An aerosol-generating article

Abstract

There is provided an aerosol-generating article (100) for use with an aerosol-generating device (6000). The aerosol-generating article (100) comprises a first plug (200), a second plug (400), and an aerosol-generating substrate plug (300) comprising an aerosol-generating substrate (345). The first plug (200) is positioned upstream of the aerosol-generating substrate plug (300) and the second plug (400) is positioned downstream of the aerosol-generating substrate plug (300). A thickness of the aerosol-generating article (100) is less than 50 percent of a length of the aerosol-generating article (100) and the thickness of the aerosol-generating article (100) is less than 50 percent of a width of the aerosol-generating article (100).

Description

[0001] AN AEROSOL-GENERATING ARTICLE

[0002] The present disclosure relates to an aerosol-generating article comprising an aerosol-generating substrate. The present disclosure also relates to an aerosol-generating device for receiving the aerosolgenerating article.

[0003] A typical aerosol-generating article may appear similar to a conventional cigarette. For example, such an aerosol-generating article may be substantially cylindrical and comprise an aerosol-generating substrate and other components such as a mouthpiece filter element and a cooling element, all arranged together in the form of a rod and wrapped in a cigarette paper. Dimensions of typical aerosol-generating articles are often similar to the dimensions of conventional cigarettes.

[0004] However, a significant portion of the aerosol-generating substrate in these cylindrical aerosolgenerating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-generating substrate contributes to the cost of manufacture and transport of the aerosol-generating article, but does not contribute to the aerosol delivered to an end user. This may be the case regardless of the way in which the aerosol-generating substrate is heated, for example regardless of whether a resistive or inductive heater is used and regardless ofwhetherthe aerosolgenerating substrate is heated from the inside or the outside.

[0005] It is an aim of the present disclosure to provide an aerosol-generating article, in which a greater portion of an aerosol-generating substrate of the aerosol-generating article is sufficiently heated to form an aerosol during use. It is also an objective of the present disclosure to provide an aerosol-generating article that can be manufactured relatively efficiently and cheaply.

[0006] There is provided an aerosol-generating article for use with an aerosol-generating device. The aerosol-generating article may comprise a first plug. The aerosol-generating article may comprise a second plug. The aerosol-generating article may comprise an aerosol-generating substrate plug comprising an aerosol-generating substrate. The first plug may be positioned upstream of the aerosol-generating substrate plug. The second plug may be positioned downstream of the aerosol-generating substrate plug. A thickness of the aerosol-generating article may be less than 50 percent of a length of the aerosolgenerating article. The thickness of the aerosol-generating article may be less than 50 percent of a width of the aerosol-generating article.

[0007] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device. The aerosol-generating article comprises a first plug, a second plug, and an aerosol-generating substrate plug comprising an aerosol-generating substrate. The first plug is positioned upstream of the aerosol-generating substrate plug and the second plug is positioned downstream of the aerosol-generating substrate plug. A thickness of the aerosol-generating article is less than 50 percent of a length of the aerosol-generating article and the thickness of the aerosol-generating article is less than 50 percent of a width of the aerosol-generating article.

[0008] Advantageously, the aerosol-generating article is assembled from pre-formed plugs (such as the first plug, the second plug, and the aerosol-generating substrate plug), thus each plug can be manufactured separately and then combined in multiple different combinations to form a number of different aerosolgenerating articles providing different smoking experiences. This may also allow the aerosol-generating articles to be manufactured with minimal modification to traditional cigarette manufacturing processes which combine multiple elements to form the cigarette.

[0009] Advantageously, the first plug and the second plug are positioned upstream and downstream of the aerosol-generating substrate plug, respectively, and therefore may protect ends of the aerosol-generating substrate plug. For example, the first plug and the second plug may prevent inadvertent ignition of the ends of the aerosol-generating substrate plug.

[0010] An aerosol-generating article having a thickness less than 50 percent of a length and width of the aerosol-generating article may provide an aerosol-generating article that is generally flat and thin. Advantageously, this may allow for a small temperature gradient across the thickness of the aerosolgenerating article and aerosol-generating substrate plug during heating, thereby allowing for heating of a greater proportion of the aerosol-generating substrate plug to a temperature at which an aerosol is released whilst minimising the risk of burning the hottest portion of the aerosol-generating substrate plug closest to the heating element. Advantageously, this may also reduce a time required to heat the aerosol-generating substrate plug sufficiently to release an aerosol. Such articles have a large base area relative to the volume of the article. Advantageously, a larger base area may provide greater surface area for heating by a planar heater of an aerosol-generating device.

[0011] The aerosol-generating article may be a planar aerosol-generating article having a base defined by a length extending in an x direction, a width extending in a y direction, and a thickness extending in a z direction.

[0012] The aerosol-generating article may comprise a substantially planar upper surface defined by a length extending in an x direction and a width extending in a y direction, and a substantially planar lower surface defined by a length extending in an x direction and a width extending in a y direction. The substantially planar upper surface and the substantially planar lower surface may be vertically spaced from each other by a thickness defined in a z direction. The substantially planar upper surface and the substantially planar lower surface may be parallel to each other.

[0013] The aerosol-generating article may have an air flow path extending through the aerosol-generating article. The aerosol-generating article may have an air-flow path defined through the aerosol-generating article in an x / y plane from one side of the aerosol-generating article to the other side of the aerosolgenerating article. The aerosol-generating article preferably has a resistance to draw (RTD) of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in the direction of the airflow path. Preferably, the aerosol-generating article has a RTD of less than 20 millimetre H2O, for example less than 10 millimetre H2O, in at least one direction in an x / y plane of the aerosol-generating article. Advantageously, an aerosolgenerating article with a low resistance air-flow path may allow for superior air-flow management and allow aerosol to be extracted more efficiently from the aerosol-generating article and guided to a user.

[0014] Unless otherwise specified, the resistance to draw (RTD) is measured in accordance with ISO 6565- 2015. The RTD refers to the pressure required to force air through the full length of a component, such as the aerosol-generating article. The terms “pressure drop” or “draw resistance” of a component or article may also refer to the “resistance to draw”. Such terms generally refer to the measurements made in accordance with ISO 6565-2015 and are normally carried out at under test at a volumetric flow rate of about 17.5 millilitres per second at the output or downstream end of the measured component at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr) and a relative humidity of about 60%.

[0015] An air flow channel may be defined between the substantially planar upper and lower surfaces. The thickness of the aerosol-generating article may be less than 5 millimetres, for example between 1 .5 millimetres and 5 millimetres, for example between 1 .5 millimetres and 4 millimetres, for example between 1 .5 millimetres and 3 millimetres, for example between 1 .5 millimetres and 2 millimetres. One or both of the substantially planar upper and lower surfaces may comprise an aerosol-generating substrate. The aerosolgenerating article may comprise upper and lower layers, the upper layer forming the substantially planar upper surface and the lower layer forming the substantially planar lower surface. At least one of the upper and lower layers may comprise or consist of aerosol-generating substrate.

[0016] The aerosol-generating article may comprise a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer. At least one of the first planar layer, the second planar layer and the corrugated layer may comprise or consist of an aerosolgenerating substrate. The corrugated layer may be the aerosol-generating substrate plug.

[0017] The use of a corrugated structure in the aerosol-generating article may advantageously allow the production of an aerosol-generating article that has extremely low RTD while still being sufficiently rigid to for a user to handle. Further, use of a corrugated structure may allow a low density, low RTD, aerosolgenerating article to be produced using high speed production methods similar to those used for production of corrugated cardboard.

[0018] The aerosol-generating article may comprise a first planar external surface, a second planar external surface, a cavity and a frame. The frame may be positioned between the first planar external surface and the second planar external surface. The frame may at least partially define the cavity. The aerosolgenerating article may comprise an air inlet and an air outlet, and an airflow passage extending between the air inlet and the air outlet through the cavity.

[0019] Preferably, the aerosol-generating substrate plug may be positioned between the first planar external surface and the second planar external surface.

[0020] The frame may comprise a peripheral wall at least partially circumscribing or encircling the cavity. The frame may comprise a peripheral wall wholly circumscribing or encircling the cavity. Advantageously, the frame may allow the aerosol-generating article to be relatively thin whilst maintaining structural rigidity.

[0021] The aerosol-generating article may comprise a first planar external layer and a second planar external layer, in which the first planar external layer forms the first planar external surface and the second planar external layer forms the second planar external surface. Optionally, at least one of the first planar external layer, the second planar external layer, and the frame may comprise or consist of aerosolgenerating substrate.

[0022] Aerosol-generating substrate plug may be positioned within the cavity.

[0023] A corrugated layer may be positioned within the cavity.

[0024] The frame may be a planar frame.

[0025] The frame may have a thickness between 50 percent and 95 percent of the thickness of the aerosolgenerating article. The frame may have a thickness between 60 percent and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 70 percent and 95 percent of the thickness of the aerosol-generating article. The frame may have a thickness between 80 percent and 95 percent of the thickness of the aerosol-generating article.

[0026] The frame may have a thickness between 1 millimetre and 5.5 millimetres. The frame may have a thickness between 1 millimetre and 5 millimetres. Preferably, the frame may have a thickness between 1 .5 millimetres and 5 millimetres.

[0027] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0028] The frame may be made from or comprise a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may comprise cellulose fibres. The cellulosic material may be paper, paperboard, or cardboard. The frame may be made from or comprise a plant material, such as tobacco. The frame may be made entirely from a cellulosic material.

[0029] The frame may be a unitary component. Alternatively, the frame may comprise two or more layers. That is, the frame may have a laminated structure.

[0030] The aerosol-generating substrate plug and one or both of the first plug and the second plug may be axially aligned in the longitudinal direction, such as in the x-direction.

[0031] One or both of the first plug and the second plug may be positioned adjacent to the aerosolgenerating substrate plug. That is, no element may be positioned between the first plug and the aerosolgenerating substrate plug or no element may be positioned between the second plug and the aerosolgenerating substrate plug.

[0032] One or both of the first plug and the second plug may be spaced from the aerosol-generating substrate plug. One or both of the first plug and the second plug may be positioned adjacent to, and spaced from, the aerosol-generating substrate plug. For example, an empty cavity may be located between the first plug and the aerosol-generating substrate plug and an empty cavity may be located between the second plug and the aerosol-generating substrate plug. One or both of the first plug and the second plug may be spaced from the aerosol-generating substrate plug by greater than or equal to 2 millimetres. One or both of the first plug and the second plug may be spaced from the aerosol-generating substrate plug by less than or equal to 5 millimetres.

[0033] One or both of the first plug and the second plug may abut the aerosol-generating substrate plug. The first plug may abut the upstream end of the aerosol-generating substrate plug. For example, a downstream end of the first plug may abut the upstream end of the aerosol-generating substrate plug. The second plug may abut the downstream end of the aerosol-generating substrate plug. For example, an upstream end of the second plug may abut the downstream end of the aerosol-generating substrate plug.

[0034] The first plug may be positioned at an extreme upstream end of the aerosol-generating article. The first plug may define or form an upstream end wall of the aerosol-generating article. The second plug may be positioned at an extreme downstream end of the aerosol-generating article. The second plug may define or form a downstream end wall of the aerosol-generating article.

[0035] The first plug may define an inlet of the aerosol-generating article. The first plug may comprise an upstream opening and a downstream opening. The upstream opening may define an inlet of the aerosolgenerating article. Therefore, the first plug may be referred to as an inlet plug or a front plug.

[0036] The second plug may define an outlet of the aerosol-generating article. The second plug may comprise an upstream opening and a downstream opening. The downstream opening may define an outlet of the aerosol-generating article. Therefore, the second plug may be referred to as an outlet plug or a mouth plug.

[0037] The upstream opening of one or both the first plug and the second plug may be aligned with the radially central axis of the aerosol-generating article. The downstream opening of one or both the first plug and the second plug may be aligned with the radially central axis of the aerosol-generating article. For example, the radially central axis of the aerosol-generating article may extend through one or both the upstream opening and the downstream opening. The upstream opening of one or both the first plug and the second plug may have a radially central axis aligned with the radially central axis of the aerosolgenerating article. The downstream opening of one or both the first plug and the second plug may have a radially central axis aligned with the radially central axis of the aerosol-generating article.

[0038] One or both of the first plug and the second plug may comprise a chamber. The chamber of the first plug (if any) may be referred to as the first plug chamber. The chamber of the second plug (if any) may be referred to as the second plug chamber. The, or each, chamber may be substantially empty.

[0039] The chamber may extend between the upstream opening and the downstream opening of the respective plug. One or both of the first plug and the second plug may comprise an airflow path extending between the upstream opening and the downstream opening through the chamber of the respective plug. For example, the first plug may comprise an airflow path extending between the upstream opening of the first plug and the downstream opening of the first plug through the first plug chamber. Similarly, the second plug may comprise an airflow path extending between the upstream opening of the second plug and the downstream opening of the second plug through the second plug chamber.

[0040] One or both of the first plug and the second plug may comprise a flavour releasing element positioned within the respective chamber. For example, the first plug may comprise a flavour releasing element positioned within the first plug chamber. As another example, the second plug may comprise a flavour releasing element positioned with the second plug chamber.

[0041] The, or each, flavour releasing element may comprise, be impregnated with, or be soaked in, one or more flavourants. The one or more flavourants may comprise one or more of: 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 a herbaceous material. Suitable herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavourants may comprise a tobacco material. The one or more flavourants may comprise one or more of sorbitol and erythritol. The flavour releasing element positioned in the first plug chamber may be different from the flavour releasing element positioned in the second plug chamber.

[0042] The first plug chamber may have a width greater than a width of one or both the upstream opening of the first plug and the downstream opening of the first plug. The first plug chamber may have a width of at least 80 percent or at least 90 percent of a width of the first plug. The first plug chamber may have a width of between 1 millimetre and 7 millimetres. Preferably, the first plug chamber may have a width between 2 millimetres and 6 millimetres. More preferably, the first plug chamber may have a width of about 4 millimetres.

[0043] The second plug chamber may have a width greaterthan a width of one or both the upstream opening of the second plug and the downstream opening of the second plug. The second plug chamber may have a width of at least 80 percent or at least 90 percent of a width of the second plug. The second plug chamber may have a width of between 1 millimetre and 7 millimetres. Preferably, the second plug chamber may have a width between 2 millimetres and 6 millimetres. More preferably, the second plug chamber may have a width of about 4 millimetres.

[0044] The first plug chamber may have a thickness greater than a thickness of one or both of the upstream opening of the first plug and the downstream opening of the first plug. The first plug chamber may have a thickness of at least 80 percent or at least 90 percent of a thickness of the first plug. The first plug chamber may have a thickness of between 0.5 millimetre and 3 millimetres. Preferably, the first plug chamber may have a thickness between 0.5 millimetres and 2 millimetres. More preferably, the first plug chamber may have a thickness of about 1 millimetres.

[0045] The second plug chamber may have a thickness greater than a thickness of one or both of the upstream opening of the second plug and the downstream opening of the second plug. The second plug chamber may have a thickness of at least 80 percent or at least 90 percent of a thickness of the second plug. The second plug chamber may have a thickness of between 0.5 millimetre and 3 millimetres. Preferably, the second plug chamber may have a thickness between 0.5 millimetres and 2 millimetres. More preferably, the second plug chamber may have a thickness of about 1 millimetres.

[0046] The first plug may comprise one or more walls extending between an upstream end of the first plug and a downstream end of the first plug. The one or more walls may enclose, or at least partially enclose, the first plug chamber. The one or more walls may have a thickness of between 0.5 millimetres and 2 millimetres. Preferably, the one or more walls may have a thickness of between 0.5 millimetres and 1 millimetre.

[0047] The first plug may have an upstream end wall. The upstream end wall may define the upstream opening of the first plug. The first plug may have a downstream end wall. The downstream end wall may define the downstream opening of the first plug.

[0048] The second plug may comprise one or more walls extending between an upstream end of the second plug and a downstream end of the second plug. The one or more walls may enclose, or at least partially enclose, the second plug chamber. The one or more walls may have a thickness of between 0.5 millimetres and 2 millimetres. Preferably, the one or more walls may have a thickness of between 0.5 millimetres and 1 millimetre.

[0049] The second plug may have an upstream end wall. The upstream end wall may define the upstream opening of the second plug. The second plug may have a downstream end wall. The downstream end wall may define the downstream opening of the second plug.

[0050] The first plug may comprise a first plug body. The first plug body may define the first plug chamber. A first flap may extend from the first plug body and a second flap may extend from the first plug body. The first flap and the second flap may overlie a downstream end of the first plug body to define the downstream opening. For example, the first flap may have a first notch and the second flap may have a second notch. The first notch and the second notch of the first plug may collectively form the downstream opening of the first plug. The first flap and the second flap may form a downstream end wall of the first plug.

[0051] The second plug may comprise a second plug body. The second plug body may define the second plug chamber. A first flap may extend from the second plug body and a second flap may extend from the second plug body. The first flap and the second flap may overlie an upstream end of the second plug body to define the upstream opening. For example, the first flap may have a first notch and the second flap may have a second notch. The first notch and the second notch of the second plug may collectively form the upstream opening of the second plug. The first flap and the second flap may form an upstream end wall of the second plug.

[0052] One or both of the first plug and the second plug may be hollow. One or both of the first plug and the second plug may comprise a lumen or bore extending from an upstream end to a downstream end of the respective plug. One or both of the first plug and the second plug may be in the form of a tube, such as a rectangular tube. One or both of the first plug and the second plug may comprise a folded sheet of material, preferably a sheet of cellulosic material such as cardboard. The sheet of material may comprise one or more lines of weakness. The one or more lines of weakness may comprise perforated lines of weakness or crimped lines of weakness. The sheet of material may be folded into a tube about the one or more lines of weakness.

[0053] Preferably, the sheet of material may comprise at least three lines of weakness in which each of the at least three lines of weakness form a longitudinally extending corner of the respective plug. Free ends of the sheet of material may be coupled together to form a further longitudinally extending corner of the respective plug.

[0054] One or both of the first plug and the second plug may be in the form of a spiral tube. For example, one or both of the first plug and the second plug may be made from a sheet of material, preferably a sheet of cellulosic material, that has been wound into an overlapping spiral to form a tube.

[0055] One or both of the first plug and the second plug may be formed from two or more geometrically identical elements. The two or more geometrically identical elements may be bonded together, such as with an adhesive. For example, the first plug may comprise a first geometrically identical element and a second geometrically identical element, each of the first geometrically identical element and the second geometrically identical element having an “L”-shape (such as an “L” cross-sectional shape) or may be an “L” beam. Similarly, the second plug may comprise a first geometrically identical element and a second geometrically identical element, each of the first geometrically identical element and the second geometrically identical element having an “L”-shape (such as an “L” cross-sectional shape) or may be an “L” beam. Each of the two or more geometrically identical elements may extend the entire length of the respective plug. Each of the two or more geometrically identical elements may extend the entire thickness of the respective plug.

[0056] One or both of the first plug and the second plug may comprise a first length portion having a width and a second length portion having a width. The width of the first length portion may be greater than the width of the second length portion, thereby forming at least one shoulder at a location between the first length portion and the second length portion. Preferably, the at least one shoulder comprises a first shoulder on a first lateral side of the respective plug and a second shoulder on a second lateral side of the respective plug.

[0057] The first length portion of the first plug may be an upstream length portion and the second length portion of the first plug may be a downstream length portion. The first length portion of the second plug may be a downstream length portion and the second length portion of the second plug may be an upstream length portion. One or both of the first plug and the second plug may have a laminated or layered structure. One or both of the first plug and the second plug may comprise two or more layers stacked or arranged in the thickness direction. One or both of the first plug and the second plug may comprise, or consist of, a first layer, a second layer, and a third layer. The second layer may be positioned between the first layer and the second layer. The upstream opening of the respective plug may extend through the second layer. The downstream opening of the respective plug may extend through the second layer. The first layer, the second layer, and the third layer may be bonded together. Each of the layers may comprise, or be formed from, a sheet of material, preferably a sheet of cellulosic material.

[0058] One or both of the first plug and the second plug may comprise a sheet of material that has been fluted, crimped, pleated, gathered, woven or folded into an element that defines a plurality of longitudinally extending channels. Preferably, the sheet of material has been fluted or crimped. The sheet of material may comprise, be, or consist of: paper, cardboard, or polymer, such as polylactic acid, or any other cellulose-based, paper-based material or bioplastic-based material. Preferably, the sheet of material is a paper or cardboard. The plurality of longitudinally extending channels may extend the entire length of the respective plug. The plurality of longitudinally extending channels may extend from an upstream end of the respective plug to a downstream end of the respective plug. The plurality of longitudinally extending channels may be uniformly or randomly distributed across the transverse cross-section of the respective plug.

[0059] One or both of the first plug and the second plug may be substantially tobacco-free or nicotine-free.

[0060] One or both of the first plug and the second plug may comprise biodegradable material. One or both of the first plug and the second plug may comprise at least 80 percent by weight of biodegradable material. One or both of the first plug and the second plug may comprise at least 90 percent by weight of biodegradable material. One or both of the first plug and the second plug may comprise at least 95 percent by weight of biodegradable material.

[0061] One or both of the first plug and the second plug may comprise, or consist of, a cellulosic material, such as paper or cardboard. One or both of the first plug and the second plug may comprise at least 80 percent by weight of cellulosic material, such as paper or cardboard. One or both of the first plug and the second plug may comprise at least 90 percent by weight of cellulosic material, such as paper or cardboard. One or both of the first plug and the second plug may comprise at least 95 percent by weight of cellulosic material, such as paper or cardboard. One or both of the first plug and the second plug may comprise at least 99 percent by weight of cellulosic material, such as paper or cardboard.

[0062] One or both of the first plug and the second plug may be formed from compressed matter, such as particulate matter, powder or pellets. The compressed matter may comprise one or both of sorbitol and erythritol.. Advantageously, forming the plugs from compressed matter may allow for manufacturing complex three dimensional shapes that are particularly suited to upstream and downstream plugs. Additionally, the compressed matter can be adapted to disaggregate after a predefined period of time, thereby improving the environmental friendliness of the aerosol-generating article. Moreover, it also allows flavour or aroma to be embedded within the structure of the plugs which may improve user experience. Furthermore, it allows for the incorporation of a bittering agent to reduce the risk of accidental ingestion. One or both of the first plug and the second plug may be formed from moulded pulp. One or both of the first plug and the second plug may be formed by extrusion, lamination, injection moulding, or additive manufacturing.

[0063] A ratio between a length of the first plug and a length of the aerosol-generating article may be greater than or equal to 0.05. A ratio between a length of the first plug and a length of the aerosol-generating article may be greater than or equal to 0.10. A ratio between a length of the first plug and a length of the aerosolgenerating article may be greater than or equal to 0.20. A ratio between a length of the first plug and a length of the aerosol-generating article may be greater than or equal to 0.30.

[0064] A ratio between a length of the first plug and a length of the aerosol-generating article may be less than or equal to 0.40. A ratio between a length of the first plug and a length of the aerosol-generating article may be less than or equal to 0.30. A ratio between a length of the first plug and a length of the aerosolgenerating article may be less than or equal to 0.20. A ratio between a length of the first plug and a length of the aerosol-generating article may be less than or equal to 0.10. A ratio between a length of the first plug and a length of the aerosol-generating article may be less than or equal to 0.05.

[0065] A ratio between a length of the first plug and a length of the aerosol-generating article may be between 0.05 and 0.40. A ratio between a length of the first plug and a length of the aerosol-generating article may be between 0.05 and 0.30. A ratio between a length of the first plug and a length of the aerosolgenerating article may be between 0.05 and 0.20. A ratio between a length of the first plug and a length of the aerosol-generating article may be between 0.10 and 0.20.

[0066] A ratio between a length of the first plug and a length of the aerosol-generating substrate plug is may be greater than or equal to 0.15. A ratio between a length of the first plug and a length of the aerosolgenerating substrate plug may be greater than or equal to 0.20. A ratio between a length of the first plug and a length of the aerosol-generating substrate plug may be greater than or equal to 0.30.

[0067] A ratio between a length of the first plug and a length of the aerosol-generating substrate plug may be less than or equal to 0.50. A ratio between a length of the first plug and a length of the aerosol-generating substrate plug may be less than or equal to about 0.45. A ratio between a length of the first plug and a length of the aerosol-generating substrate plug may be less than or equal to about 0.40.

[0068] A ratio between a length of the first plug and a length of the aerosol-generating substrate plug may be between 0.15 and 0.50. A ratio between a length of the first plug and a length of the aerosol-generating substrate plug may be between 0.15 and 0.40. A ratio between a length of the first plug and a length of the aerosol-generating substrate plug may be between 0.15 and 0.30.

[0069] A ratio between a length of the second plug and a length of the aerosol-generating article may be greater than or equal to 0.05. A ratio between a length of the second plug and a length of the aerosolgenerating article may be greater than or equal to 0.10. A ratio between a length of the second plug and a length of the aerosol-generating article may be greater than or equal to 0.20. A ratio between a length of the second plug and a length of the aerosol-generating article may be greater than or equal to 0.30.

[0070] A ratio between a length of the second plug and a length of the aerosol-generating article may be less than or equal to 0.40. A ratio between a length of the second plug and a length of the aerosolgenerating article may be less than or equal to 0.30. A ratio between a length of the second plug and a length of the aerosol-generating article may be less than or equal to 0.20. A ratio between a length of the second plug and a length of the aerosol-generating article may be less than or equal to 0.10. A ratio between a length of the second plug and a length of the aerosol-generating article may be less than or equal to 0.05.

[0071] A ratio between a length of the second plug and a length of the aerosol-generating article may be between 0.05 and 0.40. A ratio between a length of the second plug and a length of the aerosol-generating article may be between 0.05 and 0.30. A ratio between a length of the second plug and a length of the aerosol-generating article may be between 0.05 and 0.20. A ratio between a length of the second plug and a length of the aerosol-generating article may be between 0.10 and 0.20.

[0072] A ratio between a length of the second plug and a length of the aerosol-generating substrate plug is may be greater than or equal to 0.15. A ratio between a length of the second plug and a length of the aerosol-generating substrate plug may be greater than or equal to 0.20. A ratio between a length of the second plug and a length of the aerosol-generating substrate plug may be greater than or equal to 0.30.

[0073] A ratio between a length of the second plug and a length of the aerosol-generating substrate plug may be less than or equal to 0.50. A ratio between a length of the second plug and a length of the aerosolgenerating substrate plug may be less than or equal to about 0.45. A ratio between a length of the second plug and a length of the aerosol-generating substrate plug may be less than or equal to about 0.40.

[0074] A ratio between a length of the second plug and a length of the aerosol-generating substrate plug may be between 0.15 and 0.50. A ratio between a length of the second plug and a length of the aerosolgenerating substrate plug may be between 0.15 and 0.40. A ratio between a length of the second plug and a length of the aerosol-generating substrate plug may be between 0.15 and 0.30.

[0075] The aerosol-generating article may comprise an aerosol-cooling plug positioned between the aerosol-generating substrate plug and the second plug. The aerosol-cooling plug may be a hollow element. The aerosol-cooling plug may be a tubular element, such as a rectangular tubular element. The aerosolcooling plug may be adjacent to the aerosol-generating substrate plug. The aerosol-cooling plug may abut the aerosol-generating substrate plug. The aerosol-cooling plug may be adjacent to the second plug. The aerosol-cooling plug may abut the second plug.

[0076] The aerosol-generating article may comprise a flavour releasing plug positioned between the first plug and the aerosol-generating substrate plug. The aerosol-generating article may comprise a flavour releasing plug positioned between the second plug and the aerosol-generating substrate plug.

[0077] The aerosol-generating article may comprise at least one support member. Two or more plugs of: the first plug, the second plug and the aerosol-generating substrate plug may be physically coupled together by the at least one support member. The two or more plugs may be bonded directly to the at least one support member, for example with an adhesive such as guar gum or polyvinyl alcohol.

[0078] The first plug, the second plug, the at least one support member may form a frame. The frame may at least partially define a cavity. The aerosol-generating substrate plug may be positioned within the cavity.

[0079] Preferably, the at least one support member may comprise a first support member and a second support member.

[0080] The first support member and the second support member may extend along opposing lateral sides of the aerosol-generating article. That is, the first support member and the second support member may be spaced in the width direction of the aerosol generating article. The first support member and the second support member may extend along opposing lateral sides of the aerosol-generating substrate plug. The first support member and the second support member may each extend along at least 80 percent of a length of aerosol-generating substrate plug. Preferably, the first support member and the second support member may each extend along 100 percent of a length of aerosol-generating substrate plug. The first support member and the second support member may extend along opposing lateral sides of the aerosolgenerating substrate.

[0081] The first support member may extend from the first plug to the second plug. The first support member may be coupled to the first plug and the second plug. The second support member may extend from the first plug to the second plug. The second support member may be coupled to the first plug and the second plug.

[0082] The first support member may extend from the at least one shoulder, such as the first shoulder, of the first plug to the at least one shoulder, such as the first shoulder, of the second plug. The second support member may extend from the at least one shoulder, such as the second shoulder, of the first plug to the at least one shoulder, such as the second shoulder, of the second plug. The first support member, the second support member and the downstream length portion of the first plug may have a collective width equal to or less than the width of the upstream length portion of the first plug. The first support member, the second support member and the upstream length portion of the second plug may have a collective width equal to or less than the width of the downstream length portion of the second plug.

[0083] The, or each of the, at least one support member may be elongated. For example, the, or each of the at least one support member may have a length, a width, and a thickness. The length may be at least two, four, eight or ten times greater than the width or thickness.

[0084] The, or each of the, at least one support member may be in the form of a rod, a beam or a strip of material. The, or each of the, at least one support member may extend along greater than or equal to 80 percent of a length of the aerosol-generating article. The, or each of the, at least one support member may extend along greater than or equal to 90 percent of a length of the aerosol-generating article. The, or each of the, at least one support member may extend along 100 percent of a length of the aerosol-generating article.

[0085] The, or each of the, at least one support member may comprise biodegradable material. The, or each of the, at least one support member may comprise at least 80 percent by weight of biodegradable material. The, or each of the, at least one support member may comprise at least 90 percent by weight of biodegradable material. The, or each of the, at least one support member may comprise at least 95 percent by weight of biodegradable material.

[0086] The, or each of the, at least one support member may comprise, or consist of, tobacco material such as homogenised tobacco material. The, or each of the, at least one support member may comprise an aerosol former as described herein in relation to the aerosol-generating substrate. The, or each of the, at least one support member may comprise one or more flavourants as described herein in relation to the aerosol-generating substrate.

[0087] The, or each of the, at least one support member may comprise, or consist of, a cellulosic material, such as paper or cardboard. The, or each of the, at least one support member may comprise at least 80 percent by weight of cellulosic material, such as paper or cardboard. The, or each of the, at least one support member may comprise at least 90 percent by weight of cellulosic material, such as paper or cardboard. The, or each of the, at least one support member may comprise at least 95 percent by weight of cellulosic material, such as paper or cardboard. The, or each of the, at least one support member may comprise at least 99 percent by weight of cellulosic material, such as paper or cardboard.

[0088] The, or each of the, at least one support member may comprise, or consist of, corrugated cardboard. Advantageously, corrugated cardboard may provide thermal insulation. Therefore, the aerosol-generating article may lose less heat which may improve aerosol generation efficiency. Additionally, it may result in the external surface of the aerosol-generating article being cooler, thereby allowing a consumer to comfortably touch the aerosol-generating article.

[0089] The, or each of the, at least one support member may have a grammage of greater than or equal to 200 grams per square metre. The, or each of the, at least one support member may have a grammage of greater than or equal to 300 grams per square metre. The, or each of the, at least one support member may have a grammage of greater than or equal to 400 grams per square metre. The, or each of the, at least one support member may comprise, or consist of, cellulosic material, preferably cardboard.

[0090] The, or each of the, at least one support member may be formed from compressed matter, such as particulate matter, powder or pellets. The, or each of the, at least one support member may be formed from moulded pulp. The, or each of the, at least one support member may be formed by extrusion, lamination, injection moulding, or additive manufacturing.

[0091] The aerosol-generating article may comprise a primary airflow path extending from an upstream end of the aerosol-generating article to a downstream end of the aerosol-generating article. The primary airflow path may extend through the first plug, the aerosol-generating substrate, and the second plug.

[0092] The aerosol-generating article may comprise at least one auxiliary airflow path extending from an upstream end of the aerosol-generating article to a downstream end of the aerosol-generating article. The at least one auxiliary airflow path may extend through the first plug, the at least one support member (such as the first support member or the second support member), and the second plug.

[0093] The at least one auxiliary airflow path may comprise a first auxiliary airflow path extending through the first plug, the first support member, and the second plug. The at least one auxiliary airflow path may comprise a second auxiliary airflow path extending through the first plug, the second support member, and the second plug.

[0094] The primary airflow path and the at least one auxiliary airflow path may be parallel for at least a portion of the length of the aerosol-generating article. Thus, the airflow paths may be separate and distinct airflow paths for at least a portion of the length of the aerosol-generating article. For example, the primary airflow path and the at least one auxiliary airflow path may be parallel from the upstream end of the aerosolgenerating article to the downstream end of the aerosol-generating substrate plug.

[0095] The primary airflow path and the at least one auxiliary airflow path may merge downstream of the aerosol-generating substrate plug. For example, the primary airflow path and the at least one auxiliary airflow path may merge within the second plug.

[0096] The primary airflow path and the at least one auxiliary airflow path may merge upstream of the second plug. For example, the primary airflow path and the at least one auxiliary airflow path may merge within the aerosol-cooling plug.

[0097] The, or each of the, at least one support member may comprise a flavour releasing element. The flavour releasing element may be a thread or a yarn. The flavour releasing element may be positioned within the secondary airflow path. The flavour releasing element may comprise, be impregnated with, or be soaked in, one or more flavourants. The one or more flavourants may comprise one or more of: 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 a herbaceous material. Suitable herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, thyme, and caraway.

[0098] The aerosol-generating substrate plug may comprise the at least one support member. Preferably, the first support member and the second support member may extend along opposing lateral sides of the aerosol-generating substrate. Advantageously, the first support member and the second support member may provide resistance to compression of one or both of the aerosol-generating substrate plug and the aerosol-generating article. This may ensure integrity of the airflow path through the aerosol-generating article is maintained and may assist in avoiding air leaks through the sides of the aerosol-generating article or aerosol-generating substrate plug. Additionally, the support members may make it easier and convenient to shape the aerosol-generating substrate plug, thereby ensuring better alignment of the first plug, the second plug and the aerosol-generating substrate plug. Furthermore, the support elements may make the aerosol-generating substrate plug particularly robust for use in a high speed manufacturing process by providing the aerosol-generating substrate plug with additional rigidity.

[0099] Preferably, the, or each of the, at least one support member may comprise one or more of tobacco material, an aerosol former, and a flavourant. Advantageously, this may allow the aerosol-generating substrate plug to be configured to release volatile compounds during different periods of a smoking session. For example, the aerosol-generating substrate may release volatile compounds during a first period of a smoking session and the at least one support member may release volatile compounds at a second period of the smoking session, after the first period of the smoking session. This may provide an improved or unique user experience.

[0100] The aerosol-generating substrate may extend substantially the entire length of the aerosolgenerating substrate plug.

[0101] The aerosol-generating substrate may occupy at least 95 percent of the transverse cross-sectional area of the aerosol-generating substrate plug. The aerosol-generating substrate may occupy at least 95 percent of the transverse cross-sectional area of the aerosol-generating substrate plug. The aerosolgenerating substrate may occupy at least 98 percent of the transverse cross-sectional area of the aerosolgenerating substrate plug.

[0102] The aerosol-generating substrate may have a mass greater than or equal to 70 percent a mass of the aerosol-generating substrate plug. The aerosol-generating substrate may have a mass greater than or equal to 80 percent a mass ofthe aerosol-generating substrate plug. The aerosol-generating substrate may have a mass greater than or equal to 90 percent a mass of the aerosol-generating substrate plug. The aerosol-generating substrate may have a mass greater than or equal to 95 percent a mass of the aerosolgenerating substrate plug.

[0103] The aerosol-generating substrate may have a mass greater than or equal to 50 milligrams. The aerosol-generating substrate may have a mass greater than or equal to 80 milligrams. The aerosolgenerating substrate may have a mass greater than or equal to 110 milligrams. The aerosol-generating substrate may have a mass greater than or equal to 150 milligrams. The aerosol-generating substrate may have a mass greater than or equal to 170 milligrams. The aerosol-generating substrate may have a mass greater than or equal to 180 milligrams. The aerosol-generating substrate may have a mass greater than or equal to 200 milligrams. The aerosol-generating substrate may have a mass greater than or equal to 230 milligrams. The aerosol-generating substrate may have a mass greater than or equal to 250 milligrams. The aerosol-generating substrate may have a mass greater than or equal to 300 milligrams. The aerosolgenerating substrate may have a mass greater than or equal to 400 milligrams.

[0104] The aerosol-generating substrate may have a mass less than or equal to 500 milligrams. The aerosol-generating substrate may have a mass less than or equal to 400 milligrams. The aerosolgenerating substrate may have a mass less than or equal to 300 milligrams. The aerosol-generating substrate may have a mass less than or equal to 250 milligrams. The aerosol-generating substrate may have a mass less than or equal to 230 milligrams. The aerosol-generating substrate may have a mass less than or equal to 200 milligrams. The aerosol-generating substrate may have a mass less than or equal to 180 milligrams. The aerosol-generating substrate may have a mass less than or equal to 170 milligrams. The aerosol-generating substrate may have a mass less than or equal to 150 milligrams. The aerosolgenerating substrate may have a mass less than or equal to 110 milligrams. The aerosol-generating substrate may have a mass less than or equal to 80 milligrams. The aerosol-generating substrate may have a mass less than or equal to 50 milligrams.

[0105] The aerosol-generating substrate may have a mass between 50 milligrams and 500 milligrams. The aerosol-generating substrate may have a mass between 80 milligrams and 500 milligrams. The aerosolgenerating substrate may have a mass between 80 milligrams and 400 milligrams. The aerosol-generating substrate may have a mass between 80 milligrams and 300 milligrams. The aerosol-generating substrate may have a mass between 80 milligrams and 250 milligrams. The aerosol-generating substrate may have a mass between 80 milligrams and 200 milligrams. The aerosol-generating substrate may have a mass between 80 milligrams and 150 milligrams. Preferably, the aerosol-generating substrate may have a mass between 100 milligrams and 250 milligrams.

[0106] The aerosol-generating substrate may have a bulk density of greater than or equal to 0.05 milligrams per cubic millimetre. The aerosol-generating substrate may have a bulk density of greater than or equal to 0.1 milligrams per cubic millimetre. The aerosol-generating substrate may have a bulk density of greater than or equal to 0.15 milligrams per cubic millimetre. The aerosol-generating substrate may have a bulk density of greater than or equal to 0.2 milligrams per cubic millimetre. The aerosol-generating substrate may have a bulk density of greater than or equal to 0.3 milligrams per cubic millimetre. The aerosolgenerating substrate may have a bulk density of greaterthan or equal to 0.4 milligrams per cubic millimetre.

[0107] The aerosol-generating substrate may have a bulk density of less than or equal to 0.5 milligrams per cubic millimetre. The aerosol-generating substrate may have a bulk density of less than or equal to 0.4 milligrams per cubic millimetre. The aerosol-generating substrate may have a bulk density of less than or equal to 0.35 milligrams per cubic millimetre. The aerosol-generating substrate may have a bulk density of less than or equal to 0.3 milligrams per cubic millimetre.

[0108] The aerosol-generating substrate may have a bulk density of between 0.05 milligrams per cubic millimetre and 0.5 milligrams per cubic millimetre. The aerosol-generating substrate may have a bulk density of between 0.1 milligrams per cubic millimetre and 0.4 milligrams per cubic millimetre. The aerosolgenerating substrate may have a bulk density of between 0.1 and 0.3 milligrams per cubic millimetre. The aerosol-generating substrate may have a bulk density of between 0.2 and 0.3 milligrams per cubic millimetre.

[0109] The aerosol-generating substrate may have a packing density greater than or equal to 0.3. The aerosol-generating substrate may have a packing density greater than or equal to 0.4. The aerosolgenerating substrate may have a packing density greater than or equal to 0.5. The aerosol-generating substrate may have a packing density greater than or equal to 0.6. The aerosol-generating substrate may have a packing density greater than or equal to 0.7.

[0110] The aerosol-generating substrate may have a packing density less than or equal to 0.9. The aerosolgenerating substrate may have a packing density less than or equal to 0.8. The aerosol-generating substrate may have a packing density less than or equal to 0.7. The aerosol-generating substrate may have a packing density less than or equal to 0.6. The aerosol-generating substrate may have a packing density less than or equal to 0.5.

[0111] The aerosol-generating substrate may have a packing density of between 0.3 and 0.9. The aerosolgenerating substrate may have a packing density of between 0.4 and 0.9. The aerosol-generating substrate may have a packing density of between 0.5 and 0.9. The aerosol-generating substrate may have a packing density of between 0.5 and 0.8. The aerosol-generating substrate may have a packing density of between 0.5 and 0.7.

[0112] The aerosol-generating substrate may comprise one or more organic materials such as tobacco, mint, tea and cloves. The aerosol-generating substrate may comprise one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenised tobacco such as cast leaf, extruded tobacco, expanded tobacco, aerosol-generating films and gel compositions.

[0113] The aerosol-generating substrate may comprise or consist of homogenised tobacco material, for example a reconstituted tobacco material or a cast leaf tobacco material.

[0114] The aerosol-generating substrate may be in the form of shredded aerosol-generating material. The shredded aerosol-generating material may comprise one or more of: strips and strands of aerosolgenerating material, such as strips and strands of tobacco or homogenised tobacco material. The shredded aerosol-generating material may be in the form of a shredded sheet of homogenised tobacco material.

[0115] The aerosol-generating substrate may be cut filler. The aerosol-generating substrate may be tobacco cut filler. The cut filler may comprise one or more of bright tobacco, dark tobacco, aromatic tobacco and filler tobacco. Examples of bright tobaccos are Flue-Cured Brazil, Indian Flue-Cured, Chinese Flue-Cured, US Flue-Cured such as Virginia tobacco, and Flue-Cured from Tanzania. Examples of aromatic tobaccos are Oriental Turkey, Greek Oriental, semi-oriental tobacco but also Fire Cured, US Burley, such as Perique, and Rustica. Examples of dark tobacco are Dark Cured Brazil Galpao, Burley Malawi or other African Burley, Sun Cured or Air Cured Indonesian Kasturi. As used herein, the term “cut filler” is used to describe a blend of shredded plant material, such as tobacco plant material, including, in particular, one or more of leaf lamina, processed stems and ribs, homogenised plant material.

[0116] The aerosol-generating substrate may be in the form of a sheet of aerosol-generating material. As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof. The sheet of aerosol-generating material may be a sheet of plant material. The sheet of aerosol-generating material may be a sheet of tobacco material. The sheet of aerosol-generating material may be a sheet of homogenised tobacco material, such as a cast leaf sheet. The sheet of aerosol-generating material may have a grammage of between 100 grams per square metre and 600 grams per square metre. The sheet of aerosol-generating material may have a grammage of between 100 grams per square metre and 300 grams per square metre.

[0117] The sheet of aerosol-generating material may have a density greater than or equal to 0.3 grams per cubic centimetre. The sheet of aerosol-generating material may have a density greater than or equal to 0.4 grams per cubic centimetre. The sheet of aerosol-generating material may have a density greater than or equal to 0.5 grams per cubic centimetre. The sheet of aerosol-generating material may have a density greater than or equal to 0.6 grams per cubic centimetre. The sheet of aerosol-generating material may have a density greater than or equal to 0.7 grams per cubic centimetre. The sheet of aerosol-generating material may have a density less than or equal to 0.8 grams per cubic centimetre.

[0118] The sheet of aerosol-generating material may have a density less than or equal to 1 .0 grams per cubic centimetre. The sheet of aerosol-generating material may have a density less than or equal to 0.9 grams per cubic centimetre. The sheet of aerosol-generating material may have a density less than or equal to 0.8 grams per cubic centimetre. The sheet of aerosol-generating material may have a density less than or equal to 0.7 grams per cubic centimetre. The sheet of aerosol-generating material may have a density less than or equal to 0.6 grams per cubic centimetre. The sheet of aerosol-generating material may have a density less than or equal to 0.5 grams per cubic centimetre. The sheet of aerosol-generating material may have a density less than or equal to 0.4 grams per cubic centimetre.

[0119] The sheet of aerosol-generating material may have a density between 0.3 grams per cubic centimetre and 1 .3 grams per cubic centimetre. The sheet of aerosol-generating material may have a density between 0.3 grams per cubic centimetre and 1 .0 gram per cubic centimetre. The sheet of aerosolgenerating material may have a density between 0.4 grams per cubic centimetre and 1 .0 grams per cubic centimetre. The sheet of aerosol-generating material may have a density between 0.4 grams per cubic centimetre and 0.9 grams per cubic centimetre. The sheet of aerosol-generating material may have a density between 0.5 grams per cubic centimetre and 0.9 grams per cubic centimetre.

[0120] The sheet of aerosol-generating material may be a gathered sheet of aerosol-generating material. That is, the sheet of aerosol-generating material may be convoluted, folded, or otherwise compressed or constricted substantially perpendicular to the transverse direction of the aerosol-generating substrate plug.

[0121] The sheet of aerosol-generating material may be a crimped sheet of aerosol-generating material. The sheet of aerosol-generating material may be a corrugated sheet of aerosol-generating material. The crimped sheet of aerosol-generating material or the corrugated sheet of aerosol-generating material may comprise a plurality of parallel corrugations. The plurality of parallel corrugations may define, or form, a plurality of channels. The plurality of channels may be a plurality of longitudinally extending channels. That is, the plurality of channels may extend in a longitudinal direction of the aerosol-generating substrate plug.

[0122] The aerosol-generating substrate may comprise a bound collection of strips, strands or particles of tobacco material. The aerosol-generating substrate may be in the form of a compressed plug of tobacco material; for example, in which a plug having a substantially circular cross-section in an initial state of the plug is compressed into a flatter cross-sectional profile in a subsequent state of the plug. The aerosolgenerating substrate may be in the form of strips, strands or particles of tobacco material bound together in a binder matrix. The aerosol-generating substrate may comprise one or more aerosol-formers. Suitable aerosolformers are well known in the art and include, but are not limited to, one or more aerosol-formers selected from: polyhydric alcohols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1 , 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferable for the aerosol-former to be or comprise one or both of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0123] The aerosol-generating substrate may have an aerosol-former content greater than or equal to 1 , 2, 5, 10, or 15 percent by weight on a dry weight basis. The aerosol-generating substrate may have an aerosol-former content greater than or equal to 15 percent by weight on a dry weight basis, for example greater than 20 by weight on a dry weight basis, or greater than 25 by weight on a dry weight basis, or greater than 30 by weight on a dry weight basis, or greater than 40 by weight on a dry weight basis, or greater than 50 by weight on a dry weight basis.

[0124] The aerosol-generating substrate may have an aerosol-former content less than or equal to 30 percent by weight on a dry weight basis, less than or equal to 25 percent by weight on a dry weight basis, or less than or equal to 20 percent by weight on a dry weight basis. That is, the aerosol-generating material may have an aerosol-former content less than or equal to 30 by weight on a dry weight basis, less than or equal to 25 by weight on a dry weight basis, or less than or equal to 20 by weight on a dry weight basis.

[0125] The aerosol-generating substrate may have an aerosol-former content between 1 percent and 30 percent by weight on a dry weight basis, between 1 percent and 25 percent by weight on a dry weight basis, or between 1 percent and 20 percent by weight on a dry weight basis.

[0126] The aerosol-generating substrate may comprise at least 50 percent by weight of aerosol former, at least 60 percent by weight of aerosol former, or at least 70 percent by weight of aerosol former.

[0127] The aerosol-generating substrate may comprise less than or equal to 85 percent by weight of aerosol former, less than or equal to 80 percent by weight of aerosol former, or less than or equal to 75 percent by weight of aerosol former.

[0128] The aerosol-generating substrate may comprise between 50 percent and 85 percent by weight of aerosol former, between 50 percent and 80 percent by weight of aerosol former, or between 50 percent and 75 percent by weight of aerosol former.

[0129] The aerosol-generating substrate may comprise nicotine. The aerosol-generating substrate may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine. Nicotine may be present in the form of a tobacco material or may be in the form of a nicotine extract.

[0130] The aerosol-generating substrate may comprise at least 0.5 percent by weight of nicotine, at least 1 percent by weight of nicotine, at least 1 .5 percent by weight of nicotine, or at least 2 percent by weight of nicotine.

[0131] The aerosol-generating substrate may be substantially tobacco-free or nicotine-free.

[0132] The aerosol-generating substrate may comprise one or more cannabinoid compounds such as one or more of: tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannabivarin (CBV), cannabidivarin (CBDV), tetrahydrocannabivarin (THCV), cannabichromene (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), cannabicitran (CBT). It may be preferable that the cannabinoid compound is CBD or THC. It may be particularly preferable that the cannabinoid compound is CBD.

[0133] The aerosol-generating substrate may comprise one or more flavourants. The one or more flavourants may comprise one or more of: 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 a herbaceous material. Suitable herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavourants may comprise a tobacco material.

[0134] The aerosol-generating substrate may comprise one or more botanicals. For example, the aerosolgenerating substrate may comprise about 1 to 90 %, for example about 15 to 55 %, preferably of about 20 to 35 %, of botanicals such as Clove, Echinacea sp., Fennel, Ginger, Hawthorn berry, Elderberry, Monarda, Mullein leaves, Nettle, Plantain, Turmeric, Yarrow, Rooibos, Star Anise, Thyme, Anethum, Chamomile and compounds of those.

[0135] The aerosol-generating substrate may have a moisture content of about 5 to 25%, preferably of about 7 to 15%, at final product state. For example, the aerosol-generating substrate may be a homogenised tobacco material with a moisture of about 5 to 25%, preferably of about 7 to 15%, at final product state.

[0136] The aerosol-generating substrate may comprise a binder. For example, the aerosol-generating substrate may comprise about 1 to 10%, preferably of about 1 to 5%, of a binder such as any of common gums or pectins used in food and beverage (F&B) industries. Preferred binders may be natural pectins, such as fruit, for example citrus, or tobacco pectins; guar gums, land locust bean gums, such as hydroxyethyl and / or hydroxypropyl of those; starches, such as modified or derivatized starches; alginate; methyl, ethyl, ethylhydroxymethyl and carboxy methyl, celluloses; dextran; and xanthan gum. A preferable binder is guar.

[0137] The aerosol-generating substrate may comprise, or consist of, a solid aerosol-forming material. The aerosol-generating substrate may comprise a liquid aerosol-forming material, for example a liquid aerosolforming material retained within a porous matrix. The aerosol-generating substrate may comprise a gel aerosol-forming material.

[0138] The aerosol-generating substrate plug may comprise a substrate wrapper. The substrate wrapper may circumscribe the aerosol-generating substrate. The substrate wrapper may circumscribe the at least one support member. Advantageously, the at least one support member may make it easierto circumscribe the aerosol-generating substrate with the substrate wrapper.

[0139] The substrate wrapper may comprise a first substrate wrapper forming an upper layer of the aerosolgenerating substrate plug and a second substrate wrapper forming a lower layer of the aerosol-generating substrate plug.

[0140] The substrate wrapper may have a grammage greater than or equal to 20 grams per square metre, greater than or equal to 25 grams per square metre, greater than or equal to 30 grams per square metre, greater than or equal to 35 grams per square metre, greater than or equal to 40 grams per square metre, greater than or equal to 45 grams per square metre, greater than or equal to 50 grams per square metre, greater than or equal to 60 grams per square metre, or greater than or equal to 70 grams per square metre. The substrate wrapper may have a grammage less than or equal to 180 grams per square metre, less than or equal to 160 grams per square metre, less than or equal to 140 grams per square metre, less than or equal to 120 grams per square metre, or less than or equal to 100 grams per square metre.

[0141] The substrate wrapper may have a grammage of between 20 grams per square metre and 200 grams per square metre, between 25 grams per square metre and 180 grams per square metre, between 30 grams per square metre and 160 grams per square metre, between 35 grams per square metre and 140 grams per square metre, between 40 grams per square metre and 120 grams per square metre, between 45 grams per square metre and 120 grams per square metre, or between 50 grams per square metre and 100 grams per square metre.

[0142] The substrate wrapper may have a thickness of between 10 micrometres and 300 micrometres, between 10 micrometres and 200 micrometres, between 10 micrometres and 150 micrometres, between 10 micrometres and 100 micrometres, between 10 micrometres and 75 micrometres, between 10 micrometres and 50 micrometres, between 10 micrometres and 40 micrometres, between 15 micrometres and 40 micrometres, between 20 micrometres and 40 micrometres. The substrate wrapper may have a thickness of about 37 micrometres.

[0143] The substrate wrapper may have a length substantially equal to the length of the aerosol-generating substrate. The substrate wrapper may have a length substantially equal to the length of the aerosolgenerating substrate plug.

[0144] The substrate wrapper may define or form at least 60 percent of the outer surface area of the aerosolgenerating substrate plug. The substrate wrapper may define or form at least 70 percent of the outer surface area of the aerosol-generating substrate plug. The substrate wrapper may define or form at least 95 percent of the outer surface area of the aerosol-generating substrate plug. The substrate wrapper may define or form at least 98 percent of the outer surface area of the aerosol-generating substrate plug.

[0145] The substrate wrapper may define or form less than 95 percent of the outer surface area of the aerosol-generating substrate plug. The substrate wrapper may define or form less than 85 percent of the outer surface area of the aerosol-generating substrate plug. The substrate wrapper may define or form less than 75 percent of the outer surface area of the aerosol-generating substrate plug.

[0146] The substrate wrapper may form an open-ended tube and the aerosol-generating substrate may be positioned within the open-ended tube. The aerosol-generating substrate may be exposed at one or both of the distal end and the proximal end of the aerosol-generating substrate plug. That is, the aerosolgenerating substrate may be exposed at one or both of the extreme upstream end and the extreme downstream end of the aerosol-generating substrate plug. Alternatively, the substrate wrapper may completely enclose the aerosol-generating substrate.

[0147] The substrate wrapper may comprise one or more flavourants. Advantageously, the substrate wrapper flavourant may be entrained in or released in the air flowing through the aerosol-generating substrate plug. The one or more flavourant may be any flavourant described herein in relation to the aerosol-generating substrate.

[0148] The substrate wrapper may comprise one or more aerosol-formers. The one or more aerosol-formers may be any aerosol-former described herein in relation to the aerosol-generating substrate.

[0149] The substrate wrapper may comprise, or consist of, cellulosic material. The substrate wrapper may comprise, or consist of, organic material or plant material, such as tobacco, mint, tea and cloves. The substrate wrapper may comprise, or consist of, hygroscopic material. The hygroscopic material may comprise one or more materials selected from a list consisting of polyvinyl alcohol, silicon, or a combination thereof. For example, the substrate wrapper may comprise a surface treatment of hygroscopic material. Hygroscopic material may be dispersed within the substrate wrapper.

[0150] The substrate wrapper may be a sheet of material. The substrate wrapper may comprise, or consist of, a sheet of cellulosic material such as paper. The substrate wrapper may comprise, or consist of, a sheet of organic material or a sheet of plant material. The substrate wrapper may comprise, or consist of, a sheet of homogenised tobacco material.

[0151] The substrate wrapper may comprise one or more elements selected from a list consisting of ceramic fibres or particles, metallic strips or particles, or a combination thereof.

[0152] A ratio between a length of the aerosol-generating substrate plug and a length of the aerosolgenerating article may be greater than or equal to 0.4. A ratio between a length of the aerosol-generating substrate plug and a length of the aerosol-generating article may be greater than or equal to 0.5. A ratio between a length of the aerosol-generating substrate plug and a length of the aerosol-generating article may be greater than or equal to 0.6. A ratio between a length of the aerosol-generating substrate plug and a length of the aerosol-generating article may be greater than or equal to 0.7.

[0153] A ratio between a length of the aerosol-generating substrate plug and a length of the aerosolgenerating article may be less than or equal to 0.9. A ratio between a length of the aerosol-generating substrate plug and a length of the aerosol-generating article may be less than or equal to 0.8. A ratio between a length of the aerosol-generating substrate plug and a length of the aerosol-generating article may be less than or equal to 0.7. A ratio between a length of the aerosol-generating substrate plug and a length of the aerosol-generating article may be less than or equal to 0.6.

[0154] A ratio between a length of the aerosol-generating substrate plug and a length of the aerosolgenerating article may be between 0.4 and 0.9. A ratio between a length of the aerosol-generating substrate plug and a length of the aerosol-generating article may be between 0.5 and 0.9. A ratio between a length of the aerosol-generating substrate plug and a length of the aerosol-generating article may be between 0.5 and 0.8. A ratio between a length of the aerosol-generating substrate plug and a length of the aerosolgenerating article may be between 0.6 and 0.8.

[0155] The aerosol-generating substrate plug may have a length greater than or equal to 6 millimetres. The aerosol-generating substrate plug may have a length equal to a greater than 10 millimetres. The aerosolgenerating substrate plug may have a length equal to a greater than 14 millimetres. The aerosol-generating substrate plug may have a length greater than or equal to 18 millimetres. The aerosol-generating substrate plug may have a length greater than or equal to 22 millimetres. The aerosol-generating substrate plug may have a length greater than or equal to 26 millimetres. The aerosol-generating substrate plug may have a length greater than or equal to 30 millimetres.

[0156] The aerosol-generating substrate plug may have a length less than or equal to 45 millimetres. The aerosol-generating substrate plug may have a length less than or equal to 32 millimetres. The aerosolgenerating substrate plug may have a length less than or equal to 28 millimetres. The aerosol-generating substrate plug may have a length less than or equal to 24 millimetres. The aerosol-generating substrate plug may have a length less than or equal to 20 millimetres. The aerosol-generating substrate plug may have a length less than or equal to 16 millimetres. The aerosol-generating substrate plug may have a length less than or equal to 12 millimetres. The aerosol-generating substrate plug may have a length less than or equal to 8 millimetres.

[0157] The aerosol-generating substrate plug may have a length of between 6 millimetres and 45 millimetres. The aerosol-generating substrate plug may have a length of between 10 millimetres and 30 millimetres. The aerosol-generating substrate plug may have a length of between 14 millimetres and 26 millimetres. The aerosol-generating substrate plug may have a length of between 14 millimetres and 22 millimetres. The aerosol-generating substrate plug may have a length of between 14 millimetres and 18 millimetres.

[0158] The aerosol-generating substrate plug may have a width greater than or equal to 4 millimetres. The aerosol-generating substrate plug may have a width greater than or equal to 5 millimetres. The aerosolgenerating substrate plug may have a width greater than or equal to 6 millimetres. The aerosol-generating substrate plug may have a width greater than or equal to 7 millimetres. The aerosol-generating substrate plug may have a width greater than or equal to 8 millimetres.

[0159] The aerosol-generating substrate plug may have a width less than or equal to 16 millimetres. The aerosol-generating substrate plug may have a width less than or equal to 14 millimetres. The aerosolgenerating substrate plug may have a width less than or equal to 12 millimetres. The aerosol-generating substrate plug may have a width less than or equal to 11 millimetres. The aerosol-generating substrate plug may have a width less than or equal to 10 millimetres. The aerosol-generating substrate plug may have a width less than or equal to 9 millimetres. The aerosol-generating substrate plug may have a width less than or equal to 8 millimetres.

[0160] The aerosol-generating substrate plug may have a width between 4 millimetres and 16 millimetres. The aerosol-generating substrate plug may have a width between 6 millimetres and 10 millimetres.

[0161] The aerosol-generating substrate plug may have a length between 6 millimetres and 45 millimetres, a width between 4 millimetres and 16 millimetres, and a thickness between 0.5 millimetres and 5.5 millimetres.

[0162] Preferably, the aerosol-generating substrate plug may have a length between 10 millimetres and 30 millimetres, a width between 6 millimetres and 10 millimetres, and a thickness between 2 millimetres and 6 millimetres.

[0163] The aerosol-generating article may comprise at least one outer wrapper.

[0164] The at least one outer wrapper may define or form one or both of the substantially planar upper surface of the aerosol-generating article and the substantially planar lower surface of the aerosolgenerating article.

[0165] The at least one outer wrapper may fully circumscribe or encircle the aerosol-generating article. The at least one outer wrapper may fully circumscribe or encircle the aerosol-generating article along greater than or equal to 90 percent of a length of the aerosol-generating article. Preferably, the at least one outer wrapper may fully circumscribe or encircle the aerosol-generating article along 100 percent of a length of the aerosol-generating article.

[0166] The at least one outer wrapper may circumscribe or encircle only a downstream portion of the first plug. The at least one outer wrapper may circumscribe or encircle greater than or equal to 25 percent of a length of the first plug or greater than or equal to 50 percent of a length of the first plug. The at least one outer wrapper may circumscribe or encircle less than or equal to 75 percent of a length of the first plug or less than or equal to 50 percent of a length of the first plug.

[0167] The at least one outer wrapper may circumscribe or encircle only an upstream portion of the second plug. The at least one outer wrapper may circumscribe or encircle greater than or equal to 25 percent of a length of the second plug or greater than or equal to 50 percent of a length of the second plug. The at least one outer wrapper may circumscribe or encircle less than or equal to 75 percent of a length of the second plug or less than or equal to 50 percent of a length of the second plug.

[0168] The at least one outer wrapper may comprise a first outer wrapper and a second outer wrapper. The first outer wrapper may form a first external layer of the aerosol-generating article and the second outer wrapper may form a second external layer of the aerosol-generating article. The first external layer may be a first planar external layer. The second external layer may be a second planar external layer.

[0169] The at least one outer wrapper may be confined to defining or forming substantially planar upper surface of the aerosol-generating article and the substantially planar lower surface of the aerosolgenerating article, such that side portions of the aerosol-generating article between substantially planar upper surface and substantially planar lower surface are not defined or formed by the at least one outer wrapper.

[0170] The, each of the, or any of the, at least one outer wrapper may be hydrophobic. The, or any of the, at least one outer wrapper may comprise a hydrophobic material.

[0171] The, each of the, or any of the, at least one outer wrapper may comprise a sheet of material, such as a sheet of cellulosic material.

[0172] The, each of the, or any of the, at least one outer wrapper may comprise, or be made from, a cellulosic material. The cellulosic material may be paper, cigarette paper, tobacco paper, cardboard, wood, textile, natural fibres or artificial fibres. Preferably, the, each of the, or any of the, at least one outer wrapper is cigarette paper.

[0173] The, each of the, or any of the, at least one outer wrapper may be substantially tobacco-free or substantially nicotine-free.

[0174] The, each of the, or any of the, at least one outer wrapper may have a thickness greater than or equal to 250 micrometres, greater than or equal to 300 micrometres, greater than or equal to 350 micrometres, greater than or equal to 400 micrometres, or greater than or equal to 450 micrometres.

[0175] The, each of the, or any of the, at least one outer wrapper may have a thickness less than or equal to 550 micrometres, less than or equal to 500 micrometres, less than or equal to 450 micrometres, less than or equal to 400 micrometres, or less than or equal to 350 micrometres.

[0176] The, each of the, or any of the, at least one outer wrapper may have a thickness between 250 micrometres and 550 micrometres, between 250 micrometres and 450 micrometres, or between 300 micrometres and 450 micrometres.

[0177] The, or any of the, at least one outer wrapper may have a length substantially the same as the length of the aerosol-generating article. The, or any of the, at least one outer wrapper may have a width substantially the same as the width of the aerosol-generating article.

[0178] The aerosol-generating article of any of the aspects of the present disclosure may have a length (for example, an x dimension) of between 10 millimetres and 100 millimetres, or between 10 millimetres and 50 millimetres, for example between 10 millimetres and 40 millimetres, for example between 12 millimetres and 30 millimetres, for example between 14 millimetres and 26 millimetres, for example between 16 millimetres and 24 millimetres, for example between 18 millimetres and 22 millimetres, for example about 18 millimetres, or about 19 millimetres, or about 20 millimetres, or about 21 millimetres, or about 22 millimetres.

[0179] The aerosol-generating article may have a width (for example, a y dimension) of between 5 millimetres and 20 millimetres, for example between 8 millimetres and 18 millimetres, for example between 10 millimetres and 16 millimetres, for example between 11 millimetres and 15 millimetres, for example between 12 millimetres and 14 millimetres, for example about 13 millimetres.

[0180] The aerosol-generating article may have a height (for example, a z dimension) of between 1 millimetres and 10 millimetres, for example between 1 .2 millimetres and 8 millimetres, for example between 1 .4 millimetres and 7 millimetres, for example between 1 .6 millimetres and 6 millimetres, for example between 1.7 millimetres and 5 millimetres, for example about 1.7 millimetres, or about 4.5 millimetres, or about 2 millimetres, or about 3 millimetres, or about 4 millimetres.

[0181] The aerosol-generating article of any of the aspects of the present disclosure when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof. Where the aerosol-generating article comprises substantially planar upper and lower surfaces, one or both of the upper and lower surfaces when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof. A perimeter of the aerosol-generating article when viewed in plan may be formed of a plurality of straight sides, a plurality of curved sides, or a combination of straight and curved sides. Where the aerosolgenerating article comprises substantially planar upper and lower surfaces, a perimeter of one or both of the upper and lower surfaces when viewed in plan may have a shape defining a polygon, a quadrilateral (for example, a rectangle or a square), an oval, a circle, or a combination thereof.

[0182] According to the present disclosure, an aerosol-generating device for receiving an aerosolgenerating article as disclosed herein, or an aerosol-generating substrate as disclosed herein, may comprise a cavity dimensioned to receive at least a portion of the aerosol-generating article or aerosolgenerating substrate, a heater or heating means, a power source for supplying power to the heater or heating means, and a controller to control supply of power to the heater or heating means. The aerosolgenerating device is configured to heat an aerosol-generating substrate, for example an aerosol-generating substrate that is a component part of an aerosol-generating article, to form an aerosol, for example an inhalable aerosol.

[0183] The aerosol-generating device may preferably be configured to receive the entirety of the aerosolgenerating article such that the aerosol-generating article is wholly enclosed within the aerosol-generating device.

[0184] The cavity may comprise an opening into which a distal end of the aerosol-generating article can be inserted. The cavity may have any suitable cross-sectional shape. For example, the cavity may have a rectangular transverse cross-section, for example a rectangular cross-section having opposing top and bottom sides that are greater in length than left and right sides.

[0185] Preferably, at least one internal surface of the cavity is a heating surface configured to heat an aerosol-generating article. The heating surface may comprise a heater, for example a resistance heater, or an infra-red heater, or a susceptor configured to be heated by engagement with an inductor. The heating surface may comprise an inductor, for example the surface may comprise a coil arranged to generate a fluctuating electromagnetic field within a space of the cavity. The heating surface may be a surface that is permeable to a fluctuating electromagnetic field, such that an inductor arranged outside the cavity can project a fluctuating electromagnetic field through the heating surface to engage with a susceptor arranged within the cavity.

[0186] As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol.

[0187] As used herein, the term “aerosol-generating substrate” may refer to a substrate capable of releasing an aerosol or volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-generating substrate. An aerosol-generating substrate may comprise an aerosolforming material. An aerosol-generating substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. An aerosol-generating substrate may conveniently be part of an aerosolgenerating article or smoking article.

[0188] As used herein, the term “aerosol-generating device” may refer to a device for use with an aerosolgenerating article to enable the generation, or release, of an aerosol.

[0189] As used herein, the term “aerosol generating system” refers to a combination of an aerosolgenerating device and one or more aerosol-forming articles for use with the device. An aerosol-generating system may include additional components, such as a charging unit for recharging an on-board electric power supply in an electrically operated or electric aerosol-generating device.

[0190] As used herein, the term “aerosol former” may refer to any suitable known compound or mixture of compounds that, in use, facilitates formation of an aerosol. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-generating substrate or aerosol-generating article.

[0191] As used herein with reference to the invention, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.

[0192] As used herein with reference to the invention, the terms “proximal”, “distal”, “upstream” and “downstream” are used to describe the relative positions of components, or portions of components, of the aerosol-generating article.

[0193] As used herein, the term “longitudinal” refers to the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. During use, air may be drawn through the aerosol-generating article in the longitudinal direction.

[0194] As used herein, the term “sheet” denotes a laminar element having a width and length substantially greater than the thickness thereof. The width of a sheet may be greater than 10 mm, preferably greater than 20 mm or 30 mm. In certain embodiments, sheets of material for use in forming aerosol-generating substrates as described herein may have a thickness of between 10 pm and about 1000 pm, for example between 10 pm and about 300 pm.

[0195] As used herein, the term “homogenised tobacco material” encompasses any tobacco material formed by the agglomeration of particles of tobacco material. Sheets or webs of homogenised tobacco material are formed by agglomerating particulate tobacco obtained by grinding or otherwise powdering of one or both of tobacco leaf lamina and tobacco leaf stems. In addition, homogenised tobacco material may comprise a minor quantity of one or more of tobacco dust, tobacco fines, and other particulate tobacco byproducts formed during the treating, handling and shipping of tobacco. The sheets of homogenised tobacco material may be produced by casting, extrusion, paper making processes or other any other suitable processes known in the art.

[0196] The term “cast leaf’ is used herein to refer to a product made by a casting process that is based on casting a slurry comprising plant particles (for example, clove particles or tobacco particles and clove particles in a mixture) and a binder (for example, guar gum) onto a supportive surface, such as a belt conveyor, drying the slurry and removing the dried sheet from the supportive surface. An example of the casting or cast leaf process is described in, for example, US-A-5,724,998 for making cast leaf tobacco. In a cast leaf process, particulate plant materials are produced by pulverizing, grinding, or comminuting parts of the plant. The particles produced from one or more plants are mixed with a liquid component, typically water, to form a slurry. Other components in the slurry may include fibres, a binder and an aerosol former. The particulate plant materials may be agglomerated in the presence of the binder. The slurry is cast onto a supportive surface and dried into a sheet of homogenized plant material. Preferably, homogenized plant material used in articles according to the present invention may be produced by casting. Such homogenized plant material may comprise agglomerated particulate plant material.

[0197] As used herein, resistance to draw is expressed with the units of pressure “mm H2O” or “mm WG” or “mm of water gauge” and may be measured in accordance with ISO 6565:2002.

[0198] As used herein, the term “bulk density” refers to the total mass of the aerosol-generating substrate divided by the bulk volume of the aerosol-generating substrate.

[0199] As used herein, the term “packing density” refers to a ratio of the total volume of the components, such as solid and liquid components, of the aerosol-generating substrate to the bulk volume of the aerosolgenerating substrate.

[0200] The invention is defined in the claims. However, below there is provided a non-exhaustive list of nonlimiting 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.

[0201] Example 1 . An aerosol-generating article for use with an aerosol-generating device, the aerosolgenerating article comprising: a first plug, a second plug, and an aerosol-generating substrate plug comprising an aerosol-generating substrate; wherein the first plug is positioned upstream of the aerosol-generating substrate plug and the second plug is positioned downstream of the aerosol-generating substrate plug; and wherein a thickness of the aerosol-generating article is less than 50 percent of a length of the aerosol-generating article and the thickness of the aerosol-generating article is less than 50 percent of a width of the aerosol-generating article.

[0202] Example 2. An aerosol-generating article according to Example 1 , wherein the aerosol-generating article comprises a substantially planar upper surface defined by a length extending in an x direction and a width extending in a y direction, and a substantially planar lower surface defined by a length extending in an x direction and a width extending in a y direction. Example 3. An aerosol-generating article according to Example 1 or 2, wherein one or both of the first plug and the second plug are positioned adjacent to the aerosol-generating substrate plug.

[0203] Example 4. An aerosol-generating article according to any one of Examples 1 to 3, wherein one or both of the first plug and the second plug abut the aerosol-generating substrate plug.

[0204] Example 5. An aerosol-generating article according to any one of Examples 1 to 4, wherein the first plug is positioned at an extreme upstream end of the aerosol-generating article.

[0205] Example 6. An aerosol-generating article according to any one of Examples 1 to 5, wherein the second plug is positioned at an extreme downstream end of the aerosol-generating article.

[0206] Example 7. An aerosol-generating article according to any one of Examples 1 to 6, wherein the first plug defines an inlet of the aerosol-generating article.

[0207] Example 8. An aerosol-generating article according to any one of Examples 1 to 7, wherein the second plug defines an outlet of the aerosol-generating article.

[0208] Example 9. An aerosol-generating article according to any one of Examples 1 to 8, wherein the first plug comprises a first plug chamber.

[0209] Example 10. An aerosol-generating article according to Example 9, wherein the first plug chamber has a width of at least 80 percent or at least 90 percent of a width of the first plug, and the first plug chamber has a thickness of at least 80 percent or at least 90 percent of a thickness of the first plug.

[0210] Example 11. An aerosol-generating article according to Example 9 or 10, wherein the first plug comprises one or more walls extending between an upstream end of the first plug and a downstream end of the first plug and wherein the one or more walls enclose, or at least partially enclose, the first plug chamber.

[0211] Example 12. An aerosol-generating article according to any one of Examples 1 to 11 , wherein the second plug comprises a second plug chamber.

[0212] Example 13. An aerosol-generating article according to Example 12, wherein the second plug chamber has a width of at least 80 percent or at least 90 percent of a width of the second plug, and the second plug chamber has a thickness of at least 80 percent or at least 90 percent of a thickness of the second plug.

[0213] Example 14. An aerosol-generating article according to Example 12 or 13, wherein the second plug comprises one or more walls extending between an upstream end of the second plug and a downstream end of the second plug and wherein the one or more walls enclose, or at least partially enclose, the second plug chamber.

[0214] Example 15. An aerosol-generating article according to any preceding Example, when dependent on any one of Examples 9 to 11 , wherein the first plug comprises a flavour releasing element positioned within the first plug chamber.

[0215] Example 16. An aerosol-generating article according to any preceding Example, when dependent on any one of Examples 12 to 14, wherein the second plug comprises a flavour releasing element positioned within the second plug chamber.

[0216] Example 17. An aerosol-generating article according to Example 13 or 14, wherein the flavour releasing element comprises, or is impregnated with, or is soaked in, one or more flavourants.

[0217] Example 18. An aerosol-generating article according to any preceding Example, wherein the first plug comprises a first plug body and wherein a first flap extends from the first plug body and a second flap extends from the first plug body, and wherein the first flap and the second flap overlie a downstream end of the first plug body to define a downstream opening of the first plug.

[0218] Example 19. An aerosol-generating article according to any preceding Example, wherein the second plug comprises a second plug body and wherein a first flap extends from the second plug body and a second flap extends from the second plug body, and wherein the first flap and the second flap overlie an upstream end of the second plug body to define an upstream opening of the second plug.

[0219] Example 20. An aerosol-generating article according to any one of Examples 1 to 17, wherein one or both of the first plug and the second plug is in the form of a tube, such as a rectangular tube.

[0220] Example 21 . An aerosol-generating article according to any preceding Example, wherein one or both of the first plug and the second plug is formed from two or more geometrically identical elements.

[0221] Example 22. An aerosol-generating article according to Example 21 , wherein each of the two or more geometrically identical elements extend the entire length of the respective plug and the entire thickness of the respective plug.

[0222] Example 23. An aerosol-generating article according to Example 21 or 22, wherein the first plug comprises a first geometrically identical element and a second geometrically identical element, each of the first geometrically identical element and the second geometrically identical element having an “L”-shape or being an “L” beam.

[0223] Example 24. An aerosol-generating article according to any one of Examples 21 to 23, wherein the second plug comprises a first geometrically identical element and a second geometrically identical element, each of the first geometrically identical element and the second geometrically identical element having an “L”-shape or being an “L” beam

[0224] Example 25. An aerosol-generating article according to any preceding Example, wherein one or both of the first plug and the second plug comprise a first length portion having a width and a second length portion having a width and wherein the width of the first length portion is greater than the width of the second length portion, thereby forming at least one shoulder at a location between the first length portion and the second length portion.

[0225] Example 26. An aerosol-generating article according to Example 25, wherein the first length portion of the first plug is an upstream length portion and the second length portion of the first plug is a downstream length portion.

[0226] Example 27. An aerosol-generating article according to Example 25 or 26, wherein the first length portion of the second plug is a downstream length portion and the second length portion of the second plug is an upstream length portion.

[0227] Example 28. An aerosol-generating article according to any preceding Example, wherein one or both of the first plug and the second plug have a laminated or layered structure.

[0228] Example 29. An aerosol-generating article according to any preceding Example, wherein one or both of the first plug and the second plug comprise a sheet of material that has been fluted, crimped, pleated, gathered, woven or folded into an element that defines a plurality of longitudinally extending channels.

[0229] Example 30. An aerosol-generating article according to any preceding Example, wherein one or both of the first plug and the second plug comprise at least 80 percent by weight of cellulosic material, such as paper or cardboard Example 31 . An aerosol-generating article according to any preceding Example, wherein one or both of the first plug and the second plug are formed from compressed matter, such as particulate matter, powder or pellets.

[0230] Example 32. An aerosol-generating article according to any preceding Example, wherein one or both of the first plug and the second plug is formed from moulded pulp.

[0231] Example 33. An aerosol-generating article according to any preceding Example, wherein a ratio between a length of the first plug and a length of the aerosol-generating article is greater than or equal to 0.30.

[0232] Example 34. An aerosol-generating article according to any preceding Example, wherein a ratio between a length of the second plug and a length of the aerosol-generating article is greater than or equal to 0.30.

[0233] Example 35. An aerosol-generating article according to any preceding Example comprising at least one support member comprising a first support member and a second support member, wherein the first support member and the second support member extend along opposing lateral sides of the aerosol-generating substrate.

[0234] Example 36. An aerosol-generating article according to Example 35, wherein the first support member extends from the first plug to the second plug and is coupled to the first plug and the second plug, and wherein the second support member extends from the first plug to the second plug and is coupled to the first plug and the second plug.

[0235] Example 37. An aerosol-generating article according to Example 35 or 36, wherein the first plug, the second plug, and the at least one support member form a frame at least partially defining a cavity, wherein the aerosol-generating substrate plug is positioned within the cavity.

[0236] Example 38. An aerosol-generating article according to any one of Examples 35 to 37, wherein each of the at least one support member comprise corrugated cardboard.

[0237] Example 39. An aerosol-generating article according to any one of Examples 35 to 38, wherein the aerosol-generating substrate plug comprises a substrate wrapper circumscribing the aerosol-generating substrate and the at least one support member.

[0238] Example 40. An aerosol-generating article according to any preceding Example comprising at least one outer wrapper.

[0239] Example 41 . An aerosol-generating article according to Example 40, wherein the at least one outer wrapper fully circumscribes or encircles the aerosol-generating article.

[0240] Example 42. An aerosol-generating article according Example 40 or 41 , wherein the at least one outer wrapper fully circumscribes or encircles the aerosol-generating article along greater than or equal to 90 percent of a length of the aerosol-generating article.

[0241] Example 43. An aerosol-generating article according to Example 40, wherein the at least one outer wrapper comprises a first outer wrapper and a second outer wrapper, the first outer wrapper forming a first external layer of the aerosol-generating article and the second outer wrapper forming a second external layer of the aerosol-generating article.

[0242] Examples will now be further described with reference to the figures in which: Figure 1 is a perspective view of an aerosol-generating article according to a first embodiment of the present disclosure;

[0243] Figure 2 is a perspective view of an aerosol-generating article according to a second embodiment of the present disclosure;

[0244] Figure 3 is a perspective view of an aerosol-generating article according to a third embodiment of the present disclosure;

[0245] Figure 4 is a perspective view of an aerosol-generating article according to a fourth embodiment of the present disclosure ;

[0246] Figure 5 is a perspective view of an aerosol-generating article according to a fifth embodiment of the present disclosure;

[0247] Figure 6 is a perspective view of an aerosol-generating article according to a sixth embodiment of the present disclosure;

[0248] Figure 7 shows a schematic illustration of an aerosol-generating substrate plug according to a first embodiment of the present disclosure;

[0249] Figure 8 shows a schematic side view of the aerosol-generating substrate plug of Figure 7;

[0250] Figure 9 shows a schematic plan view of an aerosol-generating substrate plug of Figure 7;

[0251] Figure 10 shows a schematic illustration of a corrugated element as used in the aerosol-generating substrate plug of Figure 7;

[0252] Figure 11 shows a perspective view of an aerosol-generating substrate plug according to a second embodiment of the present disclosure;

[0253] Figure 12 shows a perspective view of an aerosol-generating substrate plug according to a third embodiment of the present disclosure;

[0254] Figure 13 shows a method of forming a first plug according to a first embodiment of the present disclosure;

[0255] Figure 14 shows the first plug according to the first embodiment of the present disclosure;

[0256] Figure 15 shows a method of forming a first plug according to a second embodiment of the present disclosure;

[0257] Figure 16 shows the first plug according to the second embodiment of the present disclosure;

[0258] Figure 17 shows a method of forming a first plug according to a third embodiment of the present disclosure;

[0259] Figure 18 shows the first plug according to the third embodiment of the present disclosure;

[0260] Figure 19 shows a first plug according to a fourth embodiment of the present disclosure;

[0261] Figure 20 shows a schematic view of an aerosol-generating device according to an embodiment of the present disclosure, the device configured to engage with an aerosol-generating article, for example the aerosol-generating article of any of figures 1 to 6;

[0262] Figure 21 shows a schematic end view of the aerosol-generating device of figure 20;

[0263] Figure 22 is a schematic view showing an aerosol-generating article (for example, the aerosolgenerating article of any of figures 1 to 6) in engagement with the aerosol-generating device of figure 20; and

[0264] Figure 23 is a schematic view of an alternative embodiment to that of figures 20 to 22, showing an aerosol-generating article in engagement with an aerosol-generating device. Figure 1 illustrates a perspective side view of an aerosol-generating article 100 according to a first embodiment of the present disclosure. The aerosol-generating article 100 has upper and lower surfaces 110, 120 which are flat or planar.

[0265] The aerosol-generating article 100 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (which may also be referred to as a thickness), extending in a z dimension, of 3.6 millimetres.

[0266] The aerosol-generating article 100 comprises an aerosol-generating substrate plug 300 comprising an aerosol-generating substrate 345, a first plug 200 positioned upstream of the aerosol-generating substrate plug 300, and a second plug 400 positioned downstream ofthe aerosol-generating substrate plug 300. The aerosol-generating substrate plug 300, the first plug 200 and the second plug 400 are axially aligned in the longitudinal direction. The first plug 200 has a length of about 20 millimetres, a width of about 15 millimetres, and a height (which may also be referred to as a thickness) of about 3.6 millimetres. The second plug 400 has a length of about 20 mm, a width of about 15 millimetres, and a height (which may also be referred to as a thickness) of about 3.6 millimetres. The aerosol-generating substrate plug 300 has a length of 40 millimetres, a width of 15 millimetres and a thickness of 3.6 millimetres.

[0267] An air flow path 130 is defined through the aerosol-generating article 100 between the upper and lower surfaces 110, 120. The air flow path 130 extends between opposed first and second ends 101 , 102 of the aerosol-generating article 100. The first end 101 may define a distal end of the aerosol-generating article 100, and the second end 102 may define a proximal or mouth end of the aerosol-generating article 100. The air flow path 130 may be directed towards a mouth of a user to allow a user to inhale aerosol generated in consequence of heating of aerosol-generating substrate of the aerosol-generating article 100.

[0268] Figure 2 illustrates a perspective view of an aerosol-generating article 100 according to a second embodiment of the present disclosure. The aerosol-generating article 100 according to the second embodiment is similar to the aerosol-generating article 100 according to the first embodiment except that the second embodiment comprises a first outer wrapper 141 forming a first planar external layer of the aerosol-generating article 100 and a second outer wrapper 142 forming a second planar external layer of the aerosol-generating article 100. The first planar external layer defines that upper surface 110 and the second planar external layer 142 defines the lower surface 120. The first plug 200, the aerosol-generating substrate plug 300 and the second plug 400 are positioned between the first outer wrapper 141 and the second outer wrapper 142. Each of the first outer wrapper 141 and the second outer wrapper 142 is cigarette paper.

[0269] The aerosol-generating article 100 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (which may also be referred to as a thickness), extending in a z dimension, of 4.2 millimetres. Each of the first outer wrapper 141 and the second outer wrapper 142 have a thickness of 300 micrometres.

[0270] Figure 3 illustrates a perspective view of an aerosol-generating article 100 according to a third embodiment of the present disclosure. The aerosol-generating article 100 according to the third embodiment is similar to the aerosol-generating article 100 of the first embodiment except that the third embodiment comprises an outer wrapper 140 circumscribing the aerosol-generating article 100 along the entire length of the aerosol-generating article 100. The outer wrapper 140 defines the upper surface 110 and the lower surface 120, and circumscribes each of the first plug (not shown), the aerosol-generating substrate plug (not shown), and the second plug 400. The outer wrapper 140 is cigarette paper.

[0271] The aerosol-generating article 100 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15.6 millimetres, and a height (which may also be referred to as a thickness), extending in a z dimension, of 4.2 millimetres. The outer wrapper 140 has a thickness of 300 micrometres.

[0272] Figure 4 illustrates a perspective view of an aerosol-generating article 100 according to a fourth embodiment of the present disclosure. The aerosol-generating article 100 according to the fourth embodiment comprises a first support member 151 and a second support member 152. Each of the first support member 151 and the second support member 152 are a strip of corrugated cardboard.

[0273] The first support member 151 and the second support member 152 extend along opposing lateral sides of the aerosol-generating substrate plug 300. The first support member 151 extends from the first plug 200 to the second plug 400 and is coupled to the first plug 200 and the second plug 400 with an adhesive. Similarly, the second support member 152 extends from the first plug 200 to the second plug 400 and is coupled to the first plug 200 and the second plug 400 with an adhesive. The first plug 200, the second plug 400, the support members 151 , 152 form a frame at least partially defining a cavity. The aerosolgenerating substrate plug 300 is positioned within the cavity and coupled to the first support member 151 and the second support member 152. The aerosol-generating article 100 may comprise a first outer wrapper 141 and a second outer wrapper 142 as in the second embodiment or an outer wrapper 140 as in the third embodiment. Therefore, the aerosol-generating substrate plug 300 may not be coupled to the first support member 151 and the second support member 152.

[0274] The first support member 151 and the second support member 152 each have a thickness and length equal to the thickness and the length, respectively, of the aerosol-generating substrate plug 300. The first support member 151 and the second support member 152 each have a width of about 3.5 millimetres.

[0275] Figure 5 illustrates a perspective view of an aerosol-generating article 100 according to a fifth embodiment of the present disclosure. The aerosol-generating article 100 according to the fifth embodiment is similar to the aerosol-generating article according to the fourth embodiment except that the first support member 151 and the second support member 152 extend the entire length of the aerosol-generating article 100.

[0276] Figure 6 illustrates a perspective view of an aerosol-generating article 100 according to a sixth embodiment of the present disclosure. The aerosol-generating article 100 according to the sixth embodiment is similar to the aerosol-generating article according to the fourth and fifth embodiment except that the first support member 151 extends from a first shoulder 232 of the first plug 200 to a first shoulder of the second plug 400, and the second member 152 extends from a second shoulder 233 of the first plug 200 to a second shoulder of the second plug 400.

[0277] As seen in more detail in Figure 19, the first plug 200 has an upstream length portion 230 having a first width and a downstream length portion 231 having a second width. The first width is greater than the second width, thereby forming the first shoulder 232 on a first lateral side of the first plug 200 and the second shoulder 233 on a second lateral side of the first plug 200. Similarly, the second plug 400 has an upstream length portion having a first width and a downstream length portion having a second width. The second width is greater than the first width, thereby forming the first shoulder on a first lateral side of the second plug 400 and the second shoulder on a second lateral side of the second plug 400.

[0278] The first support member 151 , the second support member 152 and the downstream length portion of the first plug 200 have a collective width equal to the width of the upstream length portion of the first plug 200. The first support member 151 , the second support member 152 and the upstream length portion of the second plug 400 have a collective width equal to width of the downstream length portion of the second plug 400.

[0279] Figures 7, 8, and 9 illustrate respectively an end view, a side view, and a plan view of an aerosolgenerating substrate plug 300 according to a first embodiment of the present disclosure. The aerosolgenerating articles 100 according to the first to sixth embodiment may comprise the aerosol-generating substrate plug 300. The aerosol-generating substrate plug 300 comprises a planar upper layer 310, a planar lower layer 320, and an intermediate or separation layer 340 arranged between the upper layer 310 and lower layer 320.

[0280] The planar upper layer 310 is formed from a sheet of paper having a thickness of 300 microns. The planar lower layer 320 is formed from a sheet of paper having a thickness of 300 microns. The intermediate layer 340 is a corrugated element formed from a corrugated sheet of aerosol-generating substrate 345. A suitable aerosol-generating substrate may be homogenised tobacco. Thus, the intermediate layer 340 may be formed from a corrugated sheet of homogenised tobacco material 345.

[0281] Figure 10 illustrates the corrugated sheet of aerosol-generating substrate 345. The corrugations have an amplitude 346 of 3 millimetres and a wavelength 347 of 3 millimetres. The sheet of aerosol-generating substrate 345 forming the intermediate layer 340 has a thickness of 150 microns.

[0282] Points of intersection 351 , 352 between the upper layer 310 and the intermediate layer 340 and between the lower layer 320 and the intermediate layer 340 comprise an adhesive that joins the respective layers.

[0283] Corrugations of the intermediate layer 340 form a first set of longitudinally extending channels 361 that are bounded by the upper layer 310 and the intermediate layer 340, and a second set of longitudinally extending channels 362 bounded by the lower layer 320 and the intermediate layer 340. The first and second sets of longitudinally extending channels 361 , 362 extend through the length of the aerosolgenerating substrate plug 300 between a proximal end 371 of the substrate 345 and a distal end 372 of the substrate 345. The longitudinally extending channels 361 , 362 define an air-flow path through the substrate 345. The air-flow path, therefore, passes over both sides of the sheet of aerosol-generating substrate 345. The porosity of the aerosol-generating substrate plug 300 along the air-flow path is in the region of 90 %. This provides a very low resistance to draw (RTD) of less than 5 mm H2O. In fact, the RTD is close to zero.

[0284] The aerosol-generating substrate 345 may be a sheet of any suitable aerosol-generating substrate. During use of the aerosol-generating article 100, the aerosol-generating substrate 345 is heated up to cause the aerosol-generating substrate 345 to release volatile compounds, which are then entrained in air drawn into the channels 361 , 362 via the distal end 372. The volatile compounds then cool and condense to form an aerosol which may be drawn out of the channels 361 , 362 of the aerosol-generating article 100 via the proximal end 371 .

[0285] Figure 11 illustrates perspective view of an aerosol-generating substrate plug 300 according to a second embodiment of the present disclosure. The aerosol-generating articles 100 according to the first to sixth embodiment may comprise the aerosol-generating substrate plug 300. The aerosol-generating substrate plug 300 comprises an aerosol-generating substrate 345 and a substrate wrapper 380.

[0286] The aerosol-generating substrate plug 300 comprises a substantially planar upper surface defined by a length extending in an x-direction and a width extending in a y-direction. The aerosol-generating substrate plug 300 comprises a substantially planar lower surface defined by a length extending in the x- direction and a width extending in the y-direction. The substantially planar upper surface and the substantially planar lower surface are spaced from each other by a thickness defined in a z-direction. The substantially planar upper surface and the substantially planar lower surface are parallel to each other.

[0287] The aerosol-generating substrate plug 300 has cuboid shape and the thickness of the aerosolgenerating substrate plug 300 is constant over the entire width of the aerosol-generating substrate plug 300, thereby providing the aerosol-generating substrate plug 300 with a transverse cross-section (in the y / z plane) that is substantially rectangular.

[0288] The substrate wrapper 380 is a sheet of cellulosic material having a grammage of about 40 grams per square metre and a thickness of about 40 micrometres. The substrate wrapper 380 circumscribes the aerosol-generating substrate 345 and has a length substantially equal to a length of the aerosol-generating substrate 345. The substrate wrapper 380 does not entirely enclose the aerosol-generating substrate 345 but, instead, the aerosol-generating substrate 345 is exposed at both the proximal end 371 and distal end 372 of the aerosol-generating substrate plug 300.

[0289] The aerosol-generating substrate 345 is in the form of tobacco cut filler and comprises an aerosolformer, namely glycerine, and has an aerosol-former content of about 5 percent by weight on a dry weight basis. The aerosol-generating substrate 345 extends from a proximal end 371 to the distal end 372 of the aerosol-generating substrate plug 300 and, thus, extends the entire length of the aerosol-generating substrate plug 300.

[0290] Figure 12 illustrates perspective view of an aerosol-generating substrate plug 300 according to a third embodiment of the present disclosure. The aerosol-generating articles 100 according to the first to sixth embodiment may comprise the aerosol-generating substrate plug 300. The aerosol-generating substrate plug 300 according to the third embodiment is similar to the aerosol-generating substrate plug 300 according to the second embodiment except that the third embodiment comprises a first support member 151 and a second support member 152 extending along the entire length of the aerosol-generating substrate plug 300. The substrate wrapper 380 circumscribes the aerosol-generating substrate 345, the first support member 151 and the second support member 152.

[0291] Figure 13 and 14 illustrate a method of forming a first plug 200 according to a first embodiment of the present disclosure and perspective view of the first plug 200 according to the first embodiment, respectively. The aerosol-generating articles 100 according to the first to fifth embodiment may comprise the first plug 200. The first plug 200 is in the form of a rectangular tube. The first plug 200 is formed from a sheet of cardboard 203 comprising a plurality of lines of weakness 204. The plurality of lines of weakness 204 are perforated lines of weakness. The sheet of cardboard 203 is folded into a tube about the plurality of lines of weakness 204, each of the plurality of lines of weakness forming a longitudinally extending corner of the first plug 200. Free ends 205, 206 of the sheet of cardboard 203 are coupled together with an adhesive to form a further longitudinally extending corner of the first plug 200. The first plug 200 has an upstream opening (not shown) and a downstream opening 202. The second plug 400 may have the same construction.

[0292] Figure 15 and 16 illustrate a method of forming a first plug 200 according to a second embodiment of the present disclosure and a perspective view of the first plug 200 according to the second embodiment, respectively. The aerosol-generating articles 100 according to the first to fifth embodiment may comprise the first plug 200. The first plug 200 is formed from two geometrically identical elements 211 , 212. In particular, the first plug 200 is formed from a first geometrically identical element 211 and a second geometrically identical element 212, each of the first geometrically identical element 211 and the second geometrically identical element 212 having an “L”-shape. The two geometrically identical elements 21 1 , 212 are bonded together, such as with an adhesive. The two geometrically identical elements form an upstream opening (not shown) and a downstream opening 202 of the first plug 200. The second plug 400 may have the same construction.

[0293] Figure 17 and 18 illustrate a method of forming a first plug 200 according to a third embodiment of the present disclosure and a perspective view of the first plug 200 according to the third embodiment, respectively. The aerosol-generating articles 100 according to the first to fifth embodiment may comprise the first plug 200. The first plug 200 comprises a first plug body 220 defining a first plug chamber 221 . A first flap 222 extends from the first plug body 220 and a second flap 223 extends from the first plug body 220. As seen in Figure 18, the first flap 222 and the second flap 223 are movable to overlie a downstream end of the first plug body 220 to define the downstream opening 202. In particular, the first flap 222 has a first notch 224 and the second flap 223 has a second notch 225 which collectively form the downstream opening 202 of the first plug 200. The second plug 400 may have the same construction.

[0294] Figure 19 illustrates a perspective view of a first plug 200 according to a fourth embodiment. The aerosol-generating article 100 according to the sixth embodiment may comprise the first plug 200, as previously described. The second plug 400 may have the same construction.

[0295] Figures 20 and 21 illustrate an aerosol-generating device 6000 configured for use with an aerosolgenerating article 600 comprising an aerosol-generating substrate 640, such as the aerosol-generating article according to the first to sixth embodiment. The device 6000 is an elongate aerosol-generating device extending between a proximal end 6001 and a distal end 6002. The device 6000 comprises a battery 6010, a controller 6020 and a heater 6030 located within a housing 6040. The controller 6020 controls supply of power from the battery 6010 to the heater 6030. A cavity 6050 is defined in the device 6000, the cavity having an opening 6051 defined in the proximal end 6001 of the device. The opening 6051 is rectangular in shape and is dimensioned to accommodate the transverse cross-section of the aerosol-generating article 600. The cavity 6050 comprises an upper planar surface 6052 and a lower planar surface 6053. The heater 6030 is located in the lower planar surface 6053 to heat a lower surface of the aerosol-generating article 600 inserted into the cavity 6050. An air-flow path is configured to allow air to flow into the cavity 6050 from outside the device 6000.

[0296] Figure 22 illustrates the device 6000 of figure 20 in engagement with the aerosol-generating article 600. There is little tolerance between outer surfaces of the aerosol-generating article 600 and the internal surfaces of the cavity 6050. Thus, there is a snug fit between the aerosol-generating article 600 and the device 6000. As the RTD of the aerosol-generating article 600 is negligible, the RTD of the system formed by the combination of aerosol-generating article 600 and aerosol-generating device 6000 is controlled by the air-flow path defined within the device. When a user has inserted the aerosol-generating article 600 into the cavity 6050, the device 6000 can be operated. The heater 6030 heats a lower surface of the aerosolgenerating article 600, and as a result the aerosol-generating substrate 640 of the aerosol-generating article 600 is heated. Volatile components of the aerosol-generating substrate 640 are evaporated and condense in longitudinal air-flow channels defined within the aerosol-generating article 600 to form an aerosol. The user inhales the aerosol by drawing on the proximal end 601 of the aerosol-generating article 600. Once the aerosol-generating substrate 640 of the aerosol-generating article 600 has been depleted of volatile components, the aerosol-generating article is removed from the cavity 6050 of the device 6000 and disposed of. The aerosol-generating article 600 may be any one of the aerosol-generating articles 100, 200, 300, 400, 500 previously described or any other aerosol-generating article of the present disclosure.

[0297] Although figure 22 shows part of the aerosol-generating article 600 extending outside of the aerosolgenerating device 6000, in other embodiments the entirety of an aerosol-generating article may be wholly enclosed within an aerosol-generating device. By way of example, figure 23 illustrates an alternative embodiment to that of figure 22, with like features referred to by the same reference numbers but with the addition of a prime symbol ’. For the alternative embodiment of figure 23, the entirety of aerosol-generating article 600’ is enclosed within the interior of aerosol-generating device 6000’.

[0298] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term “about”. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number “A” is understood as “A” ± 10% of “A”. Within this context, a number “A” may be considered to include numerical values that are within general standard error for the measurement of the property that the number “A” modifies. The number “A”, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which “A” deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. The terms “in which” and “wherein” are used synonymously through this specification.

Claims

CLAIMS1 . An aerosol-generating article for use with an aerosol-generating device, the aerosol-generating article comprising: a first plug, a second plug, and an aerosol-generating substrate plug comprising an aerosol-generating substrate; wherein the first plug is positioned upstream of the aerosol-generating substrate plug and the second plug is positioned downstream of the aerosol-generating substrate plug; and wherein a thickness of the aerosol-generating article is less than 50 percent of a length of the aerosolgenerating article and the thickness of the aerosol-generating article is less than 50 percent of a width of the aerosol-generating article.

2. An aerosol-generating article according to claim 1 , wherein the first plug defines an inlet of the aerosol-generating article and the second plug defines an outlet of the aerosol-generating article.

3. An aerosol-generating article according to claim 1 or 2, wherein the second plug comprises a second plug chamber, the second plug chamber having a width of at least 80 percent or at least 90 percent of a width of the second plug, and the second plug chamber having a thickness of at least 80 percent or at least 90 percent of a thickness of the second plug.

4. An aerosol-generating article according to any preceding claim, wherein one or both of the first plug and the second plug is in the form of a tube, such as a rectangular tube.

5. An aerosol-generating article according to any preceding claim, wherein one or both of the first plug and the second plug is formed from two or more geometrically identical elements.

6. An aerosol-generating article according to claim 5, wherein each of the two or more geometrically identical elements extend the entire length of the respective plug and the entire thickness of the respective plug.

7. An aerosol-generating article according to any preceding claim, wherein one or both of the first plug and the second plug comprise a first length portion having a width and a second length portion having a width and wherein the width of the first length portion is greater than the width of the second length portion, thereby forming at least one shoulder at a location between the first length portion and the second length portion.

8. An aerosol-generating article according to any preceding claim, wherein one or both of the first plug and the second plug have a laminated or layered structure.

9. An aerosol-generating article according to any preceding claim, wherein one or both of the first plug and the second plug are formed from compressed matter, such as particulate matter, powder or pellets.

10. An aerosol-generating article according to any preceding claim, wherein a ratio between a length of the first plug and a length of the aerosol-generating article is greater than or equal to 0.30 and wherein a ratio between a length of the second plug and a length of the aerosol-generating article is greater than or equal to 0.30.

11. An aerosol-generating article according to any preceding claim comprising at least one support member comprising a first support member and a second support member, wherein the first support member and the second support member extend along opposing lateral sides of the aerosol-generating substrate.

12. An aerosol-generating article according to claim 11 , wherein the first support member extends from the first plug to the second plug and is coupled to the first plug and the second plug, and wherein the second support member extends from the first plug to the second plug and is coupled to the first plug and the second plug.

13. An aerosol-generating article according to claim 11 or 12, wherein the first plug, the second plug, and the at least one support member form a frame at least partially defining a cavity, wherein the aerosolgenerating substrate plug is positioned within the cavity.

14. An aerosol-generating article according to any one of claims 11 to 13, wherein each of the at least one support member comprise corrugated cardboard.

15. An aerosol-generating article according to any one of claims 11 to 14, wherein the aerosolgenerating substrate plug comprises a substrate wrapper circumscribing the aerosol-generating substrate and the at least one support member.

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