Aerosol-generating article comprising aerosol-generating elements

Abstract

There is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article comprises an air inlet, an air outlet and an airflow passage defined between the air inlet and the air outlet. The aerosol-generating article comprises an aerosol-generating substrate. The aerosol-generating substrate comprises an array of aerosol-generating elements and a joining element linking the aerosol-generating elements. The array of aerosol-generating elements comprises a first set of aerosol-generating elements opposing a second set of aerosol-generating elements to define at least a portion of the airflow passage between the first and second sets of aerosol-generating elements.

Description

[0001] FTR3992 / PCT (P / 91018. W001)

[0002] AEROSOL-GENERATING ARTICLE COMPRISING AEROSOL-GENERATING ELEMENTS

[0003] The present disclosure relates to an aerosol-generating article comprising an aerosolgenerating substrate. The present disclosure also relates to a method to manufacturing an aerosolgenerating article.

[0004] Aerosol generating articles comprising an aerosol-generating substrate that is heated rather than combusted are known in the art. Typically, in such aerosol-generating articles an aerosol is generated by the transfer or heat from a heat source to an aerosol-generating substrate.

[0005] Electrically operated aerosol-generating devices, for example handheld aerosol- generating devices, may be used with such aerosol generating articles. Such electrically operated aerosol - generating devices may comprise a heating element configured to heat an aerosol-generating substrate. This releases volatile compounds from the aerosol-generating substrate which are entrained in air drawn through the aerosol generating article. As the released compounds cool, they condense or nucleate to form an aerosol.

[0006] Several examples of aerosol-generating devices for consuming aerosol-generating articles have been disclosed in the art. Such devices include, for example, electrically heated aerosolgenerating devices in which an aerosol is generated by the transfer of heat from one or more electrical heater elements of the aerosol-generating device to the aerosol-generating substrate of an aerosolgenerating article. To this purpose, the aerosol-generating article may be partially received within a heating cavity of the aerosol-generating device.

[0007] For example, heating of the aerosol-generating substrate has been accomplished using external heating, such as by way of a heater element that at least partially defines a heating cavity into which the aerosol-generating article is inserted. Heating of an aerosol-generating substrate by providing an inductive heating element in the form of a susceptor element thermally coupled with the aerosol-generating substrate and capable of being heated when penetrated by a varying magnetic field is also known.

[0008] A number of different aerosol-generating substrates for heated aerosol-generating articles have been disclosed. In some examples, the aerosol-generating article comprises a solid aerosolgenerating substrate, such as a cylindrical rod of a plant material, for example comprising a homogenised tobacco material or tobacco cut filler or a non-tobacco homogenised plant material. Also known is a solid aerosol-generating substrate comprising a gathered sheet of non-tobacco material loaded with nicotine and an aerosol former.

[0009] However, such cylindrical rods of plant material have been found to not always provide optimal aerosol generation when heated, rather than combusted. A rod of cut filler will typically have a relatively high density and a relatively low porosity, due to the way in which the tobacco material is compacted during manufacture. This can present challenges for the uniform heating of the tobacco material, and, in fact, research has shown that a significant proportion of the cylindrical rod may not be sufficiently heated to form an aerosol during use. This proportion of the rod is therefore effectively wasted. In addition, it is important to control to resistance to draw through the article. The air flow through these articles may be relatively random and therefore difficult to predict, providing inconsistent experiences between different articles. Furthermore, the fixed size and shape of the cylindrical rod of tobacco material provides little flexibility for the aerosol-generating substrate to be adapted for use in new, more efficient designs of aerosol-generating article and aerosol-generating device.

[0010] Furthermore, any new aerosol-generating article or substrate would need to be suitable for manufacture at high speed.

[0011] Accordingly, it would be desirable to provide an aerosol-generating article, which can achieve a more efficient generation of aerosol, and which provides an improved and consistent experience for the consumer. Further, it would be desirable to provide an aerosol-generating substrate which is able to generate an improved aerosol without increasing the resistance to draw of an aerosol-generating article including the substrate to an unacceptable level.

[0012] Further, it would be desirable to provide an aerosol-generating substrate which is suitable for use in an aerosol-generating article which is manufactured at high speed.

[0013] According to the present disclosure, there may be provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article may comprise an air inlet, an air outlet and an airflow passage defined between the air inlet and the air outlet. The aerosol-generating article may comprise an aerosol-generating substrate. The aerosolgenerating substrate may comprise an array of aerosol-generating elements. The aerosol-generating substrate may comprise a joining element linking the aerosol-generating elements. The array of aerosol-generating elements may comprise a first set of aerosol-generating elements opposing a second set of aerosol-generating elements and at least a portion of the airflow passage may be defined between the first and second sets of aerosol-generating elements.

[0014] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article comprises an air inlet, an air outlet and an airflow passage defined between the air inlet and the air outlet. The aerosol-generating article comprises an aerosol-generating substrate. The aerosol-generating substrate comprises an array of aerosol-generating elements. The aerosol-generating substrate comprises a joining element linking the aerosol-generating elements. The array of aerosol-generating elements comprises a first set of aerosol-generating elements opposing a second set of aerosolgenerating elements and at least a portion of the airflow passage is defined between the first and second sets of aerosol-generating elements.

[0015] Advantageously, the article of the present disclosure may provide a predictable airflow passage that is defined between two sets of aerosol-generating elements. This may advantageously allow an airflow in the airflow passage to contact the aerosol-generating substrate in multiple places, this may advantageously improve contact between air flow and the aerosol-forming substrate which may increase and improve aerosol formation. Providing the airflow passage that is defined between two set of aerosol-generating elements may lead to a predictable and controlled resistance to draw.

[0016] Linking and supporting the aerosol-generating elements makes it possible for a plurality of aerosol-generating elements to be provided in predefined regular arrangements, which may advantageously facilitate incorporating a given number of elements within a predefined volume. The provision of an aerosol-generating substrate in the form of an array may allow the position of the substrate within the article to be predictable, which may lead to more consistent experiences between different articles. Linking and supporting the aerosol-generating elements also reduces the likelihood of aerosol-generating element from leaking out of the aerosol-generating article.

[0017] The aerosol-generating articles in line with the present disclosure may advantageously have different overall geometries while utilising the same aerosol-forming substrate. This may lead to more efficient manufacturing processes because much of the same manufacturing equipment and processes can be used to produce different shaped articles. Additionally, the size and number of the aerosol-generating elements can be readily adapted to suit the space into which the aerosolgenerating substrate is incorporated.

[0018] The aerosol-generating substrate of the present disclosure therefore offers improved flexibility and versatility. The aerosol-generating substrate finds particular application in planar or flat aerosolgenerating articles, which offer more efficient heating and generation of aerosol due to the flat structure of the aerosol-generating substrate. However, as will become apparent from the following description of a number of different embodiments, the aerosol-generating substrates of the present disclosure can generally be adapted to fit articles of different shapes and sizes.

[0019] The provision of an aerosol-generating substrate in the form of a plurality of linked elements also advantageously provides a substrate with a desirable surface to volume ratio, which optimises release of aerosol from the substrate upon heating.

[0020] The aerosol-generating article according to the present disclosure can be advantageously produced efficiently using known apparatus and methods, with relatively minor modifications.

[0021] The first set of aerosol-generating elements may be adjacent to the second set of aerosolgenerating elements. For example, there may be no component between the adjacent first and second sets of aerosol-generating elements. In other words, no other aerosol-generating element or joining element may be present in the portion of the airflow passage defined between the first and second sets of aerosol-generating elements.

[0022] Preferably, the aerosol-generating substrate is shaped to provide the first set of aerosolgenerating elements opposing the second set of aerosol-generating elements. For example, the array may be shaped to provide the first set of aerosol-generating elements opposing the second set of aerosol-generating elements. The aerosol-generating substrate may be deformed to provide the first set of aerosol-generating elements opposing the second set of aerosol-generating elements. In other words, the aerosol-generating substrate may be formed in a first shape or arrangement, for example as a substantially planar aerosol-generating substrate and then the aerosol-generating substrate may be deformed forexample bent, folded orwound, to provide the first set of aerosol-generating elements opposing the second set of aerosol-generating elements. For example, during manufacture, the first set of aerosol-generating elements may be positioned adjacent to the second set of aerosolgenerating elements, in the final article, the aerosol-generating substrate may be folded, so that the first set of aerosol-generating elements are provided opposing the second set of aerosol-generating elements.

[0023] Advantageously, the provision of the aerosol-generating substrate being shaped or deformed in the aerosol-generating article may allow the aerosol-forming substrate to be mass manufactured using existing methods and then shaped (deformed) to suit the shape required by the aerosolgenerating article. This may allow the aerosol-generating article to be produced using efficient manufacturing techniques, and allow the same techniques for forming an aerosol-generating substrate to be used for different types and shapes of aerosol-generating article, for example the same aerosolgenerating substrate may be shaped to suit either a rod-shaped article or a substantially flat aerosolgenerating article.

[0024] The array of aerosol-generating elements may comprise multiple, or a plurality of, opposing sets of aerosol-generating elements. A portion of the airflow passage may be defined between each opposing set of aerosol-generating elements. For example, the array may be folded several times, for example 2, 3, 4 or 5 times. The array may be rolled such that there are multiple, or a plurality of, opposing sets of aerosol-generating elements, for example rolled about a central axis 2, 3, 4 or 5 full turns. For example, the array of aerosol-generating elements preferably comprises a first set of aerosol-generating elements, a second set of aerosol-generating elements, and a third set of aerosolgenerating elements. Preferably, at least a portion of the airflow passage is defined between the first, second, and third sets of aerosol-generating elements. Preferably, the first set of aerosol-generating elements opposes the second set of aerosol-generating elements. A portion of the airflow passage may be defined between the first and second sets of aerosol-generating elements. The second set of aerosol-generating elements may oppose the third set of aerosol-generating elements. A further portion of the airflow passage may be defined between the second and third set of aerosol-generating elements. Preferably, the first set of aerosol-generating elements faces a first side of the second set of aerosol-generating elements. Preferably, the third set of aerosol-generating elements faces a second side of the second set of aerosol-generating elements, wherein the second side is opposite to the first side. The second set of aerosol-generating elements may be disposed between the first set of aerosol-generating elements and the third set of aerosol-generating elements. Advantageously, providing a plurality of sets of aerosol-generating elements, preferably arranged in a thickness direction, thickness direction, may improve the distribution of aerosol-generating material, for example through the thickness of the aerosol-generating article, and in particular through the air flow passage, which may lead to improved aerosol generation.

[0025] The provision of a portion of the airflow passage being defined between each opposing set of aerosol-generating elements may provide a good dispersion of airflow and heat through the aerosolgenerating substrate during use.

[0026] Preferably, the aerosol-generating substrate is situated in the airflow passage such that air may flow across, through or around, the first set of aerosol-generating elements and the second set aerosol-generating elements. Preferably, at least 50 percent, 60 percent, 70 percent, 80 percent, or 90 percent of a total surface area of the first set of aerosol-generating elements and the second set aerosol-generating elements may be exposed to air in an airflow passage. Advantageously, an increased surface area of the aerosol-generating elements being able to contact air may enhance aerosol generation.

[0027] Preferably, the aerosol-generating substrate is positioned within the airflow passage to allow air to contact an area of the first set of aerosol-generating elements remote from the second set of aerosol-generating elements. Preferably, the aerosol-generating substrate is positioned within the airflow passage to allow air to contact an area of the second set of aerosol-generating elements remote from the first set of aerosol-generating elements.

[0028] For example, each set of aerosol-generating elements may comprise a first side and a second side opposing the first side. Preferably, both the first and second side of each set of aerosol-generating elements may be situated in the airflow passage such that, in use, air may contact both the first side and the second side. For example, when the aerosol-generating article comprises a first set of aerosol-generating elements, a second set of aerosol-generating elements, and a third set of aerosolgenerating elements, at least a portion of the airflow passage is defined between the first and second sets of aerosol-generating elements and at least a portion of the airflow passage is defined between the second and third sets of aerosol-generating elements. In this way, the second set of aerosolgenerating elements may be situated within, for example embedded within, the air flow passage.

[0029] The distance between the first set of aerosol-generating elements and the second set of aerosol-generating elements may be adjusted. The distance may be controlled by adjusting at least one of: a height of the aerosol-generating elements, structure of the joining element and number of sets of opposing of aerosol-generating elements. For example, the number of times an array is folded within a define volume may affect the distance between the first set of aerosol-generating elements and the second set of aerosol-generating elements.

[0030] By adjusting and controlling the size, number and distribution of portions of the airflow passage it is advantageously possible to adjust the heat dispersion across the entire aerosol-generating substrate.

[0031] Preferably, the distance between the first set of aerosol-generating elements and the second set of aerosol-generating elements is between about 10 and 1000 microns, for example between 20 and 800 microns, for example between about 50 and 500 microns. Advantageously, this distance provides a suitable space for air flow between the first set of aerosol-generating elements and the second set of aerosol-generating elements.

[0032] This distance may be a maximum distance taken at the point in which the first set of aerosolgenerating elements is most spaced from the second set of aerosol-generating elements

[0033] Preferably, the portion of the airflow passage between the first and second sets of aerosolgenerating elements has a height of between about 10 and 1000 microns, for example between 20 and 800 microns, for example between about 50 and 500 microns.

[0034] Preferably, the joining element may be flexible to allow the aerosol-generating substrate to be deformed. Advantageously, the joining element being flexible may allow the aerosol-generating elements to be optimised for aerosol-generation, with the joining element being provided to allow the elements to be arranged to fit the aerosol-generating article.

[0035] The aerosol-generating substrate may comprise a first layer comprising the first set of aerosolgenerating elements and a second layer comprising the second set of aerosol-generating elements.

[0036] The joining element may comprise a first joining element and a second joining element. The first joining element may link two or more aerosol generating elements of the first set of aerosolgenerating elements. The second joining element may link two or more aerosol-generating elements of the second set of aerosol-generating elements. The provision of the first joining element and second joining element may allow the first and second sets of aerosol-generating element to be provided separately within the aerosol-generating article, for example as a first layer and a second layer.

[0037] At least one, preferably each one, each of the aerosol-generating elements are substantially planar. Provision of substantially planar aerosol-generating elements may allow the elements to be manufactured using conventional techniques. At least one, preferably each one, each of the aerosolgenerating elements may comprise a crimped material. Advantageously, a material of the aerosolgenerating element being crimped may increase the surface texture of the aerosol-generating element which may increase the surface for exchange between air and the aerosol-generating substrate. This may lead to improved aerosol-generation. A material of the aerosol-generating element being crimped may also reduce the risk of adhesion between layers of the crimped material during manufacture of the aerosol-generating element and may reduce the risk of the aerosol-forming elements from sticking together.

[0038] Each one of the aerosol-generating elements may have any suitable width. At least one, preferably each one, of the aerosol-generating elements may have a width of between 1 millimetre and 30 millimetres, preferably between 2 and 10 millimetres. Preferably at least one, particularly preferably each one, of the aerosol-generating elements may have a width of between 0.25 millimetres and 12 millimetres, between 0.5 millimetres and 6 millimetres, or between 1 millimetre and 5 millimetres. For example, each one of the aerosol-generating elements may have a width of about 4.5 millimetres.

[0039] At least one, preferably each one, of aerosol-generating elements may have a width of between 1 millimetre and 25 millimetres, for example between 2 and 20 millimetres, for example between 3 and 15 millimetres, for example between 4 and 10 millimetres.

[0040] At least one, preferably each one, of the aerosol-generating elements may have a width of at least 0.25 millimetres. For example, at least one, preferably each one, of the aerosol-generating elements may have a width of at least 0.5 millimetres, at least 0.75 millimetres, or at least 1 millimetre.

[0041] At least one, preferably each one, of the aerosol-generating elements may have a width of no more than 12 millimetres. For example, the at least one aerosol-generating element may have a width of no more than 10 millimetres, no more than 8 millimetres, no more than 7 millimetres, no more than 6 millimetres, or no more than 5 millimetres.

[0042] Each one of the aerosol-generating elements may have any suitable length. At least one, preferably each one, of the aerosol-generating elements may have a length of between 1 millimetre and 30 millimetres, preferably between 2 and 10 millimetres. Preferably at least one, particularly preferably each one, of the aerosol-generating elements may have a length of between 0.25 millimetres and 12 millimetres, between 0.5 millimetres and 6 millimetres, or between 1 millimetre and 5 millimetres. For example, each one of the aerosol-generating elements may have a length of about 4.5 millimetres.

[0043] At least one, preferably each one, of aerosol-generating elements may have a length of between 1 millimetre and 25 millimetres, for example between 2 and 20 millimetres, for example between 3 and 15 millimetres, for example between 4 and 10 millimetres. At least one, preferably each one, of the aerosol-generating elements may have a length of at least 0.25 millimetres. For example, at least one, preferably each one, of the aerosol-generating elements may have a length of at least 0.5 millimetres, at least 0.75 millimetres, or at least 1 millimetre.

[0044] At least one, preferably each one, of the aerosol-generating elements may have a length of no more than 12 millimetres. For example, the at least one aerosol-generating element may have a length of no more than 10 millimetres, no more than 8 millimetres, no more than 7 millimetres, no more than 6 millimetres, or no more than 5 millimetres.

[0045] At least one, preferably each one, of aerosol-generating elements may have a thickness of between 20 and 1000 microns, preferably between 50 and 500 microns. At least one, preferably each one, of aerosol-generating elements may have a thickness of between 75 and 450 microns, for example between 100 and 400 microns, for example between 125 and 350 microns, for example between 150 and 300 microns.

[0046] At least one, preferably each one, of the aerosol-generating elements has a first planar surface and a second opposed planar surface. The first planar surface of the at least one aerosol-generating element may have any shape. The second planar surface of the at least one aerosol-generating element may have any shape. The first planar surface and the second planar surface of the at least one aerosol-generating element may have the same shape.

[0047] The first planar surface and the second planar surface of the at least one aerosol-generating element may have a circular shape.

[0048] The provision of a generally circular aerosol-generating element may advantageously make manufacture of an aerosol-generating article comprising the aerosol-generating element more straightforward since the orientation of the aerosol-generating elements when they are added to the aerosol-generating article will not matter.

[0049] The first planar surface and the second planar surface of the at least one aerosol-generating element may have a polygonal shape. For example, the first planar surface and the second planar surface of the at least one aerosol-generating element may have a triangular shape, a square shape, a pentagonal shape, a hexagonal shape, an octagonal shape, or a nonagonal shape.

[0050] Preferably, at least one, preferably each one, of the aerosol-generating elements have a circular cross-section, wherein the width and length are equal, and may be referred to as a diameter.

[0051] At least one, preferably each one, of the aerosol-generating elements has a diameter and a thickness, wherein the ratio of the diameter to the thickness is between 1 and 1000, preferably between 2 and 600. For example, the ratio of the diameter of the at least one aerosol-generating element to the thickness of the at least one aerosol-generating element may be at least 3, at least 4, at least 5, at least 10, at least 15, at least 20, at least 25, or at least 30. The ratio of the diameter of the at least one aerosol-generating element to the thickness of the at least one aerosol-generating element may be at least 40, at least 50, at least 100, at least 150, at least 200, at least 250, or at least 300.

[0052] The ratio of the diameter of the at least one aerosol-generating element to the thickness of the at least one aerosol-generating element may be no more than 550, no more than 500, no more than 450, no more than 400, no more than 350, no more than 300, no more than 250, no more than 200, no more than 150, or no more than 100. The ratio ofthe diameter ofthe at least one aerosol-generating element to the thickness of the at least one aerosol-generating element may be no more than 100, no more than 90, no more than 80, no more than 70, no more than 60, no more than 50, no more than 40, no more than 30, no more than 25, no more than 20, no more than 15, or no more than 10.

[0053] Preferably, the ratio of the diameter of the at least one aerosol-generating element to the thickness of the at least one aerosol-generating element may be between 2 and 500, between 3 and 400, between 4 and 300, between 5 and 200.

[0054] The provision of relatively thin aerosol-generating elements may advantageously increase the surface area of the aerosol-generating substrate. This may improve aerosol generation ofthe aerosolgenerating substrate. In addition, the provision of relatively thin aerosol-generating elements may reduce the thermal inertia of the aerosol-generating substrate, which may advantageously lead to the aerosol-generating substrate increasing its temperature more efficiently when it is heated by a heating element of an aerosol-generating device. This may advantageously ensure aerosol is generated at an earlier point during the heating cycle of the aerosol-generating device.

[0055] The first set of aerosol-generating elements may be arranged in a regular pattern, for example a grid-like pattern. The second set of aerosol-generating elements may be arranged in a regular pattern, for example a grid-like pattern. The array of aerosol-generating elements may be arranged in a regular pattern, for example a grid-like pattern. In other words, the array of aerosol-generating elements may be arranged in a pre-determined pattern.

[0056] The provision of the aerosol-generating elements in a predefined, regular, pattern, may advantageously facilitate incorporating a given number of elements within a predefined volume. The provision of the aerosol-generating elements in a regular pattern may allow the position of the substrate within the article to be predetermined and predictable, leading to more consistent aerosolgeneration.

[0057] Preferably, at least one of aerosol-generating elements partially overlaps with another of the aerosol-generating elements. In other words, each aerosol-generating element may be partially overlapped with an adjacent aerosol-generating element, this may be referred to as a partially overlapping pattern. Preferably, the extent of the overlap between each adjacent aerosol-generating element is the same.

[0058] Arranging the plurality of aerosol-generating elements in a partially overlapping pattern may advantageously maximise the density of aerosol-generating substrate. In addition, the provision of only a partial overlap between adjacent aerosol-generating elements may advantageously provide space for air to pass between adjacent aerosol-generating elements. This may advantageously reduce the resistance to draw (RTD) of an aerosol-generating article comprising the aerosolgenerating elements. The aerosol-generating elements being provided in a partially overlapping pattern may advantageously increase the surface area of aerosol-generating substrate in contact with air flow and thus improve aerosol generation.

[0059] Preferably, the array of aerosol-generating elements comprises a first type of aerosolgenerating element and a second type of aerosol-generating element, different from the first type. The second type of aerosol-generating element may differ from the first type of aerosol-generating element in one or more ways.

[0060] The second type of aerosol-generating element may differ from the first type of aerosolgenerating element chemically or physically or both chemically and physically.

[0061] The second type of aerosol-generating element may differ from the first type of aerosolgenerating element by at least one of: type of aerosol-generating material, amount of aerosolgenerating material, concentration of aerosol-generating material, type of aerosol-former, amount of aerosol-former, concentration of aerosol-former, type of flavourant, amount of flavourant, concentration of flavourant, shape of aerosol-generating element, or size of aerosol-generating element.

[0062] It may be desirable to provide an aerosol-generating article having an aerosol-generating substrate comprising more than one type of aerosol-generating substrate, for example comprising more than one type of aerosol-former. In known aerosol-generating articles, it may be difficult to provide an aerosol-generating article that includes the desired different portions of aerosol-generating substrate, while still providing suitable aerosol formation and having a desired RTD.

[0063] Advantageously, the provision of the aerosol-generating substrate comprising a first type of aerosol-generating element and a different second type of aerosol-generating element may allow a wide variety of flavour and smell profiles can be obtained with aerosol-generating substrates in accordance with the present disclosure. The provision of the aerosol-generating substrate comprising a first type of aerosol-generating element and a different second type of aerosol-generating element may allow the aerosol-generating substrate to have more varied properties, which may provide a more satisfactory user experience. Providing substrate having different concentrations of aerosol-formers or flavours at different portions can provide a more consistent experience, alternatively it may be used to provide an experience that varies. Providing the aerosol-generating elements in this way may allow the article to achieve the benefits of having different types of substrate, while still having a desirable RTD.

[0064] The first type of aerosol-generating element and the second type of aerosol-generating element may be arranged in an alternating pattern. In other words, the aerosol-generating elements in the array may alternate between a first type and second type of aerosol-generating element. The first type of aerosol-generating element may be adjacent to the second type of aerosol-generating element.

[0065] Providing the first and second types of aerosol-generating element in an alternating pattern may allow the different types of aerosol-generating element to be evenly distributed throughout the substrate. This may improve the consistency of aerosol-generation.

[0066] The aerosol-generating elements may further comprise a third type of aerosol-generating element. The third type may be different from the first and a second types of aerosol-generating element.

[0067] The third type of aerosol-generating element may differ from the first type of aerosolgenerating element and second type of aerosol-generating element in one or more ways. The third type of aerosol-generating element may differ from the first type of aerosol-generating element or the second type of aerosol-generating element by at least one of: type of aerosol-generating material, amount of aerosol-generating material, concentration of aerosol-generating material, type of aerosolformer, amount of aerosol-former, concentration of aerosol-former, type of flavourant, amount of flavourant, concentration of flavourant, shape of aerosol-generating element, or size of aerosolgenerating element.

[0068] Providing a third type of aerosol-generating element may provide the benefits associated with providing the first and second types as well as allowing even more variety in the type of flavour or experience to be achieved.

[0069] The aerosol-generating substrate, in particular the aerosol-generating elements, may comprise any aerosol-generating material. The aerosol-generating substrate may comprise tobacco. For example aerosol-generating substrate may comprise at least one of cast leaf tobacco material, extruded tobacco material, reconstituted tobacco material, tobacco cut filler, shredded tobacco.

[0070] Preferably, the aerosol-generating substrate comprises cast-leaf tobacco, for example at least one, preferably all, of the aerosol-generating elements comprises cast-leaf tobacco.

[0071] The aerosol-generating substrate may comprise homogenised plant material, preferably a homogenised tobacco material.

[0072] As used herein, the term “homogenised plant material” encompasses any plant material formed by the agglomeration of particles of plant. For example, sheets or webs of homogenised tobacco material for the aerosol-generating substrates of the present disclosure may be formed by agglomerating particles of tobacco material obtained by pulverising, grinding or comminuting plant material and optionally one or more of tobacco leaf lamina and tobacco leaf stems. The homogenised plant material may be produced by casting, extrusion, paper making processes or other any other suitable processes known in the art.

[0073] Each aerosol-generating element may comprise at least 10 percent by weight of an aerosol former, on a dry weight basis. For example, the aerosol-generating substrate may comprise at least 15 percent by weight of an aerosol former, on a dry weight basis.

[0074] In certain embodiments, the aerosol-generating substrate comprises at least 18 percent by weight of an aerosol former, on a dry weight basis. Preferably, the aerosol-generating substrate comprises at least 20 percent by weight of an aerosol former, on a d ry weight basis. More preferably, the aerosol-generating substrate comprises at least 25 percent by weight of an aerosol former, on a dry weight basis. Even more preferably, the aerosol-generating substrate comprises at least 30 percent by weight of an aerosol former, on a dry weight basis.

[0075] The aerosol-generating substrate may comprise less than or equal to 60, 55, 50 or 45 percent by weight of an aerosol former, on a dry weight basis.

[0076] In some examples, the aerosol-generating substrate comprises from 10 percent by weight to 60 percent by weight, preferably from 10 percent by weight to 55 percent by weight, more preferably from 10 percent by weight to 50 percent by weight, even more preferably from 10 percent by weight to 45 percent by weight of an aerosol former, on a dry weight basis.

[0077] The aerosol former may be any suitable compound or mixture of compounds that, in use, facilitates formation of a dense and stable aerosol and is substantially resistant to thermal degradation at the operating temperature of an aerosol-generating article comprising the aerosol-generating substrate. Suitable aerosol formers are for example: polyhydric alcohols such as, for example, triethylene glycol, 1 ,3-butanediol, propylene glycol and glycerine; esters of polyhydric alcohols such as, for example, glycerol mono-, di- or triacetate; aliphatic esters of mono-, di- or polycarboxylic acids such as, for example, dimethyl dodecanedioate and dimethyl tetradecanedioate; and combinations thereof.

[0078] The aerosol former may comprise a polyhydric alcohol. The aerosol former may comprise one or more of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol. The aerosol former may comprise glycerine.

[0079] The joining element may link the aerosol-generating elements to form the array. The joining element may comprise a carrier sheet for carrying the aerosol-generating elements. The provision of the carrier sheet may provide a joining element that also provides support to the array of aerosolgenerating elements, is easy to manufacture, and the resulting aerosol-generating substrate may be easy to handle.

[0080] The joining element may comprise an adhesive. The adhesive may be configured to adhere at least one, preferably each one, of the aerosol-generating elements to the carrier sheet.

[0081] The joining element may comprise at least one thread. The joining element may comprise the at least one thread passing through at least one aerosol-generating element. The joining element may comprise one thread of at least one thread passing through each one of the aerosol-generating elements. The at least one thread may comprise one thread configured to join multiple, or a plurality of, aerosol-generating elements together. The at least one thread may comprise multiple , or a plurality of, threads, each thread configure to attach an aerosol-generating element to the carrier sheet. For example, the at least one thread may comprise a first thread configured to link a first aerosolgenerating element to the carrier sheet and a second thread configured to link a second aerosolgenerating element to the carrier sheet. Advantageously, the joining element comprising at least one thread may allow the aerosol-generating element to be linked to each other with little, minimal or no adhesive. Adhesives may impart an undesirable flavour that may be generated when the aerosolgenerating article is heated.

[0082] Preferably, the array of aerosol-generating elements may be connected to the carrier sheet by the at least one thread. For example, the joining element may comprise the carrier sheet and the at least one thread.

[0083] Preferably, the carrier sheet is fluid permeable to allow air and aerosol through the carrier sheet. Advantageously, the carrier sheet does not act as a barrier to airflow and therefore does not significantly impact RTD. A further advantage of the carrier sheet being fluid permeable is that air and aerosol may be able to mix more within the substrate, leading to a more consistent aerosol.

[0084] The joining element may be substantially free of aerosol former. Alternatively, the joining element may comprise a flavourant or a further aerosol former. The joining element may comprise at least one of an aerosol-generating material, an aerosol former and a flavourant. The joining element may be coated with, sprayed with, impregnated with, or otherwise contain at least one of an aerosol-generating material, an aerosol former and a flavourant.

[0085] The joining element may comprise natural fibres such as cotton. For example, the joining element may comprise a cotton thread. The joining element may comprise a cotton carrier sheet. The carrier sheet may comprise a weaved fabric sheet.

[0086] Preferably, the aerosol-generating article may comprise a susceptor element. The susceptor element may be in thermal contact with the aerosol-generating substrate. The susceptor element may be positioned between the first set of aerosol-generating elements and the second set of aerosolgenerating elements.

[0087] Advantageously, the presence of the susceptor element may allow the aerosol-generating article, and thus the aerosol-generating substrate, to be heated by engagement with a fluctuating electromagnetic field formed by an inductor.

[0088] The susceptor element may be one or more particles, strips, threads, or wires of susceptor material. The susceptor element may be one or more sheets or layers of susceptor material. The one of more sheets or layers of susceptor material may be in the form of a mesh of susceptor material.

[0089] The susceptor element, in whatever form, may comprise one or more materials selected from the list consisting of: aluminium, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0090] The joining element may comprise the susceptor element. For example, the joining element may comprise a thread comprising one or more wires of susceptor material. Advantageously, the provision of the joining element comprising the susceptor element may allow the array of aerosolgenerating elements to be in close proximity and preferably contact with the susceptor element, to provide efficient heating of the aerosol-generating elements.

[0091] The aerosol-generating article may comprise a rod of aerosol-generating substrate. The aerosolgenerating substrate may be rolled to form a rod. Further, the aerosol-generating article may comprise a wrapper circumscribing the aerosol-generating substrate.

[0092] The aerosol-generating article preferably comprises one or more elements in addition to the rod of aerosol-generating substrate, wherein the rod and the one or more elements are assembled within a cigarette paper. For example, aerosol-generating article may further comprise at least one of: a mouthpiece, such as a mouthpiece comprising a segment of filtration material like a plug of cellulose acetate tow; an aerosol-cooling element; and a support element, such as a hollow acetate tube.

[0093] For example, in one preferred embodiment, an aerosol-generating article may comprise, in linear sequential arrangement, the rod of aerosol-generating substrate as described above, a support element located immediately downstream of the aerosol-generating substrate, an aerosol-cooling element located downstream of the support element, and an outer wrapper circumscribing the rod, the support element and the aerosol-cooling element.

[0094] The aerosol-generating article may be defined by an article length, an article width, and an article thickness. Preferably the article width is greater than the article thickness. The article length may extend in a length direction. The article width may extend in a width direction. The article thickness may extend in a thickness direction.

[0095] Preferably, the aerosol-generating article may comprise a first planar layer extending in a first plane and a second planar layer extending in a second plane, the second plane being parallel to and spaced from the first plane. A thickness of the aerosol-generating article may extend in a direction perpendicular to the first plane and the second plane.

[0096] Preferably, the first set of aerosol-generating elements and the second set of aerosolgenerating elements are arranged in the thickness direction of the aerosol-generating article. In other words, preferably the first set of aerosol-generating elements are spaced from, and opposed, to the second set of aerosol-generating elements in the thickness direction of the aerosol-generating article. The first set of aerosol-generating elements and the second set of aerosol-generating elements are preferably aligned in the width direction and the length direction but are spaced in the thickness direction.

[0097] Preferably, the aerosol-generating substrate comprises a plurality of sets of aerosolgenerating elements, arranged in the thickness direction.

[0098] The first set of aerosol-generating elements may form a first layer and the second set of aerosol-generating elements may form a second layer. Preferably, the first layer and the second layer are stacked in a thickness direction of the aerosol-generating article. When the aerosol-generating substrate comprises a plurality of sets of aerosol-generating elements, preferably each set of aerosolgenerating elements are arranged, for example, distributed, stacked, or layered, in the thickness direction of the aerosol-generating article. For example, when the aerosol-generating substrate comprises a first set of aerosol-generating elements, a second set of aerosol-generating elements, and a third set of aerosol-generating elements, the first second and third sets of aerosol-generating elements are preferably arranged, for example stacked or layered, in the thickness direction of the aerosol-generating article. Advantageously, providing a plurality of sets of aerosol-generating elements, preferably arranged in the thickness direction, may improve the distribution of aerosolgenerating substrate through the thickness of the aerosol-generating article, and in particular through the air flow passage, which may lead to improved aerosol generation.

[0099] Preferably, the aerosol-generate substrate is arranged between the first planar layer and the second planar layer. Preferably, the first set of aerosol-generating elements and the second set of aerosol-generating elements are arranged between the first planar layer and the second planar layer. Preferably, the first set of aerosol-generating elements and the second set of aerosol-generating elements are arranged substantially parallel to the first planar layer and the second planar layer.

[0100] Preferably, a cavity is defined between the first planar layer and the second planar layer. A height of the cavity may be defined by the distance between a lower surface of the first planar layer and an upper surface of the second planar layer. The thickness of the aerosol-generating article may be less than 5 millimetres. The height of the cavity may be greater than 50 percent of the thickness of the aerosol-generating article. The aerosol-generating substrate is preferably located in the cavity.

[0101] The aerosol-generating article of the present disclosure may be generally flat and thin, for example having a thickness of less than 5 millimetres. Advantageously, the provision of a generally flat and thin aerosol-generating article provides for rapid and efficient heating of aerosol-generating substrate in the aerosol-generating article and improved uniformity in through-thickness heating.

[0102] The cavity may be in fluid communication with the air inlet, the air outlet and the airflow passage. The airflow passage may extend between the air inlet and the air outlet through the cavity.

[0103] Advantageously, the cavity height is relatively tall, for example the height of the cavity may be greater than 50 percent of the thickness of the aerosol-generating article. The provision of a cavity height that is generally tall provides space for adequate airflow through the aerosol-generating article despite the article being generally flat and thin. The cavity height may allow, in use, air to flow more slowly through the cavity compared to cavity having a lesser height, thereby providing improved contact between the air flow and aerosol-forming material of the aerosol-generating article, enhanced mixing of generated aerosol and air in the cavity, and improved aerosolisation.

[0104] The aerosol-generating article may comprise a frame positioned between the first planar layer and the second planar layer, the frame at least partially defining the cavity. Advantageously, the frame may allow the aerosol-generating article to be relatively thin whilst maintaining structural rigidity. The frame may comprise a peripheral wall at least partially circumscribing or encircling the cavity. The frame may comprise a peripheral wall wholly circumscribing or encircling the cavity. Advantageously, the peripheral wall allows for a relatively large internal volume for the aerosol-generating substrate for aerosol formation whilst providing structural strength to maintain the shape of the aerosol-generating article. The frame may define the air inlet and the air outlet. The frame is a separate component to the joining element. In other words, the frame and joining element are not unitary or integral with each other. Advantageously, this may allow the manufacture of the frame separately to the aerosolgenerating substrate, the two components may then be assembled. Preferably, the planar layers are a separate component to the joining element. In other words, the planar layers and joining element are not unitary or integral with each other. Advantageously, this may allow the manufacture of the planar layers separately to the aerosol-generating substrate, the two components may then be assembled.

[0105] A resistance to draw (RTD) of the aerosol-generating article, along the airflow passage between the air inlet and the air outlet, may be less than 20 millimetre H2O.The aerosol-generating article preferably has a resistance to draw (RTD) of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in the direction of the airflow passage. Preferably, the aerosol-generating article has a RTD of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in at least one direction in an x / y plane of the aerosol-generating article. An aerosol-generating article with a low resistance airflow path may allow for superior air-flow management and allow aerosol to be extracted more efficiently from the aerosol-generating article and guided to a user.

[0106] Unless otherwise specified, the resistance to draw (RTD) is measured in accordance with ISO 6565-2015. The RTD refers to the pressure required to force air through the full length of a component, such as the aerosol-generating article. The terms “pressure drop” or “draw resistance” of a component or article may also refer to the “resistance to draw”. Such terms generally refer to the measurements made in accordance with ISO 6565-2015 and are normally carried out at under test at a volumetric flow rate of about 17.5 millilitres per second at the output or downstream end of the measured component at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr) and a relative humidity of about 60 percent.

[0107] According to the present disclosure, there may be provided a method for manufacturing an aerosol-generating article. The method may comprise forming an aerosol-generating substrate. The step of forming an aerosol-generating substrate may comprise the step of providing aerosolgenerating elements. The step of forming an aerosol-generating substrate may comprise the step of linking the aerosol-generating elements together with a joining member to form an array. The method for manufacturing an aerosol-generating article may comprise providing an air inlet, an air outlet and an airflow passage defined between the air inlet and the air outlet. The method for manufacturing an aerosol-generating article may comprise the step of shaping the aerosol-generating substrate to provide a first set of aerosol-generating elements opposing a second set of aerosol-generating elements to define at least part of the airflow passage between the first and second sets of aerosolgenerating elements.

[0108] The method of the present disclosure may be suitable for manufacturing an aerosol-generating article according to any aerosol-generating article of the present disclosure.

[0109] The step of providing aerosol-generating elements may comprise forming sheets of aerosolgenerating element material and cutting the sheets to form the aerosol-generating elements.

[0110] Cutting the sheets of aerosol-generating element material to form the aerosol-generating elements may comprise cutting a large sheet aerosol-generating element material into a number of smaller sheets of aerosol-generating element material. This step of cutting the large sheet may comprise cutting the large sheet along a longitudinal direction . Preferably, the width of the smaller sheet is between 5 and 20 centimetres, for example between 10 and 15 centimetres, preferably between 12 and 15 centimetres, for example about 12.5 centimetres. Cutting the sheets may further comprise cutting a smaller sheet of the smaller sheets of aerosol-generating element material into strips of aerosol-generating element material. This step of cutting the smaller sheet may comprise cutting the smaller sheet along a longitudinal direction of the smaller sheet to form the strips. Preferably, the width of the strip of aerosol-generating element material is between 1 and 20 millimetres, for example between 2 and 15 millimetres, preferably between 2 and 10 millimetres, for example about 5 millimetres.

[0111] The step of cutting the sheets of aerosol-generating element material to form the aerosolgenerating elements may also comprise cutting the strips of aerosol-generating element material to form aerosol-generating elements. This step of cutting the strips of aerosol-generating element material to form aerosol-generating elements may comprise cutting the strips along a lateral direction of the strips to form the aerosol-generating elements.

[0112] Advantageously, cutting the sheets of aerosol-generating element material to form the aerosolgenerating elements utilising the multiple steps of cutting advantageously requires less cutting equipment, such as the number of knives requires is reduced.

[0113] The method may comprise shaping the strips of aerosol-generating element material to form outlined strips having an outline corresponding to a shape of the aerosol-generating elements. For example, the outlined strip may represent various shapes of aerosol-generating element, for example circular disks, connected by small bars.

[0114] The method may comprise providing a removable protection layer under the sheets of aerosolgenerating element material, for example under the strip of aerosol-generating element material. The method may comprise removing the removable protection layer from the aerosol-generating element material before cutting. Advantageously, the removable protection layer may be provided to protect the aerosol-generating element material and prevent it from sticking to itself.

[0115] Preferably, the removable protection layer has a width equal to or greater than a width of the strip of aerosol-generating element material. For example the removable protection layer may have a width equal to or greater than 1 millimetre, for example 2 millimetres, for example 5 millimetres, for example 10 millimetres. The width of the removable protection layer being equal to or greater than the width of the strip of aerosol-generating element material may prevent the strip of aerosol-generating element material from contacting itself during processing, for example if the strip of aerosol-generating element material is wound into a roll for storage, it may not stick to itself. Alternatively, the removable protection layer may have a width that is less than a width of the strip of aerosol-generating element material. This may make it easier to remove the removable protection layer from the strip of aerosolgenerating element material, with a lower risk of damaging the strip of aerosol-generating element material.

[0116] The step of shaping the aerosol-generating substrate may comprise bending, folding or rolling the array.

[0117] The step of linking the aerosol-generating elements together with a joining member to form the array may comprise stitching the aerosol-generating elements to a carrier sheet for carrying the aerosol-generating elements, using a thread.

[0118] The step of linking the aerosol-generating elements together with a joining member to form the array may comprising stitching each aerosol-generating element to the carrier sheet with a different thread.

[0119] The step of linking the aerosol-generating elements together with a joining member to form the array may comprise stitching all of the aerosol-generating elements together using the thread.

[0120] As used herein, the term “aerosol-generating substrate” refers to a substrate capable of releasing upon heating volatile compounds, which can condense to form an aerosol.

[0121] As used herein, the term “aerosol” denotes a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. The aerosol may be visible or invisible. The aerosol may include vapours of substances that are ordinarily liquid or solid at room temperature as well as solid particles, or liquid droplets, or a combination of solid particles and liquid droplets.

[0122] As used herein, the term “aerosol-generating article” refers to an aerosol-generating article for producing an aerosol comprising an aerosol-generating substrate that is intended to be heated rather than combusted in order to release volatile compounds that can form an aerosol.

[0123] As used herein, the term “aerosol-generating device” denotes a device that interacts with an aerosol-generating substrate to generate an aerosol. In some examples, an aerosol-generating device heats the aerosol-generating substrate to facilitate release of volatile compounds from the aerosol-generating substrate.

[0124] As used herein, a "susceptor" refers to a conductive element that heats up when subjected to a changing magnetic field. This may be the result of eddy currents induced in the susceptor element and / or hysteresis losses.

[0125] As used herein, the term “rod” refers to a generally cylindrical element of substantially circular, oval or elliptical cross-section.

[0126] As used herein, the term “planar” refers to a feature generally formed in a single Euclidean plane and not wrapped around or otherwise conformed to fit a curved or other non -planar shape. A planar surface may extend in two dimensions in a single Euclidean plane. A planar object may extend in two dimensions in a single Euclidean plane substantially more than in a third dimension perpendicular to the plane. More specifically, a planar object may extend in a first dimension and a second dimension perpendicular to the first dimension at least two, five or ten times further than the object extends in a third dimension perpendicular to the first and second dimensions.

[0127] As used herein, the term “transverse” refers to a direction extending between a first planar external surface or layer and a second planar external surface or layer.

[0128] As used herein, the term “longitudinal” refers to a direction that is perpendicular to the transverse direction.

[0129] As used herein, the term “lateral” refers to a direction that is perpendicular to the transverse direction and the longitudinal direction.

[0130] As used herein, the term “thickness” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in a transverse direction.

[0131] As used herein, the term “length” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the longitudinal direction.

[0132] As used herein, the term “width” refers to a maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the lateral direction.

[0133] As used herein, the term “aerosol former” may refer to any suitable known compound or mixture of compounds that, in use, facilitates formation of an aerosol. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-generating substrate or aerosol-generating article.

[0134] As used herein, the term “aerosol former content” may refer to aerosol former content in percent on a dry weight basis, unless otherwise specified.

[0135] As used herein, a content of a component of the aerosol-generating substrate on a “dry weight basis” refers to the weight of a particular non-water component relative to the sum of the weights of all non-water components in a mixture, expressed as a percentage. A mass ratio of two or more components of an aerosol-generating substrate on a “dry weight basis” refers to a ratio of the weight of a particular non-water component relative to another particular non-water component.

[0136] 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. Ex1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the article comprising: an air inlet, an air outlet and an airflow passage defined between the air inlet and the air outlet; and an aerosol-generating substrate comprising: an array of aerosol-generating elements; and a joining element linking the aerosol-generating elements, wherein the array of aerosol-generating elements comprises a first set of aerosol-generating elements opposing a second set of aerosol-generating elements and at least a portion of the airflow passage is defined between the first and second sets of aerosol-generating elements.

[0137] Ex2. The aerosol-generating article according to example Ex1 , wherein the first set of aerosolgenerating elements is adjacent to the second set of aerosol-generating elements.

[0138] Ex3. The aerosol-generating article according to example Ex1 or Ex2, wherein the aerosolgenerating substrate is shaped to provide the first set of aerosol-generating elements opposing the second set of aerosol-generating elements.

[0139] Ex4. The aerosol-generating article according to example Ex3, wherein the aerosol-generating substrate is deformed, forexample bent, folded, orwound, to provide the first set of aerosol-generating elements opposing the second set of aerosol-generating elements.

[0140] Ex5. The aerosol-generating article according to example Ex4, wherein the joining element is flexible to allow the aerosol-generating substrate to be deformed.

[0141] Ex6. The aerosol-generating article according to any preceding example, wherein the aerosolgenerating substrate comprises a first layer comprising the first set of aerosol-generating elements and a second layer comprising the second set of aerosol-generating elements.

[0142] Ex7. The aerosol-generating article according to any preceding example, wherein the joining element comprises: a first joining element linking two or more aerosol-generating elements of the first set of aerosol-generating elements; and a second joining element linking two or more aerosolgenerating elements of the second set of aerosol-generating elements.

[0143] Ex8. The aerosol-generating article according to any preceding example, wherein at least one, preferably each one, each of the aerosol-generating elements comprises a crimped material.

[0144] Ex9. The aerosol-generating article according to any preceding example, wherein at least one, preferably each one, of the aerosol-generating elements is substantially planar.

[0145] Ex10. The aerosol-generating article according to any preceding example, wherein at least one, preferably each one, of the aerosol-generating elements has a first substantially planar surface and a second opposed substantially planar surface.

[0146] Ex11. The aerosol-generating article according to any preceding example, wherein at least one, preferably each one, of the aerosol-generating elements has a diameter and a thickness, wherein the ratio of the diameter to the thickness is between 1 and 1000, preferably between 2 and 600.

[0147] Ex12. The aerosol-generating article according to any preceding example, wherein at least one, preferably each one, of aerosol-generating elements has a width of between 1 millimetre and 30 millimetres, preferably between 2 and 10 millimetres. Ex13. The aerosol-generating article according to any preceding example, wherein at least one, preferably each one, of aerosol-generating elements has a length of between 1 millimetre and 30 millimetres, preferably between 2 and 10 millimetres.

[0148] Ex14. The aerosol-generating article according to any preceding example, wherein at least one, preferably each one, of aerosol-generating elements has a thickness of between 50 and 500 microns. Ex15. The aerosol-generating article according to any preceding example wherein at least one, preferably each one, of the aerosol-generating elements is preferably disc-shaped, wherein the width and length are both equal to a diameter.

[0149] Ex16. The aerosol-generating article according to any preceding example, wherein the first set of aerosol-generating elements are arranged in a regular pattern, for example a grid-like pattern.

[0150] Ex17. The aerosol-generating article according to any preceding example, wherein the second set of aerosol-generating elements are arranged in a regular pattern, for example a grid-like pattern.

[0151] Ex18. The aerosol-generating article according to any preceding example, wherein the array of aerosol-generating elements is arranged in a regular pattern.

[0152] Ex19. The aerosol-generating article according to any preceding example, wherein at least one of aerosol-generating elements partially overlaps with another of the aerosol-generating elements.

[0153] Ex20. The aerosol-generating article according to any preceding example, wherein the aerosolgenerating elements comprises a first type of aerosol-generating element and a second type of aerosol-generating element, different from the first type.

[0154] Ex21. The aerosol-generating article according to example Ex20, wherein the second type of aerosol-generating element differs from the first type of aerosol-generating element by at least one of: type of aerosol-forming material, amount of aerosol-forming material, type of aerosol-former, amount of aerosol-former, type of flavourant, amount of flavourant, shape, or size.

[0155] Ex22. The aerosol-generating article according to example Ex20 or Ex21 , wherein the first type aerosol-generating element and the second type aerosol-generating element are provided in an alternating pattern.

[0156] Ex23. The aerosol-generating article according to any preceding example, wherein the aerosolgenerating substrate comprises cast-leaf tobacco, for example at least one, preferably all, of the aerosol-generating elements comprises cast-leaf tobacco.

[0157] Ex24. The aerosol-generating article according to any preceding example, wherein the joining element comprises a thread passing through at least one aerosol-generating element.

[0158] Ex25. The aerosol-generating article according to any preceding example, wherein the joining element comprises a thread passing through each of the aerosol-generating elements.

[0159] Ex26. The aerosol-generating article according to any preceding example, wherein the joining element comprises a carrier sheet for carrying the aerosol-generating elements.

[0160] Ex27. The aerosol-generating article according to any preceding example, wherein the joining element comprises an adhesive that adheres at least two aerosol-generating elements to the carrier sheet. Ex28. The aerosol-generating article according to any preceding example, wherein the aerosolgenerating elements are connected to the carrier sheet by a thread passing through each of the aerosol-generating elements.

[0161] Ex29. The aerosol-generating article according to any preceding example, wherein the carrier sheet is fluid permeable to allow air and aerosol through the carrier sheet.

[0162] Ex30. The aerosol-generating article according to any preceding example, wherein the joining element comprises an aerosol-former.

[0163] Ex31. The aerosol-generating article according to any preceding example, wherein the joining element comprises a flavourant.

[0164] Ex32. The aerosol-generating article according to any preceding example, wherein the array of aerosol-generating elements comprises multiple, or a plurality of, opposing sets of aerosol-generating elements and a portion of the airflow passage is defined between each opposing set of aerosolgenerating elements.

[0165] Ex33. The aerosol-generating article according to any preceding example, wherein the aerosolgenerating article comprises a susceptor element.

[0166] Ex34. The aerosol-generating article according to example Ex33, wherein the susceptor element is positioned between the first set of aerosol-generating elements and the second set of aerosolgenerating elements.

[0167] Ex35. The aerosol-generating article according to example Ex33 or Ex34, wherein the joining element comprises the susceptor element.

[0168] Ex36. The aerosol-generating article according to any preceding example, wherein the aerosolgenerating article comprises a cavity.

[0169] Ex37. The aerosol-generating article according to example Ex36, wherein the aerosol-generating substrate is positioned in the cavity.

[0170] Ex38. The aerosol-generating article according to any preceding example, wherein the aerosolgenerating article comprises a first planar layer and a second planar layer facing in substantially the opposite direction to the first planar layer.

[0171] Ex39. The aerosol-generating article according to example Ex38 or Ex39, wherein the first set of aerosol-generating elements and the second set of aerosol-generating elements are arranged between and substantially parallel to the first external surface and the second external surface.

[0172] Ex40. The aerosol-generating article according to any of examples Ex36 to Ex39, wherein the aerosol-generating article cavity is located between the first planar layer and the second planar layer. Ex41. The aerosol-generating article according to example Ex40, wherein the aerosol-generating article comprising a frame positioned between the first planar layer and the second planar layer, the frame at least partially defining the cavity.

[0173] Ex42. The aerosol-generating article according to example Ex41 , wherein the frame comprises a peripheral wall circumscribing or encircling the cavity.

[0174] Ex43. The aerosol-generating article according to example Ex41 or Ex42, wherein the frame defines the air inlet and the air outlet. Ex44. The aerosol-generating article according to any preceding example, the article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness.

[0175] Ex45. A method for manufacturing an aerosol-generating article, the method comprising the steps of: forming an aerosol-generating substrate comprising the steps of: providing aerosol-generating elements; linking the aerosol-generating elements together with a joining member to form an array; providing an air inlet, an air outlet and an airflow passage defined between the air inlet and the air outlet; and shaping the aerosol-generating substrate to provide a first set of aerosol-generating elements opposing a second set of aerosol-generating elements to define at least part of the airflow passage between the first and second sets of aerosol-generating elements.

[0176] Ex46. The method for manufacturing an aerosol-generating article according to example Ex45, wherein providing aerosol-generating elements comprises forming sheets of aerosol-generating element material and cutting the sheets to form the aerosol-generating elements.

[0177] Ex47. The method for manufacturing an aerosol-generating article according to example Ex46, comprising the step of providing a removable protection layer under the sheets and removing the protection layer before cutting.

[0178] Ex48. The method for manufacturing an aerosol-generating article according to any one of examples Ex45 to Ex47, wherein shaping the aerosol-generating substrate comprises bending, folding or rolling the aerosol-generating substrate.

[0179] Ex49. The method for manufacturing an aerosol-generating article according to any one of examples Ex45 to Ex48, wherein linking the aerosol-generating elements together with a joining member to form the array comprises stitching the aerosol-generating elements to a carrier sheet for carrying the aerosol-generating elements using a thread.

[0180] Ex50. The method for manufacturing an aerosol-generating article according to any one of examples Ex45 to Ex49, comprising attaching each aerosol-generating element to the carrier sheet with a different thread.

[0181] Ex51 . The method for manufacturing an aerosol-generating article according to any one of examples Ex45 to Ex50, wherein linking the aerosol-generating elements together with a joining member to form an array comprises stitching all of the aerosol-generating elements together using a thread.

[0182] Examples will now be further described with reference to the figures in which:

[0183] Figure 1 shows an exploded perspective view of an aerosol-generating article according to a first embodiment of the disclosure;

[0184] Figure 2 shows a perspective view of the aerosol-generating article of Figure 1 ;

[0185] Figure 3a shows a cross-sectional top view of an aerosol-generating article according to a second embodiment of the present disclosure;

[0186] Figure 3b shows a cross-sectional side view of the aerosol-generating article of Figure 3a; Figure 4 shows a perspective view of an aerosol-generating article according to a third embodiment of the present disclosure;

[0187] Figure 5a shows a top view of a portion of an aerosol-generating substrate according to a fourth embodiment of the present disclosure;

[0188] Figure 5b shows a side view of the portion of the aerosol-generating substrate of Figure 5a;

[0189] Figure 6 shows a method of manufacturing an aerosol-generating article according to the present disclosure;

[0190] Figure 7 shows a perspective view of an apparatus for manufacturing an aerosol-generating substrate according to the present disclosure; and

[0191] Figure 8 shows a method of manufacturing aerosol-generating elements according to the present disclosure.

[0192] Figure 1 shows an exploded perspective view of the aerosol-generating article 10 article according to a first embodiment of the disclosure.

[0193] The aerosol-generating article 10 comprises a first planar external layer 24 forming a first planar external surface 21 , a second planarexternal Iayer25 forming a second planar external surface 22, and a frame 40 positioned between the first planarexternal layer 24 and the second planarexternal layer 25. The first planar external layer 24 and the second planar external layer 25 may be formed from a non-aerosol forming material, such as paper or card. Alternatively, either of the first planar external layer 24 and the second planar external layer 25 may comprise an aerosol-generating substrate comprising an aerosol-generating material, for example tobacco.

[0194] The aerosol-generating article 10 comprises a frame 40. The frame 40 is made from cardboard and defines a frame aperture extending through the thickness of the frame 50. The frame aperture at least partially forms a cavity 30.

[0195] The first planar external layer 24 and the second planar external layer 25 have a thickness of 200 micrometres, when the aerosol-generating article is assembled the first planar external layer 24 and the second planar external layer 25 are in physical contact with the frame 40. The first planar external layer 24 and the second planar external layer 25 are bonded to the frame with an adhesive 15 between the frame 40 and the first planar external layer 24 and between the frame 40 and the second planar external layer 25. The first planar external layer 24 overlies an end of the cavity 30 and forms a first cavity end wall 31 . The second planar external layer 25 overlies an opposite end of the cavity 30 and forms a second cavity end wall 32. That is, the frame 40, the first planar external layer 24 and the second planar external layer 25 collectively define the cavity 30. In this example, the first planar external layer 24 comprises a cellulosic material, such as for example cardboard or paper. In this example, the second planar external layer 25 comprises a cellulosic material, such as for example cardboard or paper.

[0196] The frame 40 comprises a peripheral wall 41 that circumscribes the cavity 30. The peripheral wall 41 has a radial thickness of about 2 millimetres.

[0197] An air inlet 14 and an air outlet 12 are defined by, and extend through, the peripheral wall 41 of the frame 40. The air inlet 14 is positioned opposite the air outlet 12, on the opposite wall of the frame 40. The air inlet 14 and the air outlet 12 each have a rectangular cross-section, a width of 2 millimetres, and a thickness of 0.9 millimetres. An airflow passage extends between the air inlet 14 and the air outlet 12 through the cavity 30 and through the aerosol-generating substrate 50. The air inlet 14 and air outlet 12 are aligned with the central longitudinal axis of the aerosol-generating article 10.

[0198] An aerosol-generating substrate 50 in accordance with the present disclosure (shown schematically in Figure 1) is positioned in the cavity 40. The aerosol-generating substrate 50 may alternatively be of the type described with reference to any of the Figures 3a to 5b.

[0199] In the first embodiment, the aerosol-generating substrate 40 comprises an array of aerosolgenerating elements 52 and a joining element 60 linking the aerosol-generating elements 52. The array of aerosol-generating elements 52 comprises a first set of aerosol-generating elements 54 opposing a second set of aerosol-generating elements 56 and at least a portion of the airflow passage is defined between the first set aerosol-generating elements 54 and the second set aerosol-generating elements 56. The second set aerosol-generating elements 56 are not visible in Figure 1 .

[0200] In the example shown in Figure 1 , the array of aerosol-generating elements 52 comprises a first type 54a of aerosol-generating element, a second type 54b of aerosol-generating element, and a third type 54c of aerosol-generating element. The first 54a, second 54b, and third 54c types of aerosolgenerating elements are all different. In this embodiment, the first type 54a of aerosol-generating element comprises cast leaf tobacco and about 35 percent by weight of an aerosol former on a dry weight basis, wherein the aerosol former comprises glycerine. The second type 54b of aerosolgenerating element comprises cast leaf tobacco and about 35 percent by weight of an aerosol former on a dry weight basis, wherein the aerosol former comprises glycerine, and additionally a flavourant. The third type 54c of aerosol-generating element comprises cast leaf tobacco and about 30 percent by weight of an aerosol former on a dry weight basis, wherein the aerosol former comprises glycerine, and additionally a flavourant. Each of the aerosol-generating elements comprise a crimped material.

[0201] The first 54a, second 54b, and third 54c types of aerosol-generating elements are provided in an alternating pattern. In this embodiment, the array of aerosol-generating elements are arranged in a regular pattern. The pattern comprises rows and columns of aerosol-generating elements. A first row of aerosol-generating element comprises the first 54a type of aerosol-generating elements, a second row of aerosol-generating element comprises the second 54b type of aerosol-generating elements, a third row of aerosol-generating element comprises the third 54c type of aerosol-generating elements. The columns of aerosol-generating elements therefore alternate between the first 54a, second 54b, and third 54c types of aerosol-generating elements.

[0202] Each of the aerosol-generating elements are substantially planar. Each have a first planar surface and a second opposed planar surface. The first and second planar surfaces are circular and have a diameter of about 5 millimetres wide. The first and second planar surfaces are separated by a thickness of the aerosol-generating element. The thickness of the aerosol-generating element is about 100 microns. So the ratio of the diameter to the thickness is about 50.

[0203] The joining element 60 comprises a carrier sheet 64 and an adhesive (not shown). The array of aerosol-generating elements 52 are attached to the carrier sheet 64 with the adhesive. The carrier sheet 64 is folded to form the airflow passage between the first set aerosolgenerating elements 54 and the second set aerosol-generating elements 56. By folding the carrier sheet 64, multiple, or a plurality of, layers of aerosol-generating elements are formed, with portions of the airflow passage defined between each layer. The carrier sheet 64 is fluid permeable to allow air and aerosol through the carrier sheet 64.

[0204] The carrier sheet 64 is folded twice. The first fold is configured to provide first the set of aerosolgenerating elements 54 opposing the second set of aerosol-generating elements 56 to define a portion of the airflow passage between the first 54 and second 56 sets of aerosol-generating elements. The second fold is configured to provide second the set of aerosol-generating elements 56 opposing a third set of aerosol-generating elements 58 to define a further portion of the airflow passage between the second 56 and third 58 set of aerosol-generating elements. In the example shown in Figure 1 , at least a portion of the airflow passage is defined between the first, second and second third sets of aerosol-generating elements.

[0205] Each of the aerosol-generating elements 52 has a circular cross-section, having a diameter of 5 millimetres and each aerosol-generating element has a thickness of 100 microns.

[0206] Figure 2 shows a perspective view of the aerosol-generating article 10 article.

[0207] The aerosol-generating article 10 has a length extending in the x-direction, a width extending in the y- direction and a thickness extending in the z-direction. The aerosol-generating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.1 millimetres.

[0208] The first planar external surface 21 and the second planar external surface 22 extend in the x-direction and the y-direction. That is, the first planar external surface 21 and the second planar external surface 22 extend in the x / y plane. The first planar external surface 21 is positioned parallel to the second planar external surface 22 and the first planar external surface 21 is spaced from the second planar external surface 22 in the z-direction or transverse direction. The distance between the first planar external surface 21 and the second planar external surface 22 in the z-direction or transverse direction corresponds to the thickness of the aerosol-generating article 10.

[0209] The aerosol-generating article 10 is a substantially flat aerosol-generating article or substantially planar aerosol-generating article. In particular, the thickness of the aerosol-generating article 10 is less than 50 percent of both the length and the width of the aerosol-generating article. The aerosol-generating article 10 has a generally rectangular cuboid shape and a laminated structure formed by the first planar external layer 24, the frame 40 and the second planar external layer 25. The first planar external layer 24, the frame 40 and the second planar external layer 25 are bonded together with an adhesive, in particular guar gum.

[0210] The frame 40 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 2.7 millimetres. The frame 40 is made from cardboard and defines a frame aperture extending through the thickness of the frame 40. The frame aperture at least partially forms a cavity 30. The cavity 30 has length of 26 millimetres, a width of 6 millimetres, and a thickness of 2.7 millimetres. Therefore, the cavity 30 has a volume of about 421 .2 cubic millimetres.

[0211] The aerosol-generating article 10 of Figure 1 is intended for use with an aerosol-generating device comprising a device cavity into which the aerosol-generating 10 can be inserted. In use of the aerosol-generating article 10, the array of aerosol-generating elements 52 are heated to cause the aerosol-generating substrate to release volatile compounds which are then entrained in air drawn through the air inlet 14 into the cavity 30. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the aerosol-generating article 10 through the air outlet 12.

[0212] Figure 3a shows a cross-sectional top view of a aerosol-generating article according to a second embodiment of the present disclosure.

[0213] The aerosol-generating article 110 shown in Figure 3a is identical to the article shown in the Figures 1 and 2, except where described below. Where the features are identical, the same reference number have been used.

[0214] In this embodiment, the aerosol-generating substrate 150 comprises an array of aerosolgenerating elements 152 and a joining element 160.

[0215] Each aerosol-generating element in the array of aerosol-generating elements 152 has a first planar surface and a second planar surface (shown in Figure 3b). In the example shown in Figures 3a and 3b, both the first planar surface 158 and the second planar surface 159 are circular in shape.

[0216] The joining element 160 comprises a thread 162 that attaches an aerosol-generating element to an adjacent aerosol-generating element. In this example, the thread 162 comprises multiple, or a plurality of, threads, with each thread linking a row of aerosol-generating elements to each other. The joining element 160 further comprises a carrier sheet 164. The thread 162 links the array of aerosolgenerating elements to the carrier sheet 164. The array of aerosol-generating elements 132 are arranged in a regular, partially overlapping pattern.

[0217] The thread 162 comprises threads that pass through each of the aerosol-generating elements 132 to join each of the aerosol-generating elements to the carrier sheet 164. In the example shown in Figure 3a, the thread 162 passes from the first planar surface 158 of an aerosol-generating element to the second planar surface 159 of the aerosol-generating element, and then from the second planar surface 159 through the carrier sheet 164. In Figure 3a the dotted sections of the thread 162 show where the thread passes behind the aerosol-generating element.

[0218] Figure 3b shows a cross-sectional side view of the aerosol-generating article 110 of Figure 3a. In Figure 3b the dotted sections of the thread 162 show where the thread 162 passes through the aerosol-generating element or the carrier sheet 164. The aerosol-generating substrate 150 comprises multiple, or a plurality of, layers. In this embodiment, the aerosol-generating substrate 150 comprises a first layer comprising the first set of aerosol-generating elements, a second layer comprising the second set of aerosol-generating elements, third layer comprising a third set of aerosol-generating elements, a fourth layer comprising a fourth set of aerosol-generating elements. As shown in Figure 3b, a portion of the airflow passage is defined between each set of aerosol-generating elements.

[0219] The joining element 160 comprises: a first joining element linking the aerosol-generating elements of the first set of aerosol-generating elements; a second joining element linking the aerosolgenerating elements of the second set of aerosol-generating elements; a third joining element linking the aerosol-generating elements of the third set of aerosol-generating elements; and a fourth joining element linking the aerosol-generating elements of the fourth set of aerosol-generating elements. Figure 4 shows a perspective view of an aerosol-generating substrate 250 according to a third embodiment of the present disclosure. In this embodiment, the aerosol-generating substrate 250 comprises one type of aerosol-generating element, for example the first type described in relation to Figure 1 .

[0220] An array of aerosol-generating elements 252 are linked by a carrier sheet 260. The carrier sheet 260 is rolled to provide a first set of aerosol-generating elements 254 opposing a second set of aerosolgenerating elements 256. The spacing created by the array of aerosol-generating elements in the rolled substrate provides space between the first set of aerosol-generating elements 254 and the second set of aerosol-generating elements 256. This is space is provided so that, when the aerosolgenerating substrate is arranged as part of an aerosol-generating article, a portion of the airflow passage of the aerosol-generating article is defined between the first set of aerosol-generating elements 254 and the second set of aerosol-generating elements 256. The aerosol-generating substrate 250 is a cylindrical rod.

[0221] The aerosol-generating substrate 250 comprises a susceptor element 270. The susceptor element 270 is elongate and extends longitudinally through the centre of the rolled aerosol-generating substrate 250. The carrier sheet 260 circumscribes the susceptor element 270. The susceptor element 270 is thermally coupled to the array of aerosol-generating elements 252.

[0222] The rolled aerosol-generating substrate 250 may be situated in a cavity of an article as shown in Figures 1 -3b. Alternatively, the rolled substrate may be situated between a downstream element and an upstream element. A wrapper may circumscribe the rolled substrate, downstream element and the upstream element to form a rod-shaped aerosol-generating article. The downstream element is preferably a cylindrical mouthpiece element.

[0223] Figure 5a shows a schematic top view of a portion of an aerosol-generating substrate according to a fourth embodiment of the present disclosure. In this embodiment the aerosol-generating substrate comprises a first type 354a of aerosol-generating element, a second type 354b of aerosol-generating element. The first type 354a of aerosol-generating element and second type 354b of aerosolgenerating element may be identical to the first 54a and second 54b aerosol-generating elements described with reference to Figure 1. The array of aerosol-generating elements are linked together with a joining element comprising a thread 362.

[0224] Figure 5b shows a schematic cross-sectional view of the portion of the aerosol-generating substrate shown in Figure 5a.

[0225] The first type 354a of aerosol-generating element and second type 354b of aerosol-generating element are situated next to each other and arranged in an alternating pattern. The first type 354a of aerosol-generating element and a second type 354b of aerosol-generating element are partially overlapping. As shown in Figure 5b, there is spacing between the aerosol-generating elements, such that in use, air may flow between the first type 354a of aerosol-generating element, a second type 354b of aerosol-generating element.

[0226] The joining element 360 comprises the thread 362 and carrier sheet 364. The thread 362 comprises multiple, or a plurality of, threads. Each thread extend through the carrier sheet 364 and an aerosol-generating element. Figure 6 shows a method of manufacturing an aerosol-generating article. In particular, Figure 6 shows a method of manufacturing an aerosol-generating substrate and the substrate may be used in the manufacture of a rod-shape aerosol generating article or a substantially planar aerosol-generating article.

[0227] Initially, a thin layer of slurry for forming an aerosol-generating element is casted on a metal belt conveyor. This layer passes into ovens, where it is dried. The resulting dried paper-like sheet is about 3 metres wide and is wound to be stored in large bobbins. This step is not illustrated in Figure 6.

[0228] The sheets from these large bobbins are then unwound and cut in small bands.

[0229] The method comprises winding up a small band into a small bobbin.

[0230] According to the present disclosure, the method comprises the first step 400 of providing the small bobbin 402. The small band 404 that forms the small bobbin 402 has a width WB of between about 10 and 15 centimetres.

[0231] Preferably, the method comprises a second step 410 of unwinding the small bobbin 402 and passing the small band 404 through a crimping rollers 412 to form a crimped band of aerosolgenerating element precursor 414. The crimping rollers 412 comprise transversal grooves that create longitudinal grooves in the aerosol-generating element precursor, to form the crimped aerosolgenerating element precursor 414. In other embodiments, the method may not comprise the second step 410, instead the small band may be unwound but not crimped.

[0232] These steps can use conventional manufacturing equipment and techniques.

[0233] After the second step 410, the crimped band of aerosol-generating element precursor 414 is cut, this is a third step 420. The third step 420 comprises cutting the crimped band of aerosolgenerating element precursor 414 into several smaller strips. The cutting is done with circular knives 426 each strip 424 being between 1 and 20 millimetres wide, preferable about 2 to 10 millimetres wide, for example 5 millimetres wide.

[0234] A fourth step 430 comprises winding a strip 424 into a small bobbin 432. The small bobbin has a width Wsof about 5 millimetres.

[0235] The method shown in Figure comprises an optional fifth step 440. The fifth step comprising unwinding the strip 424 form the small bobbin 432 and shaping the strip 424 to create an outlined strip 444. The shaping the strip 424 comprises passing the strip 424 between shaping rollers 442 of a rotary die to cute the strip 424 to create the outlined strip 444. The outlined strip can represent various shapes of aerosol-generating element (for example circular discs) connected by small bars. It should be understood, that in other examples, the outlines may represent different shapes, e.g. diamonds.

[0236] The fifth step 440 is optional. In other embodiments, no additional shaping of the strip 424 may be required, for example to produce aerosol-generating elements that are square or rectangular.

[0237] The outlined strips 444 can be wound up to form bobbins for storage or transport. Or the outlined strips 444 can pass directly to the next step.

[0238] In a sixth step, the outlined strip 444 is cut to form aerosol-generating elements. The sixth step comprises cutting the outlined strip 444. The sixth step 450 comprises cutting the outlined strip 444 across the small bars connecting the circular discs, to form circular aerosol-generating elements 454. The cutting is done with a simple transversal cut through the bar portions. The circular aerosol-generating elements 454 comprise a first circular planar surface and an opposing planar circular surface.

[0239] Figure 6 shows a machine 458 holding a bobbin 459 of the outlined strip 444. The bobbin 459 is unwound and cut by the machine 458.

[0240] The method of manufacturing according to this embodiment further comprises linking the aerosol-generating elements 454 together with an joining element to form an array. The joining element comprises a carrier sheet 456. Linking the aerosol-generating elements 454 together comprises attaching the aerosol-generating elements 454 to the carrier sheet 456. The carrier sheet 456 may be any as described herein, for example a woven fabric sheet.

[0241] In this embodiment the machine 458 is configured to attach the aerosol-generating elements 454 to the carrier sheet 456 to form an array of aerosol-generating elements 454. The attaching comprises attaching the aerosol-generating elements 454 to the carrier sheet 456 with adhesive. The machine 458 comprises a nozzle for applying adhesive to the aerosol-generating elements 454 or the carrier sheet 456. The aerosol-generating elements 454 are then adhered to the carrier sheet 456 by the adhesive to form an array of aerosol-generating elements.

[0242] The carrier sheet 456 with the aerosol-generating elements 454 attached cut into smaller pieces, referred to an aerosol-generating substrate, sized for use in an aerosol-generating article.

[0243] The aerosol-generating substrate may be arranged as part of a substantially planar aerosolgenerating article.

[0244] A seventh step 460 of manufacturing an aerosol-generating article 460 comprises folding the carrier sheet 456 to provide a first set of aerosol-generating elements 464 opposing a second set of aerosol-generating elements 466. The folding of the array forms a space for an airflow passage between the first set aerosol-generating elements 464 and the second set aerosol-generating elements 466. By folding the carrier sheet 456, multiple, or a plurality of, layers of aerosol-generating elements are formed. Portions of an airflow passage can be defined between each layer.

[0245] An eighth step 470 comprises providing an air inlet 474, an air outlet and an airflow passage defined between the air inlet and the air outlet. In this embodiment, the air flow passage extends through a cavity. The aerosol-generating substrate 462 is positioned in the cavity such that a portion of the airflow passage is defined between the first set aerosol-generating elements 464 and the second set aerosol-generating elements 466.

[0246] The aerosol-generating substrate is also suitable to form part of a rod-shaped aerosolgenerating article. So in an alternative seventh step, the method may comprise rolling the aerosolgenerating substrate to form a rod of aerosol-generating substrate 482. Rolling the aerosol-generating substrate provides a first set aerosol-generating elements opposing a second set aerosol-generating elements, with a space between the first set aerosol-generating elements and the second set aerosolgenerating elements for airflow to pass through. The rod of aerosol-generating substrate 482 may comprise the features described with reference to the aerosol-generating substrate 250 described with reference to Figure 4. In an alternative eighth step 490, the rod of aerosol-generating substrate 482 is assembled between upstream and downstream elements to form an aerosol-generating article. The upstream and downstream elements comprise an air inlet and an air outlet, respectively. An airflow passage is defined between the air inlet, the air outlet and through the aerosol-generating substrate 482. A portion of the airflow passage is defined between the first set aerosol-generating elements and the second set aerosol-generating elements of the rod of aerosol-generating substrate 482.

[0247] Figure 7 shows a perspective view of an apparatus for manufacturing an aerosol-generating substrate according to the present disclosure.

[0248] The apparatus comprises a machine 558. The machine 558 is similar to the machine 458 and is configured to carry out the same manufacturing step.

[0249] The machine 558 is fed by two bobbins. A first bobbin 559 comprises a first type of material for forming a first type of aerosol-generating element and the second bobbin 569 comprises a second type of aerosol-generating material for forming a second type of aerosol-generating element.

[0250] The machine 558 is situated adjacent to, for example above, a sheet of material configured to form a carrier sheet of the aerosol-generating substrate.

[0251] The machine 558 comprises at least one knife 562 configured to cut the first type of material and the second type of material, to form first and second types of aerosol-generating element.

[0252] The machine 558 unwind a portion of the first type of material and the second type of material from their respective bobbins 559, 569. The knife 562 is configured to move perpendicular to a surfaced of the first type of material and the second type of material and provide a cut through the thickness of the materials, to provide the first and second types of aerosol-generating element.

[0253] The machine 558 comprises an arm 564 that is configured to move the aerosol-generating elements to an attachment site on the carrier sheet.

[0254] The machine 558 comprises an attachment tool 566 for attaching the aerosol-generating elements to the carrier sheet. In this example, the attachment tool 566 comprises a needle bar and a needle. The attachment tool 566 in this example is configured to attach the aerosol-generating elements to the carrier sheet by sewing. The needle passes through a centre of an aerosol-generating element, with a thread to stitch it to the carrier sheet.

[0255] The attachment tool 566 is configured to attach the aerosol-generating elements in a predetermined pattern. The pattern includes an arrangement of the first type of aerosol-generating element and the second type of aerosol-generating elements in alternating rows.

[0256] The apparatus comprises actuators, such as rollers or conveyors (not shown), configured to move the carrier sheet with respect to the attachment tool 566, so that the attachment tool can attach the aerosol-generating elements according to the desired pattern to form an array of aerosolgenerating elements.

[0257] The method of manufacturing the aerosol-generating article may comprise utilising multiple, or a plurality of, machines 558 for each sheet of material configured to form a carrier sheet of the aerosol-generating substrate. These machines are coordinated (meaning they are doing simultaneously the same tasks) and are disposing the aerosol-generating elements following the same pattern.

[0258] Figure 8 shows a step in the method of manufacturing aerosol-generating elements according to the present disclosure. In particular, Figure 8 illustrates one example of the fifth method step described above with reference to Figure 6, in which a strip is cut to form an outlined strip. Figure 8 further illustrates one example of the sixth method step, described with reference to Figure 6, in which an outlined strip is cut to form aerosol-generating elements.

[0259] In the method illustrated in Figure 8, comprises shaping the strip 624. Shaping the strip 624 comprises passing the strip 624 between shaping rollers 642 of a rotary die to cut the strip 624 to create the outlined strip 644.

[0260] The method shown in Figure 8 comprises providing a removable protection layer 648. The removable protection layer 648 is provided under the layer of the outlined strip 644 of the aerosol - generating element material to protected the outlined strip 644 and prevent it from sticking to itself. The removable protection layer 648 is fed from a bobbin 658 of removable protection layer material to a roller 668. The roller 668 receives a feed of the removable protection layer 648 from the bobbin 658 and a feed of the outlined strip 644 from the cutting rollers 642. The roller 668 provides the removable protection layer 648 under the outlined strip 644, to form a combined strip 670.

[0261] The removable protection layer 648 preferably has a width equal to or greater than a maximum width of the outlined strip 644. In this embodiment, the outlined strip is rectilinear.

[0262] In a further step the combined strip may be wound up to form a roll of combined strip. The roll of combined strip may be stored. The roll of combined strip may be a convenient form for storing and transporting the combined strip. This step is optional.

[0263] The method shown in Figure 8 further comprises feeding the combined strip 670 onto a splitting roller 672. The splitting roller 672 may be configured to separate the removable protection layer 648 from the combined strip 670, so that the outlined strip 644 can be further processed without the removable protection layer 648. The removable protection layer 648, after being separated from the outlined strip 644, can be wound up to form a roll of removable protection layer 648, which may be re-used.

[0264] The method then comprises cutting the outlined strip 644 to form an aerosol-generating element, the step of cutting may be done in accordance with the description of cutting related to Figure 6 or Figure 7.

[0265] 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 percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

Claims1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the article comprising: an air inlet, an air outlet and an airflow passage defined between the air inlet and the air outlet; and an aerosol-generating substrate comprising: an array of aerosol-generating elements; and a joining element linking the aerosol-generating elements, wherein the array of aerosol-generating elements comprises a first set of aerosol-generating elements, a second set of aerosol-generating elements, and a third set of aerosol-generating elements arranged in a thickness direction of the aerosol-generating article, wherein the first set of aerosolgenerating elements opposes the second set of aerosol-generating elements, and the third set of aerosol-generating elements opposes the second set of aerosol-generating elements, and at least a portion of the airflow passage is defined between the first, second, and third sets of aerosol-generating elements.

2. The aerosol-generating article according to claim 1 , wherein the aerosol-generating substrate is shaped to provide the first set of aerosol-generating elements opposing the second set of aerosolgenerating elements.

3. The aerosol-generating article according to claim 1 or 2, wherein each of the aerosolgenerating elements are substantially planar.

4. The aerosol-generating article according to any preceding claim, wherein each of aerosolgenerating elements has a diameter of between 1 millimetre and 30 millimetres, preferably between 2 and 10 millimetres.

5. The aerosol-generating article according to any preceding claim, wherein each of aerosolgenerating elements has a thickness of between 50 and 500 microns.

6. The aerosol-generating article according to any preceding claim, wherein the array of aerosolgenerating elements are arranged in a regular pattern.

7. The aerosol-generating article according to any preceding claim, wherein the array of aerosolgenerating elements comprises a first type of aerosol-generating element and a second type of aerosol-generating element, different from the first type.

8. The aerosol-generating article according to claim 7, wherein the second type of aerosolgenerating element differs from the first type of aerosol-generating element by at least one of: type of aerosol-forming material, amount of aerosol-forming material, type of aero so I -former, amount of aerosol-former, type of flavourant, amount of flavourant, aerosol-generating element shape, or aerosol-generating element size.

9. The aerosol-generating article according to any preceding claim, wherein the joining element comprises a thread passing through at least one aerosol-generating element.

10. The aerosol-generating article according to any preceding claim, wherein the joining element comprises a carrier sheet for carrying the array of aerosol-generating elements.

11. The aerosol-generating article according to claim 10, wherein the carrier sheet is fluid permeable to allow air and aerosol through the carrier sheet.

12. The aerosol-generating article according to any preceding claim, wherein the joining element comprises a susceptor element.

13. The aerosol-generating article according to any preceding claim, wherein the aerosolgenerating article comprises a cavity, wherein the aerosol-generating substrate is positioned in the cavity.

14. The aerosol-generating article according to claim 13, wherein the aerosol-generating article comprises a first planar layer, a second planar layer, and a frame positioned between the first planar layer and the second planar layer, the frame at least partially defining the cavity.

15. A method for manufacturing an aerosol-generating article, the method comprising the steps of: forming an aerosol-generating substrate comprising the steps of: providing aerosol-generating elements; linking the aerosol-generating elements together with a joining member to form an array; providing an air inlet, an air outlet and an airflow passage defined between the air inlet and the air outlet; and shaping the aerosol-generating substrate to provide a first set of aerosol-generating elements opposing a second set of aerosol-generating elements, and a third set of aerosol-generating elements opposing the second set of aerosol-generating elements, wherein the first, second and third sets of aerosol-generating elements are arranged in a thickness direction of the aerosol-generating article, and at least part of the airflow passage being defined between the first, second, and third sets of aerosol-generating elements.

Images