An aerosol-generating article comprising a disc

Abstract

An aerosol-generating article is provided, including: a plug of aerosol-forming substrate having an upstream end and a downstream end; a downstream segment positioned at a downstream end of the aerosol-generating article; and a disc attached to the upstream end of the plug of aerosol-forming substrate, the disc being positioned at an upstream end of the aerosol-generating article, the disc defining at least one main aperture extending through the disc and at least one airflow aperture extending through the disc, each main aperture being larger than each airflow aperture, the disc having a circular shape, and the disc being attached to the upstream end of the plug of aerosol-forming substrate by an adhesive.

Description

[0001] The present disclosure relates to an aerosol-generating article comprising a disc attached to an upstream end of a plug of aerosol-forming substrate. The present disclosure also relates to a method of forming the aerosol-generating article.

[0002] Aerosol-generating articles in which an aerosol-forming substrate, such as a tobacco-containing substrate, is heated rather than combusted, are known in the art. Typically, in such heated smoking articles an aerosol is generated by the transfer of heat from a heating element to a physically separate aerosol-forming substrate or material, which may be located in contact with, within, around, or downstream of the heating element. During use of the aerosol-generating article, volatile compounds are released from the aerosol-forming substrate by heat transfer from the heating element and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol. The aerosol-generating article may be configured for insertion of a portion of the aerosol-generating article into a chamber of an aerosol-generating device.

[0003] Some aerosol-generating devices known in the art comprise an electric heater comprising a resistive heating element that is received within a portion of the aerosol-generating article when the article is inserted into a chamber of the device. Inserting an electric heater into an aerosol-generating article may provide direct contact between the electric heater and an aerosol-forming substrate of the aerosol-generating article. Direct contact between the heater and the substrate may facilitate rapid generation of an aerosol when the heater is energised.

[0004] The release of volatile compounds from the aerosol-forming substrate during heating may result in shrinkage of the aerosol-forming substrate, which may loosen the aerosol-forming substrate within the aerosol-generating article. Therefore, in embodiments in which the electric heater is received within the aerosol-forming substrate during use, shrinkage of the aerosol-forming substrate may increase the risk of the aerosol-forming substrate, or a portion of the aerosol-forming substrate, being removed from the aerosol-generating article when the article is withdrawn from the electric heater. Removal of the aerosol-forming substrate from the aerosol-generating article results in contamination of the aerosol-generating device and creates a need to clean the aerosol-generating device. Cleaning the aerosol-generating device may impose a burden on the user and increases the risk of damaging the aerosol-generating device.

[0005] Some aerosol-generating articles known in the art have attempted to overcome such problems by modifying aerosol-generating articles to include a plug of porous material upstream of the aerosol-forming substrate. For example, some known articles include a plug of cellulose acetate tow at an upstream end of the aerosol-generating article. However, the addition of an upstream plug of cellulose acetate tow introduces a number of additional problems. Firstly, the addition of an upstream plug of cellulose acetate tow significantly increases the total length of the aerosol-generating article, which requires significant modification of existing manufacturing processes and packaging. Secondly, the addition of an upstream plug of cellulose acetate tow prevents correct positioning of the aerosol-forming substrate within the chamber of existing aerosol-generating devices, which are designed for use with aerosol-generating articles in which the aerosol-forming substrate is positioned at an upstream end of the aerosol-generating article. Therefore, the addition of an upstream plug of cellulose acetate tow prevents use of the aerosol-generating article with existing aerosol-generating devices. Thirdly, the addition of an upstream plug of cellulose acetate tow may significantly increase the resistance to draw of the aerosol-generating article, which may diminish the user experience.

[0006] Therefore, it would be desirable to provide an aerosol-generating article that reduces or eliminates the risk of contaminating an aerosol-generating device with loose aerosol-forming substrate while also avoiding the problems posed by the addition of an upstream plug of cellulose acetate tow.

[0007] According to the present disclosure there is provided an aerosol-generating article. The aerosol-generating article may comprise a plug of aerosol-forming substrate. The plug of aerosol-forming substrate may have an upstream end. The plug of aerosol-forming substrate may have a downstream end. The aerosol-generating article may comprise a downstream segment. The downstream segment may be positioned at a downstream end of the aerosol-generating article. The aerosol-generating article may comprise a disc attached to an upstream end of the plug of aerosol-forming substrate. The disc may be positioned at an upstream end of the aerosol-generating article. The disc may define at least one main aperture extending through the disc and at least one airflow aperture extending through the disc, wherein each main aperture is larger than each airflow aperture.

[0008] According to the present disclosure there is also provided an aerosol-generating article comprising a plug of aerosol-forming substrate having an upstream end and a downstream end. The aerosol-generating article also comprises a downstream segment positioned at a downstream end of the aerosol-generating article. The aerosol-generating article also comprises a disc attached to the upstream end of the plug of aerosol-forming substrate. The disc is positioned at an upstream end of the aerosol-generating article. The disc defines at least one main aperture extending through the disc and at least one airflow aperture extending through the disc, wherein each main aperture is larger than each airflow aperture.

[0009] Advantageously, providing a disc positioned at the upstream end of the aerosol-generating article may reduce or prevent the risk of aerosol-forming substrate falling out of the aerosol-generating article and contaminating an aerosol-generating device when the aerosol-generating article is withdrawn from the aerosol-generating device.

[0010] Advantageously, the disc does not provide a significant contribution to a total length of the aerosol-generating article. Therefore, the disc may be added to existing designs of aerosol-generating article without requiring significant modification of existing manufacturing machines and aerosol-generating devices. For example, aerosol-generating articles according to the present disclosure may be used with existing aerosol-generating devices designed for use with aerosol-generating articles without a disc. In contrast, the addition of an upstream plug of cellulose acetate tow to an aerosol-generating article typically requires a new design of aerosol-generating device for use with the modified aerosol-generating article.

[0011] Advantageously, the at least one main aperture extending through the disc may facilitate the insertion of at least one heater of an aerosol-generating device into the aerosol-forming substrate. In particular, when the aerosol-generating article is inserted into an aerosol-generating device, at least one heater of the aerosol-generating device may be received through the at least one main aperture. Advantageously, the at least one main aperture may eliminate the need for a heater to pierce the disc, which may reduce mechanical stresses on the heater when the aerosol-generating article is inserted into an aerosol-generating device.

[0012] Advantageously, the at least one airflow aperture may facilitate a desired airflow through the aerosol-generating article during use. For example, the number, size and position of the at least one airflow aperture may be selected to provide a desired resistance to draw that is consistent between different aerosol-generating articles.

[0013] As used herein, the term “aerosol-forming substrate” denotes a substrate capable of releasing volatile compounds upon heating, which can condense to form an aerosol.

[0014] As used herein, the term “aerosol” denotes a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. The aerosol may be visible or invisible. The aerosol may include vapours of substances that are ordinarily liquid or solid at room temperature as well as solid particles, or liquid droplets, or a combination of solid particles and liquid droplets.

[0015] As used herein, the term “aerosol-generating article” denotes an article comprising an aerosol-forming substrate. An aerosol-generating article may be disposable.

[0016] As used herein, the terms “upstream”, “downstream”, “proximal” and “distal” are used to describe the relative positions of elements, or portions of elements, of aerosol-generating articles, aerosol-generating devices and aerosol-generating systems according to the disclosure. Aerosol-generating articles as described herein comprise a proximal end through which, in use, an aerosol exits the aerosol-generating article. The proximal end may also be referred to as the mouth end. In use, a user draws on the proximal end or mouth end of the aerosol-generating article in order to inhale an aerosol generated by the aerosol-generating article. The aerosol-generating article comprises a distal end opposite the proximal end or mouth end. The proximal end or mouth end of the aerosol-generating article may also be referred to as the downstream end. The distal end of the aerosol-generating article may also be referred to as the upstream end. Components, or portions of components, of the aerosol-generating article may be described as being upstream or downstream of one another based on their relative positions between the proximal or downstream end and the distal or upstream end of the aerosol-generating article.

[0017] As used herein, the term “aerosol-generating device” denotes a device that interacts with an aerosol-forming substrate to generate an aerosol. In some examples, the aerosol-generating device heats the aerosol-forming substrate to facilitate release of volatile compounds from the substrate.

[0018] As used herein, the term “aerosol-generating system” refers to the combination of an aerosol-generating device and an aerosol-generating article.

[0019] A ratio of a maximum cross-sectional area of each main aperture to a maximum cross-sectional area of each airflow aperture may be at least 1.1 to 1, at least 1.2 to 1, at least 1.3 to 1, at least 1.4 to 1, at least 1.5 to 1, at least 1.6 to 1, at least 1.7 to 1, at least 1.8 to 1, at least 1.9 to 1, or at least 2 to 1.

[0020] The aerosol-generating article may define a longitudinal direction extending between the upstream end of the aerosol-generating article and the downstream end of the aerosol-generating article. Preferably, the cross-sectional area of each main aperture and each airflow aperture is a maximum cross-sectional area in a plane perpendicular to the longitudinal direction.

[0021] Preferably, the disc has a circular shape. Advantageously, a circular shape may facilitate the addition of the disc to existing designs of aerosol-generating article.

[0022] Preferably, the at least one main aperture comprises a main aperture positioned at the centre of the disc. Advantageously, providing a main aperture positioned at the centre of the disc may facilitate the insertion of a heater of an aerosol-generating device through the main aperture regardless of a rotational orientation of the aerosol-generating article. Preferably, the main aperture positioned at the centre of the disc is the only main aperture defined by the disc. In other words, preferably, the disc comprising only a single main aperture positioned at the centre of the disc.

[0023] The at least one airflow aperture may be a single airflow aperture. In other words, the at least one airflow aperture may comprise only one airflow aperture.

[0024] Advantageously, providing only a single airflow aperture may simplify the manufacture of the disc. Advantageously, providing only a single airflow aperture may facilitate a more accurate total airflow through the aerosol-generating article during use. For example, the manufacturing tolerance of the dimensions of a single airflow aperture may be smaller than the combined manufacturing tolerances of the dimensions of a plurality of airflow apertures.

[0025] The at least one airflow aperture may comprise a plurality of airflow apertures.

[0026] Advantageously, providing a plurality of airflow apertures may enable continued airflow through the aerosol-generating article in the event that one of the airflow apertures is blocked or otherwise obstructed.

[0027] Advantageously, providing a plurality of airflow apertures may facilitate the same total airflow through the aerosol-generating article using a plurality of smaller airflow apertures compared to a single larger airflow aperture. Advantageously, smaller airflow apertures may reduce or minimise the risk of aerosol-forming substrate falling out the aerosol-generating article through the airflow apertures.

[0028] Preferably, the plurality of airflow apertures is arranged symmetrically about the centre of the disc.

[0029] Advantageously, a plurality of airflow apertures arranged symmetrically about the centre of the disc may facilitate a uniform airflow through the aerosol-generating article during use.

[0030] Advantageously, a plurality of airflow apertures arranged symmetrically about the centre of the disc may eliminate the need to insert the aerosol-generating article into an aerosol-generating device in a particular rotational orientation. In other words, a plurality of airflow apertures arranged symmetrically about the centre of the disc may facilitate the insertion of the aerosol-generating article into an aerosol-generating device using any rotational orientation.

[0031] The plurality of airflow apertures may comprise a first row of airflow apertures arranged symmetrically about the centre of the disc and a second row of airflow apertures arranged symmetrically about the centre of the disc, wherein the second row of airflow apertures is positioned between the first row of airflow apertures and a circumferential edge of the disc. Advantageously, providing first and second rows of airflow apertures may further facilitate a uniform airflow through the aerosol-generating article during use.

[0032] The second row of airflow apertures may be aligned with the first row of airflow apertures in a circumferential direction about the centre of the disc.

[0033] The second row of airflow apertures may be offset from the first row of airflow apertures in a circumferential direction about the centre of the disc.

[0034] The plurality of airflow apertures may comprise two, three, four, five, six, seven, eight, nine, ten, eleven or twelve airflow apertures. The plurality of airflow apertures may comprise at least two airflow apertures, at least three airflow apertures, at least four airflow apertures, at least five airflow apertures, at least six airflow apertures, at least seven airflow apertures, at least eight airflow apertures, at least nine airflow apertures, at least ten airflow apertures, or at least eleven airflow apertures. The plurality of airflow apertures may comprise twelve or fewer airflow apertures, eleven or fewer airflow apertures, ten or fewer airflow apertures, nine or fewer airflow apertures, eight or fewer airflow apertures, seven or fewer airflow apertures, six or fewer airflow apertures, five or fewer airflow apertures, four or fewer airflow apertures, or three or fewer airflow apertures. The plurality of airflow apertures may comprise between two and twelve airflow apertures, between three and twelve airflow apertures, between four and twelve airflow apertures, between five and twelve airflow apertures, between six and twelve airflow apertures, between seven and twelve airflow apertures, between eight and twelve airflow apertures, between nine and twelve airflow apertures, between ten and twelve airflow apertures, or between eleven and twelve airflow apertures. The plurality of airflow apertures may comprise between two and eleven airflow apertures, between two and ten airflow apertures, between two and nine airflow apertures, between two and eight airflow apertures, between two and seven airflow apertures, between two and six airflow apertures, between two and five airflow apertures, between two and four airflow apertures, or between two and three airflow apertures.

[0035] Preferably, none of the airflow apertures is positioned at the centre of the disc. In a particularly preferred embodiment, the disc comprises only a single main aperture positioned at a centre of the disc and a plurality of airflow apertures arranged symmetrically about the single main aperture.

[0036] Each main aperture may have a circular cross-sectional shape, an elliptical cross-sectional shape, a square cross-sectional shape, or a polygonal cross-sectional shape. Preferably, each main aperture has a circular cross-sectional shape. A circular cross-sectional shape may be particularly advantageous in embodiments in which the disc comprises only a single main aperture positioned at the centre of the disc, since it may facilitate insertion of the aerosol-generating article into an aerosol-generating device with any rotational orientation.

[0037] Each main aperture may have a maximum diameter of at least 3 millimetres, at least 3.5 millimetres, at least 4 millimetres, at least 4.5 millimetres, at least 5 millimetres, at least 5.5 millimetres, or at least 6 millimetres.

[0038] Each main aperture may have a maximum cross-sectional area of at least 7 square millimetre, at least 9 square millimetres, at least 12 square millimetres, at least 15 square millimetres, at least 19 square millimetres, at least 23 square millimetres, at least 28 square millimetres, at least 30 square millimetres, or at least 35 square millimetres.

[0039] A ratio of a maximum cross-sectional area of the disc to the maximum cross-sectional area of each main aperture may be between 9:1 and 1.2:1, between 6:1 and 1.2:1, between 4.7:1 and 1.2:1, between 3.5:1 and 1.2:1, between 2.8:1 and 1.2:1, between 2.2:1 and 1.2:1, between 1.8:1 and 1.2:1, between 1.5:1 and 1.2:1, or between 1.4:1 and 1.2:1. A ratio of a maximum cross-sectional area of the disc to the maximum cross-sectional area of each main aperture may be less than 9:1, less than 6:1, less than 4.7:1, less than 3.5:1, less than 2.8:1, less than 2.2:1, less than 1.8:1, less than 1.5:1, less than 1.4:1, or less than 1.2:1. A ratio of a maximum cross-sectional area of the disc to the maximum cross-sectional area of each main aperture may be greater than 1.2:1, greater than 1.4:1, greater than 1.5:1, greater than 1.8:1, greater than 2.2:1, greater than 2.8:1, greater than 3.5:1, greater than 4.7:1, greater than 6:1, or greater than 9:1.

[0040] Each airflow aperture may have a circular cross-sectional shape, an elliptical cross-sectional shape, a square cross-sectional shape, or a polygonal cross-sectional shape.

[0041] Each airflow aperture may have a maximum diameter of less than 3 millimetres, less than 2.5 millimetres, less than 2 millimetres, less than 1.5 millimetres, or less than 1 millimetre.

[0042] Each airflow aperture may have a maximum cross-sectional area of less than 7 square millimetre, less than 6 square millimetres, less than 5 square millimetres, less than 4 square millimetres, less than 3 square millimetres, less than 2 square millimetres, or less than 1 square millimetre.

[0043] A ratio of a maximum cross-sectional area of the disc to the maximum cross-sectional area of each airflow aperture may be between 64:1 and 4:1, between 42:1 and 4:1, between 21:1 and 4:1, between 14:1 and 4:1, between 11:1 and 4:1, between 9:1 and 4:1, between 7:1 and 4:1, or between 6:1 and 4:1. A ratio of a maximum cross-sectional area of the disc to the maximum cross-sectional area of each airflow aperture may be less than 64:1, less than 42:1, less than 21:1, less than 14:1, less than 11:1, less than 9:1, less than 7:1, less than 6:1, or less than 4:1. A ratio of a maximum cross-sectional area of the disc to the maximum cross-sectional area of each airflow aperture may be greater than 4:1, greater than 6:1, greater than 7:1, greater than 9:1, greater than 11:1, greater than 14:1, greater than 21:1, greater than 42:1, or greater than 64:1.

[0044] The disc may have a thickness extending in the longitudinal direction of the aerosol-generating article. Preferably, the disc a thickness of less than 5 millimetres, less than 4 millimetres, less than 3 millimetres, less than 2 millimetres, less than 1.5 millimetres, less than 1 millimetre, or less than 0.5 millimetres.

[0045] A ratio of a length of the aerosol-generating article to the thickness of the disc may be between 160:1 and 8:1, between 140:1 and 10:1, between 120:1 and 15:1, between 100:1 and 20:1, or between 80:1 and 25:1. A ratio of a length of the aerosol-generating article to the thickness of the disc may be less than 160:1, less than 140:1, less than 120:1, less than 100:1, less than 80:1, less than 60:1, less than 40:1, less than 30:1, less than 25:1, less than 20:1, less than 15:1, less than 10:1, or less than 8:1. A ratio of a length of the aerosol-generating article to the thickness of the disc may be greater than 8:1, greater than 10:1, greater than 15:1, greater than 20:1, greater than 25:1, greater than 30:1, greater than 40:1, greater than 60:1, greater than 80:1, greater than 100:1, greater than 120:1, greater than 140:1, or greater than 160:1.

[0046] The disc may comprise one or more protrusions extending from a downstream face of the disc, wherein the one or more protrusions are received in the plug of aerosol-forming substrate. The disc may be attached to the upstream end of the plug of aerosol-forming substrate by the one or more protrusions received within the plug of aerosol-forming substrate.

[0047] The disc may be attached to the upstream end of the plug of aerosol-forming substrate by an adhesive.

[0048] The aerosol-generating article may comprise a wrapper wrapped around the plug of aerosol-forming substrate, wherein the disc is positioned outside of the wrapper. Advantageously, positioning the disc outside of the wrapper may minimise required modifications to existing manufacturing processes. For example, an aerosol-generating article may be manufactured without a disc according to existing processes, and the disc may be subsequently attached to the upstream end of the plug of aerosol-forming substrate.

[0049] Preferably, the disc is formed from a non-permeable material. In other words, preferably the disc is formed from a material so that the regions of the disc located between the at least one main aperture and the at least one airflow aperture are non-permeable.

[0050] Advantageously, a non-permeable material may facilitate at least one of a desired airflow through the aerosol-generating article and a desired resistance to draw by permitting airflow through the disc only through the at least one airflow aperture.

[0051] Advantageously, a non-permeable material may reduce or minimise the migration of liquid components from the aerosol-forming substrate through the disc and into an aerosol-generating device during use.

[0052] The non-permeable material may have an oxygen permeability of between about 800 cm3·μm / (m2·d·bar) and about 1900 cm3·μm / (m2·d·bar), between about 1100 cm3·μm / (m2·d·bar) and about 1800 cm3·μm / (m2·d·bar), or between about 1400 cm3·μm / (m2·d·bar) and about 900 cm3·μm / (m2·d·bar).

[0053] The non-permeable material may have a water permeability of between about 200 g·μm / (m2·d) and about 900 g·μm / (m2·d), between about 280 g·μm / (m2·d) and about 800 g·μm / (m2·d), or between about 400 g·μm / (m2·d) and about 700 g·μm / (m2·d).

[0054] The disc may be formed from a film material. The disc may be formed from a polymeric material. The disc may be formed from a material comprising a paper and a hydrophobic material. The hydrophobic material may be dispersed within the paper, coated on at least one surface of the paper, or dispersed within the paper and coated on at least one surface of the paper.

[0055] Suitable materials for forming the disc are known in the art and include, but are not limited to: plastic materials; ceramic materials; impregnated papers, such as papers impregnated with wax and papers impregnated with glycerol; polymer films; metallised films; laminated polymer films; laminated metallised films; and combinations thereof.

[0056] Suitable polymer films include but are not limited to, films formed from one or more of: polyimide (PI); polyaryletherketones (PAEK), such as poly ether ketone (PEK), polyether ether ketone (PEEK), and polyetherketoneetherketoneketone (PEKEKK); and fluoric polymers, such as polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), electrically conductive polyvinylidene fluoride (PVDFELS), and fluorinated ethylene propylene (FEP).

[0057] The aerosol-forming substrate may comprise tobacco. The tobacco may comprise at least one of cut filler and cast leaf.

[0058] The aerosol-forming substrate may comprise tobacco material. The aerosol-forming substrate may be a solid aerosol-forming substrate.

[0059] As used herein, the term “tobacco material” is used to describe any material comprising tobacco, including, but not limited to, tobacco leaf, tobacco rib, tobacco stem, tobacco stalk, tobacco dust, expanded tobacco, reconstituted tobacco material and homogenised tobacco material.

[0060] The aerosol-forming substrate may comprise homogenised tobacco material. As used herein, the term ‘homogenised tobacco material’ denotes a material formed by agglomerating particulate tobacco.

[0061] The aerosol-forming substrate may comprise one or more sheets of homogenised tobacco material. As used herein, the term “sheet” denotes a laminar element having a width and length substantially greater than the thickness thereof.

[0062] The one or more sheets of tobacco material may each individually have a length substantially the same as the length of the plug of aerosol-forming substrate.

[0063] The aerosol-forming substrate may comprise a gathered sheet of homogenised tobacco material. As used herein, the term ‘gathered’ is used to describe a sheet that is convoluted, folded, or otherwise compressed or constricted substantially transversely to the longitudinal axis of the aerosol-generating article.

[0064] The sheet of homogenised tobacco material may be crimped. As used herein, the term ‘crimped’ denotes a sheet having a plurality of substantially parallel ridges or corrugations. The aerosol-forming substrate may comprise a gathered, crimped sheet of homogenised tobacco material. Preferably, when the aerosol-generating article has been assembled, the substantially parallel ridges or corrugations extend along or parallel to the longitudinal axis of the aerosol-generating article.

[0065] The sheet of homogenized tobacco material may be a cast sheet.

[0066] The aerosol-forming substrate may comprise tobacco cut filler and preferably an aerosol-former content in the aerosol-forming substrate is at least about 8 percent by weight.

[0067] The aerosol-forming substrate may comprise strands of reconstituted or reprocessed tobacco. The aerosol-forming substrate may comprise crimped fibre pieces of reconstituted or reprocessed tobacco.

[0068] As used herein, the term “strand” describes an elongate element of material having a length that is substantially greater than the width and thickness thereof. The term “strand” should be considered to encompass strips, shreds and any other homogenised plant material having a similar form. The strands of homogenised plant material may be formed from a sheet of homogenised plant material, for example by cutting or shredding, or by other methods, for example, by an extrusion method.

[0069] The aerosol-forming substrate may comprise nicotine.

[0070] As used herein with reference to the invention, the term “nicotine” is used to describe nicotine, a nicotine base or a nicotine salt. The aerosol-forming substrate may comprise natural nicotine or synthetic nicotine.

[0071] The aerosol-forming substrate may comprise one or more monoprotic nicotine salts.

[0072] As used herein with reference to the invention, the term “monoprotic nicotine salt” is used to describe a nicotine salt of a monoprotic acid.

[0073] The aerosol-forming substrate may comprise at least one of one or more cellulose based agents, one or more aerosol formers, and one or more carboxylic acids.

[0074] The solid aerosol-forming substrate may be one of a solid aerosol-generating film or a solid aerosol-generating gel.

[0075] As used herein, the term “film” is used to describe a solid laminar element having a thickness that is less than the width or length thereof. The film may be self-supporting. In other words, a film may have cohesion and mechanical properties such that the film, even if obtained by casting a film-forming formulation on a support surface, can be separated from the support surface. Alternatively, the film may be disposed on a support or sandwiched between other materials. This may enhance the mechanical stability of the film.

[0076] The aerosol-forming substrate may comprise a plurality of shreds of tobacco material, such as tobacco cut filler or shreds of homogenised tobacco material.

[0077] As used herein, the term “shred” denotes an element having a length substantially greater than a width and a thickness thereof.

[0078] Shreds of homogenised tobacco material may be formed from a sheet of homogenised tobacco material, for example, by cutting or shredding. Shreds of homogenised tobacco material may be formed by other methods, for example, by extrusion.

[0079] The tobacco may comprise at least one of cut filler and cast leaf.

[0080] The aerosol-forming substrate preferably comprises an aerosol former. The aerosol former may be any suitable known compound or mixture of compounds that, in use, facilitates formation of a dense and stable aerosol. The aerosol former may be facilitating that the aerosol is substantially resistant to thermal degradation at temperatures typically applied during use of the aerosol-generating article. Suitable aerosol formers are for example: polyhydric alcohols such as, for example, triethylene glycol, 1,3-butanediol, propylene glycol and glycerine; esters of polyhydric alcohols such as, for example, glycerol mono-, di-or triacetate; aliphatic esters of mono-, di-or polycarboxylic acids such as, for example, dimethyl dodecanedioate and dimethyl tetradecanedioate; and combinations thereof.

[0081] The aerosol former may comprise one or more of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0082] The plug of aerosol-forming substrate may have a length of greater than or equal to 1millimetre, greater than or equal to 3 millimetres, greater than or equal to 5 millimetres, greater than or equal to 7 millimetres, greater than or equal to 9 millimetres, greater than or equal to 10 millimetres, greater than or equal to 11 millimetres, greater than or equal to 12 millimetres, greater than or equal to 13 millimetres, greater than or equal to 14 millimetres, greater than or equal to 15 millimetres, greater than or equal to 16 millimetres, greater than or equal to 18 millimetres, greater than or equal to 20 millimetres, greater than or equal to 22 millimetres, greater than or equal to 25 millimetres, or greater than or equal to 28 millimetres.

[0083] The plug of aerosol-forming substrate may have a length of less than or equal to 3 millimetres, less than or equal to 5 millimetres, less than or equal to 7 millimetres, less than or equal to 9 millimetres, less than or equal to 10 millimetres, less than or equal to 11 millimetres, less than or equal to 12 millimetres, less than or equal to 13 millimetres, less than or equal to 14 millimetres, less than or equal to 15 millimetres, less than or equal to 16 millimetres, less than or equal to 18 millimetres, less than or equal to 20 millimetres, less than or equal to 22 millimetres, less than or equal to 25 millimetres, or less than or equal to 30 millimetres.

[0084] The plug of aerosol-forming substrate may have a length of between 1 millimetre and 30 millimetres, between 5 millimetres and 22 millimetres, between 8 millimetres and 16 millimetres, between 9 millimetres and 15 millimetres, between 10 millimetres and 14 millimetres, between 10 millimetres and 12 millimetres, between 11 millimetres and 13 millimetres, about 12 millimetres or about 11 millimetres. The plug of aerosol-forming substrate may have a length of between 11 millimetres and 15 millimetres.

[0085] Preferably, the plug of aerosol-forming substrate is free of a susceptor element.

[0086] As used herein, the term “susceptor” denotes a material that is capable of being heated when penetrated by a varying magnetic field.

[0087] The aerosol-generating article may comprise at least one hollow tubular element positioned between the plug of aerosol-forming substrate and the downstream segment.

[0088] As used herein, the term “hollow tubular element” is used to denote a generally elongate element defining a lumen or airflow passage along a longitudinal axis thereof. In particular, the term “tubular” will be used in the following with reference to a tubular element having a substantially cylindrical cross-section and defining at least one airflow conduit establishing an uninterrupted fluid communication between an upstream end of the tubular element and a downstream end of the tubular element. However, it will be understood that alternative geometries (for example, alternative cross-sectional shapes) of the tubular element may be possible.

[0089] The at least one hollow tubular element may be formed from at least one of: cardboard, paper, a polymeric material, a cellulosic material, cellulose acetate low density polyethylene (LDPE), and polyhydroxyalkanoate (PHA). Where the at least one hollow tubular element is formed from paper, the paper may be crimped paper, such as crimped heat resistant paper or crimped parchment paper.

[0090] The at least one hollow tubular element may comprise a hollow tubular element immediately downstream of the plug of aerosol-forming substrate and an aerosol-cooling element immediately downstream of the hollow tubular element.

[0091] As used herein, an “aerosol-cooling element” refers to a component of an aerosol-generating article located downstream of the aerosol-forming substrate such that, in use, an aerosol formed by volatile compounds released from the aerosol-forming substrate passes through and is cooled by the aerosol-cooling element before being inhaled by the user.

[0092] The aerosol-cooling element may comprise a gathered sheet of polylactic acid.

[0093] The hollow tubular element may be a first hollow tubular element. The aerosol-cooling element may comprise a second hollow tubular element. In other words, the aerosol-generating article may comprise a first hollow tubular element and a second hollow tubular element. The first hollow tubular element may have a first internal diameter. The second hollow tubular element may have a second internal diameter. The second internal diameter may be greater than the first internal diameter. Each of the first hollow tubular element and the second hollow tubular element may comprise a cellulose acetate tube or a cardboard tube. The first hollow tubular element may have a length of between 3 millimetres and 13 millimetres, between 6 millimetres and 10 millimetres, between 7 millimetres and 9 millimetres, or about 8 millimetres. The second hollow tubular element may have a length of between 3 millimetres and 13 millimetres, between 6 millimetres and 10 millimetres, between 7 millimetres and 9 millimetres, or about 8 millimetres.

[0094] Each of the first hollow tubular element and the second hollow tubular element may comprise an acetate tube or a cardboard tube.

[0095] The at least one hollow tubular element may be positioned between the plug of aerosol-forming substrate and the mouthpiece segment. For example, the first hollow tubular element and the second hollow tubular element may be positioned between the plug of aerosol-forming substrate and the mouthpiece segment.

[0096] The at least one hollow tubular element may comprise one or both of a hollow acetate tube (HAT) and a fine hollow acetate tube (FHAT).

[0097] The at least one hollow tubular element may comprise a HAT and a FHAT. The FHAT may be arranged downstream of the HAT. The inner width of the FHAT may be larger than the inner width of the HAT. The wall thickness of the HAT may be larger than the wall thickness of the FHAT. The HAT has a HAT length. The FHAT has a FHAT length. The HAT length may be between 3 millimetres and 13 millimetres, between 6 millimetres and 10 millimetres, between 7 millimetres and 9 millimetres, or about 8 millimetres. The FHAT length may be between 3 millimetres and 13 millimetres, between 6 millimetres and 10 millimetres, between 7 millimetres and 9 millimetres, or about 8 millimetres. One or both of the HAT and the FHAT may comprise a ventilation zone. Preferably, the FHAT comprises a ventilation zone at a location along the FHAT.

[0098] The aerosol-generating article may comprise ventilation. The aerosol-generating article may comprise one or more ventilation apertures. The aerosol-generating article may comprise at least one ventilation aperture positioned downstream of the plug of aerosol-forming substrate.

[0099] The downstream segment may be a mouthpiece segment. The downstream segment may have a length of greater than or equal to 5 millimetres, greater than or equal to 6 millimetres, greater than or equal to 10 millimetres, or greater than or equal to 11 millimetres. The downstream segment may have a length of less than or equal to 25 millimetres, less than or equal to 20 millimetres, less than or equal to 15 millimetres, less than or equal to 14 millimetres, less than or equal to 13 millimetres, less than or equal to 12 millimetres, less than or equal to 10 millimetres, or less than or equal to 8 millimetres. For example, the downstream segment may have a length of between 5 millimetres and 15 millimetres.

[0100] The downstream segment may comprise a plug of cellulose acetate.

[0101] The aerosol-generating article may have an outer diameter of between 6 millimetres and 9 millimetres, between 6.5 millimetres and 8 millimetres, or between 7 millimetres and 7.6 millimetres.

[0102] The aerosol-generating article may have a length of between 40 millimetres and 80 millimetres, between 45 millimetres and 80 millimetres, between 40 millimetres and 70 millimetres, between 45 millimetres and 70 millimetres, between 40 millimetres and 60 millimetres, between 45 millimetres and 60 millimetres, between 40 millimetres and 50 millimetres, between 45 millimetres and 50 millimetres, or about 45 millimetres.

[0103] According to the present disclosure there is also provided an aerosol-generating system comprising. The aerosol-generating system comprises an aerosol-generating article according to any of the examples or embodiments described herein. The aerosol-generating system also comprises an aerosol-generating device comprising a chamber for receiving at least a portion of the aerosol-generating article and an elongate heater extending into the chamber.

[0104] Preferably, the elongate heater is arranged to be received within each main aperture of the disc of the aerosol-generating article when the aerosol-generating article is received within the chamber. In embodiments in which the disc comprises a plurality of main apertures, preferably the elongate heater comprises a plurality of elongate heaters, wherein each elongate heater is arranged to be received within one of the main apertures of the disc. In embodiments in which the disc comprises a single main aperture, preferably the elongate heater is a single elongate heater. In other words, in embodiments in which the disc comprises a single main aperture, preferably the aerosol-generating device comprises only one elongate heater.

[0105] The elongate heater may comprise a resistive heating element. The elongate heater may have a pin shape, a blade shape, or a cone shape.

[0106] The elongate heater may comprise a susceptor element. The susceptor element may have a pin shape, a blade shape, or a cone shape. The aerosol-generating device may comprise an inductor coil extending around at least a portion of the susceptor element.

[0107] The aerosol-generating system may comprise a power supply.

[0108] The aerosol-generating system may comprise a controller. In embodiments in which the elongate heater comprises a resistive heating element, the controller may be configured to control a supply of power from the power supply to the resistive heating element. In embodiments in which the elongate heater comprises a susceptor element and the aerosol-generating device comprises an inductor coil, the controller may be configured to control a supply of alternating electric current from the power supply to the inductor coil to generate an alternating magnetic field.

[0109] According to the present disclosure there is also provided a method of forming an aerosol-generating article. The method may comprise providing a plug of aerosol-forming substrate having an upstream end and a downstream end. The method may comprise providing a downstream segment. The method may comprise providing a disc. The disc may define at least one main aperture extending through the disc. The disc may define at least one airflow aperture extending through the disc. Each main aperture may be larger than each airflow aperture. The method may comprise combining the plug of aerosol-forming substrate, the downstream segment, and the disc to form an aerosol-generating article. The downstream segment may be positioned at a downstream end of the aerosol-generating article. The disc may be attached to the upstream end of the plug of aerosol-forming substrate. The disc may be positioned at an upstream end of the aerosol-generating article.

[0110] According to the present disclosure there is also provided a method of forming an aerosol-generating article. The method comprises providing a plug of aerosol-forming substrate having an upstream end and a downstream end. The method also comprises providing a downstream segment and a disc. The disc defines at least one main aperture extending through the disc and at least one airflow aperture extending through the disc. Each main aperture is larger than each airflow aperture. The method also comprises combining the plug of aerosol-forming substrate, the downstream segment, and the disc to form an aerosol-generating article. The downstream segment is positioned at a downstream end of the aerosol-generating article. The disc is attached to the upstream end of the plug of aerosol-forming substrate so that the disc is positioned at an upstream end of the aerosol-generating article.

[0111] Aerosol-generating articles formed according to the methods described herein may comprise any of the optional or preferred features of aerosol-generating articles also described herein.

[0112] The steps of providing the plug of aerosol-forming substrate and providing the disc may comprise providing a combined plug comprising the plug of aerosol-forming substrate with the disc attached to the upstream end of the plug of aerosol-forming substrate, wherein the combining step comprises positioning the downstream segment downstream of the combined plug, and wrapping a wrapper around the combined plug and the downstream segment.

[0113] Advantageously, providing a combined plug comprising the plug of aerosol-forming substrate with the disc attached to the upstream end of the plug of aerosol-forming substrate may reduce or eliminate the need to modify existing machines and processes for manufacturing aerosol-generating articles.

[0114] The combining step may comprise positioning the downstream segment downstream of the plug of aerosol-forming substrate, wrapping a wrapper around the plug of aerosol-forming substrate and the downstream segment, and attaching the disc to the upstream end of the plug of aerosol-forming substrate.

[0115] Advantageously, attaching the disc to the upstream end of the plug of aerosol-forming substrate after the plug of aerosol-forming substrate and the downstream segment have been wrapped in a wrapper may reduce or eliminate the need to modify existing machines and processes for manufacturing aerosol-generating articles. For example, existing machines and processes may be used to form an aerosol-generating article without a disc, and the disc may be subsequently attached to the upstream end of the plug of aerosol-forming substrate.

[0116] The method may comprise a step of forming at least one ventilation aperture in the wrapper, wherein the at least one ventilation aperture is positioned downstream of the plug of aerosol-forming substrate.

[0117] The disc may be attached to the upstream end of the plug of aerosol-forming substrate by an adhesive. The method may comprise attaching the disc to the upstream end of the plug of aerosol-forming substrate by an adhesive.

[0118] The method may comprise providing at least one hollow tubular element, wherein the combining step comprises combining the plug of aerosol-forming substrate, the at least one hollow tubular element, the downstream segment, and the disc so that the at least one hollow tubular element is positioned between the plug of aerosol-forming substrate and the downstream segment.

[0119] The step of providing at least one hollow tubular element may comprise providing a hollow tubular element and an aerosol-cooling element, wherein the combining step comprises positioning the hollow tubular element immediately downstream of the plug of aerosol-forming substrate and positioning the aerosol-cooling element immediately downstream of the hollow tubular element.

[0120] Below, there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0121] Example 1: An aerosol-generating article comprising:

[0122] a plug of aerosol-forming substrate having an upstream end and a downstream end;

[0123] a downstream segment positioned at a downstream end of the aerosol-generating article; and

[0124] a disc attached to the upstream end of the plug of aerosol-forming substrate, wherein the disc is positioned at an upstream end of the aerosol-generating article, wherein the disc defines at least one main aperture extending through the disc and at least one airflow aperture extending through the disc, and wherein each main aperture is larger than each airflow aperture.

[0125] Example 2: An aerosol-generating article according to Example 1, wherein a ratio of a maximum cross-sectional area of each main aperture to a maximum cross-sectional area of each airflow aperture is at least 1.1 to 1, at least 1.2 to 1, at least 1.3 to 1, at least 1.4 to 1, at least 1.5 to 1, at least 1.6 to 1, at least 1.7 to 1, at least 1.8 to 1, at least 1.9 to 1, or at least 2 to 1.

[0126] Example 3: An aerosol-generating article according to Example 2, wherein the aerosol-generating article defines a longitudinal direction extending between the upstream end of the aerosol-generating article and the downstream end of the aerosol-generating article, and wherein the cross-sectional area of each main aperture and each airflow aperture is a maximum cross-sectional area in a plane perpendicular to the longitudinal direction.

[0127] Example 4: An aerosol-generating article according to Example 1, 2 or 3, wherein the disc has a circular shape, and wherein the at least one main aperture comprises a main aperture positioned at the centre of the disc.

[0128] Example 5: An aerosol-generating article according to Example 4, wherein the main aperture positioned at the centre of the disc is the only main aperture defined by the disc.

[0129] Example 6: An aerosol-generating article according to any preceding Example, wherein the at least one airflow aperture comprises a plurality of airflow apertures.

[0130] Example 7: An aerosol-generating article according to Example 6, wherein the disc has a circular shape, and wherein the plurality of airflow apertures are arranged symmetrically about the centre of the disc.

[0131] Example 8: An aerosol-generating article according to Example 7, wherein the plurality of airflow apertures comprises a first row of airflow apertures arranged symmetrically about the centre of the disc and a second row of airflow apertures arranged symmetrically about the centre of the disc, and wherein the second row of airflow apertures is positioned between the first row of airflow apertures and a circumferential edge of the disc.

[0132] Example 9: An aerosol-generating article according to Example 8, wherein the second row of airflow apertures is aligned with the first row of airflow apertures in a circumferential direction about the centre of the disc.

[0133] Example 10: An aerosol-generating article according to Example 8, wherein the second row of airflow apertures is offset from the first row of airflow apertures in a circumferential direction about the centre of the disc.

[0134] Example 11: An aerosol-generating article according to any of Examples 6 to 10, wherein none of the airflow apertures is positioned at the centre of the disc.

[0135] Example 12: An aerosol-generating article according to any of Examples 6 to 11, wherein the plurality of airflow apertures comprises three, four, five, six, seven, eight, nine, ten, eleven or twelve airflow apertures.

[0136] Example 13: An aerosol-generating article according to any preceding Example, wherein each main aperture has a circular cross-sectional shape, an elliptical cross-sectional shape, a square cross-sectional shape, or a polygonal cross-sectional shape.

[0137] Example 14: An aerosol-generating article according to any preceding Example, wherein each main aperture has a circular cross-sectional shape, and wherein each main aperture has a maximum diameter of at least 3 millimetres, at least 3.5 millimetres, at least 4 millimetres, at least 4.5 millimetres, at least 5 millimetres, at least 5.5 millimetres, or at least 6 millimetres.

[0138] Example 15: An aerosol-generating article according to any preceding Example, wherein each main aperture has a maximum cross-sectional area of at least 7 square millimetre, at least 9 square millimetres, at least 12 square millimetres, at least 15 square millimetres, at least 19 square millimetres, at least 23 square millimetres, at least 28 square millimetres, at least 30 square millimetres, or at least 35 square millimetres.

[0139] Example 16: An aerosol-generating article according to any preceding Example, wherein each airflow aperture has a circular cross-sectional shape, an elliptical cross-sectional shape, a square cross-sectional shape, or a polygonal cross-sectional shape.

[0140] Example 17: An aerosol-generating article according to any preceding Example, wherein each airflow aperture has a circular cross-sectional shape, and wherein each airflow aperture has a maximum diameter of less than 3 millimetres, less than 2.5 millimetres, less than 2 millimetres, less than 1.5 millimetres, or less than 1 millimetre.

[0141] Example 18: An aerosol-generating article according to any preceding Example, wherein each airflow aperture has a maximum cross-sectional area of less than 7 square millimetre, less than 6 square millimetres, less than 5 square millimetres, less than 4 square millimetres, less than 3 square millimetres, less than 2 square millimetres, or less than 1 square millimetre.

[0142] Example 19: An aerosol-generating article according to any preceding Example, wherein the disc has a thickness of less than 5 millimetres, less than 4 millimetres, less than 3 millimetres, less than 2 millimetres, less than 1.5 millimetres, less than 1 millimetre, or less than 0.5 millimetres.

[0143] Example 20: An aerosol-generating article according to any preceding Example, wherein the disc is attached to the upstream end of the plug of aerosol-forming substrate by an adhesive.

[0144] Example 21: An aerosol-generating article according to any preceding Example, further comprising a wrapper wrapped around the plug of aerosol-forming substrate, wherein the disc is positioned outside of the wrapper.

[0145] Example 22: An aerosol-generating article according to any preceding Example, wherein the disc is formed from a non-permeable material.

[0146] Example 23: An aerosol-generating article according to any preceding Example, wherein the disc is formed from a film material.

[0147] Example 24: An aerosol-generating article according to any preceding Example, wherein the disc is formed from a polymeric material.

[0148] Example 25: An aerosol-generating article according to any preceding Example, wherein the disc is formed from a paper and a hydrophobic material.

[0149] Example 26: An aerosol-generating article according to Example 25, wherein the hydrophobic material is dispersed within the paper, coated on at least one surface of the paper, or dispersed within the paper and coated on at least one surface of the paper.

[0150] Example 27: An aerosol-generating article according to any preceding Example, wherein the aerosol-forming substrate comprises tobacco.

[0151] Example 28: An aerosol-generating article according to Example 27, wherein the tobacco comprises at least one of cut filler and cast leaf.

[0152] Example 29: An aerosol-generating article according to any preceding Example, wherein the plug of aerosol-forming substrate has a length of between 11 millimetres and 15 millimetres.

[0153] Example 30: An aerosol-generating article according to any preceding Example, wherein the plug of aerosol-forming substrate is free of a susceptor element.

[0154] Example 31: An aerosol-generating article according to any preceding Example, further comprising at least one hollow tubular element positioned between the plug of aerosol-forming substrate and the downstream segment.

[0155] Example 32: An aerosol-generating article according to Example 31, wherein the at least one hollow tubular element comprises a hollow tubular element immediately downstream of the plug of aerosol-forming substrate and an aerosol-cooling element immediately downstream of the hollow tubular element.

[0156] Example 33: An aerosol-generating article according to Example 32, wherein the hollow tubular element is a first hollow tubular element and wherein the aerosol-cooling element comprises a second hollow tubular element.

[0157] Example 34: An aerosol-generating article according to Example 33, wherein the first hollow tubular element has a first internal diameter, wherein the second hollow tubular element has a second internal diameter, and wherein the second internal diameter is greater than the first internal diameter.

[0158] Example 35: An aerosol-generating article according to Example 32 or 33, wherein each of the first hollow tubular element and the second hollow tubular element comprises an acetate tube or a cardboard tube.

[0159] Example 36: An aerosol-generating article according to Example 32, wherein the aerosol-cooling element comprises a gathered sheet of polylactic acid.

[0160] Example 37: An aerosol-generating article according to any preceding Example, further comprising at least one ventilation aperture positioned downstream of the plug of aerosol-forming substrate.

[0161] Example 38: An aerosol-generating article according to any preceding Example, wherein the downstream segment comprises a plug of cellulose acetate.

[0162] Example 39: An aerosol-generating article according to any preceding Example, wherein the downstream segment has a length of between 5 millimetres and 15 millimetres.

[0163] Example 40: An aerosol-generating article according to any preceding Example, wherein the aerosol-generating article has an outer diameter of between 6 millimetres and 9 millimetres, between 6.5 millimetres and 8 millimetres, or between 7 millimetres and 7.6 millimetres.

[0164] Example 41: An aerosol-generating system comprising:

[0165] an aerosol-generating article according to any preceding Example; and

[0166] an aerosol-generating device comprising a chamber for receiving at least a portion of the aerosol-generating article and an elongate heater extending into the chamber.

[0167] Example 42: An aerosol-generating system according to Example 41, wherein the elongate heater comprises a resistive heating element.

[0168] Example 43: An aerosol-generating system according to Example 41 or 42, wherein the elongate heater has a pin shape, a blade shape, or a cone shape.

[0169] Example 44: An aerosol-generating system according to Example 41, 42 or 43, further comprising a power supply and a controller configured to control a supply of power from the power supply to the elongate heater.

[0170] Example 45: A method of forming an aerosol-generating article, the method comprising:

[0171] providing a plug of aerosol-forming substrate having an upstream end and a downstream end;

[0172] providing a downstream segment;

[0173] providing a disc defining at least one main aperture extending through the disc and at least one airflow aperture extending through the disc, wherein each main aperture is larger than each airflow aperture; and

[0174] combining the plug of aerosol-forming substrate, the downstream segment, and the disc to form an aerosol-generating article in which the downstream segment is positioned at a downstream end of the aerosol-generating article, and the disc is attached to the upstream end of the plug of aerosol-forming substrate so that the disc is positioned at an upstream end of the aerosol-generating article.

[0175] Example 46: A method according to Example 45, wherein the steps of providing the plug of aerosol-forming substrate and providing the disc comprise providing a combined plug comprising the plug of aerosol-forming substrate with the disc attached to the upstream end of the plug of aerosol-forming substrate, and wherein the combining step comprises positioning the downstream segment downstream of the combined plug, and wrapping a wrapper around the combined plug and the downstream segment.

[0176] Example 47: A method according to Example 45, wherein the combining step comprises:

[0177] positioning the downstream segment downstream of the plug of aerosol-forming substrate;

[0178] wrapping a wrapper around the plug of aerosol-forming substrate and the downstream segment; and

[0179] attaching the disc to the upstream end of the plug of aerosol-forming substrate.

[0180] Example 48: A method according to Example 46 or 47, further comprising a step of forming at least one ventilation aperture in the wrapper, wherein the at least one ventilation aperture is positioned downstream of the plug of aerosol-forming substrate.

[0181] Example 49: A method according to any of Examples 45 to 48, wherein the disc is attached to the upstream end of the plug of aerosol-forming substrate by an adhesive.

[0182] Example 50: A method according to any of Examples 45 to 49, wherein a ratio of a maximum cross-sectional area of each main aperture to a maximum cross-sectional area of each airflow aperture is at least 1.1 to 1, at least 1.2 to 1, at least 1.3 to 1, at least 1.4 to 1, at least 1.5 to 1, at least 1.6 to 1, at least 1.7 to 1, at least 1.8 to 1, at least 1.9 to 1, or at least 2 to 1.

[0183] Example 51: A method according to Example 50, wherein the aerosol-generating article defines a longitudinal direction extending between the upstream end of the aerosol-generating article and the downstream end of the aerosol-generating article, and wherein the cross-sectional area of each main aperture and each airflow aperture is a maximum cross-sectional area in a plane perpendicular to the longitudinal direction.

[0184] Example 52: A method according to any of Examples 45 to 51, wherein the disc has a circular shape, and wherein the at least one main aperture comprises a main aperture positioned at the centre of the disc.

[0185] Example 53: A method according to Example 52, wherein the main aperture positioned at the centre of the disc is the only main aperture defined by the disc.

[0186] Example 54: A method according to any of Examples 45 to 53, wherein the at least one airflow aperture comprises a plurality of airflow apertures.

[0187] Example 55: A method according to Example 53, wherein the disc has a circular shape, and wherein the plurality of airflow apertures are arranged symmetrically about the centre of the disc.

[0188] Example 56: A method according to Example 55, wherein the plurality of airflow apertures comprises a first row of airflow apertures arranged symmetrically about the centre of the disc and a second row of airflow apertures arranged symmetrically about the centre of the disc, and wherein the second row of airflow apertures is positioned between the first row of airflow apertures and a circumferential edge of the disc.

[0189] Example 57: A method according to Example 56, wherein the second row of airflow apertures is aligned with the first row of airflow apertures in a circumferential direction about the centre of the disc.

[0190] Example 58: A method according to Example 56, wherein the second row of airflow apertures is offset from the first row of airflow apertures in a circumferential direction about the centre of the disc.

[0191] Example 59: A method according to any of Examples 54 to 58, wherein none of the airflow apertures is positioned at the centre of the disc.

[0192] Example 60: A method according to any of Examples 54 to 59, wherein the plurality of airflow apertures comprises three, four, five, six, seven, eight, nine, ten, eleven or twelve airflow apertures.

[0193] Example 61: A method according to any of Examples 45 to 60, wherein each main aperture has a circular cross-sectional shape, an elliptical cross-sectional shape, a square cross-sectional shape, or a polygonal cross-sectional shape.

[0194] Example 62: A method according to any of Examples 45 to 61, wherein each main aperture has a circular cross-sectional shape, and wherein each main aperture has a maximum diameter of at least 3 millimetres, at least 3.5 millimetres, at least 4 millimetres, at least 4.5 millimetres, at least 5 millimetres, at least 5.5 millimetres, or at least 6 millimetres.

[0195] Example 63: A method according to any of Examples 45 to 62, wherein each main aperture has a maximum cross-sectional area of at least 7 square millimetre, at least 9 square millimetres, at least 12 square millimetres, at least 15 square millimetres, at least 19 square millimetres, at least 23 square millimetres, at least 28 square millimetres, at least 30 square millimetres, or at least 35 square millimetres.

[0196] Example 64: A method according to any of Examples 45 to 63, wherein each airflow aperture has a circular cross-sectional shape, an elliptical cross-sectional shape, a square cross-sectional shape, or a polygonal cross-sectional shape.

[0197] Example 65: A method according to any of Examples 45 to 64, wherein each airflow aperture has a circular cross-sectional shape, and wherein each airflow aperture has a maximum diameter of less than 3 millimetres, less than 2.5 millimetres, less than 2 millimetres, less than 1.5 millimetres, or less than 1 millimetre.

[0198] Example 66: A method according to any of Examples 45 to 65, wherein each airflow aperture has a maximum cross-sectional area of less than 7 square millimetre, less than 6 square millimetres, less than 5 square millimetres, less than 4 square millimetres, less than 3 square millimetres, less than 2 square millimetres, or less than 1 square millimetre.

[0199] Example 67: A method according to any of Examples 45 to 66, wherein the disc has a thickness of less than 5 millimetres, less than 4 millimetres, less than 3 millimetres, less than 2 millimetres, less than 1.5 millimetres, less than 1 millimetre, or less than 0.5 millimetres.

[0200] Example 68: A method according to any of Examples 45 to 67, wherein the disc is formed from a non-permeable material.

[0201] Example 69: A method according to any of Examples 45 to 68, wherein the disc is formed from a film material.

[0202] Example 70: A method according to any of Examples 45 to 69, wherein the disc is formed from a polymeric material.

[0203] Example 71: A method according to any of Examples 45 to 70, wherein the disc is formed from a paper and a hydrophobic material.

[0204] Example 72: A method according to Example 71, wherein the hydrophobic material is dispersed within the paper, coated on at least one surface of the paper, or dispersed within the paper and coated on at least one surface of the paper.

[0205] Example 73: A method according to any of Examples 45 to 72, wherein the aerosol-forming substrate comprises tobacco.

[0206] Example 74: A method according to Example 73, wherein the tobacco comprises at least one of cut filler and cast leaf.

[0207] Example 75: A method according to any of Examples 45 to 74, wherein the plug of aerosol-forming substrate has a length of between 11 millimetres and 15 millimetres.

[0208] Example 76: A method according to any of Examples 45 to 75, wherein the plug of aerosol-forming substrate is free of a susceptor element.

[0209] Example 77: A method according to any of Examples 45 to 76, further comprising providing at least one hollow tubular element, wherein the combining step comprises combining the plug of aerosol-forming substrate, the at least one hollow tubular element, the downstream segment, and the disc so that the at least one hollow tubular element is positioned between the plug of aerosol-forming substrate and the downstream segment.

[0210] Example 78: A method according to Example 77, wherein the step of providing at least one hollow tubular element comprises providing a hollow tubular element and an aerosol-cooling element, and wherein the combining step comprises positioning the hollow tubular element immediately downstream of the plug of aerosol-forming substrate and positioning the aerosol-cooling element immediately downstream of the hollow tubular element.

[0211] Example 79: A method according to Example 78, wherein the hollow tubular element is a first hollow tubular element and wherein the aerosol-cooling element comprises a second hollow tubular element.

[0212] Example 80: A method according to Example 79, wherein the first hollow tubular element has a first internal diameter, wherein the second hollow tubular element has a second internal diameter, and wherein the second internal diameter is greater than the first internal diameter.

[0213] Example 81: A method according to Example 79 or 80, wherein each of the first hollow tubular element and the second hollow tubular element comprises an acetate tube or a cardboard tube.

[0214] Example 82: A method according to Example 78, wherein the aerosol-cooling element comprises a gathered sheet of polylactic acid.

[0215] Example 83: A method according to any of Examples 45 to 82, wherein the downstream segment comprises a plug of cellulose acetate.

[0216] Example 84: A method according to any of Examples 45 to 83, wherein the downstream segment has a length of between 5 millimetres and 15 millimetres.

[0217] Example 85: A method according to any of Examples 45 to 84, wherein the aerosol-generating article has an outer diameter of between 6 millimetres and 9 millimetres, between 6.5 millimetres and 8 millimetres, or between 7 millimetres and 7.6 millimetres.

[0218] The invention will now be further described, by way of example only, with reference to accompanying drawings in which:

[0219] FIG. 1 shows a schematic cross-sectional view of an aerosol-generating article according to a first embodiment of the present disclosure;

[0220] FIG. 2 shows a front view of the upstream end of the aerosol-generating article of FIG. 1;

[0221] FIG. 3 shows a schematic cross-sectional view of an aerosol-generating article according to a second embodiment of the present disclosure;

[0222] FIG. 4 shows a schematic cross-sectional view of a first aerosol-generating system comprising the aerosol-generating article of FIG. 1; and

[0223] FIG. 5 shows a schematic cross-sectional view of a second aerosol-generating system comprising the aerosol-generating article of FIG. 1.

[0224] FIG. 1 shows a schematic cross-sectional view of an aerosol-generating article 10 according to a first embodiment of the present disclosure. The aerosol-generating article 10 has a substantially cylindrical shape along its length, wherein the length extends in a longitudinal direction 12. The aerosol-generating article 10 comprises a plug of aerosol-forming substrate 14. The plug of aerosol-forming substrate 14 has a substantially cylindrical shape along its length and comprises a gathered sheet of homogenised tobacco.

[0225] The aerosol-generating article 10 further comprises a first hollow tubular element 16 immediately downstream of the plug of aerosol-forming substrate 14, an aerosol-cooling element 18 in the form of a second hollow tubular element immediately downstream of the first hollow tubular element 16, and downstream segment 20 in the form of a mouth-end filter positioned at a downstream end 22 of the aerosol-generating article 10. Each of the first hollow tubular element 16 and the second hollow tubular element comprise a hollow acetate tube. The second hollow tubular element has a larger internal diameter than the first hollow tubular element 16. The downstream segment 20 comprises a plug of cellulose acetate tow.

[0226] The plug of aerosol-forming substrate 14, the first hollow tubular element 16 and the aerosol-cooling element 18 are circumscribed by a first wrapper 24. The first wrapper 24 does not circumscribe the downstream segment 20. The first wrapper 24 extends from an upstream end 26 of the aerosol-generating article 10. The first wrapper 24 is made of paper.

[0227] The aerosol-cooling element 18 and the downstream segment 20 are circumscribed by a second wrapper 28. The second wrapper 28 overlaps part of the first wrapper 24. The second wrapper 28 extends from the downstream end 22 of the aerosol-generating article 10. A plurality of ventilation apertures 30 extend through the second wrapper 28, the first wrapper 24 and the aerosol-cooling element 18.

[0228] The aerosol-generating article 10 also comprises a disc 32 attached to an upstream end of the plug of aerosol-forming substrate 14 and positioned at the upstream end 26 of the aerosol-generating article 10. The disc 32 is formed from a non-permeable polymeric film and is attached to the upstream end of the plug of aerosol-forming substrate 14 by an adhesive.

[0229] As shown in FIG. 2, the disc 32 comprises a main aperture 34 positioned at a centre of the disc 32 and a plurality of airflow apertures 36 arranged symmetrically about the main aperture 34. The airflow apertures 36 are arranged in a first circumferential row 38 of airflow apertures and a second circumferential row 40 of airflow apertures. During use, the plurality of airflow apertures 36 facilitates a desired airflow through the aerosol-generating article 10. During use, the main aperture34 receives a heater of an aerosol-generating device. Each of the main apertures 34 and the airflow apertures 36 has a circular shape. The main aperture 34 has a larger diameter than each of the airflow apertures 36.

[0230] FIG. 3 shows a schematic cross-sectional view of an aerosol-generating article 100 according to a second embodiment of the present disclosure. The aerosol-generating article 100 is similar to the aerosol-generating article 10 of FIG. 1 and like reference numerals are used to designate like parts.

[0231] The aerosol-generating article 100 differs from the aerosol-generating article 10 of FIG. 1 by the aerosol-cooling element 118. Specifically, the aerosol-cooling element 118 of the aerosol-generating article 100 comprises a gathered sheet of polylactic acid. Otherwise, the construction of the aerosol-generating article 100 is the same as the aerosol-generating article 10 of FIG. 1.

[0232] FIG. 4 shows a schematic cross-sectional view of an aerosol-generating system 200 according to a first embodiment. The aerosol-generating system 200 comprises an aerosol-generating device 202 comprising a housing 204 defining a chamber 206 for receiving an aerosol-generating article. In the embodiment shown in FIG. 4, the aerosol-generating system 200 comprises the aerosol-generating article 10 of FIG. 1 received within the chamber 206. It will be appreciated that the aerosol-generating system 200 may instead comprise the aerosol-generating article 100 of FIG. 3.

[0233] The aerosol-generating device 202 also comprises an elongate heater 208 extending into the chamber 206. The elongate heater 208 is a pin-shaped heater comprising a resistive heating element. The elongate heater 208 is arranged to be received through the main aperture 34 of the disc 32 when the aerosol-generating article 10 is inserted into the chamber 206 so that the elongate heater 208 is positioned within the plug of aerosol-forming substrate 14. The aerosol-generating device 202 also comprise a power supply 210 and a controller 212. During use, the controller 212 controls a supply of power from the power supply 210 to the resistive heating element of the elongate heater 208 to heat the plug of aerosol-forming substrate 14. When the aerosol-generating article 10 is fully inserted into the chamber 206, the upstream end 26 of the aerosol-generating article 10 abuts the elongate heater 208 so that the upstream end 26 of the aerosol-generating article 10 is spaced apart from a closed end 214 of the chamber 206 to form an air gap 216. During use, airflow may enter the aerosol-generating article 10 from the air gap 216 through the plurality of airflow apertures 36 in the disc 32.

[0234] FIG. 5 shows a schematic cross-sectional view of an aerosol-generating system 300 according to a second embodiment. The aerosol-generating system 300 is similar to the aerosol-generating system 200 of FIG. 4 and like reference numerals are used to designate like parts.

[0235] The aerosol-generating system 300 differs from the aerosol-generating system 200 by the configuration of the heating arrangement of the aerosol-generating device 302. Specifically, the electric heater 308 of the aerosol-generating device 302 comprises an elongate susceptor element. The aerosol-generating device 302 further comprises an inductor coil 320 extending around a portion of the chamber 206 into which the elongate susceptor element extends. During use, the controller 212 controls a supply of alternating electric current from the power supply 210 to the inductor coil 320 to generate an alternating magnetic field. The alternating magnetic field inductive heats the elongate susceptor element, which in turn heats the plug of aerosol-forming substrate 14. Otherwise, the configuration and operation of the aerosol-generating system 300 is the same as the aerosol-generating system 200 of FIG. 4.

Claims

1. -15. (canceled)16. An aerosol-generating article, comprising:a plug of aerosol-forming substrate having an upstream end and a downstream end;a downstream segment positioned at a downstream end of the aerosol-generating article; anda disc attached to the upstream end of the plug of aerosol-forming substrate,wherein the disc is positioned at an upstream end of the aerosol-generating article,wherein the disc defines at least one main aperture extending through the disc and at least one airflow aperture extending through the disc,wherein each main aperture is larger than each airflow aperture,wherein the disc has a circular shape, andwherein the disc is attached to the upstream end of the plug of aerosol-forming substrate by an adhesive.

17. The aerosol-generating article according to claim 16, wherein a ratio of a maximum cross-sectional area of each main aperture to a maximum cross-sectional area of each airflow aperture is at least 1.1 to 1, at least 1.2 to 1, at least 1.3 to 1, at least 1.4 to 1, at least 1.5 to 1, at least 1.6 to 1, at least 1.7 to 1, at least 1.8 to 1, at least 1.9 to 1, or at least 2 to 1.

18. The aerosol-generating article according to claim 17,wherein the aerosol-generating article defines a longitudinal direction extending between the upstream end of the aerosol-generating article and the downstream end of the aerosol-generating article, andwherein the cross-sectional area of each main aperture and each airflow aperture is a maximum cross-sectional area in a plane perpendicular to the longitudinal direction.

19. The aerosol-generating article according to claim 16, wherein the at least one main aperture comprises a main aperture positioned at a centre of the disc.

20. The aerosol-generating article according to claim 19, wherein the main aperture positioned at the centre of the disc is the only main aperture defined by the disc.

21. The aerosol-generating article according to claim 16,wherein the at least one airflow aperture comprises a plurality of airflow apertures, andwherein the second row of airflow apertures is positioned between the first row of airflow apertures and a circumferential edge of the disc.

22. The aerosol-generating article according to claim 21, wherein the plurality of airflow apertures are arranged symmetrically about a centre of the disc.

23. The aerosol-generating article according to claim 22, wherein the plurality of airflow apertures comprises a first row of airflow apertures arranged symmetrically about the centre of the disc and a second row of airflow apertures arranged symmetrically about the centre of the disc.

24. The aerosol-generating article according to claim 21,wherein the second row of airflow apertures is aligned with the first row of airflow apertures in a circumferential direction about the centre of the disc, orwherein the second row of airflow apertures is offset from the first row of airflow apertures in a circumferential direction about the centre of the disc.

25. The aerosol-generating article according to claim 16,wherein each main aperture has a circular cross-sectional shape, andwherein each main aperture has a maximum diameter of at least 3 millimetres, at least 3.5 millimetres, at least 4 millimetres, at least 4.5 millimetres, at least 5 millimetres, at least 5.5 millimetres, or at least 6 millimetres.

26. The aerosol-generating article according to claim 16, wherein each main aperture has a maximum cross-sectional area of at least 7 square millimetre, at least 9 square millimetres, at least 12 square millimetres, at least 15 square millimetres, at least 19 square millimetres, at least 23 square millimetres, at least 28 square millimetres, at least 30 square millimetres, or at least 35 square millimetres.

27. The aerosol-generating article according to claim 16,wherein each airflow aperture has a circular cross-sectional shape, andwherein each airflow aperture has a maximum diameter of less than 3 millimetres, less than 2.5 millimetres, less than 2 millimetres, less than 1.5 millimetres, or less than 1 millimetre.

28. The aerosol-generating article according to claim 16, wherein each airflow aperture has a maximum cross-sectional area of less than 7 square millimetres, less than 6 square millimetres, less than 5 square millimetres, less than 4 square millimetres, less than 3 square millimetres, less than 2 square millimetres, or less than 1 square millimetre.

29. The aerosol-generating article according to claim 16, wherein the disc has a thickness of less than 5 millimetres, less than 4 millimetres, less than 3 millimetres, less than 2 millimetres, less than 1.5 millimetres, less than 1 millimetre, or less than 0.5 millimetre.

30. The aerosol-generating article according to claim 16, wherein the disc is formed from a non-permeable material.

31. The aerosol-generating article according to claim 16, wherein the disc is formed from a polymeric material.

32. The aerosol-generating article according to claim 16, wherein the plug of aerosol-forming substrate is free of a susceptor element.

33. An aerosol-generating system, comprising:the aerosol-generating article according to claim 16; andan aerosol-generating device comprising a chamber configured to receive at least a portion of the aerosol-generating article and an elongate heater extending into the chamber.

34. A method of forming an aerosol-generating article, the method comprising:providing a plug of aerosol-forming substrate having an upstream end and a downstream end;providing a downstream segment;providing a disc defining at least one main aperture extending through the disc and at least one airflow aperture extending through the disc, wherein each main aperture is larger than each airflow aperture, and wherein the disc has a circular shape; andcombining the plug of aerosol-forming substrate, the downstream segment, and the disc to form an aerosol-generating article in which the downstream segment is positioned at a downstream end of the aerosol-generating article, and the disc is attached to the upstream end of the plug of aerosol-forming substrate so that the disc is positioned at an upstream end of the aerosol-generating article,wherein the disc is attached to the upstream end of the plug of aerosol-forming substrate by an adhesive.

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