Aerosol-forming cartridge comprising a tobacco-containing material

1. An aerosol-forming cartridge for an electrically operated aerosol-generating system, the cartridge comprising:

a base layer; and

at least one aerosol-forming substrate disposed on the base layer and comprising a tobacco-containing material with volatile tobacco flavour compounds that are releasable from the at least one aerosol-forming substrate,

wherein the base layer and the at least one aerosol-forming substrate are in contact at a first contact surface, which is substantially planar.

2. The aerosol-forming cartridge of claim 1 , wherein one or both of the base layer and the at least one aerosol-forming substrate is substantially flat.

3. The aerosol-forming cartridge of claim 1 ,

wherein the base layer comprises at least one cavity, and

wherein the at least one aerosol-forming substrate is held in the at least one cavity.

4. The aerosol-forming cartridge of claim 1 , wherein the at least one aerosol-forming substrate comprises a plurality of aerosol-forming substrates disposed separately on the base layer.

5. The aerosol-forming cartridge of claim 4 ,

wherein the base layer comprises a plurality of cavities, and

wherein each of the plurality of aerosol-forming substrates is held in a cavity of the plurality of cavities.

6. The aerosol-forming cartridge of claim 1 , further comprising an electric heater including at least one heating element configured to heat the at least one aerosol-forming substrate,

wherein a second contact surface between the electric heater and one or both of the base layer and the at least one aerosol-forming substrate is substantially planar and substantially parallel to the first contact surface between the base layer and the at least one aerosol-forming substrate.

7. The aerosol-forming cartridge of claim 6 ,

wherein the at least one aerosol-forming substrate comprises a plurality of aerosol-forming substrates disposed separately on the base layer, and

wherein the electric heater comprises a plurality of heating elements each configured to heat a different one of the plurality of aerosol-forming substrates.

8. The aerosol-forming cartridge of claim 1 , further comprising an integral mouthpiece portion.

9. The aerosol-forming cartridge of claim 8 , wherein the cartridge is configured such that a resistance-to-draw at a downstream end of the mouthpiece portion is from about 50 mmWG to about 130 mmWG.

10. The aerosol-forming cartridge of claim 8 , wherein the cartridge is configured such that a resistance-to-draw at a downstream end of the mouthpiece portion is from about 95 mmWG to about 105 mmWG.

11. An electrically operated aerosol-forming system, comprising:

an aerosol-forming cartridge comprising:

a base layer, and

at least one aerosol-forming substrate disposed on the base layer and comprising a tobacco-containing material with volatile tobacco flavour compounds that are releasable from the at least one aerosol-forming substrate,

wherein the base layer and the at least one aerosol-forming substrate are in contact at a first contact surface, which is substantially planar;

an electric vaporiser configured to vaporise the at least one aerosol-forming substrate; and

an aerosol-generating device comprising:

a main body defining a slot-shaped receptacle configured to removably receive the aerosol-forming cartridge, and

an electric power supply configured to supply power to the electric vaporiser.

12. A method of manufacturing an aerosol-forming cartridge for an electrically operated aerosol-generating system, the method comprising:

providing a base layer; and

placing at least one aerosol-forming substrate on the base layer such that the base layer and the at least one aerosol-forming substrate are joined at a first contact surface, which is substantially planar,

wherein the at least one aerosol-forming substrate comprises a tobacco-containing material with volatile tobacco flavour compounds, which are released from the at least one aerosol-forming substrate upon heating.

13. The method of claim 12 , further comprising forming at least one cavity in the base layer,

wherein the placing the at least one aerosol-forming substrate on the base layer further comprises placing the at least one aerosol-forming substrate in the at least one cavity.

14. The method of claim 12 , wherein the providing the base layer comprises feeding a web of base layer foil from a bobbin to an assembly line and cutting the web of base layer foil transversely to form individual base layers.

15. The method of claim 12 , further comprising attaching an electric heater to the base layer such that the electric heater and the base layer are in contact at a second contact surface, which is substantially planar and is substantially parallel to the first contact surface between the base layer and the at least one aerosol-forming substrate.

16. The method of claim 15 , wherein the attaching the electric heater comprises feeding a web of electric heater foil from a bobbin to an assembly line and cutting the web of electric heater foil transversely to form individual electric heaters.

17. The method of claim 16 , further comprising forming a plurality of aerosol-forming cartridges in parallel,

wherein the web of electric heater foil has a width from about two times to about 50 times greater than a width of each aerosol-forming cartridge of the plurality of aerosol-forming cartridges.

18. The method of claim 16 , wherein two or more webs of foil from which the aerosol-forming cartridge is made are laminated together.

19. The method of claim 16 , wherein the web of electric heater foil comprises a web of electrically insulating substrate foil to which a plurality of heating elements is attached.

20. The method of claim 19 , further comprising forming a plurality of aerosol-forming cartridges in parallel,

wherein the web of base layer foil has a width from about two times to about 50 times greater than a width of each aerosol-forming cartridge of the plurality of aerosol-forming cartridges.