WO2025132210A1

WO2025132210A1 - Aerosol-generating article

Info

Publication number: WO2025132210A1
Application number: PCT/EP2024/086562
Authority: WO
Inventors: Matteo Bologna; Onur DAYIOĞLU
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2023-12-21
Filing date: 2024-12-16
Publication date: 2025-06-26
Anticipated expiration: 2026-06-21

Abstract

There is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article is defined by an article length, an article width, and an article thickness. The article width is greater than the article thickness. The aerosol-generating article comprises opposed discrete upper and lower exterior walls, a cavity, an airflow passage and a wrapped body of aerosol-forming substrate. The upper and lower exterior walls collectively define all or a majority of a perimeter of the aerosol-generating article. The cavity is located within the aerosol-generating article between the upper exterior wall and the lower exterior wall. The airflow passage is defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity. The wrapped body of aerosol-forming substrate is disposed within the cavity. The wrapped body comprises a wrapper at least partially enclosing aerosol-forming substrate. The wrapper defines a band circumscribing the aerosol-forming substrate, the band having a length extending between opposed first and second axial end faces of the wrapped body.

Description

AEROSOL-GENERATING ARTICLE

The present disclosure relates to an aerosol-generating article comprising an aerosolforming substrate.

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

Research has shown that, in such a typical aerosol-generating article comprising a plug of aerosol-forming substrate, a significant portion of the plug of aerosol-forming substrate may not be sufficiently heated to form an aerosol during use. This is undesirable since this portion of the plug of aerosol-forming substrate contributes to the cost of manufacture and transport of the aerosol-generating article, but does not contribute to the aerosol delivered to an end user. This may be the case regardless of the way in which the aerosol-forming substrate is heated, for example regardless of whether a resistive or inductive heater is used and regardless of whether the plug of aerosol-forming substrate is heated from the inside or the outside.

It is an aim of the present disclosure to provide an aerosol-generating article, in which a greater portion of an aerosol-forming substrate of the aerosol-generating article is sufficiently heated to form an aerosol during use.

According to the present disclosure, there may be provided an aerosol-generating article comprising an aerosol-forming substrate for producing an aerosol, the aerosol-generating article being a planar aerosol-generating article having a base defined by a length extending in an x direction, a width extending in a y direction, and a height extending in a z direction. The aerosolgenerating article may comprise opposed discrete upper and lower exterior walls, the upper and lower exterior walls collectively defining all or a majority of a perimeter of the aerosol-generating article. A cavity may be located within the aerosol-generating article between the upper exterior wall and the lower exterior wall. A wrapped body of aerosol-forming substrate may be disposed within the cavity, the wrapped body comprising a wrapper at least partially enclosing aerosolforming substrate.

According to the present disclosure, there may be provided an aerosol-generating article comprising an aerosol-forming substrate for producing an aerosol, the aerosol-generating article comprising a substantially planar upper surface defined by a length extending in an x direction and a width extending in a y direction, and a substantially planar lower surface defined by a length extending in an x direction and a width extending in a y direction. The substantially planar upper surface and the substantially planar lower surface may be vertically spaced from each other by a height defined in a z direction. The upper surface may form at least part of an upper exterior wall of the aerosol-generating article and the lower surface may form at least part of a lower exterior wall of the aerosol-generating article. The upper and lower exterior walls may be discrete and distinct from each other. The upper and lower exterior walls may collectively define all or a majority of a perimeter of the aerosol-generating article. A cavity may be located within the aerosolgenerating article between the upper exterior wall and the lower exterior wall. A wrapped body of aerosol-forming substrate may be disposed within the cavity, the wrapped body comprising a wrapper at least partially enclosing aerosol-forming substrate.

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

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

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%. The aerosol-generating article according to any of the aspects disclosed herein may comprise substantially planar upper and lower surfaces. The substantially planar upper surface may form at least part of the upper exterior wall. The substantially planar lower surface may form at least part of the lower exterior wall. A vertical separation between the substantially planar upper and lower surfaces may define a height (for example, a z dimension) of the aerosol-generating article. An air flow channel may be defined between the substantially planar upper and lower surfaces. The height of the aerosol-generating article may be less than 5 millimetres, for example between 1 .5 millimetres and 5 millimetres, for example between 1 .5 millimetres and 4 millimetres, for example between 1 .5 millimetres and 3 millimetres, for example between 1 .5 millimetres and 2 millimetres. One or both of the substantially planar upper and lower surfaces may comprise an aerosol-forming substrate. The aerosol-generating article may comprise upper and lower layers. The upper layer may form at least part of the upper exterior wall. The lower layer may form at least part of the lower exterior wall.

According to the present disclosure, there may be provided an aerosol-generating article comprising a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer. At least one of the first planar layer, the second planar layer and the corrugated layer may comprise or consist of an aerosol-forming substrate. A cavity may be located within the aerosol-generating article between the first planar layer and the second planar layer. A wrapped body of aerosol-forming substrate may be disposed within the cavity, the wrapped body comprising a wrapper at least partially enclosing aerosol-forming substrate.

The cavity may be defined by the corrugated layer, for example by one or more corrugations of the corrugated layer.

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

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

Preferably, the upper exterior wall and the lower exterior wall may define respective upper and lower planar exterior surfaces.

The first exterior wall and the second exterior wall may define respective first and second outwardly convex exterior surfaces. Preferably, the first and second outwardly convex exterior surfaces may collectively define a lenticular profile.

Opposed ends of the upper exterior wall may meet corresponding opposed ends of the lower exterior wall to define a pair of laterally opposed edges of the aerosol-generating article.

The aerosol-forming substrate of the wrapped body may have a bulk density in a range of between 150 mg per cubic centimetre and 500 mg per cubic centimetre. The aerosol-generating substrate of the wrapped body may have a bulk density of between 175 mg per cubic centimetre and 475 mg per cubic centimetre. The aerosol-generating substrate of the wrapped body may have a bulk density of between 200 mg per cubic centimetre and 450 mg per cubic centimetre. The aerosol-generating substrate of the wrapped body may have a bulk density of between 225 mg per cubic centimetre and 425 mg per cubic centimetre. The aerosol-generating substrate of the wrapped body may have a bulk density of between 250 mg per cubic centimetre and 400 mg per cubic centimetre. The aerosol-generating substrate of the wrapped body may have a bulk density of between 275 mg per cubic centimetre and 375 mg per cubic centimetre. The aerosolgenerating substrate of the wrapped body may have a bulk density of between 300 mg per cubic centimetre and 350 mg per cubic centimetre.

The aerosol-generating substrate of the wrapped body may have a bulk density of between 50 mg per cubic centimetre and 900 mg per cubic centimetre. The aerosol-generating substrate of the wrapped body may have a bulk density of between 100 mg per cubic centimetre and 800 mg per cubic centimetre. The aerosol-generating substrate of the wrapped body may have a bulk density of between 200 mg per cubic centimetre and 700 mg per cubic centimetre. The aerosolgenerating substrate of the wrapped body may have a bulk density of between 200 mg per cubic centimetre and 600 mg per cubic centimetre. The aerosol-generating substrate of the wrapped body may have a bulk density of between 200 mg per cubic centimetre and 500 mg per cubic centimetre. The aerosol-generating substrate of the wrapped body may have a bulk density of between 200 mg per cubic centimetre and 400 mg per cubic centimetre.

The wrapped body of aerosol-forming substrate may occupy between 15% and 100% of an interior volume of the cavity, for example between 30% and 100% of an interior volume of the cavity, for example between 50% and 100% of an interior volume of the cavity, for example between 50% and 90% of an interior volume of the cavity, for example between 50% and 80% of an interior volume of the cavity, for example between 50% and 70% of an interior volume of the cavity. A length of the wrapped body may extend along between 15% and 100% of a length of the cavity, for example between 30% and 100% of a length of the cavity, for example between 50% and 100% of a length of the cavity, for example between 50% and 90% of a length of the cavity, for example between 50% and 80% of a length of the cavity, for example between 50% and 70% of a length of the cavity.

The wrapped body may extend across the entirety of a width of the cavity.

Conveniently, the wrapped body may be in surface contact with opposing interior walls of the cavity to maintain the wrapped body in fixed position within the cavity.

The wrapped body may extend along the entirety of a length of the cavity.

A clearance may be defined between an exterior surface of the wrapped body and an interior surface of one or more of the cavity, the first exterior wall and the second exterior wall. The clearance may define at least part of the airflow passage. The clearance may define one or more channels aligned parallel with the length of the aerosol-generating article. The clearance may comprise at least one channel having a width of less than 1 millimetre, for example a width of less than 0.5 millimetres, for example a width of less than 0.25 millimetres, for example a width of less than 0.1 millimetres. The presence of such a clearance or channel facilitates ease of insertion of the wrapped body within the interior of the aerosol-generating article between the upper exterior wall and the lower exterior wall, as well as increasing the contact area between air flow and the wrapped body of aerosol-forming substrate. Preferably, the clearance or channel extends along the entire length of the wrapped body of aerosol-forming substrate.

The wrapper may comprise or consist of a cellulosic material. By way of example, the cellulosic material may be paper or cardboard.

The wrapper may comprise or consist of a thermally-conductive material. The thermally conductive material may have a thermal conductivity of at least 10 W/mK. By way of example, the thermally-conductive material may be a metal foil. The metal foil may be an aluminium foil.

The wrapper may be configured to be porous. By way of example, the wrapper may comprise a plurality of perforations. The wrapper may be in the form of a mesh, for example the wrapper may be a metal mesh. Interstices defined by the mesh may provide a path for the passage of air flow from one side of the mesh to another side of mesh.

The wrapper may encapsulate the entirety of the aerosol-forming substrate. Where the wrapper encapsulates the entirety of the aerosol-forming substrate, the use of a porous wrapper facilitates the passage of air flow through the wrapped body of aerosol-forming substrate.

The wrapper may define a band circumscribing the aerosol-forming substrate. The band may have a length extending between opposed first and second axial end faces of the wrapped body. Preferably, the aerosol-forming substrate may be exposed at the opposed first and second axial end faces of the wrapped body. Conveniently, the wrapper comprises or consists of a sheet material having opposed first and second end portions, wherein the sheet material circumscribes the aerosol-forming substrate such that one of the first and second end portions overlaps the other of the first and second end portions to define the band.

Conveniently, a first wrapper may encapsulate the entirety of the aerosol-forming substrate and a second wrapper define a band circumscribing the aerosol-forming substrate. The band may have a length extending between opposed first and second axial end faces of the wrapped body. The first wrapper may have a greater level of porosity than the second wrapper. So, the porous nature of the first wrapper may serve to permit the passage of air flow through the aerosol-forming substrate, with the band-shaped second wrapper providing structural support surrounding the aerosol-forming substrate. Conveniently, the second wrapper comprises or consists of a sheet material having opposed first and second end portions, wherein the sheet material circumscribes the aerosol-forming substrate such that one of the first and second end portions of the second wrapper overlaps the other of the first and second end portions of the second wrapper to define the band.

The first wrapper may comprise a plurality of perforations. The first wrapper may be in the form of a mesh, for example the wrapper may be a metal mesh.

The second wrapper may be impermeable. For example, the second wrapper may be water impermeable.

The second wrapper may have a higher thermal conductivity than the first wrapper. The second wrapper may comprise or consist of a metal foil, for example the metal foil being an aluminium foil. The use of a thermally conductive material for the second wrapper assists in spreading heat imparted to the second wrapper (by a heating element) across the exterior surface of the wrapped body, thereby assisting in heating of the aerosol-forming substrate enclosed within the wrapped body. Further, the use of a thermally conductive material for the second wrapper may also reduce the likelihood of ignition of the aerosol-forming substrate in the event that a user should attempt to ignite the aerosol-generating article like a conventional cigarette. This latter advantage is particularly relevant when the aerosol-forming substrate includes an aerosol former to promote the generation of aerosol from the aerosol-forming substrate through heating rather than burning of the substrate.

In one example, the second wrapper may be positioned outward of the first wrapper. In another example, the first wrapper may be positioned outward of the second wrapper.

The aerosol-forming substrate may be in the form of any one or more of shredded aerosolforming substrate, strips of aerosol-forming substrate, strands of aerosol-forming substrate, particles of aerosol-forming substrate, one or more sheets of aerosol-forming substrate, one or more gathered sheets of aerosol-forming substrate, cut filler dispersed within a solid binder matrix, a plurality of beads of aerosol-forming substrate.

The aerosol-forming substrate preferably comprises tobacco, for example, tobacco cut filler or cast leaf tobacco. The aerosol-forming substrate may comprise an aerosol-former, for example an aerosol former selected from the list consisting of glycerine and propylene glycol, for example in which the aerosol-forming substrate has an aerosol-former content of greater than 20 wt % on a dry weight basis, for example greater than 25 wt %, or greater than 30 wt %, for example greater than 35 wt %. The use of an aerosol former may facilitate the promote the generation of aerosol from the aerosol-forming substrate through heating rather than burning of the substrate.

The aerosol-forming substrate may comprise one or more flavour compounds.

The wrapped body may comprise one or more susceptor materials arranged in thermal communication with the aerosol-forming substrate. Advantageously, one or more susceptor materials may be dispersed within the aerosol-forming substrate. For example, the susceptor materials may be in the form of metal strips, strands or particles dispersed within the aerosolforming substrate. The wrapper may comprise or consist of one or more susceptor materials - this feature may be additional to or an alternative to one or more susceptor materials being dispersed within the aerosol-forming substrate.

The wrapped body may have a width and a thickness, the width being greater than the thickness.

Preferably, the ratio of the width to the thickness of the wrapped body may be within a range of between 1 .5:1 and 20:1 , for example between 1 .5:1 and 15:1 , for example between 1 .5:1 and 10:1 , for example between 1 .5:1 and 5:1 . The width and the thickness of the wrapped body may define a transverse cross-section of the wrapped body, The transverse cross-section may have any suitable shape, such as being square, rectangular, oval or circular.

The wrapped body may have a first planar external surface and a second planar external surface. A separation between the first and second planar external surfaces of the wrapped body may define a thickness of the wrapped body.

One or both of a width and a thickness of the wrapped body vary along a length of the wrapped body. For example, the wrapped body may taper in width or thickness along the length of the wrapped body.

The aerosol-forming substrate of the wrapped body may have a mass in a range of between 50 mg and 300 mg, for example between 100 mg and 200 mg, for example between 125 mg and 175 mg, for example between 140 mg and 160 mg, for example about 140 mg, or about 150 mg or about 160 mg.

The wrapped body may have a length in a range of between 5 and 30 millimetres, for example between 8 and 25 millimetres, for example between 10 and 20 millimetres, for example between 12 and 16 millimetres.

The wrapped body may have a width in a range of between 4 and 20 millimetres, for example between 6 and 15 millimetres, for example between 8 and 11.2 millimetres.

The wrapped body may have a thickness in a range of between 0.5 millimetres and 5.5 millimetres, for example between 0.5 millimetres and 4.5 millimetres, for example between 1 millimetres and 3 millimetres, for example about 2.5 millimetres, or about 3 millimetres, or about 3.5 millimetres.

Preferably, the cavity contains a single wrapped body of aerosol-forming substrate.

In other examples, the cavity may contain a plurality of wrapped bodies of aerosol-forming substrate.

The plurality of wrapped bodies may extend across the entirety of a width of the cavity.

The plurality of wrapped bodies may be configured to be in surface contact with opposing interior walls of the cavity to maintain the plurality of wrapped bodies in fixed position within the cavity.

The plurality of wrapped bodies may extend along the entirety of a length of the cavity.

The plurality of the wrapped bodies may be aligned in end to end relationship within the cavity in one or more rows. The one or more rows may extend in a direction between the air inlet and the air outlet.

The aerosol-forming substrate of the plurality of wrapped bodies may have a cumulative mass in a range of between 50 mg and 300 mg, for example between 100 mg and 200 mg, for example between 125 mg and 175 mg, for example between 140 mg and 160 mg, for example about 140 mg, or about 150 mg or about 160 mg.

The aerosol-generating article may further comprise a frame positioned between the upper exterior wall and the lower exterior wall, the frame at least partially defining the cavity.

Preferably, laterally opposed walls of the frame may define part of the perimeter of the aerosol-generating article. Conveniently, the perimeter of the aerosol-generating article may be defined at least in part by the combination of the laterally opposed walls of the frame and the upper and lower exterior walls.

The upper exterior wall may be coupled to an upper surface of the frame and the lower exterior wall coupled to a lower surface of the frame.

An interior surface of the cavity may be at least partially defined by the frame.

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. The peripheral wall may be formed by a frame inner surface and a frame outer surface, and wherein the frame inner surface may define a cavity outer wall and the frame outer surface at least partially defines one or more external walls of the aerosol-generating article. The peripheral wall may have a radial thickness between 1 millimetre and 3 millimetres.

The frame may have a thickness greater than or equal to 80 percent of the thickness of the aerosol-generating article.

The frame may have a thickness between 80 percent and 95 percent of the thickness of the aerosol-generating article.

The frame may have a thickness between 1 millimetre and 5.5 millimetres. The frame may comprise a cellulosic material. The cellulosic material may have a grammage between 300 grams per square metre and 900 grams per square metre. The cellulosic material may be paper, paperboard, or cardboard.

The frame may be a unitary component.

The frame may comprise a first frame layer and a second frame layer. The first frame layer may be bonded to the second frame layer with an adhesive. The frame may comprise a third frame layer. The second frame layer may be positioned between the first frame layer and the third frame layer. The second frame layer may be bonded to the third frame layer with an adhesive.

Preferably, the air inlet is defined by the frame.

Preferably, the air outlet is defined by the frame.

The frame may be formed from a plastic, for example from PEEK. The use of plastic for the frame may facilitate making the frame reusable. The plastic frame may be formed as a single piece. The plastic frame may be formed by injection molding. The plastic frame may additionally comprise an air inlet and an air outlet. The air inlet and air outlet may be formed in opposing walls of the frame. The frame may at least partially define the cavity. The wrapped body of aerosolforming substrate may be placed within the cavity. Upper and lower paper-based sheets may be attached to respective upper and lower surfaces of the frame to close the cavity, thereby enclosing the wrapped body of aerosol-forming substrate within the cavity. In this manner, the cavity may be formed by the combination of the plastic frame and the upper and lower paper-based sheets. Adhesive may be used to attach the upper and lower paper-based sheets to the respective upper and lower surfaces of the plastic frame. Preferably, the adhesive used to attach the upper and lower paper-based sheets to the respective upper and lower surfaces of the plastic frame is a peelable adhesive.

Preferably, the paper-based sheets and the wrapped body of aerosol-forming substrate may be single use components of the aerosol-generating article, with the plastic frame being a reusable component. Preferably, the paper-based sheets and the wrapped body of aerosolforming substrate are configured to be compostable.

The use of paper-based sheets attached to upper and lower surfaces of the plastic frame by adhesive may allow a user to assemble and disassemble their own aerosol-generating article. For example, the user may attach one of the paper-based sheets to the lower surface of the frame (for example, via an adhesive bond), then place the wrapped body of aerosol-forming substrate within the cavity defined partially by the plastic frame and the attached paper-based sheet, followed by attaching the other paper-based sheet to the upper surface of the frame (for example, via an adhesive bond) to close off the cavity and thereby form an assembled aerosol-generating article ready for use. After the user has completed a usage session with the aerosol-generating article to deplete the aerosol-forming substrate, the user may disassemble the aerosol-generating article by removing the paper-based sheets from the plastic frame. The user may then choose to dispose of the paper-based sheets and the wrapped body of (now depleted) aerosol-forming substrate as compostable waste, whilst retaining the plastic frame for re-use in assembling a new aerosol-generating article with new paper-based sheets and a new wrapped body of aerosolforming substrate.

At least one of the upper exterior wall and the lower exterior wall preferably defines a substantially planar surface, for example in which the upper exterior wall defines a substantially planar surface, for example in which both the upper exterior wall and the lower exterior wall define a substantially planar surface.

The aerosol-generating article may comprise a first planar external layer and a second planar external layer, in which the first planar external layer forms a first planar external surface of the aerosol-generating article and the second planar external layer forms a second planar external surface of the aerosol-generating article. The first planar external layer preferably forms at least part of one of the upper and lower exterior walls and the second planar external layer preferably forms at least part of the other one of the upper and lower exterior walls. Optionally, at least one of the first planar external layer, the second planar external layer, and the frame may comprise or consist of aerosol-forming substrate.

The cavity may have a width between 30 percent and 95 percent of the width of the aerosolgenerating article.

The cavity may have a length between 30 percent and 95 percent of the length of the aerosol-generating article.

The cavity may have a thickness between 30 percent and 95 percent of the thickness of the aerosol-generating article.

The cavity may have a length between 14 millimetres and 40 millimetres, a width between 4.5 millimetres and 13 millimetres, and a thickness between 0.5 millimetres and 4.5 millimetres.

The cavity may have a length between 20 millimetres and 30 millimetres, a width between 7 millimetres and 10 millimetres, and a thickness between 2.5 millimetres and 4 millimetres.

Preferably, a thickness of the aerosol-generating article may be less than 50 percent of both a length and a width of the aerosol-generating article.

The aerosol-generating article may further comprise an outer wrapper defining the upper exterior wall and the lower exterior wall. The upper exterior wall may define a planar surface and the lower exterior wall define a planar surface.

The upper exterior wall may comprise a first planar external layer and the lower exterior wall comprise a second planar external layer. Preferably, the first planar external layer and the second planar external layer overlie opposing ends of the cavity.

One or both of the first planar external layer and the second planar external layer may comprise a cellulosic material. Conveniently, the cellulosic material is paper or cardboard.

One or both of the first planar external layer and the second planar external layer may have a length substantially the same as the length of the aerosol-generating article. One or both of the first planar external layer and the second planar external layer may have a width substantially the same as the width of the aerosol-generating article.

The air inlet may have an equivalent diameter between 0.1 millimetres and 3 millimetres.

The air inlet may have a width of between 0.3 millimetres and 3 millimetres.

The air inlet may have a thickness of between 0.3 millimetres and 3 millimetres.

The air outlet may have an equivalent diameter between 0.1 millimetres and 3 millimetres.

The air outlet may have a width of between 0.3 millimetres and 3 millimetres.

The air outlet may have a thickness of between 0.3 millimetres and 3 millimetres.

A corrugated layer may be positioned within the cavity.

The aerosol-generating article of any of the aspects of the present disclosure may have a resistance to draw between 0 millimetres H₂O and 9.9 millimetres H₂O.

For the aerosol-generating article of any of the aspects of the present disclosure, a ratio between the length and the thickness of the aerosol-generating article and a ratio between the width and the thickness of the aerosol-generating article may be between 2:1 and 15:1.

For the aerosol-generating article of any of the aspects of the present disclosure, a ratio between the length and the width of the aerosol-generating article may be between 1 :1 and 10:1 .

The aerosol-generating article of any of the aspects of the present disclosure may have a length (for example, an x dimension) of between 10 millimetres and 100 millimetres, or between 10 millimetres and 50 millimetres, for example between 12 millimetres and 30 millimetres, for example between 14 millimetres and 26 millimetres, for example between 16 millimetres and 24 millimetres, for example between 18 millimetres and 22 millimetres, for example about 18 millimetres, or about 19 millimetres, or about 20 millimetres, or about 21 millimetres, or about 22 millimetres.

The aerosol-generating article may have a length between 15 millimetres and 45 millimetres, for example between 25 millimetres and 30 millimetres.

The aerosol-generating article may have a width (for example, a y dimension) of between

5 millimetres and 20 millimetres, for example between 8 millimetres and 18 millimetres, for example between 10 millimetres and 16 millimetres, for example between 11 millimetres and 15 millimetres, for example between 12 millimetres and 14 millimetres, for example about 13 millimetres.

The aerosol-generating article may have a width between 3 millimetres and 17 millimetres, for example between 9 millimetres and 11 millimetres.

The aerosol-generating article may have a height (for example, a z dimension) of between 1 millimetres and 10 millimetres, for example between 1.2 millimetres and 8 millimetres, for example between 1.4 millimetres and 7 millimetres, for example between 1.6 millimetres and

6 millimetres, for example between 1.7 millimetres and 5 millimetres, for example about 1.7 millimetres, or about 4.5 millimetres, or about 2 millimetres, or about 3 millimetres, or about 4 millimetres. The aerosol-generating article may have a thickness between 1 millimetres and 5.5 millimetres, for example between 3 millimetres and 3.5 millimetres.

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

The aerosol-forming substrate may be one of a plurality of component parts of the aerosolgenerating article, being in the form of at least one wrapped body of aerosol-forming substrate.

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

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

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

The aerosol-forming substrate may comprise one or more aerosol-formers. Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosolformers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosolformer to be or comprise glycerine.

The aerosol-forming substrate may comprise at least 1 , 2, 5, 10, or 15 weight percent aerosol-former. The aerosol-forming substrate may comprise greater than 15 weight percent aerosol-former, for example greater than 20 weight percent, or greater than 25 weight percent, or greater than 30 weight percent, or greater than 40 weight percent, or greater than 50 weight percent aerosol-former.

The aerosol-forming substrate may comprise less than or equal to 30 percent by weight of aerosol former, less than or equal to 25 percent by weight of aerosol former, or less than or equal to 20 percent by weight of aerosol former. That is, the aerosol-forming substrate may have an aerosol former content of less than or equal to 30 percent by weight, less than or equal to 25 percent by weight, or less than or equal to 20 percent by weight.

The aerosol-forming substrate may comprise between 1 percent and 30 percent by weight of aerosol former, between 1 percent and 25 percent by weight of aerosol former, or between 1 percent and 20 percent by weight of aerosol former.

The aerosol-forming substrate may comprise between 5 percent and 30 percent by weight of aerosol former, between 5 percent and 25 percent by weight of aerosol former, or between 5 percent and 20 percent by weight of aerosol former.

The aerosol-forming substrate may comprise between 10 percent and 30 percent by weight of aerosol former, between 10 percent and 25 percent by weight of aerosol former, or between 10 percent and 20 percent by weight of aerosol former.

The aerosol-forming substrate may comprise between 15 percent and 30 percent by weight of aerosol former, between 15 percent and 25 percent by weight of aerosol former, or between 15 percent and 20 percent by weight of aerosol former.

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

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

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

The aerosol-forming substrate may comprise between 60 percent and 85 percent by weight of aerosol former, between 60 percent and 80 percent by weight of aerosol former, or between 60 percent and 75 percent by weight of aerosol former.

The aerosol-forming substrate may comprise between 70 percent and 85 percent by weight of aerosol former, between 70 percent and 80 percent by weight of aerosol former, or between 70 percent and 75 percent by weight of aerosol former.

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

The aerosol-forming substrate may comprise at least 0.5 percent by weight of nicotine, at least 1 percent by weight of nicotine, at least 1 .5 percent by weight of nicotine, or at least 2 percent by weight of nicotine. That is, the aerosol-forming substrate may have a nicotine content of at least 0.5 percent by weight, at least 1 percent by weight, at least 1 .5 percent by weight, or at least 2 percent by weight. The aerosol-forming substrate may comprise one or more cannabinoid compounds such as one or more of: tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannabivarin (CBV), cannabidivarin (CBDV), tetrahydrocannabivarin (THCV), cannabichromene (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), cannabicitran (CBT). It may be preferable that the cannabinoid compound is CBD or THC. It may be particularly preferable that the cannabinoid compound is CBD.

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

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

The aerosol-forming substrate may comprise tobacco leaf; for example about 15 to 45%, preferably of about 20 to 35% of a blend of tobacco leaf, incorporating at least one of the following tobacco types: bright tobacco; dark tobacco; aromatic tobacco. Tobacco material such as tobacco leaf is preferably ground and graded to a particle size of about 100 to 380 mesh, preferably of about 170 to 320 mesh.

“Tobacco type” means one of the different varieties of tobacco, for example based on the distinct curing process that the tobacco undergoes before it is further processed in a tobacco product.

Examples of bright tobaccos are Flue-Cured Brazil, Indian Flue-Cured, Chinese Flue- Cured, US Flue-Cured such as Virginia tobacco, and Flue-Cured from Tanzania.

Examples of aromatic tobaccos are Oriental Turkey, Greek Oriental, semi-oriental tobacco but also Fire Cured, US Burley, such as Perique, and Rustica.

Examples of dark tobacco are Dark Cured Brazil Galpao, Burley Malawi or other African Burley, Sun Cured or Air Cured Indonesian Kasturi.

The aerosol-forming substrate may comprise cellulose fibres. For example, the aerosolforming substrate may comprise about 1 to 15% of cellulose fibres, preferably of about 3 to 7% of cellulose fibres. Preferably, cellulose fibres may have a length of about 10 to 250 pm, preferably of about 10 to 120 pm. The aerosol-forming substrate may comprise organic fibres such as non-tobacco fibres, or tobacco fibres. For example, the aerosol-forming substrate may comprise about 5 to 20%, preferably about 7 to 15% of tobacco fibres. Tobacco fibres are preferably derived from stems and/or or stalks, graded to fibres of a length of about 10 to 350 pm, preferably of about 10 to 180 pm. The aerosol-forming substrate may comprise about 10 to 30 %, preferably of about 15 to 25%, of a non-tobacco organic fibre. For example, organic fibres may derive from cellulose, cotton, wood, tea botanical varieties as sub-products, and sub-processed waste, the tea industry. Organic fibres are preferably of a length of about 10 to 400 pm, preferably of about 10 to 200 pm.

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

The aerosol-forming substrate may comprise an organic botanical glycerite. For example, the aerosol-forming substrate may comprise about 15 to 55 %, preferably of about 20 to 35 %, of botanicals such as Clove, Echinacea sp., Fennel, Ginger, Hawthorn berry, Elderberry, Monarda, Mullein leaves, Nettle, Plantain, Turmeric, Yarrow, and compounds of those.

The aerosol-forming substrate may comprise organic botanical extracts. For example, the aerosol-forming substrate may comprise about 1 to 15 %, preferably of about 2 to 7 %, of any of the previously referred botanicals, as well as menthol (dl-Menthol, C10H20O, 2-lsopropyl-5- methylcyclohexanol) such as obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related botanic varieties, as well as P-menthan-3-ol, as any secondary alcohol as diastereoisomers of 5-methyl-2-(propan-2-yl)cyclohexan-1 -ol.

The aerosol-forming substrate may comprise botanical essential oils, for example about 0.5 to 5 %, preferably of about 1 to 3 %, of a botanical essential oil, for example a botanical essential oil such as of palm, coconut, and wooden-based essential oils.

The aerosol-forming substrate preferably comprises an aerosol-former, for example about 5 to 35%, preferably of about 10 to 25%, of an aerosol former. Suitable aerosol-formers known in the art include: glycerine; monohydric alcohols like menthol, polyhydric alcohols, such as triethylene glycol; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyls of those.

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

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

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

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

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

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

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

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

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

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

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

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

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

Example Ex1 : An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: opposed discrete upper and lower exterior walls, the upper and lower exterior walls collectively defining all or a majority of a perimeter of the aerosol-generating article; a cavity located within the aerosol-generating article between the upper exterior wall and the lower exterior wall; and an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity, wherein a wrapped body of aerosol-forming substrate is disposed within the cavity, the wrapped body comprising a wrapper at least partially enclosing aerosol-forming substrate.

Example Ex2: An aerosol-generating article according to Ex1 , wherein the upper exterior wall and the lower exterior wall define respective upper and lower planar exterior surfaces.

Example Ex3: An aerosol-generating article according to Ex1 , wherein the first exterior wall and the second exterior wall define respective first and second outwardly convex exterior surfaces, the first and second outwardly convex exterior surfaces collectively defining a lenticular profile.

Example Ex4: An aerosol-generating article according to any one of Ex1 to Ex3, wherein opposed ends of the upper exterior wall meet corresponding opposed ends of the lower exterior wall to define a pair of laterally opposed edges of the aerosol-generating article. Example Ex5: An aerosol-generating article according to any one of Ex1 to Ex4, wherein the aerosol-forming substrate of the wrapped body has a bulk density in a range of between 150 mg per cubic centimetre and 500 mg per cubic centimetre, for example between 175 mg per cubic centimetre and 475 mg per cubic centimetre, for example between 200 mg per cubic centimetre and 450 mg per cubic centimetre, for example between 225 mg per cubic centimetre and 425 mg per cubic centimetre, for example between 250 mg per cubic centimetre and 400 mg per cubic centimetre, for example between 275 mg per cubic centimetre and 375 mg per cubic centimetre, for example between 300 mg per cubic centimetre and 350 mg per cubic centimetre.

Example Ex6: An aerosol-generating article according to any one of Ex1 to Ex5, wherein the aerosol-generating substrate of the wrapped body has a bulk density of between 50 mg per cubic centimetre and 900 mg per cubic centimetre, for example between 100 mg per cubic centimetre and 800 mg per cubic centimetre, for example between 200 mg per cubic centimetre and 700 mg per cubic centimetre, for example between 200 mg per cubic centimetre and 600 mg per cubic centimetre, for example between 200 mg per cubic centimetre and 500 mg per cubic centimetre, for example between 200 mg per cubic centimetre and 400 mg per cubic centimetre.

Example Ex7: An aerosol-generating article according to any one of Ex1 to Ex6, wherein the wrapped body of aerosol-forming substrate occupies between 15% and 100% of an interior volume of the cavity, for example between 30% and 100% of an interior volume of the cavity, for example between 50% and 100% of an interior volume of the cavity, for example between 50% and 90% of an interior volume of the cavity, for example between 50% and 80% of an interior volume of the cavity, for example between 50% and 70% of an interior volume of the cavity.

Example Ex7A: An aerosol-generating article according to any one of Ex1 to Ex7, wherein a length of the wrapped body extends along between 15% and 100% of a length of the cavity, for example between 30% and 100% of a length of the cavity, for example between 50% and 100% of a length of the cavity, for example between 50% and 90% of a length of the cavity, for example between 50% and 80% of a length of the cavity, for example between 50% and 70% of a length of the cavity.

Example Ex8: An aerosol-generating article according to any one of Ex1 to Ex7A, wherein the wrapped body extends across the entirety of a width of the cavity.

Example Ex9: An aerosol-generating article according to any one of Ex1 to Ex8, wherein the wrapped body is configured to be in surface contact with opposing interior walls of the cavity to maintain the wrapped body in fixed position within the cavity.

Example Ex10: An aerosol-generating article according to any one of Ex1 to Ex9, wherein the wrapped body extends along the entirety of a length of the cavity.

Example Ex11 : An aerosol-generating article according to any one of Ex1 to Ex10, wherein a clearance is defined between an exterior surface of the wrapped body and an interior surface of one or more of the cavity, the first exterior wall and the second exterior wall. Example Ex12: An aerosol-generating article according to Ex11 , wherein the clearance defines at least part of the airflow passage.

Example Ex13: An aerosol-generating article according to either one of Ex11 or Ex12, wherein the clearance defines a channel aligned parallel with the length of the aerosol-generating article.

Example Ex13A: An aerosol-generating article according to any one of Ex11 to Ex13, wherein the clearance comprises at least one channel having a width of less than 1 millimetre, for example a width of less than 0.5 millimetres, for example a width of less than 0.25 millimetres, for example a width of less than 0.1 millimetres.

Example Ex14: An aerosol-generating article according to any one of Ex1 to Ex13A, wherein the wrapper comprises or consists of a cellulosic material, for example the cellulosic material being paper or cardboard.

Example Ex15: An aerosol-generating article according to any one of Ex1 to Ex14, wherein the wrapper comprises or consists of a thermally-conductive material, for example the thermally- conductive material being a metal foil, for example the metal foil being an aluminium foil.

Example Ex16: An aerosol-generating article according to Ex15, wherein the thermally conductive material has a thermal conductivity of at least 10 W/mK.

Example Ex17: An aerosol-generating article according to any one of Ex1 to Ex16, wherein the wrapper is configured to be porous, for example the wrapper comprising a plurality of perforations.

Example Ex18: An aerosol-generating article according to Ex17, wherein the wrapper is in the form of a mesh, for example the wrapper being a metal mesh.

Example Ex19: An aerosol-generating article according to either one of Ex17 or Ex18, wherein the wrapper encapsulates the entirety of the aerosol-forming substrate.

Example Ex20: An aerosol-generating article according to any one of Ex1 to Ex19, wherein the wrapper defines a band circumscribing the aerosol-forming substrate, the band having a length extending between opposed first and second axial end faces of the wrapped body.

Example Ex21 : An aerosol-generating article according to Ex20, wherein the aerosolforming substrate is exposed at the opposed first and second axial end faces of the wrapped body.

Example Ex22: An aerosol-generating article according to any one of Ex1 to Ex21 , wherein: a first wrapper encapsulates the entirety of the aerosol-forming substrate; and a second wrapper defines a band circumscribing the aerosol-forming substrate, the band having a length extending between opposed first and second axial end faces of the wrapped body; wherein the first wrapper has a greater level of porosity than the second wrapper. Example Ex23: An aerosol-generating article according to Ex22, wherein the first wrapper comprises a plurality of perforations.

Example Ex24: An aerosol-generating article according to either one of Ex22 or Ex23, wherein the first wrapper is in the form of a mesh, for example the wrapper being a metal mesh.

Example Ex25: An aerosol-generating article according to any one of Ex22 to 24, the second wrapper being impermeable.

Example Ex26: An aerosol-generating article according to any one of Ex22 to 25, wherein the second wrapper has a higher thermal conductivity than the first wrapper.

Example Ex27: An aerosol-generating article according to Ex26, the second wrapper comprising or consisting of a metal foil, for example the metal foil being an aluminium foil.

Example Ex28: An aerosol-generating article according to any one of Ex22 to Ex27, wherein the second wrapper is positioned outward of the first wrapper.

Example Ex29: An aerosol-generating article according to any one of Ex22 to Ex27, wherein the first wrapper is positioned outward of the second wrapper.

Example Ex30: An aerosol-generating article according to any one of Ex1 to Ex29, wherein the aerosol-forming substrate is in the form of any one or more of shredded aerosol-forming substrate, strips of aerosol-forming substrate, strands of aerosol-forming substrate, particles of aerosol-forming substrate, one or more sheets of aerosol-forming substrate, one or more gathered sheets of aerosol-forming substrate, cut filler dispersed within a solid binder matrix, a plurality of beads of aerosol-forming substrate.

Example Ex31 : An aerosol-generating article according to any one of Ex1 to Ex30, wherein the aerosol-forming substrate comprises tobacco, for example, tobacco cut filler or cast leaf tobacco.

Example Ex32: An aerosol-generating article according to any one of Ex1 to Ex31 , wherein the aerosol-forming substrate comprises an aerosol-former, for example an aerosol former selected from the list consisting of glycerine and propylene glycol, for example in which the aerosol-forming substrate has an aerosol-former content of greater than 20 wt % on a dry weight basis, for example greater than 25 wt %, or greater than 30 wt %, for example greater than 35 wt %.

Example Ex33: An aerosol-generating article according to any one of Ex1 to Ex32, wherein the aerosol-forming substrate comprises one or more flavour compounds.

Example Ex34: An aerosol-generating article according to any one of Ex1 to Ex33, wherein the wrapped body comprises one or more susceptor materials arranged in thermal communication with the aerosol-forming substrate.

Example Ex35: An aerosol-generating article according to Ex34, wherein one or more susceptor materials are dispersed within the aerosol-forming substrate.

Example Ex36: An aerosol-generating article according to either one of Ex34 or Ex35, wherein the wrapper comprises or consists of one or more susceptor materials. Example Ex37: An aerosol-generating article according to any one of Ex1 to Ex36, wherein the wrapped body has a width and a thickness, the width being greater than the thickness.

Example Ex38: An aerosol-generating article according to Ex37, wherein the ratio of the width to the thickness of the wrapped body is in a range of between 1 .5:1 and 20:1 , for example between 1 .5:1 and 15:1 , for example between 1 .5:1 and 10:1 , for example between 1 .5:1 and 5:1 .

Example Ex39: An aerosol-generating article according to any one of Ex1 to Ex38, wherein the wrapped body has a first planar external surface and a second planar external surface, a separation between the first and second planar external surfaces defining a thickness of the wrapped body.

Example Ex40: An aerosol-generating article according to any one of Ex1 to Ex39, wherein one or both of a width and a thickness of the wrapped body vary along a length of the wrapped body.

Example Ex41 : An aerosol-generating article according to any one of Ex1 to Ex40, wherein the aerosol-forming substrate of the wrapped body has a mass in a range of between 50 mg and 300 mg, for example between 100 mg and 200 mg, for example between 125 mg and 175 mg, for example between 140 mg and 160 mg, for example about 140 mg, or about 150 mg or about 160 mg.

Example Ex42: An aerosol-generating article according to any one of Ex1 to Ex41 , wherein the wrapped body has a length in a range of between 5 and 30 millimetres, for example between 8 and 25 millimetres, for example between 10 and 20 millimetres, for example between 12 and 16 millimetres.

Example Ex43: An aerosol-generating article according to any one of Ex1 to Ex42, wherein the wrapped body has a width in a range of between 4 and 20 millimetres, for example between 6 and 15 millimetres, for example between 8 and 11 .2 millimetres.

Example Ex44: An aerosol-generating article according to any one of Ex1 to Ex43, wherein the wrapped body has a thickness in a range of between 0.5 millimetres and 5.5 millimetres, for example between 0.5 millimetres and 4.5 millimetres, for example between 1 millimetres and 3 millimetres, for example about 2.5 millimetres, or about 3 millimetres, or about 3.5 millimetres.

Example Ex45: An aerosol-generating article according to any one of Ex1 to Ex44, wherein the cavity contains a single wrapped body of aerosol-forming substrate.

Example Ex46: An aerosol-generating article according to any one of Ex1 to Ex44, wherein the cavity contains a plurality of wrapped bodies of aerosol-forming substrate.

Example Ex47: An aerosol-generating article according to Ex46, wherein the plurality of wrapped bodies extend across the entirety of a width of the cavity.

Example Ex48: An aerosol-generating article according to either one of Ex46 or Ex47, wherein the plurality of wrapped bodies is configured to be in surface contact with opposing interior walls of the cavity to maintain the plurality of wrapped bodies in fixed position within the cavity. Example Ex49: An aerosol-generating article according to any one of Ex46 to Ex48, wherein the plurality of wrapped bodies extend along the entirety of a length of the cavity.

Example Ex50: An aerosol-generating article according to any one of Ex46 to Ex49, wherein the plurality of the wrapped bodies are aligned in end to end relationship within the cavity in one or more rows.

Example Ex51 : An aerosol-generating article according to Ex50, wherein the one or more rows extend in a direction between the air inlet and the air outlet.

Example Ex52: An aerosol-generating article according to any one of Ex46 to Ex52, wherein the aerosol-forming substrate of the plurality of wrapped bodies has a cumulative mass in a range of between 50 mg and 300 mg, for example between 100 mg and 200 mg, for example between 125 mg and 175 mg, for example between 140 mg and 160 mg, for example about 140 mg, or about 150 mg or about 160 mg.

Example Ex53: An aerosol-generating article according to any one of Ex1 to Ex52, further comprising a frame positioned between the upper exterior wall and the lower exterior wall, the frame at least partially defining the cavity.

Example Ex54: An aerosol-generating article according to Ex53, wherein laterally opposed walls of the frame define part of the perimeter of the aerosol-generating article.

Example Ex55: An aerosol-generating article according to Ex54, wherein the perimeter of the aerosol-generating article may be defined at least in part by the combination of the laterally opposed walls of the frame and the upper and lower exterior walls.

Example Ex56: An aerosol-generating article according to any one of Ex53 to Ex55, wherein the upper exterior wall is coupled to an upper surface of the frame and the lower exterior wall is coupled to a lower surface of the frame.

Example Ex57: An aerosol-generating article according to any one of Ex53 to Ex56, wherein an interior surface of the cavity is at least partially defined by the frame.

Example Ex58: An aerosol-generating article according to any of Ex53 to Ex57, wherein the frame comprises a peripheral wall at least partially circumscribing or encircling the cavity.

Example Ex59: An aerosol-generating article according to Ex58, wherein the peripheral wall is formed by a frame inner surface and a frame outer surface, and wherein the frame inner surface defines a cavity outer wall and the frame outer surface at least partially defines one or more external walls of the aerosol-generating article.

Example Ex60: An aerosol-generating article according to either one of Ex58 or Ex59, wherein the peripheral wall has a radial thickness between 1 millimetre and 3 millimetres.

Example Ex61 : An aerosol-generating article according to any of Ex53 to Ex60, wherein the frame has a thickness greater than or equal to 80 percent of the thickness of the aerosolgenerating article. Example Ex62: An aerosol-generating article according to any of Ex53 to Ex61 , wherein the frame has a thickness between 80 percent and 95 percent of the thickness of the aerosolgenerating article.

Example Ex63: An aerosol-generating article according to any of Ex53 to Ex62, wherein the frame has a thickness between 1 millimetre and 5.5 millimetres.

Example Ex64: An aerosol-generating article according to any of Ex53 to Ex63, wherein the frame comprises a cellulosic material.

Example Ex65: An aerosol-generating article according to Ex64, wherein the cellulosic material has a grammage between 300 grams per square metre and 900 grams per square metre.

Example Ex66: An aerosol-generating article according to Ex64 or Ex65, wherein the cellulosic material is paper, paperboard, or cardboard.

Example Ex67: An aerosol-generating article according to any of Ex53 to Ex66, wherein the frame is a unitary component.

Example Ex68: An aerosol-generating article according to any of Ex53 to Ex67, wherein the frame comprises a first frame layer and a second frame layer.

Example Ex69: An aerosol-generating article according to Ex68, wherein the first frame layer is bonded to the second frame layer with an adhesive.

Example Ex70: An aerosol-generating article according to Ex68 or Ex69, wherein the frame comprises a third frame layer.

Example Ex71 : An aerosol-generating article according to Ex70, wherein the second frame layer is positioned between the first frame layer and the third frame layer.

Example Ex72: An aerosol-generating article according to Ex70 or Ex71 , wherein the second frame layer is bonded to the third frame layer with an adhesive.

Example Ex73: An aerosol-generating article according to any one of Ex53 to Ex72, wherein the air inlet is defined by the frame.

Example Ex74: An aerosol-generating article according to any one of Ex53 to Ex73, wherein the air outlet is defined by the frame.

Example Ex75: An aerosol-generating article according to any one of Ex1 to Ex74, wherein at least one of the upper exterior wall and the lower exterior wall defines a substantially planar surface, for example in which the upper exterior wall defines a substantially planar surface, for example in which both the upper exterior wall and the lower exterior wall define a substantially planar surface.

Example Ex76: An aerosol-generating article according to any one of Ex1 to Ex75, wherein the cavity has a width between 30 percent and 95 percent of the width of the aerosol-generating article.

Example Ex77: An aerosol-generating article according to any one of Ex1 to Ex76, wherein the cavity has a length between 30 percent and 95 percent of the length of the aerosol-generating article. Example Ex78: An aerosol-generating article according to any one of Ex1 to Ex77, wherein the cavity has a thickness between 30 percent and 95 percent of the thickness of the aerosolgenerating article.

Example Ex79: An aerosol-generating article according to any one of Ex1 to Ex78, wherein the cavity has a length between 14 millimetres and 40 millimetres, a width between 4.5 millimetres and 13 millimetres, and a thickness between 0.5 millimetres and 4.5 millimetres.

Example Ex80: An aerosol-generating article according to any one of Ex1 to Ex79, wherein the cavity has a length between 20 millimetres and 30 millimetres, a width between 7 millimetres and 10 millimetres, and a thickness between 2.5 millimetres and 4 millimetres.

Example Ex81 : An aerosol-generating article according to any one of Ex1 to Ex80, wherein a thickness of the aerosol-generating article is less than 50 percent of both a length and a width of the aerosol-generating article.

Example Ex82: An aerosol-generating article according to any one of Ex1 to Ex81 , comprising an outer wrapper defining the upper exterior wall and the lower exterior wall.

Example Ex83: An aerosol-generating article according to Ex82, wherein the upper exterior wall defines a planar surface and the lower exterior wall defines a planar surface.

Example Ex84: An aerosol-generating article according to any one of Ex1 to Ex83, wherein the upper exterior wall comprises a first planar external layer and the lower exterior wall comprises a second planar external layer.

Example Ex85: An aerosol-generating article according to Ex85, wherein the first planar external layer and the second planar external layer overlie opposing ends of the cavity.

Example Ex86: An aerosol-generating article according to either one of Ex84 or Ex85, wherein one or both of the first planar external layer and the second planar external layer comprise a cellulosic material.

Example Ex87: An aerosol-generating article according to Ex86, wherein the cellulosic material is paper or cardboard.

Example Ex88: An aerosol-generating article according to any one of Ex84 to Ex87, wherein one or both of the first planar external layer and the second planar external layer has a length substantially the same as the length of the aerosol-generating article.

Example Ex89: An aerosol-generating article according to any one of Ex84 to Ex88, wherein one or both of the first planar external layer and the second planar external layer has a width substantially the same as the width of the aerosol-generating article.

Example Ex90: An aerosol-generating article according to any one of Ex1 to Ex89, wherein the air inlet has an equivalent diameter between 0.1 millimetres and 3 millimetres.

Example Ex91 : An aerosol-generating article according to any one of Ex1 to Ex90, wherein the air inlet has a width of between 0.3 millimetres and 3 millimetres.

Example Ex92: An aerosol-generating article according to any one of Ex1 to Ex91 , wherein the air inlet has a thickness of between 0.3 millimetres and 3 millimetres. Example Ex93: An aerosol-generating article according to any one of Ex1 to Ex92, wherein the air outlet has an equivalent diameter between 0.1 millimetres and 3 millimetres.

Example Ex94: An aerosol-generating article according to any one of Ex1 to Ex93, wherein the air outlet has a width of between 0.3 millimetres and 3 millimetres.

Example Ex95: An aerosol-generating article according to any one of Ex1 to Ex94, wherein the air outlet has a thickness of between 0.3 millimetres and 3 millimetres.

Example Ex96: An aerosol-generating article according to any one of Ex1 to Ex95, wherein a ratio between the length and the thickness of the aerosol-generating article, and between the width and the thickness of the aerosol-generating article is between 2:1 and 15:1 .

Example Ex92: An aerosol-generating article according to any one of Ex1 to Ex91 , wherein a ratio between the length and the width of the aerosol-generating article is between 1 :1 and 10:1.

Example Ex93: An aerosol-generating article according to any one of Ex1 to Ex92, wherein the aerosol-generating article has a length between 15 millimetres and 45 millimetres, for example between 25 millimetres and 30 millimetres.

Example Ex94: An aerosol-generating article according to any one of Ex1 to Ex93, wherein the aerosol-generating article has a width between 3 millimetres and 17 millimetres, for example between 9 millimetres and 11 millimetres.

Example Ex95: An aerosol-generating article according to any one of Ex1 to Ex94, wherein the aerosol-generating article has a thickness between 1 millimetres and 5.5 millimetres, for example between 3 millimetres and 3.5 millimetres.

Example Ex96: An aerosol-generating article according to any one of Ex1 to Ex95, wherein the aerosol-generating article has a resistance to draw between 0 millimetres H₂O and 9.9 millimetres H₂O.

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

Figure 1 is a perspective side view of an aerosol-generating article according to a first embodiment of the present disclosure;

Figure 2 is a perspective side view of an aerosol-generating article according to a second embodiment of the present disclosure;

Figure 3 is a perspective end view of a wrapped body of aerosol-forming substrate as used in the aerosol-generating articles of figures 1 and 2;

Figure 4 is a perspective end view of an alternative example of a wrapped body of aerosolforming substrate suitable for use in the aerosol-generating articles of figures 1 and 2;

Figure 5 is a view on a transverse cross-section of a further alternative example of a wrapped body of aerosol-forming substrate suitable for use in the aerosol-generating article of figures 1 and 2;

Figure 6 is a view on a transverse cross-section of a further alternative example of a wrapped body of aerosol-forming substrate suitable for use in the aerosol-generating article of figures 1 and 2; Figures 7a-7f are views on a transverse cross-section of various examples of a wrapped body of aerosol-forming substrate;

Figure 8 is a schematic end view of an aerosol-generating article according to a third embodiment of the present disclosure;

Figure 9 is a schematic side view of the aerosol-generating article of figure 8;

Figure 10 is a schematic plan view of the aerosol-generating article of figure 8;

Figure 11 shows a schematic illustration of a corrugated element as used in the aerosolgenerating article of figure 8;

Figure 12 shows a perspective view of an aerosol-generating article according to a fourth embodiment of the present disclosure;

Figure 13 shows an exploded perspective view of the aerosol-generating article of Figure 12;

Figure 14 shows a further exploded perspective view of the aerosol-generating article of Figure 12;

Figure 15 shows a schematic transverse cross-sectional view of the aerosol-generating article of Figure 12;

Figure 16 shows a schematic longitudinal cross-sectional view of the aerosol-generating article of Figure 12;

Figure 17 shows an exploded perspective view of a variant to the aerosol-generating article illustrated in Figure 13;

Figure 18 shows an exploded perspective view of a further variant to the aerosol-generating article illustrated in Figure 13;

Figure 19 shows an exploded perspective view of an aerosol-generating article according to a fifth embodiment of the present disclosure;

Figure 20 shows a schematic transverse cross-sectional view of the aerosol-generating article of Figure 19;

Figure 21 shows a schematic lateral cross-sectional view of the aerosol-generating article of Figure 19.

Figure 1 illustrates a perspective side view of an aerosol-generating article 100 according to a first embodiment of the present disclosure. The aerosol-generating article 100 has upper and lower surfaces 110, 120 which are flat or planar. The upper and lower surfaces are defined by opposed discrete upper and lower layers 111 , 121 of a cellulose-based substrate, such as paper or cardboard. Opposing lateral edges of the upper and lower layers 111 , 121 meet at an interface 1 15, the interface represented by a dashed line in figure 1 . The opposing lateral edges of the upper and lower layers 111 , 121 may be bonded to each other along the interface 115 with an adhesive. A wrapped body 160 of aerosol-forming substrate is positioned within a cavity defined within the aerosol-generating article between the upper and lower surfaces 110, 120. The wrapped body 160 has a wrapper 161 which at least partially encloses aerosol-forming substrate 162.

A suitable aerosol-forming substrate may be homogenised tobacco.

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

Figure 2 illustrates a perspective side view of an aerosol-generating article 200 according to a second embodiment of the present disclosure, being a variant of aerosol-generating article 100. Features in common with aerosol-generating article 100 are referred to with like reference signs. An air flow path 230 is defined through the aerosol-generating article 200 between the upper and lower surfaces 110, 120. The air flow path 230 extends between opposed first and second ends 201 , 202 of the aerosol-generating article 200, through the wrapped body 160 of aerosol-forming substrate 162. The first end 201 may define a distal end of the aerosol-generating article 200, and the second end 202 may define a proximal end of the aerosolgenerating article. The proximal end 202 may be a mouth end of the aerosol-generating article 200. The air flow path 230 may be directed towards a mouth of a user to allow a user to inhale aerosol generated in consequence of heating of aerosol-forming substrate of the aerosolgenerating article 200.

Figure 3 shows a view of the wrapped body 160 of aerosol-forming substrate when viewed in the direction of arrow A in figures 1 and 2. The wrapped body 160 defines a generally cuboid shape. The wrapper 161 defines a band circumferentially enclosing the aerosol-forming substrate 162. In the illustrated embodiment, the wrapper 161 is formed from a sheet of paper or cardboard. However, in other embodiments the wrapper 161 may be formed from a sheet of thermally conductive material, such as a sheet of aluminium or other metal. In still other alternative embodiments, the wrapper 161 may be formed as a laminate of different materials, such a metal foil (for example, aluminium foil) bonded to a paper sheet. Forming the wrapper 161 as a band has the effect that opposed axial end faces of the aerosol-forming substrate 162 located at either end 166, 167 of the wrapped body 160 are exposed and free of any wrapping, thereby reducing impeding of air flow through the wrapped body 160.

Figure 4 illustrates a perspective view of an alternative example of a wrapped body 160’ of aerosol-forming substrate 162’ suitable for use in place of the wrapped body 160 of figure 3. The wrapped body 160’ of figure 4 differs from that of figure 3 in that the wrapper 161 ’ has a meshed construction and extends around each of the faces of the wrapped body. The wrapper 161 ' may be in the form of a steel mesh, with figure 4 illustrating distinct wires or filaments of the mesh. The use of meshed construction facilitates the passage of air flow across the thickness of the wrapper 161 ’, with air flow entering and exiting the wrapped body 160’ through interstices 168’ of the mesh. The meshed construction for the wrapper 161 ’ has the effect of making the wrapper 160’ porous to air flow therethrough.

In an alternative embodiment to the use of a meshed construction, the wrapper may be formed from paper or cardboard completely encapsulating the aerosol-forming substrate, but with the paper or cardboard configured to make the wrapper porous to air flow therethrough. By way of example, one or more perforations may be formed in the wrapper to permit the passage of air flow across the thickness of the wrapper.

Figure 5 is a view on a transverse cross-section of a further alternative example of a wrapped body 160” of aerosol-forming substrate suitable for use in the aerosol-generating article 100, 200 of figures 1 and 2. The wrapped body 160” of figure 5 differs from that of figure 3 in that particles or shreds of susceptor material 169” are dispersed throughout the structure of the wrapper 161 ”. Where the aerosol-generating article 100, 200 containing the wrapped body 160” is located in the vicinity of an oscillating magnetic field, the time-varying nature of the magnetic field would result in heating of the particles or shreds of susceptor material 169” by eddy current heating or magnetic hysteresis. In turn, heat generated by the particles or shreds of susceptor material 169” would be conducted through the wrapper 161 ” and into the aerosol-forming substrate 162” enclosed by the wrapper 161 ”. Such an oscillating magnetic field may result from supplying an induction coil of an aerosol-generating device with an alternating current. The inductor coil may be arranged to surround a cavity of the device dimensioned to receive the aerosol-generating article. The supply of alternating current to the inductor coil would result in the oscillating magnetic field. The susceptor material(s) may comprise one or more materials selected from a list consisting of: aluminium, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

Figure 6 is a view on a transverse cross-section of a further alternative example of a wrapped body 160’” of aerosol-forming substrate suitable for use in the aerosol-generating article 100, 200 of figures 1 and 2. The wrapped body 160’” of figure 6 differs from the wrapped body 160” of figure s in that particles or shreds of susceptor material 169’” are dispersed throughout the aerosol-forming substrate 162’” rather than in the wrapper 161 ’”. The principle by which the particles or shreds of susceptor material 169’” may be heated is similar to as described above for the wrapped body of figure 5.

Although figures 1 -6 show a wrapped body which is rectangular in transverse cross-section, in other examples the wrapped body may have a different profile in transverse cross-section. Figures 7a-7f illustrates various non-limiting examples of wrapped bodies 160a-160e of aerosolforming substrate having different geometric profiles in transverse cross-section. The wrapped body 160a of figure 7a has a wrapper 161 a enclosing aerosol-forming substrate 162a. The wrapped body 160a is rectangular in transverse cross-section, in common with the wrapped body of the embodiments of figures 3 to 6 discussed in the preceding paragraphs. The wrapped body 160b of figure 7b has a wrapper 161 b enclosing aerosol-forming substrate 162b. The wrapped body 160b is generally rectangular in transverse cross-section, but has curved corners connecting upper and lower portions of the wrapper 161 b with side portions of the wrapper 161 b. The wrapped body 160c of figure 7c has a wrapper 161c enclosing aerosol-forming substrate 162c. The wrapped body 160c is formed as a hexagon in transverse cross-section, with planar upper and lower surfaces aligned parallel to each other. The wrapped body 160d of figure 7d has a wrapper 161d enclosing aerosol-forming substrate 162d, with the wrapped body 160d being elliptical or oval in transverse cross-section. The wrapped body 160e of figure 7e has a wrapper 161 e enclosing aerosol-forming substrate 162e, with the wrapped body 160e being circular in transverse cross-section.

The cavity of the aerosol-generating article in which the wrapped body (for example, any of wrapped body 160, 160’, 160”, 160”', or 160a-e) is positioned may have a size and shape in transverse cross-section identical to that of the wrapped body. Alternatively, one or both of the size and shape of the cavity may be mismatched with the wrapped body, thereby defining one or more channels between the wrapped body and interior surfaces of the cavity. These one or more channels may serve to allow a portion of air flow through the cavity to bypass the aerosol-forming substrate of the wrapped body.

By way of example, figure 7f shows a wrapped body 160f having a wrapper 161 f enclosing aerosol-forming substrate 162f. The perimeter of the wrapped body 160f is formed with channels or grooves 170 extending along the length of the wrapped body 160f. The channels or grooves 170 each have a width w of less than 1 millimetre, for example a width w of less than 0.5 millimetres, for example a width w of less than 0.25 millimetres, for example a width w of less than 0.1 millimetres. When the wrapped body 160f is placed within the interior of an aerosolgenerating article (for example, the article 100, 200 of figures 1 or 2), the channels or grooves 170 provide an air flow path for the passage of air between the wrapped body 160f and an interior surface of the aerosol-generating article.

Figures 8, 9, and 10 illustrate respectively an end view, a side view, and a plan view of an aerosol-generating article 300 according to a third embodiment of the present disclosure. The aerosol-generating article 300 comprises a planar upper layer 310, a planar lower layer 320, and an intermediate or separation layer 340 arranged between the upper layer 310 and lower layer 320.

The planar upper layer 310 is formed from a sheet of paper having a thickness of 300 microns. The planar lower layer 320 is formed from a sheet of paper having a thickness of 300 microns. The intermediate layer 340 is a corrugated element formed from a corrugated sheet of cardboard 345.

Figure 1 1 illustrates the corrugated sheet of cardboard 345. The corrugations have an amplitude 346 of 3 millimetres and a wavelength 347 of 3 millimetres. The sheet of cardboard 345 forming the intermediate layer 340 has a thickness of 150 microns. Points of intersection 351 , 352 between the upper layer 310 and the intermediate layer 340 and between the lower layer 320 and the intermediate layer 340 comprise an adhesive that joins the respective layers.

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

Corrugations of the intermediate layer 340 form a first set of longitudinally extending channels 341 that are bounded by the upper layer 310 and the intermediate layer 340, and a second set of longitudinally extending channels 342 bounded by the lower layer 320 and the intermediate layer 340. The first and second sets of longitudinally extending channels 341 , 342 extend through the length of the corrugated sheet of cardboard 345 between a proximal end 371 of the corrugated sheet 345 and a distal end 372 of the corrugated sheet 345. An elongate wrapped body 360 of aerosol-forming substrate is positioned within each of one of the longitudinally extending channels 341 , 342. Each wrapped body 360 is cylindrical in shape, having a wrapper 361 enclosing a rod of aerosol-forming substrate 362 so that the aerosol-forming substrate 362 is exposed at opposed end faces of the wrapped body (see figure 8). Each elongate wrapped body 360 is circular in transverse cross-section, in common with figure 7e. The intermediate layer 340 and each cylindrical wrapped body 360 are configured such the wrapped body 360 is in contact with two points of the intermediate layer 340 and one point of the upper layer 310 (for wrapped bodies 360 located within channels 341 ) or one point of the lower layer 320 (for wrapped bodies 360 located within channels 342). The longitudinally extending channels 341 , 342 define air-flow paths through the aerosol-generating article 300.

During use of the aerosol-generating article 300, a portion of the air flow through each channel 341 , 342 passes through the respective wrapped body 360 of aerosol-forming substrate located in the channel, with the remaining air flow bypassing the wrapped body 360 to flow through gaps defined between the wrapped body 360 and the surfaces of the intermediate layer 340 and the upper or lower layers 310, 320. The presence of the elongate wrapped bodies 360 of aerosol-forming substrate within the channels 341 , 342 increases the resistance to air flow through the channels compared to the channels being empty. However, air flow through the channels 341 , 342 is facilitated by the gaps defined between each of the wrapped bodies 360 and the surfaces of the corrugated sheet 345 and the planar upper or lower layer 310, 320. The level of air flow through the wrapped bodies 360 located within the channels 341 , 342 is dependent on the porosity and/or compaction of the aerosol-forming substrate 362 enclosed by wrapper 361. It will be understood that the resistance to draw of the aerosol-generating article 300 will be a function of both: i) the gaps defined between the wrapped bodies 360 and the surfaces of intermediate layer 340 and upper or lower layers 310, 320, and ii) the porosity and/or compaction of the aerosol-forming substrate 362 of the wrapped bodies 360. During use of the aerosol-generating article 300, the aerosol-forming substrate 362 within each of the elongate wrapped bodies 360 is heated up to cause the aerosol-forming substrate 362 to release volatile compounds. These volatile compounds become entrained in air drawn through the aerosol-forming substrate 362 and in air drawn through the gaps defined between the wrapped bodies 360 and the surfaces of intermediate layer 340 and upper or lower layers 310, 320, via the distal end 372. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the channels 341 , 342 of the aerosol-generating article 300 via the proximal end 371 for inhalation by a user.

Figure 12 shows an aerosol-generating article 400 according to a fourth embodiment of the present disclosure. The aerosol-generating article 400 comprises a first planar external layer 424 forming a first planar external surface 421 , a second planar external layer 425 forming a second planar external surface 422, and a frame 450 positioned between the first planar external layer 424 and the second planar external layer 425. The second planar external surface 422 is positioned parallel to the first planar external surface 421 .

Figures 13 and 14 show exploded views of the aerosol-generating article 400 of Figure 12. The frame 450 circumscribes and at least partially defines a cavity 430. Figure 13 shows a wrapped body 460 of aerosol-forming substrate positioned above the cavity 430. The wrapped body 460 is cuboid in shape, being rectangular in transverse cross-section. The wrapped body 460 has a wrapper 461 defining a band enclosing a portion of aerosol-forming substrate 462. Opposed end faces of the substrate 462 are free of any wrapper so as to be exposed at opposite ends 463, 464 of the wrapped body 460. The size of the wrapped body 460 corresponds to the interior volume of the cavity 430, resulting in the wrapped body 460 filling the entirety of the interior volume of the cavity 430. Figure 13 shows the cavity 430 in an empty state. Figure 14 shows the wrapped body 460 of aerosol-forming substrate positioned within the cavity 430. Figures 15 and 16 show respective transverse and longitudinal cross-sectional views of the aerosol-generating article 400 with the wrapped body 460 is positioned within the cavity 430.

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

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

450 and the outer transverse surface 453 of the frame 450 of about 5 millimetres.

An air inlet 411 and an air outlet 412 are defined by, and extend through, the peripheral wall

451 of the frame 450. More specifically, the air inlet 411 extends through the front wall 413 and the air outlet 412 extends through the back wall 414. The air inlet 411 and the air outlet 412 have an equivalent diameter of 5 millimetres. An airflow passage extends between the air inlet 411 and the air outlet 412 through the cavity 430. The exposed axial end faces of the aerosol-forming substrate 462 located at opposite ends 463, 464 of the wrapped body 460 are positioned adjacent to the air inlet 411 and the air outlet 412 (see figure 16). The aerosol-forming substrate 462 of the wrapped body 460 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-former content of 5 percent by weight on a dry weight basis.

In alternative embodiments, one or both of a length and a width dimension of the wrapped body 460 may be smaller than a length or width dimension of the cavity 430, with the cavity thereby only partially filled with aerosol-forming substrate. By way of example, the length dimensions may extend in an x dimension and the width dimension extend in a y dimension.

In an alternative embodiment, the frame 450 may instead be formed from plastic, for example PEEK. This would provide for the frame 450 to be reusable. The cigarette paper of the first planar external layer 424 and the second planar external layer 425 may be bonded to respective surfaces of the frame 450 by use of an adhesive, such as a peelable adhesive. In this manner, a user may be able to assemble frame 450, the wrapped body 460 of aerosol-forming substrate and the first and second planar external layers 424, 425 of cigarette paper to form the aerosol-generating article 400. Similarly, after use of the aerosol-generating article 400, the user may be able to readily disassemble the used aerosol-generating article 400, disposing of the wrapped body 460 of (now depleted) aerosol-forming substrate 462 and the first and second planar external layers 424, 425 of cigarette paper as compostable waste, whilst retaining the plastic frame 450. The frame 450 may then be re-used alongside a new wrapped body 460 of aerosol-forming substrate 462 and new first and second planar external layers 424, 425 of cigarette paper to assemble a new aerosol-generating article 400.

Figure 17 shows a variant to the aerosol-generating article 400 illustrated in figure 13. The aerosol-generating article 400 of figure 17 differs from that of figure 13 in that two wrapped bodies 460a, 460b of aerosol-forming substrate are positioned in end-to-end alignment along a length direction of the cavity 430. Wrapped body 460a has a wrapper 461 a enclosing aerosol-forming substrate 462a. Wrapped body 460b has a wrapper 461 b enclosing aerosol-forming substrate 462b. The size and shape of the wrapped bodies 460a, 460b is such that on insertion into the cavity 430, the wrapped bodies 460a, 460b collectively fill the entire volume of the cavity 430, with each wrapped body 460a, 460b extending across the entire width of the cavity 430. The aerosol-forming substrates 462a, 462b may be different to each other, with the aerosol inhaled by a user consequently containing a combination of different volatile compounds evolved from the two different substrates 462a, 462b.

Figure 18 shows a further variant to the aerosol-generating article 400 illustrated in figure 13. The aerosol-generating article 400 of figure 18 differs from that of figure 13 in that two wrapped bodies 460c, 460d of aerosol-forming substrate are positioned in side-by-side alignment along a width direction of the cavity 430. The wrapped bodies 460c, 460d collectively extend across the entire width of the cavity 430, but each only extend for around 50% of the length of the cavity 430. Wrapped body 460c has a wrapper 461c enclosing aerosol-forming substrate 462c. Wrapped body 460d has a wrapper 461 d enclosing aerosol-forming substrate 462d. The aerosol-forming substrates 462c, 462d may be different to each other, in a similar manner to substrates 462a, 462b of figure 17. The aerosol-generating article 400 of figures 12 to 18 has a cuboid shape and has a height (or thickness) extending in a z dimension, as measured between the first planar external surface 421 and the second planar external surface 422, of 8 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The frame 450 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The cavity 430 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 39.93 millimetres and a length extending in an x dimension of 52 millimetres.

Figure 19 shows an aerosol-generating article 500 according to a fifth embodiment of the present disclosure. Features in common with aerosol-generating article 400 are referred to with like reference signs. Aerosol-generating article 500 differs from aerosol-generating article 400 in that a corrugated sheet of cardboard 540 and multiple elongate cylindrical wrapped bodies 560 of aerosol-forming substrate are positioned within the cavity 430. Figures 20 and 21 show respective transverse and lateral cross-section views of the aerosol-generating article 500 of Figure 19.

The corrugated sheet of cardboard 540 comprises a plurality of parallel corrugations having a plurality of substantially parallel peaks 543 and troughs 544. The plurality of parallel corrugations are defined by a corrugation profile which, as seen in Figure 20, is sinusoidal. The plurality of parallel corrugations have a corrugation wavelength of about 4.6 millimetres. The corrugation amplitude is approximately the same as the height (or thickness) of the cavity 430, as shown by the peaks 543 and troughs 544 coinciding with the first cavity end wall 431 and the second cavity end wall 432, respectively.

The plurality of parallel corrugations form a plurality of channels 545 between the cardboard sheet 540 and the first cavity end wall 431 , and a plurality of channels 546 between the cardboard sheet 540 and the second cavity end wall 432. The plurality of channels 545, 546 extend in a longitudinal direction of the aerosol-generating article 500 and form at least a portion of the airflow passage extending between the air inlet 411 and the air outlet 412. A single one of the cylindrical shaped wrapped bodies 560 is positioned within each of one of the channels 545. Each wrapped body 560 has a cylindrical wrapper 561 enclosing a rod of aerosol-forming substrate 562. For each wrapped body 560, opposed end faces of the substrate 562 are free of any wrapper so as to be exposed at opposite ends 563, 564 of the wrapped body 560. Each cylindrical wrapped body 560 is circular in transverse cross-section, in common with figure 7e. Each cylindrical wrapped body 560 is positioned in a corresponding one of the channels 545 to be wedged between opposed surfaces of the corrugated cardboard sheet 540 defining each channel 545. In this manner, each one of the wrapped bodies 560 is held in place within a respective one of the channels 545 through friction between the wrapped body 560 and the opposed surfaces of the corrugated sheet 540 defining each channel 545.

During use of the aerosol-generating article 500, a portion of the air flow through each channel 545 passes through a respective wrapped body 560 of aerosol-forming substrate, with the remaining air flow bypassing the wrapped body and passing through gaps defined between the wrapped body and the surfaces of the corrugated cardboard sheet 540 and the first planar external layer 424.

In an alternative embodiment, each of the channels 546 may also contain a single one of the cylindrical shaped wrapped bodies 560. In other alternative embodiments, the aerosol-forming substrate 562 may be different for different ones of the cylindrical wrapped bodies 560, with the aerosol inhaled by a user consequently containing a combination of different volatile compounds evolved from the different substrates.

During use of each of the aerosol-generating articles 400, 500, the aerosol-forming substrate 462, 562 is heated up to cause the aerosol-forming substrate to release volatile compounds, which are then entrained in air drawn through the air inlet 411 into the cavity 430. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the aerosol-generating article 400, 500 through the air outlet 412.

For exemplary purposes applicable to any of the embodiments described above, a composition of a suitable aerosol-forming substrate may be as follows. Percentages are given in weight percent with respect to the product in its final state. The aerosol-forming substrate may have a moisture of about 5 to 25%, preferably of about 7 to 15%, at final product state. The aerosol-forming substrate may further comprise the following:

1 . Tobacco leaf; for example about 15 to 45%, preferably of about 20 to 35% of a blend of tobacco leaf, incorporating at least one of the following tobacco types: bright tobacco; dark tobacco; aromatic tobacco. Tobacco material is ground and graded to a particle size of about 100 to 380 mesh, preferably of about 170 to 320 mesh. 2. Cellulose fibres; for example about 1 to 15%, preferably of about 3 to 7%, of cellulose fibres, of a length of about 10 to 250 pm, preferably of about 10 to 120 pm.

3. Tobacco fibres; for example about 5 to 20%, preferably of about 7 to 15% of tobacco fibres, as filler, of any tobacco type or a blend of tobacco types. Tobacco fibres are preferably derived from stems and/or or stalks, graded to fibres of a length of about 10 to 350 pm, preferably of about 10 to 180 pm.

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

5. Aerosol-former; for example about 5 to 35%, preferably of about 10 to 25%, of an aerosol former. Suitable aerosol-formers known in the art include: glycerine; monohydric alcohols like menthol, polyhydric alcohols, such as triethylene glycol; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyls of those.

For exemplary purposes, a composition of a further aerosol-forming substrate, which may also be suitable for use as the aerosol-forming substrate in any of the embodiments described above is described below. Percentages are given in weight percent with respect to the product in its final state. The aerosol-forming substrate may comprise:

1 . An aerosol-former such as Glycerin; for example about 10 to 40 %, preferably of about 20 to 30 %.

2. Organic fibres; for example about 10 to 30 %, preferably of about 15 to 25%, of any botanical variety suitable and with purity to comply with applicable FDA F&B grade requirements, as commonly available in the market. For example, organic fibres may derive from cellulose, cotton, wood, tea botanical varieties as sub-products, and subprocessed waste, of F&B tea industry. Organic fibres are preferably of a length of about 10 to 400 pm, preferably of about 10 to 200 pm.

3. Organic botanical glycerite; for example about 15 to 55 %, preferably of about 20 to 35 %, of botanicals such as Clove, Echinacea sp., Fennel, Ginger, Hawthorn berry, Elderberry, Monarda, Mullein leaves, Nettle, Plantain, Turmeric, Yarrow, and compounds of those. 4. Organic botanical extracts; for example about 1 to 15 %, preferably of about 2 to 7 %, of any of the previously referred botanicals, as well as menthol (dl-Menthol, C10H20O, 2-lsopropyl-5-methylcyclohexanol) such as obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related botanic varieties, as well as P-menthan-3-ol, as any secondary alcohol as diastereoisomers of 5-methyl-2-(propan- 2-yl)cyclohexan-1 -oL

Alternatively, such aerosol-forming substrate may also contain botanical essential oils of about 0.5 to 5 %, preferably of about 1 to 3 %, such as of palm, coconut, and wooden-based essential oils.

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

Claims

1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article being defined by an article length, an article width, and an article thickness, the article width being greater than the article thickness, the aerosol-generating article comprising: opposed discrete upper and lower exterior walls, the upper and lower exterior walls collectively defining all or a majority of a perimeter of the aerosol-generating article; a cavity located within the aerosol-generating article between the upper exterior wall and the lower exterior wall; and an airflow passage defined through the aerosol-generating article between an air inlet and an air outlet, the airflow passage extending through the cavity, wherein a wrapped body of aerosol-forming substrate is disposed within the cavity, the wrapped body comprising a wrapper at least partially enclosing aerosol-forming substrate, the wrapper defining a band circumscribing the aerosol-forming substrate, the band having a length extending between opposed first and second axial end faces of the wrapped body.

2. An aerosol-generating article according to claim 1 , wherein the wrapper is configured to be porous, for example the wrapper comprising a plurality of perforations, for example the wrapper having the form of a mesh, for example the wrapper being a metal mesh.

3. An aerosol-generating article according to either one of claim 1 or claim 1 , wherein the aerosol-forming substrate is exposed at the opposed first and second axial end faces of the wrapped body.

4. An aerosol-generating article according to any one of claims 1 to 3, wherein the upper exterior wall and the lower exterior wall define respective upper and lower planar exterior surfaces.

5. An aerosol-generating article according to any one of claims 1 to 4, wherein opposed ends of the upper exterior wall meet corresponding opposed ends of the lower exterior wall to define a pair of laterally opposed edges of the aerosol-generating article.

6. An aerosol-generating article according to any one of claims 1 to 5, wherein the wrapped body of aerosol-forming substrate occupies between 15% and 100% of an interior volume of the cavity, for example between 30% and 100% of an interior volume of the cavity, for example between 50% and 100% of an interior volume of the cavity, for example between 50% and 90% of an interior volume of the cavity, for example between 50% and 80% of an interior volume of the cavity, for example between 50% and 70% of an interior volume of the cavity.

7. An aerosol-generating article according to any one of claims 1 to 6, wherein the wrapped body is configured to be in surface contact with opposing interior walls of the cavity to maintain the wrapped body in fixed position within the cavity.

8. An aerosol-generating article according to any one of claims 1 to 7, wherein a clearance is defined between an exterior surface of the wrapped body and an interior surface of one or more of the cavity, the first exterior wall and the second exterior wall.

9. An aerosol-generating article according to claim 8, wherein the clearance defines at least part of the airflow passage.

10. An aerosol-generating article according to any one of claims 1 to 9, wherein the wrapper comprises or consists of a thermally-conductive material, for example the thermally-conductive material being a metal foil, for example the metal foil being an aluminium foil.

11. An aerosol-generating article according to any one of claims 1 to 10, wherein the aerosolforming substrate is in the form of any one or more of shredded aerosol-forming substrate, strips of aerosol-forming substrate, strands of aerosol-forming substrate, particles of aerosol-forming substrate, one or more sheets of aerosol-forming substrate, one or more gathered sheets of aerosol-forming substrate, cut filler dispersed within a solid binder matrix, a plurality of beads of aerosol-forming substrate.

12. An aerosol-generating article according to any one of claims 1 to 11 , wherein the wrapped body comprises one or more susceptor materials arranged in thermal communication with the aerosol-forming substrate.

13. An aerosol-generating article according to any one of claims 1 to 12, wherein the wrapped body has a first planar external surface and a second planar external surface, a separation between the first and second planar external surfaces defining a thickness of the wrapped body.

14. An aerosol-generating article according to any one of claims 1 to 13, further comprising a frame positioned between the upper exterior wall and the lower exterior wall, the frame at least partially defining the cavity.

15. An aerosol-generating article according to any one of claims 1 to 14, wherein the wrapper comprises or consists of a sheet material having opposed first and second end portions, wherein the sheet material circumscribes the aerosol-forming substrate such that one of the first and second end portions overlaps the other of the first and second end portions to define the band.