Aerosol generating device plug

Abstract

An aerosol generating material plug (10) for a heated aerosol generating article (1) is provided. The aerosol generating material plug (10) comprises an aerosol generating material (20). The aerosol generating material (20) comprises one or more aerosol forming agents. The aerosol generating material (20) comprises an aerosol forming agent content of 5% by weight or more based on dry weight. The aerosol generating material plug (10) comprises a wrapper (30). The wrapper (30) has a basis weight of 20 g / m2 to 200 g / m2. The wrapper (20) surrounds the aerosol generating material (20). The thickness of the aerosol generating material plug (10) is less than 50% of the length of the aerosol generating material plug (10). The thickness of the aerosol generating material plug (10) is less than 50% of the width of the aerosol generating material plug (10). The thickness of the aerosol generating material plug (10) is constant over at least 90% of the width of the aerosol generating material plug (10). Additionally, an aerosol generating article (1) including the aerosol generating material plug (10) and a method for manufacturing the aerosol generating material plug (10) are provided.

Description

Technology Field

[0001] The present disclosure relates to an aerosol generating material plug for a heated aerosol generating article. The present disclosure also relates to an aerosol generating article comprising an aerosol generating material plug, and a method for manufacturing the aerosol generating material plug. Background Technology

[0002] Typically, conventional smoking articles, such as tobacco-containing cigarettes, are in the form of a cylindrical rod having a tobacco material located at an upstream end and a filter element located at a downstream end. During use, the consumer ignites the upstream end of the smoking article and inhales the downstream end of the smoking article to inhale the combustion products. The combustion line extends across the entire cross-section of the tobacco material and proceeds toward the downstream end of the smoking article as the tobacco material is consumed, allowing the entire tobacco material to reach a temperature sufficient to generate inhalable combustion products.

[0003] In recent years, heated aerosol generating articles containing an aerosol generating material have become available. In these heated aerosol generating articles, the aerosol generating material is heated rather than burned. Typically, an aerosol generating device is arranged to heat a heating element located near or in contact with the aerosol generating material, causing the material to be heated to release volatile compounds. These volatile compounds are then entrained into air drawn through the aerosol generating article. As the released compounds cool, they condense to form an aerosol that can be inhaled by consumers.

[0004] Conventional heated aerosol generating articles may look similar to conventional inhalation articles and may have similar dimensions. For example, such aerosol generating articles may be substantially cylindrical and may include an aerosol generating material in addition to other components such as a mouthpiece filter element and a cooling element arranged in the form of a cylindrical rod and wrapped in cigarette paper.

[0005] However, in heated aerosol generating articles, the absence of the previously mentioned combustion line implies that a significant portion of the aerosol generating material may not be heated sufficiently to form an aerosol during use. This is because, for example, some parts of the aerosol generating material may be further from the heating element than other parts of the material. This is undesirable because the insufficiently heated portion of the aerosol generating material contributes to the manufacturing and transportation costs of the aerosol generating article but does not contribute to the aerosol delivered to the consumer.

[0006] The object of the present disclosure is to provide an aerosol generating substrate for a heated aerosol generating article in which a larger portion of the aerosol generating substrate can be heated sufficiently to form an aerosol during use. Additionally, the object of the present disclosure is to provide an aerosol generating substrate that can be manufactured relatively efficiently and at a low cost.

[0007] The present disclosure provides an aerosol generating substrate plug for a heated aerosol generating article. The aerosol generating substrate plug may comprise an aerosol generating substrate. The aerosol generating substrate may comprise one or more aerosol forming agents. The aerosol generating substrate may comprise an aerosol forming agent content of 5% by weight or more based on dry weight. The aerosol generating substrate plug may comprise a wrapper. The wrapper may have a basis weight of 20 g / m² to 200 g / m². The wrapper may surround the aerosol generating substrate. The thickness of the aerosol generating substrate plug may be less than 50% of the length of the aerosol generating substrate plug. The thickness of the aerosol generating substrate plug may be less than 50% of the width of the aerosol generating substrate plug. The thickness of the aerosol generating substrate plug may be constant over at least 90% of the width of the aerosol generating substrate plug.

[0008] According to the present disclosure, an aerosol generating substrate plug for an aerosol generating article is provided. The aerosol generating substrate plug comprises an aerosol generating substrate. The aerosol generating substrate comprises one or more aerosol forming agents. The aerosol generating substrate comprises an aerosol forming agent content of 5% by weight or more based on dry weight. The aerosol generating substrate plug comprises a wrapper. The wrapper has a basis weight of 20 g / m² to 200 g / m². The wrapper surrounds the aerosol generating substrate. The thickness of the aerosol generating substrate plug is less than 50% of the length of the aerosol generating substrate plug. The thickness of the aerosol generating substrate plug is less than 50% of the width of the aerosol generating substrate plug. The thickness of the aerosol generating substrate plug is constant over at least 90% of the width of the aerosol generating substrate plug.

[0009] An aerosol generator plug having a thickness of less than 50% of its length and width and a constant thickness over 90% of its width is generally a flat and thin aerosol generator plug. Advantageously, this allows for a small temperature gradient across the thickness of the aerosol generator plug during heating, thereby allowing a larger proportion of the aerosol generator plug to be heated to the aerosol-releasing temperature while minimizing the risk of the hottest part of the aerosol generator plug closest to the heating element burning. Advantageously, this can also reduce the time required to heat the aerosol generator plug sufficiently to release the aerosol.

[0010] The dimensions of the aerosol generating material plug imply that the cross-section of the aerosol generating material plug is advantageously non-circular. However, the aerosol generating material within such aerosol generating material plugs, such as tobacco sticks, tends to expand in all directions, which can cause the cross-sectional shape of the aerosol generating material plug to become distorted from the intended shape. For example, over time, the cross-sectional shape may become circular due to the expansion of the aerosol generating material or even normal handling of the aerosol generating material plug. Providing a wrapper with a basis weight of 20 g / m² to 200 g / m² implies that the wrapper can possess structural rigidity to maintain the advantageous cross-sectional shape of the aerosol generating material plug. Additionally, while a wrapper with a low basis weight provides advantageous flexibility in continuous manufacturing processes, a wrapper with too low a basis weight may imply that the wrapper cannot maintain the cross-sectional shape of the aerosol generating material plug. On the other hand, a wrapper with too high a basis weight can provide the required structural rigidity but may result in reduced flexibility. Advantageously, a wrapper having a basis weight of 20 g / m2 to 200 g / m2 provides a balance between the flexibility of the wrapper and the structural rigidity of the wrapper.

[0011] Additionally, the wrapper can seal the airflow path through the aerosol generating material plug from one end of the aerosol generating material plug to the other end of the aerosol generating material plug. Advantageously, this can avoid aerosol loss, particularly when used with an aerosol generator. Furthermore, this can also ensure that air flows through the entire aerosol generating material.

[0012] The aerosol generating material plug may include a substantially flat upper surface defined by a length extending in the x-direction and a width extending in the y-direction. The aerosol generating material plug may have a substantially flat lower surface defined by a length extending in the x-direction and a width extending in the y-direction. The substantially flat upper surface and the substantially flat lower surface may be spaced apart from each other by a thickness defined in the z-direction. The substantially flat upper surface and the substantially flat lower surface may be parallel to each other.

[0013] The aerosol generating material plug may include a first side surface extending substantially from a planar upper surface to a planar lower surface. The aerosol generating material plug may include a second side surface extending substantially from a planar upper surface to a planar lower surface. The first side surface may be a planar first side surface. The second side surface may be a planar second side surface. The first side surface may be positioned opposite to the second side surface. The first side surface may be parallel to the second side surface. The first side surface may be defined by a length extending in the x-direction and a width extending in the y-direction. The second side surface may be defined by a length extending in the x-direction and a thickness extending in the z-direction. The first side surface and the second side surface may be spaced apart from each other by a width in the y-direction. The first side surface may be substantially perpendicular to one or both of the planar upper surface and the planar lower surface. The second side surface may be substantially perpendicular to one or both of the substantially planar upper surface and the substantially planar lower surface.

[0014] The thickness of the aerosol generating material plug may be less than 40% of the width of the aerosol generating material plug. The thickness of the aerosol generating material plug may be less than 35% of the width of the aerosol generating material plug. The thickness of the aerosol generating material plug may be less than 30% of the width of the aerosol generating material plug. The thickness of the aerosol generating material plug may be less than 25% of the width of the aerosol generating material plug. The thickness of the aerosol generating material plug may be less than 20% of the width of the aerosol generating material plug.

[0015] The thickness of the aerosol generating material plug may be constant over at least 95% of the width of the aerosol generating material plug. The thickness of the aerosol generating material plug may be constant over at least 99% of the width of the aerosol generating material plug. As used herein, the term "constant" is used to mean that the thickness does not change by more than ±5% when referring to the thickness of the aerosol generating material plug.

[0016] The aerosol generating plug may have a substantially rectangular cross-section. The cross-section of the aerosol generating plug may be substantially rectangular along at least 90% of the length of the aerosol generating plug. The cross-section of the aerosol generating plug may be substantially rectangular along at least 95% of the length of the aerosol generating plug. The cross-section of the aerosol generating plug may be substantially rectangular along substantially the entire length of the aerosol generating plug.

[0017] All internal angles of one or any cross-section of the aerosol generating material plug may be 85 degrees or more. All internal angles of one or any cross-section of the aerosol generating material plug may be 90 degrees or more. All internal angles of one or any cross-section of the aerosol generating material plug may be 115 degrees or more.

[0018] All internal angles of one or any cross-section of the aerosol generating material plug may be 120 degrees or less. All internal angles of one or any cross-section of the aerosol generating material plug may be 115 degrees or more. All internal angles of one or any cross-section of the aerosol generating material plug may be 105 degrees or more. All internal angles of one or any cross-section of the aerosol generating material plug may be 95 degrees or more.

[0019] All internal angles of one or any cross-section of the aerosol generating material plug may be 85 to 120 degrees. All internal angles of one or any cross-section of the aerosol generating material plug may be 85 to 115 degrees. All internal angles of one or any cross-section of the aerosol generating material plug may be 85 to 105 degrees. All internal angles of one or any cross-section of the aerosol generating material plug may be 85 to 95 degrees.

[0020] The thickness of the aerosol generating material plug may be constant over at least 90% of the length of the aerosol generating material plug. The thickness of the aerosol generating material plug may be constant over at least 95% of the length of the aerosol generating material plug. The thickness of the aerosol generating material plug may be constant over at least 99% of the length of the aerosol generating material plug. Preferably, the thickness of the aerosol generating material plug may be constant over the entire length of the aerosol generating material plug.

[0021] The aerosol generating material plug may have a substantially rectangular longitudinal cross-section.

[0022] The aerosol generating device plug may have a rectangular prism shape. The aerosol generating device plug may have a cube shape. The aerosol generating device plug may have a rectangular prism shape. The aerosol generating device plug may have a rectangular prism shape.

[0023] The wrapper may have a basis weight of 25 g / m2 or more. The wrapper may have a basis weight of 30 g / m2 or more. The wrapper may have a basis weight of 35 g / m2 or more. The wrapper may have a basis weight of 40 g / m2 or more. The wrapper may have a basis weight of 45 g / m2 or more. The wrapper may have a basis weight of 50 g / m2 or more. The wrapper may have a basis weight of 60 g / m2 or more. The wrapper may have a basis weight of 70 g / m2 or more.

[0024] The wrapper may have a basis weight of 180 g / m2 or less. The wrapper may have a basis weight of 160 g / m2 or less. The wrapper may have a basis weight of 140 g / m2 or less. The wrapper may have a basis weight of 120 g / m2 or less. The wrapper may have a basis weight of 100 g / m2 or less.

[0025] The wrapper may have a basis weight of 25 g / m2 to 180 g / m2. The wrapper may have a basis weight of 30 g / m2 to 160 g / m2. The wrapper may have a basis weight of 35 g / m2 to 140 g / m2. The wrapper may have a basis weight of 40 g / m2 to 120 g / m2. The wrapper may have a basis weight of 45 g / m2 to 120 g / m2. The wrapper may have a basis weight of 50 g / m2 to 100 g / m2.

[0026] The wrapper may have a mass of 5 mg to 40 mg. The wrapper may have a mass of 10 mg to 40 mg. Preferably, the wrapper may have a mass of 10 mg to 30 mg.

[0027] The wrapper may have a thickness of 10 μm to 300 μm. The wrapper may have a thickness of 10 μm to 200 μm. The wrapper may have a thickness of 10 μm to 150 μm. The wrapper may have a thickness of 10 μm to 100 μm. The wrapper may have a thickness of 10 μm to 75 μm. The wrapper may have a thickness of 10 μm to 50 μm. The wrapper may have a thickness of 10 μm to 40 μm. The wrapper may have a thickness of 15 μm to 40 μm. The wrapper may have a thickness of 20 μm to 40 μm. The wrapper may have a thickness of about 37 μm.

[0028] The wrapper may have a length substantially equal to the length of the aerosol generating material. The wrapper may have a length substantially equal to the length of the aerosol generating material plug.

[0029] The wrapper may define or form an outer surface of the aerosol generating material plug. The wrapper may define or form a substantially flat upper surface of the aerosol generating material plug. The wrapper may define or form a substantially flat lower surface of the aerosol generating material plug. The wrapper may define or form a first side surface of the aerosol generating material plug. The wrapper may define or form a second side surface of the aerosol generating material plug. Preferably, the wrapper defines or forms a substantially flat upper surface of the aerosol generating material plug, a substantially flat lower surface of the aerosol generating material plug, a first side surface of the aerosol generating material plug, and a second side surface of the aerosol generating material plug.

[0030] The wrapper may define or form all longitudinal outer surfaces of the aerosol generating substrate plug. That is, the wrapper may define or form all outer surfaces of the aerosol generating substrate plug extending in the x and y directions, or in the x and z directions. The wrapper may define or form at least 99% of the surface area of ​​all longitudinal outer surfaces of the aerosol generating substrate plug.

[0031] The wrapper may define or form at least 60% of the external surface area of ​​the aerosol generating substrate plug. The wrapper may define or form at least 70% of the external surface area of ​​the aerosol generating substrate plug. The wrapper may define or form at least 95% of the external surface area of ​​the aerosol generating substrate plug. The wrapper may define or form at least 98% of the external surface area of ​​the aerosol generating substrate plug.

[0032] The wrapper may define or form less than 95% of the external surface area of ​​the aerosol generating substrate plug. The wrapper may define or form less than 85% of the external surface area of ​​the aerosol generating substrate plug. The wrapper may define or form less than 75% of the external surface area of ​​the aerosol generating substrate plug.

[0033] The wrapper may form an open end tube, and the aerosol generating material may be located within the open end tube. The aerosol generating material may be exposed at one or both of the distal and proximal ends of the aerosol generating material plug. That is, the aerosol generating material may be exposed at one or both of the extreme upstream and extreme downstream ends of the aerosol generating material plug. Alternatively, the wrapper may completely surround the aerosol generating material.

[0034] The wrapper may include an overlapping region in which a first part of the wrapper overlaps with a second part of the wrapper. For example, opposing longitudinal edges of the wrapper may overlap to form an overlapping region.

[0035] The overlapping region may be located on the upper surface of the aerosol generating material plug. The overlapping region may be located on the lower surface of the aerosol generating material plug.

[0036] The overlapping area may have a width of 2 mm or more. The overlapping area may have a width of 3 mm or more. The overlapping area may have a width of 4 mm or more. The overlapping area may have a width of 5 mm or more.

[0037] The overlapping area may have a width of 6 mm or less. The overlapping area may have a width of 5 mm or less. The overlapping area may have a width of 4 mm or less. The overlapping area may have a width of 3 mm or less.

[0038] The overlapping area may have a width of 2 mm to 6 mm. The overlapping area may have a width of 2 mm to 4 mm.

[0039] The overlapping area may have a width less than the width of the aerosol generating material plug. The overlapping area may have a width less than 50% of the width of the aerosol generating material plug. The overlapping area may have a width less than 25% of the width of the aerosol generating material plug. The overlapping area may have a width less than 15% of the width of the aerosol generating material plug.

[0040] The overlapping area may have a width exceeding 5% of the width of the aerosol generating material plug. The overlapping area may have a width exceeding 10% of the width of the aerosol generating material plug. The overlapping area may have a width exceeding 15% of the width of the aerosol generating material plug. The overlapping area may have a width exceeding 20% ​​of the width of the aerosol generating material plug.

[0041] The overlapping region may include a first surface of the wrapper coupled to a second surface of the wrapper. The overlapping region may include an inner surface of the wrapper coupled to an outer surface of the wrapper. For example, the overlapping region may include a wrap seal. The overlapping region may include an inner surface of the wrapper coupled to an inner surface of the wrapper. For example, the overlapping region may include a pin seal.

[0042] The surfaces of the wrappers within the overlapping region may be bonded with an adhesive. The surfaces of the wrappers within the overlapping region may be bonded with a strip or an adhesive line. The strip or adhesive line may extend longitudinally. The strip or adhesive line may have a length of 90% to 100% of the length of the aerosol generating substrate plug. The strip or adhesive line may have a length substantially equal to the length of the aerosol generating substrate plug. The strip or adhesive line may extend from the distal end of the aerosol generating substrate plug to the proximal end of the aerosol generating substrate plug.

[0043] The adhesive may include gum. The adhesive may include guar gum. The adhesive may include polyvinyl alcohol. The adhesive may include an aerosol generating substrate. The adhesive may be composed of an aerosol generating substrate. For example, the adhesive may be a homogenized tobacco slurry. The adhesive may be a flavoring agent and / or an aerosol forming agent, or may include the same.

[0044] The wrapper can come into physical contact with the aerosol generating substrate. For example, the inner surface of the wrapper can come into physical contact with the entire circumference of the aerosol generating substrate.

[0045] The wrapper, or a part of the wrapper, may be air permeable.

[0046] The wrapper, or a part of the wrapper, may have an air permeability of about 10 Coresta units to about 200 Coresta units. The wrapper, or a part of the wrapper, may have an air permeability of about 20 Coresta units to about 150 Coresta units. The wrapper, or a part of the wrapper, may have an air permeability of about 30 Coresta units to about 100 Coresta units. The wrapper, or a part of the wrapper, may have an air permeability of about 40 Coresta units to about 80 Coresta units.

[0047] The wrapper, or a part of the wrapper, may have an air permeability of about 5,000 Coresta units to about 12,000 Coresta units. The wrapper, or a part of the wrapper, may have an air permeability of about 7,500 Coresta units to about 12,000 Coresta units.

[0048] Air permeability in units of coresta is the amount of air per cubic centimeters per minute passing through one square centimeter of a wrapper at a constant pressure difference of 1 kilopascal (kPa) (i.e., 1 coresta unit corresponds to an air permeability of 1 cm³ / min·cm² at a pressure difference of 1 kPa). Air permeability in units of coresta can be measured according to ISO 2965:2009.

[0049] The wrapper may include one or more flavoring agents. Advantageously, the wrapper may be entrained or released into air flowing through an aerosol generating material plug. One or more flavoring agents may be any flavoring agents described herein in relation to the aerosol generating material.

[0050] The wrapper may include one or more aerosol-forming agents. The one or more aerosol-forming agents may be any aerosol-forming agents described herein in relation to the aerosol-generating material.

[0051] The wrapper may contain or be made of cellulose material. The wrapper may contain or be made of organic or plant material such as tobacco, mint, tea, and cloves.

[0052] The wrapper may include or be made of a hygroscopic material. The hygroscopic material may include one or more materials selected from a list consisting of polyvinyl alcohol, silicone, or combinations thereof. For example, the wrapper may include a surface treatment of the hygroscopic material. The hygroscopic material may be dispersed within the wrapper.

[0053] The wrapper may be a sheet of material. The wrapper may include or be made of a sheet of cellulose material such as paper. The wrapper may include or be made of a sheet of organic material or a sheet of plant material. The wrapper may include or be made of a sheet of homogenized tobacco material.

[0054] The wrapper may include one or more elements selected from a list consisting of ceramic fibers or particles, metal strips or particles, or a combination thereof.

[0055] The wrapper may be a first wrapper, and the aerosol generating material plug may include a second wrapper. The second wrapper may surround or enclose the aerosol generating material. The first wrapper may be in physical contact with the second wrapper. The aerosol generating material plug may include a stacked wrapper comprising the first wrapper and the second wrapper.

[0056] The second wrapper can have the same length as the first wrapper.

[0057] The second wrapper may be positioned between the first wrapper and the aerosol generating substrate. The second wrapper may come into physical contact with the aerosol generating substrate.

[0058] The first wrapper may be positioned between the second wrapper and the aerosol generating substrate. The first wrapper may physically contact the aerosol generating substrate.

[0059] The second wrapper may have a higher thermal conductivity than the first wrapper. The second wrapper may include or be composed of a thermally conductive material. The thermally conductive material may have a thermal conductivity of at least 10 W / mK. The thermally conductive material may be a metallic material. The thermally conductive material may include one or more materials selected from a list consisting of aluminum, stainless steel, or a combination thereof. The wrapper may include or be composed of a sheet of the thermally conductive material.

[0060] The second wrapper may include or be composed of a metallic material such as aluminum. The second wrapper may include or be composed of a sheet of a metallic material such as a sheet of aluminum. The second wrapper may include or be composed of a ceramic material. The second wrapper may include or be composed of a sheet of a ceramic material.

[0061] The first wrapper may include or be composed of a sheet of cellulose material, and the second wrapper may include or be composed of a sheet of a thermally conductive material such as aluminum, and one or both of the first wrapper and the second wrapper may include a surface treatment of a hygroscopic material.

[0062] The aerosol generating material can be extended substantially to the entire length of the aerosol generating material plug.

[0063] The aerosol generating material may occupy at least 95% of the cross-sectional area of ​​the aerosol generating material plug. The aerosol generating material may occupy at least 95% of the cross-sectional area of ​​the aerosol generating material plug. The aerosol generating material may occupy at least 98% of the cross-sectional area of ​​the aerosol generating material plug.

[0064] The aerosol generating material may have a mass of 70% or more of the mass of the aerosol generating material plug. The aerosol generating material may have a mass of 80% or more of the mass of the aerosol generating material plug. The aerosol generating material may have a mass of 90% or more of the mass of the aerosol generating material plug. The aerosol generating material may have a mass of 95% or more of the mass of the aerosol generating material plug.

[0065] The aerosol generating device may have a mass of 50 mg or more. The aerosol generating device may have a mass of 80 mg or more. The aerosol generating device may have a mass of 110 mg or more. The aerosol generating device may have a mass of 150 mg or more. The aerosol generating device may have a mass of 170 mg or more. The aerosol generating device may have a mass of 180 mg or more. The aerosol generating device may have a mass of 200 mg or more. The aerosol generating device may have a mass of 230 mg or more. The aerosol generating device may have a mass of 250 mg or more. The aerosol generating device may have a mass of 300 mg or more. The aerosol generating device may have a mass of 400 mg or more.

[0066] The aerosol generating device may have a mass of 500 mg or less. The aerosol generating device may have a mass of 400 mg or less. The aerosol generating device may have a mass of 300 mg or less. The aerosol generating device may have a mass of 250 mg or less. The aerosol generating device may have a mass of 230 mg or less. The aerosol generating device may have a mass of 200 mg or less. The aerosol generating device may have a mass of 180 mg or less. The aerosol generating device may have a mass of 170 mg or less. The aerosol generating device may have a mass of 150 mg or less. The aerosol generating device may have a mass of 110 mg or less. The aerosol generating device may have a mass of 80 mg or less. The aerosol generating device may have a mass of 50 mg or less.

[0067] The aerosol generating material may have a mass of 50 mg to 500 mg. The aerosol generating material may have a mass of 80 mg to 500 mg. The aerosol generating material may have a mass of 80 mg to 400 mg. The aerosol generating material may have a mass of 80 mg to 300 mg. The aerosol generating material may have a mass of 80 mg to 250 mg. The aerosol generating material may have a mass of 80 mg to 200 mg. The aerosol generating material may have a mass of 80 mg to 150 mg. Preferably, the aerosol generating material may have a mass of 100 mg to 250 mg.

[0068] The aerosol generating material may have a bulk density of 0.05 mg / mm³ or more. The aerosol generating material may have a bulk density of 0.1 mg / mm³ or more. The aerosol generating material may have a bulk density of 0.15 mg / mm³ or more. The aerosol generating material may have a bulk density of 0.2 mg / mm³ or more. The aerosol generating material may have a bulk density of 0.3 mg / mm³ or more. The aerosol generating material may have a bulk density of 0.4 mg / mm³ or more.

[0069] The aerosol generating material may have a bulk density of 0.5 mg / mm³ or less. The aerosol generating material may have a bulk density of 0.4 mg / mm³ or less. The aerosol generating material may have a bulk density of 0.35 mg / mm³ or less. The aerosol generating material may have a bulk density of 0.3 mg / mm³ or less.

[0070] The aerosol generating material may have a bulk density of 0.05 mg / mm³ to 0.5 mg / mm³. The aerosol generating material may have a bulk density of 0.1 mg / mm³ to 0.4 mg / mm³. The aerosol generating material may have a bulk density of 0.1 to 0.3 mg / mm³. The aerosol generating material may have a bulk density of 0.2 to 0.3 mg / mm³.

[0071] The aerosol generating substrate may have a packing density of 0.3 or higher. The aerosol generating substrate may have a packing density of 0.4 or higher. The aerosol generating substrate may have a packing density of 0.5 or higher. The aerosol generating substrate may have a packing density of 0.6 or higher. The aerosol generating substrate may have a packing density of 0.7 or higher.

[0072] The aerosol generating substrate may have a packing density of 0.9 or less. The aerosol generating substrate may have a packing density of 0.8 or less. The aerosol generating substrate may have a packing density of 0.7 or less. The aerosol generating substrate may have a packing density of 0.6 or less. The aerosol generating substrate may have a packing density of 0.5 or less.

[0073] The aerosol generating substrate may have a packing density of 0.3 to 0.9. The aerosol generating substrate may have a packing density of 0.4 to 0.9. The aerosol generating substrate may have a packing density of 0.5 to 0.9. The aerosol generating substrate may have a packing density of 0.5 to 0.8. The aerosol generating substrate may have a packing density of 0.5 to 0.7.

[0074] The aerosol generating material may include or be composed of a solid aerosol generating material.

[0075] The aerosol generating substrate may include a porous substrate. The porous substrate may include natural materials, synthetic materials, or semi-synthetic materials, or a combination thereof. The porous substrate may include sheet materials, foams, or fibers, for example, loose fibers; or a combination thereof. The porous substrate may include woven fabrics, nonwoven fabrics, or extruded materials, or a combination thereof. Preferably, the porous substrate includes cotton, paper, viscose, PLA, or cellulose acetate, or a combination thereof. The porous substrate may include a corrugated sheet material made of, for example, cotton or cellulose acetate.

[0076] The porous substrate may retain or possess an aerosol generating medium. The aerosol generating medium may include a liquid or gel that impregnates the porous substrate. The aerosol generating medium may include a gel comprising an alkaloid compound; an aerosol forming agent; and at least one gelling agent.

[0077] The aerosol generating substrate may include or be composed of a homogenized plant material, such as a homogenized tobacco material. As used herein, the term "homogenized plant material" encompasses any plant material formed by the aggregation of plant particles. For example, a sheet or web of homogenized tobacco material for the aerosol generating substrate of the present invention may be formed by aggregating particles of tobacco material obtained by micronizing, milling, or crushing one or more of tobacco leaf blades and tobacco leaf stalks. Homogenized plant material, such as a homogenized tobacco material, may be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0078] The aerosol generating material may include a shredded aerosol generating material. For example, the aerosol generating material may include: one or both of a strip of the aerosol generating material and a strand of the aerosol generating material. The shredded aerosol generating material may be shredded tobacco material. The shredded aerosol generating material may be shredded homogenized tobacco material. The shredded aerosol generating material may be a shredded sheet of homogenized tobacco material, such as a shredded cast leaf tobacco sheet.

[0079] The aerosol generating material may include tobacco sticks. The tobacco sticks may include one or more of bright tobacco, dark tobacco, flavored tobacco, and filler tobacco. Examples of bright tobacco include Brazilian yellow tobacco, Indian yellow tobacco, Chinese yellow tobacco, American yellow tobacco such as Virginia tobacco, and Tanzanian yellow tobacco. Examples of flavored tobacco include Oriental Turkish tobacco, Greek Oriental tobacco, and semi-Oriental tobacco, as well as American Burley smoked tobacco such as Perique and Rustica. Examples of dark tobacco include dark-cured Brazilian Galpao, Burley Malawi or other African Burley, and sun-cured or air-cured Indonesian Kasturi. As used herein, the term “cut grass” is used to describe a blend of crushed plant material, such as tobacco plant material or homogenized plant material, comprising one or more of leaf blades, processed stems and ribs, in particular.

[0080] The aerosol generating material may include or be composed of a sheet of an aerosol generating material. The sheet of the aerosol generating material may be a sheet of tobacco material. The sheet of the aerosol generating material may be a sheet of homogenized tobacco material, such as a cast leaf tobacco sheet.

[0081] The sheet of the aerosol generating material may have a basis weight of 100 g / m2 to 600 g / m2. The sheet of the aerosol generating material may have a basis weight of 100 g / m2 to 300 g / m2.

[0082] A sheet of aerosol-generating material may have a density of 0.3 g / cm³ or more. A sheet of aerosol-generating material may have a density of 0.4 g / cm³ or more. A sheet of aerosol-generating material may have a density of 0.5 g / cm³ or more. A sheet of aerosol-generating material may have a density of 0.6 g / cm³ or more. A sheet of aerosol-generating material may have a density of 0.7 g / cm³ or more. A sheet of aerosol-generating material may have a density of 0.8 g / cm³ or less.

[0083] A sheet of aerosol-generating material may have a density of 1.0 g / cm³ or less. A sheet of aerosol-generating material may have a density of 0.9 g / cm³ or less. A sheet of aerosol-generating material may have a density of 0.8 g / cm³ or less. A sheet of aerosol-generating material may have a density of 0.7 g / cm³ or less. A sheet of aerosol-generating material may have a density of 0.6 g / cm³ or less. A sheet of aerosol-generating material may have a density of 0.5 g / cm³ or less. A sheet of aerosol-generating material may have a density of 0.4 g / cm³ or less.

[0084] A sheet of aerosol-generating material may have a density of 0.3 g / cm³ to 1.3 g / cm³. A sheet of aerosol-generating material may have a density of 0.3 g / cm³ to 1.0 g / cm³. A sheet of aerosol-generating material may have a density of 0.4 g / cm³ to 1.0 g / cm³. A sheet of aerosol-generating material may have a density of 0.4 g / cm³ to 0.9 g / cm³. A sheet of aerosol-generating material may have a density of 0.5 g / cm³ to 0.9 g / cm³.

[0085] The sheet of aerosol generating material may be a corrugated sheet of aerosol generating material. That is, the sheet of aerosol generating material may be wavy, folded, or otherwise compressed or contracted substantially perpendicular to the transverse direction of the aerosol generating material plug.

[0086] The sheet of aerosol generating material may be a crimped sheet of aerosol generating material. The sheet of aerosol generating material may be a wavy sheet of aerosol generating material. The crimped sheet of aerosol generating material or the wavy sheet of aerosol generating material may include a plurality of parallel wavy folds. The plurality of parallel wavy folds may define or form a plurality of channels. The plurality of channels may be channels extending in a plurality of longitudinal directions. That is, the plurality of channels may extend in the longitudinal direction of the aerosol generating material plug.

[0087] The aerosol generating material may include one or more aerosol-forming agents. Suitable aerosol-forming agents are known in the art and include, but are not limited to, polyhydric alcohols such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable that the aerosol-forming agent is glycerin or includes it.

[0088] The aerosol generating substrate may contain an aerosol forming agent content of 10% by weight or more based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 15% by weight or more based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 20% by weight or more based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 25% by weight or more based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 30% by weight or more based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 40% by weight or more based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 50% by weight or more based on dry weight.

[0089] The aerosol generating substrate may contain an aerosol forming agent content of 60% by weight or less based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 50% by weight or less based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 40% by weight or less based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 30% by weight or less based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 25% by weight or less based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 20% by weight or less based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 15% by weight or less based on dry weight.

[0090] The aerosol generating substrate may contain an aerosol forming agent content of 5% to 30% by weight based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 5% to 25% by weight based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 5% to 20% by weight based on dry weight.

[0091] The aerosol generating substrate may contain an aerosol forming agent content of 10% to 30% by weight based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 10% to 25% by weight based on dry weight. The aerosol generating substrate may contain an aerosol forming agent content of 10% to 20% by weight based on dry weight.

[0092] The aerosol generating material may include nicotine. The aerosol generating material may include natural nicotine, synthetic nicotine, or a combination of natural and synthetic nicotine. The aerosol generating material may include nicotine in the form of particles or powder.

[0093] The aerosol generating material may contain at least 0.5% by weight of nicotine, at least 1% by weight of nicotine, at least 1.5% by weight of nicotine, or at least 2% by weight of nicotine. That is, the aerosol generating material may have a nicotine content of at least 0.5% by weight, at least 1% by weight, at least 1.5% by weight, or at least 2% by weight.

[0094] The aerosol generating device may substantially be tobacco-free or nicotine-free.

[0095] The aerosol generating material may include one or more cannabinoid compounds such as tetrahydrocannabinol (THC), tetrahydrocannabinol acid (THCA), cannabidiol (CBD), cannabidiol acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannavivarin (CBV), cannavivarin (CBDV), tetrahydrocannavivarin (THCV), cannabicromin (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), and cannabicitran (CBT). The cannabinoid compound may preferably be CBD or THC. The cannabinoid compound may particularly preferably be CBD.

[0096] The aerosol generating material may include one or more flavoring agents. One or more flavoring agents may include one or more essential oils such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and one or more herbal materials. Suitable herbal materials include, but are not limited to, mints such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway, and other herbal materials derived from herb leaves or herbal plants. One or more flavoring agents may include tobacco substances.

[0097] The aerosol generating material may have a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state. For example, the aerosol generating material may be a homogenized tobacco material having a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state.

[0098] The aerosol generating material may comprise tobacco leaves: for example, about 15 to 45%, preferably about 20 to 35%, of a blend of tobacco leaves, which comprises at least one of the following tobacco types: bright tobacco; dark tobacco; flavored tobacco. Tobacco materials such as tobacco leaves are preferably crushed and graded to a particle size of about 100 to 380 mesh, preferably about 170 to 320 mesh.

[0099] The aerosol generating substrate may include cellulose fibers. For example, the aerosol generating substrate may include about 1 to 15% cellulose fibers, preferably about 3 to 7% cellulose fibers. Preferably, the cellulose fibers may have a length of about 10 to 250 µm, preferably about 10 to 120 µm.

[0100] The aerosol generating substrate may comprise organic fibers, such as non-tobacco fibers, or tobacco fibers. For example, the aerosol generating substrate may comprise about 5 to 20%, preferably about 7 to 15%, of tobacco fibers. The tobacco fibers are preferably derived from stems and / or leaf stalks graded into fibers with a length of about 10 to 350 μm, preferably about 10 to 180 μm. The aerosol generating substrate may comprise about 10 to 30%, preferably about 15 to 25%, of non-tobacco organic fibers. For example, the organic fibers may be derived from cellulose, cotton, wood, or tea plant varieties as by-products and reprocessed waste of the tea industry. The organic fibers are preferably about 10 to 400 μm, preferably about 10 to 200 μm in length.

[0101] The aerosol generating substrate may include a binder. For example, the aerosol generating substrate may include about 1 to 10%, preferably about 1 to 5%, of a binder such as either a common gum or pectin used in the food and beverage (F&B) industry. Preferred binders may be natural pectins, e.g., fruit, e.g., citrus or tobacco pectin; guar gum, land locust bean gum, e.g., their hydroxyethyl and hydroxypropyl forms; starch, e.g., modified or derivatized starch; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; dextran; and xanthan gum. Preferred binders are guar or carboxymethyl cellulose.

[0102] The aerosol generating material may include organic vegetable glycerin. For example, the aerosol generating material may include about 15 to 55%, preferably about 20 to 35%, of plant components, such as clove, Echinacea, fennel, ginger, hawthorn berry, elderberry, monarda, mullein leaf, nettle, plantain, turmeric, yarrow, and compounds thereof.

[0103] The aerosol generating material may include organic plant extracts. For example, the aerosol generating material may include about 1 to 15%, preferably about 2 to 7%, of any of the previously mentioned plant materials, as well as menthol (dl-menthol, C10H20O, 2-isopropyl-5-methylcyclohexanol) obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium or other related plant varieties, and p-mentan-3-ol, which is any secondary alcohol that is a diastereomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.

[0104] The aerosol generating material may include vegetable essential oils, for example, about 0.5 to 5%, preferably about 1 to 3%, of vegetable essential oils, such as palm, coconut, and wood essential oils.

[0105] The aerosol generating material may be in the form of multiple beads. The multiple beads may have an average particle diameter of 0.1 mm to 4 mm, for example, 0.5 mm to 4 mm.

[0106] The term "bead" refers to distinct solid particles formed from an aerosol-generating substrate. Beads may have a round shape, typically spherical. Other terms may be used to define the substrate, such as "granule."

[0107] Providing an aerosol generating substrate as multiple beads can offer specific advantages. Beads can be handled more easily compared to other aerosol generating substrates. Beads can also be cleaner to handle than powders and shavings, which can cause dust in the factory and leak from the aerosol generating article during transport or use. By selecting beads with appropriate bead size and appropriate particle size distribution, the airflow through the aerosol generating substrate plug can be controlled more reproducibly, so to speak, than in the case of shaving substrates.

[0108] When a particle is not perfectly spherical but its diameter is referred to, the term "diameter" may refer to the largest dimension of the particle. Alternatively, the term "diameter" may refer to the diameter of a perfectly spherical particle having the same volume as a non-spherical particle.

[0109] The term "average particle diameter" as used herein may refer to the number average particle diameter. Other methods for determining the average particle diameter are known. Thus, the average particle diameter may be, for example, the volume average particle diameter.

[0110] The aerosol generating material plug may have a volume of 150 mm³ or more. The aerosol generating material plug may have a volume of 200 mm³ or more. The aerosol generating material plug may have a volume of 250 mm³ or more. The aerosol generating material plug may have a volume of 350 mm³ or more.

[0111] The aerosol generating material plug may have a volume of 1000 mm³ or less. The aerosol generating material plug may have a volume of 900 mm³ or less. The aerosol generating material plug may have a volume of 800 mm³ or less. The aerosol generating material plug may have a volume of 700 mm³ or less.

[0112] The aerosol generating material plug may have a volume of 100 mm³ to 1000 mm³. The aerosol generating material plug may have a volume of 200 mm³ to 1000 mm³. The aerosol generating material plug may have a volume of 350 mm³ to 650 mm³. The aerosol generating material plug may have a volume of 450 mm³ to 550 mm³.

[0113] The aerosol generating material plug may have a thickness of 0.5 mm or more. The aerosol generating material plug may have a thickness of 1 mm or more. The aerosol generating material plug may have a thickness of 1.5 mm or more. The aerosol generating material plug may have a thickness of 2 mm or more. The aerosol generating material plug may have a thickness of 2.5 mm or more. The aerosol generating material plug may have a thickness of 3 mm or more. The aerosol generating material plug may have a thickness of 3.5 mm or more. The aerosol generating material plug may have a thickness of 4 mm or more. The aerosol generating material plug may have a thickness of 4.5 mm or more. The aerosol generating material plug may have a thickness of 5 mm or more.

[0114] The aerosol generating material plug may have a thickness of 5.5 mm or less. The aerosol generating material plug may have a thickness of 5 mm or less. The aerosol generating material plug may have a thickness of 4.5 mm or less. The aerosol generating material plug may have a thickness of 4 mm or less. The aerosol generating material plug may have a thickness of 3.5 mm or less. The aerosol generating material plug may have a thickness of 2.5 mm or less. The aerosol generating material plug may have a thickness of 2 mm or less. The aerosol generating material plug may have a thickness of 1.5 mm or less.

[0115] The aerosol generating material plug may have a thickness of 0.5 mm to 6.5 mm. The aerosol generating material plug may have a thickness of 1 mm to 6 mm. The aerosol generating material plug may have a thickness of 2 mm to 6 mm. The aerosol generating material plug may have a thickness of 2 mm to 5 mm. The aerosol generating material plug may have a thickness of 2 mm to 4.5 mm. The aerosol generating material plug may have a thickness of 2 mm to 4 mm. Preferably, the aerosol generating material plug may have a thickness of 2.8 mm to 3.3 mm.

[0116] The aerosol generating plug may have a length of 6 mm or more. The aerosol generating plug may have a length of 10 mm or more. The aerosol generating plug may have a length of 14 mm or more. The aerosol generating plug may have a length of 18 mm or more. The aerosol generating plug may have a length of 22 mm or more. The aerosol generating plug may have a length of 26 mm or more. The aerosol generating plug may have a length of 30 mm or more.

[0117] The aerosol generating device plug may have a length of 32 mm or less. The aerosol generating device plug may have a length of 28 mm or less. The aerosol generating device plug may have a length of 24 mm or less. The aerosol generating device plug may have a length of 20 mm or less. The aerosol generating device plug may have a length of 16 mm or less. The aerosol generating device plug may have a length of 12 mm or less. The aerosol generating device plug may have a length of 8 mm or less.

[0118] The aerosol generating material plug may have a length of 6 mm to 34 mm. The aerosol generating material plug may have a length of 10 mm to 30 mm. The aerosol generating material plug may have a length of 14 mm to 26 mm. The aerosol generating material plug may have a length of 14 mm to 22 mm. The aerosol generating material plug may have a length of 14 mm to 18 mm.

[0119] The aerosol generating plug may have a length of 80 mm or more. The aerosol generating plug may have a length of 100 mm or more. The aerosol generating plug may have a length of 120 mm or more. The aerosol generating plug may have a length of 160 mm or more. The aerosol generating plug may have a length of 200 mm or more. The aerosol generating plug may have a length of 240 mm or more.

[0120] The aerosol generating device plug may have a length of 400 mm or less. The aerosol generating device plug may have a length of 360 mm or less. The aerosol generating device plug may have a length of 320 mm or less. The aerosol generating device plug may have a length of 280 mm or less. The aerosol generating device plug may have a length of 240 mm or less. The aerosol generating device plug may have a length of 200 mm or less.

[0121] The aerosol generating material plug may have a length of 80 mm to 400 mm. The aerosol generating material plug may have a length of 100 mm to 400 mm. The aerosol generating material plug may have a length of 120 mm to 400 mm. The aerosol generating material plug may have a length of 160 mm to 400 mm. The aerosol generating material plug may have a length of 200 mm to 400 mm.

[0122] The aerosol generating material plug may have a width of 4 mm or more. The aerosol generating material plug may have a width of 5 mm or more. The aerosol generating material plug may have a width of 6 mm or more. The aerosol generating material plug may have a width of 7 mm or more. The aerosol generating material plug may have a width of 8 mm or more.

[0123] The aerosol generating material plug may have a width of 12 mm or less. The aerosol generating material plug may have a width of 11 mm or less. The aerosol generating material plug may have a width of 10 mm or less. The aerosol generating material plug may have a width of 9 mm or less. The aerosol generating material plug may have a width of 8 mm or less.

[0124] The aerosol generating material plug may have a width of 4 mm to 12 mm. The aerosol generating material plug may have a width of 6 mm to 10 mm.

[0125] The aerosol generating material plug may have a length of 6 mm to 32 mm, a width of 4 mm to 12 mm, and a thickness of 0.5 mm to 5.5 mm.

[0126] The aerosol generating material plug may have a length of 10 mm to 30 mm, a width of 6 mm to 10 mm, and a thickness of 2 mm to 6 mm.

[0127] According to the present disclosure, an aerosol generating article is provided comprising an aerosol generating material plug, a first plug, and an outer wrapper as described herein. The outer wrapper may surround the first plug and the aerosol generating material plug. The aerosol generating article may be intended for use with an aerosol generating device to generate an aerosol, for example, the aerosol generating article may be intended for use with an electrically operated aerosol generating device.

[0128] An aerosol generating article may include a substantially flat top surface defined by a length extending in the x-direction and a width extending in the y-direction. An aerosol generating article may have a substantially flat bottom surface defined by a length extending in the x-direction and a width extending in the y-direction. The substantially flat top surface and the substantially flat bottom surface may be spaced apart from each other by a thickness defined in the z-direction. The substantially flat top surface and the substantially flat bottom surface may be parallel to each other.

[0129] The aerosol generating article may include a first side surface extending substantially from a planar upper surface to a planar lower surface. The aerosol generating article may include a second side surface extending substantially from a planar upper surface to a planar lower surface. The first side surface may be a planar first side surface. The second side surface may be a planar second side surface. The first side surface may be positioned opposite to the second side surface. The first side surface may be parallel to the second side surface. The first side surface may be defined by a length extending in the x-direction and a width extending in the y-direction. The second side surface may be defined by a length extending in the x-direction and a thickness extending in the z-direction. The first side surface and the second side surface may be spaced apart from each other by a width in the y-direction. The first side surface may be substantially perpendicular to one or both of the planar upper surface and the planar lower surface. The second side surface may be substantially perpendicular to one or both of the substantially planar upper surface and the substantially planar lower surface.

[0130] The first plug and the aerosol generating material plug may be aligned longitudinally and axially. The first plug may be located adjacent to the aerosol generating material plug. That is, no element may be located between the first plug and the aerosol generating material plug. The first plug may be located adjacent to the aerosol generating material plug and spaced apart from the aerosol generating material plug. For example, an empty cavity may be located between the first plug and the aerosol generating material plug. The first plug may be spaced at least 2 mm apart from the aerosol generating material plug. The first plug may be spaced at least 5 mm apart from the aerosol generating material plug.

[0131] The first plug may be located upstream or downstream of the aerosol generating material plug. The first plug may be in contact with the upstream or downstream end of the aerosol generating material plug. The first plug may be spaced apart from the upstream or downstream end of the aerosol generating material plug. The first plug may be located at the extreme upstream or extreme downstream end of the aerosol generating article. The first plug may define or form the upstream end wall or downstream end wall of the aerosol generating article.

[0132] The first plug may be substantially air-impermeable. The first plug may include a solid cross-section of the material. That is, the first plug does not define any cavities, gaps, voids, or apertures, unlike those already defined by the material properties themselves, such as pores. The first plug may be configured so that, during use, an airflow path can be formed through the first plug, for example by an aerosol generating device.

[0133] The first plug may be substantially air-permeable. The first plug may include one or more apertures or through holes defined by the length of the first plug. The first plug may be a hollow element, for example, a rectangular tube. The first plug may include a plug made of a porous material.

[0134] The first plug may have a suction resistance of 0 mmH2O to 5 mmH2O. The first plug may have a suction resistance of 0 mmH2O to 4 mmH2O. The first plug may have a suction resistance of 0 mmH2O to 3 mmH2O. The first plug may have a suction resistance of 0 mmH2O to 2.5 mmH2O. The first plug may have a suction resistance of 0 mmH2O to 2 mmH2O. The first plug may have a suction resistance of 0 mmH2O to 1 mmH2O. The first plug may have a suction resistance of 0 mmH2O to 0.75 mmH2O.

[0135] The first plug may substantially be free of any aerosol-generating compound. The first plug may include one or more flavoring agents described herein.

[0136] The first plug may include or be composed of a fibrous material. The first plug may include or be composed of a porous material. The first plug may include or be composed of a fluid or air permeable material. The first plug may include or be composed of a biodegradable material. The first plug may include or be composed of a cellulose material such as cellulose acetate or paper. For example, the first plug may be formed from a bundle of cellulose acetate fibers having a denier per filament of about 10 to about 15. As another example, the first plug may be formed from a relatively low-density cellulose acetate tow, such as a cellulose acetate tow containing fibers with a denier per filament of about 12, which may provide an RTD per unit length of about 0.8 to about 2.5 mmH2O / mm.

[0137] The first plug may include or be composed of a polylactic acid-based material. The first plug may include or be composed of a bioplastic material, preferably a starch-based bioplastic material. The first plug may be manufactured by injection molding or extrusion.

[0138] The first plug may include or be composed of a cellulose material or paper. The first plug may include at least 80 weight percent of a cellulose material or paper. The first plug may include at least 90 weight percent of a cellulose material or paper. The first plug may include at least 95 weight percent of a cellulose material or paper.

[0139] The first plug may comprise or be composed of a sheet of material that is fluted, crimped, pleated, corrugated, woven, or folded as an element defining a plurality of longitudinally extending channels. Preferably, the sheet of material is fluted or crimped. Such a suitable sheet of material may comprise, be, or consist of paper, cardboard, a polymer such as polylactic acid, or any other cellulose-based, paper-based, or bioplastic-based material. Preferably, the sheet of material is a cellulose-based material. The plurality of longitudinally extending channels may extend from an upstream end of the first plug to a downstream end of the first plug. The plurality of longitudinally extending channels may be distributed uniformly or randomly across a cross-section of the first plug. The first plug may comprise a peripheral wall surface on which the sheet of material is located. The peripheral wall surface may form a tube, preferably a rectangular tube.

[0140] The first plug may be formed in any other suitable manner. For example, the first plug may be formed from a bundle of tubes positioned longitudinally. The longitudinally extended tubes may be formed from polylactic acid. The first plug may be formed by extrusion, molding, lamination, injection, or crushing of a suitable material.

[0141] The first plug may have the same cross-sectional shape as the aerosol generating material plug. The first plug may have a substantially rectangular cross-section.

[0142] The first plug may have a width of at least 95% of the width of the aerosol-generating article. The first plug may have a width of at least 98% of the width of the aerosol-generating article.

[0143] The first plug may have the same width as the aerosol generating material plug. The first plug may have the same thickness as the aerosol generating material plug.

[0144] The first plug may have a length of 2 mm or more. The first plug may have a length of 3 mm or more. The first plug has a length of 4 mm or more.

[0145] The first plug may have a length of 10 mm or less. The first plug may have a length of 7 mm or less. The first plug may have a length of about 5 mm or less.

[0146] The first plug may have a length of 2 mm to 10 mm. The first plug may have a length of 3 mm to 10 mm. The first plug may have a length of 4 mm to 10 mm.

[0147] The ratio between the length of the first plug and the length of the aerosol-generating article may be 0.05 or greater. The ratio between the length of the first plug and the length of the aerosol-generating article may be 0.1 or greater. The ratio between the length of the first plug and the length of the aerosol-generating article may be 0.2 or greater. The ratio between the length of the first plug and the length of the aerosol-generating article may be 0.3 or greater.

[0148] The ratio between the length of the first plug and the length of the aerosol-generating article may be 0.4 or less. The ratio between the length of the first plug and the length of the aerosol-generating article may be 0.3 or less. The ratio between the length of the first plug and the length of the aerosol-generating article may be 0.2 or less. The ratio between the length of the first plug and the length of the aerosol-generating article may be 0.1 or less. The ratio between the length of the first plug and the length of the aerosol-generating article may be 0.05 or less.

[0149] The ratio between the length of the first plug and the length of the aerosol-generating article may be 0.05 to 0.4. The ratio between the length of the first plug and the length of the aerosol-generating article may be 0.05 to 0.3. The ratio between the length of the first plug and the length of the aerosol-generating article may be 0.05 to 0.2. The ratio between the length of the first plug and the length of the aerosol-generating article may be 0.1 to 0.2.

[0150] The ratio between the length of the first plug and the length of the aerosol generating material plug may be 0.15 or more. The ratio between the length of the first plug and the length of the aerosol generating material plug may be 0.2 or more. The ratio between the length of the first plug and the length of the aerosol generating material plug may be 0.3 or more.

[0151] The ratio between the length of the first plug and the length of the aerosol generating material plug may be 0.5 or less. The ratio between the length of the first plug and the length of the aerosol generating material plug may be about 0.45 or less. The ratio between the length of the first plug and the length of the aerosol generating material plug may be about 0.4 or less.

[0152] The ratio between the length of the first plug and the length of the aerosol generating material plug may be 0.15 to 0.5. The ratio between the length of the first plug and the length of the aerosol generating material plug may be 0.2 to 0.5. The ratio between the length of the first plug and the length of the aerosol generating material plug may be 0.3 to 0.5.

[0153] The aerosol generating article may include a second plug. An outer wrapper may surround the first plug, the second plug, and the aerosol generating material plug.

[0154] The first plug, the second plug, and the aerosol generating material plug may be aligned longitudinally and axially. The second plug may be located adjacent to the aerosol generating material plug. That is, no element may be located between the second plug and the aerosol generating material plug. The second plug may be located adjacent to the aerosol generating material plug and spaced apart from the aerosol generating material plug. For example, an empty cavity may be located between the second plug and the aerosol generating material plug. The second plug may be spaced at least 2 mm away from the aerosol generating material plug. The second plug may be spaced at least 5 mm away from the aerosol generating material plug.

[0155] The second plug may be located upstream or downstream of the aerosol generating material plug. The second plug may be in contact with the upstream or downstream end of the aerosol generating material plug. The second plug may be spaced apart from the upstream or downstream end of the aerosol generating material plug. The second plug may be located at the extreme upstream or extreme downstream end of the aerosol generating article. The second plug may define or form the upstream end wall or downstream end wall of the aerosol generating article.

[0156] The aerosol generating material plug may be located between the first plug and the second plug. For example, the first plug may be located upstream of the aerosol generating material plug, and the second plug may be located downstream of the aerosol generating material plug. As an alternative example, the first plug may be located downstream of the aerosol generating material plug, and the second plug may be located upstream of the aerosol generating material plug.

[0157] The second plug may be substantially air-impermeable. The second plug may include a solid cross-section of the material. That is, the second plug does not define any cavities, gaps, voids, or apertures, unlike those already defined by the material properties themselves, such as pores. The second plug may be configured so that, during use, an airflow path can be formed through the second plug, for example by an aerosol generating device.

[0158] The second plug may be substantially air-permeable. The second plug may include one or more apertures or through holes defined by the length of the second plug. The second plug may be a hollow element, for example, a rectangular tube. The second plug may include a plug made of a porous material.

[0159] The second plug may have an inhalation resistance (RTD) of 0 mmH2O to 5 mmH2O. The second plug may have an inhalation resistance (RTD) of 0 mmH2O to 4 mmH2O. The second plug may have an inhalation resistance (RTD) of 0 mmH2O to 3 mmH2O. The second plug may have an inhalation resistance (RTD) of 0 mmH2O to 2.5 mmH2O. The second plug may have an inhalation resistance (RTD) of 0 mmH2O to 2 mmH2O. The second plug may have an inhalation resistance (RTD) of 0 mmH2O to 1 mmH2O. The second plug may have an inhalation resistance (RTD) of 0 mmH2O to 0.75 mmH2O.

[0160] The second plug may substantially be free of any aerosol-generating compound. The second plug may include one or more flavoring agents described herein.

[0161] The second plug may include or be composed of a fibrous material. The second plug may include or be composed of a porous material. The second plug may include or be composed of a fluid or air permeable material. The second plug may include or be composed of a biodegradable material. The second plug may include or be composed of a cellulose material such as cellulose acetate or paper. For example, the second plug may be formed from a bundle of cellulose acetate fibers having a denier per filament of about 10 to about 15. As another example, the second plug may be formed from a relatively low-density cellulose acetate tow, such as a cellulose acetate tow containing fibers with a denier per filament of about 12, which may provide an RTD per unit length of about 0.8 to about 2.5 mmH2O / mm.

[0162] The second plug may include or be composed of a polylactic acid-based material. The second plug may include or be composed of a bioplastic material, preferably a starch-based bioplastic material. The second plug may be manufactured by injection molding or extrusion.

[0163] The second plug may include or be composed of a cellulose material or paper. The second plug may include at least 80 weight percent of a cellulose material or paper. The second plug may include at least 90 weight percent of a cellulose material or paper. The second plug may include at least 95 weight percent of a cellulose material or paper.

[0164] The second plug may comprise or be composed of a sheet of material that is fluted, crimped, pleated, corrugated, woven, or folded, as an element defining a plurality of longitudinally extending channels. Preferably, the sheet of material is fluted or crimped. Such a suitable sheet of material may comprise, be, or consist of paper, cardboard, a polymer such as polylactic acid, or any other cellulose-based, paper-based, or bioplastic-based material. Preferably, the sheet of material is a cellulose-based material. The plurality of longitudinally extending channels may extend from an upstream end of the second plug to a downstream end of the second plug. The plurality of longitudinally extending channels may be distributed uniformly or randomly across the cross-section of the second plug. The second plug may comprise a peripheral wall surface on which the sheet of material is located. The peripheral wall surface may form a tube, preferably a rectangular tube.

[0165] The second plug may be formed in any other suitable manner. For example, the second plug may be formed from a bundle of tubes positioned longitudinally. The longitudinally extended tubes may be formed from polylactic acid. The second plug may be formed by extrusion, molding, lamination, injection, or crushing of a suitable material.

[0166] The second plug may have the same cross-sectional shape as the aerosol generating material plug. The second plug may have a substantially rectangular cross-section.

[0167] The second plug may have a width of at least 95% of the width of the aerosol-generating article. The second plug may have a width of at least 98% of the width of the aerosol-generating article.

[0168] The second plug may have the same width as the aerosol generating material plug. The second plug may have the same thickness as the aerosol generating material plug.

[0169] The second plug may have a length of 2 mm or more. The second plug may have a length of 3 mm or more. The second plug has a length of 4 mm or more.

[0170] The second plug may have a length of 10 mm or less. The second plug may have a length of 7 mm or less. The second plug may have a length of about 5 mm or less.

[0171] The second plug may have a length of 2 mm to 10 mm. The second plug may have a length of 3 mm to 10 mm. The second plug may have a length of 4 mm to 10 mm.

[0172] The ratio between the length of the second plug and the length of the aerosol-generating article may be 0.05 or greater. The ratio between the length of the second plug and the length of the aerosol-generating article may be 0.1 or greater. The ratio between the length of the second plug and the length of the aerosol-generating article may be 0.2 or greater. The ratio between the length of the second plug and the length of the aerosol-generating article may be 0.3 or greater.

[0173] The ratio between the length of the second plug and the length of the aerosol-generating article may be 0.4 or less. The ratio between the length of the second plug and the length of the aerosol-generating article may be 0.3 or less. The ratio between the length of the second plug and the length of the aerosol-generating article may be 0.2 or less. The ratio between the length of the second plug and the length of the aerosol-generating article may be 0.1 or less. The ratio between the length of the second plug and the length of the aerosol-generating article may be 0.05 or less.

[0174] The ratio between the length of the second plug and the length of the aerosol-generating article may be 0.05 to 0.4. The ratio between the length of the second plug and the length of the aerosol-generating article may be 0.05 to 0.3. The ratio between the length of the second plug and the length of the aerosol-generating article may be 0.05 to 0.2. The ratio between the length of the second plug and the length of the aerosol-generating article may be 0.1 to 0.2.

[0175] The ratio between the length of the second plug and the length of the aerosol generating material plug may be 0.15 or more. The ratio between the length of the second plug and the length of the aerosol generating material plug may be 0.2 or more. The ratio between the length of the second plug and the length of the aerosol generating material plug may be 0.3 or more.

[0176] The ratio between the length of the second plug and the length of the aerosol generating material plug may be 0.5 or less. The ratio between the length of the second plug and the length of the aerosol generating material plug may be about 0.45 or less. The ratio between the length of the second plug and the length of the aerosol generating material plug may be about 0.4 or less.

[0177] The ratio between the length of the second plug and the length of the aerosol generating material plug may be 0.15 to 0.5. The ratio between the length of the second plug and the length of the aerosol generating material plug may be 0.2 to 0.5. The ratio between the length of the second plug and the length of the aerosol generating material plug may be 0.3 to 0.5.

[0178] The outer wrapper may be arranged to cover at least 20%, or at least 50%, or at least 80%, or at least 90%, or at least 95%, or the entire length of the aerosol-generating article.

[0179] The outer wrapper may completely wrap or enclose the aerosol generating article along at least 50% of the length of the aerosol generating article. The outer wrapper may completely wrap or enclose the aerosol generating article along at least 75% of the length of the aerosol generating article. The outer wrapper may completely wrap or enclose the aerosol generating article along at least 90% of the length of the aerosol generating article. Preferably, the outer wrapper may completely wrap or enclose the aerosol generating article along 100% of the length of the aerosol generating article.

[0180] An outer wrapper may define or form an outer surface of an aerosol generating article. An outer wrapper may define or form a substantially flat upper surface of an aerosol generating article. An outer wrapper may define or form a substantially flat lower surface of an aerosol generating article. An outer wrapper may define or form a first side surface of an aerosol generating article. An outer wrapper may define or form a second side surface of an aerosol generating article. Preferably, the outer wrapper defines or forms a substantially flat upper surface of an aerosol generating article, a substantially flat lower surface of an aerosol generating article, a first side surface of an aerosol generating article, and a second side surface of an aerosol generating article.

[0181] The outer wrapper may define or form all longitudinal outer surfaces of the aerosol-generating article. That is, the outer wrapper may define or form all outer surfaces of the aerosol-generating article extending in the x and y directions, or in the x and z directions. The outer wrapper may define or form at least 99% of the surface area of ​​all longitudinal outer surfaces of the aerosol-generating article.

[0182] The outer wrapper may be limited to defining or forming the upper surface and the lower surface of the aerosol-generating article, such that the lateral portion of the aerosol-generating article between the upper surface and the lower surface is not defined or formed by the outer wrapper.

[0183] The outer wrapper may be limited to extending no more than 80% of the circumference of the aerosol-generating article, no more than 75% of the circumference of the aerosol-generating article, no more than 60% of the circumference of the aerosol-generating article, or no more than 50% of the circumference of the aerosol-generating article.

[0184] The outer wrapper may have a length greater than the length of the wrapper of the aerosol generating material plug. The outer wrapper may wrap around or encircle the entire length of the aerosol generating material.

[0185] The outer wrapper may surround or enclose only the downstream or upstream portion of the first plug. For example, when the first plug is upstream of the aerosol generating material plug, the outer wrapper may surround or enclose only the downstream portion of the first plug, and the upstream portion of the first plug may extend past the outer wrapper. As another example, when the first plug is downstream of the aerosol generating material plug, the outer wrapper may surround or enclose only the upstream portion of the first plug, and the downstream portion of the first plug may extend past the outer wrapper.

[0186] The outer wrapper may wrap around or encircle at least 10% of the length of the first plug. The outer wrapper may wrap around or encircle at least 25% of the length of the first plug. The outer wrapper may wrap around or encircle at least 50% of the length of the first plug. The outer wrapper may wrap around or encircle at least 75% of the length of the first plug. The outer wrapper may wrap around or encircle the entire length of the first plug.

[0187] The outer wrapper may wrap or encircle up to 75% of the length of the first plug. The outer wrapper may wrap or encircle up to 50% of the length of the first plug. The outer wrapper may wrap or encircle up to 25% of the length of the first plug.

[0188] The outer wrapper may surround or enclose only the downstream or upstream portion of the second plug. For example, when the second plug is upstream of the aerosol generating material plug, the outer wrapper may surround or enclose only the downstream portion of the second plug, and the upstream portion of the second plug may extend past the outer wrapper. As another example, when the second plug is downstream of the aerosol generating material plug, the outer wrapper may surround or enclose only the upstream portion of the second plug, and the downstream portion of the second plug may extend past the outer wrapper.

[0189] The outer wrapper may wrap around or encircle at least 10% of the length of the second plug. The outer wrapper may wrap around or encircle at least 25% of the length of the second plug. The outer wrapper may wrap around or encircle at least 50% of the length of the second plug. The outer wrapper may wrap around or encircle at least 75% of the length of the second plug. The outer wrapper may wrap around or encircle the entire length of the second plug.

[0190] The outer wrapper may wrap or encircle up to 75% of the length of the second plug. The outer wrapper may wrap or encircle up to 50% of the length of the second plug. The outer wrapper may wrap or encircle up to 25% of the length of the second plug.

[0191] The outer wrapper may include or be made of cellulose material. The outer wrapper may include or be made of organic or plant material such as tobacco, mint, tea, and cloves.

[0192] The outer wrapper may include or be made of a hygroscopic material. The hygroscopic material may include one or more materials selected from a list consisting of polyvinyl alcohol, silicone, or combinations thereof. For example, the outer wrapper may include a surface treatment of the hygroscopic material. The hygroscopic material may be dispersed within the outer wrapper.

[0193] The outer wrapper may be a sheet of material. The outer wrapper may include or be made of a sheet of cellulose material such as paper. The outer wrapper may include or be made of a sheet of organic material or a sheet of plant material. The outer wrapper may include or be made of a sheet of homogenized tobacco material.

[0194] The outer wrapper may include one or more elements selected from a list consisting of ceramic fibers or particles, metal strips or particles, or a combination thereof.

[0195] The outer wrapper may have a thickness of 10 μm to 200 μm. The outer wrapper may have a thickness of 10 μm to 150 μm. The outer wrapper may have a thickness of 10 μm to 100 μm. The outer wrapper may have a thickness of 10 μm to 75 μm. The outer wrapper may have a thickness of 10 μm to 50 μm. The outer wrapper may have a thickness of 10 μm to 40 μm. The outer wrapper may have a thickness of 15 μm to 40 μm. The outer wrapper may have a thickness of 20 μm to 40 μm. Preferably, the outer wrapper may have a thickness of about 37 μm.

[0196] The outer wrapper may have a basis weight of 10 to 150 g / m2. The outer wrapper may have a basis weight of 10 to 75 g / m2. The outer wrapper may have a basis weight of 10 to 50 g / m2. The outer wrapper may have a basis weight of 20 to 40 g / m2. Preferably, the outer wrapper has a basis weight of about 30 g / m2.

[0197] The outer wrapper, or a part of the outer wrapper, may be air permeable.

[0198] The outer wrapper, or a part of the outer wrapper, may have an air permeability of about 10 Coresta units to about 200 Coresta units. The outer wrapper, or a part of the outer wrapper, may have an air permeability of about 20 Coresta units to about 150 Coresta units. The outer wrapper, or a part of the outer wrapper, may have an air permeability of about 30 Coresta units to about 100 Coresta units. The outer wrapper, or a part of the outer wrapper, may have an air permeability of about 40 Coresta units to about 80 Coresta units.

[0199] The outer wrapper, or a part of the outer wrapper, may have an air permeability of about 5,000 Coresta units to about 12,000 Coresta units. The outer wrapper, or a part of the outer wrapper, may have an air permeability of about 7,500 Coresta units to about 12,000 Coresta units.

[0200] The aerosol generating material plug may be located closer to the downstream end of the aerosol generating article than to the upstream end of the aerosol generating article. Alternatively, the aerosol generating material plug may be located closer to the upstream end of the aerosol generating article than to the downstream end of the aerosol generating article.

[0201] The thickness of the aerosol-generating article may be less than 50% of the length of the aerosol-generating article.

[0202] The thickness of the aerosol-generating article may be less than 50% of the width of the aerosol-generating article. The thickness of the aerosol-generating article may be less than 40% of the width of the aerosol-generating article. The thickness of the aerosol-generating article may be less than 35% of the width of the aerosol-generating article. The thickness of the aerosol-generating article may be less than 30% of the width of the aerosol-generating article. The thickness of the aerosol-generating article may be less than 25% of the width of the aerosol-generating article. The thickness of the aerosol-generating article may be less than 20% of the width of the aerosol-generating article.

[0203] The thickness of the aerosol-generating article may be constant over 90% of the width of the aerosol-generating article. The thickness of the aerosol-generating article may be constant over 95% of the width of the aerosol-generating article. The thickness of the aerosol-generating article may be constant over 99% of the width of the aerosol-generating article. As used herein, when referring to the thickness of the aerosol-generating article, the term "constant" is used to mean that the thickness varies by ±10% or less, preferably ±5% or less.

[0204] The aerosol generating article may have a substantially rectangular cross-section. The cross-section of the aerosol generating article may be substantially rectangular along at least 90% of the length of the aerosol generating article. The cross-section of the aerosol generating article may be substantially rectangular along at least 95% of the length of the aerosol generating article. The cross-section of the aerosol generating article may be substantially rectangular along substantially the entire length of the aerosol generating article.

[0205] All internal angles of one or any cross-section of an aerosol-generating article may be 85 degrees or greater. All internal angles of one or any cross-section of an aerosol-generating article may be 90 degrees or greater. All internal angles of one or any cross-section of an aerosol-generating article may be 115 degrees or greater.

[0206] All internal angles of one or any cross-section of an aerosol-generating article may be 120 degrees or less. All internal angles of one or any cross-section of an aerosol-generating article may be 115 degrees or more. All internal angles of one or any cross-section of an aerosol-generating article may be 105 degrees or more. All internal angles of one or any cross-section of an aerosol-generating article may be 95 degrees or more.

[0207] All internal angles of one or any cross-section of the aerosol-generating article may be 85 to 120 degrees. All internal angles of one or any cross-section of the aerosol-generating article may be 85 to 115 degrees. All internal angles of one or any cross-section of the aerosol-generating article may be 85 to 105 degrees. All internal angles of one or any cross-section of the aerosol-generating article may be 85 to 95 degrees.

[0208] The thickness of the aerosol generating article may be constant over at least 90% of the length of the aerosol generating article. The thickness of the aerosol generating article may be constant over at least 95% of the length of the aerosol generating article. The thickness of the aerosol generating article may be constant over at least 99% of the length of the aerosol generating article. The thickness of the aerosol generating article may be constant over the entire length of the aerosol generating article.

[0209] Aerosol-generating articles may have a longitudinal cross-section that is substantially rectangular.

[0210] The aerosol generating article can have a right-angled prism shape. The aerosol generating article can have a cube shape. The aerosol generating article can have a rectangular prism shape. The aerosol generating article can have a right-angled rectangular prism shape.

[0211] An aerosol generating item may have an airflow path defined through the aerosol generating item between the upstream and downstream ends of the aerosol generating item. An aerosol generating item may have an airflow path extending through the aerosol generating item. An aerosol generating item may have an airflow path defined through the aerosol generating item in the x / y plane from one side of the aerosol generating item to the other side of the aerosol generating item.

[0212] The aerosol generating article may have an inhalation resistance (RTD) of less than 20 mm H2O, for example, less than 10 mm H2O, in the direction of the airflow path. Preferably, the aerosol generating article has an RTD of less than 20 mm H2O, for example, less than 10 mm H2O, in at least one direction in the x / y plane of the aerosol generating article.

[0213] The aerosol generating article may have a length (e.g., x dimension) of 10 mm to 100 mm, or 10 mm to 50 mm, for example 12 mm to 30 mm, for example 14 mm to 26 mm, for example 16 mm to 24 mm, for example 18 mm to 22 mm, for example about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.

[0214] The aerosol generating article may have a width (e.g., y dimension) of 5 mm to 20 mm, e.g. 8 mm to 18 mm, e.g. 10 mm to 16 mm, e.g. 11 mm to 15 mm, e.g. 12 mm to 14 mm, e.g. about 13 mm.

[0215] The aerosol generating article may have a thickness (e.g., z-dimension) of 1 mm to 10 mm, for example 1.2 mm to 8 mm, for example 1.4 mm to 7 mm, for example 1.6 mm to 6 mm, for example 1.7 mm to 5 mm, for example about 1.7 mm, or about 4.5 mm, or about 2 mm, or about 3 mm, or about 4 mm.

[0216] According to the present disclosure, a method for manufacturing an aerosol generating substrate plug for a heated aerosol generating article is provided. The method comprises the step of providing a continuous mass of an aerosol generating substrate. The aerosol generating substrate has one or more aerosol forming agents and an aerosol forming agent content of 5% by weight or more based on dry weight. The method comprises the step of dimensioning the continuous mass of the aerosol generating substrate to have a uniform thickness over at least 90% of the width of the aerosol generating substrate and a thickness of less than 50% of the width of the aerosol generating substrate. The method comprises the step of wrapping the continuous mass of the aerosol generating substrate with a wrapper to form a continuous aerosol generating substrate plug. The wrapper has a basis weight of 20 g / m² to 200 g / m². The method comprises the step of cutting the continuous aerosol generating substrate plug into a plurality of individual aerosol generating substrate plugs. Each of the plurality of individual aerosol generating substrate plugs has a thickness and a length, and the thickness is less than 50% of the length.

[0217] The continuous mass of the aerosol generating material may be any aerosol generating material described herein. Preferably, the aerosol generating material may comprise a crushed aerosol generating material, such as tobacco chips. Preferably, one or more aerosol forming agents comprise glycerin. Preferably, the aerosol generating material comprises a binder, such as guar or carboxymethyl cellulose.

[0218] The step of dimensioning the continuous mass of the aerosol generating material may include the step of moving the continuous mass of the aerosol generating material through a contraction portion, preferably a converging contraction portion.

[0219] The wrapper may contain or be made of cellulose material. The wrapper may be a continuous sheet of material such as a continuous sheet of cellulose material. The continuous sheet of material may be supplied from a bobbin.

[0220] As used herein, the term "aerosol generating device" may refer to a device for use with an aerosol generating article to enable the generation or release of an aerosol.

[0221] As used herein, the term “aerosol generating system” refers to a combination of an aerosol generating device and one or more aerosol forming articles for use with a device. The aerosol generating system may include additional components, such as a charging unit for recharging an embedded power supply within an electrically operated or electric aerosol generating device.

[0222] As used herein, the term "aerosol-forming agent" may refer to any suitable known compound or mixture of compounds that facilitates the formation of an aerosol upon use. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-forming substrate or the aerosol-generating article.

[0223] As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salt.

[0224] As used herein with respect to the present invention, the terms "proximal," "distal," "upstream," and "downstream" are used to describe the relative positions of a component of an aerosol-generating article, or a part of a component.

[0225] As used herein, the term "longitudinal" refers to a direction corresponding to the main longitudinal axis of the aerosol generating article extending between the upstream and downstream ends of the aerosol generating article. During use, air may be drawn longitudinally through the aerosol generating article.

[0226] As used herein, the term “sheet” refers to a laminated element having a width and length substantially greater than its thickness. The width of the sheet may be greater than 10 mm, preferably greater than 20 mm or 30 mm. In certain embodiments, the sheet of material to be used to form an aerosol-forming substrate as described herein may have a thickness of 10 μm to about 1000 μm, for example, 10 μm to about 300 μm.

[0227] As used herein, the term “homogenized tobacco material” encompasses any tobacco material formed by the aggregation of particles of tobacco material. A sheet or web of homogenized tobacco material is formed by aggregating fine tobacco obtained by crushing or otherwise pulverizing one or both of tobacco leaf blades and tobacco leaf stalks. Additionally, the homogenized tobacco material may contain trace amounts of one or more of tobacco powder, tobacco fines, and other fine tobacco by-products formed during the processing, handling, and delivery of tobacco. A sheet of homogenized tobacco material may be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0228] The term “cast leaf” is used herein to refer to a product produced by a casting process based on casting a slurry comprising plant particles (e.g., clove particles, or a mixture of tobacco particles and clove particles) and a binder (e.g., guar gum) onto a supporting surface, such as a belt conveyor, drying the slurry, and removing the dried sheet from the supporting surface. Examples of casting or cast leaf processes are described, for instance, in US-A-5,724,998 for the production of cast leaf tobacco. In a cast leaf process, particulate plant material is produced by pulverizing, grinding, or crushing a portion of a plant. Particles produced from one or more plants are mixed with a liquid component, typically water, to form a slurry. Other components within the slurry may include fibers, a binder, and an aerosol-forming agent. The particulate plant material may aggregate in the presence of a binder. The slurry is cast onto a supporting surface and dried to become a sheet of homogenized plant material. Preferably, the homogenized plant material used in the article according to the present invention can be produced by casting. Such homogenized plant material may comprise aggregated particulate plant material.

[0229] As used herein, suction resistance is expressed in pressure units "mm H2O" or "mm WG" or "mm of water gauge" and can be measured according to ISO 6565:2002.

[0230] As used herein, the term "bulk density" refers to the total weight of an aerosol generating material divided by the bulk volume of the aerosol generating material.

[0231] As used herein, the term "packing density" refers to the ratio of the total volume of components, such as solid and liquid components of the aerosol generating substrate, to the bulk volume of the aerosol generating substrate.

[0232] A non-limiting, non-comprehensive list of embodiments is provided below. Any one or more features of these embodiments may be combined with any one or more features of other embodiments, embodiments, or aspects described herein.

[0233] Example 1. As an aerosol generating material plug for a heated aerosol generating article, the aerosol generating material plug is:

[0234] As an aerosol generating substrate, the aerosol generating substrate comprises one or more aerosol forming agents and an aerosol forming agent content of 5% by weight or more based on dry weight;

[0235] It includes a wrapper having a basis weight of 20 g / m2 to 200 g / m2, wherein the wrapper surrounds the aerosol generating substrate,

[0236] The thickness of the aerosol generating material plug is less than 50% of the length of the aerosol generating material plug, the thickness of the aerosol generating material plug is less than 50% of the width of the aerosol generating material plug, and the thickness of the aerosol generating material plug is constant over at least 90% of the width of the aerosol generating material plug.

[0237] Example 2. In Example 1, the aerosol generating material plug comprises a substantially flat upper surface defined by a length extending in the x-direction and a width extending in the y-direction, and the aerosol generating material plug comprises a substantially flat lower surface defined by a length extending in the x-direction and a width extending in the y-direction.

[0238] Example 3. An aerosol generating material plug in Example 1 or Example 2, wherein the thickness of the aerosol generating material plug is less than 40% of the width of the aerosol generating material plug, or the thickness of the aerosol generating material plug is less than 30% of the width of the aerosol generating material plug, or the thickness of the aerosol generating material plug is less than 20% of the width of the aerosol generating material plug.

[0239] Example 4. In any one of the prior embodiments, the thickness of the aerosol generating material plug is constant over at least 95% of the width of the aerosol generating material plug, or the thickness of the aerosol generating material plug is constant over at least 99% of the width of the aerosol generating material plug.

[0240] Example 5. In any one of the prior embodiments, the aerosol generating material plug has a substantially rectangular cross section.

[0241] Example 6. An aerosol generating material plug, wherein in any one of the previous embodiments, all internal angles of one or any cross-section of the aerosol generating material plug are 85 to 95 degrees.

[0242] Example 7. In any one of the previous embodiments, the aerosol generating material plug is an aerosol generating material plug having a rectangular prism shape.

[0243] Example 8. An aerosol generating substrate plug, wherein in any one of the prior embodiments, the wrapper has a basis weight of 35 g / m2 or more, or the wrapper has a basis weight of 40 g / m2 or more, or the wrapper has a basis weight of 45 g / m2 or more, or the wrapper has a basis weight of 50 g / m2 or more.

[0244] Example 9. An aerosol generating substrate plug, wherein in any one of the previous embodiments, the wrapper has a basis weight of 120 g / m2 or less, or the wrapper has a basis weight of 100 g / m2 or less.

[0245] Example 10. In any one of the previous embodiments, the wrapper is an aerosol generating material plug having a length substantially equal to the length of the aerosol generating material.

[0246] Example 11. In any one of the prior embodiments, the wrapper has a length substantially equal to the length of the aerosol generating material plug.

[0247] Example 12. In any one of the prior embodiments, the wrapper defines or forms a substantially flat upper surface of the aerosol generating material plug, a substantially flat lower surface of the aerosol generating material plug, a first side surface of the aerosol generating material plug, and a second side surface of the aerosol generating material plug.

[0248] Example 13. In any one of the prior embodiments, the wrapper defines or forms at least 60% of the outer surface area of ​​the aerosol generating substrate plug, or the wrapper defines or forms at least 70% of the outer surface area of ​​the aerosol generating substrate plug.

[0249] Example 14. In any one of the previous embodiments, the wrapper forms an open end tube, and the aerosol generating material is located within the open end tube, an aerosol generating material plug.

[0250] Example 15. In any one of the previous embodiments, the aerosol generating material is an aerosol generating material plug exposed at one or both of the distal end and the proximal end of the aerosol generating material plug.

[0251] Example 16. In any one of the prior embodiments, the wrapper comprises an overlapping region in which a first portion of the wrapper overlaps with a second portion of the wrapper, an aerosol generating material plug.

[0252] Example 17. In Example 16, the opposing longitudinal edges of the wrapper overlap to form the overlapped region, an aerosol generating substrate plug.

[0253] Example 18. An aerosol generating material plug in Example 16 or 17, wherein the overlapping region is located on the upper surface of the aerosol generating material plug or the overlapping region is located on the lower surface of the aerosol generating material plug.

[0254] Example 19. An aerosol generating substrate plug, wherein in any one of Examples 16 to 18, the overlapping region comprises a first surface of the wrapper coupled to a second surface of the wrapper.

[0255] Example 20. An aerosol generating substrate plug, wherein in any one of Examples 16 to 19, the overlapping region comprises an inner surface of the wrapper coupled to an outer surface of the wrapper.

[0256] Example 21. In Example 20, the overlapping region comprises an aerosol generating substrate plug including a wrap seal.

[0257] Example 22. An aerosol generating substrate plug, wherein in any one of Examples 16 to 19, the overlapping region comprises the inner surface of the wrapper coupled to the inner surface of the wrapper.

[0258] Example 23. In Example 22, the overlapping region comprises an aerosol generating substrate plug including a pin seal.

[0259] Example 24. An aerosol generating substrate plug in Examples 16 to 23, wherein the surface of the wrapper within the overlapping region is bonded with an adhesive.

[0260] Example 25. An aerosol generating substrate plug in Examples 16 to 24, wherein the surface of the wrapper within the overlapping region is bonded by a strip or adhesive line.

[0261] Example 26. In Example 25, the strip or the adhesive line is extended in the longitudinal direction, an aerosol generating substrate plug.

[0262] Example 27. In Example 25 or 26, the strip or adhesive line has a length of 90% to 100% of the length of the aerosol generating substrate plug.

[0263] Example 28. An aerosol generating substrate plug, wherein in any one of Examples 25 to 27, the strip or the adhesive line has a length substantially equal to the length of the aerosol generating substrate plug.

[0264] Example 29. An aerosol generating substrate plug in any one of Examples 25 to 28, wherein the strip or adhesive line extends from the distal end of the aerosol generating substrate plug to the proximal end of the aerosol generating substrate plug.

[0265] Example 30. In any one of the previous embodiments, the wrapper is an aerosol generating substrate plug that is in physical contact with the aerosol generating substrate.

[0266] Example 31. In any one of the previous embodiments, an aerosol generating material plug in which the inner surface of the wrapper is in physical contact with the entire circumference of the aerosol generating material.

[0267] Example 32. In any one of the previous embodiments, the wrapper comprises one or more flavoring agents, an aerosol generating substrate plug.

[0268] Example 33. In any one of the previous embodiments, the wrapper comprises one or more aerosol-forming agents, an aerosol-generating substrate plug.

[0269] Example 34. In any one of the previous embodiments, the wrapper comprises or is made of a sheet of a cellulose material such as paper, an aerosol generating substrate plug.

[0270] Example 35. In any one of the prior embodiments, the wrapper is a first wrapper, and the aerosol generating material plug comprises a second wrapper.

[0271] Example 36. In Example 35, the first wrapper is in physical contact with the second wrapper, an aerosol generating substrate plug.

[0272] Example 37. In Example 35 or 36, the second wrapper comprises or is made of a metal material such as aluminum, an aerosol generating substrate plug.

[0273] Example 38. In any one of the prior embodiments, the aerosol generating material is an aerosol generating material plug that extends substantially over the entire length of the aerosol generating material plug.

[0274] Example 39. In any one of the previous embodiments, the aerosol generating material is an aerosol generating material plug having a mass of 90% or more of the mass of the aerosol generating material plug.

[0275] Example 40. In any one of the previous embodiments, the aerosol generating material is an aerosol generating material plug having a mass of 100 mg to 250 mg.

[0276] Example 41. In any one of the previous embodiments, the aerosol generating substrate is an aerosol generating substrate plug having a bulk density of 0.05 mg / mm³ to 0.5 mg / mm³.

[0277] Example 42. In any one of the previous embodiments, the aerosol generating substrate is an aerosol generating substrate plug having a packing density of 0.3 to 0.9.

[0278] Example 43. In any one of the previous embodiments, the aerosol generating substrate comprises a homogenized plant material such as a homogenized tobacco material, an aerosol generating substrate plug.

[0279] Example 44. In any one of the previous embodiments, the aerosol generating substrate comprises an aerosol generating substrate plug comprising a crushed aerosol generating substrate.

[0280] Example 45. In any one of the previous embodiments, the aerosol generating substrate comprises an aerosol generating substrate plug including a sheet of an aerosol generating material.

[0281] Example 46. An aerosol generating article comprising an aerosol generating material plug, a first plug, and an outer wrapper according to any one of the prior embodiments.

[0282] Example 47. In Example 46, the outer wrapper is an aerosol generating article surrounding the first plug and the aerosol generating substrate plug.

[0283] Example 48. In Example 46 or 47, the aerosol generating article comprises a second plug.

[0284] Example 49. In Example 48, the outer wrapper surrounds the first plug, the second plug, and the aerosol generating material plug, forming an aerosol generating article.

[0285] Example 50. In Example 48 or 49, the first plug, the second plug, and the aerosol generating material plug are aligned axially in the longitudinal direction.

[0286] Example 51. In any one of Examples 48 to 50, the aerosol generating article, wherein the aerosol generating material plug is located between the first plug and the second plug.

[0287] Example 52. A method for manufacturing the aerosol generating substrate plug according to any one of Examples 1 to 45, wherein the method comprises:

[0288] A step of providing a continuous mass of an aerosol generating substrate, wherein the aerosol generating substrate comprises one or more aerosol forming agents and has an aerosol forming agent content of 5% by weight or more based on dry weight;

[0289] A step of dimensioning a continuous mass of the aerosol generating substrate such that it has a constant thickness over at least 90% of the width of the aerosol generating substrate and a thickness of less than 50% of the width of the aerosol generating substrate;

[0290] A step of surrounding a continuous mass of the aerosol generating substrate with a wrapper to form a continuous aerosol generating substrate plug, wherein the wrapper has a basis weight of 20 g / m2 to 200 g / m2; and

[0291] A method comprising the step of cutting the continuous aerosol generating material plug into a plurality of individual aerosol generating material plugs, wherein each of the plurality of individual aerosol generating material plugs has a thickness and a length, and the thickness is less than 50% of the length.

[0292] Example 53. Brief explanation of the drawing

[0293] Now, embodiments will be further described with reference to the drawings. FIG. 1 shows a perspective view of a first embodiment of an aerosol generating material plug according to the present disclosure; FIG. 2 shows a plan view of the aerosol generating device plug of FIG. 1; FIG. 3 illustrates a cross-sectional view of a second embodiment of an aerosol generating substrate plug according to the present disclosure; FIG. 4 illustrates a cross-sectional view of a third embodiment of an aerosol generating substrate plug according to the present disclosure; FIG. 5 illustrates an exploded view of a first embodiment of an aerosol generating article according to the present disclosure; FIG. 6 illustrates an exploded view of a second embodiment of an aerosol-generating article according to the present disclosure; FIG. 7 illustrates a perspective view of a first embodiment of an aerosol generating article according to the present disclosure; and FIG. 8 illustrates a perspective view of a third embodiment of an aerosol generating article according to the present disclosure. Specific details for implementing the invention

[0294] FIG. 1 illustrates an aerosol generating material plug (10) for a heated aerosol generating article (1). The aerosol generating material plug (10) includes an aerosol generating material (20) and a wrapper (30).

[0295] The aerosol generating material plug (10) comprises a substantially flat upper surface (11) defined by a length extending in the x-direction and a width extending in the y-direction. The aerosol generating material plug (10) comprises a substantially flat lower surface (12) defined by a length extending in the x-direction and a width extending in the y-direction. The substantially flat upper surface (11) and the substantially flat lower surface (12) are spaced apart from each other by a thickness defined in the z-direction. The substantially flat upper surface (11) and the substantially flat lower surface (12) are parallel to each other.

[0296] The aerosol generating material plug (10) includes a substantially flat first side surface (13) that extends substantially from a substantially flat upper surface (11) to a substantially flat lower surface (12). The aerosol generating material plug (10) includes a substantially flat second side surface (14) that extends substantially from a substantially flat upper surface (11) to a substantially flat lower surface (12). The substantially flat first side surface (13) is positioned opposite to and parallel to the substantially flat second side surface (14).

[0297] The aerosol generating material plug (10) has a rectangular shape, and the thickness of the aerosol generating material plug (10) is constant over the entire width of the aerosol generating material plug (10), thereby providing an aerosol generating material plug (10) having a substantially rectangular cross section (in the y / z plane). The aerosol generating material plug (10) has a length of 26 mm, a width of 8 mm, and a thickness of 3 mm.

[0298] The wrapper (30) surrounds the aerosol generating substrate (20). The wrapper (30) forms a substantially flat upper surface (11) of the aerosol generating substrate plug (10), a substantially flat lower surface (12) of the aerosol generating substrate plug (10), a first side surface (13) of the aerosol generating substrate plug (10), and a second side surface (14) of the aerosol generating substrate plug (10).

[0299] The wrapper (30) is a sheet of cellulose material having a basis weight of about 40 g / m2 and a thickness of about 40 μm. The wrapper (30) has substantially the same length as the aerosol generating substrate (20). The wrapper (30) does not completely surround the aerosol generating substrate (20), but instead the aerosol generating substrate (20) is exposed at both the proximal end (15) and the distal end (16) of the aerosol generating substrate plug (10).

[0300] The aerosol generating material (20) is in the form of a tobacco stick, contains an aerosol forming agent, namely glycerin, and has an aerosol forming agent content of about 5% by weight based on dry weight. The aerosol generating material (20) extends from the proximal end (15) of the aerosol generating material plug (10) to the distal end (16), and thus extends along the entire length of the aerosol generating material plug (10).

[0301] The aerosol generating material (20) has a bulk density of about 0.24, a packing density of about 0.80, a density of about 0.3 g / cm³, and a mass of about 144 mg.

[0302] FIG. 2 illustrates a planar view of the aerosol generating material plug (10) of FIG. 1, and in particular, a substantially flat upper surface (11) of the aerosol generating material plug (10) is illustrated.

[0303] The wrapper (30) includes an overlapping region (31) in which a first portion of the wrapper (30) overlaps with a second portion of the wrapper (30). More specifically, opposing longitudinal edges (32) of the wrapper (30) overlap to form a wrap seal. The inner surface of the wrapper (30) is bonded to the outer surface of the wrapper (30) by an adhesive line (33), namely guar gum. The adhesive line (33) extends longitudinally from the proximal end (15) of the aerosol generating material plug (10) to the distal end (16) of the aerosol generating material plug (10).

[0304] FIG. 3 illustrates a cross-section (17) of a second embodiment of an aerosol generating material plug (10). The aerosol generating material plug (10) is similar to the aerosol generating material plug (10) of FIG. 1 and FIG. 2. However, in this embodiment, the aerosol generating material (20) comprises a wavy sheet of homogenized tobacco material including a plurality of parallel wavy folds. The plurality of parallel wavy folds form a plurality of longitudinally extending channels (21) that extend along the entire length of the aerosol generating material plug (10).

[0305] FIG. 4 illustrates a cross section (17) of a third embodiment of an aerosol generating substrate plug (10). In this embodiment, the thickness of the aerosol generating substrate plug (10) is not uniform over the entire width of the aerosol generating substrate plug (10). This is because the cross section (17) has rounded corners. However, the radius of the rounded corners ensures that the thickness of the aerosol generating substrate plug (10) is uniform over at least 90% of the width of the aerosol generating substrate plug (10). Additionally, in this embodiment, the aerosol generating substrate (20) comprises a porous substrate impregnated with a liquid aerosol generating medium.

[0306] FIG. 5 illustrates an exploded view of a first embodiment of an aerosol generating article (1). The aerosol generating article (1) includes the aerosol generating material plug (10), the first plug (40), the second plug (50), and the outer wrapper (60) of FIG. 1.

[0307] As illustrated in FIG. 7, an outer wrapper (60) surrounds the first plug (40), the second plug (50), and the aerosol generating material plug (10). The aerosol generating article (1) comprises a substantially flat upper surface (2) defined by a length extending in the x-direction and a width extending in the y-direction. The aerosol generating article (1) comprises a substantially flat lower surface (3) defined by a length extending in the x-direction and a width extending in the y-direction. The substantially flat upper surface (2) and the substantially flat lower surface (3) are spaced apart from each other by a thickness defined in the z-direction. The substantially flat upper surface (2) and the substantially flat lower surface (3) are parallel to each other.

[0308] The aerosol generating article (1) includes a substantially flat first side surface (4) extending substantially from a substantially flat upper surface (2) to a substantially flat lower surface (3). The aerosol generating article (1) includes a substantially flat second side surface (5) extending substantially from a substantially flat upper surface (2) to a substantially flat lower surface (3). The substantially flat first side surface (4) is positioned opposite to and parallel to the substantially flat second side surface (5).

[0309] The aerosol generating article (1) has a rectangular shape, and the thickness of the aerosol generating article (1) is constant over the entire width of the aerosol generating article (1), thereby providing an aerosol generating article (1) having a substantially rectangular cross section (in the y / z plane). The aerosol generating article (1) has a length of 38 mm, a width of 8.2 mm, and a thickness of 3.2 mm.

[0310] The first plug (40), the second plug (50), and the aerosol generating material plug (10) are aligned axially in the longitudinal direction. The first plug (40) is located upstream of the aerosol generating material plug (10) and the second plug (50) is located downstream of the aerosol generating material plug (10) so that the aerosol generating material plug (10) is positioned between the first plug (40) and the second plug (50). More specifically, the first plug (40) is located at the extreme upstream end of the aerosol generating article (1) and defines the upstream end wall or distal end wall of the aerosol generating article (1), and the second plug (50) is located at the extreme downstream end of the aerosol generating article (1) and defines the downstream end wall or proximal end wall of the aerosol generating article (1).

[0311] The first plug (40) is located adjacent to the aerosol generating material plug (10) but spaced about 2 mm apart from the aerosol generating material plug (10), forming an empty cavity between the first plug (40) and the aerosol generating material plug (10). Similarly, the second plug (50) is located adjacent to the aerosol generating material plug (10) but spaced about 2 mm apart from the aerosol generating material plug (10), forming another empty cavity between the second plug (50) and the aerosol generating material plug (10). However, in another embodiment, one or both of the first plug (40) and the second plug (50) may be in contact with the aerosol generating material plug (10).

[0312] The first plug (40) is made entirely of cellulose material and includes an aperture (41) defined by the length of the first plug (40). The first plug (40) has a length of about 4 mm. The first plug (40) has a width equal to the width of the aerosol generating material plug (10) and a thickness equal to the thickness of the aerosol generating material plug (10).

[0313] The second plug (50) is made entirely of cellulose material and includes an aperture (51) defined by the length of the second plug (50). The second plug (50) has a length of about 4 mm. The second plug (50) has a width equal to the width of the aerosol generating material plug (50) and a thickness equal to the thickness of the aerosol generating material plug (10).

[0314] The first plug (40) and the second plug (50) substantially do not contain any aerosol-generating compound.

[0315] The outer wrapper (60) is a sheet of cellulose material having a thickness of about 100 μm. The outer wrapper (60) has a length equal to the length of the aerosol generating article (1) and surrounds the entire length of the aerosol generating article (1).

[0316] FIG. 6 illustrates an exploded view of a second embodiment of an aerosol generating article (1). The aerosol generating article (1) is similar to the aerosol generating article (1) of FIG. 5, except for the configuration of the first plug (40) and the second plug (50). In this example, the first plug (40) and the second plug (50) comprise a corrugated sheet of cellulose material (42, 52) forming a plurality of longitudinally extending channels (43, 53). The plurality of longitudinally extending channels (43, 53) extend from the upstream end of each plug to the downstream end of each plug. The first plug (40) and the second plug (50) also comprise a peripheral wall surface on which the respective corrugated sheet of cellulose material (42, 52) is located.

[0317] FIG. 7 illustrates the aerosol generating article (1) of FIG. 5.

[0318] FIG. 8 illustrates a third embodiment of an aerosol generating article (1). The aerosol generating article (1) is similar to the aerosol generating article (1) of FIG. 5. However, in this embodiment, the first plug (40) has a length of about 7 mm and forms the curved distal end surface of the aerosol generating article (1). The outer wrapper (60) also surrounds only the downstream portion of the first plug (40), and in particular, the outer wrapper (60) surrounds only 4 mm of the length of the first plug (40). Similarly, the second plug (50) has a length of about 7 mm and forms the curved proximal end surface of the aerosol generating article (1). The outer wrapper (60) also surrounds only the upstream portion of the second plug (50), and in particular, the outer wrapper (60) surrounds only 4 mm of the length of the second plug (50).

[0319] In each of the examples of FIGS. 5 through 8, the first plug (40) and the second plug (50) have similar configurations. However, in other examples, the first plug (40) and the second plug (50) may each have different configurations. For example, the first plug (40) may have the configuration of FIG. 5, while the second plug (50) may have the configuration of FIG. 6. As another example, the first plug (40) or the second plug (50) may be substantially air impermeable. Other combinations are possible.

[0320] For the purposes of this description and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, etc., shall be understood in all cases to be modified by the term “about.” Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein. Accordingly, in this context, the number A is understood as 5% of A ± A.

Claims

Claim 1 An aerosol generating substrate plug for a heated aerosol generating article, wherein the aerosol generating substrate plug comprises: an aerosol generating substrate, wherein the aerosol generating substrate comprises one or more aerosol forming agents and an aerosol forming agent content of 5% by weight or more based on dry weight; and a wrapper having a basis weight of 20 g / m2 to 200 g / m2, wherein the wrapper surrounds the aerosol generating substrate, and the thickness of the aerosol generating substrate plug is less than 50% of the length of the aerosol generating substrate plug, the thickness of the aerosol generating substrate plug is less than 50% of the width of the aerosol generating substrate plug, and the thickness of the aerosol generating substrate plug is constant over at least 90% of the width of the aerosol generating substrate plug. Claim 2 In claim 1, the aerosol generating material plug has a substantially rectangular cross section. Claim 3 In claim 1 or 2, the wrapper is an aerosol generating substrate plug having a basis weight of 40 g / m2 or more. Claim 4 In any one of claims 1 to 3, the aerosol generating material plug, wherein the wrapper has a length substantially equal to the length of the aerosol generating material. Claim 5 An aerosol generating substrate plug according to any one of claims 1 to 4, wherein the wrapper defines or forms at least 70% of the outer surface area of ​​the aerosol generating substrate plug. Claim 6 In any one of claims 1 to 5, the aerosol generating material is an aerosol generating material plug exposed at one or both of the distal end and the proximal end of the aerosol generating material plug. Claim 7 An aerosol generating material plug according to any one of claims 1 to 6, wherein the aerosol generating material plug comprises a substantially flat upper surface defined by a length extending in the x-direction and a width extending in the y-direction, and the aerosol generating material plug comprises a substantially flat lower surface defined by a length extending in the x-direction and a width extending in the y-direction. Claim 8 An aerosol generating material plug according to any one of claims 1 to 7, wherein the wrapper comprises an overlapping region in which a first portion of the wrapper overlaps with a second portion of the wrapper, the overlapping region comprises a first surface of the wrapper coupled to a second surface of the wrapper by a strip or adhesive line, and the strip or adhesive line has a length of 90% to 100% of the length of the aerosol generating material plug. Claim 9 An aerosol generating substrate plug according to any one of claims 1 to 8, wherein the wrapper is a sheet of material, preferably a sheet of cellulose material. Claim 10 An aerosol generating substrate plug according to any one of claims 1 to 9, wherein the wrapper is a first wrapper, and the aerosol generating substrate plug includes a second wrapper surrounding the aerosol generating substrate, wherein the second wrapper has higher thermal conductivity than the first wrapper. Claim 11 In any one of claims 1 to 10, the aerosol generating material is an aerosol generating material plug having a bulk density of 0.5 mg / mm³ or less. Claim 12 In any one of claims 1 to 11, the aerosol generating material is an aerosol generating material plug having a packing density of 0.5 to 0.

9. Claim 13 An aerosol generating material plug according to any one of claims 1 to 12, wherein the aerosol generating material comprises a crushed aerosol generating material such as a cigarette stick. Claim 14 In any one of claims 1 to 13, the aerosol generating material plug has a length of 100 mm or more. Claim 15 A method for manufacturing the aerosol generating substrate plug according to any one of claims 1 to 14, the method comprising: providing a continuous mass of an aerosol generating substrate, wherein the aerosol generating substrate comprises one or more aerosol forming agents and has an aerosol forming agent content of 5% by weight or more based on dry weight; dimensioning the continuous mass of the aerosol generating substrate such that it has a constant thickness over at least 90% of the width of the aerosol generating substrate and has a thickness of less than 50% of the width of the aerosol generating substrate; wrapping the continuous mass of the aerosol generating substrate with a wrapper to form a continuous aerosol generating substrate plug, wherein the wrapper has a basis weight of 20 g / m2 to 200 g / m2; and cutting the continuous aerosol generating substrate plug into a plurality of individual aerosol generating substrate plugs, wherein each of the plurality of individual aerosol generating substrate plugs has a thickness and a length, and the thickness is less than 50% of the length.

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