Aerosol-generating article

Abstract

There is provided an aerosol-generating article (400) for use with an aerosol-generating device to generate an aerosol. The aerosol-generating article (400) comprising a first external surface (421) and a second external surface (422) opposing the first external surface (421). The aerosol-generating article (400) comprising a cavity (430) positioned between the first external surface (421) and the second external surface (422). The aerosol-generating article (400) comprising an aerosol-forming element (470) positioned within the cavity (430), the aerosol-forming element (470) comprising a first plug element (481) comprising an aerosol-forming substrate, and a second plug element (482) different to the first plug element (481), wherein the first plug element (481) and the second plug element (482) are physically coupled to each other. There is also provided an aerosol-generating system.

Description

[0001] AEROSOL-GENERATING ARTICLE

[0002] The present disclosure relates to an aerosol-generating article comprising an aerosol-forming substrate. The present disclosure further relates to an aerosol-generating system comprising an aerosolgenerating article and a method for forming an aerosol-generating 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-forming 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-forming substrate in these cylindrical aerosol-generating articles may not be sufficiently heated to form an aerosol during use. This is undesirable since the insufficiently heated portion of the aerosol-forming 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-forming substrate is heated, for example regardless of whether a resistive or inductive heater is used and regardless of whether the aerosol-forming substrate is heated from the inside or the outside. Moreover, the components of these cylindrical aerosolgenerating articles normally need to have the same or very similar outer diameters so that they can be brought together, accurately positioned in co-axial alignment and wrapped in a cigarette paper. This can lead to increased cost and complexity of manufacture.

[0005] It is an aim of the present disclosure to provide an aerosol-generating article, in which a greater portion of an aerosol-forming 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 to generate an aerosol. The aerosol-generating article may comprise a first external surface and a second external surface opposing the first external surface. The aerosol-generating article may comprise a cavity positioned between the first external surface and the second external surface. The aerosol-generating article may comprise an aerosol-forming element positioned within the cavity. The aerosol-forming element may comprise a first plug element comprising an aerosol-forming substrate for producing an aerosol. The aerosol-forming element may comprise a second plug element different to the first plug element. The first plug element and the second plug element may be physically coupled to one another. The aerosolgenerating article may have an article length, an article width and an article thickness. The article length and the article width being greater than the article thickness.

[0007] Advantageously, the article thickness being relatively small may reduce a temperature gradient across the article, or across the substrate of the article, during use. This may mean that a greater proportion of the substrate is able to reach a sufficiently high temperature to form an aerosol, without a significant risk of burning the substrate, compared with a thicker article or substrate.

[0008] Advantageously, providing a first plug element comprising an aerosol-forming substrate may allow a defined quantity of aerosol-forming substrate to be inserted into the aerosol-generating article. The aerosol-forming substrate in this form may be easy to insert and may have consistent properties, for example heat conduction properties, from article to article.

[0009] Advantageously, the first plug element being physically coupled to the second plug element may allow the aerosol-generating article to be assembled more efficiently, to allow high speed and precise manufacture of the aerosol-generating article. Advantageously, there may be a reduced risk of aerosolforming substrate being wasted or lost during manufacturing compared to a loose aerosol-forming substrate, or multiple plug elements (not physically coupled together) being inserted directly into an aerosolgenerating article. Advantageously, fewer steps are required to insert multiple plug elements into the articles because they are pre-assembled, therefore the manufacturing process may be carried out more efficiently.

[0010] Preferably, the article length may be at least two times the article thickness.

[0011] Preferably, the article width may be at least two times the article thickness.

[0012] The aerosol-generating article may be a planar aerosol-generating article having a base defined by the article length extending in an x direction, the article width extending in a y direction, and the article thickness extending in a z direction.

[0013] For the purpose of the present disclosure, the article thickness of the aerosol-generating article may also be referred to as the article height of the aerosol-generating article.

[0014] 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 height defined in a z direction. The first external surface may be the substantially planar upper surface. The second external surface may be the substantially planar lower surface.

[0015] The aerosol-generating article may preferably be substantially flat article or substantially planar article. Such articles have a large base area, for example the surface area of the first external surface, the surface area of the second external surface, or the surface areas of both the first and second external surfaces, relative to the volume of the article. In particular, the article height of the aerosol-generating article may be less than 50 percent of both the article length and article width of the aerosol-generating article. Advantageously, a larger base area may provide greater surface area for heating by a planar heater of an aerosol-generating device. Advantageously, a smaller height may allow a smaller temperature gradient or difference across the height of the aerosol-generating article during heating. For example, where the base of the aerosol-generating article is in contact with, and heated by, a planar heater, there may be a smaller temperature difference between the base and an upper surface opposing the base if the spacing, or height, between the base and the upper surface is smaller. Advantageously, this may allow heating of a greater proportion of the aerosol-forming substrate of the aerosol-generating article to a temperature at which an aerosol is released, whilst minimising the risk of burning the hottest portion of the substrate closest to the heater. Alternatively, or in addition, this may reduce a time required to heat the aerosol-forming substrate sufficiently to release an aerosol.

[0016] The first plug element and the second plug element may be physically coupled to each other by means of a coupling member. The coupling member may comprise a strip of material simultaneously attached to both first plug element and second plug element. For example, the coupling member may comprise a strip of paper attached to both first plug element and second plug element. The coupling member may comprise a thread attached to both first plug element and second plug element. The coupling member may comprise wrapper at least partially circumscribing to both the first plug element and second plug element. The wrapper may circumscribe both first plug element and second plug element. The wrapper 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. Preferably, the wrapper is a paper wrapper. Advantageously, a paper wrapper provides a simple and lightweight means for coupling the first plug element and the second plug element together.

[0017] The second plug element may comprise a portion of sensorial media. As used herein, the term “sensorial media” relates to a substrate capable of releasing one or more volatile compounds that can form an aerosol or a vapor or that can be brought into the gaseous phase. The sensorial media may serve as one or more of a nicotine provider, a flavour enhancer, and a volume enhancer.

[0018] The portion of sensorial media may comprise a second aerosol-forming substrate. The second aerosol-forming substrate may have a different composition to the aerosol-forming substrate of the first plug element.

[0019] The portion of sensorial media may comprise a flavourant, for example a flavour releasing element. The second plug element may have a different density to the first plug element. The second plug element may have different dimensions to the first plug element. For example, the second plug element may be shorter or longer than the first plug element.

[0020] Advantageously, the second plug element being different to the first plug element but being physical ly coupled to the first plug element allows the aerosol-generating element comprising two different plug elements that may be inserted into the aerosol-generating article in a single manufacturing step. This may lead to more efficient manufacturing of the aerosol-generating element.

[0021] The second plug element may comprise a crimped sheet of material. The second plug element may comprise a perforated sheet of material. The second plug element may comprise grooves, such as corrugations. The sheet of material may be made from or comprise a cellulosic material. The cellulosic material may comprise cellulose fibres. The cellulosic material may be paper, paperboard, or cardboard.

[0022] Advantageously, the second plug element may conduct less heat when comprising at least one of a crimped sheet of material, a perforated sheet of material, or grooves. This is particularly preferable if the second plug element comprises a sensorial media that is not configured to be heated, for example not comprising an aerosol-forming substrate. For example, if the sensorial media comprises a flavourant. Therefore, thermal losses from the heated aerosol-forming substrate to the second plug element are reduced.

[0023] The second plug element may comprise a sheet of paper. The sheet of paper may be at least of crimped, perforated or grooved. The sheet of paper may be impregnated with the sensorial media, for example a flavourant.

[0024] The second plug element may comprise a hollow tube impregnated with the portion of sensorial media. For example, the second plug element may comprise a hollow tube impregnated with a flavourant. The hollow tube may comprise a cardboard tube. Advantageously, the hollow tube may allow air and aerosol to travel through the second plug element and entraining the sensorial media such as a flavourant, without adding filtration or causing unnecessary condensation of the generated aerosol.

[0025] The first plug element and the second plug element may be coaxially aligned with each other. The first plug element and the second plug element may be adjacent to each other and aligned along a longitudinal axis of the aerosol-generating article.

[0026] The first plug element may be in physical contact with the second plug element.

[0027] The first plug element may spaced from the second plug element. For example, the first plug element may not be in physical contact with the second plug element. For example, there may be a gap between the first plug element and the second plug element. For example, the first plug element maybe spaced from the second plug element by between 0.1 millimetres and 10 millimetres, for example between 0.2 and 8 millimetres, for example between 0.3 millimetres and 5 millimetres, for example between 0.4 millimetres and 4 millimetres, for example between 0.5 and 3 millimetres, for example between 0.6 millimetres and 2 millimetres, for example 1 millimetre. At least a portion of the coupling member may be positioned between the first plug element and the second plug element to space the first plug element from the second plug element.

[0028] Advantageously, the space between the first plug element and the second plug element may reduce thermal conduction between the first plug element and the second plug element. This is particularly advantageous when the portion of sensorial media is configured not to be heated, because the reduced thermal conduction between the first plug element and the second plug element reduces the risk of the portion of sensorial media being overheated. The aerosol-forming substrate may also be heated more efficiently because the thermal losses of the aerosol-forming substrate by conduction of heat to the second plug element may be reduced.

[0029] At least a portion of the coupling member may provide a physical barrier between the first plug element and the second plug element to prevent physical contact between the first plug element and the second plug element. For example, the physical barrier may be a wall that is formed by the coupling member between the first plug element and the second plug element. Advantageously, this may also reduce thermal conduction between the first plug element and the second plug element. For example, the coupling member may comprise a paper wrapper and the paper wrapper may be folded between the first plug element to partially cover a first end of the first plug element and partially cover a second end of the second plug element and to prevent physical contact between the first plug element and the second plug element. Advantageously, the paper wrapper being folded may produce an aerosol-generating element that may be simple to manufacture and where thermal conduction between the first plug element and the second plug element may be reduced.

[0030] The aerosol-generating article may comprise a third plug element being different to the first plug element.

[0031] The first plug element may be positioned between the second plug element and the third plug element. The third plug element may be physically coupled to the first plug element. The third plug element may be physically coupled to the first plug element by the coupling member. The first plug element and the third plug element may be coaxially aligned with each other. Preferably, the first, second and third plug element are coaxially aligned with each other.

[0032] The third plug element may comprise a second portion of sensorial media. The third plug element may be the same as the second plug element. For example, the second portion of sensorial media may be the same as the portion of sensorial media of the second plug element. The second portion of sensorial media may have the same composition as the portion of sensorial media of the second plug element. The second portion of sensorial media may comprise the second aerosolforming substrate. The second portion of sensorial media may comprise a flavourant.

[0033] The third plug element may comprise a crimped sheet of material. The third plug element may comprise a perforated sheet of material. The third plug element may comprise grooves, such as corrugations. 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. Advantageously, the third plug element may conduct less heat when comprising at least one of a crimped sheet of material, a perforated sheet of material, or grooves. This is particularly preferable if the third plug element comprises a sensorial media that is not configured to be heated, for example not comprising an aerosol-forming substrate. For example, if the second portion of sensorial media comprises a flavourant. Therefore, thermal losses from the heated aerosol-forming substrate to the second plug element are reduced.

[0034] The second plug element may comprise a sheet of paper. The sheet of paper may be at least of crimped, perforated or grooved. The sheet of paper may be impregnated with the sensorial media, for example a flavourant.

[0035] The second plug element may comprise a hollow tube impregnated with the portion of sensorial media. For example, the second plug element may comprise a hollow tube impregnated with a flavourant. The hollow tube may comprise a cardboard tube. Advantageously, the hollow tube may allow air and aerosol to travel through the second plug element and entraining the sensorial media such as a flavourant, without adding filtration or causing unnecessary condensation of the generated aerosol.

[0036] The third plug element may be different to the second plug element. For example, the third plug element may have different characteristics or properties to the second plug element.

[0037] The second portion of sensorial media may comprise a third aerosol-forming substrate, being different to the aerosol-forming substrate of the first plug element and being different to the second aerosolforming substrate.

[0038] The third plug element may have a different density to the first plug element. The third plug element may have a different density to the second plug element. The third plug element may have different dimensions to the first plug element. The third plug element may have different dimensions to the second plug element.

[0039] The second portion of sensorial media having a different composition to the portion of sensorial media of the first plug element. The third plug element may have a different flavour, for example comprising a different flavourants, compared to the second plug element. The third plug element may have a different intensity of flavour, for example by comprising a different amount of flavourants, compared to the second plug element. The third plug element may comprise no flavourants, while the second plug element does comprise a flavourants. The second and third plug element may comprise different resistances to draw. The second and third plug element may comprise amounts of filtration. Advantageously, the third plug element being different to the second plug element may provide an aerosol-generating element that is capable of providing more than one type of user experience. For example, an aerosol-generating article comprising the aerosol-generating element may be inserted into an aerosol-generating device in one of two directions. In a first direction, the second plug element may be upstream of the first plug element, in the second direction the third plug element may be upstream of the first plug element, and therefore a single aerosol-generating element may provide two different user experiences because the second plug element is different to the third plug element.

[0040] The first plug element may be in contact with the third plug element.

[0041] The first plug element may spaced from the third plug element. For example, the first plug element may not be in physical contact with the third plug element. For example, there may be a gap between the first plug element and the third plug element. For example, the first plug element maybe spaced from the third plug element by between 0.1 millimetres and 10 millimetres, for example between 0.2 and 8 millimetres, for example between 0.3 millimetres and 5 millimetres, for example between 0.4 millimetres and 4 millimetres, for example between 0.5 and 3 millimetres, for example between 0.6 millimetres and 2 millimetres, for example 1 millimetre. At least a portion of the coupling member may be positioned between the first plug element and the third plug element to space the first plug element from the second plug element.

[0042] Advantageously, the space between the first plug element and the third plug element may reduce thermal conduction between the first plug element and the third plug element. This is particularly advantageous when the second portion of sensorial media is configured to be heated, because the reduced thermal conduction between the first plug element and the third plug element reduces the risk of the second portion of sensorial media being overheated. The aerosol-forming substrate may also be heated more efficiently because the thermal losses of the aerosol-forming substrate by conduction of heat to the third plug element may be reduced.

[0043] At least a portion of the coupling member may provide a physical barrier between the first plug element and the third plug element to prevent physical contact between the first plug element and the third plug element. For example, the physical barrier may be a wall that is formed by the coupling member between the first plug element and the third plug element. Advantageously, this may also reduce thermal conduction between the first plug element and the third plug element. For example, the coupling member may comprise a paper wrapper and the paper wrapper may be folded between the first plug element to partially cover a second end of the first plug element and partially cover a first end of the third plug element and to prevent physical contact between the first plug element and the third plug element. Advantageously, the paper wrapper being folded may produce an aerosol-generating element that may be simple to manufacture and where thermal conduction between the first plug element and the third plug element may be reduced.

[0044] The aerosol-generating article may comprise an air flow path extending through the aerosolgenerating article. The aerosol-generating article may have an air-flow path defined through the aerosolgenerating article in an x / y plane from one side of the aerosol-generating article to the other side of the aerosol-generating 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. An aerosol- generating 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.

[0045] 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%.

[0046] Preferably, the airflow path extends through the aerosol-generating element. The air flow path may extend through the first plug element. The air flow path may extend through the second plug element. The air flow path may extend through the third plug element. Preferably, the air flow path extends through both the first and second plug elements. Preferably, the air flow path extends through the first, second and third plug elements.

[0047] The aerosol-generating article may comprise substantially planar upper and lower surfaces.

[0048] Preferably, the first external surface is the substantially planar upper surface, and the second external surface is the substantially planar lower surface. A vertical separation between the first and second external surfaces may define a height (for example, a z dimension) of the aerosol-generating article. An air flow channel may be defined between the first and second external surfaces. The height of the aerosolgenerating 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-forming substrate. The aerosol-generating article may comprise upper and lower layers, the upper layer forming the first external surface and the lower layer forming the second external surface. At least one of the upper and lower layers may comprise or consist of an aerosol-forming material.

[0049] The aerosol-forming element may be a rod. The aerosol-forming element may have a circular crosssection. The aerosol-forming element may have a rectangular cross-section. The aerosol-forming element may have an elliptical cross-section. Preferably, the aerosol-forming element is substantially planar.

[0050] 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 aerosolforming substrate. The first planar layer may form the first external surface. The second planar layer may form the second external surface.

[0051] 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.

[0052] The corrugated layer may comprise a corrugated sheet of cellulosic material. The aerosol-generating element may be positioned in a corrugation of the corrugated layer. A corrugation of a corrugated layer may define the cavity between the corrugated layer and the first planar layer. A corrugation of a corrugated layer may define the cavity between the corrugated layer and the second planar layer.

[0053] The aerosol-generating article may comprise a frame. The frame may be positioned between the first external surface and the second external surface. The first external surface may be a first planar external surface and the second external surface may be a second planar external surface.

[0054] Advantageously, the first planar external surface and the second planar external surface allow for good contact with an external heater, particularly a planar external heater, of an aerosol-generating device, thereby providing optimum heating of the aerosol-generating substrate.

[0055] Advantageously, the aerosol-generating article may be manufactured by layering sheet materials which can be achieved through a continuous manufacturing process, thereby resulting in an aerosolgenerating article that is relatively easy and cheap to manufacture.

[0056] The aerosol-generating 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.

[0057] The aerosol-generating article may comprise an outer wrapper defining the first planar external surface and the second planar external surface.

[0058] Preferably, the frame at least partially defines the cavity. 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.

[0059] The aerosol-generating article may comprise a first planar external layer and a second planar external layer. Preferably, the first planar external layer forms the first external surface, and the second planar external layer forms the second 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 aerosol-forming substrate.

[0060] A corrugated layer may be positioned within the cavity.

[0061] The frame may be a planar frame.

[0062] The frame may have a height between 50 percent and 95 percent of the height of the aerosolgenerating article. The frame may have a height between 60 percent and 95 percent of the height of the aerosol-generating article. The frame may have a height between 70 percent and 95 percent of the height of the aerosol-generating article. The frame may have a height between 80 percent and 95 percent of the height of the aerosol-generating article.

[0063] The frame may have a height between 1 millimetre and 5.5 millimetres. The frame may have a height between 1 millimetre and 5 millimetres. Preferably, the frame may have a height between 1.5 millimetres and 5 millimetres. Preferably, the frame may have a height between 2 millimetres and 4 millimetres.

[0064] The frame may be made from or comprise a biodegradable material. The frame may be made entirely from a biodegradable material.

[0065] 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. 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.

[0066] During the manufacturing process the aerosol-generating element may be positioned in the cavity. The cavity may subsequently be enclosed by the first planar external layer and the second planar external layer, to form the assembled aerosol-generating article. Advantageously, this may provide an aerosolgenerating article comprising more than one plug-element that is simple and efficient to manufacture, to allow fast and precise production, with reduced risk of aerosol-generating substrate being wasted or lost during manufacturing, compared to a loose aerosol-generating substrate, or multiple plug elements (not physically coupled together) being inserted directly into the cavity.

[0067] The aerosol-generating article 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.

[0068] 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 1 1 millimetres and 15 millimetres, for example between 12 millimetres and 14 millimetres, for example about 13 millimetres.

[0069] 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.

[0070] The first plug element may have a mass of between 80 milligrams and 500 milligrams, for example between 100 milligrams and 400 milligrams, for example between 110 milligrams and 350 milligrams, for example between 150 milligrams and 300 milligrams, for example between 170 milligrams and 250 milligrams, for example between 200 milligrams and 230 milligrams. Preferably, the first plug element has a mass of between 100 milligrams and 200 milligrams.

[0071] The second plug element may have a mass of between 80 milligrams and 500 milligrams, for example between 100 milligrams and 400 milligrams, for example between 1 10 milligrams and 350 milligrams, for example between 150 milligrams and 300 milligrams, for example between 170 milligrams and 250 milligrams, for example between 200 milligrams and 230 milligrams. Preferably, the second plug element has a mass of between 100 milligrams and 200 milligrams.

[0072] The third plug element may have a mass of between 80 milligrams and 500 milligrams, for example between 100 milligrams and 400 milligrams, for example between 110 milligrams and 350 milligrams, for example between 150 milligrams and 300 milligrams, for example between 170 milligrams and 250 milligrams, for example between 200 milligrams and 230 milligrams. Preferably, the third plug element has a mass of between 100 milligrams and 200 milligrams. Preferably, the first plug element has a different mass to the second plug element. Preferably, the first plug element has a different mass to the third plug element. Preferably, the second plug element has a different mass to the third plug element.

[0073] The first plug element may have a length of between 6 and 20 millimetres, for example between 8 and 18 millimetres, for example between 10 and 16 millimetres. The first plug element preferably has a length of between 12 and 16 millimetres, for example between 13 and 15 millimetres.

[0074] The second plug element may have a length of between 6 and 20 millimetres, for example between 8 and 18 millimetres, for example between 10 and 16 millimetres. The second plug element preferably has a length of between 12 and 16 millimetres, for example between 13 and 15 millimetres.

[0075] The third plug element may have a length of between 6 and 20 millimetres, for example between 8 and 18 millimetres, for example between 10 and 16 millimetres. The third plug element preferably has a length of between 12 and 16 millimetres, for example between 13 and 15 millimetres.

[0076] Preferably, the first plug element has a different length to the second plug element. Preferably, the first plug element has a different length to the third plug element. Preferably, the second plug element has a different length to the third plug element.

[0077] The first plug element may have a width of between 4 and 10 millimetres, for example between 5 and 8 millimetres, for example between 5.5 and 7. 5 millimetres. The first plug element may have a circular or oval cross section; therefore the width may be a diameter.

[0078] The second plug element may have a width of between 4 and 10 millimetres, for example between 5 and 8 millimetres, for example between 5.5 and 7. 5 millimetres. The second plug element may have a circular or oval cross section; therefore the width may be a diameter.

[0079] The third plug element may have a width of between 4 and 10 millimetres, for example between 5 and 8 millimetres, for example between 5.5 and 7. 5 millimetres. The third plug element may have a circular or oval cross section; therefore the width may be a diameter.

[0080] The volume of the aerosol-generating element may be between 650 millimetres cubed and 300 millimetres cubed, preferably between 625 millimetres cubed and 360 millimetres cubed, for example 480 millimetres cubed.

[0081] The aerosol-generating article 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 aerosol-generating 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.

[0082] The aerosol-forming substrate may comprise nicotine. Nicotine may be present in the form of a tobacco material or may be in the form of a nicotine extract.

[0083] The aerosol-forming substrate may comprise one or more organic materials such as tobacco, mint, tea and cloves. The aerosol-forming 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. The aerosol-generating element may comprise at least one of a powder, beads, granules, or a gel comprising the aerosol-forming substrate.

[0084] The aerosol-forming substrate may comprise or consist of homogenised tobacco material, for example a reconstituted tobacco material or a cast leaf tobacco material.

[0085] The aerosol-forming 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.

[0086] The aerosol-generating element may comprise crimped sheets of the aerosol-forming substrate. The aerosol-generating element may comprise aerosol-forming substrate may be in the form of shredded aerosol-generating material. For example, the first plug element may comprise crimped sheets of the first aerosol-forming substrate. The first plug element may comprise shreds of the first aerosol-forming substrate.

[0087] The aerosol-forming substrate may be cut filler. The aerosol-forming 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.

[0088] The aerosol-forming 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.

[0089] The aerosol-forming substrate may comprise a bound collection of strips, strands or particles of tobacco material. The aerosol-forming 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 tobacco material may be enclosed by a wrapper. The aerosol-forming substrate may be in the form of strips, strands or particles of tobacco material bound together in a binder matrix.

[0090] The aerosol-forming substrate may comprise one or more aerosol-formers. Suitable aerosol-formers 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.

[0091] The aerosol-forming 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-forming substrate may have an aerosolformer 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.

[0092] The aerosol-forming 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.

[0093] The aerosol-forming 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.

[0094] The aerosol-forming 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.

[0095] The aerosol-forming 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.

[0096] The aerosol-forming 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.

[0097] The aerosol-forming substrate may comprise nicotine. The aerosol-forming substrate may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0098] The aerosol-forming 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.

[0099] The aerosol-forming 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.

[0100] The aerosol-forming substrate may comprise one or more botanicals. For example, the aerosolforming 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. The aerosol-forming 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-forming 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.

[0101] The aerosol-forming substrate may comprise a binder. For example, the aerosol-forming 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 carboxymethyl, celluloses; dextran; and xanthan gum. A preferable binder is guar.

[0102] The aerosol-forming substrate may comprise, or consist of, a solid aerosol-forming material. The aerosol-forming substrate may comprise a liquid aerosol-forming material, for example a liquid aerosolforming material retained within a porous matrix. The aerosol-forming substrate may comprise a gel aerosol-forming material.

[0103] Optionally, the aerosol-forming substrate comprises hydroxypropylmethyl cellulose. Optionally, the aerosol-forming substrate comprises one or more cellulose-based strengthening agents. Optionally, the aerosol-forming substrate comprises hydroxypropyl methyl cellulose and one or more cellulose-based strengthening agents. Optionally, the aerosol-forming substrate comprises hydroxypropylmethyl cellulose and one or more cellulose-based strengthening agents, and preferably also one or both of: is tobacco-free; and comprises one or more aerosol formers. Thus, optionally, the aerosol-forming substrate comprises hydroxypropylmethyl cellulose and one or more cellulose-based strengthening agents, is tobacco-free, and also comprises one or more aerosol formers.

[0104] An aerosol-forming substrate that includes hydroxypropylmethyl cellulose and one or more cellulose- based strengthening agent may have a number of advantages.

[0105] The inclusion of hydroxypropylmethyl cellulose in the aerosol-forming substrate may improve the manufacturing process of the aerosol-forming substrate. For example, hydroxypropylmethyl cellulose may reduce the viscosity of the slurry that is mixed when making the aerosol-forming substrate. A lower viscosity slurry may flow more easily compared to conventional slurries, and a lower viscosity slurry is easier to mix, transfer and handle during the manufacturing process.

[0106] The inclusion of a cellulose-based strengthening agent in the aerosol-forming substrate may increase the tensile strength of the aerosol-forming substrate. This may be particularly beneficial if hydroxypropylmethyl cellulose is present because hydroxypropylmethyl cellulose can reduce the tensile strength of the substrate. An aerosol-forming substrate with a higher tensile strength may be less likely to deteriorate or break, for example during transit or during the manufacturing process.

[0107] Optionally, the aerosol-forming substrate comprises, on a dry weight basis, at least 0.5, 1 , 5, 10, 15 or 20 weight percent hydroxypropylmethyl cellulose. Optionally, the aerosol-forming substrate comprises, on a dry weight basis, no more than 50, 45, 40, 35, 30, 25 or 20 weight percent hydroxypropylmethyl cellulose. It may be preferable for the aerosol-forming substrate to comprise, on a dry weight basis, between 5 and 50, more preferably between 10 and 50, most preferably between 20 and 50 weight percent hydroxypropylmethyl cellulose.

[0108] Optionally, the aerosol-forming substrate comprises, on a dry weight basis, at least 0.5, 1 , 5, 10, 15 or 20 weight percent of the one or more cellulose-based strengthening agents. Optionally, the aerosol-forming substrate comprises, on a dry weight basis, no more than 50, 45, 40, 35, 30, 25 or 20 weight percent of the one or more cellulose-based strengthening agents. It may be preferable for the aerosol-forming substrate to comprise, on a dry weight basis, between 5 and 50, more preferably between 10 and 50, most preferably between 20 and 50 weight percent of the one or more cellulose-based strengthening agents.

[0109] The one or more cellulose-based strengthening agents may comprise or consist of one or more of: cellulose fibres, microcrystalline cellulose, and cellulose powder. Advantageously, such cellulose-based strengthening agents may be particularly effective at increasing the tensile strength of an aerosol-forming substrate.

[0110] The aerosol-forming substrate may have a mass of between 80 milligrams and 500 milligrams, for example between 100 milligrams and 400 milligrams, for example between 1 10 milligrams and 350 milligrams, for example between 150 milligrams and 300 milligrams, for example between 170 milligrams and 250 milligrams, for example between 200 milligrams and 230 milligrams.

[0111] The density of the aerosol-forming substrate may be than 1 gram per cubic centimetre, for example less than 0.9 grams per cubic centimetre, for example less than 0.8 grams per cubic centimetre, for example less than 0.7 grams per cubic centimetre, for example less than 0.6 grams per cubic centimetre, for example 0.5 grams per cubic centimetre.

[0112] The bulk density of the aerosol-generating substrate may be around 0.6 milligrams per cubic millimetre, 0.5 milligrams per cubic millimetre, 0.4 milligrams per cubic millimetre, or around 0.3 milligrams per cubic millimetre.

[0113] The bulk density of the aerosol-generating substrate is preferably less than 0.5 milligrams per cubic millimetre.

[0114] All of the features above relating to the aerosol-forming substrate, such as what the aerosol-forming substrate may comprise, are equally applicable to the aerosol-forming substrate, the second aerosolforming substrate, and the third aerosol-forming substrate. The aerosol-forming substrate, the second aerosol-forming substrate, and the third aerosol-forming substrate may have substantially identical or different compositions. For example, the aerosol-forming substrate and the second aerosol-forming may comprise different flavourants.

[0115] According to the present disclosure, an aerosol-generating device for receiving an aerosolgenerating article as disclosed herein. The aerosol-generating device comprises a chamber dimensioned to receive at least a portion of the aerosol-generating article. The aerosol-generating device comprises 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 aerosol-generating device is configured to heat an aerosol-forming substrate, for example an aerosol-forming substrate that is a component part of an aerosol-generating article, to form an aerosol, for example an inhalable aerosol.

[0116] The aerosol-generating device may be configured to heat each of the one or more aerosolgenerating substrates to form an aerosol, for example an inhalable aerosol.

[0117] 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. The chamber may comprise an opening into which a distal end of the aerosol-generating article can be inserted. The chamber may have any suitable cross-sectional shape. For example, the chamber 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.

[0118] Preferably, at least one internal surface of the chamber 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 an alternating or fluctuating magnetic field within a space of the chamber. The heating surface may be a surface that is permeable to an alternating or fluctuating magnetic field, such that an inductor arranged outside the cavity can project an alternating or fluctuating magnetic field through the heating surface to engage with a susceptor arranged within the chamber.

[0119] According to the present disclosure, there is provided an aerosol-generating system. The aerosolgenerating system may comprise an aerosol-generating article as described herein, for example according to the first aspect. The aerosol-generating system may comprise an aerosol-generating device for use with the aerosol-generating article to generate an inhalable aerosol. The aerosol-generating device may comprise a heater or heating means configured to heat the aerosol-forming substrate of the aerosolgenerating article. The heater may be configured to heat a second aerosol-forming substrate of the aerosolgenerating article The heater may be configured to heat a third aerosol-forming substrate of the aerosolgenerating article. The aerosol-generating device may comprise 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.

[0120] The aerosol-generating device may comprise a chamber for receiving at least a portion of the aerosol-generating article. The chamber may be dimensioned to receive at least a portion of the aerosolgenerating article. The chamber may comprise an opening into which a distal end of the aerosol-generating article can be inserted. The chamber may have any suitable cross-sectional shape. For example, the chamber 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.

[0121] Preferably, at least one internal surface of the chamber is a heating surface configured to heat the aerosol-generating article. The heating surface may comprise the heater. The heater may comprise 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 or alternating magnetic field within a space of the chamber. The heating surface may be a surface that is permeable to a fluctuating or alternating magnetic field, such that an inductor arranged outside the chamber can project a fluctuating or alternating magnetic field through the heating surface to engage with a susceptor arranged within the chamber.

[0122] According to the present disclosure, there is provided a method for forming an aerosol-generating article. The method may be provided for forming an aerosol-generating article as provided herein. The method may comprise physically coupling a first plug element comprising an aerosol-forming substrate to a second plug element that is different to the first plug element, to form an aerosol-generating element. The method may comprise positioning the aerosol-generating element within a cavity positioned between a first external surface and a second external surface opposing the first external surface. The method may comprise forming an aerosol-generating article, in which the article may have an article length, an article width and an article thickness. The article length and the article width being greater than the article thickness.

[0123] The method may comprise forming an aerosol-generating element having a circular cross-section and subsequently pressing the aerosol-generating element to form an aerosol-generating element having an oval cross-section.

[0124] The method may comprise providing a first sheet of material, a second sheet of material for forming the first external surface and a third sheet of material for forming the second external surface; forming an cavity through the first sheet of material to form a frame; positioning the cavity between the second sheet of material and the third sheet of material; and bonding the first sheet of material, the second sheet of material, and the third sheet of material to form the aerosol-generating article.

[0125] Preferably, the method comprises positioning the aerosol-generating element into the cavity prior to bonding the third sheet of material to the first sheet of material. Preferably, the method comprises positioning the aerosol-generating element into the cavity after bonding the second sheet of material to the first sheet of material.

[0126] Prior to positioning the aerosol-generating element into the cavity, the aerosol-generating element may have a height greater than the height of the frame. So the aerosol-generating element may be compressed to reduce its height prior to forming the aerosol-generating article.

[0127] The method may comprise positioning the aerosol-generating element into the cavity and then subsequently compressing the aerosol-generating element to reduce the height of the aerosol-forming element. The height of the aerosol-forming element may be compressed to approximately the height of the frame.

[0128] Alternatively, or in addition, the method may comprise compressing the aerosol-generating element prior to positioning the aerosol-generating element into the cavity. For example, the aerosol-generating element may be compressed to reduce the height of the aerosol-forming element and subsequently the aerosol-generating element may be positioned into the cavity.

[0129] As used herein, the term “aerosol-generating article” may refer to an article able to generate, or release, an aerosol.

[0130] As used herein, the term “aerosol-forming 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-forming substrate. An aerosol-forming substrate may comprise an aerosol-forming material. An aerosol-forming substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. An aerosol-forming substrate may conveniently be part of an aerosol-generating article or smoking article.

[0131] 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.

[0132] 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. 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-forming substrate or aerosol-generating article.

[0133] As used herein, the term “nicotine”, is used to describe nicotine, nicotine base or a nicotine salt.

[0134] As used herein, 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.

[0135] 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.

[0136] 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-forming 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.

[0137] 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.

[0138] 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.

[0139] 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.

[0140] 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. Ex1 . An aerosol-generating article for use with an aerosol-generating device to generate an aerosol, the aerosol-generating article comprising: a first external surface and a second external surface opposing the first external surface; a cavity positioned between the first external surface and the second external surface; and an aerosol-forming element positioned within the cavity, the aerosol-forming element comprising a first plug element comprising an aerosol-forming substrate, and a second plug element different to the first plug element, wherein the first plug element and the second plug element are physically coupled to each other, wherein the aerosol-generating article has an article length, an article width and an article thickness, the article length and the article width being greater than the article thickness.

[0141] Ex2. An aerosol-generating article according to example Ex1 in which the first plug element and the second plug element are physically coupled to one another by means of a coupling member.

[0142] Ex3. An aerosol-generating article according to example Ex2, in which the coupling member comprises a strip of material simultaneously attached to both first plug element and second plug element.

[0143] Ex4. An aerosol-generating article according to example Ex3, in which the coupling member comprises a strip of paper attached to both first plug element and second plug element.

[0144] Ex5. An aerosol-generating article according to example Ex3 or Ex4, in which the coupling member comprises a thread attached to both first plug element and second plug element.

[0145] Ex6. An aerosol-generating article according to any one of examples Ex2 to Ex5, in which the coupling member comprises wrapper at least partially circumscribing to both first plug element and second plug element.

[0146] Ex7. The aerosol-generating article according to example Ex6, wherein the wrapper is a paper wrapper. Ex8. The aerosol-generating article according to any one of examples Ex2 to Ex7, wherein at least a portion of the coupling member is positioned between the first plug element and the second plug element to space the first plug element from the second plug element.

[0147] Ex9. The aerosol-generating article according to example Ex8, wherein the at least a portion of the coupling member provides a physical barrier between the first plug element and the second plug element to prevent physical contact between the first plug element and the second plug element.

[0148] Ex10. An aerosol-generating article according to any preceding example in which the first plug element and the second plug element are coaxially aligned with each other.

[0149] Ex11 . The aerosol-generating article according to any preceding example, wherein the second plug element comprises a portion of sensorial media.

[0150] Ex12. The aerosol-generating article according to any preceding example, wherein the portion of sensorial media comprises a second aerosol-forming substrate.

[0151] Ex13. The aerosol-generating article according to example Ex12, wherein the second aerosol-forming substrate has a different composition to the aerosol-forming substrate of the first plug element.

[0152] Ex14. The aerosol-generating article according to any one of examples Ex11 to Ex13, wherein the portion of sensorial media comprises a flavourant.

[0153] Ex15. The aerosol-generating article according to any preceding example, wherein the second plug element has different dimensions to the first plug element.

[0154] Ex16. The aerosol-generating article according to any preceding example, wherein the second plug element has a different density to the first plug element. Ex17. The aerosol-generating article according to any preceding example, wherein the second plug element comprises a crimped sheet of material.

[0155] Ex18. The aerosol-generating article according to any preceding example, wherein the second plug element comprises a perforated sheet of material.

[0156] Ex19. The aerosol-generating article according to any preceding example, wherein the second plug element comprises grooves.

[0157] Ex20. The aerosol-generating article according to any preceding example, wherein the second plug element comprises a sheet of paper.

[0158] Ex21 . The aerosol-generating article according to any of examples Ex11 to Ex20, wherein the second plug element comprises a hollow tube impregnated with the portion of sensorial media.

[0159] Ex22. The aerosol-generating article according to any preceding example, comprising a third plug element being different to the first plug element.

[0160] Ex23. The aerosol-generating article according to example Ex22, wherein the first plug element is positioned between the second plug element and the third plug element, the third plug element being physical ly coupled to the first plug element.

[0161] Ex24. The aerosol-generating article according to example Ex23, wherein the third plug element comprises a second portion of sensorial media.

[0162] Ex25. The aerosol-generating article according to example Ex24, the second portion of sensorial media having a different composition to the portion of sensorial media of the second plug element.

[0163] Ex26. The aerosol-generating article according to example Ex24, the second portion of sensorial media having the same composition as the portion of sensorial media of the second plug element.

[0164] Ex27. The aerosol-generating article according to any one of examples Ex22 to Ex26, wherein the first plug element is in contact with the third plug element.

[0165] Ex28. The aerosol-generating article according to any one of examples Ex22 to Ex26, wherein the first plug element is spaced from the third plug element.

[0166] Ex29. The aerosol-generating article according to any one of examples Ex22 to Ex28, wherein the third plug element comprises a crimped sheet of material.

[0167] Ex30. The aerosol-generating article according to any one of examples Ex22 to Ex29, wherein the third plug element comprises a perforated sheet of material.

[0168] Ex31 . The aerosol-generating article according to any one of examples Ex22 to Ex30, wherein the third plug element comprises a sheet of paper.

[0169] Ex32. The aerosol-generating article according to any one of examples Ex22 to Ex31 , wherein the third plug element comprises a hollow tube impregnated with the second portion of sensorial media.

[0170] Ex33. The aerosol-generating article according to any one of examples Ex22 to Ex32, wherein the third plug element comprises grooves.

[0171] Ex34. An aerosol-generating article according to any preceding example, further comprising a frame positioned between the first external surface and the second external surface, the frame at least partially defining the cavity.

[0172] Ex35. The aerosol-generating article according to any preceding example, wherein the first external surface is a first planar external surface, and the second external surface is a second planar external surface. Ex36. The aerosol-generating article according to example Ex35, comprising a first planar external layer and a second planar external layer, wherein the first planar external layer defines the first external surface, and the second planar external layer defines the second external surface.

[0173] Ex37. The aerosol-generating article according to example Ex36, comprising an outer wrapper defining the first planar external layer and the second planar external layer.

[0174] Ex38. An aerosol-generating article according to any preceding example, wherein the first plug element comprises crimped sheets of the aerosol-forming substrate.

[0175] Ex39. An aerosol-generating article according to any preceding example, wherein the first plug element comprises shreds of the aerosol-forming substrate.

[0176] Ex40. An aerosol-generating article according to any preceding example, wherein the first plug element comprises at least one of a powder, beads, granules, or a gel comprising the aerosol-forming substrate.

[0177] Ex41 . An aerosol-generating article according to any preceding example, wherein the aerosol-forming substrate comprises at least one of cut filler tobacco, cast leaf tobacco, film tobacco, homogenised tobacco or expanded tobacco, botanicals, or herbs.

[0178] Ex42. The aerosol-generating article according to any preceding example, wherein the aerosol-forming substrate has a mass of between 80 milligrams and 500 milligrams, for example between 100 milligrams and 400 milligrams, for example between 1 10 milligrams and 350 milligrams, for example between 150 milligrams and 300 milligrams, for example between 170 milligrams and 250 milligrams, for example between 200 milligrams and 230 milligrams.

[0179] Ex43. The aerosol-generating article according to any preceding example, wherein the volume of the aerosol-generating element is between 650 millimetres cubed and 300 millimetres cubed, preferably between 625 millimetres cubed and 360 millimetres cubed, for example 480 millimetres cubed.

[0180] Ex44. The aerosol-generating article according to any preceding example, wherein the density of the aerosol-forming substrate is less than 1 gram per cubic centimetre, for example less than 0.9 grams per cubic centimetre, for example less than 0.8 grams per cubic centimetre, for example less than 0.7 grams per cubic centimetre, for example less than 0.6 grams per cubic centimetre, for example 0.5 grams per cubic centimetre.

[0181] Ex45. The aerosol-generating article according to any preceding example, wherein the bulk density of the aerosol-generating substrate is around 0.6 milligrams per cubic millimetre, 0.5 milligrams per cubic millimetre, 0.4 milligrams per cubic millimetre, or around 0.3 milligrams per cubic millimetre,

[0182] Ex46. The aerosol-generating article according to any preceding example, wherein the bulk density of the aerosol-generating substrate is preferably less than 0.5 milligrams per cubic millimetre.

[0183] Ex47. The aerosol-generating article according to any preceding example, wherein the aerosol-forming element is a rod.

[0184] Ex48. The aerosol-generating article according to any preceding example, wherein the aerosol-forming element has a circular cross-section.

[0185] Ex49. The aerosol-generating article according to any preceding example, wherein the aerosol-forming element has a rectangular cross-section.

[0186] Ex50. The aerosol-generating article according to any preceding example, wherein the aerosol-forming element has an elliptical cross-section. Ex51 . The aerosol-generating article according to any preceding example, wherein both the article length and the article width are both at least two times the article thickness.

[0187] Ex52. The aerosol-generating article according to any preceding example, wherein the aerosolgenerating article is a planar aerosol-generating article.

[0188] Ex53. An aerosol-generating system comprising an aerosol-generating article according to any preceding example and an aerosol-generating device for use with the aerosol-generating article to generate an inhalable aerosol.

[0189] Ex54. An aerosol-generating system according to example Ex53, wherein the aerosol-generating device comprises a heater configured to heat the aerosol-forming substrate of the aerosol-generating article.

[0190] Ex55. A method for forming an aerosol-generating article according to any one of examples Ex1 to Ex52 comprising: physical ly coupling a first plug element comprising an aerosol forming substrate and a second plug element that is different to the first plug element, to form an aerosol-generating element; and positioning the aerosol-generating element within a cavity positioned between a first external surface and a second external surface opposing the first external surface.

[0191] Ex56. The method for forming an aerosol-generating article according to example Ex55, comprising forming an aerosol-generating element having a circular cross-section and subsequently pressing the aerosol-generating element to form an aerosol-generating element having an oval cross-section.

[0192] Examples will now be further described with reference to the figures in which:

[0193] Figure 1 is a perspective side view of an aerosol-generating element according to a first embodiment of the present disclosure;

[0194] Figure 2 is a perspective side view of an aerosol-generating element according to a second embodiment of the present disclosure;

[0195] Figure 3 is a schematic end view of an aerosol-generating article according to a third embodiment of the present disclosure;

[0196] Figure 4 is a schematic side view of the aerosol-generating article of figure 3;

[0197] Figure 5 is a schematic plan view of the aerosol-generating article of figure 3;

[0198] Figure 6 shows a schematic illustration of a corrugated element as used in the aerosol-generating article of figure 3;

[0199] Figure 7 shows a perspective view of an aerosol-generating article according to a fourth embodiment of the present disclosure;

[0200] Figure 8A shows an exploded perspective view of the aerosol-generating article of figure 7;

[0201] Figure 8B shows a further exploded perspective view of the aerosol-generating article of figure 7;

[0202] Figure 8C shows a schematic transverse cross-sectional view of the aerosol-generating article of figure 7;

[0203] Figure 8D shows a schematic longitudinal cross-sectional view of the aerosol-generating article of figure 7;

[0204] Figure 9A a schematic perspective view of an aerosol-generating element according to a fifth embodiment of the present disclosure, prior to assembly;

[0205] Figure 9B shows a schematic perspective view of the aerosol-generating element of figure 9A after assembly; Figure 9C shows a schematic longitudinal cross-sectional view of the aerosol-generating element of figure 9B;

[0206] Figure 10A shows a schematic perspective view of an aerosol-generating element according to a sixth embodiment of the present disclosure, prior to assembly;

[0207] Figure 10B shows a schematic transverse cross-sectional view of the aerosol-generating article of figure 10A;

[0208] Figure 11 shows a schematic longitudinal cross-sectional view of an aerosol-generating element according to a seventh embodiment of the present disclosure;

[0209] Figure 12 shows a schematic longitudinal cross-sectional view of an aerosol-generating element according to a eighth embodiment of the present disclosure; Figure 13 shows a schematic longitudinal cross-sectional view of an aerosol-generating element according to a ninth embodiment of the present disclosure;

[0210] Figure 14A shows a schematic perspective view of an aerosol-generating element according to a tenth embodiment of the present disclosure, prior to assembly;

[0211] Figure 14B shows a longitudinal cross-sectional view of the aerosol-generating element of Figure 14A;

[0212] Figure 15 shows a schematic perspective view of an aerosol-generating element according to an eleventh embodiment of the present disclosure, prior to assembly;

[0213] Figure 16A shows a schematic perspective view of an aerosol-generating element according to a twelfth embodiment of the present disclosure, prior to assembly;

[0214] Figure 16B shows a schematic plan view of the aerosol-generating element according of Figure 16A, during assembly;

[0215] Figure 16C shows a longitudinal cross-sectional view of the aerosol-generating element of Figure 16A, after assembly;

[0216] Figure 17 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 3 to 8;

[0217] Figure 18 shows a schematic end view of the aerosol-generating device of figure 17;

[0218] Figure 19 is a schematic view showing an aerosol-generating article (for example, the aerosolgenerating article of any of figures 3 to 8) in engagement with the aerosol-generating device of figure 17.

[0219] Figure 20 is a schematic view of an alternative embodiment to that of figures 17 to 19, showing an aerosol-generating article in engagement with an aerosol-generating device.

[0220] Figure 1 illustrates a perspective side view of an aerosol-generating element 100 according to a first embodiment of the present disclosure.

[0221] The aerosol-generating element 100 comprises an upper layer 108 forming an upper surface 110. The aerosol-generating element 100 comprises a lower surface 120 opposing the upper surface 110. The upper and lower surfaces 1 10, 120 are flat or planar.

[0222] The aerosol-generating element 100 comprises a first plug element 181 comprising an aerosolforming substrate and a second plug element 182, the second plug element 182 being different to the first plug element 181 . The upper layer 108 is comprises a sheet of paper adhered to the first plug element 181 and the second plug element 182. The upper layer 108 is a coupling member for coupling the first plug element 181 and the second plug element together. For example, the first plug element 181 and the second plug element 182 are physically coupled to each other by the upper layer 108. The lower surface 120 is formed of an external surface of the first plug element 181 and the second plug element 182.

[0223] In one embodiment, the aerosol-generating element 100 may consist substantially of aerosol-forming substrate, for example the second plug element 182 may comprise a second aerosol-forming substrate being different to the aerosol-forming substrate of the first plug element 181. In another embodiment, the aerosol-forming substrate may be one of a plurality of component parts of the aerosol-generating element 100. For example, the second plug element 182 may not comprise an aerosol-forming substrate.

[0224] A suitable aerosol-forming substrate may be homogenised tobacco.

[0225] The aerosol-generating element 100 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of between 10 and 15 millimetres, and a height (which may also be referred to as a thickness), extending in a z dimension, of between 3 and 3.6 millimetres. The first plug element 181 has a length of 40 millimetres and the second plug element 182 has a length of 40 millimetres.

[0226] Figure 2 illustrates a perspective side view of an aerosol-generating element 200 according to a second embodiment of the present disclosure, being a variant of aerosol-generating element 100. Features in common with aerosol-generating element 100 are referred to with like reference signs but commencing with numeral 2 instead of numeral 1 . An air flow path 230 is defined through the aerosol-generating element 200 between the upper and lower surfaces 210, 220. The air flow path 230 extends between opposed first and second ends 201 , 202 of the aerosol-generating element 200. The first end 201 may define a distal end of the aerosol-generating element 200, and the second end 202 may define a proximal or mouth end of the aerosol-generating element. The air flow path 230 may be directed towards a mouth of a user to allow a user to inhale aerosol generated in consequence of heating of aerosol-forming substrate of the aerosol-generating element 200.

[0227] In this embodiment, the coupling member comprises the upper layer 208 for coupling the first plug element 281 to the second plug element 282.

[0228] Figures 3, 4, and 5 illustrate respectively an end view, a side view, and a plan view of an aerosolgenerating article 300 according to a third embodiment of the present disclosure. The aerosol-generating article 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.

[0229] 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-forming substrate 345. A suitable aerosol-forming substrate may be homogenised tobacco. Thus, the intermediate layer 340 may be formed from a corrugated sheet of homogenised tobacco material 345.

[0230] The aerosol-generating article 300 comprises an aerosol-generating element 370 comprising first and second plug elements (not shown in Figure 3). The corrugated sheet of aerosol-forming substrate 345 forms a cavity between the planar upper layer 310 and the intermediate layer 340. The aerosol-generating element 370 is positioned in the cavity. In this embodiment, the aerosol-generating element 370 is a cylindrical rod. In this embodiment, the coupling member for coupling the first plug element to the second plug element is a paper wrapper 390 that circumscribes both the first and second plug elements.

[0231] The aerosol-generating element 370 would not be visible in the view in Figure 4 but has nonetheless been illustrated in a dotted line to indicate its position along the length of the article 300, and the first plug element 381 and the second plug element 382. The first plug element 381 and the second plug element 382 are aligned along the longitudinal axis of the aerosol-generating article 300.

[0232] Figure 6 illustrates the corrugated sheet of aerosol-forming substrate 345. The corrugations have an amplitude 346 of 3 millimetres and a wavelength 347 of 3 millimetres. The sheet of aerosol-forming substrate 345 forming the intermediate layer 340 has a thickness of 150 microns.

[0233] 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.

[0234] The aerosol-generating article 300 has a length, extending in an x dimension, of 80 millimetres, a width, extending in a y dimension, of 15 millimetres, and a height (or thickness), extending in a z dimension, of 3.6 millimetres.

[0235] 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 aerosol-forming substrate 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-forming substrate 345. The porosity of the aerosol-generating article 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.

[0236] The aerosol-forming substrate 345 may be a sheet of any suitable aerosol-forming substrate.

[0237] During use of the aerosol-generating article 300, the aerosol-forming substrate 345 is heated up to cause the aerosol-forming 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 300 via the proximal end 371 . It is to be understood that in other embodiments the intermediate layer 340 may be a corrugated element formed from a corrugated sheet of a different material, for example cardboard. In such embodiments, the only aerosol-forming substrate of the aerosol-generating article is the aerosolforming substrate of the aerosol-generating element 370, and all aerosol produced during use of the aerosol-generating article is generated from the aerosol-forming substrate of the aerosol-generating element 370.

[0238] Figure 7 shows an aerosol-generating article 400 according to a fourth embodiment of the present disclosure. The aerosol-generating article 400 comprises a first planar external layer 424 forming a first planar external surface 421 , a second planar external layer 425 forming a second planar external surface 422, and a frame 450 positioned between the first planar external layer 424 and the second planar external layer 425. The second planar external surface 422 is positioned parallel to the first planar external surface 421. Figures 8 shows an exploded view of the aerosol-generating article 400 of figure 7. The frame 450 circumscribes and at least partially defines a cavity 430. Figure 8A shows the cavity 430 in an empty state, prior to insertion of an aerosol-forming element 470. Figure 8B shows the cavity 430 filled with the aerosolforming element 470. Figures 8C and 8D show respective transverse and longitudinal cross-sectional views of the aerosol-generating article 400 when the cavity 430 is filled with the aerosol-forming element 470.

[0239] The first planar external layer 424 and the second planar external layer 425 are made from cigarette paper having a thickness of 35 micrometres and are in physical contact, with and bonded to, the frame 450. The first planar external layer 424 overlies a first end of the cavity 430 and forms a first cavity end wall 431 . The second planar external layer 425 overlies a second end of the cavity 430 and forms a second cavity end wall 432, the second cavity end wall 432 being opposite to the first cavity end wall 431 . That is, the frame 450, the first planar external layer 424 and the second planar external layer 425 collectively define the cavity 430.

[0240] The frame 450 has a hollow cuboid shape and is made from cardboard. The frame 450 defines an aperture extending through the height (also referred to as the thickness) of the frame 450 and the aperture at least partially forms the cavity 430 of the aerosol-generating article 400. The frame 450 comprises a peripheral wall 451 that circumscribes the cavity 430. The peripheral wall 451 includes a front wall 413 and a back wall 414. In more detail, the peripheral wall 451 is defined by an inner transverse surface 452 of the frame 450 and an outer transverse surface 453 of the frame 450. The inner transverse surface 452 of the peripheral wall 451 at least partially defines a perimeter of the cavity 430. The outer transverse surface 453 of the peripheral wall 451 at least partially defines a perimeter of the aerosol-generating article 400. The peripheral wall 451 has a radial thickness measured between the inner transverse surface 452 of the frame 450 and the outer transverse surface 453 of the frame 450 of about 5 millimetres.

[0241] An air inlet 41 1 and an air outlet 412 are defined by, and extend through, the peripheral wall 451 of the frame 450. More specifically, the air inlet 41 1 extends through the front wall 413 and the air outlet 412 extends through the back wall 414. The air inlet 41 1 and the air outlet 412 have an equivalent diameter of 5 millimetres. An airflow passage extends between the air inlet 41 1 and the air outlet 412 through the cavity 430.

[0242] As shown in figures 8B to 8D, the aerosol-forming element 470 is positioned within the cavity 430. The aerosol-generating element 470 is positioned within the cavity 430 of the aerosol-generating article 400. The aerosol-generating element 470 is a variant of aerosol-generating element 100. The aerosolgenerating element 470 comprises a first plug element 481 comprising an aerosol-forming substrate. In this embodiment, the aerosol-generating element 470 comprises a second plug element 482 comprising a portion of sensorial media. The aerosol-generating element 470 comprises an upper layer 408 and a lower layer 409. The first plug element 181 and the second plug element 182 are physically coupled to each other by the upper layer 408 and the lower layer 409.

[0243] The aerosol-forming element 470 comprises an aerosol-forming substrate. The aerosol-forming substrate comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosolformer content of 5 percent by weight on a dry weight basis. As shown in Figures 8B to 8D, the aerosolforming element 470 fills the entire volume of the cavity 430. However, it should be appreciated that in alternative embodiments, the aerosol-forming element 470 may be smaller than the cavity 430 such that the aerosol-forming substrate does not fill the cavity 430. The aerosol-generating article 400 has a cuboid shape and has a height (or thickness) extending in a z dimension, as measured between the first planar external surface 421 and the second planar external surface 422, of 8 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The frame 450 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 40 millimetres and a length extending in an x dimension of 60 millimetres. The cavity 430 has a height (or thickness) extending in a z dimension of 7.93 millimetres, a width extending in a y dimension of 30 millimetres and a length extending in an x dimension of 50 millimetres.

[0244] To manufacture the aerosol-generating article 400 an adhesive is applied to a lower surface of the frame 450. A sheet of second (lower) external layer 425 is bonded to the frame 450 by the adhesive applied to the lower surface of frame 450. The aerosol-generating element 470 is placed into the cavity 430. An adhesive is applied to an upper surface of the frame 450. A sheet of first (upper) external layer 424 is bonded to the frame 450 by the adhesive applied to the upper surface of the frame 450, thereby forming the aerosol-generating article.

[0245] Figures 9A to 9C show an aerosol-generating element 500 according to a fifth embodiment of the present disclosure. The aerosol-generating element 500 comprises a first plug element 581 comprising a first aerosol-forming substrate. The aerosol-generating element 500 comprises a second plug element 582 comprising a second aerosol-forming substrate that is different to the first aerosol-forming substrate. The aerosol-generating element 500 further comprises a third plug element 583 that also comprises aerosolforming substrate, in this example the aerosol-forming substrate of the third plug element 583 is the second aerosol-forming substrate. However, it should be appreciated that a different aerosol-forming substrate may be selected for the third plug element. The aerosol-generating element comprises a paper wrapper 590, which is shown unwrapped in Figure 9A. The first, second, and third plug elements 581 , 582, 583 are axially aligned and assembled end-to-end in the wrapper 590. In this example, each of the second plug element 582 and the third plug element 583 are in physical contact with the first plug element 581 . Therefore, in this embodiment, in use the aerosol-generating element may be aligned with a heater configured to heat the first, second, and third plug elements 581 , 582, 583 to vaporise the first and second aerosol-forming substrates.

[0246] Figure 9B shows a schematic perspective view of the aerosol-generating element 500 of figure 9A after assembly. The pre-assembled aerosol-generating element 500 shown in Figure 9B. The paper wrapper 590 circumscribes the first, second, and third plug elements 581 , 582, 583. The wrapper 590 is a coupling member to physically couple the first plug element 581 to the second plug element 582 and the third plug element 583. The aerosol-generating element 500 is compressed to flatten to cylindrical element into an element having an oval or elliptical axial cross-section, as shown in Figure 9B. The aerosolgenerating element 500 may be inserted into a cavity of an aerosol-generating article, for example the article shown in Figures 7 and 8.

[0247] Figure 9C shows a schematic longitudinal cross-sectional view of the aerosol-generating element of figure 9B in the x / y plane.

[0248] Figure 10A shows a schematic perspective view of an aerosol-generating element 700 according to a sixth embodiment of the present disclosure, prior to assembly. The aerosol-generating element 700 is the same as the aerosol-generating element 500, except where described below. In this embodiment, the first, second and third plug elements 781 , 782, 783 are cuboid. The wrapper 790 is wrapped around the first, second and third plug elements 781 , 782, 783 to physically couple first, second and third plug elements 781 , 782, 783 to each other. Again, the aerosol-generating element 700 may be inserted into a cavity of an aerosol-generating article, for example the article shown in Figures 7 and 8A-D.

[0249] Figure 10B shows a schematic transverse cross-sectional view of the aerosol-generating element of figure 10A. Figure 10B shows an end view of the aerosol-generation element 70 and so only the second plug element 782 is visible. The wrapper 790 is shown wrapped around the second plug element 782 to circumscribe the second plug element 782. However, it should be understood that the wrapper 790 is also wrapped around the first and third plug elements 781 , 783 (not shown in Figure 10B) to physically couple them to each other. The wrapper 790 is shown to connect at point 791 to, joined by an adhesive. In other examples, the wrapper may overlap.

[0250] Figure 11 shows a schematic longitudinal cross-sectional view of an aerosol-generating element according to a seventh embodiment of the present disclosure. The aerosol-generating element 800 comprises a first plug element 881 comprising an aerosol-forming substrate as described in Figure 1 . The second plug element 882 comprises a portion of sensorial media being different to the aerosol-forming substrate of the first plug element 881 . For example, the portion of sensorial media comprises a flavour releasing element. The aerosol-generating element further comprises a third plug element 883, coupled to the first plug element 881 . The third plug element 883 is identical to the second plug element 882.

[0251] Figure 12 shows a schematic longitudinal cross-sectional view of an aerosol-generating element 900 according to a eighth embodiment of the present disclosure. The aerosol-generating element 900 is the same as the aerosol-generating element 800, except where described below. The features of the aerosol-generating element 900 that are the same as the features of the aerosol-generating element 800 are denoted with the same reference numerals. In this example, the second plug element comprises a second aerosol-forming substrate 982. So the third plug element 883 is different from the second plug element 982

[0252] Figure 13 shows a schematic longitudinal cross-sectional view of an aerosol-generating element 1000 according to a ninth embodiment of the present disclosure. The aerosol-generating element 1000 is the same as the aerosol-generating element 800, except where described below. The features of the aerosol-generating element 1000 that are the same as the features of the aerosol-generating element 800 are denoted with the same reference numerals. In this embodiment, the first plug element 1081 has different dimensions to second and third plug elements 1082, 1083. As shown in Figure 13, the first plug element has a greater length than the second and third plug elements. However, it should be appreciated that in other examples, the first plug element may be shorter than the second and third plug elements 1082, 1083.

[0253] The second plug element 1082 and the third plug element 1083 are both different to the first plug element 1081 and different to each other. The second plug element 1082 comprises a portion of sensorial media. The third plug element 1083 comprises a second portion of sensorial media, which is different to the portion of sensorial media of the second plug element 1082.

[0254] Figure 14A shows a schematic perspective view of an aerosol-generating element 1100 according to a tenth embodiment of the present disclosure, prior to assembly. The aerosol-generating element 1 100 is the same as the aerosol-generating element 1000, except where described below. The second plug element 1182 and the third plug element 1 183 are both different to the first plug element 1081 and different to each other.

[0255] The second plug element 1182 is spaced from the first plug element 1081 . When assembled, the wrapper 590 maintains a gap of between 0.5 and 1 millimetres between the second plug element 1 182 from the first plug element 1081 .

[0256] The third plug element 1 183 is spaced from the first plug element 1081. When assembled, the wrapper 590 maintains a gap of between 0.5 and 1 millimetres between the second plug element 1 183 from the first plug element 1081 .

[0257] The second plug element 1 182 comprises a portion of sensorial media being different to the aerosolforming substrate of the first plug element 1081 , the portion of sensorial media of the second plug element 1182 of this embodiment is a flavourant. The second plug element 1182 comprises a sheet of paper impregnated with the flavourant. The sheet of paper is crimped to form the second plug element 1 182 having grooves 1 184 on a surface of the second plug element 1182. The grooves 1 184 reduce the amount of the surface of the second plug element 1 1 182 that is in physical contact with the wrapper 590, when the aerosol-generating element 1100 is assembled. The grooves 1184 therefore may reduce the amount of heat transferred by conduction from the wrapper 590 to the second plug element 1 182.

[0258] The third plug element 1 183 comprises a second portion of sensorial media being different to the portion of sensorial media of the first second element 1182, the second portion of sensorial media of the third plug element 1 183 of this embodiment is a flavourant. The third plug element 1183 comprises a sheet of paper impregnated with the flavourant. The sheet of paper is perforated. For example, the sheet of paper has apertures 1185 extending through the sheet of paper.

[0259] Figure 14B shows a longitudinal cross-sectional view of the aerosol-element article of Figure 14A after assembly.

[0260] Figure 15 shows a schematic perspective view of an aerosol-generating element according to an eleventh embodiment of the present disclosure, prior to assembly.

[0261] The aerosol-generating element 1200 is the same as the aerosol-generating element 1100, except where described below.

[0262] The second plug element 1282 comprises a portion of sensorial media being different to the aerosolforming substrate of the first plug element 1081 , the portion of sensorial media of the second plug element 1282 of this embodiment is a flavourant. The second plug element 1282 comprises a hollow tube of cardboard impregnated with the flavourant. In use, the airflow path is defined through the centre of the hollow tube and the flavourant is entrained by the air and aerosol flowing through the aerosol-generating element 1200.

[0263] The third plug element 1283 comprises a second portion of sensorial media being different to the portion of sensorial media of the first second element 1282, the second portion of sensorial media of the third plug element 1283 of this embodiment is a flavourant different to the flavourant of the second plug element. The third plug element 1283 comprises a hollow tube of cardboard impregnated with the flavourant. In use, the airflow path is defined through the centre of the hollow tube of the third plug element and the flavourant is entrained by the air and aerosol flowing through the aerosol-generating element 1200.

[0264] Figure 16A shows a schematic perspective view of an aerosol-generating element 1300 according to a twelfth embodiment of the present disclosure, prior to assembly. The aerosol-generating element 1300 is the same as the aerosol-generating element 500 according to a fifth embodiment of the present disclosure, except where described below.

[0265] The first plug element 581 is spaced from the second plug element 583 and the third plug element 583 so that there is a first gap 1392 between the first and second plug elements 581 , 582 and there is a second gap 1394 between the first and third plug elements 581 , 583.

[0266] Figure 16B shows a schematic plan view of the aerosol-generating element according of Figure 16A, during assembly. During assembly, the paper wrapper 1390 circumscribes the first, second and third plug elements 581 , 582, 583. The paper wrapper 1390 is pushed to enter the gaps 1392 and 1394 as shown by arrows in Figure 16B.

[0267] Figure 16C shows a longitudinal cross-sectional view of the aerosol-generating element of Figure 16A, after assembly. The paper wrapper 1390 forms a physical barrier between the first plug element 581 and the second plug element 582 and between the first plug element 581 and the third plug element 583. The physical barrier comprises a first wall 1396 that is formed by folded paper wrapper 1390 between the first plug element 581 and the second plug element 582. The physical barrier comprises a second wall 1398 that is formed by folded paper wrapper 1390 between the first plug element 581 and the second plug element 583. The first wall 1396 and the second wall 1398 both prevent physical contact between adjacent plug elements. Both the first wall 1396 and the second wall 1398 extend radially inward from the outer surface of the outer wrapper 1390. Both the first wall 1396 and the second wall 1398 extend only partially into the aerosol-forming element 1300. The first wall 1396 defines a first opening 1397. In this example, the first opening 1397 is in a radially central position of the aerosol-forming element 1300. The second wall 1398 defines a second opening 1399. In this example, the second opening 1399 is in a radially central position of the aerosol-forming element 1300. The first and second opening 1397, 1399 are aligned such that, in use, an airflow path is defined through the aerosol-forming element 1300 through the first and second openings 1397, 1399 to allow air and aerosol to flow through the aerosol-forming element 1300.

[0268] Figures 17 and 18 illustrate an aerosol-generating device 6000 configured for use with an aerosolgenerating article 600 comprising or consisting of aerosol-forming substrate 640. 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.

[0269] Figure 19 illustrates the device 6000 of figure 17 in engagement with the aerosol-generating article 600. The device 6000 in engagement with the aerosol-generating article 600 may together be referred to as an aerosol-generating system. 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 aerosolgenerating 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 aerosol-generating article 600, and as a result the aerosol-forming substrate 640 of the aerosol-generating article 600 is heated. Volatile components of the aerosol-forming 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 aerosolgenerating articles 100, 200, 300, 400 previously described or any other aerosol-generating article comprising any of the aerosol-generating elements 500, 700, 800, 900, 1000, 1200, or 1300 of the present disclosure.

[0270] Although figure 19 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 20 illustrates an alternative embodiment to that of figure 19, with like features referred to by the same reference numbers but with the addition of a prime symbol ’. For the alternative embodiment of figure 20, the entirety of aerosol-generating article 600’ is enclosed within the interior of aerosol-generating device 6000’.

[0271] 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 to generate an aerosol, the aerosol-generating article comprising: a first external surface and a second external surface opposing the first external surface; a cavity positioned between the first external surface and the second external surface; and an aerosol-forming element positioned within the cavity, the aerosol-forming element comprising a first plug element comprising an aerosol-forming substrate, and a second plug element which is different to the first plug element, wherein the first plug element and the second plug element are physically coupled to each other, wherein the aerosol-generating article has an article length, an article width and an article thickness, the article length and the article width being greater than the article thickness.

2. The aerosol-generating article according to claim 1 or 2, in which the first plug element and the second plug element are physically coupled to one another by means of a coupling member, for example a wrapper at least partially circumscribing to both first plug element and second plug element.

3. The aerosol-generating article according to any preceding claim, in which the first plug element and the second plug element are coaxially aligned with one another.

4. The aerosol-generating article according to any preceding claim, wherein the second plug element comprises a portion of sensorial media.

5. The aerosol-generating article according to claim 4, wherein the portion of sensorial media comprises a second aerosol-forming substrate, wherein the second aerosol-forming substrate has a different composition to the aerosol-forming substrate of the first plug element.

6. The aerosol-generating article according to claim 4 or 5, wherein the portion of sensorial media comprises a flavourant.

7. The aerosol-generating article according to any preceding claim, wherein the second plug element has different dimensions to the first plug element.

8. The aerosol-generating article according to any preceding claim, wherein the first plug element is spaced from the second plug element.

9. The aerosol-generating article according to any one of claims 2 to 8, wherein at least a portion of the coupling member is positioned between the first plug element and the second plug element to prevent physical contact between the first plug element and the second plug element.

10. The aerosol-generating article according to claim 9, wherein the portion of the coupling member is folded between the first plug element and the second plug element to prevent physical contact between the first plug element and the second plug element.11 . The aerosol-generating article according to any preceding claim, wherein the second plug element comprises a sheet of material, preferably a sheet of material that is at least one of crimped, grooved or perforated.

12. The aerosol-generating article according to any preceding claim comprising a third plug element comprising a second portion of sensorial media, wherein the first plug element is positioned between the second plug element and the third plug element.

13. The aerosol-generating article according to claim 12, wherein the second portion of sensorial media has a different composition to the portion of sensorial media of the second plug element.

14. The aerosol-generating article according to any preceding claim comprising a frame positioned between the first external surface and the second external surface, the frame at least partially defining the cavity.

15. An aerosol-generating system comprising the aerosol-generating article according to any preceding claim and an aerosol-generating device for use with the aerosol-generating article to generate an inhalable aerosol.

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