WO2025132377A1

WO2025132377A1 - Aerosol-generating article comprising a frame

Info

Publication number: WO2025132377A1
Application number: PCT/EP2024/086820
Authority: WO
Inventors: Matteo Bologna; Pedro Santos EFFERTZ
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2023-12-21
Filing date: 2024-12-17
Publication date: 2025-06-26
Anticipated expiration: 2026-06-21

Abstract

An aerosol-generating article (10) for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article (10) having a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction, the aerosol-generating article (10) comprising: one or more aerosol-generating substrates; a cavity (30); a first planar external surface (21); a second planar external surface (22); a frame (50) positioned between the first planar external surface (21) and the second planar external surface (22), wherein the frame (50) comprises a peripheral wall (51) circumscribing at least a portion of the cavity (30), and wherein the cavity (30) has a width less than or equal to 80 percent of the width of the aerosol-generating article (10).

Description

AEROSOL-GENERATING ARTICLE COMPRISING A FRAME

The present disclosure relates to an aerosol-generating article. The present disclosure also relates to an aerosol-generating device for use with the aerosol-generating article. The present disclosure also relates to an aerosol-generating system comprising the aerosolgenerating device and the aerosol-generating article.

A typical aerosol-generating system comprises an aerosol-generating device and an aerosol-generating article comprising an aerosol-generating substrate. In use, the aerosolgenerating device is arranged to heat a heating element that is positioned near, or in contact with, the aerosol-generating substrate which causes the aerosol-generating substrate to heat up and release volatile compounds. These volatile compounds are then entrained in air that is drawn through the aerosol-generating article. As the volatile compounds cool, they condense to form an aerosol that can be inhaled by a consumer.

A typical aerosol-generating article may appear similar and have similar dimensions to a conventional cigarette. For example, such an aerosol-generating article may be substantially cylindrical and comprise an aerosol-generating substrate in addition to other components such as mouthpiece filter element and a cooling element, which are arranged in the form of a rod and wrapped in a cigarette paper.

However, a significant portion of the aerosol-generating substrate in these cylindrical aerosol-generating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-generating substrate contributes to the cost of manufacture and transport of the aerosol-generating article but does not contribute to the aerosol delivered to the consumer. Moreover, the components of these cylindrical aerosol-generating articles normally need to have the same or very similar outer diameters so that they can be brought together, accurately positioned in axial alignment and wrapped in a cigarette paper. This can lead to increased cost and complexity of manufacture.

It is an objective of the present disclosure to provide an aerosol-generating article in which a greater portion of the aerosol-generating substrate is sufficiently heated to form an aerosol during use. It is an objective of the present disclosure to provide an aerosol-generating article in which the quality and quantity of aerosol delivered to a user is optimised. It is an objective of the present disclosure to provide an aerosol-generating article with improved mechanical rigidity. It is an objective of the present disclosure to provide an aerosol-generating article that can be manufactured relatively efficiently and cheaply.

According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article has a length extending in an x-direction, a width extending in a y-direction, and a thickness extending in a z-direction. the aerosol-generating article may comprise one or more aerosol- generating substrate. The aerosol-generating article may comprise a cavity. The aerosolgenerating article may comprise a first planar external surface. The aerosol-generating article may comprise a second planar external surface. The aerosol-generating article may comprise a frame positioned between the first planar external surface and the second planar external surface. The frame may comprise a peripheral wall circumscribing or defining at least a portion of the cavity. The cavity may have a width less than or equal to 80 percent of the width of the aerosol-generating article.

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

Advantageously, the frame may allow the aerosol-generating article to be relatively thin whilst maintaining structural rigidity.

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

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

Where the aerosol-generating article comprises an aerosol-generating substrate in the cavity, the cavity having a width of less than or equal to 80 percent of the width of the aerosolgenerating article may advantageously improve packing and the density of the aerosolgenerating substrate in the cavity. The packing density of the aerosol-generating substrate may be increased. This may improve heat conduction from a heater of an aerosol-generating device to the aerosol-generating substrate and through the aerosol-generating substrate for improved aerosol delivery.

Increasing the packing density of the aerosol-generating substrate in the cavity may result in a desired increase in the resistance to draw through the aerosol-generating article, which may improve the quality of aerosol delivered to a user.. Increasing the packing density of the aerosol-generating substrate in the cavity may further improve the structural rigidity of the aerosol-generating article. This may be particularly desirable where the aerosol-generating article is relatively thin.

The cavity having a width less than or equal to 80 percent of the width of the aerosolgenerating article may advantageously mean that the frame or components of the frame, such as the peripheral wall and one or more side walls, may have sufficient radial thickness or width to provide the aerosol-generating article with desired mechanical strength.

During use of the aerosol-generating article, the aerosol-generating article may be handled the most by the user across the y-direction, for example by the user holding the side walls of the frame. The cavity having a width less than or equal to 80 percent of the width of the aerosol-generating article may mean that the aerosol-generating article has the desired mechanical resistance to deformation at desired locations. This may allow the overall size of the cavity to be optimised for desired aerosol delivery whilst maintaining structural rigidity of the aerosol-generating article.

Increasing the radial thickness or width of the frame or components of the frame may advantageously reduce the permeability of the frame. For example, one or more side walls of the frame may have an increased width, which may reduce the air permeability of the frame. Reducing the permeability of the frame may improve sealing of the one or more aerosolgenerating substrates of the aerosol-generating article to improve the shelf-life of the aerosolgenerating article and improve the quality and quantity of aerosol delivered to a user. Reducing the permeability of the frame may ensure air and aerosol travel along desired airflow pathways through the aerosol-generating article. This may improve the quality and quantity of aerosol delivered to a user.

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

The cavity having a width less than or equal to 80 percent of the width of the aerosolgenerating article may mean that a surface of the frame may have an increased area for simpler and better adherence of the frame to other components of the aerosol-generating article, such as a first planar external layer forming the first planar external surface and a second planar external layer forming the second planar external surface, by use of an adhesive. This may help to increase the structural rigidity of the aerosol-generating article and avoid delamination of the aerosol-generating article. Where the frame is formed from multiple layers, increasing the width and area of at least a section of the frame may mean that the layers of the frame may be simply and strongly adhered to one another. This may help to increase the structural rigidity of the frame and avoid delamination of the frame. Avoiding delamination of the frame and of the aerosol-generating article may advantageously reduce air permeability of the frame and reduce unwanted airflow pathways forming through the aerosol-generating article. This may improve the quality and quantity of aerosol delivered to a user.

The aerosol-generating article may be a substantially flat aerosol-generating article or a substantially planar aerosol-generating article. In particular, a thickness of the aerosolgenerating article may be less than both a length and a width of the aerosol-generating article. For example, a thickness of the aerosol-generating article may less than 50 percent of both a length and a width of the aerosol-generating article. Advantageously, a smaller thickness may provide a small temperature gradient or difference across the thickness of the aerosolgenerating substrate during heating.

The aerosol-generating article may have a quadrilaterally-faced hexahedron shape. The aerosol-generating article may have a rectangular prism shape. The aerosol-generating article may have a cuboid shape. The aerosol-generating article may have a cylindrical shape. The aerosol-generating article may have a right-angled cylinder shape.

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

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

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

The frame may at least partially define the cavity.

The frame may be a planar frame.

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

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

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

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

The aerosol-generating article may comprise one or more external walls extending between the first planar external surface and the second planar external surface. The one or more external walls may collectively define an entire transverse external area of the aerosolgenerating article. The frame may at least partially define each of the one or more external walls. The one or more external walls may circumscribe or encircle the cavity. The frame may define at least 60 percent, at least 70 percent, at least 80 percent, or at least 90 percent of the entire transverse external area of the aerosol-generating article.

The cavity has a width less than or equal to 80 percent of the width of the aerosolgenerating article. The cavity may have a width less than or equal to 70 percent of the width of the aerosol-generating article. The cavity may have a width less than or equal to 60 percent of the width of the aerosol-generating article. The cavity may have a width less than or equal to 55 percent of the width of the aerosol-generating article.

The cavity may have a width greater than or equal to 30 percent of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 40 percent of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 50 percent of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 60 percent of the width of the aerosol-generating article. The cavity may have a width greater than or equal to 70 percent of the width of the aerosol-generating article.

The width of the cavity may be selected based on a desired balance between the space available for any aerosol-generating substrate in the cavity, the resistance to draw through the cavity, the structural rigidity of the aerosol-generating article, and the overall size of the aerosol-generating article. The cavity may have a width between 30 percent and 80 percent of the width of the aerosol-generating article, between 30 percent and 70 percent of the width of the aerosolgenerating article, between 30 percent and 60 percent of the width of the aerosol-generating article, or between 30 percent and 55 percent of the width of the aerosol-generating article.

The cavity may have a width between 40 percent and 80 percent of the width of the aerosol-generating article, between 40 percent and 70 percent of the width of the aerosolgenerating article, between 40 percent and 60 percent of the width of the aerosol-generating article, or between 40 percent and 55 percent of the width of the aerosol-generating article.

The cavity may have a width between 50 percent and 80 percent of the width of the aerosol-generating article, between 50 percent and 70 percent of the width of the aerosolgenerating article, between 50 percent and 60 percent of the width of the aerosol-generating article, or between 50 percent and 55 percent of the width of the aerosol-generating article.

The cavity may have a width between 60 percent and 80 percent of the width of the aerosol-generating article, or between 60 percent and 70 percent of the width of the aerosolgenerating article.

The cavity may have a width between 70 percent and 80 percent of the width of the aerosol-generating article.

The frame may comprise a peripheral wall circumscribing or encircling at least a portion of the cavity. The peripheral wall may circumscribe or encircle the cavity. The peripheral wall may define at least a portion of the cavity. The peripheral wall may circumscribe or encircle at least a portion of the frame aperture extending through the thickness of the frame. The peripheral wall may circumscribe or encircle the frame aperture extending through the thickness of the frame.

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

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

The peripheral wall may have a radial thickness greater than or equal to 1.5 millimetres. The peripheral wall may have a radial thickness of greater than or equal to 1.75 millimetres. The peripheral wall may have a radial thickness greater than or equal to 2 millimetres. The peripheral wall may have a radial thickness of greater than or equal to 2.25 millimetres. The peripheral wall may have a radial thickness greater than or equal to 2.5 millimetres. The peripheral wall may have a radial thickness of greater than or equal to 2.25 millimetres. The peripheral wall may have a radial thickness greater than or equal to 3 millimetres.

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

The peripheral wall may have a radial thickness between 1.5 millimetres and 4 millimetres, between 1.5 millimetres and 3.5 millimetres, between 1.5 millimetres and 3 millimetres, between 1.5 millimetres and 2.5 millimetres, or between 1.5 millimetres and 2 millimetres.

The peripheral wall may have a radial thickness between 1.75 millimetres and 4 millimetres, between 1.75 millimetres and 3.5 millimetres, between 1.75 millimetres and 3 millimetres, between 1.75 millimetres and 2.5 millimetres, or between 1.75 millimetres and 2 millimetres.

The peripheral wall may have a radial thickness between 2 millimetres and 4 millimetres, between 2 millimetres and 3.5 millimetres, between 2 millimetres and 3 millimetres, or between 2 millimetres and 2.5 millimetres.

The peripheral wall may have a radial thickness between 2.25 millimetres and 4 millimetres, between 2.25 millimetres and 3.5 millimetres, between 2.25 millimetres and 3 millimetres, or between 2.25 millimetres and 2.5 millimetres.

The peripheral wall may have a radial thickness between 2.5 millimetres and 4 millimetres, between 2.5 millimetres and 3.5 millimetres, or between 2.5 millimetres and 3 millimetres.

The peripheral wall may have a radial thickness between 2.75 millimetres and 4 millimetres, between 2.75 millimetres and 3.5 millimetres, or between 2.75 millimetres and 3 millimetres.

The peripheral wall may have a radial thickness between 3 millimetres and 4 millimetres, or between 3 millimetres and 3.5 millimetres.

Advantageously, the peripheral wall having a radial thickness between 1.5 millimetres and 4 millimetres has been found to provide good structural strength for the aerosol-generating article whilst not using excess amounts of material which may increase manufacturing costs, and may limit the amount of heat that is undesirably transferred to the frame rather than the aerosol-generating substrate. In particular, it has been advantageously found that the peripheral wall having a radial thickness between 1.5 millimetres and 4 millimetres may be wide enough such that the peripheral wall may be cut from a large sheet of material with minimal excess material surrounding the peripheral wall while avoiding breakage of the peripheral wall. This may particularly relevant where a large number of peripheral walls are cut from the large sheet with minimal spacing between the peripheral walls. Accordingly, a peripheral wall having a radial thickness of between 1 .5 millimetres and 4 millimetres has been found to avoid both waste of material (from the large sheet of material) that is not used to form the peripheral wall and waste from excess material being used to form the peripheral wall.

The peripheral wall having a radial thickness between 1.5 millimetres and 4 millimetres may provide the aerosol-generating article with a cavity with desired width.

The peripheral wall may comprise a portion having a width between 1 .5 millimetres and 5 millimetres, between 2 millimetres and 5 millimetres, between 2.5 millimetres and 5 millimetres, between 3 millimetres and 5 millimetres.

The peripheral wall may comprise one or more side walls defining at least a portion of the length of the cavity. In other words, the one or more side walls extend in the x-direction. The one or more side walls may each extend in the x-direction and the z-direction. The one or more side walls may each extend in the x/z plane.

The length of the aerosol-generating article may be greater than both the width of the aerosol-generating article and the thickness of the aerosol-generating article. The one or more side walls of the peripheral wall, which define at least a portion of the length of the cavity, may therefore significantly contribute to the structural rigidity of the aerosol-generating article. The radial thickness and width of the one or more side walls may be selected based on a desired mechanical strength of the aerosol-generating article. The radial thickness and width of the one or more side walls may be selected based on a desired balance between the mechanical strength of the aerosol-generating article, the size of the cavity, and the overall size of the aerosol-generating article.

At least one of or each of the one or more side walls may have a radial thickness greater than or equal to 1 .5 millimetres, greater than or equal to 1 .75 millimetres, greater than or equal to 2 millimetres, greater than or equal to 2.25 millimetres, greater than or equal to 2.5 millimetres, greater than or equal to 2.75 millimetres, or greater than or equal to 3 millimetres.

At least one of or each of the one or more side walls may have a radial thickness less than or equal to 4 millimetres, less than or equal to 3.5 millimetres, less than or equal to 3 millimetres, less than or equal to 2.5 millimetres, or less than or equal to 2 millimetres.

At least one of or each of the one or more side walls may have a radial thickness between 1.5 millimetres and 4 millimetres, between 1.5 millimetres and 3.5 millimetres, between 1.5 millimetres and 3 millimetres, between 1.5 millimetres and 2.5 millimetres, or between 1.5 millimetres and 2 millimetres.

At least one of or each of the one or more side walls may have a radial thickness between 1.75 millimetres and 4 millimetres, between 1.75 millimetres and 3.5 millimetres, between 1.75 millimetres and 3 millimetres, between 1.75 millimetres and 2.5 millimetres, or between 1.75 millimetres and 2 millimetres.

At least one of or each of the one or more side walls may have a radial thickness between 2 millimetres and 4 millimetres, between 2 millimetres and 3.5 millimetres, between 2 millimetres and 3 millimetres, or between 2 millimetres and 2.5 millimetres.

At least one of or each of the one or more side walls may have a radial thickness between 2.25 millimetres and 4 millimetres, between 2.25 millimetres and 3.5 millimetres, between 2.25 millimetres and 3 millimetres, or between 2.25 millimetres and 2.5 millimetres.

At least one of or each of the one or more side walls may have a radial thickness between 2.5 millimetres and 4 millimetres, between 2.5 millimetres and 3.5 millimetres, or between 2.5 millimetres and 3 millimetres.

At least one of or each of the one or more side walls may have a radial thickness between 2.75 millimetres and 4 millimetres, between 2.75 millimetres and 3.5 millimetres, or between 2.75 millimetres and 3 millimetres.

At least one of or each of the one or more side walls may have a radial thickness between 3 millimetres and 4 millimetres, or between 3 millimetres and 3.5 millimetres.

At least one of or each of the one or more side walls may have a width greater than or equal to 1.5 millimetres, greater than or equal to 1 .75 millimetres, greater than or equal to 2 millimetres, greater than or equal to 2.25 millimetres, greater than or equal to 2.5 millimetres, greater than 2.75 millimetres, or greater than or equal to 3 millimetres.

At least one of or each of the one or more side walls may have a width less than or equal to 4 millimetres, less than or equal to 4.5 millimetres, less than or equal to 4 millimetres, less than or equal to 3.5 millimetres, less than or equal to 3 millimetres, less than or equal to 2.5 millimetres, or less than or equal to 2 millimetres.

At least one of or each of the one or more side walls may have a width between 1 .5 millimetres and 4 millimetres, between 1.5 millimetres and 3.5 millimetres, between 1.5 millimetres and 3 millimetres, between 1.5 millimetres and 2.5 millimetres, or between 1.5 millimetres and 2 millimetres.

At least one of or each of the one or more side walls may have a width between 1 .75 millimetres and 4 millimetres, between 1.75 millimetres and 3.5 millimetres, between 1.75 millimetres and 3 millimetres, between 1.75 millimetres and 2.5 millimetres, or between 1.75 millimetres and 2 millimetres.

At least one of or each of the one or more side walls may have a width between 2 millimetres and 4 millimetres, between 2 millimetres and 3.5 millimetres, between 2 millimetres and 3 millimetres, or between 2 millimetres and 2.5 millimetres. At least one of or each of the one or more side walls may have a width between 2.25 millimetres and 4 millimetres, between 2.25 millimetres and 3.5 millimetres, between 2.25 millimetres and 3 millimetres, or between 2.25 millimetres and 2.5 millimetres.

At least one of or each of the one or more side walls may have a width between 2.5 millimetres and 4 millimetres, between 2.5 millimetres and 3.5 millimetres, or between 2.5 millimetres and 3 millimetres.

At least one of or each of the one or more side walls may have a width between 2.75 millimetres and 4 millimetres, between 2.75 millimetres and 3.5 millimetres, or between 2.75 millimetres and 3 millimetres.

At least one of or each of the one or more side walls may have a width between 3 millimetres and 4 millimetres, or between 3 millimetres and 3.5 millimetres.

The one or more side walls of the peripheral portion may be or consist of: a first side wall and a second side wall.

The first side wall may be substantially planar. The first side wall may extend substantially parallel to the x-direction. The first side wall may extend in the x/z plane. The first side wall may extend from a front wall of the peripheral wall to a back wall of the peripheral wall. The front wall may be referred to as the first end wall. The back wall may be referred to as the second end wall.

The second side wall may be substantially planar. The second side wall may extend substantially parallel to the x-direction. The first side wall may extend in the x/z plane. The second side wall may extend from a front wall of the peripheral wall to a back wall of the peripheral wall.

The first side wall and the second side wall may oppose one another. The first side wall and the second side wall may be parallel to one another. The separation between the first side wall and the second side wall may define the width of the cavity.

The sum of the width of the first side wall and the second side wall may be greater than or equal to 20 percent of the width of the aerosol-generating article. For example, the peripheral wall may comprise a first side wall and a second side wall each defining at least a portion of the length of the cavity, wherein the first side wall opposes the second side wall, and wherein the sum of the width of the first side wall and the width of the second side wall is greater than or equal to 20 percent of the width of the aerosol-generating article.

The sum of the width of the first side wall and the second side wall may be greater than or equal to 30 percent of the width of the aerosol-generating article, greater than or equal to 40 percent of the width of the aerosol-generating article, or greater than or equal to 45 percent of the width of the aerosol-generating article.

The sum of the width of the first side wall and the second side wall may be less than or equal to 70 percent of the width of the aerosol-generating article, less than or equal to 60 percent of the width of the aerosol-generating article, less than or equal to 50 percent of the width of the aerosol-generating article, less than or equal to 40 percent of the width of the aerosol-generating article, or less than or equal to 30 percent of the width of the aerosolgenerating article.

The sum of the width of the first side wall and the second side wall may be between 20 percent and 70 percent of the width of the aerosol-generating article, between 20 percent and 60 percent of the width of the aerosol-generating article, between 20 percent and 50 percent of the width of the aerosol-generating article, between 20 percent and 40 percent of the width of the aerosol-generating article, or between 20 percent and 30 percent of the width of the aerosol-generating article.

The sum of the width of the first side wall and the second side wall may be between 30 percent and 70 percent of the width of the aerosol-generating article, between 30 percent and 60 percent of the width of the aerosol-generating article, between 30 percent and 50 percent of the width of the aerosol-generating article, between 30 percent and 40 percent of the width of the aerosol-generating article.

The sum of the width of the first side wall and the second side wall may be between 40 percent and 70 percent of the width of the aerosol-generating article, between 40 percent and 60 percent of the width of the aerosol-generating article, or between 40 percent and 50 percent of the width of the aerosol-generating article.

The sum of the width of the first side wall and the second side wall may be between 45 percent and 70 percent of the width of the aerosol-generating article, between 45 percent and 60 percent of the width of the aerosol-generating article, or between 45 percent and 50 percent of the width of the aerosol-generating article..

The sum of the width of the first side wall and the second side wall may be greater than or equal to 3 millimetres, greater than or equal to 3.5 millimetres, greater than or equal to 4 millimetres, greater than or equal to 4.5 millimetres, greater than or equal to 5 millimetres, greater than or equal to 5.5 millimetres, or greater than or equal to 6 millimetres.

The sum of the width of the first side wall and the second side wall may be less than or equal to 8 millimetres, less than or equal to 7 millimetres, less than or equal to 6 millimetres, less than or equal to 5 millimetres, or less than or equal to 4 millimetres.

The sum of the width of the first side wall and the second side wall may be between 3 millimetres and 8 millimetres, between 3 millimetres and 7 millimetres, between 3 millimetres and 6 millimetres, between 3 millimetres and 5 millimetres, or between 3 millimetres and 4 millimetres.

The sum of the width of the first side wall and the second side wall may be between

3.5 millimetres and 8 millimetres, between 3.5 millimetres and 7 millimetres, between 3.5 millimetres and 6 millimetres, between 3.5 millimetres and 5 millimetres, or between 3.5 millimetres and 4 millimetres.

The sum of the width of the first side wall and the second side wall may be between 4 millimetres and 8 millimetres, between 4 millimetres and 7 millimetres, between 4 millimetres and 6 millimetres, or between 4 millimetres and 5 millimetres.

4.5 millimetres and 8 millimetres, between 4.5 millimetres and 7 millimetres, between 4.5 millimetres and 6 millimetres, or between 4.5 millimetres and 5 millimetres.

The sum of the width of the first side wall and the second side wall may be between 5 millimetres and 8 millimetres, between 5 millimetres and 7 millimetres, or between 5 millimetres and 6 millimetres.

5.5 millimetres and 8 millimetres, between 5.5 millimetres and 7 millimetres, or between 5.5 millimetres and 6 millimetres.

The sum of the width of the first side wall and the second side wall may be between 6 millimetres and 8 millimetres, or between 6 millimetres and 7 millimetres.

The frame may comprise one or more elongate channels extending through it. The one or more elongate channels are therefore provided internally within the structure of the frame, for example within a wall of the frame. For example, the frame may comprise one or more elongate channels extending longitudinally through it. In other words, the frame may comprise one or more elongate channels extending in the x-direction through the frame. Alternatively or in addition, the frame may comprise one or more elongate channels extending transversely through it. The one or more elongate channels provide air flow pathways through the frame.

The aerosol-generating article may comprise an elongate flavour-bearing element. The elongate flavour-bearing element may be provided within the one or more elongate channels defined within the frame. The position of the one or more elongate channels may be adapted in order to control the distance between the elongate flavour-bearing element and the heating element when the aerosol-generating article is in place within an aerosol-generating device.

The first side wall may comprise a first elongate channel extending longitudinally through it. The first elongate channel may extend along the entire length of the first side wall. The first elongate channel may be enclosed laterally and transversely by the first wall material. The width or radial thickness of the first side wall may be such that the first side wall may have a first elongate channel extending longitudinally through it while retaining sufficient structural rigidity of the first side wall.

The second side wall may comprise a second elongate channel extending through it. The second elongate channel may extend along the entire length of the second side wall. The second elongate channel may be enclosed laterally and transversely by the second side wall material. The width or radial thickness of the second side wall may be such that the first side wall may have a second elongate channel extending longitudinally through it while retaining sufficient structural rigidity of the second side wall.

At least one of the first elongate channel and the second elongate channel may contain an elongate flavour-bearing element. The frame may further comprise a first end wall and a second end wall. The first and second elongate channels may each extend through at least one of the first end wall and the second end wall. The first and second elongate channels may each extend through both of the first end wall and the second end wall. This may be such that the elongate channels provide an airflow pathway all of the way through the frame between the downstream end and the upstream end. The first and second elongate channels may each be in fluid communication with at least one of the air inlet and the air outlet. For example, the air outlet may have a sufficiently large width such that the first and second elongate channels each extend to the air outlet and an airflow pathway is formed through the first elongate channel and the air outlet, and another airflow pathway is formed through the second elongate channel and the air outlet.

The elongate flavour-bearing element or elements can conveniently be incorporated into the one or more elongate channels within the frame, which also act as air flow pathways through the frame. The positioning of an elongate flavour-bearing element within an air flow pathway may enable the flavourant to be effectively released into the air passing through the frame and subsequently carried through the aerosol-generating article and mixed with the aerosol generated from the aerosol-forming substrate.

The peripheral wall may have a non-uniform radial thickness. The peripheral wall may have a non-uniform radial thickness around the peripheral wall. For example, the peripheral walls may comprise one or more side walls extending between a front wall and a back wall, the radial thickness of at least one of the one or more side walls may be different from the radial thickness of at least one of the front wall and the back wall. This may be such that the aerosol-generating article is provided with increased mechanical strength at desired specific locations while allowing for design of, for example, the cavity to optimise aerosol delivery.

A maximum radial thickness of the peripheral wall may be at the one or more side walls. The maximum radial thickness of the peripheral wall being at the one or more side walls may advantageously allow for an increased size of the cavity while providing an increased mechanical strength at locations where the aerosol-generating article is handled the most by the user. The maximum radial thickness the peripheral wall being at the one or more side walls may advantageously provide a desired balance between the structural rigidity of the aerosolgenerating article and the size of the cavity.

A minimum radial thickness of the peripheral wall may be at the one or more side walls. The minimum radial thickness of the peripheral wall being at the one or more side walls in combination with the cavity having a width of less than or equal to 80 percent of a width of the aerosol-generating article may advantageously mean that the radial thickness of the peripheral wall at all locations around the peripheral wall is such that the aerosol-generating article has improved structural rigidity at all locations around the aerosol-generating article.

The peripheral wall may comprise a front wall and a back wall, wherein each of the one or more side walls extend from the front wall to the back wall. For example, the peripheral wall may comprise a first side wall extending from the front wall to the back wall. The peripheral wall may comprise a second side wall extending from the front wall to the back wall.

The front wall and the back wall may oppose one another. The front wall and the back wall may be substantially parallel to one another.

A radial thickness of at least one of or each of the one or more side walls may be greater than a radial thickness of each of the front wall and the back wall. For example, a radial thickness of each of the one or more side walls may be greater than a radial thickness of each of the front wall and the back wall.

A width of at least one of or each of the one or more side walls may be greater than a length of each of the front wall and the back wall. For example, a width of each of the one or more side walls may be greater than a length of each of the front wall and the back wall.

A radial thickness of at least one of or each of the one or more side walls may be less than a radial thickness of each of the front wall and the back wall. For example, a radial thickness of each of the one or more side walls may be less than a radial thickness of each of the front wall and the back wall.

A width of at least one of or each of the one or more side walls may be less than a length of each of the front wall and the back wall. For example, a width of each of the one or more side walls may be less than a length of each of the front wall and the back wall.

A ratio of a width of the cavity to a width of the aerosol-generating article may be different from the ratio of a length of the cavity to a length of the aerosol-generating article. A ratio of a width of the cavity to a width of the aerosol-generating article may be less than a ratio of the length of the cavity to the length of the aerosol-generating article.

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

The frame may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may comprise cellulose fibres. The cellulosic material may be paper, paperboard, or cardboard. The frame may be made from or comprise a plant material, such as tobacco. The frame may be made entirely from a cellulosic material. The frame may not be an aerosol-generating substrate. The frame may comprise less than or equal to 5 percent of aerosol former, less than or equal to 2 percent of aerosol former, or less than or equal to 1 percent of aerosol former, on a dry weight basis. The peripheral wall of the frame may be made from or comprise a biodegradable material. The peripheral wall of the frame may be made entirely from a biodegradable material.

The peripheral wall of the frame may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may comprise cellulose fibres. The cellulosic material may be paper, paperboard, or cardboard. The peripheral wall of the frame may be made from or comprise a plant material, such as tobacco. The peripheral wall of the frame may be made entirely from a cellulosic material. The peripheral wall of the frame may not be an aerosol-generating substrate. The peripheral wall of the frame may comprise less than or equal to 5 percent of aerosol former, less than or equal to 2 percent of aerosol former, or less than or equal to 1 percent of aerosol former, on a dry weight basis.

The aerosol-generating article may comprise one or more susceptor materials. The frame may comprise one or more susceptor materials. The one more susceptor materials may be in thermal contact with the aerosol-generating substrate. The one more susceptor materials may be in thermal contact with the cavity. The one or more susceptor materials may be incorporated within the material of the frame. For example, the one or more susceptor material may be incorporated within the peripheral wall of the frame.

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

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

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

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

The frame may have a thickness between 50 percent of the thickness of the aerosolgenerating article and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 70 percent of the thickness of the aerosol-generating article and 95 percent of the thickness of the aerosol-generating article.

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

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

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

The frame may be a unitary component. Alternatively, the frame may comprise two or more layers. That is, the frame may have a laminated structure. Advantageously, the properties of each layer may be individually optimised depending on the relative distance between the layer and aerosol-generating substrate or heater of the aerosol-generating device.

The frame may comprise a first frame layer and a second frame layer. The first frame layer and the second frame layer may be the only layers of the frame. That is, the frame may comprise no more than two layers or may comprise exactly two layers. The frame aperture may be defined through both the first frame layer and the second frame layer.

The frame may comprise a first frame layer, a second frame layer and a third frame layer. The second frame layer may be positioned between the first frame layer and the third frame layer. The first frame layer, the second frame layer and the third frame layer may be the only layers of the frame. That is, the frame may comprise no more than three layers or may comprise exactly three layers.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may overlie opposing ends of the cavity. The first aerosol-generating substrate layer and the second aerosol-generating substrate layer may define or form opposing end walls of the cavity. That is, the frame, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may collectively define the cavity.

One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness greater than or equal to 100 micrometres, greater than or equal to 200 micrometres, greater than or equal to 300 micrometres, greater than or equal to 400 micrometres, or greater than or equal to 500 micrometres.

One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness less than or equal to 600 micrometres, less than or equal to 500 micrometres, less than or equal to 400 micrometres, less than or equal to 300 micrometres, or less than or equal to 300 micrometres.

One or more of the aerosol-generating substrate layer, the first aerosol-generating substrate layer and the second aerosol-generating substrate layer may have a thickness between 100 micrometres and 600 micrometres, between 200 micrometres and 500 micrometres, between 200 micrometres and 400 micrometres, or between 200 micrometres and 300 micrometres.

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

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

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

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

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

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

The first planar external surface may be a planar upper surface and the second planar external surface may be a planar lower surface. The first planar external surface may be positioned parallel to the second planar external surface. The first planar external surface may extend in the x/y plane. The second planar external surface may extend in the x/y plane. The second planar external surface may be spaced from the first planar external surface in the z- direction or transverse direction. The distance between the first planar external surface and the second planar external surface in the z-direction or transverse direction may define the thickness of the aerosol-generating article.

The aerosol-generating article may comprise an outer wrapper. The outer wrapper may be hydrophobic. The outer wrapper may comprise a hydrophobic material. The outer wrapper may define or form the first planar external surface. The outer wrapper may define or form the second planar external surface. The outer wrapper may define or form both the first planar external surface and the second planar external surface.

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

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

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

The aerosol-generating article may comprise a first planar external layer and a second planar external layer. The first planar external layer may be an upper layer and the second planar external layer may be a lower layer.

The first planar external layer may define or form the first planar external surface. The first planar external layer may extend in the x/y plane. The second planar external layer may define or form the second planar external surface. The second planar external layer may extend in the x/y plane.

The frame may be positioned between the first planar external layer and the second planar external layer. The cavity may be defined by the frame, the first planar external layer and the second planar external layer.

The first planar external layer may be in physical contact with, and may be bonded to, the frame. The first planar external layer may overlie an end of the cavity. The first planar external layer may define or form a wall of the cavity, such as the first cavity end wall or top wall.

The second planar external layer may be in physical contact with, and may be bonded to, the frame. The second planar external layer may overlie an end of the cavity. The second planar external layer may define or form a wall of the cavity, such as the second cavity end wall or bottom wall.

The first planar external layer and the second planar external layer may overlie opposing ends of the cavity. The first planar external layer and the second planar external layer may define or form opposing end walls of the cavity, such as the first cavity end wall or top wall and the second cavity end wall or bottom wall. That is, the frame, the first planar external layer and the second planar external layer may collectively define the cavity.

At least one of the one or more aerosol-generating substrates may be located between the first planar external layer and the second planar external layer.

The first planar external layer may be spaced, such as in a transverse direction, from the frame. For example, the aerosol-generating substrate layer or the first aerosol-generating substrate layer may be positioned between the first planar external layer and the frame. The first planar external layer may be in physical contact with, and may be bonded to, the aerosolgenerating substrate layer or the first aerosol-generating substrate layer.

The second planar external layer may be spaced, such as in a transverse direction, from the frame. For example, the aerosol-generating substrate layer or the second aerosolgenerating substrate layer may be positioned between the second planar external layer and the frame. The second planar external layer may be in physical contact with, and may be bonded to, the aerosol-generating substrate layer or the second aerosol-generating substrate layer.

The first planar external layer may be hydrophobic. The first planar external layer may comprise a hydrophobic material. The second planar external layer may be hydrophobic. The second planar external layer may comprise a hydrophobic material.

One or more of the outer wrapper, the first planar external layer and the second planar external layer may comprise, or be made from, a cellulosic material. The cellulosic material may be paper, cigarette paper, tobacco paper, cardboard, wood, textile, natural fibres or artificial fibres.

One or more of the outer wrapper, the first planar external layer and the second planar external layer may be an aerosol-generating substrate comprising an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. In particular, the aerosol-generating material may be in the form of a sheet of aerosolgenerating material. The sheet of aerosol-generating material may be any sheet of aerosolgenerating material described herein. Alternatively, one or more of the outer wrapper, the first planar external layer and the second planar external layer may not comprise any aerosolgenerating material, particularly in embodiments comprising an aerosol-generating substrate layer, a first aerosol-generating substrate layer, a second aerosol-generating substrate layer or an aerosol-generating substrate positioned within the cavity. One or more of the outer wrapper, the first planar external layer and the second planar external layer may be substantially nicotine-free.

One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness greater than or equal to 25 micrometres, greater than or equal to 30 micrometres, greater than or equal to 35 micrometres, greater than or equal to 40 micrometres, or greater than or equal to 45 micrometres.

One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness less than or equal to 55 micrometres, less than or equal to 50 micrometres, less than or equal to 45 micrometres, less than or equal to 40 micrometres, or less than or equal to 35 micrometres.

One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a thickness between 25 micrometres and 55 micrometres, between 25 micrometres and 45 micrometres, or between 30 micrometres and 45 micrometres.

One or more of the outer wrapper, the first planar external layer and the second planar external layer may have a length substantially the same as the length of the frame. One or more of the outer wrapper, 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 more of the first planar external layer and the second planar external layer may have a width substantially the same as the width of the frame. One or more 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 cavity may have a thickness greater than or equal to 0.5 millimetres. The cavity may have a thickness greater than or equal to 1 .5 millimetres. The cavity may have a thickness greater than or equal to 2.5 millimetres. The cavity may have a thickness greater than or equal to 3.5 millimetres.

The cavity may have a thickness less than or equal to 4.5 millimetres. The cavity may have a thickness less than or equal to 3.5 millimetres. The cavity may have a thickness less than or equal to 2.5 millimetres. The cavity may have a thickness less than or equal to 1.5 millimetres.

The cavity may have a thickness between 0.5 millimetres and 4.5 millimetres. The cavity may have a thickness between 1 millimetre and 4.5 millimetres. Preferably, the cavity may have a thickness between 2.8 millimetres and 3.3 millimetres.

The cavity may have a length greater than or equal to 14 millimetres. The cavity may have a length equal to a greater than 18 millimetres. The cavity may have a length greater than or equal to 22 millimetres. The cavity may have a length greater than or equal to 30 millimetres. The cavity may have a length greater than or equal to 38 millimetres.

The cavity may have a length less than or equal to 40 millimetres. The cavity may have a length less than or equal to 34 millimetres. The cavity may have a length less than or equal to 28 millimetres. The cavity may have a length less than or equal to 22 millimetres. The cavity may have a length less than or equal to 18 millimetres. The cavity may have a length between 14 millimetres and 40 millimetres. The cavity may have a length between 14 millimetres and 34 millimetres. . The cavity may have a length between 24 millimetres and 28 millimetres.

The cavity may have a width greater than or equal to 4.5 millimetres. The cavity may have a width greater than or equal to 7 millimetres. The cavity may have a width greater than or equal to 11 millimetres.

The cavity may have a width less than or equal to 13 millimetres. The cavity may have a width less than or equal to 11 millimetres. The cavity may have a width less than or equal to 7 millimetres. The cavity may have a width less than or equal to 5 millimetres.

The cavity may have a width between 4.5 millimetres and 13 millimetres. The cavity may have a width between 7 millimetres and 10 millimetres. The cavity may have a width between 7.5 millimetres and 8.5 millimetres.

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.

Preferably, 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.

Most preferably, the cavity may have a length of 26 millimetres, a width of 8 millimetres, and a thickness of 3.1 millimetres.

The cavity may have a volume of greater than or equal to 30 cubic millimetres, greater than or equal to 100 cubic millimetres, greater than or equal to 300 cubic millimetres, greater than or equal to 500 cubic millimetres, greater than or equal to 700 cubic millimetres, greater than or equal to 900 cubic millimetres, greater than or equal to 1000 cubic millimetres, greater than or equal to 2000 cubic millimetres, or greater than or equal to 30 cubic millimetres.

The cavity may have a volume of less than or equal to 3500 cubic millimetres, less than or equal to 2500 cubic millimetres, less than or equal to 1500 cubic millimetres, less than or equal to 1000 cubic millimetres, less than or equal to 800 cubic millimetres, less than or equal to 600 cubic millimetres, less than or equal to 500 cubic millimetres, less than or equal to 400 cubic millimetres, or less than or equal to 300 cubic millimetres.

The cavity may have a volume between 30 cubic millimetres and 3500 cubic millimetres. The cavity may have a volume between 30 cubic millimetres and 2500 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 1500 cubic millimetres. The cavity may have a volume between 100 cubic millimetres and 1000 cubic millimetres.

The cavity may be substantially empty. The one or more aerosol-generating substrates may comprise an aerosol-generating substrate positioned within the cavity. The aerosol-generating substrate positioned within the cavity may fill the cavity.

The aerosol-generating substrate positioned within the cavity may comprise an aerosol-generating material. The aerosol-generating material may be any aerosol-generating material described herein. For example, the aerosol-generating material may be in the form of shredded aerosol-generating material.

The aerosol-generating material may be in the form of a sheet of aerosol-generating material. The sheet of aerosol-generating material may be any sheet of aerosol-generating material described herein. For example, the sheet of aerosol-generating material may be a sheet of homogenised tobacco material.

The sheet of aerosol-generating material may extend the entire length of the cavity. The sheet of aerosol-generating material may extend the entire width of the cavity.

The sheet of aerosol-generating material may be a gathered sheet of aerosolgenerating material. That is, the sheet of aerosol-generating material may be convoluted, folded, or otherwise compressed or constricted substantially perpendicular to the transverse direction of the aerosol-generating article.

The sheet of aerosol-generating material may be a crimped sheet of aerosolgenerating material. The sheet of aerosol-generating material may be a corrugated sheet of aerosol-generating material. The crimped sheet of aerosol-generating material or the corrugated sheet of aerosol-generating material may comprise a plurality of parallel corrugations. For example, the crimped sheet of aerosol-generating material may comprise a plurality of substantially parallel peaks and troughs.

The plurality of parallel corrugations may be defined by a corrugation profile, in which the corrugation profile is sinusoidal, or triangular, or rectangular, or trapezoidal, or toroidal, or parabolic.

The plurality of parallel corrugations may define, or form, a plurality of channels between the sheet of aerosol-generating material and one or more walls of the cavity. The plurality of channels may be a plurality of longitudinally extending channels. The plurality of channels may be a plurality of laterally extending channels. The plurality of channels may defined, or form, at least a portion of an airflow passage extending between the air inlet and air outlet of the aerosol-generating article.

The aerosol-generating material may comprise one or more organic materials such as tobacco, mint, tea and cloves. The aerosol-generating material may comprise one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenised tobacco such as cast leaf, extruded tobacco, expanded tobacco, aerosol-generating films and gel compositions. The aerosol-generating material may be in the form of shredded aerosol-generating material. The shredded aerosol-generating material may comprise one or more of: strips and strands of aerosol-generating material, such as strips and strands of tobacco or homogenised tobacco material. The shredded aerosol-generating material may be in the form of a shredded sheet of homogenised tobacco material.

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

The aerosol-generating material may be in the form of a sheet of aerosol-generating material. As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenised tobacco material, such as a cast leaf sheet.

The aerosol-generating material may comprise one or more aerosol-formers. Suitable aerosol-formers are well known in the art and include, but are not limited to, one or more aerosol-formers 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 aerosol-former to be or comprise one or both of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

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

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

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

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

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

The aerosol-generating material may comprise at least 0.5 percent by weight of nicotine, at least 1 percent by weight of nicotine, at least 1 .5 percent by weight of nicotine, or at least 2 percent by weight of nicotine. That is, the aerosol-generating material may have a nicotine content of at least 0.5 percent by weight, at least 1 percent by weight, at least 1.5 percent by weight, or at least 2 percent by weight.

The aerosol-generating material may be in the form of a plurality of beads. The plurality of beads may have an average particle diameter of between 0.1 mm and 4 mm, for example between 0.5 mm and 4 mm.

The term “bead” refers to a discrete, solid particle formed of the aerosol-generating substrate. A bead may have a rounded, typically spherical, form. Other terms may be used to define the substrate such as, for example, “granule”.

Providing the aerosol-generating material as a plurality of beads may provide certain advantages. Beads can be easily handled compared to other aerosol-forming substrates such as fine powders or cut filler. The beads flow easily, and so can reliably and consistently fill the cavity of the aerosol-generating article during manufacture. This may allow a consistent and reproducible amount of aerosol-forming substrate to be loaded into each article during manufacture. Beads may also be cleaner to handle than powders and cut fillers, which may cause dust in factories, and may leak from aerosol-generating articles in transit or in use. By selecting beads with appropriate bead sizes and appropriate particle size distributions, air flow through the cavity of the aerosol-generating article may be controlled more reproducibly than would be the case for, say, a cut filler substrate.

Where a particle is not perfectly spherical, but a diameter of the particle is referred to, the term “diameter” may refer to a largest dimension of the particle. Alternatively, the term “diameter” may refer to the diameter of a perfectly spherical particle having the same volume as the not perfectly spherical particle.

The term “average particle diameter”, as used herein, may refer to a number average particle diameter. Other methods of determining average particle diameter are known. Thus, the average particle diameter may be, for example, a volume average particle diameter. The aerosol-generating material may be in form of a wrapped body of aerosolgenerating material, the wrapped body comprising a wrapper at least partially enclosing aerosol-generating material.

The wrapped body of aerosol-generating material may occupy between 15% and 100% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 30% and 100% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 50% and 100% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 50% and 80% of the interior volume of the cavity. The wrapped body of aerosol-generating material may occupy between 50% and 70% of the interior volume of the cavity.

The aerosol-generating article may comprise a substrate wrapper. The substrate wrapper may circumscribe or encircle the aerosol-generating substrate. The substrate wrapper may circumscribe or encircle the aerosol-generating substrate, a first side wall of the frame and a second side wall of the frame. The substrate wrapper may be in physical contact with, and may be bonded to, the first side wall and the second side wall.

The substrate wrapper may be may comprise, or be made from, a cellulosic material. The cellulosic material may be paper, cigarette paper, tobacco paper, cardboard, wood, textile, natural fibres or artificial fibres.

The aerosol-generating article may comprise an air inlet and an air outlet. The aerosolgenerating article may comprise an airflow passage extending between the air inlet and the air outlet. The airflow passage may extend between the air inlet and the air outlet through the cavity. The airflow passage may extend from the air inlet to the air outlet. The airflow passage may extend from the air inlet to the air outlet through the cavity.

The air inlet may be defined by, and may extend through, the frame. The air inlet may be defined by the peripheral wall of the frame. The air inlet may extend through the peripheral wall of the frame. The air inlet may be defined by the front wall of the aerosol-generating article. The air inlet may extend through the front wall of the aerosol-generating article. The air outlet may be defined by, and may extend through, the frame. The air outlet may be defined by the peripheral wall of the frame. The outlet may extend though the peripheral wall of the frame. The air outlet may be defined by the back wall of the aerosol-generating article. The air outlet may extend through the back wall of the aerosol-generating article.

The air inlet may have a round cross-section, a circular cross-section, an oval crosssection, a square cross-section, or a rectangular cross-section. The air outlet may have a round cross-section, a circular cross-section, an oval cross-section, a square cross-section, or a rectangular cross-section.

The air inlet may be defined by, and may extend through, the first planar external surface. The air inlet may be defined by, and may extend through, the outer wrapper. The air inlet may be defined by, and may extend through, the outer wrapper and the aerosolgenerating substrate layer. The air inlet may be defined by, and may extend through, the outer wrapper and the first aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the first planar external layer and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the first planar external layer and the first aerosol-generating substrate layer.

The air inlet may be defined by, and may extend through, the second planar external surface. The air inlet may be defined by, and may extend through, the outer wrapper and the second aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the second planar external layer and the aerosol-generating substrate layer. The air inlet may be defined by, and may extend through, the second planar external layer and the second aerosol-generating substrate layer.

The air outlet may be defined by, and may extend through, the first planar external surface. The air outlet may be defined by, and may extend through, the outer wrapper. The air outlet may be defined by, and may extend through, the outer wrapper and the aerosolgenerating substrate layer. The air outlet may be defined by, and may extend through, the outer wrapper and the first aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the first planar external layer and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the first planar external layer and the first aerosol-generating substrate layer.

The air outlet may be defined by, and may extend through, the second planar external surface. The air outlet may be defined by, and may extend through, the outer wrapper and the second aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the second planar external layer and the aerosol-generating substrate layer. The air outlet may be defined by, and may extend through, the second planar external layer and the second aerosol-generating substrate layer.

One or both of the air inlet and the air outlet may have an equivalent diameter greater than or equal to 0.1 millimetres, greater than or equal to 0.4 millimetres, greater than or equal to 0.7 millimetres, or greater than or equal to 1 .0 millimetres.

One or both of the air inlet and the air outlet may have an equivalent diameter less than or equal to 3 millimetres, less than or equal to 2.7 millimetres, less than or equal to 2.4 millimetres, less than or equal to 2.1 millimetres. The air inlet may have an equivalent diameter less than or equal to 2.7 millimetres, less than or equal to 1.8 millimetres, or less than or equal to 1.5 millimetres.

One or both of the air inlet and the air outlet may have an equivalent diameter between 0.1 millimetres and 3 millimetres, between 0.1 millimetres and 2.4 millimetres, between 0.4 millimetres and 2.1 millimetres, between 0.4 millimetres and 1.8 millimetres, between 0.7 millimetres and 1.5 millimetres, or between 1.0 millimetres and 1.5 millimetres.

The air inlet may have a width less than a width of the cavity. The air outlet may have a width less than a width of the cavity. The air inlet may have a thickness less than a thickness of the cavity. The air outlet may have a thickness less than a thickness of the cavity.

One or both of the air inlet and the air outlet may a width of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres.

One or both of the air inlet and the air outlet may have a thickness of between 0.3 millimetres and 3 millimetres or between 0.5 millimetres and 2 millimetres.

Preferably, the air inlet may have a width of between 0.3 millimetres and 3 millimetres, and a thickness of between 0.3 millimetres and 3 millimetres.

Preferably, the air outlet may have a width of between 0.3 millimetres and 3 millimetres, and a thickness of between 0.3 millimetres and 3 millimetres.

Advantageously, an aerosol-generating article having an air outlet or air inlet with a width of between 0.3 millimetres and 3 millimetres and a thickness of between 0.3 millimetres and 3 millimetres may provide for a relatively large inlet or outlet opening while allowing for improved retention of the aerosol-generating substrate within the aerosol-generating article. Improved retention of the aerosol-generating substrate within the aerosol-generating article may reduce the risk of aerosol-generating substrate falling out of the aerosol-generating article.

A ratio of the width of the air inlet to the thickness of the air inlet may be between 0.33 and 3. A ratio of the width of the air inlet to the thickness of the air inlet may be between 0.5 and 1.5. A ratio of the width of the air inlet to the thickness of the air inlet may be between 0.75 and 1.25.

A ratio of the width of the air outlet to the thickness of the air outlet may be between 0.33 and 3. A ratio of the width of the air outlet to the thickness of the air outlet may be between 0.5 and 1 .5. A ratio of the width of the air outlet to the thickness of the air outlet may be between 0.75 and 1.25.

The aerosol-generating article may comprise a plurality of air inlets. One or each of the air inlets may have one or more of the features of the air inlet described herein.

The aerosol-generating article may comprise a plurality of air outlets. One or each of the air outlets may have one or more of the features of the air outlet described herein.

The aerosol-generating article may comprise a filter element positioned downstream of the aerosol-forming substrate. The aerosol-generating article may comprise a filter element positioned downstream of the cavity. The aerosol-generating article may comprise a filter element at least partially positioned within the air outlet. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at a downstream end of, the cavity.

The aerosol-generating article may comprise a filter element positioned upstream of the aerosol-forming substrate. The aerosol-generating article may comprise a filter element positioned upstream of the cavity. The aerosol-generating article may comprise a filter element at least partially positioned within the air inlet. The aerosol-generating article may comprise a filter element positioned within, and may be positioned at an upstream end of, the cavity.

The filter element may comprise one or more segments of a fibrous filtration material. Suitable fibrous filtration materials would be known to the skilled person. The filter element may comprise a cellulose acetate.

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 may be greater than 2:1 , greater than 5:1 , greater than 10:1 , greater than 12:1 , or greater than 15:1.

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 may be less than 15:1 , less than 12:1 , less than 10:1 , less than 5:1 , or less than 2.5:1

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 may be between 2:1 and 15:1 , between 2:1 and 12:1 , between 2:1 and 10:1 , or between 5:1 and 10:1.

A ratio between the length and the width of the aerosol-generating article may be greater than 1 :1 , greater than 2:1 , greater than 3: 1 , greater than 4: 1 , or greater than 5:1.

A ratio between the length and the width of the aerosol-generating article may be less than 10:1 , less than 8:1 , less than 5:1 , less than 4:1 , less than 3:1 , or less than 2:1.

A ratio between the length and the width of the aerosol-generating article may be between 1 :1 and 10:1 , between 1 :1 and 5:1 , between 1 :1 and 4:1 , between 1 :1 and 3:1 , between 2:1 and 4:1 , or between 2:1 and 3:1.

The aerosol-generating article may have a length greater than or equal to 15 millimetres, greater than or equal to 20 millimetres, greater than or equal to 25 millimetres, greater than or equal to 30 millimetres, greater than or equal to 35 millimetres, or greater than or equal to 40 millimetres.

The aerosol-generating article may have a length less than or equal to 45 millimetres, less than or equal to 40 millimetres, less than or equal to 35 millimetres, or less than or equal to 30 millimetres.

The aerosol-generating article may have a length between 15 millimetres and 45 millimetres, between 20 millimetres and 40 millimetres, between 20 millimetres and 35 millimetres, or between 25 millimetres and 30 millimetres. The aerosol-generating article may have a width greater than or equal to 3 millimetres, greater than or equal to 5 millimetres, greater than or equal to 7.5 millimetres, greater than or equal to 9 millimetres, greater than 1 or equal to 1 millimetres, or greater than or equal to 13 millimetres.

The aerosol-generating article may have a width less than or equal to 17 millimetres, less than or equal to 15 millimetres, less than or equal to 12.5 millimetres, less than or equal to 11 millimetres, or less than or equal to 9 millimetres.

The aerosol-generating article may have a width between 3 millimetres and 17 millimetres, between 5 millimetres and 15 millimetres, between 7.5 millimetres and 12.5 millimetres, or between 9 millimetres and 11 millimetres.

The aerosol-generating article may have a thickness greater than or equal to 1 millimetre, greater than or equal to 1.5 millimetres, greater than or equal to 2 millimetres, greater than or equal to 2.5 millimetres, greater than or equal to 3 millimetres, greater than or equal to 3.5 millimetres, greater than or equal to 4 millimetres, or greater than or equal to 4.5 millimetres.

The aerosol-generating article may have a thickness less than or equal to 5.5 millimetres, less than or equal to 5 millimetres, less than or equal to 4.5 millimetres, less than or equal to 4 millimetres, less than or equal to 3.5 millimetres, less than or equal to 3 millimetres, less than or equal to 2.5 millimetres, or less than or equal to 2 millimetres.

The aerosol-generating article may have a thickness between 1 millimetres and 5 millimetres, between 1.5 millimetres and 5 millimetres, between 2 millimetres and 4.5 millimetres, between 2.5 millimetres and 4 millimetres, or between 3 millimetres and 3.5 millimetres.

For example, the aerosol-generating article may have a length between 15 millimetres and 45 millimetres, a width between 5 millimetres and 15 millimetres, and a thickness between 1 millimetre and 5 millimetres. In particular, the aerosol-generating article may comprise: a first planar external surface; a second planar external surface; a cavity; a frame positioned between the first planar external surface and the second planar external surface, the frame at least partially defining the cavity; and one or more aerosol-generating substrates, wherein the aerosol-generating article has a a length between 15 millimetres and 45 millimetres, a width between 5 millimetres and 15 millimetres, and a thickness between 1 millimetre and 5 millimetres, and wherein a width of the cavity is less than or equal to 80 percent of a width of the aerosol-generating article.

According to the present disclosure, there is provided an aerosol-generating device for receiving an aerosol-generating article as disclosed herein. The aerosol-generating device comprises a cavity dimensioned to receive at least a portion of the aerosol-generating article. The aerosol-generating device comprises a heater or heating means, a power source for supplying power to the heater or heating means, and a controller to control a supply of power to the heater or heating means. The aerosol-generating device is configured to heat at least one of the one or more aerosol-generating substrates to form an aerosol, for example an inhalable aerosol. The aerosol-generating device may be configured to heat each of the one or more aerosol-generating substrates to form an aerosol, for example an inhalable aerosol.

According to the present disclosure, an aerosol-generating system comprises an aerosol-generating device as disclosed herein and an aerosol-generating article as disclosed herein. The system may comprise a plurality of such articles for use with the aerosolgenerating device.

As used herein, the term “aerosol-generating article” refers to an article comprising an aerosol-generating substrate. The article may be heated in use to produce and deliver an inhalable aerosol to a consumer.

As used herein, the term “aerosol-generating substrate” refers to a substrate capable of releasing volatile compounds upon heating, for example compounds which, in use, cool and condense to generate an aerosol.

As used herein, the term “aerosol-generating device” refers to a device that, in use, interacts with, for example heats, an aerosol-generating substrate of an aerosol-generating article to generate an aerosol.

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

As used herein, the term “transverse” refers to a direction extending between the first planar external surface and the second planar external surface. The transverse direction may also be referred to as the “z-di recti on”.

As used herein, the term “longitudinal” refers to a direction that is perpendicular to the transverse direction. For example, a direction between the front wall and the back wall of the aerosol-generating article. The longitudinal direction may also be referred to as the “x- di recti on”.

As used herein, the term “lateral” refers to a direction that is perpendicular to the transverse direction and the longitudinal direction. For example, a direction from a first side wall to a second side wall of the aerosol-generating article. The lateral direction may also be referred to as the “y direction”. As used herein, the term “thickness” refers to a maximum dimension of the aerosolgenerating article or a component of the aerosol-generating article in the transverse direction.

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

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

As used herein, the terms “upstream” and “downstream” refer to the relative positions of components, or portions of components, of the aerosol-generating article in relation to the direction in which the air or aerosol is transported through the aerosol-generating article during use. The “upstream end” of the aerosol-generating article, components of the aerosolgenerating article, or portions of components of the aerosol-generating article may be referred to as the “first end” or “distal end” of the aerosol-generating article, components of the aerosolgenerating article, or portions of components of the aerosol-generating article, respectively. The “downstream end” of the aerosol-generating article, components of the aerosolgenerating article, or portions of components of the aerosol-generating article may be referred to as the “second end” or “proximal end” of the aerosol-generating article, components of the aerosol-generating article, or portions of components of the aerosol-generating article, respectively.

As used herein, the term “bulk density” may refer to the total weight of the aerosolgenerating substrate divided by the bulk volume of the aerosol-generating substrate.

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

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

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

As used herein, the term “hydrophobic” refers to a surface exhibiting water repelling properties. One useful way to determine this is to measure the water contact angle. The “water contact angle” is the angle, conventionally measured through the liquid, where a liquid/vapour interface meets a solid surface. It quantifies the wettability of a solid surface by a liquid via the Young equation.

As used herein, the term “equivalent diameter” of an opening or an aperture is used herein to denote the diameter of a circular opening or aperture having the same cross- sectional area as the opening or aperture. The invention is defined in the claims. However, below there is provided a non- exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein. EX1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article having a length-extending in an x- direction, a width extending in a y-direction, and a thickness extending in a z-direction, the aerosol-generating article comprising: one or more aerosol-generating substrates; a cavity; a first planar external surface, and a second planar external surface.

EX2: An aerosol-generating article according to EX1 , wherein the cavity has a width less than or equal to 80 percent of the aerosol-generating article.

EX3: An aerosol-generating article according to EX1 or EX2 further comprising a frame positioned between the first planar external surface and the second planar external surface.

EX4: An aerosol-generating article according to EX3, wherein the frame comprises a peripheral wall circumscribing or defining at least a portion of the cavity.

EX5: An aerosol-generating article according to any one of EX1 to EX4, wherein the aerosol-generating article is a planar aerosol-generating article. EX6: An aerosol-generating article according to any one of EX1 to EX5, wherein a thickness of the aerosol-generating article is less than both a length and a width of the aerosol-generating article.

EX7: An aerosol-generating article according to any one of EX1 to EX6, wherein the aerosol-generating article has a laminated structure.

EX8: An aerosol-generating article according to any one of EX1 to EX7, wherein substantially the entirety of the aerosol-generating article, excluding the one or more aerosolgenerating substrates is paper or cardboard.

EX9: An aerosol-generating article according to any one of EX1 to EX8, wherein the cavity has a width of greater than or equal to 30 percent of the width of the aerosol-generating article.

EX10: An aerosol-generating article according to any one of EX4 to EX9, wherein the peripheral wall has a radial thickness greater than or equal to 1.5 millimetres.

EX11 : An aerosol-generating article according to any one of EX4 to EX10, wherein the peripheral wall has a radial thickness less than or equal to 4 millimetres.

EX12: An aerosol-generating article according to any one of EX4 to EX11 , wherein the peripheral wall comprises a portion having a width between 1.5 millimetres and 5 millimetres.

EX13. An aerosol-generating article according to any one of EX4 to EX12, wherein the peripheral wall comprises one or more side walls defining at least a portion of the length of the cavity.

EX14: An aerosol-generating article according to EX13, wherein at least one of or each of the one or more side walls has a radial thickness greater than or equal to 1 .5 millimetres. EX15: An aerosol-generating article according to EX13 or EX14, wherein at least one of or each of the one or more side walls has a radial thickness less than or equal to 4 millimetres.

EX16: An aerosol-generating article according to any one of EX13 to EX15, wherein at least one of or each of the one or more side walls has a width greater than or equal to 1.5 millimetres.

EX17: An aerosol-generating article according to any one of EX13 to EX16, wherein at least one of or each of the one or more side walls has a width less than or equal to 4 millimetres.

EX18: An aerosol-generating article according to any one of EX4 to EX17, wherein the peripheral wall comprises a first side wall and a second side wall, the first side wall and the second side wall both defining at least a portion of the length of the cavity, wherein the first side wall opposes the second side wall.

EX19: An aerosol-generating article according to EX18, wherein the sum of the width of the first side wall and the width of the second side wall is greater than or equal to 20 percent of the width of the aerosol-generating article.

EX20: An aerosol-generating article according to EX18 or EX19, wherein the sum of the width of the first side wall and the width of the second side wall is less than or equal to 70 percent of the width of the aerosol-generating article.

EX21 : An aerosol-generating article according to any one of EX18 to EX20, wherein the sum of the width of the first side wall and the width of the second side wall is greater than or equal to 30 percent of the width of the aerosol-generating article.

EX22: An aerosol-generating article according to any one of EX18 to EX21 , wherein the sum of the width of the first side wall and the width of the second side wall is greater than or equal to 3 millimetres.

EX23: An aerosol-generating article according to any one of EX18 to EX22, wherein the sum of the width of the first side wall and the width of the second side wall is less than or equal to 8 millimetres.

EX24: An aerosol-generating article according to any one of EX4 to EX23, wherein the peripheral wall has a non-uniform radial thickness.

EX25: An aerosol-generating article according to any one of EX4 to EX24, wherein a maximum radial thickness of the peripheral wall is at the one or more side walls.

EX26: An aerosol-generating article according to any one of EX4 to EX24, wherein a minimum radial thickness of the peripheral wall is at the one or more side walls.

EX27: An aerosol-generating article according to any one of EX4 to EX26, wherein the peripheral wall comprises a front wall and a back wall, and wherein each of the one or more side walls extend from the front wall to the back wall. EX28: An aerosol-generating article according to EX27, wherein a width of each of the one or more side walls is greater than a length of each of the front wall and the back wall.

EX29: An aerosol-generating article according to EX27, wherein a width of each of the one or more side walls is less than a length of each of the front wall and the back wall.

EX30: An aerosol-generating article according to any one of EX4 to EX29, wherein the peripheral wall is made from paper, paperboard, or cardboard.

EX31 : An aerosol-generating article according to any one of EX4 to EX30, wherein the peripheral wall comprises less than or equal to 5 percent of aerosol former.

EX32: An aerosol-generating article according to any one of EX1 to EX31 , comprising one or more susceptor materials.

EX33: An aerosol-generating article according to any one of EX3 to EX32, wherein the aerosol-generating article or the frame has a laminated structure.

EX34: An aerosol-generating article according to any one of EX1 to EX33, wherein the one or more aerosol-generating substrates comprise a sheet of aerosol-generating material.

EX35: An aerosol-generating article according to EX34, wherein the sheet of aerosolgenerating material defines at least a portion of the cavity.

EX36: An aerosol-generating article according to EX34 or EX35, wherein the sheet of aerosol-generating material has a width substantially the same as a width of the frame, and a length substantially the same as a length of the frame.

EX37: An aerosol-generating article according to any one of EX1 to EX36, comprising an outer wrapper.

EX38: An aerosol-generating article according to EX37, wherein the outer wrapper defines or forms at least one of the first planar external surface and the second external planar surface.

EX39: An aerosol-generating article according to any one of EX1 to EX38, wherein the cavity has a thickness between 0.5 millimetres and 4.5 millimetres.

EX40: An aerosol-generating article according to any one of EX1 to EX39, wherein the cavity has a length between 4 millimetres and 40 millimetres.

EX41 : An aerosol-generating article according to any one of EX1 to EX40, wherein the cavity has a width between 4.5 millimetres and 13 millimetres.

EX42: An aerosol-generating article according to any one of EX1 to EX41 , wherein the cavity is substantially empty.

EX43: An aerosol-generating article according to any one of EX1 to EX40, wherein at least one of the one or more aerosol-generating substrates is located in the cavity.

EX44: An aerosol-generating article according to any one of EX1 to EX43, wherein each of the one or more aerosol-generating substrates comprise at least 5 percent by weight of aerosol former on a dry weight basis. EX45: An aerosol-generating article according to any one of EX1 to EX43, comprising an air inlet and an air outlet.

EX46: An aerosol-generating article according to EX45, comprising an airflow passage extending between the air inlet and the air outlet through the cavity.

EX47: An aerosol-generating article according to EX45 or EX46, wherein the air inlet is defined by the frame, such as by the peripheral wall of the frame, such as by the front wall.

EX48: An aerosol-generating article according to any one of EX45 to EX47, wherein the air outlet is defined by the frame, such as by the peripheral wall of the frame, such as by the back wall.

EX49: An aerosol-generating article according to any one of EX3 to EX48, comprising one or more elongate channels extending through the frame.

EX50: An aerosol-generating article according to any one of EX18 to EX49, wherein the first side wall comprises a first elongate channel extending longitudinally through the first side wall along the entire length of the first side wall, and wherein the second side wall comprises a second elongate channel extending longitudinally through the second side wall along the entire length of the second side wall.

EX51 : An aerosol-generating system comprising: an aerosol-generating article according to any one of EX1 to EX50 and an aerosol-generating device configured to heat at least one of the one or more aerosol-generating substrates of the aerosol-generating article.

EX52: An aerosol-generating system according to EX51 , wherein the aerosolgenerating device comprises a cavity dimensioned to receive at least a portion of the aerosolgenerating article, a heater, a power source for supplying power to the heater, and a controller to control a supply of power to the heater.

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

Figure 1 shows a perspective view of an aerosol-generating article according to the present disclosure;

Figure 2 shows an exploded perspective view of the aerosol-generating article of Figure 1 ;

Figure 3 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

Figure 4 shows a perspective view of an aerosol-generating article according to the present disclosure;

Figure 5 shows a perspective view of an aerosol-generating article according to the present disclosure;

Figure 6 shows an exploded perspective view of an aerosol-generating article according to the present disclosure; Figure 7 shows a perspective view of an aerosol-generating article according to the present disclosure;

Figure 8 shows an exploded perspective view of an aerosol-generating article according to the present disclosure;

Figure 9 shows a perspective view of an aerosol-generating article according to the present disclosure in a first stage of a manufacturing process;

Figure 10 shows a perspective view of the aerosol-generating article of Figure 9 in a second stage of a manufacturing process;

Figure 11 shows a perspective view of an aerosol-generating article of Figure 9 in a third stage of a manufacturing process;

Figure 12 shows a perspective view of an aerosol-generating article of Figure 9 in a fourth stage of a manufacturing process;

Figure 13 shows a perspective view of an aerosol-generating article according to the present disclosure in a first stage of a manufacturing process;

Figure 14 shows a perspective view of the aerosol-generating article of Figure 13 in a second stage of a manufacturing process;

Figure 15 shows a perspective view of an aerosol-generating article of Figure 13 in a third stage of a manufacturing process;

Figure 16 shows a perspective view of an aerosol-generating article of Figure 14 in a fourth stage of a manufacturing process;

Figure 17 shows a cross-sectional view of the aerosol-generating article shown in Figure 16;

Figure 18 shows a schematic cross-sectional view of an aerosol-generating device according to the present disclosure; and

Figure 19 shows a schematic cross-sectional view of an aerosol-generating system with the aerosol-generating device of Figure 18 in engagement with an aerosol-generating article of the present disclosure.

Figure 1 shows an aerosol-generating article 10 comprising a first planar external layer 24 forming a first planar external surface 21 , a second planar external layer 25 forming a second planar external surface 22, and a frame 50 positioned between the first planar external layer 24 and the second planar external layer 25. The first planar external layer 24 and the second planar external layer 25 both comprise an aerosol-generating substrate comprising an aerosol-generating material, namely tobacco. However, it will be understood that in some embodiments only one of the first planar external layer 24 and the second planar external layer 25 may comprise an aerosol-generating substrate. Alternatively, or additionally, the aerosol-generating substrate may be positioned elsewhere within the aerosol-generating article 10. The aerosol-generating article 10 has a length extending in the x-direction, a width extending in the y-direction and a thickness extending in the z-direction. The aerosolgenerating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.1 millimetres.

The aerosol-generating article 10 is a substantially flat aerosol-generating article or substantially planar aerosol-generating article. In particular, the thickness of the aerosolgenerating article 10 is less than 50 percent of both the length and the width of the aerosolgenerating article. The aerosol-generating article 10 has a generally rectangular cuboid shape and a laminated structure formed by the first planar external layer 24, the frame 50 and the second planar external layer 25. The first planar external layer 24, the frame 50 and the second planar external layer 25 are bonded together with an adhesive, in particular guar gum, as discussed in more detail below in relation to Figure 2.

Figure 2 shows an exploded view of the aerosol-generating article 10 of Figure 1.

The frame 50 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 2.7 millimetres. The frame 50 is made from cardboard and defines a frame aperture extending through the thickness of the frame 50. The frame aperture at least partially forms a cavity 30. The cavity 30 has length of 26 millimetres, a width of 6 millimetres, and a thickness of 2.7 millimetres. Therefore, the cavity 30 has a volume of about 421.2 cubic millimetres. The width of the cavity is 60 percent of the width of the aerosol-generating article. In this embodiment, the cavity 30 is substantially empty.

The frame 50 has a frame inner surface 52 extending in the z-direction or the transverse direction between the first planar external surface 21 and the second planar external surface 22. The frame inner surface 52 defines a cavity outer wall. The frame 50 has a frame outer surface 53 extending in the z-direction or the transverse direction between the first planar external surface 21 and the second planar external surface 22. The frame outer surface 53 at least partially defines one or more external surfaces of the aerosol-generating article, such as the front wall 13 and the back wall 14.

The frame 50 comprises a peripheral wall 51 that circumscribes the cavity 30. In more detail, the peripheral wall 51 is defined by the frame inner surface 52 and the frame outer surface 53. The peripheral wall 51 has a radial thickness, as measured between the frame inner surface 52 and the frame outer surface 53 in the x/y plane, of about 2 millimetres.

The first planar external layer 24 and the second planar external layer 25 have a thickness of 200 micrometres and are in physical contact with the frame 50. The first planar external layer 24 and the second planar external layer 25 are bonded to the frame with an adhesive 15. The first planar external layer 24 defines at least a portion of the cavity 30. The second planar external layer 25 defines at least a portion of the cavity 30. The aerosol-generating article 10 comprises an air inlet 11 and an air outlet 12. The air inlet 11 and the air outlet 12 are defined by, and extend through, the peripheral wall 51 of the frame 50. The air inlet 11 and the air outlet 12 each have a rectangular cross-section, a width of 2 millimetres, and a thickness of 0.9 millimetres. An airflow passage extends between the air inlet 11 and the air outlet 12 through the cavity 30.

Figure 3 shows an exploded view of an aerosol-generating article that is similar to the aerosol-generating article 10 of Figure 1 except that the first planar external layer 24 and the second planar external layer 25 do not comprise an aerosol-generating substrate. Instead, an aerosol-generating substrate 40 is positioned within the cavity 30. The aerosol-generating substrate 40 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. As shown, the aerosolgenerating substrate 40 fills the entire volume of the cavity 30. In the example of Figure 3, the aerosol-generating substrate 40 has a packing density of about 0.87, a density of about 0.3 grams per cubic centimetre, and a mass of about 110 milligrams. In another example, the aerosol-generating substrate 40 may have a different packing density, a different density and a different mass. For example, aerosol-generating substrate may have a packing density of 0.64, a density of 0.35 grams per cubic centimetre, and a mass of about 95 milligrams.

Figure 4 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figures 1 and 3 except that the aerosol-generating article 10 of Figure 4 comprises an outer wrapper 23 defining the first planar external surface 21 and the second planar external surface 22 instead of the first planar external layer 24 and the second planar external layer 25.

Figure 5 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 1 except that the aerosol-generating article 10 of Figure 5 further comprises a first aerosol-generating substrate layer 41 and a second aerosol-generating substrate layer 42. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are formed from a sheet of aerosol-generating material. In particular, a sheet of homogenised tobacco material having an aerosol-former content of 5 percent by weight on a dry weight basis. The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 each have a length equal to the length of the aerosolgenerating article 10, a width equal to the width of the aerosol-generating article 10 and a thickness of 200 micrometres. That is, the aerosol-generating article 10 has a length of 30 millimetres, a width of 10 millimetres, and a thickness of 3.5 millimetres.

The first aerosol-generating substrate layer 41 and the second aerosol-generating substrate layer 42 are in physical contact with the frame 50 and are bonded to the frame with an adhesive 15. The first aerosol-generating substrate layer 41 defines at least a portion of the cavity. The second aerosol-generating layer 42 defines at least a portion of the cavity. The first planar external layer 24 is in physical contact with the first aerosol-generating substrate layer 41 and are bonded together with an adhesive 15. The second planar external layer 25 is in physical contact with the second aerosol-generating substrate layer 42 and are bonded together with an adhesive 15.

Figure 6 shows an exploded view of an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 5 except that an aerosol-generating substrate 40 is positioned within the cavity 30 as described in relation to Figure 3. The aerosol-generating substrate 40 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. As shown, the aerosolgenerating substrate 40 fills the entire volume of the cavity 30.

Figure 7 shows an aerosol-generating article 10 similar to the aerosol-generating article 10 of Figure 5 except that the aerosol-generating article 10 of Figure 7 comprises an outer wrapper 23 defining the first planar external surface 21 and the second planar external surface 22 instead of the first planar external layer 24 and the second planar external layer 25.

Figure 8 shows an exploded view of an aerosol-generating article 10 that is similar to the aerosol-generating article 10 of Figure 1 except that the width of the first planar external layer 124, the width of the frame 150, the width second planar external layer 125 of the article 10 shown in Figure 8 are different from the width of the first planar external layer 24, the width of the frame 50, and the width of the second planar external layer 25 of the article 10 shown in Figure 1 , respectively. Accordingly, the width of the aerosol-generating article 10 shown in Figure 8 is different from the width of the aerosol-generating article 10 shown in Figure 1.

The thickness and the length of the components of the aerosol-generating article 10 shown in Figure 8 are the same as the thickness and the length of corresponding components of the aerosol-generating article 10 shown in Figure 1 , respectively. The cavity 30 of the aerosol-generating articles 10 shown in Figures 1 and 8 are the same. In particular, the dimensions of the cavity 30 of the aerosol-generating articles 10 shown in Figures 1 and 8 are the same.

The width of the aerosol-generating article, the width of the first planar external layer 124, the width of the frame 150, and the width of the second planar external layer 125 are each 12 millimetres.

In particular, the frame 150 comprises a first side wall 116 and a second side wall 117, both forming a part of the peripheral wall of the frame 150. The first side wall 116 extends in the x-z plane and extends from the front wall 13 to the back wall 14. The second side wall 117 opposes the first side wall 116, extends in the x-z plane and extends from the front wall 13 to the back wall 14. The first side wall 116 and the second side wall 117 are spaced apart by 6 millimetres, which corresponds to the width of the cavity 30. The first side wall 116 has a radial thickness or width of 3 millimetres. The radial thickness or width of the first side wall 116 is therefore greater than the radial thickness or length of each of the front wall 13 and the back wall 14.

The second side wall 116 has a radial thickness or width of 3 millimetres. The radial thickness or width of the second side wall 117 is therefore greater than the radial thickness or length of each of the front wall 13 and the back wall 14.

The adhesive 15 in the article 10 shown in Figure 8 is applied to a larger area than the adhesive 15 in the article 10 shown in Figure 1.

Figures 9 to 12 show the manufacture of an aerosol-generating article 10 according to the present disclosure. The aerosol-generating article 10 shown in Figure 12 is similar to the aerosol-generating article 10 shown in Figure 3, except that the frame 50 of the aerosolgenerating article shown in Figure 12 is formed from non-integral parts: a first side wall 54, a second side wall 56, a first end wall 58 and a second end wall 60.

Figure 9 shows a part of the aerosol-generating article 10. The aerosol-generating article 10 comprises an aerosol-generating substrate 40, a first side wall 54 and a second side wall 56. The first side wall 54 and the second side wall 56 are both parts of the peripheral wall of the frame of the aerosol-generating article 10 and provides the aerosol-generating article with structural rigidity. The first side wall 54 and the second side wall 56 may act as support elements for the aerosol-generating substrate 40. The first side wall 54 and the second side wall 56 are elongate members located at lateral edges of the aerosol-generating substrate 40 and both extend along the longitudinal axis or x-direction of the aerosol-generating article 10. The first side wall 54 and the second side wall 56 each have a width of 2 millimetres and have a separation therebetween of 6 millimetres. The width of the first side wall 54 and the width of the second side wall 56 may be such that the first side wall 54 and the second side wall 56 advantageously provide the frame with structural rigidity.

The aerosol-generating substrate 40 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.

Figure 10 shows the part of the aerosol-generating article 10 of Figure 9 comprising a substrate wrapper 62 wrapped around the aerosol-generating substrate 40, the first side wall 54 and the second side wall 56.

Figure 11 shows the part of the aerosol-generating article 10 of Figure 10 in addition to a first end wall 58 and a second end wall 60. The first end wall 58 and the second end wall 60 are both parts of the peripheral wall of the frame of the aerosol-generating article 10. The peripheral wall is formed of the first side wall 54, the second side wall 56, the first end wall 58 and the second end wall 60. The first end wall 58 is located at an upstream end of the first side wall 54 and the second side wall 56. The first end wall 58 is attached to the first side wall 54 and the second side portion 56. In this example, the first end wall 58 is bonded to the first side wall 54 and the second side wall 56 using an adhesive. The width of the first side wall 54 and the width of the second side wall 56 are such that the first end wall 58 is strongly bonded to the first side wall 54 and the second side wall 56. The air inlet 10 is defined through the first end wall 58.

The second end wall 60 is located at a downstream end of the first side wall 54 and the second side wall 56. The second end wall 60 is attached to the first side wall 54 and the second side wall 56. In this example, the second end wall 60 is bonded to the first side wall 54 and the second side wall 56 using an adhesive. The width of the first side wall 54 and the width of the second side wall 56 are such that the second end wall 60 is easily and strongly bonded to the first side wall 54 and the second side wall 56. The air outlet 12 is defined through the second end wall 60.

The first end wall 58 and the second end wall 60 both have a length greater than the width of either the first side wall 54 or the second side wall 56. Accordingly, the minimum radial thickness of the peripheral wall is at the first side wall 54 and the second side wall 56.

Figure 12 shows an aerosol-generating article 10 comprising the part of the aerosolgenerating article 10 of Figure 11 wrapped in an outer wrapper 64. The outer wrapper 64 defines the first planar external surface 21 and the second planar external surface 22.

Figures 13 to 16 show the manufacture of an aerosol-generating article 10 according to the present disclosure.

Figure 13 shows a part of the aerosol-generating article 10. The part of the aerosolgenerating article 10 is similar to the part of the aerosol-generating article 10 in Figure 9, except that an elongate channel 66, 68 extends longitudinally through each of the first side wall 54 and the second side wall 56.

In the example of Figure 13, the first side wall 54 comprises a first elongate channel 66. The first elongate channel 66 extends longitudinally (in the x-direction) through the first side wall 54 from an upstream end of the first side wall 54 to a downstream end of the first side wall 54. The second side wall 56 comprises a second elongate channel 68. The second elongate channel 68 extends longitudinally through the second side wall 56 from an upstream end of the second side wall 56 to a downstream end of the second side wall 56.

Figure 14 shows the part of the aerosol-generating article 10 of Figure 13 comprising a substrate wrapper 62 wrapped around the aerosol-generating substrate 40, the first side wall 54 and the second side wall 56. The part of the aerosol-generating article in Figure 14 is similar to the part of the aerosol-generating article 10 shown in Figure 10 except that an elongate channel extends longitudinally through each of the first side wall 54 and the second side wall 56, as discussed above. Figure 15 shows the part of the aerosol-generating article 10 of Figure 14 in addition to a first end wall 58 and a second end wall 60. The parts of the aerosol-generating article in Figure 15 are similar to the parts of the aerosol-generating article 10 shown in Figure 11 except that an elongate channel extends longitudinally through each of the first side wall 54 and the second side wall 56, as discussed above. In addition, the first end wall 58 comprises a first channel 70 and a second channel 72 extending longitudinally from an upstream end of the first end wall 58 to a downstream end of the first end wall 58. The first channel 70 of the first end wall 58 and the first elongate channel 54 of the first side wall 54 are positioned such that they are fluidly connected with one another, allowing, for example, air to flow between the first channel 70 and the first elongate channel 54. The second channel 72 of the first end wall 58 and the second elongate channel 56 of the second side wall 56 are positioned such that they are fluidly connected with one another, allowing, for example, air to flow between the second channel 72 and the second elongate channel 56.

The air outlet 12 is defined through the second end wall 60. In the part of the aerosolgenerating article of Figure 15 (and of the aerosol-generating article of Figure 16), the air outlet 12 is wider than the air outlet 12 of the part of the aerosol-generating article of Figure 11 (and of the aerosol-generating article of Figure 12, respectively). A wider air outlet 12 provides for the fluid connection between the air outlet 12 and the first elongate channel 66 and the second elongate channel 68. Fluid connection between the air outlet 12 and the first elongate channel 66 and the second elongate channel 68 allows, for example, air to flow between the air outlet 12 and the first elongate channel 66, and air to flow between the air outlet 12 and the second elongate channel 68.

Figure 16 shows an aerosol-generating article 10 comprising the parts of the aerosolgenerating article shown in Figure 15 assembled and wrapped in an outer wrapper 64. The outer wrapper 64 defines the planar external surface 21 and the second planar external surface 22.

Figure 17 shows a cross-sectional view of the aerosol-generating article 10 of Figure 16, taken along the longitudinal axis of the aerosol-generating article 10. The cross-section shown in Figure 17 is in the x-y plane and through the cavity and substrate 40 of the aerosolgenerating article 10.

Figure 18 shows a schematic cross-sectional view of an aerosol-generating device 90 configured for use with an aerosol-generating article 10 described herein. The aerosolgenerating device 90 is an elongate aerosol-generating device extending between a proximal end 91 and a distal end 92. The aerosol-generating device 90 comprises a battery 93, a controller 94, a first heater 95 and a second heater 96 located within a housing 97. The controller 94 controls supply of power from the battery 93 to the first heater 95 and the second heater 96. A cavity 1000 is defined in the device 90, the cavity 1000 having an opening 1010 defined in the proximal end 91 of the device 90. The opening 1010 is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosol-generating article 10. The cavity 1000 comprises an upper planar surface 1020 and a lower planar surface 1030. The first heater 95 is located in the upper planar surface 1020 to heat the first planar external surface 21 of an aerosol-generating article 10 inserted into the cavity 1000, and the second heater 96 is located in the lower planar surface 1030 to heat the second planar external surface 22 of an aerosol-generating article 10 inserted into the cavity 1000. The device 90 comprises an air inlet 98 defining an air-flow path configured to allow air to flow into the cavity 1000 from outside the device.

Figure 19 shows a schematic cross-sectional view of an aerosol-generating system with the aerosol-generating device 90 of Figure 18 in engagement with the aerosol-generating article 10 of Figure 1. There is little tolerance between the first planar external surface 21 and the second planar external surface 22 of the aerosol-generating article 10 and the internal surfaces 1020, 1030 of the cavity 1000. Thus, there is a snug fit between the aerosolgenerating article 10 and the aerosol-generating device 90. When a consumer has inserted the aerosol-generating article 10 into the cavity 1000, the device can be operated. The first heater 95 heats the first planar external surface 21 of the aerosol-generating article 10 and the second heater 96 heats the second planar external surface 22 of the aerosol-generating article, and as a result the aerosol-generating substrate is heated. Volatile components of the aerosol-generating substrate are evaporated and condense in the cavity 30 of the aerosolgenerating article 10 to form an aerosol. The consumer inhales the aerosol by drawing on the end of the aerosol-generating article 10 comprising the air outlet 12. Once the aerosolgenerating substrate has been depleted of volatile components, the aerosol-generating article 10 is removed from the cavity 1000 and disposed of.

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

Claims

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

2. An aerosol-generating article according to claim 1, wherein the peripheral wall has a radial thickness greater than or equal to 1.5 millimetres.

3. An aerosol-generating article according to claim 1 or 2, wherein the peripheral wall comprises a portion having a width between 1.5 millimetres and 5 millimetres.

4. An aerosol-generating article according to any one of the preceding claims, wherein the peripheral wall has a non-uniform radial thickness.

5. An aerosol-generating article according to any one of the preceding claims, wherein the peripheral wall comprises one or more side walls defining at least a portion of the length of the cavity.

6. An aerosol-generating article according to claim 5, wherein the one or more side walls is a first side wall and a second side wall, wherein the first side wall opposes the second side wall, and wherein the sum of the width of the first side wall and the width of the second side wall is greater than or equal to 20 percent of the width of the aerosol-generating article.

7. An aerosol-generating article according to claim 5 or 6, wherein each of the one or more side walls has a width greater than or equal to 1.5 millimetres.

8. An aerosol-generating article according to any one of claims 5 to 7, wherein a maximum radial thickness of the peripheral wall is at the one or more side walls.

9. An aerosol-generating article according to any one of claims 5 to 7, wherein a minimum radial thickness of the peripheral wall is at the one or more side walls.

10. An aerosol-generating article according to any one of claims 5 to 9, wherein the peripheral wall comprises a front wall and a back wall, wherein each of the one or more side walls extend from the front wall to the back wall.

11. An aerosol-generating article according to claim 10, wherein a width of each of the one or more side walls is greater than a length of each of the front wall and the back wall.

12. An aerosol-generating article according to claim 10, wherein a width of each of the one or more side walls is less than a length of each of the front wall and the back wall.

13. An aerosol-generating article according to any one of claims 5 to 12, wherein the first side wall comprises a first elongate channel extending longitudinally through the first side wall along the entire length of the first side wall, and wherein the second side wall comprises a second elongate channel extending longitudinally through the second side wall along the entire length of the second side wall.

14. An aerosol-generating article according to any one of the preceding claims, wherein a ratio of a width of the cavity to a width of the aerosol-generating article is less than a ratio of a length of the cavity to a length of the aerosol-generating article.

15. An aerosol-generating article according to any one of the preceding claims, wherein the aerosol-generating article has a length between 15 millimetres and 45 millimetres, a width between 5 millimetres and 15 millimetres, and a thickness between 1 millimetre and 5 millimetres.