Aerosol-generating article having a rod of aerosol-generating substrate

Abstract

An aerosol-generating article (10, 20, 30, 40) comprising a rod (11, 21, 31, 41) of an aerosol-generating substrate having a rod width (19, 29, 39, 49) and a rod length (18, 28, 38, 48), wherein the ratio of the rod width (19, 29, 39, 49) to the rod length (18, 28, 38, 48) is 0.5 to 0.56, and the total dry mass of the rod (11, 21, 31, 41) of the aerosol-generating substrate is 220 milligrams or less; and an aerosol-generating system (1000, 2000) comprising the aerosol-generating article (10, 20, 30, 40) and an aerosol generating device (100, 200).

Description

[Technical Field]

[0001] The present disclosure relates to an aerosol-generating article comprising a rod of an aerosol-generating substrate. [Background technology]

[0002] It is known to provide a heating element for heating an aerosol-generating substrate of an aerosol-generating article. The heating element may be provided in the article in the form of a susceptor element that can be heated when penetrated by a changing magnetic field. Alternatively, or additionally, the heating element may be provided in an aerosol-generating device for generating inhalable vapor. Such a device may heat the aerosol-generating substrate contained in the aerosol-generating article without burning the aerosol-generating substrate. The aerosol-generating article may have a rod shape configured for insertion of a portion of the aerosol-generating article into a device cavity of the aerosol-generating device. The aerosol-generating device may also include a heating element. The heating element may be in the form of a pin configured for insertion into the rod of the aerosol-generating substrate. The pin may be located within the device cavity. When the aerosol-generating substrate of the aerosol-generating article is received in the device cavity, the pin heating element may penetrate the aerosol-generating substrate and be inserted into the aerosol-generating substrate to heat the aerosol-generating substrate from the inside.

[0003] During use, the outer peripheral portion of the aerosol-generating substrate furthest from the heating element may not receive enough heat from the heating element to vaporize volatile compounds within the substrate and form an aerosol. Summary of the Invention [Problem to be solved by the invention]

[0004] It would be desirable to provide an aerosol-generating article and / or an aerosol-generating system that provides improved heating of the aerosol-generating substrate within the aerosol-generating article. It would also be desirable to provide an aerosol-generating article and / or an aerosol-generating system that provides more uniform heating of the aerosol-generating substrate within the aerosol-generating article. It would also be desirable to reduce or eliminate waste of aerosol-generating substrate in an aerosol-generating system. It would also be desirable to provide an aerosol-generating article and / or an aerosol-generating system that requires fewer aerosol-generating substrates to deliver a desired amount of aerosol. [Means for solving the problem]

[0005] According to the present invention, there is provided an aerosol-generating article. The aerosol-generating article may comprise a rod of aerosol-generating substrate. The rod may have a rod width. The rod may have a rod length. The ratio of the rod width to the rod length may be 0.5 to 0.56. The rod of aerosol-generating substrate may have a total dry mass of 220 milligrams or less.

[0006] According to the present invention, there is provided an aerosol-generating article. The aerosol-generating article comprises a rod of an aerosol-generating substrate having a rod width and a rod length. The ratio of the rod width to the rod length is 0.5 to 0.56. The total dry mass of the rod of the aerosol-generating substrate is 220 milligrams or less.

[0007] Advantageously, providing an aerosol-generating article having a rod of aerosol-generating substrate with a rod width to rod length ratio of 0.5 to 0.56 can provide improved heat transfer from a heating element (such as a pin heating element of an aerosol generator) to the outer peripheral portion of the rod of aerosol-generating substrate. Surprisingly, through experimental data, it has been found that such improved heat transfer can provide more efficient aerosol delivery and an increased amount of aerosol delivered per unit mass of aerosol-generating substrate. This can also result in more uniform heating of the rod of aerosol-generating substrate.

[0008] Improved heat transfer from the heating element to the outer peripheral portion of the aerosol-generating substrate may reduce the amount of aerosol-generating substrate in the aerosol-generating article that is wasted because it is not heated to the temperature required to vaporize volatile compounds and generate an aerosol. Reducing the amount of wasted aerosol-generating substrate may allow a reduction in the amount of aerosol-generating substrate provided in the aerosol-generating article, which may also reduce the cost of the aerosol-generating article.

[0009] Improved heat transfer from the heating element to the outer peripheral portion of the rod of the aerosol-generating substrate may allow a desired amount of aerosol to be generated from a given amount of aerosol-generating substrate using less power. Reducing power usage may extend the duration of use of the aerosol generating device before the power supply needs to be recharged or replaced. Reducing power usage may allow the size of the power supply to be reduced, which may allow the overall size of the aerosol generating device to be reduced.

[0010] As used herein, the term "aerosol-generating substrate" means a substrate that is capable of condensing to form an aerosol and that is capable of releasing volatile compounds upon heating.

[0011] As used herein, the term "aerosol" means a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets in a gas. An aerosol can be visible or invisible. An aerosol may contain not only vapor of a substance that is normally a liquid or solid at room temperature, but also solid particles or liquid droplets, or a combination of solid particles and liquid droplets.

[0012] As used herein, the term "aerosol-generating article" means an article comprising an aerosol-generating substrate capable of emitting a volatile compound capable of forming an aerosol. The aerosol-generating article may be disposable.

[0013] As used herein, the term "aerosol-generating device" refers to a device that interacts with an aerosol-generating substrate to generate an aerosol. The aerosol-generating device may interact with an aerosol-generating article that includes the aerosol-generating substrate. In some examples, the aerosol-generating device heats the aerosol-generating substrate to promote release of volatile compounds from the substrate.

[0014] As used herein, the term "aerosol-generating system" refers to the combination of an aerosol-generating device and an aerosol-generating substrate. Where the aerosol-generating substrate forms part of an aerosol-generating article, the aerosol-generating system refers to the combination of an aerosol-generating device and an aerosol-generating article. In an aerosol-generating system, the aerosol-generating substrate and the aerosol-generating device work together to generate an aerosol.

[0015] As used herein, the terms "upstream," "downstream," "proximal," and "distal" are used to describe the relative positions of elements or portions of elements of aerosol-generating articles, aerosol-generating devices, and aerosol-generating systems according to the present disclosure. The aerosol-generating articles described herein have a proximal end through which aerosol is expelled from the aerosol-generating article during use. The proximal end may also be referred to as the mouth end. During use, to inhale the aerosol generated by the aerosol-generating article, a user draws on the proximal or mouth end of the aerosol-generating article. The aerosol-generating article has a distal end opposite the proximal or mouth end. The proximal or mouth end of the aerosol-generating article may sometimes be referred to as the downstream end. The distal end of the aerosol-generating article may also be referred to as the upstream end. Components, or portions of components, of an aerosol-generating article may be described as being upstream or downstream of one another based on the relative positions between the proximal or downstream end and the distal or upstream end of the aerosol-generating article.

[0016] As used herein, the term "longitudinal direction" is used to describe the direction between a downstream or proximal end and an opposing upstream or distal end of aerosol-generating articles, aerosol generating devices, and aerosol-generating systems according to the present invention.

[0017] As used herein, the term "length" is used to describe the maximum longitudinal dimension of an element, or portion of an element, of an aerosol-generating article, aerosol-generating device, and aerosol-generating system according to the present disclosure.

[0018] The term "transverse" as used herein is used to describe the direction perpendicular to the longitudinal axis.

[0019] As used herein, the term "width" is used to describe the largest transverse dimension of an element, or portion of an element, of the aerosol-generating articles, aerosol-generating devices, and aerosol-generating systems of the present disclosure. For the avoidance of doubt, as used herein, the term "diameter" may be used to refer to the "width" of an element, or portion of an element, having a circular transverse cross-section of the aerosol-generating articles, aerosol-generating devices, and aerosol-generating systems of the present disclosure.

[0020] Unless otherwise specified, references to a "cross section" of an aerosol-generating article or a component of an aerosol-generating article refer to a transverse cross section taken perpendicular to the longitudinal axis or axis.

[0021] The rod of the aerosol-generating substrate has a rod width. The rod of the aerosol-generating substrate may also have a rod length. The rod length is the maximum dimension of the rod in the longitudinal direction of the aerosol-generating article. The rod width is the maximum dimension of the rod in the transverse direction perpendicular to the longitudinal direction.

[0022] For the avoidance of doubt, in embodiments in which the aerosol-generating article is part of an aerosol-generating system comprising an aerosol-generating device having a heating element in the form of a pin configured for insertion into a rod of an aerosol-generating substrate, the width of the rod before the pin heating element is inserted into the rod is substantially the same as the width of the rod when the pin heating element is fully inserted into the rod.

[0023] The rod width may be substantially uniform along the length of the rod.

[0024] The rod width may be measured 50% along the length of the rod from the end of the rod.

[0025] The rod width may be 5 millimeters or more, 5.3 millimeters or more, 5.5 millimeters or more, 5.7 millimeters or more, 6.1 millimeters or more, 6.3 millimeters or more, or 6.7 millimeters or more.

[0026] The rod width is 7 millimeters or less, and may be 6.7 millimeters or less, 6.3 millimeters or less, 6.1 millimeters or less, 5.7 millimeters or less, 5.5 millimeters or less, 5.3 millimeters or less, or 5 millimeters or less.

[0027] The rod width can be 5mm~7mm, 5mm~6.7mm, 5mm~6.3mm, 5mm~6.1mm, 5mm~5.7mm, 5mm~5.5mm, 5mm~5.3mm, 5.3mm~7mm, 5.3mm~6.7mm, 5.3mm~6.3mm, 5.3mm~6.1mm, and optionally 5.3mm~5.7mm, 5.3mm~5.5mm, 5.5mm~7mm, 5 It may be 0.5mm to 6.7mm, 5.5mm to 6.3mm, 5.5mm to 6.1mm, 5.5mm to 5.7mm, 5.7mm to 7mm, 5.7mm to 6.7mm, 5.7mm to 6.3mm, 5.7mm to 6.1mm, 6.1mm to 7mm, 6.1mm to 6.7mm, 6.1mm to 6.3mm, 6.3mm to 7mm, 6.3mm to 6.7mm, or 6.7mm to 7mm.

[0028] The aerosol generation system has a rod cross-sectional area perpendicular to the rod length, which may be the cross-sectional area of ​​the rod measured 50 percent along the length of the rod from the end of the rod.

[0029] The rod cross-sectional area may be substantially uniform along the rod length.

[0030] The rod cross-sectional area may be 38.5 square millimeters or less, 35.3 square millimeters or less, 31.2 square millimeters or less, 29.2 square millimeters or less, 25.5 square millimeters or less, 23.8 square millimeters or less, 22.1 square millimeters or less, or 19.6 square millimeters or less.

[0031] The rod cross-sectional area may be 19.6 square millimeters or more, 22.1 square millimeters or more, 23.8 square millimeters or more, 25.5 square millimeters or more, 29.2 square millimeters or more, 31.2 square millimeters or more, or 35.3 square millimeters or more.

[0032] The rod cross-sectional area is 19.6 square millimeters to 38.5 square millimeters, 19.6 square millimeters to 35.3 square millimeters, 19.6 square millimeters to 31.2 square millimeters, 19.6 square millimeters to 29.2 square millimeters, 19.6 square millimeters to 25.5 square millimeters, 19.6 square millimeters to 23.8 square millimeters, 19.6 square millimeters to 22.1 square millimeters, 22.1 square millimeters to 38.5 square millimeters, 22.1 square millimeters to 35.3 square millimeters, 22.1 square millimeters to 31.2 square millimeters, 22.1 square millimeters to 29.2 square millimeters, 22.1 square millimeters to 25.5 square millimeters, 22.1 square millimeters to 23.8 square millimeters, 23.8 square millimeters to 38.5 square millimeters, 2 The size may be 3.8 square millimeters to 35.3 square millimeters, 23.8 square millimeters to 31.2 square millimeters, 23.8 square millimeters to 29.2 square millimeters, 23.8 square millimeters to 25.5 square millimeters, 25.5 square millimeters to 38.5 square millimeters, 25.5 square millimeters to 35.3 square millimeters, 25.5 square millimeters to 31.2 square millimeters, 25.5 square millimeters to 29.2 square millimeters, 29.2 square millimeters to 38.5 square millimeters, 29.2 square millimeters to 35.3 square millimeters, 29.2 square millimeters to 31.2 square millimeters, 31.2 square millimeters to 38.5 square millimeters, 31.2 square millimeters to 35.3 square millimeters, or 35.3 square millimeters to 38.5 square millimeters.

[0033] The rod of aerosol-generating substrate may have one of the following cross-sectional shapes: polygonal, substantially triangular, substantially elliptical, substantially rectangular or substantially circular. Preferably, the rod of aerosol-generating substrate has a substantially circular cross-sectional shape.

[0034] The rod length may be 1 mm or more, 3 mm or more, 5 mm or more, 7 mm or more, 9 mm or more, 10 mm or more, 11 mm or more, 12 mm or more, 13 mm or more, 14 mm or more, 15 mm or more, 16 mm or more, 18 mm or more, 20 mm or more, 22 mm or more, 25 mm or more, or 28 mm or more.

[0035] The rod length may be 3 mm or less, 5 mm or less, 7 mm or less, 9 mm or less, 10 mm or less, 11 mm or less, 12 mm or less, 13 mm or less, 14 mm or less, 15 mm or less, 16 mm or less, 18 mm or less, 20 mm or less, 22 mm or less, 25 mm or less, or 30 mm or less. The rod length may be 1 mm to 30 mm, 5 mm to 22 mm, 8 mm to 16 mm, 9 mm to 15 mm, 9 mm to 14 mm, 10 mm to 14 mm, 11 mm to 13 mm, or about 12 mm.

[0036] It is contemplated that the ratio of rod width to rod length may be 0.25-0.60, 0.30-0.60, 0.35-0.60, 0.40-0.60, 0.45-0.60, 0.50-0.60, 0.25-0.56, 0.30-0.56, 0.35-0.56, 0.40-0.56, 0.45-0.56, 0.50-0.56, 0.25-0.50, 0.25-0.40, or 0.35-0.50. However, in accordance with the present invention, the ratio of rod width to rod length is 0.50-0.56.

[0037] In some preferred embodiments, the rod of aerosol-generating substrate is a planar rod of aerosol-generating substrate. The planar rod of aerosol-generating substrate may extend generally in a plane. The planar rod of aerosol-generating substrate may have a length, a width, and a thickness.

[0038] The rod of the planar aerosol-generating substrate may have a first planar outer surface extending in a first plane and a second planar outer surface extending in a second plane, the second plane being parallel to the first plane. The first planar outer surface may have a length and a width. The length and width of the first planar outer surface may define the rod length and width of the planar aerosol-generating substrate. The second planar outer surface may have a length and a width. The length and width of the second planar outer surface may define the rod length and width of the planar aerosol-generating substrate. The length and width of the second planar outer surface may be the same as the length and width of the first planar outer surface. The first and second planar outer surfaces may be separated by a distance. The distance between the first and second planar outer surfaces may define the rod thickness of the planar aerosol-generating substrate.

[0039] The rod thickness of the planar aerosol-generating substrate may be at least three times smaller than the rod width of the planar aerosol-generating substrate, or at least four times smaller than the rod width of the planar aerosol-generating substrate, or at least five times smaller than the rod width of the planar aerosol-generating substrate. The rod thickness of the planar aerosol-generating substrate may be at least six times smaller than the rod length of the planar aerosol-generating substrate, or at least seven times smaller than the rod length of the planar aerosol-generating substrate, or at least eight times smaller than the rod length of the planar aerosol-generating substrate, or at least nine times smaller than the rod length of the planar aerosol-generating substrate, or at least ten times smaller than the rod length of the planar aerosol-generating substrate.

[0040] The rod thickness of the planar aerosol-forming substrate may be 1 millimeter or more, 2 millimeters or more, 3 millimeters or more, 4 millimeters or more, 5 millimeters or more, 6 millimeters or more, 7 millimeters or more, millimeters or more, 9 millimeters or more, 10 millimeters or more, 11 millimeters or more, or 12 millimeters or more.

[0041] The rod thickness of the planar aerosol-forming substrate may be 12 millimeters or less, 11 millimeters or less, 10 millimeters or less, 9 millimeters or less, 8 millimeters or less, 7 millimeters or less, 6 millimeters or less, 5 millimeters or less, 4 millimeters or less, 3 millimeters or less, or 2 millimeters or less.

[0042] The rod thickness of the planar aerosol-forming substrate may have a thickness of 1 mm to 12 mm, or 1 mm to 10 mm, or 1 mm to 8 mm, or 1 mm to 6 mm, or 1 mm to 4 mm, or 1 mm to 3 mm.

[0043] The rod of the planar aerosol-forming substrate may have any of the rod lengths and rod widths described above. In some preferred embodiments, the rod of the planar aerosol-forming substrate has a length of about 20 millimeters, a width of about 10 millimeters, and a thickness of about 2 millimeters.

[0044] The rod of aerosol-generating substrate may have a volume of 235 cubic millimeters or more, 265 cubic millimeters or more, 306 cubic millimeters or more, 351 cubic millimeters or more, 374 cubic millimeters or more, 423 cubic millimeters or more, or 462 cubic millimeters or more.

[0045] The rod of aerosol-generating substrate may have a volume of 462 cubic millimeters or less, 423 cubic millimeters or less, 374 cubic millimeters or less, 351 cubic millimeters or less, 306 cubic millimeters or less, 265 cubic millimeters or less, or 235 cubic millimeters or less.

[0046] The rod of aerosol-generating substrate may have a volume of between 235 cubic millimeters and 462 cubic millimeters.

[0047] It is contemplated that the mass of the aerosol-generating substrate within the rod of aerosol-generating substrate may be 300 milligrams or less, 280 milligrams or less, 270 milligrams or less, 260 milligrams or less, or 250 milligrams or less. However, in accordance with the present invention, the mass of the aerosol-generating substrate within the rod of aerosol-generating substrate is 220 milligrams or less. Preferably, the mass of the aerosol-generating substrate within the rod of aerosol-generating substrate is 210 milligrams or less, or 200 milligrams or less.

[0048] It is envisaged that the mass of the aerosol-generating substrate in the rod of aerosol-generating substrate may be from 10 milligrams to 300 milligrams, from 50 milligrams to 280 milligrams, or from 100 milligrams to 270 milligrams. Preferably, the mass of the aerosol-generating substrate in the rod of aerosol-generating substrate is from 10 milligrams to 220 milligrams, from 50 milligrams to 220 milligrams, from 100 milligrams to 220 milligrams, or from 150 milligrams to 200 milligrams.

[0049] As used herein, the mass of the aerosol-generating substrate within the rod of aerosol-generating substrates refers to the total mass of the aerosol-generating substrates contained within the volume defined by the rod of aerosol-generating substrates. To measure the mass of the aerosol-generating substrates within the rod of aerosol-generating substrates, the aerosol-generating substrates are removed from the rod of aerosol-generating substrates and weighed. This may be repeated 20 times for 20 different individual aerosol-generating articles to obtain an average value. The mass of the aerosol-generating substrate within the rod of aerosol-generating substrates may be the dry mass of the aerosol-generating substrates within the rod of aerosol-generating substrates. The mass of the rod of aerosol-generating substrates may be determined after conditioning the aerosol-generating articles in accordance with ISO Standard 3402:1999.

[0050] It is contemplated that the mass of the rod of aerosol-generating substrate may be 300 milligrams or less, 280 milligrams or less, 270 milligrams or less, 260 milligrams or less, or 250 milligrams or less. However, in accordance with the present invention, the mass of the rod of aerosol-generating substrate is 220 milligrams or less. Preferably, the mass of the aerosol-generating substrate within the rod of aerosol-generating substrate is 210 milligrams or less, or 200 milligrams or less.

[0051] It is envisaged that the mass of the rod of aerosol-generating substrate may be 10 milligrams to 300 milligrams, 50 milligrams to 280 milligrams, or 100 milligrams to 270 milligrams. Preferably, the mass of the rod of aerosol-generating substrate may be 10 milligrams to 220 milligrams, 50 milligrams to 220 milligrams, 100 milligrams to 220 milligrams, or 150 milligrams to 200 milligrams.

[0052] As used herein, the mass of an aerosol-generating substrate rod refers to the total mass of material received within the volume defined by the aerosol-generating substrate rod. This may be repeated 20 times for 20 different individual aerosol-generating articles to obtain an average value. For the avoidance of doubt, if the aerosol-generating substrate rod is surrounded by one or more wrappers, the mass of the wrappers themselves is not taken into account when calculating the mass of the aerosol-generating substrate rod. The mass of the aerosol-generating substrate rod may be the dry mass of the aerosol-generating substrate rod. The mass of the aerosol-generating substrate rod may be determined after conditioning the aerosol-generating articles in accordance with ISO Standard 3402:1999.

[0053] The density of the aerosol-generating substrate within the rod of aerosol-generating substrate may be 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or less, 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or less, 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or less, or 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or less.

[0054] The density of the aerosol-generating substrate within the rod of aerosol-generating substrate may be 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more, 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or more, or 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or more.

[0055] The density of the aerosol-generating substrate within the rod of aerosol-generating substrate may range from 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter), from 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), from 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), cubic millimeter), 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) to 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) to 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), or 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) to 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter).

[0056] Advantageously, having an aerosol-generating substrate density within the rod of aerosol-generating substrate of 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or less may improve the ease of inserting a heated pin into the rod of aerosol-generating substrate.

[0057] Advantageously, having an aerosol-generating substrate density within the rod of aerosol-generating substrate of 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more can improve heat transfer between the heating pin and the rod of aerosol-generating substrate.

[0058] The density of the aerosol-generating substrate within the rod of aerosol-generating substrates is calculated by dividing the sum of the masses of the aerosol-generating substrates within the rod of aerosol-generating substrates by the volume of the rod of aerosol-generating substrates. The volume of the rod of aerosol-generating substrates is calculated using the dimensions of the aerosol-generating substrates. The mass of the aerosol-generating substrate within the rod of aerosol-generating substrates is determined by removing the aerosol-generating substrates from the rod of aerosol-generating substrates and weighing the aerosol-generating substrates. This may be repeated 20 times for 20 different individual aerosol-generating articles to obtain an average value for the density of the aerosol-generating substrates within the rod of aerosol-generating substrates. The density of the aerosol-generating substrates within the rod of aerosol-generating substrates may be calculated on a dry weight basis. The density of the aerosol-generating substrate within the rod of aerosol-generating substrates may be determined after conditioning the aerosol-generating articles in accordance with ISO Standard 3402:1999.

[0059] For the avoidance of doubt, in embodiments in which the aerosol-generating article is part of an aerosol-generating system comprising an aerosol-generating device having a heating element in the form of a pin configured for insertion into a rod of aerosol-generating substrate, references to "density of the aerosol-generating substrate within the rod of aerosol-generating substrate" when used alone refer to the density of the aerosol-generating substrate before the pin heating element is inserted into the rod.

[0060] The density of the rods of the aerosol-generating substrate may be 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or less, 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or less, 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or less, or 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or less.

[0061] The density of the rods of the aerosol-generating substrate may be 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more, 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or more, or 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or more.

[0062] The density of the rod of the aerosol-generating substrate is 350 kilograms / cubic meter (0.35 milligrams / cubic millimeter) to 400 kilograms / cubic meter (0.40 milligrams / cubic millimeter), 350 kilograms / cubic meter (0.35 milligrams / cubic millimeter) to 450 kilograms / cubic meter (0.45 milligrams / cubic millimeter), 350 kilograms / cubic meter (0.35 milligrams / cubic millimeter) to 500 kilograms / cubic meter (0.50 milligrams / cubic millimeter). The concentration may be 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) to 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) to 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), or 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) to 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter).

[0063] Advantageously, having a density of the aerosol-generating substrate rod of 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or less may improve the ease of inserting a heated pin into the aerosol-generating substrate rod.

[0064] Advantageously, having a density of the aerosol-generating substrate rod of 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more can improve heat transfer between the heating pin and the aerosol-generating substrate rod.

[0065] As used herein, the density of an aerosol-generating substrate rod refers to the total mass of the aerosol-generating substrate rod divided by the volume of the aerosol-generating substrate rod. This may be repeated 20 times for 20 different individual aerosol-generating articles to obtain an average value. For the avoidance of doubt, if the aerosol-generating substrate rod is surrounded by one or more wrappers, the mass and volume of the wrappers themselves are not taken into account when calculating the density of the aerosol-generating substrate rod. The density of the aerosol-generating substrate rod may be calculated on a dry weight basis. The density of the aerosol-generating substrate rod may be determined after conditioning the aerosol-generating article in accordance with ISO Standard 3402:1999.

[0066] For the avoidance of doubt, in embodiments in which the aerosol-generating article is part of an aerosol-generating system comprising an aerosol-generating device having heating elements in the form of pins configured for insertion into a rod of an aerosol-generating substrate, references to "the density of the rod of the aerosol-generating substrate" when used alone refer to the density of the rod of the aerosol-generating substrate before the pin heating elements are inserted into the rod.

[0067] The rod of aerosol-generating substrate comprises an aerosol-generating substrate.

[0068] The aerosol-generating substrate rod may include an aerosol-generating substrate and one or more additional components. For example, the aerosol-generating substrate rod may include a susceptor. For example, the aerosol-generating substrate rod may include a filler material that does not release volatile compounds when heated. The aerosol-generating substrate rod may include a support material onto which the aerosol-generating substrate is deposited, loaded, or coated.

[0069] The aerosol-generating substrate may be a solid aerosol-generating substrate.

[0070] The aerosol-generating substrate may comprise tobacco material.

[0071] As used herein, the term "tobacco material" is used to describe any material containing tobacco, including, but not limited to, tobacco leaves, tobacco veins, tobacco stems, tobacco stems, tobacco dust, expanded tobacco, reconstituted tobacco materials, and homogenized tobacco materials.

[0072] The aerosol-generating substrate within the rod of aerosol-generating substrate may comprise homogenized tobacco material, the term "homogenized tobacco material" as used herein meaning a material formed by agglomerating particulate tobacco.

[0073] The aerosol-generating substrate may comprise one or more sheets of homogenized tobacco material. As used herein, the term "sheet" refers to a layered element having a width and length that is substantially greater than its thickness.

[0074] The one or more sheets of tobacco material may each individually have a length substantially the same as the length of the rod of aerosol-generating substrate.

[0075] The aerosol-generating substrate may comprise an assembly of sheets of homogenized tobacco material. As used herein, the term "assemblage" is used to describe a sheet that has been rolled, folded, or otherwise compressed or contracted substantially transverse to the longitudinal axis of the aerosol-generating article.

[0076] The sheet of homogenized tobacco material may be crimped. As used herein, the term "crimped" refers to a sheet having a plurality of substantially parallel ridges or corrugations. The aerosol-generating substrate may comprise an assembly of crimped sheets of homogenized tobacco material. Preferably, when the aerosol-generating article is assembled, the substantially parallel ridges or corrugations extend along or parallel to the longitudinal axis of the aerosol-generating article.

[0077] The sheet of homogenized tobacco material may be a cast sheet, which may comprise tobacco particles having an average particle size (D95) of greater than 50 micrometers, between 50 micrometers and 100 micrometers, between 60 micrometers and 80 micrometers, between 65 micrometers and 75 micrometers, or about 70 micrometers prior to the molding process.

[0078] As used herein, the term "average particle size (D95)" is used to indicate the volume-based median of the particle size distribution, which is the particle diameter value at 95% of the cumulative distribution. The particle size of the particles can be analyzed by laser diffraction.

[0079] The aerosol-generating substrate preferably includes an aerosol former. The aerosol former can be any suitable known compound or mixture of compounds that promotes the formation of a dense, stable aerosol during use. The aerosol former can promote the aerosol to be substantially resistant to thermal decomposition at temperatures typically encountered during use of the aerosol-generating article. Suitable aerosol formers include, for example, polyhydric alcohols such as triethylene glycol, 1,3-butanediol, propylene glycol, and glycerin; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate; and combinations thereof.

[0080] The aerosol former may include one or more of glycerin and propylene glycol. The aerosol former may consist of glycerin or propylene glycol, or a combination of glycerin and propylene glycol.

[0081] The aerosol-generating substrate may comprise at least 5 percent, at least 10 percent, or at least 12 percent by weight of aerosol formers, based on the dry weight of the aerosol-generating substrate.

[0082] The aerosol-generating substrate may comprise 30 weight percent or less, 25 weight percent or less, or 20 weight percent or less of aerosol formers, based on the dry weight of the aerosol-generating substrate.

[0083] The aerosol-generating substrate may comprise from 5 to 30 percent, from 5 to 25 percent, or from 5 to 20 percent by weight of aerosol-forming material, based on the dry weight of the aerosol-generating substrate.

[0084] The aerosol-generating substrate may comprise from about 10 weight percent to about 30 weight percent, from about 10 weight percent to about 25 weight percent, or from about 10 weight percent to about 20 weight percent aerosol-forming material, based on the dry weight of the aerosol-generating substrate.

[0085] The aerosol-generating substrate may comprise from about 12 weight percent to about 30 weight percent, from about 12 weight percent to about 25 weight percent, or from about 12 weight percent to about 20 weight percent aerosol former, based on the dry weight of the aerosol-generating substrate.

[0086] The aerosol-generating substrate may include at least one tobacco material, on a dry weight basis, from about 1 percent to about 5 percent binder, and from about 10 percent to about 30 percent glycerin.

[0087] The aerosol-generating substrate may include tobacco cut filler, and preferably the aerosol-forming material content in the aerosol-generating substrate is at least about 8 percent by weight.

[0088] The aerosol-generating substrate may comprise strands of reconstituted or recycled tobacco.The aerosol-generating substrate may comprise crimped fibre pieces of reconstituted or recycled tobacco.

[0089] As used herein, the term "strand" describes an elongated element of material having a length substantially greater than its width and thickness. The term "strand" should be considered to encompass pieces, fragments, and any other homogenized plant material having a similar morphology. Strands of homogenized plant material may be formed from a sheet of homogenized plant material, for example, by cutting or chopping, or by other methods, such as extrusion.

[0090] The aerosol-generating substrate may comprise at least one of a solid aerosol-generating substrate comprising nicotine, one or more cellulosic agents, one or more aerosol formers, and one or more carboxylic acids.

[0091] As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salts. The aerosol-generating film may include natural or synthetic nicotine.

[0092] The aerosol-generating film may include one or more monobasic nicotine salts.

[0093] As used herein in connection with the present invention, the term "monobasic nicotine salt" is used to describe a nicotine salt of a monobasic acid.

[0094] The solid aerosol-generating substrate may be one of a solid aerosol-generating film or a solid aerosol-generating gel.

[0095] The term "film" as used herein is used to describe a solid layered element having a thickness smaller than its width or length. The film can be self-supporting. In other words, even if the film is obtained by casting a film-forming formulation on a support surface, it can have cohesive and mechanical properties that allow it to be separated from the support surface. Alternatively, the film can be placed on a support or sandwiched between other materials. This can enhance the mechanical stability of the film.

[0096] The aerosol-generating substrate may comprise a plurality of strips of tobacco material, such as tobacco cut filler or strips of homogenized tobacco material.

[0097] As used herein, the term "strip" means an element having a length that is substantially greater than its width and thickness.

[0098] The strips of homogenized tobacco material may be formed from a sheet of homogenized tobacco material, for example, by cutting or chopping. The strips of homogenized tobacco material may also be formed by other methods, for example, by extrusion.

[0099] The strips of tobacco material may have a width of at least about 0.3 millimeters, at least about 0.5 millimeters, or at least about 0.6 millimeters.

[0100] The strips of tobacco material may have a width of about 2 millimeters or less, about 1.2 millimeters or less, or less than about 0.9 millimeters.

[0101] The strips of tobacco material may have a width of about 0.3 millimeters to about 2 millimeters, about 0.3 millimeters to about 1.2 millimeters, or about 0.3 millimeters to about 0.9 millimeters.

[0102] The strips of tobacco material may have a width of about 0.5 millimeters to about 2 millimeters, about 0.5 millimeters to about 1.2 millimeters, or about 0.5 millimeters to about 0.9 millimeters.

[0103] The strips of tobacco material may have a width of about 0.6 millimeters to about 2 millimeters, about 0.6 millimeters to about 1.2 millimeters, or about 0.6 millimeters to about 0.9 millimeters.

[0104] The strips of tobacco material may have a length of at least about 10 millimeters.

[0105] The strips of tobacco material may have a length of about 40 millimeters or less.

[0106] The strips of tobacco material may have a length of from about 10 millimeters to about 40 millimeters.

[0107] On a dry weight basis, at least about 20 weight percent of the plurality of strips of tobacco material may extend along the entire length of the rod of aerosol-generating substrate.On a dry weight basis, at least about 20 weight percent of the plurality of strips of tobacco material may have a length substantially the same as the length of the rod of aerosol-generating substrate.

[0108] On a dry weight basis, about 60 percent by weight or less of the plurality of strips of tobacco material may extend along the entire length of the rod of aerosol-generating substrate.On a dry weight basis, about 60 percent by weight or less of the plurality of strips of tobacco material may have a length substantially the same as the length of the rod of aerosol-generating substrate.

[0109] On a dry weight basis, between about 20 percent and 60 percent by weight of the plurality of strips of tobacco material may extend along the entire length of the rod of aerosol-generating substrate.On a dry weight basis, between about 20 percent and 60 percent by weight of the plurality of strips of tobacco material may have a length substantially the same as the length of the rod of aerosol-generating substrate.

[0110] The aerosol-generating substrate may comprise a plurality of pellets or granules of tobacco material, such as homogenized tobacco material.

[0111] At least about 60 percent by weight of the plurality of pellets or granules may have a largest dimension greater than about 1 millimeter, at least about 70 percent by weight of the plurality of pellets or granules may have a largest dimension greater than about 1 millimeter, or at least about 80 percent by weight of the plurality of pellets or granules may have a largest dimension greater than about 1 millimeter.

[0112] If the homogenized plant material is in the form of a plurality of pellets or granules, at least about 70 percent by weight of the plurality of pellets or granules may have a maximum dimension greater than about 0.5 millimeters, at least about 80 percent by weight of the plurality of pellets or granules may have a maximum dimension greater than about 0.5 millimeters, or at least about 90 percent by weight of the plurality of pellets or granules may have a maximum dimension greater than about 0.5 millimeters.

[0113] For example, at least about 80 weight percent of the plurality of pellets or granules may have a maximum dimension greater than about 1 millimeter, and at least about 90 weight percent of the plurality of pellets or granules may have a maximum dimension greater than about 0.5 millimeters.

[0114] The aerosol-generating article has an article length.

[0115] The article length may be 50 mm to 90 mm, 60 mm to 90 mm, 70 mm to 90 mm, 50 mm to 85 mm, 60 mm to 85 mm, 70 mm to 85 mm, 50 mm to 80 mm, 60 mm to 80 mm, 70 mm to 80 mm, or about 75 mm.

[0116] The article length may be 40 mm to 70 mm, 45 mm to 70 mm, 40 mm to 60 mm, 45 mm to 60 mm, 40 mm to 50 mm, 45 mm to 50 mm, or about 45 mm.

[0117] The ratio between the rod length and the article length may be 0.20 to 0.60, 0.20 to 0.55, 0.20 to 0.50, 0.25 to 0.60, 0.25 to 0.55, 0.25 to 0.50, 0.30 to 0.60, 0.30 to 0.55, or 0.30 to 0.50.

[0118] The aerosol-generating article may be provided with a vent.The aerosol-generating article may be provided with a vent hole.

[0119] The aerosol-generating article may have a breathability level of at least 40 percent, at least 45 percent, at least 50 percent, at least 50 percent, at least 60 percent, or at least 70 percent. The aerosol-generating article may have a breathability level of 90 percent or less, 85 percent or less, or less than 80 percent. The aerosol-generating article may have a breathability level of 40 percent to 90 percent, 50 percent to 90 percent, 60 percent to 90 percent, or about 75 percent.

[0120] As used herein, the term "ventilation level" refers to the volume ratio of the airflow entering the aerosol-generating article through the ventilation zone (ventilation airflow) to the sum of the aerosol airflow and the ventilation airflow. The greater the ventilation level, the greater the dilution of the aerosol stream delivered to the consumer.

[0121] The draw resistance of the aerosol-generating article may be between 10 mm and 70 mm of water column, between 20 mm and 65 mm of water column, between 30 mm and 60 mm of water column, between 35 mm and 55 mm of water column, or between 40 mm and 50 mm of water column.

[0122] Unless otherwise specified, the resistance to draw (RTD) of a component or aerosol-generating article is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through the entire length of the component. The terms "pressure drop" or "draw resistance" of a component or article may also refer to "resistance to draw." Such terms generally refer to measurements in accordance with ISO 6565-2015 normally performed at a temperature of 22 degrees Celsius, a pressure of 101 kPa (approximately 760 Torr), and 60% relative humidity, with a volumetric flow rate of 17.5 milliliters per second at the output or downstream end of the measured component. Smoking conditions and smoking machine specifications are provided in ISO Standard 3308 (ISO 3308:2000). Conditioning and testing atmospheres are provided in ISO Standard 3402 (ISO 3402:1999).

[0123] The resistance to withdrawal (RTD) may be expressed in units of pressure "millimeters of water column" (mmWG).

[0124] The aerosol-generating article may further comprise a downstream section located downstream of the rod of aerosol-generating substrate. The downstream section may extend between the rod of aerosol-generating substrate and the downstream end of the aerosol-generating article. The downstream section may comprise one or more elements.

[0125] The downstream section has a length that may be 10 millimeters or more, 20 millimeters or more, 25 millimeters or more, or 30 millimeters or more.

[0126] The length of the downstream section may be 70 millimeters or less, 60 millimeters or less, or 50 millimeters or less.

[0127] The length of the downstream section may be between 20 millimeters and 70 millimeters, between 20 millimeters and 60 millimeters, or between 30 millimeters and 50 millimeters.

[0128] The withdrawal resistance of the downstream section may be at least 0 millimeters of water column, at least 3 millimeters of water column, or at least 6 millimeters of water column.

[0129] The withdrawal resistance of the downstream section may be 12 millimeters of water column or less, 11 millimeters of water column or less, or 10 millimeters of water column or less.

[0130] The withdrawal resistance of the downstream section may be between 0 mm and 12 mm of water column, between 3 mm and 11 mm of water column, or between 6 mm and 10 mm of water column.

[0131] The aerosol-generating article may comprise one or more hollow tubular elements. The downstream section may comprise one or more hollow tubular elements. The one or more hollow tubular elements may be provided downstream of the rod of the aerosol-forming substrate. One of the one or more hollow tubular elements may abut the downstream end of the rod of the aerosol-generating substrate.

[0132] As used herein, the term "hollow tubular element" is used to mean an elongated element that defines a lumen or airflow passage along its longitudinal axis.

[0133] One of the one or more hollow tubular elements has a hollow tubular element length that may be between 15 mm and 50 mm, between 20 mm and 45 mm, between 20 mm and 40 mm, between 20 mm and 30 mm, between 25 mm and 40 mm, or about 26 mm.

[0134] One of the one or more hollow tubular elements has a wall thickness, which may be between 100 micrometers and 2 millimeters, between 150 micrometers and 1.5 millimeters, or between 200 micrometers and 1.25 millimeters.

[0135] The aerosol-generating article has an outer article width. One of the hollow tubular elements has an outer hollow tubular element width. The outer width of the hollow tubular element may be approximately equal to the outer width of the article.

[0136] One of the one or more hollow tubular elements may have a lumen. The lumen of the one or more hollow tubular elements may have a substantially circular cross-sectional shape. The width of the lumen of the hollow tubular element may be referred to as the internal width.

[0137] In some embodiments, the aerosol-generating article may include a ventilation zone located along one or more of the hollow tubular elements, which may include a plurality of perforations or holes through one or more walls of the one or more hollow tubular elements.

[0138] In some embodiments, the aerosol-generating article may be an aerosol-generating article that does not include a ventilation zone.

[0139] One of the one or more hollow tubular elements may be formed from at least one of cardboard, paper, a polymeric material, a cellulosic material, cellulose acetate low density polyethylene (LDPE), and polyhydroxyalkanoate (PHA). When the hollow tubular element is formed from paper, the paper may be a crimped paper, such as crimped heat-resistant paper or crimped parchment paper.

[0140] The one or more hollow tubular elements may comprise a first hollow tubular element and a second hollow tubular element. The first hollow tubular element may be a hollow acetate tube or a cardboard tube. The second hollow tubular element may be a hollow acetate tube or a cardboard tube. The second hollow tubular element may have an inner width greater than the inner width of the first hollow tubular element. The second hollow tubular element may have a wall thickness less than the wall thickness of the first hollow tubular element. The second hollow tubular element may be disposed downstream of the first hollow tubular element. One or both of the first hollow tubular element and the second hollow tubular element may comprise a ventilation zone. Preferably, the second hollow tubular element comprises a ventilation zone located along the second hollow tubular element.

[0141] The one or more hollow tubular elements may comprise one or both of hollow acetate tubing (HAT) or fine hollow acetate tubing (FHAT).

[0142] The one or more hollow tubular elements may include a HAT and a FHAT. The FHAT may be disposed downstream of the HAT. The inner width of the FHAT may be greater than the inner width of the HAT. The wall thickness of the HAT may be greater than the wall thickness of the FHAT. The HAT has a HAT length. The FHAT has a FHAT length. The HAT length may be 3 mm to 13 mm, 6 mm to 10 mm, 7 mm to 9 mm, or about 8 mm. The FHAT length may be 3 mm to 13 mm, 6 mm to 10 mm, 7 mm to 9 mm, or about 8 mm. One or both of the HAT and the FHAT may include a ventilation zone. The FHAT preferably includes a ventilation zone located along the FHAT.

[0143] The hollow tubular element may have a withdrawal resistance of 10 millimeters of water column or less, 5 millimeters of water column or less, 2.5 millimeters of water column or less, 2 millimeters of water column or less, or 1 millimeter of water column or less.

[0144] The hollow tubular element may have a resistance to withdrawal of at least 0 millimeters of water column, at least 0.25 millimeters of water column, at least 0.5 millimeters of water column, or at least 1 millimeter of water column.

[0145] The aerosol-generating article may further comprise a PLA (polylactic acid) plug. The PLA plug may be downstream of one of the one or more hollow tubular elements. In embodiments of the aerosol-generating article comprising a first hollow tubular element and a second tubular element, the PLA plug may be omitted.

[0146] One of the one or more hollow tubular elements may comprise a hollow tubular cooling element. One of the one or more hollow tubular elements comprises a hollow tubular support element.

[0147] The one or more hollow tubular elements may comprise a hollow tubular support element upstream of the hollow tubular cooling element. The hollow tubular support element may abut the downstream end of the rod of the aerosol-generating substrate. The hollow tubular support element may abut the upstream end of the hollow tubular cooling element.

[0148] The hollow tubular support element may be formed from one or more materials selected from the group consisting of cellulose acetate, cardboard, crimped paper such as crimped heat-resistant paper or crimped parchment paper, and polymeric materials such as low-density polyethylene (LDPE).

[0149] The aerosol-generating article may comprise a tubular element positioned upstream or downstream of the rod of aerosol-generating substrate. The tubular element may include a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body, and a folded end forming a first end wall at the first end of the tubular body, the first end wall defining an opening for airflow between the cavity and the exterior of the tubular element. The first end wall may be adjacent to the rod of aerosol-generating substrate.

[0150] Surprisingly, experimental data have shown that providing a tubular element having a folded end portion downstream of the rod of an aerosol-generating substrate, where the rod width to rod length ratio is between 0.5 and 0.56, can improve aerosol delivery compared to exemplary known downstream cooling elements. This improved aerosol delivery can be particularly noticeable when the total dry mass of the rod of the aerosol-generating substrate is 220 milligrams or less.

[0151] In the context of the present application, the tubular body of the tubular element provides an unrestricted flow channel. This means that the tubular body portion of the tubular element provides a negligible level of resistance to withdrawal (RTD). Therefore, the flow channel should not include any components that would obstruct the longitudinal air flow. Preferably, the flow channel is substantially empty. In such a case, the tubular body of the tubular element defines an empty cavity.

[0152] The tubular element of the present disclosure provides an improved component for an aerosol-generating article. By forming the tubular element from a tubular body defining a cavity extending from the first end of the tubular body to the second end of the tubular body, a relatively large percentage of the tubular element can be empty and allow unimpeded airflow. When the tubular element is downstream of the aerosol-generating substrate, this can help improve aerosol cooling and nucleation. Furthermore, such a configuration can also help minimize filtration of any compounds emitted from the aerosol-generating substrate, particularly when compared to prior art hollow acetate tubing.

[0153] By providing the tubular element with a folded end portion that forms a first end wall at a first end of the tubular body, the tubular element can be configured to have a desired RTD through configuration of the size and shape of the first end wall. In particular, the tubular element and its first end wall may be manufactured efficiently and quickly with a satisfactory RTD and low RTD variability between articles. Furthermore, the configuration of the tubular element and its first end wall means that the RTD can be localized to a specific longitudinal location of the tubular element, rather than being continuously distributed along the length of the tubular element.

[0154] When the first end wall of the tubular element is adjacent to the aerosol-generating substrate, the first end wall can provide a barrier that can limit movement of the aerosol-generating substrate. This arrangement can also advantageously allow air and / or aerosol to flow through the opening into the cavity.

[0155] The barrier provided by the first end wall of the tubular element may be more effective than the barrier provided by the end of the hollow acetate tube because the first end wall may be less deformable than the end of the hollow acetate tube. The structure of the tubular element may also be better suited to withstand temperatures generated by heating elements such as pins or susceptor elements of aerosol generating devices.

[0156] The term "adjacent" is used herein with respect to a tubular element and a rod of aerosol-generating substrate to indicate that the tubular element is longitudinally positioned next to the rod of aerosol-generating substrate within the rod of assembled elements. In particular, this term indicates that no other element of the assembled rod is longitudinally disposed between the rod of aerosol-generating substrate and the tubular element.

[0157] The rod of the aerosol-generating substrate and the tubular element may be adjacent to and in contact with each other, for example, the first end wall of the tubular element may be adjacent to and in contact with the rod of the aerosol-generating substrate.

[0158] The rod of the aerosol-generating substrate and the tubular element may be adjacent to each other, but not in contact with each other, with a small gap of empty space separating the rod of the aerosol-generating substrate from the tubular element along the longitudinal axis of the aerosol-generating article. For example, the first end wall of the tubular element may be adjacent to the aerosol-generating substrate, but not in contact with the aerosol-generating substrate. The gap may be 2 millimeters or less. The gap may be 1 millimeter or less.

[0159] The tubular element may be positioned entirely upstream of the rod of the aerosol-generating substrate, in such an embodiment the tubular element may be referred to as the upstream tubular element.

[0160] The tubular element may be positioned entirely downstream of the rod of the aerosol-generating substrate, in such an embodiment the tubular element may be referred to as the downstream tubular element.

[0161] The aerosol-generating article may comprise two tubular elements, a first tubular element positioned entirely downstream of the rod of aerosol-generating substrate, and a second tubular element positioned entirely upstream of the rod of aerosol-generating substrate, each of which may have any feature or combination of features described above or below with respect to the tubular elements of the present disclosure.

[0162] For example, the tubular element may be a first tubular element located downstream of the aerosol-forming substrate, with a first end wall of the first tubular element adjacent to the downstream end of the aerosol-generating substrate. In such an embodiment, the aerosol-generating article may further comprise a second tubular element. The second tubular element may be located upstream of the rod of the aerosol-generating substrate. The second tubular element may comprise a tubular body defining a cavity extending from the first end of the tubular body to the second end of the tubular body, and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall defining an opening for airflow between the cavity and the exterior of the second tubular element. The first end wall of the second tubular element may be adjacent to the upstream end of the aerosol-generating substrate. Thus, in such embodiments, the rod of aerosol-generating substrate may be sandwiched between a first tubular element and a second tubular element, each tubular element having a folded end portion providing a respective end wall adjacent the upstream or downstream end of the rod of aerosol-generating substrate, In such embodiments, the second tubular element may be referred to as the upstream tubular element and the first tubular element may be referred to as the downstream tubular element.

[0163] The second tubular element may further include a folded end portion forming a second end wall at the second end of the tubular body. The second end wall of the second tubular element may define an opening for airflow between the cavity and the exterior of the second tubular element. The opening defined by the second end wall of the second tubular element may be smaller than the opening defined by the first end wall of the second tubular element. For example, the size of the opening defined by the second end wall of the second tubular element may be between about 20 percent and about 80 percent of the size of the opening defined by the first end wall of the second tubular element. The size of the opening defined by the second end wall of the second tubular element may be between about 40 percent and about 60 percent of the size of the opening defined by the first end wall of the second tubular element, more preferably between about 45 percent and about 55 percent of the size of the opening defined by the first end wall of the second tubular element.

[0164] As described in more detail below, the aerosol-generating article may further comprise a ventilation zone at a location along the tubular element. Where the aerosol-generating article comprises first and second tubular elements as described above, the ventilation zone is preferably located along the first tubular element.

[0165] The first end wall may extend substantially transverse to the longitudinal axis of the aerosol-generating article.The first end wall may extend substantially transverse to the longitudinal axis of the tubular body.

[0166] The first end wall may extend partially into the cavity of the tubular body, forming an angle of less than 90 degrees with the inner surface of the tubular body, more preferably an angle of less than 80 degrees with the inner surface of the tubular body, and even more preferably an angle of less than 70 degrees with the inner surface of the tubular body. This may be achieved by ensuring that a folding force is applied to the tubular element during manufacture such that at least a portion of the first end of the tubular element is forced into the cavity of the tubular body. Such an arrangement may advantageously increase the likelihood that the first end wall will remain stationary relative to the tubular body after the tubular element is manufactured. In particular, such an arrangement helps to overcome any natural elasticity of the material forming the tubular element, such that the folded end of the tubular element is less likely to return to its pre-folded state after manufacture.

[0167] The opening defined by the first end wall may be the only opening in the first end wall. The opening may be located at a generally radially central location of the tubular element. The first end wall may be generally annular in shape.

[0168] The first end wall may extend from a fold point on the tubular element toward a radially central location of the tubular element. The fold point may generally correspond to a first end of the tubular body of the tubular element.

[0169] Preferably, at least a first portion of the tubular element forming the first end wall is substantially impermeable. In other words, preferably, the first end wall is substantially non-porous. Preferably, the first end wall does not include any perforations. The material forming the first end wall may have a porosity of less than 2000 Coresta units. The material forming the first end wall may have a porosity of less than 1000 Coresta units. The material forming the first end wall may have a porosity of less than 500 Coresta units.

[0170] Preferably, the tubular element has an equivalent inner diameter of at least about 5.5 millimeters. More preferably, the tubular element has an equivalent inner diameter of at least about 6 millimeters. Even more preferably, the tubular element has an equivalent inner diameter of at least about 7 millimeters. The term "equivalent inner diameter" is used herein to mean the diameter of a circle having the same surface area as the cross-section of the airflow conduit defined therein by the hollow tubular segment. The cross-section of the airflow conduit may have any suitable shape. However, as briefly mentioned above, a circular cross-section is preferred, i.e., the hollow tubular segment is a substantially cylindrical tube. In that case, the equivalent inner diameter of the hollow tubular segment substantially corresponds to the inner diameter of the cylindrical tube.

[0171] Preferably, the equivalent inner diameter of the hollow tubular segment is less than about 10 millimeters, more preferably less than about 9.5 millimeters, and even more preferably less than 9 millimeters.

[0172] Preferably, the tubular element has a wall thickness of at least about 0.1 millimeter, more preferably at least about 0.2 millimeter.

[0173] The tubular elements preferably have a wall thickness of less than about 1.5 millimeters, preferably less than about 1.25 millimeters. In one preferred embodiment, the tubular elements have a wall thickness of less than about 1 millimeter.

[0174] The tubular element therefore preferably has a wall thickness of from about 0.1 millimeters to about 1.5 millimeters, or from about 0.2 millimeters to about 1.25 millimeters, or from about 0.5 millimeters to about 1 millimeter.

[0175] Providing a tubular element with such a wall thickness helps to improve the resistance of the tubular body to collapse or deformation, while allowing the first end wall to be formed by the folded end of the tubular element.

[0176] The wall thickness of the tubular element may be the same as the wall thickness of one or both of the tubular bodies and the first end wall.

[0177] The length of the tubular element may be substantially the same as the length of the tubular body.

[0178] Preferably, the tubular element has a length of at least about 10 millimeters, more preferably at least about 15 millimeters.

[0179] The tubular element preferably has a length of less than about 30 millimeters, preferably less than about 25 millimeters, and more preferably less than about 20 millimeters.

[0180] The tubular element may have a length of about 10 millimeters to about 30 millimeters, preferably about 15 millimeters to about 25 millimeters, and more preferably about 15 millimeters to about 20 millimeters. For example, in one particularly preferred embodiment, the tubular element has a length of 18 millimeters. Such a length may be preferred, especially in embodiments where the tubular element is located downstream of the aerosol-generating substrate, with the first end wall of the tubular element adjacent the downstream end of the aerosol-generating substrate.

[0181] The tubular element may have a length of about 5 mm to about 20 mm, preferably about 8 mm to about 15 mm, and more preferably about 10 mm to about 13 mm. For example, in one particularly preferred embodiment, the tubular element has a length of 12 mm. Such a length may be preferred, particularly in embodiments where the tubular element is located upstream of the aerosol-generating substrate, with the first end wall of the tubular element adjacent the upstream end of the aerosol-generating substrate.

[0182] Preferably, the tubular element is adapted to generate an RTD of approximately 0 millimeters of H2O (about 0 Pa) to approximately 20 millimeters of H2O (about 100 Pa), more preferably approximately 0 millimeters of H2O (about 0 Pa) to approximately 10 millimeters of H2O (about 100 Pa).

[0183] The tubular element is preferably formed from a paper material such as paper, paperboard, or cardboard. The tubular element may also be formed from multiple overlapping paper layers, such as multiple parallel wound paper layers or multiple spirally wound paper layers. Forming the tubular element from multiple overlapping paper layers helps to improve the resistance of the tubular body to collapse or deformation, while allowing the first end wall to be formed by the folded end of the tubular element.

[0184] The tubular element may comprise at least two paper layers. The tubular element may preferably comprise less than 11 paper layers.

[0185] When the tubular element is formed from a paper material, the paper material may have a basis weight of at least about 90 grams per square meter. The paper material may have a basis weight of less than about 300 grams per square meter. The paper material may have a basis weight of about 100 to 200 grams per square meter. Providing a tubular element with such a wall basis weight helps improve the resistance of the tubular body to collapse or deformation, while allowing the first end wall to be formed by the folded end of the tubular element.

[0186] The aerosol-generating article may include a mouthpiece element. The downstream section may include the mouthpiece element. The mouthpiece element may be located downstream of at least one of the one or more hollow tubular elements. The mouthpiece element may be located at a downstream end of the aerosol-generating article.

[0187] The mouthpiece element may be a mouthpiece filter. The mouthpiece element may be formed from a fibrous filtering material. The mouthpiece element may be formed from cellulose acetate.

[0188] The mouthpiece element may have a mouthpiece length of 5 millimeters or more, or 10 millimeters or more.

[0189] The mouthpiece element may have a mouthpiece length of less than 25 millimeters, or less than 20 millimeters.

[0190] The mouthpiece element may have a mouthpiece length of 5 mm to 25 mm, 10 mm to 25 mm, 5 mm to 20 mm, 10 mm to 20 mm, 10 mm to 14 mm, 11 mm to 13 mm, or about 12 mm.

[0191] The mouthpiece element may have a length of 5 millimeters to 10 millimeters, 6 millimeters to 8 millimeters, or about 7 millimeters.

[0192] The mouthpiece element may have a resistance to withdrawal per millimeter of length along the longitudinal axis of the aerosol-generating article of between 0.1 millimeters of water column and 20 millimeters of water column, between 0.2 millimeters of water column and 10 millimeters of water column, between 0.5 millimeters of water column and 5 millimeters of water column or more, between 1 millimeter of water column and 2 millimeters of water column, between 1.3 millimeters of water column and 1.7 millimeters of water column, between 1.4 millimeters of water column and 1.6 millimeters of water column, or about 1.5 millimeters of water column.

[0193] The mouthpiece element may have a draw resistance of 1 to 100 millimeters of water column, 2 to 50 millimeters of water column, 5 to 40 millimeters of water column, 10 to 30 millimeters of water column, 16 to 20 millimeters of water column, 17 to 19 millimeters of water column, or about 18 millimeters of water column.

[0194] The mouthpiece element may have a draw resistance of 1 to 60 millimeters of water column, 2 to 30 millimeters of water column, 4 to 25 millimeters of water column, 5 to 18 millimeters of water column, 6 to 13 millimeters of water column, 9 to 12 millimeters of water column, or about 10.5 millimeters of water column.

[0195] The mouthpiece element may include a flavorant, which may be provided in any suitable form, for example, the mouthpiece element may include one or more capsules, flavorant beads or granules, or one or more flavor-loaded threads or filaments.

[0196] The aerosol-generating article may comprise a flavour capsule, preferably within the mouthpiece element.

[0197] The aerosol-generating article may further comprise a substrate wrapper at least partially surrounding the rod of aerosol-generating substrate. The substrate wrapper may comprise one or more layers having the same length as the aerosol-generating article.

[0198] The substrate wrapper may have a thickness of at least 50 micrometers, at least 60 micrometers, at least 70 micrometers, at least 75 micrometers, at least 80 micrometers, at least 90 micrometers, at least 100 micrometers, at least 110 micrometers, at least 120 micrometers, at least 130 micrometers, at least 140 micrometers, at least 145 micrometers, or at least 150 micrometers.

[0199] Advantageously, a substrate wrapper having a thickness of 50 micrometers or more can advantageously replace an insufficiently heated portion of the aerosol-generating substrate. Thus, the amount of aerosol-generating substrate can be reduced. A more efficient aerosol-generating article can be provided.

[0200] The thickness of the substrate wrapper may be determined in accordance with ISO 534:2011.

[0201] The ratio of substrate wrapper thickness to rod width may be 1:120 to 1:20 (0.0083 to 0.050), 1:100 to 1:30 (0.010 to 0.030), 1:80 to 1:35 (0.013 to 0.029), and 1:60 to 1:40 (0.017 to 0.025).

[0202] The substrate wrapper may have a density of 800 kilograms per cubic meter or less, 750 kilograms per cubic meter or less, 700 kilograms per cubic meter or less, 650 kilograms per cubic meter or less, 600 kilograms per cubic meter or less, 550 kilograms per cubic meter or less, 500 kilograms per cubic meter or less, 450 kilograms per cubic meter or less, 400 kilograms per cubic meter or less, 350 kilograms per cubic meter or less, or about 320 kilograms per cubic meter.

[0203] Advantageously, a substrate wrapper having a thickness of at least 50 micrometers and a density of 800 kilograms per cubic meter or less can be more rigid than conventional thin wrappers. This can provide a mechanically more robust aerosol-generating article. A mechanically more robust aerosol-generating article can be particularly advantageous when the aerosol-generating article is arranged to be inserted into a device cavity of an aerosol-generating device.

[0204] The density of the substrate wrapper may be determined according to ISO 534:2011. The thickness of the substrate wrapper may be determined according to ASTM E252-06(2021)e1. Generally, for an embossed wrapper, the local thickness at the embossed location may be less than the thickness at a non-embossed location. As used herein, for an embossed wrapper, the thickness of the wrapper refers to the thickness at a non-embossed location. For an embossed wrapper, the thickness of the wrapper may be determined before the wrapper is embossed.

[0205] Unless otherwise defined, all measurements described herein are performed after sample conditioning according to ISO standard 3402:1999.

[0206] The density of the substrate wrapper can be calculated by dividing the basis weight of the substrate wrapper by the thickness of the substrate wrapper. Basis weight, also called grammage, refers to the mass of the substrate wrapper per sheet size and is usually expressed in grams per square meter. Basis weight can be obtained, for example, by weighing a one square meter sheet of the substrate wrapper.

[0207] The substrate wrapper may comprise one or more of cardboard, plastic, and metal foil. The substrate wrapper may comprise a cellulosic material. The substrate wrapper may comprise a cellulosic material selected from one or more of paper, wood, textiles, natural fibers, and man-made fibers.

[0208] The aerosol-generating article may further comprise an outer wrapper at least partially surrounding the other elements of the aerosol-generating article. The outer wrapper may extend along only a portion of the length of the aerosol-generating article. For example, in some embodiments, the outer wrapper may not extend along the mouthpiece element. The outer wrapper may extend the entire length of the aerosol-generating article. The outer wrapper may include tipping paper.

[0209] When the aerosol-generating device is provided as part of an aerosol-generating system, for example, comprising an aerosol-generating article, the device may comprise a heating element in the form of a pin configured for insertion into a rod of an aerosol-generating substrate of the aerosol-generating article. The pin may have a pin width. The pin may also have a pin length. The pin length is the maximum dimension of the pin in the longitudinal direction of the aerosol-generating device. The pin width is the maximum dimension of the pin in a transverse direction perpendicular to the longitudinal direction.

[0210] The pin may have a tip. The tip may have a tip length. The tip may be configured to penetrate the rod of the aerosol-generating substrate. The tip end may be defined as the extreme point of the tip along the tip length. The tip end may be defined as the extreme point of the pin along the pin length. The tip may be one of tapered, pointed, or sharp towards the tip end. The tip may be defined as the portion of the pin along which the width of the pin decreases. The tip may be defined as the portion of the pin that is tapered, pointed, or sharp.

[0211] The tip may have a tip length of 0.1 millimeters or more, 0.2 millimeters or more, 0.5 millimeters or more, 0.8 millimeters or more, 1 millimeter or more, 1.2 millimeters or more, or 1.5 millimeters or more.

[0212] The tip may have a tip length of 1.8 millimeters or less, 1.5 millimeters or less, 1.2 millimeters or less, 1 millimeter or less, 0.8 millimeters or less, 0.5 millimeters or less, 0.2 millimeters or less, or 0.1 millimeters or less.

[0213] The tip may have a tip length of 1 percent or more of the pin length, 2 percent or more of the pin length, 4 percent or more of the pin length, 6 percent or more of the pin length, 8 percent or more of the pin length, 10 percent or more of the pin length, 12 percent or more of the pin length, 15 percent or more of the pin length, 18 percent or more of the pin length, or 20 percent or more of the pin length.

[0214] The tip may have a tip length of 25 percent or less of the pin length, 20 percent or less of the pin length, 18 percent or less of the pin length, 15 percent or less of the pin length, 12 percent or less of the pin length, 10 percent or less of the pin length, 8 percent or less of the pin length, 6 percent or less of the pin length, 4 percent or less of the pin length, 2 percent or less of the pin length, or 1 percent or less of the pin length.

[0215] The width of the tip, measured at a distance of 1 millimeter from the end of the tip, may be 2 millimeters or less, 1.8 millimeters or less, 1.5 millimeters or less, 1.2 millimeters or less, 1 millimeter or less, 0.8 millimeters or less, 0.5 millimeters or less, or 0.2 millimeters or less.

[0216] Advantageously, providing a tip width measured at a distance of 1 millimeter from the end of the tip of 2 millimeters or less may facilitate insertion of the pin into the rod of the aerosol-generating substrate.

[0217] Returning to pin width, it is envisioned that pin width may be measured in a variety of suitable ways.

[0218] The pin width may be measured at one of 2 mm, 3 mm, 4 mm, 5 mm, or 6 mm from the end of the tip, preferably 3 mm or 4 mm from the end of the tip, and most preferably 4 mm from the end of the tip.

[0219] The pin width may be a maximum pin width, which refers to the largest width of the pin along its length.

[0220] The pin width may be the width of the pin measured at a position along the section of the pin that is configured to be inserted into the rod of the aerosol-generating substrate that is the furthest distance from the tip end of the pin.

[0221] The pin width may be measured at multiple locations along the length of the pin, excluding the tip. The pin width may be measured at one or more of a distance of 2 millimeters, 3 millimeters, 4 millimeters, 5 millimeters, or 6 millimeters from the end of the tip. The pin width may be the average width of the pin measured at multiple locations along the length of the pin, excluding the tip.

[0222] The pin width may be the average width of the pin measured over at least 70 percent of the pin length, over at least 80 percent of the pin length, over at least 90 percent of the pin length, or over at least 95 percent of the pin length.

[0223] The pin width may be the pin width measured at 50 percent of the pin length from the tip end of the pin.

[0224] The pin width may be 0.5 mm or greater, 0.8 mm or greater, 1.0 mm or greater, 1.2 mm or greater, 1.5 mm or greater, 1.8 mm or greater, 2.0 mm or greater, or 2.2 mm or greater.

[0225] The pin width may be 2.5 mm or greater.

[0226] The pin width may be 2.6 millimeters or more, 2.7 millimeters or more, 2.8 millimeters or more, or 2.9 millimeters or more.

[0227] The pin width may be 7.0 mm or less, 6.0 mm or less, 5.0 mm or less, 4.0 mm or less, 3.0 mm or less, 2.9 mm or less, 2.8 mm or less, 2.7 mm or less, or 2.6 mm or less.

[0228] The pin width may be 2.5 mm to 7.0 mm, 2.5 mm to 6.0 mm, or 2.5 mm to 5.0 mm. In some preferred embodiments, the pin width may be 2.5 mm to 4.0 mm. The pin width may be 2.5 mm to 3.5 mm. The pin width may be 2.5 mm to 3.0 mm.

[0229] The ratio of rod width to pin width may be 2.8 or less, 2.7 or less, 2.6 or less, 2.5 or less, 2.4 or less, 2.3 or less, 2.2 or less, 2.1 or less, 2.0 or less, 1.9 or less, or 1.8 or less.

[0230] The ratio of rod width to pin width may be 1.6 or greater, 1.7 or greater, 1.8 or greater, 1.9 or greater, 2.0 or greater, 2.1 or greater, 2.2 or greater, 2.3 or greater, 2.4 or greater, 2.5 or greater, or 2.6 or greater.

[0231] The ratio of the rod width to the pin width may be 1.6 to 2.8.

[0232] Advantageously, it has been found that providing an aerosol-generating system having a rod width to pin width ratio of 1.6 to 2.8 provides particularly improved heat transfer from the pin to the outer peripheral portion of the aerosol-generating substrate rod. Such improved heat transfer can provide more efficient aerosol delivery, increased aerosol delivery per unit mass of aerosol-generating substrate, and more uniform heating of the aerosol-generating substrate rod.

[0233] The pin may have a minimum transverse pin dimension. The minimum transverse pin dimension is the smallest dimension of the pin in a transverse direction perpendicular to the longitudinal axis. In other words, the minimum transverse pin dimension is the smallest cross-sectional dimension of the pin. The minimum transverse pin dimension may be perpendicular to the pin width.

[0234] The minimum transverse pin dimension may be measured at one of 2 millimeters, 3 millimeters, 4 millimeters, 5 millimeters, or 6 millimeters from the end of the tip. Preferably, the minimum transverse pin dimension may be measured at a distance of 3 millimeters or 4 millimeters from the end of the tip, and most preferably at a distance of 4 millimeters from the end of the tip.

[0235] The minimum transverse pin dimension may be the smallest dimension of the pin in a direction transverse to the pin along the length of the pin excluding the tip.

[0236] The minimum transverse pin dimension may be the minimum transverse pin dimension measured at a position along the section of the pin configured to be inserted into the rod of the aerosol-generating substrate that is the furthest distance from the tip end of the pin.

[0237] The minimum transverse pin dimension can be the average minimum transverse pin dimension measured over at least 70 percent of the pin length excluding the tip, over at least 80 percent of the pin length excluding the tip, over at least 90 percent of the pin length excluding the tip, or over at least 95 percent of the pin length excluding the tip.

[0238] The minimum transverse pin dimension may be the minimum transverse pin dimension measured 50 percent of the pin length from the tip end of the pin.

[0239] The minimum transverse pin dimension may be 1.6 mm or more, 1.7 mm or more, 1.8 mm or more, 1.9 mm or more, 2.0 mm or more, 2.1 mm or more, 2.2 mm or more, 2.3 mm or more, 2.4 mm or more, 2.5 mm or more, 2.6 mm or more, 2.7 mm or more, 2.8 mm or more, or 2.9 mm or more. The minimum transverse pin dimension may be 3.0 mm or less. The minimum transverse pin dimension may be between 2.5 mm and 3.0 mm.

[0240] The pin has a pin cross-sectional area perpendicular to the pin length.

[0241] It is contemplated that the pin cross-sectional area may be measured in a variety of suitable ways.

[0242] The pin cross-sectional area may be measured at one of 2 millimeters, 3 millimeters, 4 millimeters, 5 millimeters, or 6 millimeters from the tip end of the pin. Preferably, the pin cross-sectional area is measured at a distance of 3 millimeters or 4 millimeters from the tip end, and most preferably at a distance of 4 millimeters from the tip end.

[0243] The pin cross-sectional area may be a maximum pin cross-sectional area, which refers to the largest cross-sectional area of ​​the pin along the length of the pin.

[0244] The pin cross-sectional area may be the pin cross-sectional area measured at a position along the section of the pin configured to be inserted into the rod of the aerosol-generating substrate that is the furthest distance from the tip end of the pin.

[0245] The pin cross-sectional area may be the average cross-sectional area of ​​the pin measured over at least 70 percent of the pin length, over at least 80 percent of the pin length, over at least 90 percent of the pin length, or over at least 95 percent of the pin length.

[0246] The pin cross-sectional area may be the pin cross-sectional area measured at 50 percent of the pin length from the end of the tip.

[0247] The pin cross-sectional area may be 0.2 square millimeters or more, 0.5 square millimeters or more, 0.8 square millimeters or more, 1.1 square millimeters or more, 1.8 square millimeters or more, 2.5 square millimeters or more, 3.1 square millimeters or more, or 3.8 square millimeters or more.

[0248] The pin cross-sectional area may be 4.9 square millimeters or greater.

[0249] The pin cross-sectional area may be 38.5 square millimeters or less, 28.3 square millimeters or less, 19.6 square millimeters or less, or 12.6 square millimeters or less.

[0250] The pin cross-sectional area may be equal to or less than 7.1 square millimeters. The pin cross-sectional area may be between 4.9 square millimeters and 7.1 square millimeters.

[0251] The ratio of rod cross-sectional area to pin cross-sectional area may be 7.9 or less, 7.5 or less, 7.0 or less, 6.5 or less, 6.0 or less, 5.5 or less, 5.0 or less, 4.5 or less, 4.0 or less, 3.5 or less, or 3.0 or less.

[0252] The ratio of rod cross-sectional area to pin cross-sectional area may be 2.8 or greater, 3.0 or greater, 3.5 or greater, 4.0 or greater, 4.5 or greater, 5.0 or greater, 5.5 or greater, 6.0 or greater, 6.5 or greater, 7.0 or greater, or 7.5 or greater.

[0253] The ratio of the rod cross-sectional area to the pin cross-sectional area may be 2.8 to 7.9.

[0254] Advantageously, it has been found that providing an aerosol-generating system having a rod cross-sectional area and a pin cross-sectional area ratio of 1.6 to 2.8 provides particularly improved heat transfer from the pin to the outer peripheral portion of the aerosol-generating substrate rod. Such improved heat transfer can provide more efficient aerosol delivery, an increased amount of aerosol delivered per unit mass of aerosol-generating substrate, and more uniform heating of the aerosol-generating substrate rod.

[0255] The cross-sectional area of ​​the pin, measured at a distance of 1 millimeter from the end of the tip, may be 3.1 square millimeters or less, 2.5 square millimeters or less, 1.8 square millimeters or less, 1.1 square millimeters or less, 0.8 square millimeters or less, 0.5 square millimeters or less, or 0.2 square millimeters or less.

[0256] Advantageously, providing a cross-sectional area of ​​the pin measured at a distance of 1 millimeter from the tip end of 3.1 square millimeters or less may facilitate insertion of the pin into the rod of the aerosol-generating substrate.

[0257] The pin may have one of a polygonal cross-sectional shape, a substantially oval cross-sectional shape, a substantially triangular cross-sectional shape, a substantially rectangular cross-sectional shape or a substantially circular cross-sectional shape. Preferably, the pin has a substantially circular cross-sectional shape.

[0258] Preferably, at least a portion of the pin heating element configured to be inserted into the rod of the aerosol-generating substrate has the same cross-sectional shape as the rod of the aerosol-generating substrate. The pin heating element may have the same cross-sectional shape as the rod of the aerosol-generating substrate. Advantageously, providing a pin heater having substantially the same cross-sectional shape as the rod of the aerosol-generating substrate can result in more uniform heat transfer from the pin heating element to all portions of the rod of the aerosol-generating substrate. For example, providing a pin heater having a substantially circular cross-section inserted into a rod of the aerosol-generating substrate having a substantially circular cross-section can result in more uniform heat transfer from the heating pin around the entire circumference of the rod of the aerosol-generating substrate.

[0259] As mentioned above, the pin may have a tip, which may be configured to penetrate the rod of the aerosol-generating substrate, and which may be one of tapered, pointed, or sharp towards the end of the tip.

[0260] The pins may have a pin length of 1 millimeter or more, 3 millimeters or more, 5 millimeters or more, 7 millimeters or more, 9 millimeters or more, 10 millimeters or more, 11 millimeters or more, 12 millimeters or more, 13 millimeters or more, 14 millimeters or more, 15 millimeters or more, 16 millimeters or more, 18 millimeters or more, 20 millimeters or more, 22 millimeters or more, 25 millimeters or more, or 28 millimeters or more.

[0261] The pins may have a pin length of 3 mm or less, 5 mm or less, 7 mm or less, 9 mm or less, 10 mm or less, 11 mm or less, 12 mm or less, 13 mm or less, 14 mm or less, 15 mm or less, 16 mm or less, 18 mm or less, 20 mm or less, 22 mm or less, 25 mm or less, or 30 mm or less.

[0262] The pins may have a pin length of 1 mm to 30 mm, 5 mm to 22 mm, 8 mm to 16 mm, 9 mm to 15 mm, 10 mm to 14 mm, 11 mm to 13 mm, or about 12 mm.

[0263] The pin length may be equal to or less than the rod length, or equal to or less than 99 percent of the rod length, or equal to or less than 95 percent of the rod length, or equal to or less than 90 percent of the rod length, or equal to or less than 85 percent of the rod length, or equal to or less than 80 percent of the rod length, or equal to or less than 70 percent of the rod length, or equal to or less than 60 percent of the rod length, or equal to or less than 50 percent of the rod length.

[0264] The pin length may be 50 percent or more of the rod length, 60 percent or more of the rod length, 70 percent or more of the rod length, 80 percent or more of the rod length, 85 percent or more of the rod length, 90 percent or more of the rod length, 95 percent or more of the rod length, or 99 percent or more of the rod length.

[0265] The pin length may be between 70 percent and 99 percent of the rod length, between 75 percent and 95 percent of the rod length, between 80 percent and 95 percent of the rod length, or between 85 percent and 95 percent of the rod length.

[0266] Advantageously, providing a pin length that is equal to or less than the rod length may ensure that the pin remains completely encompassed by the aerosol-generating substrate rod when inserted into the aerosol-generating substrate rod, thereby improving heating efficiency. Advantageously, providing a pin length that is equal to or less than the rod length may prevent damage to components of the aerosol-generating article downstream of the aerosol-generating substrate rod when the pin is inserted into the aerosol-generating substrate rod. Advantageously, providing a pin length that is equal to or greater than 50 percent of the rod length may result in more uniform heating along the aerosol-generating substrate rod length and may reduce insufficient heating of downstream portions of the aerosol-generating substrate rod when the pin is inserted into the aerosol-generating substrate rod.

[0267] The pin may have a volume of 59 cubic millimeters or more, 64 cubic millimeters or more, 69 cubic millimeters or more, 74 cubic millimeters or more, 79 cubic millimeters or more, or 84 cubic millimeters or more.

[0268] The pin may have a volume of 84 cubic millimeters or less, 79 cubic millimeters or less, 74 cubic millimeters or less, 69 cubic millimeters or less, or 64 cubic millimeters or less.

[0269] The pin may have a volume of between 59 cubic millimeters and 84 cubic millimeters.

[0270] The increase in density of the aerosol-generating substrate within the rod of the aerosol-generating substrate from a state in which the pin heating element is not inserted into the rod to a state in which the pin heating element is fully inserted into the rod is 10 kilograms per cubic meter (0.01 milligrams per cubic millimeter) or more, 20 kilograms per cubic meter (0.02 milligrams per cubic millimeter) or more, 30 kilograms per cubic meter (0.03 milligrams per cubic millimeter) or more, 40 kilograms per cubic meter (0.04 milligrams per cubic millimeter) or more, 50 kilograms per cubic meter (0.05 milligrams per cubic millimeter) or more, 60 kilograms per cubic meter (0.06 milligrams per cubic millimeter) or more, 70 kilograms per cubic meter (0.07 milligrams per cubic millimeter) or more, 80 kilograms per cubic meter (0.08 milligrams per cubic millimeter) or more. It may be 90 kilograms per cubic meter (0.09 milligrams per cubic millimeter) or more, 100 kilograms per cubic meter (0.10 milligrams per cubic millimeter) or more, 150 kilograms per cubic meter (0.15 milligrams per cubic millimeter) or more, 200 kilograms per cubic meter (0.20 milligrams per cubic millimeter) or more, 250 kilograms per cubic meter (0.25 milligrams per cubic millimeter) or more, 300 kilograms per cubic meter (0.30 milligrams per cubic millimeter) or more, 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more, 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or more, or 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or more.

[0271] The increase in density of the aerosol-generating substrate within the rod of the aerosol-generating substrate from a state in which the pin heating element is not inserted into the rod to a state in which the pin heating element is fully inserted into the rod is not more than 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), not more than 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), not more than 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter), not more than 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter), not more than 300 kilograms per cubic meter (0.30 milligrams per cubic millimeter), not more than 250 kilograms per cubic meter (0.25 milligrams per cubic millimeter), not more than 200 kilograms per cubic meter (0.20 milligrams per cubic millimeter), not more than 150 kilograms per cubic meter (0.15 milligrams per cubic millimeter), 100 kilograms per cubic meter (0.10 milligrams per cubic millimeter), 90 kilograms per cubic meter (0.09 milligrams per cubic millimeter), 80 kilograms per cubic meter (0.08 milligrams per cubic millimeter), 70 kilograms per cubic meter (0.07 milligrams per cubic millimeter), 60 kilograms per cubic meter (0.06 milligrams per cubic millimeter), 50 kilograms per cubic meter (0.05 milligrams per cubic millimeter), 40 kilograms per cubic meter (0.04 milligrams per cubic millimeter), 30 kilograms per cubic meter (0.03 milligrams per cubic millimeter), or 20 kilograms per cubic meter (0.02 milligrams per cubic millimeter).

[0272] The percentage increase in density of the aerosol-generating substrate within the rod of the aerosol-generating substrate from when the pin heating element is not inserted into the rod to when the pin heating element is fully inserted into the rod may be 1 percent or more, 2 percent or more, 3 percent or more, 4 percent or more, 5 percent or more, 6 percent or more, 7 percent or more, 8 percent or more, 9 percent or more, 10 percent or more, 11 percent or more, 12 percent or more, 13 percent or more, 14 percent or more, 15 percent or more, 16 percent or more, 17 percent or more, 18 percent or more, 19 percent or more, or 20 percent or more.

[0273] The percentage increase in density of the aerosol-generating substrate within the rod of the aerosol-generating substrate from a state in which the pin heating element is not inserted into the rod to a state in which the pin heating element is fully inserted into the rod may be 20 percent or less, 19 percent or less, 18 percent or less, 17 percent or less, 16 percent or less, 15 percent or less, 14 percent or less, 13 percent or less, 12 percent or less, 11 percent or less, 10 percent or less, 9 percent or less, 8 percent or less, 7 percent or less, 6 percent or less, 5 percent or less, 4 percent or less, 3 percent or less, 2 percent or less, or 1 percent or less.

[0274] The ratio of the density of the aerosol-generating substrate within the rod of the aerosol-generating substrate when the pin heating element is not inserted into the rod to the density of the aerosol-generating substrate within the rod of the aerosol-generating substrate when the pin heating element is fully inserted into the rod may be 1:1.02 or more, 1:1.04 or more, 1:1.06 or more, 1:1.08 or more, 1:1.10 or more, 1:1.12 or more, 1:1.14 or more, 1:1.16 or more, 1:1.18 or more, or 1:1.20 or more.

[0275] The ratio of the density of the aerosol-generating substrate within the rod of the aerosol-generating substrate when the pin heating element is not inserted into the rod to the density of the aerosol-generating substrate within the rod of the aerosol-generating substrate when the pin heating element is fully inserted into the rod may be 1:1.20 or less, 1:1.18 or less, 1:1.16 or less, 1:1.14 or less, 1:1.12 or less, 1:1.10 or less, 1:1.08 or less, 1:1.06 or less, 1:1.04 or less, or 1:1.02 or less.

[0276] The density of the aerosol-generating substrate within the rod of aerosol-generating substrate when the pin heating element is fully inserted into the rod may be 550 kilograms per cubic meter (0.55 milligrams per cubic millimeter) or less, 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or less, 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or less, 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or less, or 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or less.

[0277] The density of the aerosol-generating substrate within the rod of aerosol-generating substrate when the pin heating element is fully inserted into the rod may be 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more, 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or more, 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or more, or 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or more.

[0278] The density of the aerosol-generating substrate within the rod of aerosol-generating substrate when the pin heating element is fully inserted into the rod is 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter), 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 550 kilograms per cubic meter (0.55 milligrams per cubic millimeter), 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) to 450 kilograms per cubic meter. The range may be 400 kilograms / cubic meter (0.45 milligrams / cubic millimeter), 400 kilograms / cubic meter (0.40 milligrams / cubic millimeter) to 500 kilograms / cubic meter (0.50 milligrams / cubic millimeter), 400 kilograms / cubic meter (0.40 milligrams / cubic millimeter) to 550 kilograms / cubic meter (0.55 milligrams / cubic millimeter), 450 kilograms / cubic meter (0.45 milligrams / cubic millimeter) to 500 kilograms / cubic meter (0.50 milligrams / cubic millimeter), 450 kilograms / cubic meter (0.45 milligrams / cubic millimeter) to 550 kilograms / cubic meter (0.55 milligrams / cubic millimeter), or 500 kilograms / cubic meter (0.50 milligrams / cubic millimeter) to 550 kilograms / cubic meter (0.55 milligrams / cubic millimeter).

[0279] The increase in density of the aerosol-generating substrate within the rod of the aerosol-generating substrate from a state where the pin heating element is not inserted into the rod to a state where the pin heating element is fully inserted into the rod may be calculated by subtracting the density of the aerosol-generating substrate within the rod of the aerosol-generating substrate before the pin is inserted into the rod from the density of the aerosol-generating substrate within the rod of the aerosol-generating substrate after the pin is fully inserted into the rod.

[0280] The density of the aerosol-generating substrate within the rod of the aerosol-generating substrate when the pin heating element is fully inserted within the rod is calculated using substantially the same method as calculating the density of the aerosol-generating substrate within the rod of the aerosol-generating substrate before the pin heating element is inserted within the rod, except that the volume used to calculate the density of the aerosol-generating substrate within the rod of the aerosol-generating substrate when the pin is fully inserted within the rod is the volume of the rod of the aerosol-generating substrate minus the volume of the portion of the pin inserted within the rod.

[0281] The increase in density of the rod of the aerosol-generating substrate from a state in which the pin heating element is not inserted into the rod to a state in which the pin heating element is fully inserted into the rod is 10 kilograms per cubic meter (0.01 milligrams per cubic millimeter) or more, 20 kilograms per cubic meter (0.02 milligrams per cubic millimeter) or more, 30 kilograms per cubic meter (0.03 milligrams per cubic millimeter) or more, 40 kilograms per cubic meter (0.04 milligrams per cubic millimeter) or more, 50 kilograms per cubic meter (0.05 milligrams per cubic millimeter) or more, 60 kilograms per cubic meter (0.06 milligrams per cubic millimeter) or more, 70 kilograms per cubic meter (0.07 milligrams per cubic millimeter) or more, 80 kilograms per cubic meter (0.08 milligrams per cubic millimeter) or more. It may be 90 kilograms per cubic meter (0.09 milligrams per cubic millimeter) or more, 100 kilograms per cubic meter (0.10 milligrams per cubic millimeter) or more, 150 kilograms per cubic meter (0.15 milligrams per cubic millimeter) or more, 200 kilograms per cubic meter (0.20 milligrams per cubic millimeter) or more, 250 kilograms per cubic meter (0.25 milligrams per cubic millimeter) or more, 300 kilograms per cubic meter (0.30 milligrams per cubic millimeter) or more, 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more, 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or more, or 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or more.

[0282] The increase in density of the rod of aerosol-generating substrate from a state in which the pin heating element is not inserted into the rod to a state in which the pin heating element is fully inserted into the rod is not more than 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), not more than 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), not more than 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter), not more than 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter), not more than 300 kilograms per cubic meter (0.30 milligrams per cubic millimeter), not more than 250 kilograms per cubic meter (0.25 milligrams per cubic millimeter), not more than 200 kilograms per cubic meter (0.20 milligrams per cubic millimeter), not more than 150 kilograms per cubic meter (0.15 milligrams per cubic millimeter). It may be 100 kilograms per cubic meter (0.10 milligrams per cubic millimeter), 90 kilograms per cubic meter (0.09 milligrams per cubic millimeter), 80 kilograms per cubic meter (0.08 milligrams per cubic millimeter), 70 kilograms per cubic meter (0.07 milligrams per cubic millimeter), 60 kilograms per cubic meter (0.06 milligrams per cubic millimeter), 50 kilograms per cubic meter (0.05 milligrams per cubic millimeter), 40 kilograms per cubic meter (0.04 milligrams per cubic millimeter), 30 kilograms per cubic meter (0.03 milligrams per cubic millimeter), or 20 kilograms per cubic meter (0.02 milligrams per cubic millimeter).

[0283] The percentage increase in density of the rod of the aerosol-generating substrate from when the pin heating element is not inserted into the rod to when the pin heating element is fully inserted into the rod may be 1 percent or more, 2 percent or more, 3 percent or more, 4 percent or more, 5 percent or more, 6 percent or more, 7 percent or more, 8 percent or more, 9 percent or more, 10 percent or more, 11 percent or more, 12 percent or more, 13 percent or more, 14 percent or more, 15 percent or more, 16 percent or more, 17 percent or more, 18 percent or more, 19 percent or more, or 20 percent or more.

[0284] The percentage increase in density of the rod of the aerosol-generating substrate from a state in which the pin heating element is not inserted into the rod to a state in which the pin heating element is fully inserted into the rod may be 20 percent or less, 19 percent or less, 18 percent or less, 17 percent or less, 16 percent or less, 15 percent or less, 14 percent or less, 13 percent or less, 12 percent or less, 11 percent or less, 10 percent or less, 9 percent or less, 8 percent or less, 7 percent or less, 6 percent or less, 5 percent or less, 4 percent or less, 3 percent or less, 2 percent or less, or 1 percent or less.

[0285] The ratio of the density of the rod of the aerosol-generating substrate when the pin heating element is not inserted into the rod to the density of the rod of the aerosol-generating substrate when the pin heating element is fully inserted into the rod may be 1:1.02 or more, 1:1.04 or more, 1:1.06 or more, 1:1.08 or more, 1:1.10 or more, 1:1.12 or more, 1:1.14 or more, 1:1.16 or more, 1:1.18 or more, or 1:1.20 or more.

[0286] The ratio of the density of the rod of the aerosol-generating substrate when the pin heating element is not inserted into the rod to the density of the rod of the aerosol-generating substrate when the pin heating element is fully inserted into the rod may be 1:1.20 or less, 1:1.18 or less, 1:1.16 or less, 1:1.14 or less, 1:1.12 or less, 1:1.10 or less, 1:1.08 or less, 1:1.06 or less, 1:1.04 or less, or 1:1.02 or less.

[0287] The density of the rod of the aerosol-generating substrate when the pin heating element is fully inserted into the rod may be 550 kilograms per cubic meter (0.55 milligrams per cubic millimeter) or less, 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or less, 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or less, 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or less, or 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or less.

[0288] The density of the rod of the aerosol-generating substrate when the pin heating element is fully inserted into the rod may be 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more, 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or more, 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or more, or 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or more.

[0289] The density of the rod of aerosol-generating substrate when the pin heating element is fully inserted into the rod is 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter), 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 550 kilograms per cubic meter (0.55 milligrams per cubic millimeter), 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) to 450 kilograms per cubic meter (0.45 The range may be 400 kilograms / cubic meter (0.40 milligrams / cubic millimeter) to 500 kilograms / cubic meter (0.50 milligrams / cubic millimeter), 400 kilograms / cubic meter (0.40 milligrams / cubic millimeter) to 550 kilograms / cubic meter (0.55 milligrams / cubic millimeter), 450 kilograms / cubic meter (0.45 milligrams / cubic millimeter) to 500 kilograms / cubic meter (0.50 milligrams / cubic millimeter), 450 kilograms / cubic meter (0.45 milligrams / cubic millimeter) to 550 kilograms / cubic meter (0.55 milligrams / cubic millimeter), or 500 kilograms / cubic meter (0.50 milligrams / cubic millimeter) to 550 kilograms / cubic meter (0.55 milligrams / cubic millimeter).

[0290] The increase in density of the rod of the aerosol-generating substrate from a state in which the pin heating element is not inserted into the rod to a state in which the pin heating element is fully inserted into the rod may be calculated by subtracting the density of the rod of the aerosol-generating substrate before the pin is inserted into the rod from the density of the rod of the aerosol-generating substrate after the pin is fully inserted into the rod.

[0291] The density of the rod of the aerosol-generating substrate when the pin heating element is fully inserted into the rod is calculated using substantially the same method as calculating the density of the rod of the aerosol-generating substrate before the pin heating element is inserted into the rod, except that the volume used to calculate the density of the rod of the aerosol-generating substrate when the pin is fully inserted into the rod is the volume of the rod of the aerosol-generating substrate minus the volume of the portion of the pin that is inserted into the rod.

[0292] The aerosol-generating device may further include a device cavity configured to receive at least a portion of the aerosol-generating article. The device cavity may have a closed end and an open end. The aerosol-generating article may be insertable into the device cavity through the open end. The device cavity may have substantially the same cross-sectional shape as the aerosol-generating article.

[0293] The device cavity has a device cavity length, which may be substantially the same as or longer than the rod length. The device cavity length may be such that when the aerosol-generating article is received within the aerosol-generating device, at least 75 percent of the rod length is received within the device cavity, at least 80 percent of the rod length is received within the device cavity, or at least 90 percent of the rod length is received within the device cavity.

[0294] Advantageously, providing a device cavity length that is substantially the same as or longer than the rod length ensures that the entire rod of aerosol-generating substrate can be received within the device cavity, which can reduce insufficient heating of downstream portions of the rod of aerosol-generating substrate and result in more uniform heating along the length of the rod.

[0295] When the aerosol-generating article is received by an aerosol-generating device, the pin may penetrate the rod of the aerosol-generating substrate substantially through the centre of a cross-sectional surface of the rod perpendicular to the length of the rod.

[0296] Advantageously, providing a pin that penetrates the rod of the aerosol-generating substrate through the centre of a cross-sectional surface of the rod substantially perpendicular to the rod length can result in more uniform heating of the rod of the aerosol-generating substrate.

[0297] The pin may comprise one of a resistive heating element and a susceptor element.

[0298] The pins may include resistive heating elements.The pins may be resistive heating elements.

[0299] The pin may comprise an electrically resistive material. Suitable electrically resistive materials include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide), carbon, graphite, metals, alloys, and composites made of ceramic and metallic materials. Such composites may include doped or undoped ceramics. An example of a suitable doped ceramic is doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable alloys include stainless steel, constantan, nickel-, cobalt-, chromium-, aluminum-, titanium-, zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese-, and iron-containing alloys, as well as nickel-, iron-, cobalt-, and stainless steel-based superalloys, Timetal®, iron-aluminum-based alloys, and iron-manganese-aluminum-based alloys. Timetal® is a registered trademark of Titanium Metals Corporation, 1999 Broadway Suite 4300, Denver, Colorado. In composite materials, the electrically resistive material may optionally be embedded in, encapsulated in, or coated with an insulating material, or vice versa, depending on the required energy transfer kinetics and external physicochemical properties. The heating element may comprise a metallic, etched foil insulated between two layers of inert material. In this case, the inert material may comprise Kapton®, an all-layer polyimide, or mica foil. Kapton® is a registered trademark of EI du Pont de Nemours and Company, 1007 Market Street, Wilmington, Delaware 19898, United States of America.

[0300] The pins may include susceptor elements. The pins may be susceptor elements. As used herein, the term "susceptor" means a material that can be heated when penetrated by a changing magnetic field.

[0301] The aerosol generating device may be capable of generating a fluctuating electromagnetic field of 1 to 30 MHz, for example, 2 to 10 MHz, for example, 5 to 7 MHz. The device may be capable of generating a fluctuating magnetic field having a field strength (H field) of 1 to 5 kA / m, for example, 2 to 3 kA / m, for example, about 2.5 kA / m.

[0302] The susceptor may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-generating substrate. For example, the susceptor may comprise metal or carbon.

[0303] The susceptor may include or consist of a ferromagnetic material (e.g., a ferromagnetic alloy, ferritic iron, or ferromagnetic steel or stainless steel). A suitable susceptor may be or include aluminum. The susceptor may be formed from 400 series stainless steel, such as grade 410, or grade 420, or grade 430 stainless steel.

[0304] Different materials dissipate different amounts of energy when placed in electromagnetic fields with similar frequencies and field strengths. Thus, susceptor parameters such as material type, length, width, and thickness may all be modified to provide a desired power dissipation within a known electromagnetic field. The susceptor may be heated to temperatures in excess of 250 degrees Celsius.

[0305] If the pin comprises a susceptor element, the aerosol generation device may comprise an inductor coil arranged to inductively heat the pin. The aerosol generation device may comprise an inductor coil. If the aerosol generation device comprises a device cavity, the inductor coil may at least partially surround the device cavity. The inductor coil may be arranged to coaxially surround the device cavity.

[0306] The aerosol generating device may further comprise a controller.

[0307] In use, the heating element may be controlled to operate such that the operating temperature range of the heating element is between 150 degrees Celsius and 350 degrees Celsius, between 200 degrees Celsius and 330 degrees Celsius, or between 260 degrees Celsius and 320 degrees Celsius.

[0308] In use, the heating element may be controlled to heat to a peak temperature of 350 degrees Celsius or less, 335 degrees Celsius or less, or 320 degrees Celsius or less.

[0309] In use, the heating element may be controlled to heat to a peak temperature of between 220 degrees Celsius and 350 degrees Celsius, between 240 degrees Celsius and 335 degrees Celsius, or between 260 degrees Celsius and 320 degrees Celsius.

[0310] The aerosol generating device may further include a power source. The power source may be a DC power source. The power source may be a battery. The power source may be a nickel metal hydride battery, a nickel cadmium battery, or a lithium-based battery, such as a lithium cobalt, lithium-oxygen-phosphate, or lithium polymer battery. The power source may also be another form of charge storage device, such as a capacitor. The power source may be rechargeable and may have a capacity capable of storing sufficient energy for one or more user operations, such as one or more aerosol generating experiences.

[0311] The invention will now be further described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0312] [Figure 1] FIG. 1 is a cross-sectional view of an aerosol-generating article according to a first embodiment of the present disclosure. [Figure 2] FIG. 2 is a cross-sectional view of an aerosol generating device according to a first embodiment of the present disclosure. [Figure 3] FIG. 3 is a cross-sectional view of an aerosol generating system including the aerosol-generating article of FIG. 1 and the aerosol generating device of FIG. [Figure 4] FIG. 4 is a cross-sectional view of the aerosol generation system of FIG. 3 along plane II. [Figure 5] FIG. 5 is a cross-sectional view of an aerosol-generating article according to a second embodiment of the present disclosure. [Figure 6] FIG. 6 is a cross-sectional view of an aerosol generating device according to a second embodiment of the present disclosure. [Figure 7] FIG. 7 is a cross-sectional view of an aerosol generating system including the aerosol-generating article of FIG. 5 and the aerosol generating device of FIG. [Figure 8] FIG. 8 is a cross-sectional view of the aerosol generation system of FIG. 7 along plane II-II. [Figure 9] FIG. 9 is a cross-sectional view of an aerosol-generating article according to a third embodiment of the present disclosure. [Figure 10] FIG. 10 is a cross-sectional view of an aerosol-generating article according to a fourth embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0313] FIG. 1 shows a schematic cross-sectional view of an aerosol-generating article 10. The aerosol-generating article 10 has a substantially cylindrical shape along its length. The aerosol-generating article 10 comprises a rod of aerosol-generating substrate 11 at a distal end of the article 10. The rod of aerosol-generating substrate 11 has a substantially cylindrical shape along its length and comprises a collection of homogenized tobacco sheets. The article further comprises a downstream section 12 located downstream of the rod of aerosol-forming substrate 11. The downstream section 12 comprises a hollow tubular cooling element 13, a PLA (polylactic acid) plug 14, and a mouth-end filter 15. The mouth-end filter 15 is at the proximal end of the article 10. A longitudinal axis 17 extends centrally along the longitudinal axis of the aerosol-generating article 10. The aerosol-forming substrate rod 11, hollow tubular cooling element 13, PLA plug 14, and mouth-end filter 15 are arranged end-to-end along a longitudinal axis 17 and are surrounded by an outer wrapper 16 that extends along the entire length of the aerosol-generating article 10. It will be appreciated that in other embodiments, the outer wrapper may not extend along the entire length of the aerosol-generating article, for example, may not surround the mouth-end filter. The downstream section 12 and outer wrapper 16 are described in more detail below.

[0314] The aerosol-generating substrate rod 11 has a rod length 18 parallel to the longitudinal axis 17 of the aerosol-generating article 10. The aerosol-generating substrate rod 11 has a rod width 19 perpendicular to the longitudinal axis 17 of the aerosol-generating article 10. The rod width 19 is measured at a position 50% along the rod length 18 from the end of the aerosol-generating substrate rod 11. In other words, the rod width 19 is measured at a position midway along the length of the aerosol-generating substrate rod 11. The rod width 19 is substantially uniform along the rod length 18. In this example, the rod width 19 is 6.7 millimeters. In this example, the rod length 18 is 12 millimeters. In this example, the ratio of the rod width 19 to the rod length 18 is 0.558. In this example, the aerosol-generating substrate rod 11 has a mass of 210 milligrams and a density of the aerosol-generating substrate rod 11 is 496 kilograms per cubic meter (0.50 milligrams per cubic millimeter). The length of the aerosol-generating article is 45 millimeters. The ratio of the rod length 18 to the length of the aerosol-generating article 10 is 0.267.

[0315] As mentioned above, the downstream section 12 includes a mouth-end filter 15, a PLA (polylactic acid) plug 14, and a hollow tubular cooling element 13. The downstream section 12 extends between the aerosol-generating substrate rod 11 and the downstream end of the aerosol-generating article 10. The downstream section 12 has a length of 33 millimeters.

[0316] The PLA plug 14 is downstream of the hollow tubular cooling element 13. The hollow tubular cooling element 13 is a hollow acetate tube. The hollow tubular cooling element 13 abuts the downstream end of the aerosol-generating substrate rod 11. The combined length of the hollow tubular cooling element 13 and the PLA plug 14 is approximately 26 millimeters. The hollow tubular cooling element 13 includes a lumen. The lumen of the hollow tubular cooling element 13 has a substantially circular cross-sectional shape. The wall thickness of the hollow tubular cooling element 13 is 0.25 millimeters. The outer diameter of the hollow tubular cooling element 13 is 6.7 millimeters. The RTD of the hollow tubular cooling element 13 is approximately 0 millimeters of water column. The hollow tubular cooling element 13 includes a ventilation zone located along the hollow tubular cooling element 13. The ventilation zone includes one or more rows of ventilation holes 13a arranged circumferentially around the hollow tubular cooling element 13 in a cross section taken substantially perpendicular to the longitudinal axis 17 of the aerosol-generating article 10. The ventilation holes 13a are perforations through the wall of the hollow tubular cooling element 13. The ventilation level of the aerosol-generating article 10 is approximately 75 percent. Each circumferential row of ventilation holes 13a includes between 8 and 30 holes.

[0317] The mouth-end filter 15 is located at the downstream end of the aerosol-generating article 10. The mouth-end filter 15 abuts the downstream end of the PLA plug 14. The mouth-end filter 15 comprises low-density cellulose acetate filter segments. The RTD of the mouth-end filter 15 is approximately 8 millimeters of water column. The length of the mouth-end filter 15 is approximately 7 millimeters.

[0318] The outer wrapper 16 is made of tipping paper. The outer wrapper 16 does not extend beyond the end of the aerosol-generating article 10 in a direction parallel to the longitudinal axis 17. The vent holes 13a extend through the outer wrapper 16 in a direction perpendicular to the longitudinal axis 17.

[0319] 2 shows a schematic cross-sectional view of a portion of an aerosol-generating device 100 including a heating element in the form of a pin 120. The pin 120 is a resistive heating element. The pin 120 is mounted within a device cavity 121. The device cavity 121 is configured to receive at least a portion of an aerosol-generating article 10. The distal end of the device cavity 121 has a closed end. The proximal end of the device cavity 121 has an open end. The aerosol-generating article 10 is insertable into the device cavity 121 via the open end of the device cavity 121.

[0320] In use, a user inserts the aerosol-generating article 10 into the device cavity 121 of the aerosol-generating device 100 so that the pin 120 is inserted into the rod 11 of the aerosol-generating substrate of the aerosol-generating article 10 .

[0321] The pin 120 has a pin length 122 that extends from an end 123a of the tip 123 of the pin 120 to the base of the pin 120 at the opposite end. The pin length 122 is substantially the same as the rod length 18. The pin length 122 is approximately 12 millimeters. The tip of the pin has a tip length 122a. In this embodiment, the tip length 122a is 1.5 millimeters.

[0322] The pin 120 has a pin width 124 perpendicular to the pin length 122. The pin width 124 is measured at a distance 125 from the end 123a of the tip 123 of the pin 120. In this example, the distance 125 from the end 123a of the tip 123 of the pin 120 is 4 millimeters. In this example, the pin width 124 at a distance of 4 millimeters from the end 123a of the tip 123 is 2.5 millimeters. The pin width 124 is substantially uniform along the length of the pin 120, except for the tip 123 of the pin 120.

[0323] The tip 123 of the pin 120 tapers towards the end 123a of the pin such that the tip 123 of the pin 120 is configured to penetrate the rod 11 of the aerosol-generating substrate (as shown in FIG. 3).

[0324] The aerosol-generating device 100 further comprises a power source (not shown) and electronics (not shown) that enable actuation of the pins 120 to heat the rod 11 of the aerosol-forming substrate when the aerosol-generating article 10 is received within the device cavity 121. Such actuation may be manual, or may occur automatically in response to a user inhaling the aerosol-generating article 10 when it is inserted into the device cavity 121.

[0325] FIG. 3 shows a cross-sectional view of a portion of an aerosol-generating system 1000 including the aerosol-generating article 10 of FIG. 1 and the aerosol-generating device 100 of FIG. 2. In FIG. 3, a portion of the aerosol-generating article 10 is received within a device cavity 121 of the aerosol-generating device 10, and a pin 120 penetrates the rod 11 of the aerosol-generating substrate along the longitudinal axis 17 of the aerosol-generating article. The device cavity 121 has a length parallel to the longitudinal axis 17 that is greater than the rod length 13. The entire length of the rod 11 of the aerosol-generating substrate is received within the device cavity 121. The vent hole 13a of the hollow tubular element 13 is not received within the device cavity 121. During use, the pin 120 is controlled to operate within a defined operating temperature range that is less than the maximum operating temperature. The operating temperature of the pin 120 is approximately 350 degrees Celsius.

[0326] Figure 4 shows a cross-sectional view of a portion of the aerosol-generating system 1000 of Figure 3 taken along plane I-I. The rod width 19 and pin width 124 are also shown in Figure 4. The aerosol-generating substrate rod 11 has a rod cross-sectional area perpendicular to the rod length 18. The rod cross-sectional area is measured 50% along the rod length 18 from the end of the aerosol-generating substrate rod 11. In this example, the rod cross-sectional area is 35.3 square millimeters. In this example, the aerosol-generating substrate rod 11 has a substantially circular cross-sectional shape along its entire length 18, such that the rod cross-sectional area is substantially uniform along the rod length 18.

[0327] The pin 120 has a pin cross-sectional area perpendicular to the pin length 122. The pin cross-sectional area is measured at a distance 125 from the end 123a of the tip 123 of the pin 120. As described above, the pin width 124 at a distance of 4 millimeters from the end 123a of the tip 123 is 2.5 millimeters. In this example, the pin cross-sectional area at a distance of 4 millimeters from the end 123a of the tip 123 is 4.91 square millimeters. The pin 120 has a substantially circular cross-sectional shape at a distance of 4 millimeters from the end 123a of the tip 123. Therefore, in this example, the minimum transverse pin dimension is equal to the pin width. In this example, the ratio of the rod width 19 to the pin width 124 is 2.7. In this example, the ratio of the rod cross-sectional area to the pin cross-sectional area is 7.18. The pin cross-sectional shape at a distance of 4 millimeters from the end 123a of the tip 123 is substantially the same as the rod cross-sectional shape.

[0328] The device cavity 121 has a substantially circular cross-sectional shape. The device cavity 121 has substantially the same cross-sectional shape as the aerosol-generating substrate rod 11. As shown in Figure 4, when the pin 120 penetrates the aerosol-generating substrate rod 11, the pin 120 penetrates the aerosol-generating substrate rod 11 substantially through the center of the cross-section of the aerosol-generating substrate rod 11.

[0329] 5 shows a schematic cross-sectional view of an aerosol-generating article 20. The aerosol-generating article 20 has a substantially elliptical cross-sectional shape along its length. It will be understood that articles having other cross-sectional shapes along their length are possible, such as substantially circular, substantially square, and substantially triangular cross-sectional shapes.

[0330] The aerosol-generating article 20 comprises a rod 21 of aerosol-generating substrate at the distal end of the article 20. The rod 21 of aerosol-generating substrate has a substantially cylindrical shape with an elliptical cross-section along its length, similar to the cross-section of the article 20, and comprises a collection of crimped sheets of homogenized tobacco.

[0331] The article 20 further comprises a downstream section 22 located downstream of the rod 21 of the aerosol-forming substrate. The downstream section 22 includes a mouth-end filter 25. The mouth-end filter 25 is at the proximal end of the article 20. A longitudinal axis 27 extends centrally along the longitudinal direction of the aerosol-generating article 20. The downstream section 22 also includes a tubular element 23 including a tubular body defining a cavity 23b extending from the upstream end of the tubular body to the downstream end of the tubular body. The tubular element (hereinafter referred to as the flange tube 23) also includes a folded end that forms an upstream end wall 23c at the upstream end of the tubular body.

[0332] The aerosol-forming substrate rod 21, flanged tube 23, and mouth-end filter 25 are arranged end-to-end along a longitudinal axis 27 and are surrounded by an outer wrapper 26 that extends along the entire length of the aerosol-generating article 20. It will be appreciated that in other embodiments, the outer wrapper may not extend along the entire length of the aerosol-generating article, for example, may not surround the mouth-end filter. The downstream section 22 and outer wrapper 26 are described in more detail below.

[0333] The aerosol-generating substrate rod 21 has a rod length 28 parallel to the longitudinal axis 27 of the aerosol-generating article 20. The aerosol-generating substrate rod 21 has a rod width 29 perpendicular to the longitudinal axis 27 of the aerosol-generating article 20. The rod width 29 is measured at a position 50% along the rod length 28 from the end of the aerosol-generating substrate rod 21. In other words, the rod width 29 is measured at a midpoint along the length of the aerosol-generating substrate rod 21. As discussed in more detail with reference to FIG. 8 , the aerosol-generating substrate rod 21 has a substantially elliptical cross-sectional shape. In other words, the rod width 29 refers to the maximum dimension of the aerosol-generating substrate rod 21 parallel to the major axis of the elliptical cross-section of the aerosol-generating substrate rod 21, measured at a position 50% along the rod length 28 from the end of the aerosol-generating substrate rod 21. The rod width 29 is substantially uniform along the rod length 28. In this example, the rod width 29 is 6.3 millimeters. As discussed in more detail below, the cross-sectional dimension of the aerosol-generating substrate rod 21 perpendicular to the rod width 29 is 6.1 millimeters. In this example, the rod length 28 is 12 millimeters. In this example, the ratio of the rod width 29 to the rod length 28 is 0.525. In this example, the aerosol-generating substrate rod 21 has a mass of 180 milligrams and a density of the aerosol-generating substrate rod 21 is 497 kilograms per cubic meter (0.50 milligrams per cubic millimeter). The length of the aerosol-generating article is 45 millimeters. The ratio of the rod length 28 to the length of the aerosol-generating article 20 is 0.267.

[0334] As mentioned above, the downstream section 22 includes the mouth end filter 25 and the flanged pipe 23. The downstream section 22 extends between the aerosol-generating substrate rod 21 and the downstream end of the aerosol-generating article 20. The downstream section 22 has a length of 33 millimeters.

[0335] The flange tube 23 abuts the downstream end of the aerosol-generating substrate rod 21. The upstream end wall 23c of the flange tube 23 defines an opening 23d, which allows airflow between the cavity 23b and the exterior of the flange tube 23. In particular, aerosol can flow from the aerosol-generating substrate rod 21 into the cavity 23b through the opening 23d. The cavity 23b of the flange tube 23 is substantially empty, allowing substantially unrestricted airflow along the cavity 23b. As a result, the RTD of the flange tube 23 can be localized to a particular longitudinal location of the flange tube 23, i.e., the upstream end wall 23c, and can be controlled through the selected configuration of the upstream end wall 23c and its corresponding opening 23d. In this example, the RTD of the flange tube 23 (which is essentially the RTD of the upstream end wall 23c) is approximately 10 millimeters of water column.

[0336] The upstream end wall 23c extends substantially transversely to the longitudinal axis 27 of the aerosol-generating article 20. The opening 23d is the only opening in the upstream end wall 23c, and the opening 23d is located at a generally radially central position of the flange pipe 23. As a result, the upstream end wall 23c is generally annular in shape. The combination of the upstream end wall 23c and its corresponding opening 23d provides an effective barrier arrangement that can restrict movement of the aerosol-generating substrate rod 21 while simultaneously allowing aerosol to flow from the aerosol-generating substrate rod 21 through the opening 23d and into the cavity 23b.

[0337] The flange tube 23 has a length of approximately 26 millimeters, an outer width of approximately 6.3 millimeters, and an inner width of approximately 5.6 millimeters. Accordingly, the thickness of the peripheral wall of the flange tube 23 is approximately 0.7 millimeters. The flange tube 23 is formed from a paper material, such as paper, paperboard, or cardboard. In this embodiment, the cavity 23b of the flange tube 23 has a substantially elliptical cross-sectional shape. It will be understood that other cross-sectional shapes for the flange tube, such as a substantially circular cross-sectional shape, are possible. The flange tube 23 includes a ventilation zone located along the flange tube 23. The ventilation zone includes one or more rows of ventilation holes 23a arranged circumferentially around the hollow tube in a cross section substantially perpendicular to the longitudinal axis 27 of the aerosol-generating article 20. The ventilation holes 23a are perforations through the wall of the flange tube 23. The ventilation level of the aerosol-generating article 20 is approximately 75 percent. Each circumferential row of ventilation holes 23a includes between 8 and 30 holes.

[0338] The mouth-end filter 25 is located at the downstream end of the aerosol-generating article 10. The mouth-end filter 25 abuts the flanged pipe 23. The mouth-end filter 25 comprises a low-density cellulose acetate filter segment. The RTD of the mouth-end filter 25 is approximately 8 millimeters of water column. The length of the mouth-end filter 25 is approximately 7 millimeters.

[0339] The outer wrapper 26 is made of tipping paper. The outer wrapper 26 does not extend beyond the end of the aerosol-generating article 20 in a direction parallel to the longitudinal axis 27. The vent holes 23a extend through the outer wrapper 26 in a direction perpendicular to the longitudinal axis 27.

[0340] 6 shows a schematic cross-sectional view of a portion of an aerosol-generating device 200 including a heating element in the form of a pin 220. In this embodiment, the pin 220 is a susceptor element configured to be heated when penetrated by a changing magnetic field. The pin 220 is mounted within a device cavity 221. The aerosol-generating device 200 further comprises an inductor coil 226 surrounding the device cavity 221 and surrounding the susceptor pin 220. The inductor coil 226 is arranged to generate a changing magnetic field within the device cavity 221 that penetrates the susceptor pin 220 and inductively heats the susceptor element pin 220. The device cavity 221 is configured to receive at least a portion of the aerosol-generating article 20. The distal end of the device cavity 221 has a closed end. The proximal end of the device cavity 221 has an open end. The aerosol-generating article 20 is insertable into the device cavity 221 via the open end of the device cavity 221 .

[0341] In use, the user inserts the aerosol-generating article 20 into the device cavity 221 of the aerosol-generating device 200 so that the pin 220 is inserted into the rod 21 of the aerosol-generating substrate of the aerosol-generating article 20 .

[0342] The pin 220 has a pin length 222 that extends from the tip 223 end of the pin 220 to the opposite end, the base of the pin 220. The pin length 222 is substantially the same as the rod length 28. The pin length 222 is approximately 12 millimeters. The tip of the pin has a tip length 222a. In this example, the tip length 222a is 1.5 millimeters.

[0343] The pin 220 has a pin width 224 perpendicular to the pin length 222. The pin width 224 is measured at a distance 225 from the end 223a of the tip 223 of the pin 220. In this example, the distance 225 from the end 223a of the tip 223 of the pin 220 is 4 millimeters. In this example, the pin width 224 at a distance of 4 millimeters from the end 223a of the tip 223 is 3 millimeters. As discussed in more detail with reference to FIG. 8 , the pin 220 has a substantially elliptical cross-sectional shape. In other words, the pin width 224 refers to the largest dimension of the pin 220 parallel to the major axis of the elliptical cross-section of the pin 220 at a distance of 4 millimeters from the end 223a of the tip 223. The pin width 224 is substantially uniform along the length of the pin 220, except for the tip 223 of the pin 220.

[0344] The tip 223 of the pin 220 tapers towards the end 223a of the pin such that the tip 223 of the pin 220 is configured to penetrate the rod of the aerosol-generating substrate 21 (as shown in FIG. 7).

[0345] The aerosol-generating device 200 further comprises a power supply (not shown) and electronics (not shown) arranged to supply power to the inductor coil 226 to generate a varying magnetic field within the device cavity 221 to inductively heat the susceptor pin 220. The susceptor pin 220 heats the aerosol-forming substrate rod 21 when the aerosol-generating article 20 is received within the device cavity 221. Such activation of the inductor coil 226 may be manual or may occur automatically in response to a user inhaling the aerosol-generating article 20 when it is inserted into the device cavity 221.

[0346] FIG. 7 shows a cross-sectional view of a portion of an aerosol-generating system 2000 including the aerosol-generating article 20 of FIG. 5 and the aerosol-generating device 200 of FIG. 6. In FIG. 7, a portion of the aerosol-generating article 20 is received within a device cavity 221 of the aerosol-generating device 20, and a pin 220 penetrates the rod 21 of the aerosol-generating substrate along the longitudinal axis 27 of the aerosol-generating article. The device cavity 221 has a length parallel to the longitudinal axis 27 that is greater than the rod length 23. The entire length of the rod 21 of the aerosol-generating substrate is received within the device cavity 221. The vent hole 23a of the flange tube 23 is not received within the device cavity 221. During use, the inductor coil 226 is controlled to heat the susceptor pin 220 within a defined operating temperature range below the maximum operating temperature. The operating temperature of the susceptor pin 220 is approximately 350 degrees Celsius.

[0347] FIG. 8 shows a cross-sectional view of a portion of the aerosol-generating system 2000 of FIG. 7 along plane I-I. The rod width 29 and pin width 224 are also shown in FIG. 8. The aerosol-generating substrate rod 21 has a rod cross-sectional area perpendicular to the rod length 28. The rod cross-sectional area is measured 50% along the rod length 28 from the end of the aerosol-generating substrate rod 21. In this example, the aerosol-generating substrate rod 21 has a substantially elliptical cross-sectional shape along its entire length 28, such that the rod cross-sectional area is substantially uniform along the rod length 28. In this example, the cross-sectional dimension of the aerosol-generating substrate rod 21 perpendicular to the rod width 29 is 6.1 millimeters (i.e., the dimension of the aerosol-generating substrate rod 21 parallel to the minor axis of the elliptical cross-section of the aerosol-generating substrate rod 21 is 6.1 millimeters). As noted above, the rod width 29 is 6.3 millimeters. Thus, the rod cross-sectional area is 30.2 square millimeters. It will be appreciated that in other embodiments the rod may have other cross-sectional shapes along the length of the rod 21 of the aerosol-generating substrate, such as a substantially circular, triangular or square shape.

[0348] The pin 220 has a pin cross-sectional area perpendicular to the pin length 222. The pin 220 has a substantially oval cross-sectional shape at a distance of 4 millimeters from the end 223a of the tip 223, although it will be understood that other cross-sectional shapes are possible, such as a substantially circular shape at a distance of 4 millimeters from the end 223a of the tip 223. The pin cross-sectional area is measured at a distance 225 from the end 223a of the tip 223 of the pin 220. As noted above, the pin width 224 at a distance of 4 millimeters from the end 223a of the tip 223 is 3 millimeters. In this example, the minimum transverse pin dimension is the cross-sectional dimension of the pin 220 perpendicular to the pin width 224. In this example, the minimum transverse pin dimension is 2.9 millimeters (i.e., the dimension of the pin 220 parallel to the minor axis of the oval cross-section of the pin 220 at a distance of 4 millimeters from the end 223a of the tip 223 is 2.9 millimeters). Thus, the pin cross-sectional area at a distance of 4 millimeters from end 223a of tip 223 is 6.83 square millimeters. In this example, the ratio of rod width 29 to pin width 224 is 2.1. In this example, the ratio of rod cross-sectional area to pin cross-sectional area is 4.42. The cross-sectional shape of the pin at a distance of 4 millimeters from end 223a of tip 223 is substantially the same as the cross-sectional shape of the rod.

[0349] In this embodiment, the device cavity 221 has a substantially elliptical cross-sectional shape, although it will be appreciated that in other embodiments the device cavity may have other cross-sectional shapes, such as a substantially circular, triangular, or square shape for the device cavity 221. The device cavity 221 has substantially the same cross-sectional shape as the rod 21 of the aerosol-generating substrate. As shown in Figure 8, when the pin 220 penetrates the rod 21 of the aerosol-generating substrate, the pin 220 penetrates the rod 21 of the aerosol-generating substrate substantially through the center of the cross-section of the rod 21 of the aerosol-generating substrate.

[0350] Figure 9 shows a schematic cross-sectional view of an aerosol-generating article 30. The aerosol-generating article 30 has a substantially cylindrical shape along its length. The aerosol-generating article 30 comprises a rod of aerosol-generating substrate 31 at the distal end of the article 30. The rod of aerosol-generating substrate 31 has a substantially cylindrical shape along its length and comprises an assembly of homogenized tobacco sheets. The article further comprises a downstream section 32 located downstream of the rod of aerosol-forming substrate 31. The downstream section 32 comprises a first hollow tubular cooling element 33, a second hollow tubular cooling element 34, and a mouth-end filter 35. The mouth-end filter 35 is at the proximal end of the article 30. A longitudinal axis 37 extends centrally along the longitudinal direction of the aerosol-generating article 30. The aerosol-forming substrate rod 31, first tubular cooling element 33, second tubular cooling element 34, and mouth-end filter 35 are arranged end-to-end along a longitudinal axis 37 and are surrounded by an outer wrapper 36 that extends along the entire length of the aerosol-generating article 30. The downstream section 32 and outer wrapper 36 are described in more detail below.

[0351] The aerosol-generating substrate rod 31 has a rod length 38 parallel to the longitudinal axis 37 of the aerosol-generating article 30. The aerosol-generating substrate rod 31 has a rod width 39 perpendicular to the longitudinal axis 37 of the aerosol-generating article 30. The rod width 39 is measured at a position 50% along the rod length 38 from the end of the aerosol-generating substrate rod 31. In other words, the rod width 39 is measured at a position midway along the length of the aerosol-generating substrate rod 31. The rod width 39 is substantially uniform along the rod length 38. In this example, the rod width 39 is 6.7 millimeters. In this example, the rod length 38 is 12 millimeters. In this example, the ratio of the rod width 39 to the rod length 38 is 0.558. In this example, the aerosol-generating substrate rod 31 has a mass of 162 milligrams and a density of the aerosol-generating substrate rod 31 is 383 kilograms per cubic meter (0.38 milligrams per cubic millimeter). The length of the aerosol-generating article 30 is 45 millimeters. The ratio of the rod length 38 to the length of the aerosol-generating article 30 is 0.267.

[0352] As mentioned above, the downstream section 32 includes the mouth-end filter 35, the second hollow tubular cooling element 34, and the first hollow tubular cooling element 33. The downstream section 32 extends between the aerosol-generating substrate rod 31 and the downstream end of the aerosol-generating article 30. The downstream section 32 has a length of 33 millimeters.

[0353] The second hollow tubular cooling element 34 is downstream of the first hollow tubular cooling element 33. The first hollow tubular cooling element 33 is a hollow acetate tube. The second hollow tubular cooling element 34 is a hollow acetate tube. The first hollow tubular cooling element 33 abuts the downstream end of the aerosol-generating substrate rod 31. The combined length of the first hollow tubular cooling element 33 and the second hollow tubular cooling element 34 is approximately 26 millimeters. The first hollow tubular cooling element 33 includes a lumen. The lumen of the first hollow tubular cooling element 33 has a substantially circular cross-sectional shape. The second hollow tubular cooling element 34 includes a lumen. The lumen of the second hollow tubular cooling element 34 has a substantially circular cross-sectional shape. The width of the lumen of the second tubular cooling element 34 is greater than the width of the lumen of the first tubular cooling element 33. The wall thickness of the second hollow tubular cooling element 34 is less than the wall thickness of the first hollow tubular cooling element 33. The second hollow tubular cooling element may also be referred to as fine hollow acetate tubing (FHAT). The wall thickness of the second hollow tubular cooling element 34 is 0.15 millimeters. The wall thickness of the second hollow tubular cooling element 33 is 0.25 millimeters. The outer diameter of both the first hollow tubular cooling element 33 and the second hollow tubular cooling element 34 is 6.7 millimeters. The RTD of the first hollow tubular cooling element 33 and the second hollow tubular cooling element 34 is approximately 0 millimeters of water column. The second hollow tubular cooling element 34 includes a ventilation zone located along the second hollow tubular cooling element 34. It will be understood that, alternatively or additionally, a ventilation zone may be provided along the first hollow tubular cooling element 33. The ventilation zone includes one or more rows of ventilation holes 33a arranged circumferentially around the second hollow tubular cooling element 34 in a cross section substantially perpendicular to the longitudinal axis 37 of the aerosol-generating article 30. The ventilation holes 33a are perforations through the wall of the second hollow tubular cooling element 34. The ventilation level of the aerosol-generating article 30 is about 75 percent. Each circumferential row of ventilation holes 33a includes between 8 and 30 holes.

[0354] The mouth-end filter 35 is located at the downstream end of the aerosol-generating article 30. The mouth-end filter 35 abuts the downstream end of the second hollow tubular cooling element 34. The mouth-end filter 35 comprises a low-density cellulose acetate filter segment. The RTD of the mouth-end filter 35 is approximately 8 millimeters of water column. The length of the mouth-end filter 35 is approximately 7 millimeters.

[0355] The outer wrapper 36 is made of tipping paper. The outer wrapper 36 does not extend beyond the end of the aerosol-generating article 30 in a direction parallel to the longitudinal axis 37. The vent holes 33a extend through the outer wrapper 36 in a direction perpendicular to the longitudinal axis 37.

[0356] FIG. 10 shows a schematic cross-sectional view of an aerosol-generating article 40. The aerosol-generating article 40 is substantially the same as the aerosol-generating article 10. The only difference between the aerosol-generating article 40 and the aerosol-generating article 10 is that the aerosol-generating article 40 does not include a ventilation zone. Thus, the aerosol-generating article 40 does not include one or more rows of ventilation holes circumferentially arranged around the hollow tubular cooling element 43. The aerosol-generating article 40 includes a rod of aerosol-generating substrate 41 at the distal end of the article, and a downstream section 42 including a first hollow tubular cooling element 43, a second hollow tubular cooling element 44, and a mouth-end filter 45 at the proximal end of the article 40. A longitudinal axis 47 extends centrally along the longitudinal direction of the aerosol-generating article 40. The aerosol-forming substrate rod 41, first tubular cooling element 43, second tubular cooling element 44, and mouth-end filter 45 are arranged end-to-end along a longitudinal axis 47 and are surrounded by an outer wrapper 46 that extends along the entire length of the aerosol-generating article 40.

[0357] The aerosol-generating substrate rod 41 has a rod length 48 parallel to the longitudinal axis 47 of the aerosol-generating article 40. The aerosol-generating substrate rod 41 has a rod width 49 perpendicular to the longitudinal axis 47 of the aerosol-generating article 40. The rod width 49 is measured at a position 50% along the rod length 48 from the end of the aerosol-generating substrate rod 41. In other words, the rod width 49 is measured at a position midway along the length of the aerosol-generating substrate rod 41. The rod width 49 is substantially uniform along the rod length 48. In this example, the rod width 49 is 6.7 millimeters. In this example, the rod length 48 is 12 millimeters. In this example, the ratio of the rod width 49 to the rod length 48 is 0.558.

[0358] The following provides 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 of the features described above, for example, with any one or more features of another example, embodiment, or aspect described herein.

[0359] Example 1: An aerosol-generating article comprising a rod of aerosol-generating substrate. Example 2: 10. The aerosol-generating article of Example 1, wherein the rod of the aerosol-generating substrate has a rod width and a rod length, and the ratio of rod width to rod length is 0.25 to 0.60, optionally 0.30 to 0.60, optionally 0.35 to 0.60, optionally 0.40 to 0.60, optionally 0.45 to 0.60, 0.50 to 0.60, optionally 0.25 to 0.56, optionally 0.30 to 0.56, 0.35 to 0.56, optionally 0.40 to 0.56, optionally 0.45 to 0.56, optionally 0.50 to 0.56, optionally 0.25 to 0.50, optionally 0.25 to 0.40, or optionally 0.35 to 0.50. Example 3: An aerosol-generating article according to example 1 or 2, wherein the mass of the aerosol-generating substrate within the rod of aerosol-generating substrate is 220 milligrams or less, optionally 210 milligrams or less, or optionally 200 milligrams or less. Example 4: An aerosol-generating article according to any one of Examples 1 to 3, wherein the mass of the aerosol-generating substrate in the rod of aerosol-generating substrate is from 10 milligrams to 220 milligrams, optionally from 50 milligrams to 220 milligrams, optionally from 100 milligrams to 220 milligrams, or optionally from 150 milligrams to 200 milligrams. Example 5: An aerosol-generating article according to any one of Examples 1 to 4, wherein the mass of the rod of aerosol-generating substrate is 300 milligrams or less, optionally 280 milligrams or less, optionally 270 milligrams or less, optionally 260 milligrams or less, optionally 250 milligrams or less, preferably the mass of the rod of aerosol-generating substrate is 220 milligrams or less, more preferably 210 milligrams or less, and more preferably 200 milligrams or less. Example 6: An aerosol-generating article according to any one of Examples 1 to 5, wherein the mass of the rod of aerosol-generating substrate is from 10 milligrams to 300 milligrams, optionally from 50 milligrams to 280 milligrams, optionally from 100 milligrams to 270 milligrams, preferably from 10 milligrams to 220 milligrams, more preferably from 50 milligrams to 220 milligrams, more preferably from 100 milligrams to 220 milligrams, more preferably from 150 milligrams to 200 milligrams. Example 7: 7. An aerosol-generating article according to any one of Examples 1 to 6, wherein the density of the aerosol-generating substrate within the rod of aerosol-generating substrate is 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or less, optionally 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or less, optionally 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or less, or optionally 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or less. Example 8: An aerosol-generating article according to any one of Examples 1 to 7, wherein the density of the aerosol-generating substrate within the rod of aerosol-generating substrate is 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more, optionally 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or more, or optionally 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or more. Example 9: The density of the aerosol-generating substrate within the rod of aerosol-generating substrate is between 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) and 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter), optionally between 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) and 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), optionally between 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) and 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), optionally The aerosol-generating article of any of Examples 1 to 8, optionally having a saturation density of 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) to 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), optionally 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) to 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), or optionally 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) to 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter). Example 10: 10. An aerosol-generating article according to any one of Examples 1 to 9, wherein the density of the rods of the aerosol-generating substrate is 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or less, optionally 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or less, optionally 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or less, or optionally 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or less. Example 11: 11. An aerosol-generating article according to any one of Examples 1 to 10, wherein the density of the rods of the aerosol-generating substrate is 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more, optionally 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or more, or optionally 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or more. Example 12: The density of the rods of the aerosol-generating substrate is from 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter), optionally from 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), optionally from 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) to 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), optionally from 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter). 12. The aerosol-generating article of any one of Examples 1 to 11, wherein the aerosol-generating article has a saturation energy of between 0.40 milligrams per cubic millimeter (1000 kJ / cubic meter) and 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), optionally between 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) and 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), or optionally between 0.450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) and 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter). Example 13: An aerosol-generating article according to any one of Examples 1 to 12, wherein the rod of the aerosol-generating substrate has a rod width. Example 14: An aerosol-generating article as described in Example 13, wherein the rod of the aerosol-generating substrate has a rod length, and optionally the rod width is substantially uniform along the rod length. Example 15: An aerosol-generating article as described in Example 14, wherein the rod width is measured at a position 50% along the rod length from the end of the rod. Example 16: 16. An aerosol-generating article according to any one of Examples 13 to 15, wherein the rod width is 5 millimeters or more, optionally 5.3 millimeters or more, optionally 5.5 millimeters or more, optionally 5.7 millimeters or more, optionally 6.1 millimeters or more, optionally 6.3 millimeters or more, or optionally 6.7 millimeters or more. Example 17: 17. An aerosol-generating article according to any one of Examples 13 to 16, wherein the rod width is 7 millimeters or less, optionally 6.7 millimeters or less, optionally 6.3 millimeters or less, optionally 6.1 millimeters or less, optionally 5.7 millimeters or less, optionally 5.5 millimeters or less, or optionally 5.3 millimeters or less. Example 18: The rod width is 5 mm to 7 mm, optionally 5 mm to 6.7 mm, optionally 5 mm to 6.3 mm, optionally 5 mm to 6.1 mm, optionally 5 mm to 5.7 mm, optionally 5 mm to 5.5 mm, optionally 5 mm to 5.3 mm, optionally 5.3 mm to 7 mm, optionally 5.3 mm to 6.7 mm, optionally 5.3 mm to 6.3 mm, optionally 5.3 mm to 6.1 mm, optionally 5.3 mm to 5.7 mm, optionally 5.3 mm to 5.5 mm, optionally 5.5 mm to 7 mm, optionally 5.5 mm to 6.7 mm. 18. The aerosol-generating article of any one of Examples 13-17, wherein the aerosol-generating article has a thickness of 5.5 mm to 6.3 mm, optionally 5.5 mm to 6.1 mm, optionally 5.5 mm to 5.7 mm, optionally 5.7 mm to 7 mm, optionally 5.7 mm to 6.7 mm, optionally 5.7 mm to 6.3 mm, optionally 5.7 mm to 6.1 mm, optionally 6.1 mm to 7 mm, optionally 6.1 mm to 6.7 mm, optionally 6.1 mm to 6.3 mm, optionally 6.3 mm to 7 mm, optionally 6.3 mm to 6.7 mm, or optionally 6.7 mm to 7 mm. Example 19: 19. An aerosol-generating article according to any one of Examples 1 to 18, wherein the rod of the aerosol-generating substrate has a rod length, and the rod of the aerosol-generating substrate has a rod cross-sectional area perpendicular to the rod length. Example 20: 20. The aerosol-generating article of Example 19, wherein the rod cross-sectional area is measured 50 percent along the length of the rod from the end of the rod. Example 21: 21. The aerosol-generating article of Example 19 or 20, wherein the rod cross-sectional area is substantially uniform along the length of the rod. Example 22: 22. An aerosol-generating article according to any one of Examples 19 to 21, wherein the rod cross-sectional area is 38.5 square millimeters or less, optionally 35.3 square millimeters or less, optionally 31.2 square millimeters or less, optionally 29.2 square millimeters or less, optionally 25.5 square millimeters or less, optionally 23.8 square millimeters or less, optionally 22.1 square millimeters or less, or optionally 19.6 square millimeters or less. Example 23: An aerosol-generating article described in any one of Examples 19 to 22, wherein the rod cross-sectional area is 19.6 square millimeters or more, optionally 22.1 square millimeters or more, optionally 23.8 square millimeters or more, optionally 25.5 square millimeters or more, optionally 29.2 square millimeters or more, optionally 31.2 square millimeters or more, or optionally 35.3 square millimeters or more. Example 24: The rod cross-sectional area is 19.6 square millimeters to 38.5 square millimeters, optionally 19.6 square millimeters to 35.3 square millimeters, optionally 19.6 square millimeters to 31.2 square millimeters, optionally 19.6 square millimeters to 29.2 square millimeters, optionally 19.6 square millimeters to 25.5 square millimeters, optionally 19.6 square millimeters to 23.8 square millimeters, optionally 19.6 square millimeters to 22.1 square millimeters, optionally 2 2.1 square millimeters to 38.5 square millimeters, optionally 22.1 square millimeters to 35.3 square millimeters, optionally 22.1 square millimeters to 31.2 square millimeters, optionally 22.1 square millimeters to 29.2 square millimeters, optionally 22.1 square millimeters to 25.5 square millimeters, optionally 22.1 square millimeters to 23.8 square millimeters, optionally 23.8 square millimeters to 38.5 square millimeters, optionally 23.8 square millimeters 23.8 sq mm to 35.3 sq mm, optionally 23.8 sq mm to 31.2 sq mm, optionally 23.8 sq mm to 29.2 sq mm, optionally 23.8 sq mm to 25.5 sq mm, optionally 25.5 sq mm to 38.5 sq mm, optionally 25.5 sq mm to 35.3 sq mm, optionally 25.5 sq mm to 31.2 sq mm, optionally 25.5 sq mm to 29.2 sq mm 24. The aerosol-generating article of any one of Examples 19 to 23, wherein the aerosol-generating article has an average particle size of 29.2 square millimeters, optionally 29.2 square millimeters to 38.5 square millimeters, optionally 29.2 square millimeters to 35.3 square millimeters, optionally 29.2 square millimeters to 31.2 square millimeters, optionally 31.2 square millimeters to 38.5 square millimeters, optionally 31.2 square millimeters to 35.3 square millimeters, or optionally 35.3 square millimeters to 38.5 square millimeters. Example 25: An aerosol-generating article according to any one of Examples 1 to 24, wherein the rod of the aerosol-generating substrate has one of a polygonal cross-sectional shape, a substantially triangular cross-sectional shape, a substantially elliptical cross-sectional shape, a substantially rectangular cross-sectional shape, and a substantially circular cross-sectional shape, and it is preferred that the rod of the aerosol-generating substrate has a substantially circular cross-sectional shape.

[0360] Example 26: 26. An aerosol-generating article according to any one of Examples 1 to 25, wherein the rod of the aerosol-generating substrate has a rod length, the rod length being at least 1 millimeter, optionally at least 3 millimeters, optionally at least 5 millimeters, optionally at least 7 millimeters, optionally at least 9 millimeters, optionally at least 10 millimeters, optionally at least 11 millimeters, optionally at least 12 millimeters, optionally at least 13 millimeters, optionally at least 14 millimeters, optionally at least 15 millimeters, optionally at least 16 millimeters, optionally at least 18 millimeters, optionally at least 20 millimeters, optionally at least 22 millimeters, optionally at least 25 millimeters, or optionally at least 28 millimeters. Example 27: 27. An aerosol-generating article according to any one of Examples 1 to 26, wherein the rod of the aerosol-generating substrate has a rod length of 3 mm or less, optionally 5 mm or less, optionally 7 mm or less, optionally 9 mm or less, optionally 10 mm or less, optionally 11 mm or less, optionally 12 mm or less, optionally 13 mm or less, optionally 14 mm or less, optionally 15 mm or less, optionally 16 mm or less, optionally 18 mm or less, optionally 20 mm or less, optionally 22 mm or less, optionally 25 mm or less, or optionally 30 mm or less. Example 28: An aerosol-generating article according to any one of Examples 1 to 27, wherein the rod of the aerosol-generating substrate has a rod length of from 1 millimeter to 30 millimeters, optionally from 5 millimeters to 22 millimeters, optionally from 8 millimeters to 16 millimeters, optionally from 9 millimeters to 15 millimeters, optionally from 9 millimeters to 14 millimeters, optionally from 10 millimeters to 14 millimeters, optionally from 11 millimeters to 13 millimeters, or optionally about 12 millimeters. Example 29: 29. An aerosol-generating article according to any one of Examples 1 to 28, wherein the rod of the aerosol-generating substrate has a rod volume of 235 cubic millimeters or more, optionally 265 cubic millimeters or more, 306 cubic millimeters or more, optionally 351 cubic millimeters or more, optionally 374 cubic millimeters or more, optionally 423 cubic millimeters or more, or optionally 462 cubic millimeters or more. Example 30: 30. An aerosol-generating article according to any one of Examples 1 to 29, wherein the rod of the aerosol-generating substrate has a rod volume of 462 cubic millimeters or less, optionally 423 cubic millimeters or less, optionally 374 cubic millimeters or less, optionally 351 cubic millimeters or less, optionally 306 cubic millimeters or less, optionally 265 cubic millimeters or less, or optionally 235 cubic millimeters or less. Example 31: An aerosol-generating article according to any one of Examples 1 to 30, wherein the rod of the aerosol-generating substrate has a rod volume of 235 cubic millimeters to 462 cubic millimeters. Example 32: An aerosol-generating article according to any one of Examples 1 to 31, wherein the aerosol-generating substrate comprises homogenized tobacco material, and optionally the aerosol-generating substrate comprises an assembly of sheets of homogenized tobacco material, and optionally the homogenized tobacco material is a cast sheet. Example 33: An aerosol-generating article according to any one of Examples 1 to 33, wherein the aerosol-generating substrate comprises an assembly of crimped sheets of homogenized tobacco material. Example 34: An aerosol-generating article as described in Example 32 or 33, wherein the homogenized tobacco material is formed by a casting process and comprises tobacco particles having an average particle size (D95) of greater than 50 micrometers, optionally between 50 micrometers and 100 micrometers, optionally between 60 micrometers and 80 micrometers, optionally between 65 micrometers and 75 micrometers, and optionally about 70 micrometers prior to the casting process. Example 35: 35. An aerosol-generating article according to any one of Examples 1 to 34, wherein the aerosol-generating substrate comprises tobacco material, about 1 percent to about 5 percent binder, and about 10 percent to about 30 percent glycerin, on a dry weight basis. Example 36: An aerosol-generating article according to any one of Examples 1 to 35, wherein the aerosol-generating substrate comprises tobacco cut filler, and optionally the aerosol-former content in the aerosol-generating substrate is at least about 8 percent on a dry weight basis. Example 37: 37. An aerosol-generating article according to any one of Examples 1 to 36, wherein the aerosol-generating substrate comprises at least one of strands of reconstituted or reprocessed tobacco and crimped fiber pieces. Example 38: 38. The aerosol-generating article of any one of Examples 1 to 37, wherein the aerosol-generating substrate comprises a solid aerosol-generating substrate comprising nicotine, one or more cellulosic agents, one or more aerosol formers, and one or more carboxylic acids. Example 39: An aerosol-generating article according to any one of Examples 1 to 38, wherein the solid aerosol-generating substrate is one of a solid aerosol-generating film or a solid aerosol-generating gel. Example 40: 39. An aerosol-generating article according to any one of Examples 1 to 39, wherein the aerosol-generating article has an article length of 40 mm to 90 mm, optionally 50 mm to 90 mm, optionally 60 mm to 90 mm, optionally 70 mm to 90 mm, optionally 50 mm to 85 mm, optionally 60 mm to 85 mm, optionally 70 mm to 85 mm, optionally 50 mm to 80 mm, optionally 60 mm to 80 mm, optionally 70 mm to 80 mm, or optionally about 75 mm. Example 41: 41. An aerosol-generating article according to any one of Examples 1 to 40, wherein the aerosol-generating article has an article length of 40 millimeters to 70 millimeters, optionally 45 millimeters to 70 millimeters, optionally 40 millimeters to 60 millimeters, optionally 45 millimeters to 60 millimeters, optionally 40 millimeters to 50 millimeters, optionally 45 millimeters to 50 millimeters, or optionally about 45 millimeters. Example 42: 42. An aerosol-generating article according to any one of Examples 1 to 41, wherein the rod of the aerosol-generating substrate has a rod length and the aerosol-generating article has an article length, and wherein the ratio between the rod length and the article length is 0.20 to 0.60, optionally 0.20 to 0.55, optionally 0.20 to 0.50, optionally 0.25 to 0.60, optionally 0.25 to 0.55, optionally 0.25 to 0.50, optionally 0.30 to 0.60, optionally 0.30 to 0.55, or optionally 0.30 to 0.50. Example 43: An aerosol-generating article according to any one of Examples 1 to 42, wherein the aerosol-generating article comprises a ventilation hole. Example 44: An aerosol-generating article according to any of Examples 1 to 43, wherein the aerosol-generating article has a breathability level of at least 40 percent, optionally at least 45 percent, optionally at least 50 percent, optionally at least 50 percent, optionally at least 60 percent, optionally at least 70 percent, optionally up to 90 percent, optionally up to 85 percent, optionally less than 80 percent, optionally between 40 percent and 90 percent, optionally between 50 percent and 90 percent, or optionally between 60 percent and 90 percent, or optionally about 75 percent. Example 45: An aerosol-generating article according to any one of Examples 1 to 44, wherein the aerosol-generating article has a draw resistance of between 10 millimeters of water column and 70 millimeters of water column, optionally between 20 millimeters of water column and 65 millimeters of water column, optionally between 30 millimeters of water column and 60 millimeters of water column, optionally between 35 millimeters of water column and 55 millimeters of water column, and optionally between 40 millimeters of water column and 50 millimeters of water column. Example 46: An aerosol-generating article as described in any of Examples 1 to 45, wherein the aerosol-generating article further comprises a downstream section located downstream of the rod of the aerosol-generating substrate, optionally extending between the rod of the aerosol-generating substrate and the downstream end of the aerosol-generating article, and optionally comprising one or more elements. Example 47: 47. An aerosol-generating article as described in Example 46, wherein the downstream section has a downstream section length of 10 millimeters or more, optionally 20 millimeters or more, optionally 25 millimeters or more, or optionally 30 millimeters or more. Example 48: 48. The aerosol-generating article of example 46 or 47, wherein the downstream section has a downstream section length of 70 millimeters or less, optionally 60 millimeters or less, or optionally 50 millimeters or less. Example 49: An aerosol-generating article described in any one of Examples 46 to 48, wherein the downstream section has a downstream section length of 10 millimeters to 70 millimeters, optionally 20 millimeters to 60 millimeters, or optionally 30 millimeters to 50 millimeters. Example 50: 50. An aerosol-generating article described in any one of Examples 46 to 49, wherein the withdrawal resistance in the downstream section is at least 0 millimeters of water column, optionally at least 3 millimeters of water column, or optionally at least 6 millimeters of water column. Example 51: An aerosol-generating article described in any one of Examples 46 to 50, wherein the withdrawal resistance in the downstream section is 12 millimeters of water column or less, optionally 11 millimeters of water column or less, or optionally 10 millimeters of water column or less. Example 52: 52. An aerosol-generating article according to any one of Examples 46 to 51, wherein the withdrawal resistance of the downstream section is between 0 millimeters of water column and 12 millimeters of water column, optionally between 3 millimeters of water column and 11 millimeters of water column, or optionally between 6 millimeters of water column and 10 millimeters of water column. Example 53: 53. The aerosol-generating article of any one of Examples 46-52, wherein the downstream section comprises one or more hollow tubular elements. Example 54: An aerosol-generating article according to any one of Examples 1 to 53, wherein the aerosol-generating article comprises one or more hollow tubular elements, optionally the one or more hollow tubular elements being provided downstream of the rod of the aerosol-forming substrate.

[0361] Example 55: 55. An aerosol-generating article according to any one of Examples 53 to 54, wherein one of the one or more hollow tubular elements abuts the downstream end of the rod of the aerosol-generating substrate. Example 56: An aerosol-generating article described in any one of Examples 53 to 55, wherein one of the one or more hollow tubular elements has a length of the hollow tubular element that is 15 millimeters to 50 millimeters, optionally 20 millimeters to 45 millimeters, optionally 20 millimeters to 40 millimeters, optionally 20 millimeters to 30 millimeters, optionally 25 millimeters to 40 millimeters, or optionally about 26 millimeters. Example 57: An aerosol-generating article described in any one of Examples 53 to 56, wherein one of the one or more hollow tubular elements has a wall thickness, and the wall thickness of the hollow tubular element is 100 micrometers to 2 millimeters, optionally 150 micrometers to 1.5 millimeters, or optionally 200 micrometers to 1.25 millimeters. Example 58: An aerosol-generating article described in any one of Examples 53 to 57, wherein the aerosol-generating article has an article outer width, and one of the one or more hollow tubular elements has a hollow tubular element outer width, and the hollow tubular element outer width is approximately equal to the article outer width. Example 59: An aerosol-generating article described in any one of Examples 53 to 58, wherein one of the one or more hollow tubular elements has an inner cavity, and optionally, the inner cavity of the hollow tubular element has a substantially circular cross-sectional shape. Example 60: An aerosol-generating article described in any one of Examples 53 to 59, wherein one of the one or more hollow tubular elements is formed from at least one of cardboard, paper, a polymeric material, a cellulosic material, cellulose acetate, low-density polyethylene (LDPE), and a polyhydroxyalkanoate (PHA). Example 61: An aerosol-generating article described in any one of Examples 53 to 60, wherein the one or more hollow tubular elements comprise one or both of hollow acetate tubing (HAT) and fine hollow acetate tubing (FHAT). Example 62: An aerosol-generating article described in any one of Examples 53 to 61, wherein one or more hollow tubular elements include a HAT and a FHAT, optionally wherein the FHAT is arranged downstream of the HAT, and optionally wherein the inner diameter of the FHAT is larger than the inner diameter of the HAT. Example 63: An aerosol-generating article as described in Example 62, wherein the HAT has a HAT length of 6 millimeters to 10 millimeters, optionally 7 millimeters to 9 millimeters, or optionally about 8 millimeters. Example 64: An aerosol-generating article described in any one of Examples 53 to 63, wherein the resistance to withdrawal of one of the one or more hollow tubular elements is 10 millimeters of water column or less, optionally 5 millimeters of water column or less, optionally 2.5 millimeters of water column or less, optionally 2 millimeters of water column or less, or optionally 1 millimeter of water column or less. Example 65: An aerosol-generating article described in any one of Examples 53 to 64, wherein the resistance to withdrawal of one of the one or more hollow tubular elements is at least 0 millimeters of water column, optionally at least 0.25 millimeters of water column, optionally at least 0.5 millimeters of water column, or optionally at least 1 millimeter of water column. Example 66: An aerosol-generating article described in any one of Examples 53 to 65, wherein the aerosol-generating article further comprises a PLA (polylactic acid) plug, optionally the PLA plug being downstream of one of the one or more hollow tubular elements. Example 67: 67. An aerosol-generating article according to any one of Examples 53 to 66, wherein one of the one or more hollow tubular elements comprises a hollow tubular cooling element. Example 68: An aerosol-generating article described in any one of Examples 53 to 67, wherein one of the one or more hollow tubular elements comprises a hollow tubular support element. Example 69: An aerosol-generating article described in any one of Examples 53 to 68, wherein the one or more hollow tubular elements comprise a hollow tubular support element upstream of the hollow tubular cooling element, and optionally the hollow tubular support element abuts the downstream end of the rod of the aerosol-generating substrate, and optionally the hollow tubular support element abuts the upstream end of the hollow tubular cooling element. Example 70: An aerosol-generating article described in Example 68 or 69, wherein the hollow tubular support element is formed from one or more materials selected from the group consisting of cellulose acetate, cardboard, crimped paper such as crimped heat-resistant paper or crimped parchment paper, and polymeric materials such as low-density polyethylene (LDPE). Example 71: An aerosol-generating article described in any one of Examples 53 to 70, wherein the aerosol-generating article has a ventilation zone at a position along the one or more hollow tubular elements, and optionally the ventilation zone has a plurality of perforations or holes through the wall of the one or more hollow tubular elements. Example 72: An aerosol-generating article described in any of Examples 1 to 71, wherein the aerosol-generating article comprises a tubular element having a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body, and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall defining an opening for airflow between the cavity and the exterior of the tubular element. Example 73: An aerosol-generating article according to any one of Examples 1 to 72, wherein the aerosol-generating article comprises a mouthpiece element. Example 74: 74. The aerosol-generating article of Example 73, wherein the mouthpiece element is located at a downstream end of the aerosol-generating article. Example 75: An aerosol-generating article described in any one of Examples 53 to 72, wherein the downstream section comprises a mouthpiece element. Example 76: An aerosol-generating article described in any one of Examples 73 to 75, wherein the mouthpiece element is located downstream of at least one of the one or more hollow tubular elements. Example 77: 77. The aerosol-generating article of any one of Examples 73-76, wherein the mouthpiece element is formed from a fibrous filtering material, and optionally, the mouthpiece element is formed from cellulose acetate. Example 78: 78. An aerosol-generating article according to any one of Examples 73 to 77, wherein the mouthpiece element has a length of 5 millimeters or more, or preferably 10 millimeters or more. Example 79: 79. An aerosol-generating article according to any one of Examples 73 to 78, wherein the mouthpiece element has a length of less than 25 millimeters, or preferably less than 20 millimeters. Example 80: 80. An aerosol-generating article according to any one of Examples 73 to 79, wherein the mouthpiece element has a mouthpiece length of 5 millimeters to 25 millimeters, 10 millimeters to 25 millimeters, 5 millimeters to 20 millimeters, 10 millimeters to 20 millimeters, 10 millimeters to 14 millimeters, 11 millimeters to 13 millimeters, or about 12 millimeters. Example 81: An aerosol-generating article described in any one of Examples 73 to 80, wherein the mouthpiece element has a mouthpiece length of 5 millimeters to 10 millimeters, 6 millimeters to 8 millimeters, or about 7 millimeters. Example 82: An aerosol-generating article described in any one of Examples 73 to 81, wherein the withdrawal resistance of the mouthpiece element per millimeter of length along the longitudinal axis of the aerosol-generating article is between 0.1 millimeters of water column and 20 millimeters of water column, optionally between 0.2 millimeters of water column and 10 millimeters of water column, optionally between 0.5 millimeters of water column and 5 millimeters of water column, optionally between 1 millimeter of water column and 2 millimeters of water column, optionally between 1.3 millimeters of water column and 1.7 millimeters of water column, optionally between 1.4 millimeters of water column and 1.6 millimeters of water column, or optionally about 1.5 millimeters of water column. Example 83: An aerosol-generating article described in any one of Examples 73 to 82, wherein the withdrawal resistance of the mouthpiece element is between 1 millimeter of water column and 100 millimeters of water column, optionally between 2 millimeters of water column and 50 millimeters of water column, optionally between 5 millimeters of water column and 40 millimeters of water column, optionally between 10 millimeters of water column and 30 millimeters of water column, optionally between 16 millimeters of water column and 20 millimeters of water column, optionally between 17 millimeters of water column and 19 millimeters of water column, or optionally about 18 millimeters of water column. Example 84: An aerosol-generating article described in any one of Examples 73 to 83, wherein the withdrawal resistance of the mouthpiece element is between 1 millimeter of water column and 60 millimeters of water column, optionally between 2 millimeters of water column and 30 millimeters of water column, optionally between 4 millimeters of water column and 25 millimeters of water column, optionally between 5 millimeters of water column and 18 millimeters of water column, optionally between 6 millimeters of water column and 13 millimeters of water column, optionally between 9 millimeters of water column and 12 millimeters of water column, or optionally about 10.5 millimeters of water column. Example 85: An aerosol-generating article as described in any of Examples 1 to 84, wherein the aerosol-generating article further comprises a substrate wrapper at least partially surrounding the rod of the aerosol-generating substrate, and optionally the substrate wrapper comprises one or more layers having the same length in the longitudinal direction of the aerosol-generating article. Example 86: An aerosol-generating article as described in Example 85, wherein the substrate wrapper has a thickness of at least 50 micrometers, optionally at least 60 micrometers, optionally at least 70 micrometers, optionally at least 75 micrometers, optionally at least 80 micrometers, optionally at least 90 micrometers, optionally at least 100 micrometers, optionally at least 110 micrometers, optionally at least 120 micrometers, optionally at least 130 micrometers, optionally at least 140 micrometers, optionally at least 145 micrometers, or optionally at least 150 micrometers. Example 87: 87. An aerosol-generating article as described in Example 85 or 86, wherein the rod of the aerosol-generating substrate has a rod width and the ratio of the thickness of the substrate wrapper to the rod width is 1:120 to 1:20 (0.0083 to 0.050), optionally 1:100 to 1:30 (0.010 to 0.030), optionally 1:80 to 1:35 (0.013 to 0.029), and optionally 1:60 to 1:40 (0.017 to 0.025).

[0362] Example 88: 88. The aerosol-generating article of any one of Examples 85-87, wherein the wrapper has a density of 800 kilograms per cubic meter or less, optionally 750 kilograms per cubic meter or less, optionally 700 kilograms per cubic meter or less, optionally 650 kilograms per cubic meter or less, optionally 600 kilograms per cubic meter or less, optionally 550 kilograms per cubic meter or less, optionally 500 kilograms per cubic meter or less, optionally 450 kilograms per cubic meter or less, optionally 400 kilograms per cubic meter or less, optionally 350 kilograms per cubic meter or less, or optionally a density of about 320 kilograms per cubic meter. Example 89: 89. The aerosol-generating article of any one of Examples 85-88, wherein the substrate wrapper comprises one or more of cardboard, plastic, and metal foil. Example 90: 89. An aerosol-generating article according to any one of Examples 85 to 89, wherein the substrate wrapper comprises a cellulosic material, preferably a cellulosic material selected from one or more of paper, wood, textiles, natural fibers, and man-made fibers. Example 91: An aerosol-generating article as described in any of Examples 1 to 90, wherein the aerosol-generating article further comprises an outer wrapper at least partially surrounding other elements of the aerosol-generating article, optionally the outer wrapper extending the entire length of the aerosol-generating article, and optionally the outer wrapper comprising tipping paper. Example 92: 1. An aerosol generating system comprising: An aerosol-generating article according to any one of Examples 1 to 91, an aerosol generating device including a heating element in the form of a pin configured for insertion into a rod of an aerosol-generating substrate of an aerosol-generating article; Example 93: the increase in density of the aerosol-generating substrate within the rod of aerosol-generating substrate from a state in which the pin heating element is not inserted into the rod to a state in which the pin heating element is fully inserted into the rod is 10 kilograms / cubic meter (0.01 milligrams / cubic millimeter) or more, optionally 20 kilograms / cubic meter (0.02 milligrams / cubic millimeter) or more, optionally 30 kilograms / cubic meter (0.03 milligrams / cubic millimeter) or more, optionally 40 kilograms / cubic meter (0.04 milligrams / cubic millimeter) or more, optionally 50 kilograms / cubic meter (0.05 milligrams / cubic millimeter) or more, optionally 60 kilograms / cubic meter (0.06 milligrams / cubic millimeter) or more, optionally 70 kilograms / cubic meter (0.07 milligrams / cubic millimeter) or more, optionally 80 kilograms / cubic meter (0.08 milligrams / cubic millimeter) or more, optionally 90 kilograms / cubic meter (0.09 milligrams / cubic millimeter) or more cubic millimeter) or more, optionally 100 kilograms per cubic meter (0.10 milligrams per cubic millimeter) or more, optionally 150 kilograms per cubic meter (0.15 milligrams per cubic millimeter) or more, optionally 200 kilograms per cubic meter (0.20 milligrams per cubic millimeter) or more, optionally 250 kilograms per cubic meter (0.25 milligrams per cubic millimeter) or more, optionally 300 kilograms per cubic meter (0.30 milligrams per cubic millimeter) or more, optionally 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more, optionally 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or more, or optionally 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or more, and Not more than 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), optionally not more than 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), optionally not more than 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter), optionally not more than 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter), optionally not more than 300 kilograms per cubic meter (0.30 milligrams per cubic millimeter), optionally not more than 250 kilograms per cubic meter (0.25 milligrams per cubic millimeter), optionally not more than 200 kilograms per cubic meter (0.20 milligrams per cubic millimeter), optionally not more than 150 kilograms per cubic meter (0.15 milligrams per cubic millimeter), optionally not more than 100 kilograms per cubic meter (0.10 milligrams per cubic millimeter) 93. The aerosol generating system of Example 92, having at least one of the following: 90 kilograms / cubic meter (0.09 milligrams / cubic millimeter) or less, optionally 80 kilograms / cubic meter (0.08 milligrams / cubic millimeter) or less, optionally 70 kilograms / cubic meter (0.07 milligrams / cubic millimeter) or less, optionally 60 kilograms / cubic meter (0.06 milligrams / cubic millimeter) or less, optionally 50 kilograms / cubic meter (0.05 milligrams / cubic millimeter) or less, optionally 40 kilograms / cubic meter (0.04 milligrams / cubic millimeter) or less, optionally 30 kilograms / cubic meter (0.03 milligrams / cubic millimeter) or less, or optionally 20 kilograms / cubic meter (0.02 milligrams / cubic millimeter) or less. Example 94: the increase in density of the rod of the aerosol-generating substrate from a state in which the pin heating element is not inserted into the rod to a state in which the pin heating element is fully inserted into the rod is 10 kilograms / cubic meter (0.01 milligrams / cubic millimeter) or more, optionally 20 kilograms / cubic meter (0.02 milligrams / cubic millimeter) or more, optionally 30 kilograms / cubic meter (0.03 milligrams / cubic millimeter) or more, optionally 40 kilograms / cubic meter (0.04 milligrams / cubic millimeter) or more, optionally 50 kilograms / cubic meter (0.05 milligrams / cubic millimeter) or more, optionally 60 kilograms / cubic meter (0.06 milligrams / cubic millimeter) or more, optionally 70 kilograms / cubic meter (0.07 milligrams / cubic millimeter) or more, optionally 80 kilograms / cubic meter (0.08 milligrams / cubic millimeter) or more, optionally 90 kilograms / cubic meter (0.09 milligrams / cubic millimeter) or more cubic millimeter) or more, optionally 100 kilograms per cubic meter (0.10 milligrams per cubic millimeter) or more, optionally 150 kilograms per cubic meter (0.15 milligrams per cubic millimeter) or more, optionally 200 kilograms per cubic meter (0.20 milligrams per cubic millimeter) or more, optionally 250 kilograms per cubic meter (0.25 milligrams per cubic millimeter) or more, optionally 300 kilograms per cubic meter (0.30 milligrams per cubic millimeter) or more, optionally 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more, optionally 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or more, or optionally 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or more, and Not more than 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), optionally not more than 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), optionally not more than 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter), optionally not more than 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter), optionally not more than 300 kilograms per cubic meter (0.30 milligrams per cubic millimeter), optionally not more than 250 kilograms per cubic meter (0.25 milligrams per cubic millimeter), optionally not more than 200 kilograms per cubic meter (0.20 milligrams per cubic millimeter), optionally not more than 150 kilograms per cubic meter (0.15 milligrams per cubic millimeter), optionally not more than 100 kilograms per cubic meter (0.10 milligrams per cubic millimeter), 94. The aerosol generating system of any one of Examples 92-93, optionally having at least one of 90 kilograms / cubic meter (0.09 milligrams / cubic millimeter) or less, optionally 80 kilograms / cubic meter (0.08 milligrams / cubic millimeter) or less, optionally 70 kilograms / cubic meter (0.07 milligrams / cubic millimeter) or less, optionally 60 kilograms / cubic meter (0.06 milligrams / cubic millimeter) or less, optionally 50 kilograms / cubic meter (0.05 milligrams / cubic millimeter) or less, optionally 40 kilograms / cubic meter (0.04 milligrams / cubic millimeter) or less, optionally 30 kilograms / cubic meter (0.03 milligrams / cubic millimeter) or less, or optionally 20 kilograms / cubic meter (0.02 milligrams / cubic millimeter) or less. Example 95: the density of the aerosol-generating substrate within the rod of aerosol-generating substrate when the pin heating element is fully inserted into the rod is Not more than 550 kilograms per cubic meter (0.55 milligrams per cubic millimeter), not more than 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), optionally not more than 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), optionally not more than 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter), or optionally not more than 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter), and An aerosol generating system described in any one of Examples 92 to 94, having at least one of 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more, optionally 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or more, optionally 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or more, and optionally 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or more. Example 96: The density of the rod of the aerosol-generating substrate when the pin heating element is fully inserted into the rod is Not more than 550 kilograms per cubic meter (0.55 milligrams per cubic millimeter), not more than 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter), optionally not more than 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter), optionally not more than 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter), or optionally not more than 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter), and An aerosol generating system described in any one of Examples 92 to 95, having at least one of 350 kilograms per cubic meter (0.35 milligrams per cubic millimeter) or more, optionally 400 kilograms per cubic meter (0.40 milligrams per cubic millimeter) or more, optionally 450 kilograms per cubic meter (0.45 milligrams per cubic millimeter) or more, or optionally 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or more. Example 97: An aerosol generation system described in any one of Examples 92 to 96, wherein the pin has a pin width and optionally the pin has a tip.

[0363] Example 98: An aerosol generation system as described in Example 97, wherein the pin width is measured at a distance of 2 millimeters from the end of the tip, or optionally at a distance of 3 millimeters, 4 millimeters, 5 millimeters, or 6 millimeters from the end of the tip, preferably at a distance of 3 millimeters or 4 millimeters from the end of the tip. Example 99: An aerosol generation system as described in Example 97 or 98, wherein the pin width is measured at a distance of 4 millimeters from the end of the tip. Example 100: An aerosol generating system described in any one of Examples 97 to 99, wherein the pin has a pin width measured at a position along a section of the pin configured to be inserted into the rod of the aerosol generating substrate that is the farthest distance from the tip end. Example 101: 101. The aerosol generating system of any one of Examples 97 to 100, wherein the pin width is the maximum pin width. Example 102: An aerosol generation system described in any one of Examples 97 to 101, wherein the pin width is the pin width measured at a position 50 percent of the pin length from the end of the tip. Example 103: An aerosol generation system described in any one of Examples 97 to 102, wherein the pin has a pin length and the pin width is an average pin width measured over at least 70 percent of the pin length, optionally over at least 80 percent of the pin length, optionally over at least 90 percent of the pin length, or optionally over at least 95 percent of the pin length. Example 104: An aerosol generation system described in any one of Examples 97 to 103, wherein the pin width is 2.5 millimeters or more, optionally 2.6 millimeters or more, optionally 2.7 millimeters or more, optionally 2.8 millimeters or more, or optionally 2.9 millimeters or more. Example 105: An aerosol generation system described in any one of Examples 97 to 104, wherein the pin width is 3.0 millimeters or less, optionally 2.9 millimeters or less, optionally 2.8 millimeters or less, optionally 2.7 millimeters or less, or optionally 2.6 millimeters or less. Example 106: An aerosol generation system described in any one of Examples 97 to 105, wherein the pin width is 2.5 millimeters to 4.0 millimeters, or the pin width is 2.5 millimeters to 3.0 millimeters. Example 107: An aerosol generating system described in any one of Examples 97 to 106, wherein the rod of the aerosol-generating substrate has a rod width and the ratio of the rod width to the pin width is 2.8 or less, optionally 2.7 or less, optionally 2.6 or less, optionally 2.5 or less, optionally 2.4 or less, optionally 2.3 or less, optionally 2.2 or less, optionally 2.1 or less, optionally 2.0 or less, optionally 1.9 or less, or optionally 1.8 or less. Example 108: An aerosol generating system described in any one of Examples 97 to 107, wherein the rod of the aerosol-generating substrate has a rod width and the ratio of rod width to pin width is 1.6 or more, optionally 1.7 or more, optionally 1.8 or more, optionally 1.9 or more, optionally 2.0 or more, optionally 2.1 or more, optionally 2.2 or more, optionally 2.3 or more, optionally 2.4 or more, optionally 2.5 or more, or optionally 2.6 or more. Example 109: 109. The aerosol-generating system according to any one of Examples 97 to 108, wherein the rod of the aerosol-generating substrate has a rod width, and the ratio of the rod width to the pin width is 1.6 to 2.8. Example 110: An aerosol generation system described in any one of Examples 97 to 109, wherein the pin has a minimum transverse pin dimension perpendicular to the pin width. Example 111: An aerosol generation system as described in Example 110, wherein the minimum transverse pin dimension is measured at a distance of 2 millimeters from the end of the tip, or optionally at a distance of 3 millimeters, 4 millimeters, 5 millimeters, or 6 millimeters from the end of the tip, or preferably at a distance of 3 millimeters or 4 millimeters from the end of the tip, or most preferably at a distance of 4 millimeters from the end of the tip. Example 112: 112. The aerosol generation system of Example 110 or 111, wherein the smallest transverse pin dimension is 1.6 millimeters or more, optionally 1.7 millimeters or more, optionally 1.8 millimeters or more, optionally 1.9 millimeters or more, optionally 2.0 millimeters or more, optionally 2.1 millimeters or more, optionally 2.2 millimeters or more, optionally 2.3 millimeters or more, optionally 2.4 millimeters or more, optionally 2.5 millimeters or more, optionally 2.6 millimeters or more, optionally 2.7 millimeters or more, optionally 2.8 millimeters or more, or optionally 2.9 millimeters or more. Example 113: An aerosol generation system described in any one of Examples 110 to 112, wherein the smallest transverse pin dimension is 3.0 millimeters or less. Example 114: An aerosol generation system described in any one of Examples 110 to 113, wherein the minimum transverse pin dimension is between 2.5 millimeters and 3.0 millimeters. Example 115: 115. The aerosol generation system of any one of Examples 92-114, wherein the pin has a pin length and the pin has a pin cross-sectional area perpendicular to the pin length. Example 116: An aerosol generation system as described in Example 115, wherein the pin cross-sectional area is measured at a distance of 2 millimeters from the end of the tip, or optionally at a distance of 3 millimeters, 4 millimeters, 5 millimeters, or 6 millimeters from the end of the tip, or preferably at a distance of 3 millimeters or 4 millimeters from the end of the tip, or most preferably at a distance of 4 millimeters from the end of the tip. Example 117: 117. An aerosol generation system as described in Example 115 or 116, wherein the pin cross-sectional area is the maximum pin cross-sectional area. Example 118: An aerosol generating system described in any one of Examples 115 to 117, wherein the pin cross-sectional area is the pin cross-sectional area measured at a position along the section of the pin configured to be inserted into the rod of the aerosol generating substrate that is the farthest distance from the end of the tip. Example 119: An aerosol generation system described in any one of Examples 115 to 118, wherein the pin cross-sectional area is an average pin cross-sectional area measured over at least 70 percent of the pin length, optionally over at least 80 percent of the pin length, optionally over at least 90 percent of the pin length, or optionally over at least 95 percent of the pin length. Example 120: 120. The aerosol generating system of any one of Examples 115 to 119, wherein the pin cross-sectional area is the pin cross-sectional area measured at a position 50% of the pin length from the tip end. Example 121: 121. The aerosol generating system of any one of Examples 115 to 120, wherein the pin cross-sectional area is 4.9 square millimeters or more. Example 122: 122. The aerosol generating system of any one of Examples 115 to 121, wherein the pin cross-sectional area is 7.1 square millimeters or less. Example 123: 123. The aerosol generating system of any one of Examples 115 to 122, wherein the pin cross-sectional area is between 4.9 square millimeters and 7.1 square millimeters. Example 124: 124. An aerosol generating system according to any one of Examples 115 to 123, wherein the rod of the aerosol-generating substrate has a rod length, the rod of the aerosol-generating substrate has a rod cross-sectional area perpendicular to the rod length, and the ratio of the rod cross-sectional area to the pin cross-sectional area is 7.9 or less, optionally 7.5 or less, optionally 7.0 or less, optionally 6.5 or less, optionally 6.0 or less, optionally 5.5 or less, optionally 5.0 or less, optionally 4.5 or less, optionally 4.0 or less, optionally 3.5 or less, or optionally 3.0 or less. Example 125: 125. An aerosol generating system according to any one of Examples 115 to 124, wherein the rod of the aerosol-generating substrate has a rod length, the rod of the aerosol-generating substrate has a rod cross-sectional area perpendicular to the rod length, and the ratio of the rod cross-sectional area to the pin cross-sectional area is 2.8 or more, optionally 3.0 or more, optionally 3.5 or more, optionally 4.0 or more, optionally 4.5 or more, optionally 5.0 or more, optionally 5.5 or more, optionally 6.0 or more, optionally 6.5 or more, optionally 7.0 or more, or optionally 7.5 or more. Example 126: 126. An aerosol generating system according to any one of Examples 115 to 125, wherein the rod of the aerosol-generating substrate has a rod length, the rod of the aerosol-generating substrate has a rod cross-sectional area perpendicular to the rod length, and the ratio of the rod cross-sectional area to the pin cross-sectional area is 2.8 to 7.9. Example 127: An aerosol generation system described in any of Examples 92 to 126, wherein the pin has one of a polygonal cross-sectional shape, a substantially elliptical cross-sectional shape, a substantially triangular cross-sectional shape, a substantially rectangular cross-sectional shape, and a substantially circular cross-sectional shape, preferably the pin has a substantially circular cross-sectional shape. Example 128: The aerosol generation according to any one of Examples 92-127, wherein the pin has a tip, and optionally the tip is one of tapered, pointed, or sharp towards the end of the tip. Example 129: 129. The aerosol-generating system of Example 128, wherein the tip is configured to penetrate the rod of the aerosol-generating substrate. Example 130: An aerosol generation system described in any one of Examples 92 to 129, wherein the pin has a pin length of 1 millimeter or more, optionally 3 millimeters or more, optionally 5 millimeters or more, optionally 7 millimeters or more, optionally 9 millimeters or more, optionally 10 millimeters or more, optionally 11 millimeters or more, optionally 12 millimeters or more, optionally 13 millimeters or more, optionally 14 millimeters or more, optionally 15 millimeters or more, optionally 16 millimeters or more, optionally 18 millimeters or more, optionally 20 millimeters or more, optionally 22 millimeters or more, optionally 25 millimeters or more, or optionally 28 millimeters or more.

[0364] Example 131: 131. An aerosol generation system described in any one of Examples 92 to 130, wherein the pin has a pin length of 3 millimeters or less, optionally 5 millimeters or less, optionally 7 millimeters or less, optionally 9 millimeters or less, optionally 10 millimeters or less, optionally 11 millimeters or less, optionally 12 millimeters or less, optionally 13 millimeters or less, optionally 14 millimeters or less, optionally 15 millimeters or less, optionally 16 millimeters or less, optionally 18 millimeters or less, optionally 20 millimeters or less, optionally 22 millimeters or less, optionally 25 millimeters or less, or optionally 30 millimeters or less. Example 132: An aerosol generation system described in any one of Examples 92 to 131, wherein the pin has a pin length of 1 millimeter to 30 millimeters, optionally 5 millimeters to 22 millimeters, optionally 8 millimeters to 16 millimeters, optionally 9 millimeters to 15 millimeters, optionally 10 millimeters to 14 millimeters, optionally 11 millimeters to 13 millimeters, or optionally about 12 millimeters. Example 133: 133. The aerosol-generating system of any one of Examples 92 to 132, wherein the pin has a pin length and the rod of the aerosol-generating substrate has a rod length, and the pin length is equal to or less than the rod length. Example 134: An aerosol generating system described in any of Examples 92 to 133, wherein the rod of the aerosol-generating substrate has a rod length and the pin has a pin length that is 99 percent or less of the rod length, optionally 95 percent or less of the rod length, optionally 90 percent or less of the rod length, optionally 85 percent or less of the rod length, optionally 80 percent or less of the rod length, optionally 70 percent or less of the rod length, optionally 60 percent or less of the rod length, or optionally 50 percent or less of the rod length. Example 135: An aerosol generating system described in any one of Examples 92 to 134, wherein the rod of the aerosol-generating substrate has a rod length and the pin has a pin length that is at least 50 percent of the rod length, optionally at least 60 percent of the rod length, optionally at least 70 percent of the rod length, optionally at least 80 percent of the rod length, optionally at least 85 percent of the rod length, optionally at least 90 percent of the rod length, optionally at least 95 percent of the rod length, or optionally at least 99 percent of the rod length. Example 136: An aerosol generating system described in any one of Examples 92 to 135, wherein the rod of the aerosol-generating substrate has a rod length and the pin has a pin length that is 70 percent to 99 percent of the rod length, optionally 75 percent to 95 percent of the rod length, optionally 80 percent to 95 percent of the rod length, or optionally 85 percent to 95 percent of the rod length. Example 137: An aerosol generation system described in any one of Examples 92 to 135, wherein the pin has a pin volume of 59 cubic millimeters or more, optionally 64 cubic millimeters or more, optionally 69 cubic millimeters or more, optionally 74 cubic millimeters or more, optionally 79 cubic millimeters or more, or optionally 84 cubic millimeters or more. Example 138: An aerosol generation system described in any one of Examples 92 to 137, wherein the pin has a pin volume of 84 cubic millimeters or less, optionally 79 cubic millimeters or less, optionally 74 cubic millimeters or less, optionally 69 cubic millimeters or less, or optionally 64 cubic millimeters or less. Example 139: The aerosol generating system of any one of Examples 92 to 138, wherein the pin has a pin volume of 59 cubic millimeters to 84 cubic millimeters. Example 140: An aerosol generating system according to any one of Examples 92 to 139, wherein the aerosol generating device further comprises a device cavity configured to receive at least a portion of the aerosol-generating article. Example 141: An aerosol generating system as described in Example 140, wherein the device cavity has a closed end and an open end, and optionally the aerosol-generating article is insertable into the device cavity via the open end, and optionally the device cavity has substantially the same cross-sectional shape as the aerosol-generating article. Example 142: An aerosol generating system as described in Example 140 or 141, wherein the device cavity has a cavity length that is the same as or greater than the length of the rod of the aerosol-generating substrate, and optionally the cavity length is such that when the aerosol-generating article is received together with the aerosol-generating device, at least 75 percent of the rod length is received within the device cavity, optionally at least 80 percent, or at least 90 percent of the rod length of the aerosol-generating substrate is received within the device cavity. Example 143: An aerosol generating system described in any one of Examples 92 to 142, wherein when the aerosol-generating article is received by the aerosol-generating device, the pin penetrates the rod of the aerosol-generating substrate substantially through the center of a cross section of the rod perpendicular to the rod length. Example 144: An aerosol generation system described in any one of Examples 92 to 143, wherein the pin comprises one of a resistive heating element and a susceptor element. Example 145: The aerosol generating system of any one of Examples 92 to 144, wherein the pin comprises a resistive heating element. Example 146: An aerosol generation system described in any one of Examples 92 to 144, wherein the aerosol generation device comprises an inductor coil, optionally at least partially surrounding the device cavity, and optionally the inductor coil is arranged to coaxially surround the device cavity. Example 147: An aerosol generation system as described in Example 146, wherein the pin includes a susceptor element and the inductor coil is arranged to inductively heat the pin. Example 148: The aerosol generating system of any one of Examples 92 to 147, wherein the aerosol generating device further comprises a controller. Example 149: An aerosol generating system as described in Example 148, wherein, during use, the controller is configured to control the heating element so that the operating temperature range of the heating element is 150 degrees Celsius to 350 degrees Celsius, optionally so that the operating temperature range of the heating element is 200 degrees Celsius to 330 degrees Celsius, and optionally so that the operating temperature range is 260 degrees Celsius to 320 degrees Celsius. Example 150: An aerosol generation system as described in Example 148 or 149, wherein during use, the controller is configured to control the heating element so that the heating element is heated to a peak temperature of 350 degrees Celsius or less, optionally 335 degrees Celsius or less, or optionally 320 degrees Celsius or less. Example 151: An aerosol generation system described in any one of Examples 148 to 150, wherein during use, the controller is configured to control the heating element so that the heating element is heated to a peak temperature of between 220 degrees Celsius and 350 degrees Celsius, optionally between 240 degrees Celsius and 335 degrees Celsius, or optionally between 260 degrees Celsius and 320 degrees Celsius. Example 152: The aerosol generation of any one of Examples 92-151, wherein the aerosol generation device further comprises a power source, and optionally the power source is a battery.

Claims

1. An aerosol-generating article, comprising:

1. An aerosol-generating article comprising a rod of an aerosol-generating substrate having a rod width and a rod length, wherein the ratio of the rod width to the rod length is 0.5 to 0.56, and the total dry mass of the rod of the aerosol-generating substrate is 220 milligrams or less.

2. 2. The aerosol-generating article according to claim 1, wherein the dry mass of the aerosol-generating substrate within the rod of aerosol-generating substrate is between 100 milligrams and 220 milligrams.

3. 3. An aerosol-generating article according to claim 1 or 2, wherein the density of the aerosol-generating substrate within the rod of aerosol-generating substrate is 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or less.

4. The rod width is 5 millimeters or more, and The aerosol-generating article according to any one of claims 1 to 3, wherein the aerosol-generating article has a diameter of at least one of 7 mm or less.

5. 5. An aerosol-generating article according to any one of claims 1 to 4, wherein the rod width is measured at a position 50% along the rod length from the end of the rod.

6. The rod length is 9 millimeters or more, and 6. The aerosol-generating article according to claim 1, wherein the aerosol-generating article has a diameter of at least one of 14 mm or less.

7. The rod of the aerosol-generating substrate has a rod cross-sectional area perpendicular to the rod length, the rod cross-sectional area being: 38.5 square millimeters or less, and 7. The aerosol-generating article according to claim 1, wherein the aerosol-generating article has at least one of a surface area of ​​19.6 square millimeters or more.

8. 8. The aerosol-generating article of claim 7, wherein the rod cross-sectional area is measured 50 percent along the rod length from the end of the rod.

9. 8. An aerosol-generating article according to any one of claims 1 to 7, wherein the aerosol-generating article has an article length, and the ratio of the rod length to the article length is between 0.20 and 0.

60.

10. a tubular element positioned downstream of the rod of the aerosol-generating substrate, a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body; 10. The aerosol-generating article of claim 1, further comprising a tubular element including a folded end forming a first end wall at the first end of the tubular body, the folded end defining an opening for airflow between the cavity and the exterior of the tubular element.

11. 1. An aerosol generating system comprising: The aerosol-generating article according to any one of claims 1 to 10. an aerosol generating device including a heating element in the form of a pin configured for insertion into a rod of the aerosol-generating substrate of the aerosol-generating article;

12. the increase in density of the aerosol-generating substrate within the rod of aerosol-generating substrate from a state in which the pin is not inserted into the rod to a state in which the pin is fully inserted into the rod is 50 kilograms per cubic meter (0.05 milligrams per cubic millimeter) or more, and 12. The aerosol generating system of claim 11, wherein the aerosol density is at least one of 500 kilograms per cubic meter (0.50 milligrams per cubic millimeter) or less.

13. The pin is 2.5 millimeters or more, and 13. The aerosol generation system of claim 11 or 12, having a pin width that is at least one of 3.0 millimeters or less.

14. 14. The aerosol generation system of claim 11, wherein the pin has a tip and the pin width is measured at a distance of 4 millimeters from the end of the tip.

15. The pin has a pin width, and the ratio of the rod width to the pin width is: 2.8 or less, and 15. The aerosol generating system according to any one of claims 11 to 14, wherein the viscosity is at least one of 1.6 or more.

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