comprising a sheet of the aerosol-generating material sandwiched between a sheet of the air permeable material and a sheet of the air impermeable material. In a third step, individual aerosol-generating elements 16 are punched from the substrate precursor sheet 406, each aerosol-generating element 16 comprising a layer of air impermeable material 120, a layer of the aerosol-generating material 122, and a layer of air permeable material 124, as described with reference to Figure 3.

[0242] The skilled person will appreciate that the method illustrated in Figure 6 can also be used to form the aerosol-generating elements 16 described with reference to Figures 4 and 5 by omitting one or both of the continuous web of air impermeable material 404 and the continuous web of air permeable material 400.

[0243] Figure 7 illustrates a method of forming an aerosol-generating article according to the present disclosure. In particular, Figure 7 illustrates a method of forming an aerosol-generating article 110 described with reference to Figure 3.

[0244] In a first step, a continuous web 500 of support layer material is provided. The skilled person will understand that the support layer material could instead be provided as a discrete sheet.

[0245] In a second step, a plurality of cavities 14 are punched in the continuous web 500 of support layer material to form an article precursor sheet 502 comprising a sheet of the support layer material defining the plurality of cavities 14.

[0246] In a third step, a plurality of aerosol-generating elements 16 are provided. In this embodiment, the aerosol-generating elements 16 are the aerosol-generating elements 16 described with reference to Figure 3. However, the skilled person will appreciate that the method is equally applicable to forming aerosol-generating articles comprising different aerosolgenerating elements, such as the aerosol-generating elements described with reference to Figures 4 and 5.

[0247] In a fourth step, each aerosol-generating element 16 is inserted into one of the cavities 16 of the article precursor sheet 502.

[0248] In a fifth step, a plurality of apertures 18 and a plurality of disc-shaped aerosol-generating articles 110 are punched from the article precursor sheet 502 so that each aerosol-generating articles 110 comprises a disc-shaped support layer 12 comprising the support material and defining a plurality of cavities 14 and an aperture 18, and an aerosol-generating element 16 positioned within each cavity 14.

[0249] The skilled person will appreciate that the method illustrated in Figure 7 can also be used to form the aerosol-generating articles 110 described with reference to Figures 4 and 5 by providing one or both of a continuous web of air impermeable material and a continuous web of air permeable material, and combining one or both of these additional webs with the continuous web 500 of substrate material after punching the plurality of cavities 16 from the continuous web 500 of substrate material. Figure 8 shows a top view of an aerosol-generating article 210 according to a third embodiment of the present disclosure. The aerosol-generating article 210 is similar to the aerosol-generating article 10 of Figure 1 and like reference numerals designate like parts.

[0250] The aerosol-generating article 210 differs from the aerosol-generating article 10 by the addition of a protruding tab 211 connected along a weakened line 213 to an edge of the discshaped support layer 12. The weakened line 213 is a perforated line. A cut-out 215 extending through a centre portion of the protruding tab 211 facilitates connection of the aerosol-generating article 210 to a container for storing one or more aerosol-generating articles 210.

[0251] The protruding tab 211 is formed continuously with the support layer 12. The protruding tab 211, the weakened line 213 and the cut-out 215 may be formed at the same time as forming the support layer 12, for example using a punching step described with reference to the fifth step of the method illustrated in Figure 7 for forming the aerosol-generating article 10 of Figure 1.

[0252] The skilled person will appreciate that the aerosol-generating article 110 of Figure 2 may also be provided with a protruding tab. Preferably, the protruding tab has a laminated structure and is connected along a weakened line to the support layer 12, the base layer 220 and the cover layer 324 so that the protruding tab can be formed at the same time as forming the support layer 12, the base layer 220 and the cover layer 324 using a single punching step.

[0253] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 10% of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

1. Claims1. An aerosol-generating article comprising:3.a disc-shaped support layer defining a plurality of cavities; and4.a plurality of aerosol-generating elements, wherein each aerosol-generating element comprises an aerosol-generating material, and wherein each aerosol-generating element is positioned at least partially within one of the cavities.

2. An aerosol-generating article according to claim 1, wherein the cavities are arranged symmetrically about a centre of the support layer.

3. An aerosol-generating article according to claim 1 or 2, further comprising at least one aperture extending through the support layer.

4. An aerosol-generating article according to claim 3, wherein the at least one aperture is arranged so that the aerosol-generating article has no rotational symmetry.

5. An aerosol-generating article according to claim 3 or 4, wherein the at least one aperture comprises a first aperture and a second aperture spaced apart from the first aperture.

6. An aerosol-generating article according to claim 3 or 4, wherein the at least one aperture is a single aperture positioned at a centre of the support layer, preferably wherein the single aperture has a shape with no rotational symmetry.

7. An aerosol-generating article according to any preceding claim, wherein each of the cavities has a circular shape, a triangular shape, a rounded triangular shape, a trapezoidal shape, or a rounded trapezoidal shape.

8. An aerosol-generating article according to any preceding claim, further comprising a base layer, wherein the support layer overlies the base layer.

9. An aerosol-generating article according to any preceding claim, further comprising a protruding tab connected along a weakened line to an edge of the support layer.

10. An aerosol-generating article according to claim 9, wherein the protruding tab comprises a cut-out extending through the protruding tab.

11. A method of forming an aerosol-generating element for an aerosol-generating article, the method comprising:14.providing a substrate precursor sheet comprising a sheet of aerosol-generating material; and15.cutting a plurality of aerosol-generating elements from the substrate precursor sheet so that each aerosol-generating element comprises a layer of the aerosol-generating material.

12. A method according to claim 11, wherein the step of providing the substrate precursor sheet comprises:17.providing the sheet of aerosol-generating material, the sheet of aerosol-generating material having a first surface and a second surface opposite the second surface;18.providing a sheet of air permeable material; and19.attaching the sheet of air permeable material to the first surface of the sheet of aerosolgenerating material; and20.wherein each aerosol-generating element comprises a layer of the aerosol-generating material and a layer of the air permeable material overlying the layer of the aerosol-generating material.

13. A method according to claim 12, wherein the sheet of air permeable material is a first sheet of air permeable material, wherein the step of providing the substrate precursor sheet comprises providing a second sheet of air permeable material and attaching the second sheet of air permeable material to the second surface of the sheet of aerosol-generating material, and wherein each aerosol-generating element comprises a layer of the aerosol-generating material, a first layer of air permeable material overlying a first side of the layer of the aerosol-generating material, and a second layer of air permeable material overlying a second side of the layer of aerosol-generating material.

14. A method according to claim 12, wherein the step of providing the substrate precursor sheet comprises providing a sheet of air impermeable material and attaching the sheet of air impermeable material to the second surface of the sheet of aerosol-generating material, and wherein each aerosol-generating element comprises a layer of the aerosol-generating material, a layer of the air permeable material overlying a first side of the layer of the aerosol-generating material, and a layer of the air impermeable material overlying a second side of the layer of aerosol-generating material.

15. A method of forming an aerosol-generating article, the method comprising: providing an article precursor sheet comprising a sheet of support layer material, the sheet of support layer material defining a plurality of cavities;23.providing a plurality of aerosol-generating elements each comprising an aerosolgenerating material;24.inserting each aerosol-generating element into one of the cavities; and25.cutting at least one aerosol-generating article from the article precursor sheet so that each aerosol-generating article comprises a disc-shaped support layer comprising the support layer material, wherein the support layer comprises at least two of the cavities and wherein the aerosolgenerating article comprises at least two of the aerosol-generating elements.

16. A method according to claim 15, wherein the cavities of each aerosol-generating article are arranged symmetrically about a centre of the support layer.

17. A method according to claim 15 or 16, wherein the step of providing an article precursor sheet comprises providing a sheet of base layer material and attaching the sheet of support layer material to the sheet of base layer material to form the article precursor sheet, wherein each aerosol-generating article comprises a base layer comprising the base layer material, and wherein the support layer overlies the base layer.

18. A method according to claim 15, 16 or 17, wherein the cutting step comprises cutting at least one aerosol-generating article from the article pre-cursor sheet so that each aerosolgenerating article further comprises a protruding tab connected along a weakened line to an edge of the support layer.

19. A method according to claim 18, wherein the cutting step comprises cutting a cut-out extending through the protruding tab of each aerosol-generating article.

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