Aerosol-generating article with downstream section

Abstract

An aerosol-generating article (100) comprising: a substrate element comprising an aerosol-generating substrate (12), the aerosol-generating substrate (12) comprising one or more aerosol formers; and a downstream section (14) provided downstream of the substrate element, the downstream section (14) comprising: a mouthpiece element (24), the mouthpiece element (24) comprising a tubular portion (32) and a plug portion (34), wherein the aerosol-generating substrate (12) has an aerosol former content of greater than 30 percent by weight, wherein the mouthpiece element (24) is provided at a downstream end of the aerosol-generating article (100), and wherein the tubular portion (32) and the plug portion (34) are formed as a unitary element.

Description

[0001] P / 90986.W001

[0002] -1- AEROSOL-GENERATING ARTICLE WITH DOWNSTREAM SECTION

[0003] The present disclosure relates to an aerosol-generating article for generating an inhalable aerosol upon heating. The present disclosure also relates to an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device.

[0004] Aerosol-generating articles in which an aerosol-generating substrate, such as a tobaccocontaining substrate, is heated rather than combusted, are known in the art. Typically, in such heated smoking articles an aerosol is generated by the transfer of heat from a heat source to a physically separate aerosol-generating substrate or material, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[0005] A number of prior art documents disclose aerosol-generating devices for consuming aerosol-generating articles. Such devices include, for example, electrically heated aerosolgenerating devices in which an aerosol is generated by the transfer of heat from one or more electrical heater elements of the aerosol-generating device to the aerosol-generating substrate of a heated aerosol-generating article. For example, electrically heated aerosol-generating devices have been proposed that comprise an internal heater blade which is adapted to be inserted into the aerosol-generating substrate. As an alternative, inductively heatable aerosol-generating articles comprising an aerosol-generating substrate and a susceptor element arranged within the aerosol-generating substrate have been described in WO 2015 / 176898 A1.

[0006] Aerosol-generating articles in which a tobacco-containing substrate is heated rather than combusted present a number of challenges that were not encountered with conventional smoking articles.

[0007] First of all, tobacco-containing substrates are typically heated to significantly lower temperatures compared with the temperatures reached by the combustion front in a conventional cigarette. This may have an impact on nicotine release from the tobacco-containing substrate and nicotine delivery to the consumer. At the same time, if the heating temperature is increased in an attempt to boost nicotine delivery, then the generated aerosol typically needs to be cooled to a greater extent and more rapidly before it reaches the consumer. However, technical solutions that were commonly used for cooling the mainstream smoke in conventional smoking articles, such as the provision of a high filtration efficiency segment at the mouth end of a cigarette, may have undesirable effects in an aerosol-generating article wherein a tobacco-containing substrate is heated rather than combusted, as they may reduce nicotine delivery.

[0008] Secondly, a need is generally felt for aerosol-generating articles that are easy to use and have improved practicality.Further, it would be desirable to provide one such aerosol-generating article that can be manufactured efficiently and at high speed, preferably with low variability in terms of aerosol delivery and resistance to draw (RTD) from one article to another.

[0009] Therefore, it would be desirable to provide a new and improved aerosol-generating article adapted to achieve at least one of the desirable results described above. Further, it would be desirable to provide one such aerosol-generating article that can be manufactured efficiently and at high speed.

[0010] The present disclosure relates to an aerosol-generating article comprising: a substrate element comprising an aerosol-generating substrate, the aerosol-generating substrate comprising one or more aerosol formers; and a downstream section provided downstream of the substrate element, the downstream section comprising: a mouthpiece element, the mouthpiece element comprising a tubular portion and a plug portion, wherein the aerosol-generating substrate has an aerosol former content of greater than 30 percent by weight, wherein the mouthpiece element is provided at a downstream end of the aerosol-generating article.

[0011] The present disclosure also relates to an aerosol-generating article. The aerosolgenerating article may comprise a substrate element. The substrate element may comprise an aerosol-generating substrate. The aerosol-generating substrate may comprise one or more aerosol formers. The aerosol-generating article may comprise a downstream section provided downstream of the substrate element. The downstream section may comprise a mouthpiece element. The mouthpiece element may comprise a tubular portion. The mouthpiece element may comprise a plug portion. The aerosol-generating substrate may have an aerosol former content of greater than 30 percent by weight. The mouthpiece element may be provided at a downstream end of the aerosol-generating article.

[0012] The present disclosure also relates to an aerosol-generating system comprising an aerosol-generating article as described above and an aerosol-generating device, wherein the aerosol-generating device comprises a heating arrangement configured to heat at least a portion of the aerosol-generating substrate to generate an aerosol.

[0013] Advantageously, the provision of a mouthpiece element having both a tubular portion and a solid plug portion may facilitate the use of a longer than typical mouthpiece element without resulting in over filtration of a generated aerosol, which would consequently detract from the user experience. Use of a long mouthpiece may advantageously provide a more rigid aerosolgenerating article. Allowing the aerosol-generating article to have a long mouthpiece without over filtration of the generated aerosol may advantageously provide for a more uniform manufacturing process because one mouthpiece element could be used to manufacture a plurality of different aerosol-generating articles.

[0014] The term “aerosol-generating article” is used herein to denote an article wherein an aerosol-generating substrate is heated to produce and deliver inhalable aerosol to a consumer. Asused herein, the term “aerosol-generating substrate” denotes a substrate capable of releasing volatile compounds upon heating to generate an aerosol.

[0015] A conventional cigarette is lit when a user applies a flame to one end of the cigarette and draws air through the other end. The localised heat provided by the flame and the oxygen in the air drawn through the cigarette causes the end of the cigarette to ignite, and the resulting combustion generates an inhalable smoke. By contrast, in heated aerosol generating articles, an aerosol is generated by heating a flavour generating substrate, such as tobacco. Known heated aerosol generating articles include, for example, electrically heated aerosol-generating articles and aerosol-generating articles in which an aerosol is generated by the transfer of heat from a combustible fuel element or heat source to a physically separate aerosol forming material.

[0016] As used herein, the term “aerosol-generating device” refers to a device comprising a heater element that interacts with the aerosol-generating substrate of the aerosol generating article to generate an aerosol. For example, aerosol-generating devices are known wherein heating of the aerosol-generating substrate is achieved inductively by means of a susceptor element provided within the aerosol-generating substrate.

[0017] Upon heating, volatile compounds are released from the aerosol-generating substrate and entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol that is inhaled by the consumer. The aerosol generated upon heating the aerosol-generating substrate is a dispersion of solid particles or liquid droplets (or a combination of solid particles and liquid droplets) in a gas. The aerosol may be visible or invisible and may include vapours of substances that are ordinarily liquid or solid at room temperature as well as solid particles or liquid droplets ora combination of solid particles and liquid droplets.

[0018] As used herein with reference to the present disclosure, the term “rod” is used to denote a generally cylindrical element of substantially circular, oval or elliptical cross-section.

[0019] 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.

[0020] As used herein, the terms ‘“distal”, “upstream” “proximal” and “downstream” describe the relative positions of components, or portions of components, of an aerosol-generating article or aerosol generating device. Aerosol generating articles and devices according to the present disclosure have a proximal end through which, in use, an aerosol exits the article or device for delivery to a user, and have an opposing distal end. The proximal end of the aerosol generating article and device may also be referred to as the mouth end. In use, a user draws on the proximal end of the aerosol-generating article in order to inhale the aerosol generated by the aerosol generating article or device. The terms upstream and downstream are relative to the direction of aerosol movement through the aerosol-generating article or aerosol-generating device when a user draws on the proximal end of the aerosol-generating article. The proximal end of the aerosolgenerating article is downstream of the distal end of the aerosol-generating article. The proximalend of the aerosol-generating article may also be referred to as the downstream end of the aerosolgenerating article and the distal end of the aerosol-generating article may also be referred to as the upstream end of the aerosol-generating article.

[0021] During use, air is drawn through the aerosol-generating article in the longitudinal direction. The term “transverse” refers to the direction that is perpendicular to the longitudinal axis. Any reference to the “cross-section” of the aerosol-generating article or a component of the aerosolgenerating article refers to the transverse cross-section unless stated otherwise.

[0022] The term “length” denotes the maximum dimension of the aerosol-generating article or of a component of the aerosol-generating article in the longitudinal direction.

[0023] As used herein with reference to the invention, the term “transverse” is used to describe the direction perpendicular to the longitudinal direction. Unless otherwise stated, references to the “cross-section” of the aerosol-generating article or aerosol-generating device or a component of the aerosol-generating article or aerosol-generating device refer to the transverse cross-section. As used herein with reference to the invention, the term “width” denotes the maximum dimension of the aerosol-generating article or device or of a component of the aerosol-generating article or device in a transverse direction. For example, where the aerosol-generating article has a substantially circular cross-section, the width of the aerosol-generating article corresponds to the diameter of the aerosol-generating article. Where a component of the aerosol-generating article has a substantially circular cross-section, the width of the component of the aerosol-generating article substantially corresponds to the diameter of the component of the aerosol-generating article.

[0024] The aerosol-generating article may be an aerosol-generating article for producing an inhalable aerosol upon heating.

[0025] The aerosol-generating article may have a length of at least 38 millimetres. The aerosolgenerating article may have a length of at least 40 millimetres. The aerosol-generating article may have a length of at least 42 millimetres.

[0026] The aerosol-generating article may have a length of less than or equal to 70 millimetres. The aerosol-generating article may have a length of less than or equal to 60 millimetres. The aerosol-generating article may have a length of less than or equal to 50 millimetres.

[0027] The aerosol-generating article may have a length of between 35 millimetres and 100 millimetres.

[0028] The aerosol-generating article may have a length of between 38 millimetres and 70 millimetres. The aerosol-generating article may have a length of between 40 millimetres and 70 millimetres. The aerosol-generating article may have a length of between 42 millimetres and 70 millimetres.

[0029] The aerosol-generating article may have a length of between 38 millimetres and 60 millimetres. The aerosol-generating article may have a length of between 40 millimetres and 60 millimetres. The aerosol-generating article may have a length of between 42 millimetres and 60 millimetres.The aerosol-generating article may have a length of between 38 millimetres and 50 millimetres. The aerosol-generating article may have a length of between 40 millimetres and 50 millimetres. The aerosol-generating article may have a length of between 42 millimetres and 50 millimetres.

[0030] The aerosol-generating article may have a length of 45 millimetres.

[0031] The aerosol-generating article may have an external diameter of at least 4 millimetres. The aerosol-generating article may have an external diameter of at least 5 millimetres. The aerosolgenerating article may have an external diameter of at Ieast6 millimetres. The aerosol-generating article may have an external diameter of at least 7 millimetres.

[0032] The aerosol-generating may have an external diameter of less than or equal to 12 millimetres. The aerosol-generating may have an external diameter of less than or equal to 10 millimetres. The aerosol-generating may have an external diameter of less than or equal to 8 millimetres.

[0033] The aerosol-generating article may have an external diameter of between 5 millimetres and 12 millimetres. The aerosol-generating article may have an external diameter of between 6 millimetres and 12 millimetres. The aerosol-generating article may have an external diameter of between 7 millimetres and 12 millimetres.

[0034] The aerosol-generating article may have an external diameter of between 5 millimetres and 10 millimetres. The aerosol-generating article may have an external diameter of between 6 millimetres and 10 millimetres. The aerosol-generating article may have an external diameter of between 7 millimetres and 10 millimetres.

[0035] The aerosol-generating article may have an external diameter of between 5 millimetres and 8 millimetres. The aerosol-generating article may have an external diameter of between 6 millimetres and 8 millimetres. The aerosol-generating article may have an external diameter of between 7 millimetres and 8 millimetres.

[0036] The aerosol-generating article may comprise an upstream section provided upstream of the substrate element. The upstream section may extend from the upstream end of the aerosolgenerating article to the upstream end of the substrate element.

[0037] The upstream section may comprise an upstream element. The upstream element may extend the entire length of the upstream section.

[0038] The upstream element may be arranged immediately upstream of the substrate element. The upstream element may abut the upstream end of the substrate element. The upstream element may extend from the upstream end of the aerosol-generating article. The upstream element may be located at the upstream end of the aerosol-generating article. The upstream end of the upstream element may define the upstream end of the aerosol-generating article. The upstream element may extend from the upstream end of the aerosol-generating article to the upstream end of the substrate element.The upstream element may advantageously prevent direct physical contact with the upstream end of the aerosol-generating substrate. In particular, where the aerosol-generating substrate comprises a susceptor, the upstream element may prevent direct physical contact with the upstream end of the susceptor. Preventing direct physical with the upstream end of the susceptor may help to prevent the displacement or deformation of the susceptor during handling or transport of the aerosol-generating article. This in turn helps to secure the form and position of the susceptor. Furthermore, the presence of an upstream element may help to prevent any loss of the aerosol-generating substrate, which may be advantageous, for example, if the aerosolgenerating substrate contains particulate plant material.

[0039] The upstream element may also provide an improved appearance to the upstream end of the aerosol-generating article. Furthermore, if desired, the upstream element may be used to provide information on the aerosol-generating article, such as information on brand, flavour, content, or details of the aerosol-generating device that the article is intended to be used with.

[0040] The upstream element may be in the form of a tube defining a longitudinal flow channel that is substantially empty. The longitudinal flow channel may be substantially exclusively defined by the tube.

[0041] The upstream element may be a plug element. The upstream element may be a porous plug element. The upstream element may be a solid cylindrical plug element having a filled crosssection.

[0042] An upstream element in the form of a plug element may have improved rigidity compared to a tubular element.

[0043] The plug element may be referred to as a ‘plain’ element. The plug element may be porous, as described above, but does not have a tubular form defining a longitudinal flow channel that is substantially empty. The plug element may have a substantially uniform transverse cross-section.

[0044] A porous plug element may not alter the resistance to draw of the aerosol-generating article.

[0045] The upstream element may have a porosity of at least about 50 percent in the longitudinal direction of the aerosol-generating article. The upstream element may have a porosity of between about 50 percent and about 90 percent in the longitudinal direction. The porosity of the upstream element in the longitudinal direction is defined by the ratio of the cross-sectional area of material forming the upstream element and the internal cross-sectional area of the aerosol-generating article at the position of the upstream element.

[0046] The upstream element may be made of a porous material or may comprise a plurality of openings. This may, for example, be achieved through laser perforation. The plurality of openings may be distributed homogeneously over the cross-section of the upstream element.

[0047] The porosity or permeability of the upstream element may advantageously be varied in order to provide a desirable overall resistance to draw of the aerosol-generating article.The upstream element may comprise cellulose acetate (such as a solid plug of cellulose acetate), paper or viscose. The upstream element may comprise paper or viscose. The upstream element may be made of orformed from cellulose acetate, paperorviscose. The upstream element may be made of or formed from paper or viscose.

[0048] The upstream element may be formed of a non-woven material, such as an airlaid nonwoven material. The airlaid non-woven material may comprise a biodegradable material. The airlaid non-woven material may comprise cellulose fibres. The airlaid non-woven material may comprise at least 90 percent by weight cellulose. The formation of an upstream element from an airlaid non-woven material enables the manufacture of the upstream element from more sustainable, for example, natural or biodegradable materials, without compromising on the functional and mechanical properties of the upstream element.

[0049] A content of cellulose acetate in the upstream element may be less than or equal to 15 percent by weight. A content of cellulose acetate in the upstream element may be less than or equal to 10 percent by weight. A content of cellulose acetate in the upstream element may be less than or equal to 5 percent by weight. The upstream element may be substantially free of cellulose acetate.

[0050] The upstream element may be in the form of a plug element comprising a tubular portion defining an inner region of the upstream element and a crimped sheet or a convoluted sheet located in the inner region. The crimped sheet or the convoluted sheet may define a plurality of longitudinally extending channels in the inner region.

[0051] As an example, the upstream element may comprise a crimped sheet of paper or a convoluted sheet of paper.

[0052] The upstream element may have has an external diameter that is approximately equal to the external diameter of the aerosol-generating article. The upstream element may have an external diameter that is approximately equal to the external diameter of the substrate element.

[0053] The external diameter of the upstream element may be between 5 millimetres and 12 millimetres. The external diameter of the upstream element may be between 5 millimetres and 10 millimetres. The external diameter of the upstream element may be between 6 millimetres and 8 millimetres. The external diameter of the upstream element may be between 7 millimetres and 8 millimetres.

[0054] The upstream element may have a length of at least 2 millimetres. The upstream element may have a length of at least 3 millimetres. The upstream element may have a length of at least 4 millimetres.

[0055] The upstream element may have a length of less than or equal to 10 millimetres. The upstream element may have a length of less than or equal to 8 millimetres. The upstream element may have a length of less than or equal to 6 millimetres.The upstream element may have a length of between 2 millimetres and 10 millimetres. The upstream element may have a length of between 2 millimetres and 8 millimetres. The upstream element may have a length of between 2 millimetres and 6 millimetres.

[0056] The upstream element may have a length of between 3 millimetres and 10 millimetres. The upstream element may have a length of between 3 millimetres and 8 millimetres. The upstream element may have a length of between 3 millimetres and 6 millimetres.

[0057] The upstream element may have a length of between 4 millimetres and 10 millimetres. The upstream element may have a length of between 4 millimetres and 8 millimetres. The upstream element may have a length of between 4 millimetres and 6 millimetres.

[0058] The upstream element may have a length of 5 millimetres.

[0059] A ratio of the length of the mouthpiece element to the length of the upstream element may be at least 1.8. A ratio of the length of the mouthpiece element to the length of the upstream element may be at least 2. A ratio of the length of the mouthpiece element to the length of the upstream element may be at least 2.4.

[0060] A ratio of the length of the mouthpiece element to the length of the upstream element may be less than or equal to 4. A ratio of the length of the mouthpiece element to the length of the upstream element may be less than or equal to 3.5. A ratio of the length of the mouthpiece element to the length of the upstream element may be less than or equal to 3.

[0061] A ratio of the length of the mouthpiece element to the length of the upstream element may be between 1.8 and 4. A ratio of the length of the mouthpiece element to the length of the upstream element may be between 1.8 and 3.5. A ratio of the length of the mouthpiece element to the length of the upstream element may be between 1.8 and 3.

[0062] A ratio of the length of the mouthpiece element to the length of the upstream element may be between 2 and 4. A ratio of the length of the mouthpiece element to the length of the upstream element may be between 2 and 3.5. A ratio of the length of the mouthpiece element to the length of the upstream element may be between 2 and 3.

[0063] A ratio of the length of the mouthpiece element to the length of the upstream element may be between 2.2 and 4. A ratio of the length of the mouthpiece element to the length of the upstream element may be between 2.2 and 3.5. A ratio of the length of the mouthpiece element to the length of the upstream element may be between 2.2 and 3.

[0064] Advantageously, the mouthpiece element being substantially longer than the upstream element may provide a user with a mechanism to identify the upstream and downstream ends of the aerosol-generating article, this may be due to a difference in the hardness of the aerosolgenerating article at the mouthpiece element and at the upstream element.

[0065] The ratio of the length of the mouthpiece element to the length of the upstream element described herein may provide a desired balance between the filtration level of the aerosolgenerating article and the ease at identifying the upstream and downstream ends of the aerosolgenerating article.The substrate element may comprise a rod of aerosol-generating substrate. The substrate element may be provided in the form of a rod of aerosol-generating substrate.

[0066] The aerosol-generating substrate may comprise a solid aerosol-generating substrate. The aerosol-generating substrate may be in the form of one or more sheets. One or more of the sheets forming the aerosol-generating substrate may be crimped.

[0067] The substrate element may have a length of at least 8 millimetres. The substrate element may have a length of at least 10 millimetres. The substrate element may have a length of at least 12 millimetres.

[0068] The substrate element may have a length of less than or equal to 16 millimetres. The substrate element may have a length of less than or equal to 14 millimetres. The substrate element may have a length of less than or equal to 12 millimetres.

[0069] The substrate element may have a length of between 8 millimetres and 16 millimetres. The substrate element may have a length of between 8 millimetres and 14 millimetres. The substrate element may have a length of between 10 millimetres and 14 millimetres.

[0070] The aerosol-generating substrate may have an aerosol former content of greater than 30 percent by weight. The aerosol-generating substrate may have an aerosol former content of greater than 40 percent by weight. The aerosol-generating substrate may have an aerosol former content of greater than 45 percent by weight. The aerosol-generating substrate may have an aerosol former content of greater than 50 percent by weight.

[0071] The aerosol-generating substrate may have an aerosol former content of less than or equal to 90 percent by weight. The aerosol-generating substrate may have an aerosol former content of less than or equal to 80 percent by weight. The aerosol-generating substrate may have an aerosol former content of less than or equal to 70 percent by weight. The aerosol-generating substrate may have an aerosol former content of less than or equal to 60 percent by weight.

[0072] The aerosol-generating substrate may have an aerosol former content of between 30 percent and 90 percent. The aerosol-generating substrate may have an aerosol former content of between 30 percent and 80 percent. The aerosol-generating substrate may have an aerosol former content of between 30 percent and 70 percent. The aerosol-generating substrate may have an aerosol former content of between 30 percent and 60 percent.

[0073] The aerosol-generating substrate may have an aerosol former content of between 30 percent and 80 percent. The aerosol-generating substrate may have an aerosol former content of between 30 percent and 70 percent. The aerosol-generating substrate may have an aerosol former content of between 30 percent and 60 percent.

[0074] The aerosol-generating substrate may have an aerosol former content of between 40 percent and 60 percent. The aerosol-generating substrate may have an aerosol former content of between 50 percent and 60 percent.The one or more aerosol formers may comprise glycerine. The one or more aerosol formers may comprise propylene glycol. The one or more aerosol formers may include a combination of glycerine and propylene glycol.

[0075] The aerosol-generating substrate may comprise nicotine.

[0076] The nicotine may comprise one or more nicotine salts. The one or more nicotine salts may be selected from the list consisting of nicotine lactate, nicotine citrate, nicotine pyruvate, nicotine bitartrate, nicotine benzoate, nicotine pectate, nicotine alginate, and nicotine salicylate.

[0077] The nicotine may comprise an extract of tobacco.

[0078] The aerosol-generating substrate may have a nicotine content of greater than 0.5 percent by weight. The aerosol-generating substrate may have a nicotine content of greater than 1 percent by weight. The aerosol-generating substrate may have a nicotine content of greater than 1.5 percent by weight. The aerosol-generating substrate may have a nicotine content of greater than 2 percent by weight.

[0079] The aerosol-generating substrate may have a nicotine content of less than 5 percent by weight. The aerosol-generating substrate may have a nicotine content of less than 3 percent by weight. The aerosol-generating substrate may have a nicotine content of less than 2 percent by weight. The aerosol-generating substrate may have a nicotine content of less than 1 percent by weight.

[0080] The aerosol-generating substrate may have a nicotine content of between 0.5 percent by weight and 5 percent by weight. The aerosol-generating substrate may have a nicotine content of between 0.5 percent by weight and 3 percent by weight. The aerosol-generating substrate may have a nicotine content of between 0.5 percent by weight and 2 percent by weight. The aerosolgenerating substrate may have a nicotine content of between 0.5 percent by weight and 1.5 percent by weight. The aerosol-generating substrate may have a nicotine content of between 0.5 percent by weight and 1 percent by weight.

[0081] The aerosol-generating substrate may have a nicotine content of between 1 percent by weight and 5 percent by weight. The aerosol-generating substrate may have a nicotine content of between 1 percent by weight and 3 percent by weight. The aerosol-generating substrate may have a nicotine content of between 1 percent by weight and 2 percent by weight.

[0082] The aerosol-generating substrate may comprise a film-forming agent.

[0083] The film-forming agent may comprise hydroxypropyl methyl cellulose.

[0084] The aerosol-generating substrate may have a film-forming agent content of greater than 10 percent by weight. The aerosol-generating substrate may have a film-forming agent content of greater than 12 percent by weight. The aerosol-generating substrate may have a film-forming agent content of greater than 14 percent by weight. The aerosol-generating substrate may have a film-forming agent content of greater than 16 percent by weight. The aerosol-generating substrate may have a film-forming agent content of greater than 18 percent by weight. The aerosolgenerating substrate may have a film-forming agent content of greater than 20 percent by weight.The aerosol-generating substrate may have a film-forming agent content of greater than 22 percent by weight. The aerosol-generating substrate may have a film-forming agent content of greater than 24 percent by weight. The aerosol-generating substrate may have a film-forming agent content of greater than 26 percent by weight. The aerosol-generating substrate may have a film-forming agent content of greater than 28 percent by weight. The aerosol-generating substrate may have a film-forming agent content of greater than 30 percent by weight.

[0085] The aerosol-generating substrate may have a film-forming agent content of less than or equal to 40 percent by weight. The aerosol-generating substrate may have a film-forming agent content of less than or equal to 38 percent by weight. The aerosol-generating substrate may have a film-forming agent content of less than or equal to 36 percent by weight. The aerosol-generating substrate may have a film-forming agent content of less than or equal to 34 percent by weight. The aerosol-generating substrate may have a film-forming agent content of less than or equal to 32 percent by weight. The aerosol-generating substrate may have a film-forming agent content of less than or equal to 30 percent by weight. The aerosol-generating substrate may have a film-forming agent content of less than or equal to 28 percent by weight. The aerosol-generating substrate may have a film-forming agent content of less than or equal to 26 percent by weight. The aerosolgenerating substrate may have a film-forming agent content of less than or equal to 24 percent by weight.

[0086] The aerosol-generating substrate may have a film-forming agent content of between 10 percent by weight and 40 percent by weight. The aerosol-generating substrate may have a filmforming agent content of between 10 percent by weight and 38 percent by weight. The aerosolgenerating substrate may have a film-forming agent content of between 10 percent by weight and 36 percent by weight. The aerosol-generating substrate may have a film-forming agent content of between 10 percent by weight and 34 percent by weight. The aerosol-generating substrate may have a film-forming agent content of between 10 percent by weight and 32 percent by weight. The aerosol-generating substrate may have a film-forming agent content of between 10 percent by weight and 30 percent by weight. The aerosol-generating substrate may have a film-forming agent content of between 10 percent by weight and 28 percent by weight. The aerosol-generating substrate may have a film-forming agent content of between 10 percent by weight and 26 percent by weight. The aerosol-generating substrate may have a film-forming agent content of between 10 percent by weight and 24 percent by weight.

[0087] The aerosol-generating substrate may have a film-forming agent content of between 12 percent by weight and 30 percent by weight. The aerosol-generating substrate may have a filmforming agent content of between 14 percent by weight and 30 percent by weight. The aerosolgenerating substrate may have a film-forming agent content of between 16 percent by weight and 30 percent by weight. The aerosol-generating substrate may have a film-forming agent content of between 18 percent by weight and 30 percent by weight. The aerosol-generating substrate may have a film-forming agent content of between 20 percent by weight and 30 percent by weight.The aerosol-generating substrate may have a film-forming agent content of between 20 percent by weight and 28 percent by weight. The aerosol-generating substrate may have a filmforming agent content of between 20 percent by weight and 26 percent by weight.

[0088] Advantageously, inclusion of a film-forming agent in the aerosol-forming substrate may help in improving the manufacturing process of the aerosol-forming substrate.

[0089] The aerosol-generating substrate may comprise one or more cellulose based strengthening agents.

[0090] The one or more cellulose based strengthening agents may comprise one or more of: cellulose powder, cellulose fibres, and microcrystalline cellulose. The one or more cellulose based strengthening agents may comprise cellulose powder. The one or more cellulose based strengthening agents may comprise cellulose fibres. The one or more cellulose based strengthening agents may comprise microcrystalline cellulose.

[0091] The aerosol-generating substrate may have a cellulose based strengthening agent content of greater than 1 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of greater than 5 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of greater than 10 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of greater than 12 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of greater than 14 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of greater than 16 percent by weight.

[0092] The aerosol-generating substrate may have a cellulose based strengthening agent content of less than or equal to 50 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of less than or equal to 40 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of less than or equal to 30 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of less than or equal to 25 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of less than or equal to 20 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of less than or equal to 18 percent by weight.

[0093] The aerosol-generating substrate may have a cellulose based strengthening agent content of between 1 percent by weight and 50 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of between 1 percent by weight and 40 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of between 1 percent by weight and 30 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of between 1 percent by weight and 20 percent by weight.The aerosol-generating substrate may have a cellulose based strengthening agent content of between 10 percent by weight and 50 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of between 10 percent by weight and 40 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of between 10 percent by weight and 30 percent by weight. The aerosol-generating substrate may have a cellulose based strengthening agent content of between 10 percent by weight and 20 percent by weight.

[0094] Advantageously, the inclusion of a cellulose based strengthening agent in the aerosolgenerating substrate may increase the tensile strength of the aerosol-generating substrate. An aerosol-generating substrate with a higher tensile strength may be less likely to deteriorate or break, for example during transit or during the manufacturing process.

[0095] The aerosol-generating substrate may comprise one or more thickening agents. The one or more thickening agents may comprise a carboxymethyl cellulose. The one or more thickening agents may comprise sodium carboxymethyl cellulose.

[0096] Advantageously, using a carboxymethyl cellulose may help to reduce crusting of the aerosol-forming substrate when used in an aerosol-generating article

[0097] The aerosol-generating substrate may have a thickening agent content of greater than 1 percent by weight. The aerosol-generating substrate may have a thickening agent content of greater than 2 percent by weight. The aerosol-generating substrate may have a thickening agent content of greater than 3 percent by weight. The aerosol-generating substrate may have a thickening agent content of greater than 4 percent by weight. The aerosol-generating substrate may have a thickening agent content of greater than 5 percent by weight.

[0098] The aerosol-generating substrate may have a thickening agent content of less than or equal to 20 percent by weight. The aerosol-generating substrate may have a thickening agent content of less than or equal to 15 percent by weight. The aerosol-generating substrate may have a thickening agent content of less than or equal to 10 percent by weight. The aerosol-generating substrate may have a thickening agent content of less than or equal to 8 percent by weight. The aerosol-generating substrate may have a thickening agent content of less than or equal to 6 percent by weight.

[0099] The aerosol-generating substrate may have a thickening agent content of between 1 percent by weight and 20 percent by weight. The aerosol-generating substrate may have a thickening agent content of between 1 percent by weight and 10 percent by weight. The aerosolgenerating substrate may have a thickening agent content of between 1 percent by weight and 8 percent by weight. The aerosol-generating substrate may have a thickening agent content of between 1 percent by weight and 6 percent by weight.

[0100] The aerosol-generating substrate may have a thickening agent content of between 3 percent by weight and 20 percent by weight. The aerosol-generating substrate may have a thickening agent content of between 3 percent by weight and 10 percent by weight. The aerosol-generating substrate may have a thickening agent content of between 3 percent by weight and 8 percent by weight. The aerosol-generating substrate may have a thickening agent content of between 3 percent by weight and 6 percent by weight.

[0101] The aerosol-generating substrate may comprise one or more carboxylic acids. The one or more carboxylic acids may comprise one or more of fumaric acid, lactic acid and levulinic acid. The one or more carboxylic acids may comprise fumaric acid. The one or more carboxylic acids may comprise lactic acid. The one or more carboxylic acids may comprise levulinic acid.

[0102] The aerosol-generating substrate may have a carboxylic acid content of greater than 0.5% by weight. The aerosol-generating substrate may have a carboxylic acid content of greater than 1% by weight. The aerosol-generating substrate may have a carboxylic acid content of greater than 1.5% by weight.

[0103] The aerosol-generating substrate may have a carboxylic acid content of less than or equal to 5% by weight. The aerosol-generating substrate may have a carboxylic acid content of less than or equal to 4% by weight. The aerosol-generating substrate may have a carboxylic acid content of less than or equal to 3% by weight. The aerosol-generating substrate may have a carboxylic acid content of less than or equal to 2% by weight.

[0104] The aerosol-generating substrate may have a carboxylic acid content of between 0.5% by weight and 5% by weight. The aerosol-generating substrate may have a carboxylic acid content of between 0.5% by weight and 4% by weight. The aerosol-generating substrate may have a carboxylic acid content of between 0.5% by weight and 3% by weight. The aerosol-generating substrate may have a carboxylic acid content of between 0.5% by weight and 2% by weight.

[0105] The aerosol-generating substrate may have a carboxylic acid content of between 1% by weight and 5% by weight. The aerosol-generating substrate may have a carboxylic acid content of between 1% by weight and 4% by weight. The aerosol-generating substrate may have a carboxylic acid content of between 1% by weight and 3% by weight. The aerosol-generating substrate may have a carboxylic acid content of between 1% by weight and 2% by weight.

[0106] Advantageously, including one or more carboxylic acids in the aerosol-generating substrate may help to create a nicotine salt.

[0107] The aerosol-generating article may comprise a susceptor. The susceptor may be located within the substrate element. The susceptor may be located within the rod of aerosol-generating substrate.

[0108] The susceptor may be arranged substantially longitudinally within the substrate element. That is, a longitudinal axis of the susceptor may be approximately parallel to a longitudinal axis of the substrate element. For example, a longitudinal axis of the susceptor may be within plus or minus 10 degrees of parallel to a longitudinal axis of the substrate element.

[0109] The susceptor may be arranged centrally within the substrate element. The susceptor may extend along a longitudinal axis of the substrate element.As used herein with reference to the present disclosure, the term “susceptor” refers to an element comprising a material that can convert electromagnetic energy into heat. When located within a fluctuating electromagnetic field, eddy currents induced in the susceptor cause heating of the susceptor. As the susceptor is located in thermal contact with the aerosol-generating substrate, the aerosol-generating substrate is heated by the susceptor.

[0110] Suitable susceptors for use in the aerosol-generating substrate of aerosol-generating articles according to the present disclosure are described in WO-A-2021 / 170673.

[0111] The susceptor may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-generating substrate. For example, the susceptor may comprise a metal. The susceptor may comprise carbon.

[0112] The susceptor may comprise or consist of a ferromagnetic material, for example a ferromagnetic alloy, ferritic iron, or a ferromagnetic steel or stainless steel. A suitable susceptor may be, or comprise, aluminium. The susceptor may be formed from 400 series stainless steels, for example grade 410, or grade 420, or grade 430 stainless steel. Different materials will dissipate different amounts of energy when positioned within electromagnetic fields having similar values of frequency and field strength. Thus, parameters of the susceptor such as material type, length, width, and thickness may all be altered to provide a desired power dissipation within a known electromagnetic field. A susceptor may be heated to a temperature in excess of 250 degrees Celsius.

[0113] Suitable susceptors may comprise a non-metallic core with a metal layer disposed on the non-metallic core, for example metallic tracks formed on a surface of a ceramic core. A susceptor may have a protective external layer, for example a protective ceramic layer or protective glass layer encapsulating the susceptor. The susceptor may comprise a protective coating formed by a glass, a ceramic, or an inert metal, formed over a core of susceptor material.

[0114] The susceptor may be in the form of a strip or blade.

[0115] The susceptor may have a thickness of at least 50 micrometres. The susceptor may have a thickness of at least 55 micrometres. The susceptor may have a thickness of at least 60 micrometres.

[0116] The susceptor may have a thickness of less than or equal to 80 micrometres. The susceptor may have a thickness of less than or equal to 75 micrometres. The susceptor may have a thickness of less than or equal to 70 micrometres.

[0117] The susceptor may have a thickness of between 50 micrometres and 80 micrometres. The susceptor may have a thickness of between 50 micrometres and 75 micrometres. The susceptor may have a thickness of between 50 micrometres and 70 micrometres.

[0118] The susceptor may have a thickness of between 55 micrometres and 80 micrometres. The susceptor may have a thickness of between 55 micrometres and 75 micrometres. The susceptor may have a thickness of between 55 micrometres and 70 micrometres.The susceptor may have a thickness of between 60 micrometres and 80 micrometres. The susceptor may have a thickness of between 60 micrometres and 75 micrometres. The susceptor may have a thickness of between 60 micrometres and 70 micrometres.

[0119] The susceptor may have a length of at least 50 percent of the length of the substrate element. The susceptor may have a length of at least 75 percent of the length of the substrate element. The susceptor may have a length of at least 95 percent of the length of the substrate element. The susceptor may have a length that is substantially equal to the length of the substrate element. The susceptor may have a length that is equal to the length of the substrate element.

[0120] The susceptor may have a width of between 3 millimetres and 5 millimetres. For example, the susceptor may have a width of 4 millimetres.

[0121] Alternatively, the aerosol-generating article may not comprise a susceptor.

[0122] The downstream section may comprise one or more hollow tubular elements.

[0123] The downstream section may comprise a first hollow tubular element. The first hollow tubular element may be the only hollow tubular element of the downstream section.

[0124] The downstream section may comprise a second hollow tubular element. The downstream section may comprise a first hollow tubular element and a second hollow tubular element.

[0125] The downstream section may extend from the downstream end of the substrate element to the downstream end of the aerosol-generating article.

[0126] The overall length of the downstream section may correspond to the sum of the lengths of the one or more hollow tubular elements, and the length of the mouthpiece element. The overall length of the downstream section may correspond to the sum of the length of the first hollow tubular element, the length of the second hollow tubular element and the length of the mouthpiece element. Where the downstream section comprises only one hollow tubular element, the overall length of the downstream section may correspond to the sum of the length of the first hollow tubular element and the length of the mouthpiece element.

[0127] A content of cellulose acetate in the downstream section may be less than or equal to 15 percent by weight. A content of cellulose acetate in the downstream section may be less than or equal to 10 percent by weight. A content of cellulose acetate in the downstream section may be less than or equal to 5 percent by weight. The downstream section may be substantially free of cellulose acetate.

[0128] The downstream section may have a length of greater than 20 millimetres. The downstream section may have a length of greater than 22 millimetres. The downstream section may have a length of greater than 24 millimetres. The downstream section may have a length of greater than 26 millimetres.

[0129] The downstream section may have a length of less than or equal to 36 millimetres. The downstream section may have a length of less than or equal to 34 millimetres. The downstream section may have a length of less than or equal to 32 millimetres. The downstream section mayhave a length of less than or equal to 30 millimetres. The downstream section may have a length of less than or equal to 28 millimetres.

[0130] The downstream section may have a length of between 20 millimetres and 36 millimetres. The downstream section may have a length of between 20 millimetres and 34 millimetres. The downstream section may have a length of between 20 millimetres and 32 millimetres. The downstream section may have a length of between 20 millimetres and 30 millimetres. The downstream section may have a length of between 20 millimetres and 28 millimetres.

[0131] The downstream section may have a length of between 22 millimetres and 36 millimetres. The downstream section may have a length of between 24 millimetres and 36 millimetres. The downstream section may have a length of between 26 millimetres and 36 millimetres. The downstream section may have a length of between 28 millimetres and 36 millimetres.

[0132] The first hollow tubular element may be a hollow cylindrical tube. The first hollow tubular element may define a hollow section of the aerosol-generating article. The first hollow tubular element may define a hollow section of the downstream section.

[0133] The first hollow tubular element may define an internal cavity. The internal cavity may extend from an upstream end of the first hollow tubular element to a downstream end of the first hollow tubular element. The internal cavity may have an internal dimeter which is substantially constant along the entire length of the first hollow tubular element. The internal cavity may be substantially empty.

[0134] The first hollow tubular element may be in longitudinal alignment with the substrate element. The first hollow tubular element may be in longitudinal alignment with the second hollow tubular element.

[0135] The first hollow tubular element may extend from a downstream end of the substrate element. The first hollow tubular element may be located at the downstream end of the substrate element. The first hollow tubular element may be provided at the downstream end of the substrate element. The first hollow tubular element may abut the substrate element.

[0136] The first hollow tubular element may be located upstream of a second hollow tubular element. The first hollow tubular element may be located upstream of the mouthpiece element. The first hollow tubular element may extend between the substrate element and the second hollow tubular element. The first hollow tubular element may abut the second hollow tubular element.

[0137] Where the first hollow tubular element is only hollow tubular element of the downstream section, the first hollow tubular element may abut the mouthpiece element.

[0138] The first hollow tubular element may comprise cellulose acetate, paper, carboard, viscose, or lyocell.

[0139] The first hollow tubular element may be made from or comprise a cellulosic material. The first hollow tubular element may be made entirely from 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. The first hollow tubular element may comprise at least one layer of paper. The paper may be very rigid paper. The paper may be crimped paper, such as crimped heat resistant paper or crimped parchment paper.

[0140] The cellulosic material may be cardboard. The first hollow tubular element may be a cardboard tube. Advantageously, cardboard is a cost-effective material that provides a balance between being deformable in order to provide ease of insertion of the article into an aerosolgenerating device and being sufficiently stiff to provide suitable engagement of the article with the interior of the device. A cardboard tube may therefore provide suitable resistance to deformation or compression during use.

[0141] The first hollow tubular element may be a tube formed from spirally wound paper. The hollow tubular element may be formed from a plurality of layers of paper. For example, the hollow tubular element may be a cardboard tube formed from spirally wound paper.

[0142] The cellulosic material may be paperboard.

[0143] The cellulosic material may comprise natural fibres. The cellulosic material may comprise artificial fibres.

[0144] The first hollow tubular element may have a length of greater than 5 millimetres. The first hollow tubular element may have a length of greater than 6 millimetres. The first hollow tubular element may have a length of greater than 7 millimetres.

[0145] The first hollow tubular element may have a length of less than or equal to 12 millimetres. The first hollow tubular element may have a length of less than or equal to 11 millimetres. The first hollow tubular element may have a length of less than or equal to 10 millimetres. The first hollow tubular element may have a length of less than or equal to 9 millimetres. The first hollow tubular element may have a length of less than or equal to 8 millimetres.

[0146] The first hollow tubular element may have a length of between 5 millimetres and 12 millimetres. The first hollow tubular element may have a length of between 5 millimetres and 11 millimetres. The first hollow tubular element may have a length of between 5 millimetres and 10 millimetres. The first hollow tubular element may have a length of between 5 millimetres and 9 millimetres. The first hollow tubular element may have a length of between 5 millimetres and 8 millimetres.

[0147] The first hollow tubular element may have a length of between 6 millimetres and 12 millimetres. The first hollow tubular element may have a length of between 7 millimetres and 12 millimetres. The first hollow tubular element may have a length of between 8 millimetres and 12 millimetres.

[0148] The first hollow tubular element may have a length of between 6 millimetres and 10 millimetres. The first hollow tubular element may have a length of between 6 millimetres and 9 millimetres. The first hollow tubular element may have a length of between 7 millimetres and 9 millimetres.Where the downstream section comprises only one hollow tubular element, the first hollow tubular element may have a length of at least 10 millimetres. The first hollow tubular element may have a length of at least 12 millimetres. The first hollow tubular element may have a length of at least 14 millimetres. The first hollow tubular element may have a length of at least 15 millimetres. The first hollow tubular element may have a length of at least 16 millimetres.

[0149] Where the downstream section comprises only one hollow tubular element, the first hollow tubular element may have a length of less than or equal to 24 millimetres. The first hollow tubular element may have a length of less than or equal to 23 millimetres. The first hollow tubular element may have a length of less than or equal to 22 millimetres. The first hollow tubular element may have a length of less than or equal to 21 millimetres. The first hollow tubular element may have a length of less than or equal to 20 millimetres. The first hollow tubular element may have a length of less than or equal to 18 millimetres. The first hollow tubular element may have a length of less than or equal to 16 millimetres.

[0150] Where the downstream section comprises only one hollow tubular element, the first hollow tubular element may have a length of between 10 millimetres and 24 millimetres. The first hollow tubular element may have a length of between 10 millimetres and 23 millimetres. The first hollow tubular element may have a length of between 10 millimetres and 22 millimetres. The first hollow tubular element may have a length of between 10 millimetres and 20 millimetres.

[0151] Where the downstream section comprises only one hollow tubular element, the first hollow tubular element may have a length of between 12 millimetres and 24 millimetres. The first hollow tubular element may have a length of between 12 millimetres and 23 millimetres. The first hollow tubular element may have a length of between 12 millimetres and 22 millimetres. The first hollow tubular element may have a length of between 12 millimetres and 20 millimetres.

[0152] Where the downstream section comprises only one hollow tubular element, the first hollow tubular element may have a length of between 14 millimetres and 24 millimetres. The first hollow tubular element may have a length of between 14 millimetres and 23 millimetres. The first hollow tubular element may have a length of between 14 millimetres and 22 millimetres. The first hollow tubular element may have a length of between 14 millimetres and 20 millimetres.

[0153] Where the downstream section comprises only one hollow tubular element, the first hollow tubular element may have a length of between 15 millimetres and 24 millimetres. The first hollow tubular element may have a length of between 15 millimetres and 23 millimetres. The first hollow tubular element may have a length of between 15 millimetres and 22 millimetres. The first hollow tubular element may have a length of between 15 millimetres and 21 millimetres. The first hollow tubular element may have a length of between 15 millimetres and 20 millimetres.

[0154] Advantageously, the length of the first hollow tubular element may be optimised to provide high structural integrity of the aerosol-generating article.

[0155] A relatively long first hollow tubular element may provide and define a relatively long internal cavity within the aerosol-generating article and downstream of the aerosol-generatingsubstrate. As discussed in the present disclosure, providing an empty cavity downstream (preferably, immediately downstream) of the aerosol-generating substrate may enhance the nucleation of aerosol particles generated by the aerosol-generating substrate. Providing a relatively long cavity maximises such nucleation benefits, thereby improving aerosol formation and cooling.

[0156] The desired length of the first hollow tubular element is based on a balance between maximising nucleation benefits and the structural strength of the first hollow tubular element and thus the structural strength of the downstream section of the aerosol-generating article. Increasing the strength of the first hollow tubular element may provide an aerosol-generating article that is resistant to deformation during handling by a user, such as during insertion and removal of the aerosol-generating article from an aerosol-generating device.

[0157] The first hollow tubular element may have an internal diameter which is substantially constant along the entire length of the first hollow tubular element.

[0158] The first hollow tubular element may have an internal diameter of greater than 0.5 millimetres. The first hollow tubular element may have an internal diameter of greater than 1 millimetres. The first hollow tubular element may have an internal diameter of greater than 1.5 millimetres. The first hollow tubular element may have an internal diameter of greater than 1.75 millimetres.

[0159] The first hollow tubular element may have an internal diameter of less than or equal to 3 millimetres. The first hollow tubular element may have an internal diameter of less than or equal to 2.5 millimetres. The first hollow tubular element may have an internal diameter of less than or equal to 2 millimetres.

[0160] The first hollow tubular element may have an internal diameter of between 0.5 millimetres and 3 millimetres. The first hollow tubular element may have an internal diameter of between 0.5 millimetres and 2.5 millimetres. The first hollow tubular element may have an internal diameter of between 0.5 millimetres and 2 millimetres.

[0161] The first hollow tubular element may have an internal diameter of between 1 millimetres and 3 millimetres. The first hollow tubular element may have an internal diameter of between 1.5 millimetres and 3 millimetres.

[0162] The first hollow tubular element may have an internal diameter of between 1 millimetres and 2 millimetres. The first hollow tubular element may have an internal diameter of between 1.5 millimetres and 2 millimetres.

[0163] The first hollow tubular element may have an internal diameter that is less than the internal diameter of the second hollow tubular element. The first hollow tubular element may have an internal diameter that is less than the internal diameter of the tubular portion of the mouthpiece element.

[0164] Where the downstream section comprises only one hollow tubular element, the first hollow tubular element may have an internal diameter of at least 4 millimetres. The first hollow tubularelement may have an internal diameter of at least 4.5 millimetres. The first hollow tubular element may have an internal diameter of at least 5 millimetres. The first hollow tubular element may have an internal diameter of at least 5.5 millimetres. The first hollow tubular element may have an internal diameter of at least 6 millimetres. The first hollow tubular element may have an internal diameter of at least 6.5 millimetres. The first hollow tubular element may have an internal diameter of at least 7 millimetres.

[0165] Where the downstream section comprises only one hollow tubular element, the first hollow tubular element may have an internal diameter of less than or equal to 8 millimetres. The first hollow tubular element may have an internal diameter of less than or equal to 7.5 millimetres. The first hollow tubular element may have an internal diameter of less than or equal to 7 millimetres. The first hollow tubular element may have an internal diameter of less than or equal to 6.5 millimetres. The first hollow tubular element may have an internal diameter of less than or equal to 6 millimetres. The first hollow tubular element may have an internal diameter of less than or equal to 5.5 millimetres.

[0166] Where the downstream section comprises only one hollow tubular element, the first hollow tubular element may have an internal diameter of between 4 millimetres and 8 millimetres. The first hollow tubular element may have an internal diameter of between 5 millimetres and 7.5 millimetres. The first hollow tubular element may have an internal diameter of between 5 millimetres and 7 millimetres. The first hollow tubular element may have an internal diameter of between 6 millimetres and 7 millimetres.

[0167] The first hollow tubular element may have an external diameter which is substantially constant along the entire length of the first hollow tubular element.

[0168] The first hollow tubular element may have an external diameter of at least 6 millimetres. The first hollow tubular element may have an external diameter of at least 6.5 millimetres. The first hollow tubular element may have an external diameter of at least 7 millimetres.

[0169] The first hollow tubular element may have an external diameter of less than or equal to 9 millimetres. The first hollow tubular element may have an external diameter of less than or equal to 8.5 millimetres. The first hollow tubular element may have an external diameter of less than or equal to 8 millimetres. The first hollow tubular element may have an external diameter of less than or equal to 7.5 millimetres.

[0170] The first hollow tubular element may have an external diameter of between 6 millimetres and 9 millimetres. The first hollow tubular element may have an external diameter of between 6 millimetres and 8.5 millimetres. The first hollow tubular element may have an external diameter of between 6 millimetres and 8 millimetres. The first hollow tubular element may have an external diameter of between 6 millimetres and 7.5 millimetres. The first hollow tubular element may have an external diameter of between 6 millimetres and 7 millimetres.

[0171] The first hollow tubular element may have an external diameter of between 7 millimetres and 9 millimetres. The first hollow tubular element may have an external diameter of between 7millimetres and 8.5 millimetres. The first hollow tubular element may have an external diameter of between 7 millimetres and 8 millimetres. The first hollow tubular element may have an external diameter of between 7 millimetres and 7.5 millimetres.

[0172] The downstream section may comprise a single hollow tubular element corresponding to the first hollow tubular element. Alternatively, as mentioned herein, the downstream section may comprise a further hollow tubular element, a second hollow tubular element.

[0173] Each hollow tubular element may consist of a single hollow tubular segment. Each hollow tubular element may consist of a single continuous hollow tubular segment.

[0174] The second hollow tubular element may be a hollow cylindrical tube. The second hollow tubular element may define a hollow section of the aerosol-generating article. The second hollow tubular element may define a hollow section of the downstream section.

[0175] The second hollow tubular element may define an internal cavity. The internal cavity may extend from an upstream end of the second hollow tubular element to a downstream end of the second hollow tubular element. The internal cavity may have an internal dimeter which is substantially constant along the entire length of the second hollow tubular element. The internal cavity may be substantially empty.

[0176] The second hollow tubular element may be in longitudinal alignment with the substrate element. The second hollow tubular element may be in longitudinal alignment with the first hollow tubular element.

[0177] The second hollow tubular element may extend from a downstream end of the first hollow tubular element. The second hollow tubular element may be located at the downstream end of the first hollow tubular element. The second hollow tubular element may be provided at the downstream end of the first hollow tubular element. The second hollow tubular element may abut the first hollow tubular element.

[0178] The second hollow tubular element may be located upstream of a mouthpiece element. The second hollow tubular element may be located upstream of the mouthpiece element. The second hollow tubular element may extend between the mouthpiece element and the first hollow tubular element. The second hollow tubular element may abut the mouthpiece element.

[0179] The second hollow tubular element may comprise cellulose acetate, paper, viscose, or lyocell.

[0180] The second hollow tubular element may have a length of greater than 5 millimetres. The second hollow tubular element may have a length of greater than 6 millimetres. The second hollow tubular element may have a length of greater than 7 millimetres.

[0181] The second hollow tubular element may have a length of less than or equal to 12 millimetres. The second hollow tubular element may have a length of less than or equal to 11 millimetres. The second hollow tubular element may have a length of less than or equal to 10 millimetres. The second hollow tubular element may have a length of less than or equal to 9millimetres. The second hollow tubular element may have a length of less than or equal to 8 millimetres.

[0182] The second hollow tubular element may have a length of between 5 millimetres and 12 millimetres. The second hollow tubular element may have a length of between 5 millimetres and 11 millimetres. The second hollow tubular element may have a length of between 5 millimetres and 10 millimetres. The second hollow tubular element may have a length of between 5 millimetres and 9 millimetres. The second hollow tubular element may have a length of between 5 millimetres and 8 millimetres.

[0183] The second hollow tubular element may have a length of between 6 millimetres and 12 millimetres. The second hollow tubular element may have a length of between 7 millimetres and 12 millimetres. The second hollow tubular element may have a length of between 8 millimetres and 12 millimetres.

[0184] The second hollow tubular element may have a length of between 6 millimetres and 10 millimetres. The second hollow tubular element may have a length of between 6 millimetres and 9 millimetres. The second hollow tubular element may have a length of between 7 millimetres and 9 millimetres.

[0185] The second hollow tubular element may have an internal diameter which is substantially constant along the entire length of the second hollow tubular element.

[0186] The second hollow tubular element may have an internal diameter of greater than 2 millimetres. The second hollow tubular element may have an internal diameter of greater than 2.5 millimetres. The second hollow tubular element may have an internal diameter of greater than 3 millimetres.

[0187] The second hollow tubular element may have an internal diameter of less than or equal to 5 millimetres. The second hollow tubular element may have an internal diameter of less than or equal to 4.5 millimetres. The second hollow tubular element may have an internal diameter of less than or equal to 4 millimetres. The second hollow tubular element may have an internal diameter of less than or equal to 3.5 millimetres. The second hollow tubular element may have an internal diameter of less than or equal to 3.25 millimetres.

[0188] The second hollow tubular element may have an internal diameter of between 2 millimetres and 5 millimetres. The second hollow tubular element may have an internal diameter of between 2 millimetres and 4.5 millimetres. The second hollow tubular element may have an internal diameter of between 2 millimetres and 4 millimetres. The second hollow tubular element may have an internal diameter of between 2 millimetres and 3.5 millimetres.

[0189] The second hollow tubular element may have an internal diameter of between 2.5 millimetres and 5 millimetres. The second hollow tubular element may have an internal diameter of between 3 millimetres and 5 millimetres.

[0190] The second hollow tubular element may have an internal diameter of between 3 millimetres and 4.5 millimetres. The second hollow tubular element may have an internal diameter of between3 millimetres and 4 millimetres. The second hollow tubular element may have an internal diameter of between 3 millimetres and 3.5 millimetres.

[0191] The second hollow tubular element may have an internal diameter that is greater than the internal diameter of the first hollow tubular element. The second hollow tubular element may have an internal diameter that is greater than the internal diameter of the tubular portion of the mouthpiece element. The second hollow tubular element may have an internal diameter that is the same as the internal diameter of the tubular portion of the mouthpiece element.

[0192] The second hollow tubular element may have an external diameter which is substantially constant along the entire length of the second hollow tubular element.

[0193] The second hollow tubular element may have an external diameter of at least 6 millimetres. The second hollow tubular element may have an external diameter of at least 6.5 millimetres. The second hollow tubular element may have an external diameter of at least 7 millimetres.

[0194] The second hollow tubular element may have an external diameter of less than or equal to 9 millimetres. The second hollow tubular element may have an external diameter of less than or equal to 8.5 millimetres. The second hollow tubular element may have an external diameter of less than or equal to 8 millimetres. The second hollow tubular element may have an external diameter of less than or equal to 7.5 millimetres.

[0195] The second hollow tubular element may have an external diameter of between 6 millimetres and 9 millimetres. The second hollow tubular element may have an external diameter of between 6 millimetres and 8.5 millimetres. The second hollow tubular element may have an external diameter of between 6 millimetres and 8 millimetres. The second hollow tubular element may have an external diameter of between 6 millimetres and 7.5 millimetres. The second hollow tubular element may have an external diameter of between 6 millimetres and 7 millimetres.

[0196] The second hollow tubular element may have an external diameter of between 7 millimetres and 9 millimetres. The second hollow tubular element may have an external diameter of between 7 millimetres and 8.5 millimetres. The second hollow tubular element may have an external diameter of between 7 millimetres and 8 millimetres. The second hollow tubular element may have an external diameter of between 7 millimetres and 7.5 millimetres.

[0197] The aerosol-generating article may further comprise a ventilation zone at a location along the downstream section. The aerosol-generating article may comprise a ventilation zone at a location along the first hollow tubular element. The ventilation zone may enable ingress of air from an exterior of the aerosol-generating article into the internal cavity of the first hollow tubular element when the consumer draws upon a mouth end of the aerosol-generating article, which is associated with a number of benefits.

[0198] The aerosol-generating article may comprise a ventilation zone at a location along the second hollow tubular element. The ventilation zone may enable ingress of air from an exterior of the aerosol-generating article into the internal cavity of the second hollow tubular element whenthe consumer draws upon a mouth end of the aerosol-generating article, which is associated with a number of benefits.

[0199] Where the aerosol-generating article comprises a ventilation zone located along the first hollow tubular element or the second hollow tubular element, the first or second hollow tubular element having a length as described herein may advantageously have sufficient rigidity to resist deformation by a user, such as during handling or insertion or removal of the aerosol-generating article from an aerosol-generating device.

[0200] The ventilation zone may comprise a plurality of openings or perforations through a component of the aerosol-generating article, such as through the peripheral wall of the second hollow tubular element when the ventilation zone is at a location along the second hollow tubular element.

[0201] The ventilation zone may comprise at least one circumferential row of openings or perforations. The ventilation zone may comprise two circumferential rows of openings or perforations. For example, the openings or perforations may be formed online during manufacturing of the aerosol-generating article. Each circumferential row of openings or perforations may comprise from 8 to 30 perforations.

[0202] The openings or perforations may each have a width ora length of at least 0.05 millimetres. A distance between the ventilation zone and the downstream end of the aerosol-generating article may be at least 12 millimetres. A distance between the ventilation zone and the downstream end of the aerosol-generating article may be at least 14 millimetres. A distance between the ventilation zone and the downstream end of the aerosol-generating article may be at least 16 millimetres.

[0203] A distance between the ventilation zone and the downstream end of the aerosol-generating article may be less than or equal to 24 millimetres. A distance between the ventilation zone and the downstream end of the aerosol-generating article may be less than or equal to 22 millimetres. A distance between the ventilation zone and the downstream end of the aerosol-generating article may be less than or equal to 20 millimetres.

[0204] A distance between the ventilation zone and the downstream end of the aerosol-generating article may be between 12 millimetres and 24 millimetres. A distance between the ventilation zone and the downstream end of the aerosol-generating article may be between 12 millimetres and 22 millimetres. A distance between the ventilation zone and the downstream end of the aerosolgenerating article may be between 12 millimetres and 20 millimetres.

[0205] A distance between the ventilation zone and the downstream end of the aerosol-generating article may be between 14 millimetres and 24 millimetres. A distance between the ventilation zone and the downstream end of the aerosol-generating article may be between 14 millimetres and 22 millimetres. A distance between the ventilation zone and the downstream end of the aerosolgenerating article may be between 14 millimetres and 20 millimetres.A distance between the ventilation zone and the downstream end of the aerosol-generating article may be between 16 millimetres and 24 millimetres. A distance between the ventilation zone and the downstream end of the aerosol-generating article may be between 16 millimetres and 22 millimetres. A distance between the ventilation zone and the downstream end of the aerosolgenerating article may be between 16 millimetres and 20 millimetres.

[0206] Preferably, a distance between the ventilation zone and the downstream end of the aerosol-generating article is 18 millimetres.

[0207] Adistance between the ventilation zone and the upstream end of the second hollow tubular element may be at least 6 millimetres. Adistance between the ventilation zone and the upstream end of the second hollow tubular element may be at least 8 millimetres. A distance between the ventilation zone and the upstream end of the second hollow tubular element may be at least 10 millimetres.

[0208] Adistance between the ventilation zone and the upstream end of the second hollow tubular element may be less than or equal to 16 millimetres. A distance between the ventilation zone and the upstream end of the second hollow tubular element may be less than or equal to 14 millimetres. A distance between the ventilation zone and the upstream end of the second hollow tubular element may be less than or equal to 12 millimetres.

[0209] Adistance between the ventilation zone and the upstream end of the second hollow tubular element may be between 6 millimetres and 16 millimetres. Adistance between the ventilation zone and the upstream end of the second hollow tubular element may be between 6 millimetres and 14 millimetres. A distance between the ventilation zone and the upstream end of the second hollow tubular element may be between 6 millimetres and 12 millimetres.

[0210] Adistance between the ventilation zone and the upstream end of the second hollow tubular element may be between 8 millimetres and 16 millimetres. Adistance between the ventilation zone and the upstream end of the second hollow tubular element may be between 8 millimetres and 14 millimetres. A distance between the ventilation zone and the upstream end of the second hollow tubular element may be between 8 millimetres and 12 millimetres.

[0211] Adistance between the ventilation zone and the upstream end of the second hollow tubular element may be between 10 millimetres and 16 millimetres. A distance between the ventilation zone and the upstream end of the second hollow tubular element may be between 10 millimetres and 14 millimetres. A distance between the ventilation zone and the upstream end of the second hollow tubular element may be between 10 millimetres and 12 millimetres.

[0212] Preferably, a distance between the ventilation zone and the upstream end of the second hollow tubular element is about 10 millimetres.

[0213] Adistance between the ventilation zone and the upstream end of the second hollow tubular element discussed herein is based on a desired level of cooling of aerosol through the second hollow tubular element upstream of the ventilation zone and cooling of aerosol through admission of cooler air into the second hollow tubular element at the ventilation zone.A distance between the ventilation zone and the upstream end of the mouthpiece element may be at least 2 millimetres. A distance between the ventilation zone and the upstream end of the mouthpiece element may be at least 4 millimetres. A distance between the ventilation zone and the upstream end of the mouthpiece element may be at least 6 millimetres.

[0214] A distance between the ventilation zone and the upstream end of the mouthpiece element may be less than or equal to 12 millimetres. A distance between the ventilation zone and the upstream end of the mouthpiece element may be less than or equal to 10 millimetres. A distance between the ventilation zone and the upstream end of the mouthpiece element may be less than or equal to 8 millimetres.

[0215] A distance between the ventilation zone and the upstream end of the mouthpiece element may be between 2 millimetres and 12 millimetres. A distance between the ventilation zone and the upstream end of the mouthpiece element may be between 2 millimetres and 10 millimetres. A distance between the ventilation zone and the upstream end of the mouthpiece element may be between 2 millimetres and 8 millimetres.

[0216] A distance between the ventilation zone and the upstream end of the mouthpiece element may be between 4 millimetres and 12 millimetres. A distance between the ventilation zone and the upstream end of the mouthpiece element may be between 4 millimetres and 10 millimetres. A distance between the ventilation zone and the upstream end of the mouthpiece element may be between 4 millimetres and 8 millimetres.

[0217] A distance between the ventilation zone and the upstream end of the mouthpiece element may be between 6 millimetres and 12 millimetres. A distance between the ventilation zone and the upstream end of the mouthpiece element may be between 6 millimetres and 10 millimetres. A distance between the ventilation zone and the upstream end of the mouthpiece element may be between 6 millimetres and 8 millimetres.

[0218] Preferably, a distance between the ventilation zone and the upstream end of the mouthpiece element is about 6 millimetres.

[0219] A distance between the ventilation zone and the downstream end of the second hollow tubular element may be at least 2 millimetres. A distance between the ventilation zone and the downstream end of the second hollow tubular element may be at least 4 millimetres. A distance between the ventilation zone and the downstream end of the second hollow tubular element may be at least 6 millimetres.

[0220] A distance between the ventilation zone and the downstream end of the second hollow tubular element may be less than or equal to 12 millimetres. A distance between the ventilation zone and the downstream end of the second hollow tubular element may be less than or equal to 10 millimetres. A distance between the ventilation zone and the downstream end of the second hollow tubular element may be less than or equal to 8 millimetres.

[0221] A distance between the ventilation zone and the downstream end of the second hollow tubular element may be between 2 millimetres and 12 millimetres. A distance between theventilation zone and the downstream end of the second hollow tubular element may be between 2 millimetres and 10 millimetres. A distance between the ventilation zone and the downstream end of the second hollow tubular element may be between 2 millimetres and 8 millimetres.

[0222] A distance between the ventilation zone and the downstream end of the second hollow tubular element may be between 4 millimetres and 12 millimetres. A distance between the ventilation zone and the downstream end of the second hollow tubular element may be between 4 millimetres and 10 millimetres. A distance between the ventilation zone and the downstream end of the second hollow tubular element may be between 4 millimetres and 8 millimetres.

[0223] A distance between the ventilation zone and the downstream end of the second hollow tubular element may be between 6 millimetres and 12 millimetres. A distance between the ventilation zone and the downstream end of the second hollow tubular element may be between 6 millimetres and 10 millimetres. A distance between the ventilation zone and the downstream end of the second hollow tubular element may be between 6 millimetres and 8 millimetres.

[0224] Preferably, a distance between the ventilation zone and the downstream end of the second hollow tubular element is about 6 millimetres.

[0225] The distance between the ventilation zone and the downstream end of the second hollow tubular element or the upstream end of the mouthpiece element discussed herein is based on a desired level of mixing of aerosol generated by the aerosol-generating substrate and air admitted into the aerosol-generating article through the ventilation zone prior to delivery to a user.

[0226] An aerosol-generating article in accordance with the present disclosure may have a ventilation level of at least 5 percent.

[0227] The term “ventilation level” is used throughout the present specification to denote a volume ratio between of the airflow admitted into the aerosol-generating article via the ventilation zone (ventilation airflow) and the sum of the aerosol airflow and the ventilation airflow. The greater the ventilation level, the higher the dilution of the aerosol flow delivered to the consumer.

[0228] The aerosol-generating article may have a ventilation level of at least 10 percent.

[0229] The aerosol-generating article may have a ventilation level of at least 15 percent. The aerosol-generating article may have a ventilation level of at least 20 percent. The aerosolgenerating article may have a ventilation level of at least 25 percent.

[0230] The aerosol-generating article may have a ventilation level of less than 60 percent. The aerosol-generating article may have a ventilation level of less than or equal to 45 percent. The aerosol-generating article may have a ventilation level of less than or equal to 40 percent. The aerosol-generating article may have a ventilation level of less than or equal to 35 percent.

[0231] The aerosol-generating article may have a ventilation level of between 20 percent and 60 percent. The aerosol-generating article may have a ventilation level of between 20 percent and 45 percent. The aerosol-generating article may have a ventilation level of between 20 percent and 40 percent.The aerosol-generating article may have a ventilation level of between 25 percent and 60 percent. The aerosol-generating article may have a ventilation level of between 25 percent and 45 percent. The aerosol-generating article may have a ventilation level of between 25 percent and 40 percent.

[0232] The aerosol-generating article may have a ventilation level of between 30 percent and 60 percent. The aerosol-generating article may have a ventilation level of between 30 percent and 45 percent. The aerosol-generating article may have a ventilation level of between 30 percent and 40 percent.

[0233] The aerosol-generating article may have a ventilation level of between 28 percent and 42 percent. The aerosol-generating article may have a ventilation level of 30 percent.

[0234] Without wishing to be bound by theory, the inventors have found that the temperature drop caused by the admission of cooler, external air into the second hollow tubular element via the ventilation zone may have an advantageous effect on the nucleation and growth of aerosol particles.

[0235] Formation of an aerosol from a gaseous mixture containing various chemical species depends on a delicate interplay between nucleation, evaporation, and condensation, as well as coalescence, all the while accounting for variations in vapour concentration, temperature, and velocity fields. The so-called classical nucleation theory is based on the assumption that a fraction of the molecules in the gas phase are large enough to stay coherent for long times with sufficient probability (for example, a probability of one half). These molecules represent some kind of a critical, threshold molecule clusters among transient molecular aggregates, meaning that, on average, smaller molecule clusters are likely to disintegrate rather quickly into the gas phase, while larger clusters are, on average, likely to grow. Such critical cluster is identified as the key nucleation core from which droplets are expected to grow due to condensation of molecules from the vapour. It is assumed that virgin droplets that just nucleated emerge with a certain original diameter, and then may grow by several orders of magnitude. This is facilitated and may be enhanced by rapid cooling of the surrounding vapour, which induces condensation. In this connection, it helps to bear in mind that evaporation and condensation are two sides of one same mechanism, namely gasliquid mass transfer. While evaporation relates to net mass transfer from the liquid droplets to the gas phase, condensation is net mass transfer from the gas phase to the droplet phase. Evaporation (or condensation) will make the droplets shrink (or grow), but it will not change the number of droplets.

[0236] In this scenario, which may be further complicated by coalescence phenomena, the temperature and rate of cooling can play a critical role in determining how the system responds. In general, different cooling rates may lead to significantly different temporal behaviours as concerns the formation of the liquid phase (droplets), because the nucleation process is typically nonlinear. Without wishing to be bound by theory, it is hypothesised that cooling can cause a rapid increase in the number concentration of droplets, which is followed by a strong, short-lived increase in thisgrowth (nucleation burst). This nucleation burst would appear to be more significant at lower temperatures. Further, it would appear that higher cooling rates may favour an earlier onset of nucleation. By contrast, a reduction of the cooling rate would appear to have a favourable effect on the final size that the aerosol droplets ultimately reach.

[0237] Therefore, the rapid cooling induced by the admission of external air into the second hollow tubular element via the ventilation zone can be favourably used to favour nucleation and growth of aerosol droplets. However, at the same time, the admission of external air into the second hollow tubular element has the immediate drawback of diluting the aerosol stream delivered to the consumer.

[0238] The inventors have surprisingly found how the favourable effect of enhanced nucleation promoted by the rapid cooling induced by the introduction of ventilation air into the article is capable of significantly countering the less desirable effects of dilution. As such, satisfactory values of aerosol delivery are consistently achieved with aerosol-generating articles in accordance with the present disclosure.

[0239] This is particularly advantageous with “short” aerosol-generating articles, such as ones wherein a length of the aerosol-generating substrate is less than 40 millimetres, preferably less than 25 millimetres, even more preferably less than 20 millimetres, or wherein an overall length of the aerosol-generating article is less than 70 millimetres, preferably less than 60 millimetres, even more preferably less than 50 millimetres. As will be appreciated, in such aerosol-generating articles, there is little time and space for the aerosol to form and for the particulate phase of the aerosol to become available for delivery to the consumer.

[0240] The mouthpiece element may be in longitudinal alignment with the substrate element. The mouthpiece element may be in longitudinal alignment with the first hollow tubular element. The mouthpiece element may be in longitudinal alignment with the second hollow tubular element.

[0241] The mouthpiece element may extend from a downstream end of the downstream section. The mouthpiece element may be located at the downstream end of the aerosol-generating article. The mouthpiece element may be provided at the downstream end of the aerosol-generating article. The downstream end of the mouthpiece element may define the downstream end of the aerosolgenerating article.

[0242] The mouthpiece element may be located downstream of the one or more hollow tubular elements. The mouthpiece element may be located downstream of the first hollow tubular element. The mouthpiece element may be located downstream of the second hollow tubular element. The mouthpiece element may extend between the second hollow tubular element and the downstream end of the aerosol-generating article. The mouthpiece element may abut the second hollow tubular element.

[0243] Where the downstream section comprises only one hollow tubular element, which may be the first hollow tubular element, the mouthpiece element may extend between the first hollowtubular element and the downstream end of the aerosol-generating article. The mouthpiece element may abut the first hollow tubular element.

[0244] The mouthpiece element may be connected to one or more of the adjacent upstream components of the aerosol-generating article by means of a tipping wrapper. For example, the mouthpiece element may be connected to the second hollow tubular element by a tipping wrapper.

[0245] The mouthpiece element may be formed of a fibrous material. The mouthpiece element may be formed of a fibrous filtration material.

[0246] The mouthpiece element may be formed from a bundle of fibres having a denier per filament of between about 10 and about 15.

[0247] The fibrous filtration material may be for filtering the aerosol that is generated from the aerosol-generating substrate. The mouthpiece element may be formed of cellulose acetate tow.

[0248] The mouthpiece element may comprise cellulose acetate, paper, viscose, or lyocell. The mouthpiece element may comprise paper, viscose, or lyocell. The mouthpiece element may comprise viscose or lyocell.

[0249] A mouthpiece element made of or formed from paper, viscose, or lyocell may provide a balance between the desired level of filtration for the aerosol-generating article while allowing desired nicotine and aerosol former deliveries and the strength and rigidity of the mouthpiece element.

[0250] A content of cellulose acetate in the mouthpiece element may be less than or equal to 15 percent by weight. A content of cellulose acetate in the mouthpiece element is less than or equal to 10 percent by weight. A content of cellulose acetate in the mouthpiece element may be less than or equal to 5 percent by weight. The mouthpiece element may be substantially free of cellulose acetate.

[0251] The mouthpiece element may have a length of less than or equal to 20 millimetres. The mouthpiece element may have a length of less than or equal to 18 millimetres. The mouthpiece element may have a length of less than or equal to 16 millimetres. The mouthpiece element may have a length of less than or equal to 15 millimetres. The mouthpiece element may have a length of less than or equal to 14 millimetres. The mouthpiece element may have a length of less than or equal to 12 millimetres.

[0252] The mouthpiece element may have a length of greater than 8 millimetres. The mouthpiece element may have a length of greater than 9 millimetres. The mouthpiece element may have a length of greater than 10 millimetres. The mouthpiece element may have a length of greater than 11 millimetres.

[0253] The mouthpiece element may have a length of between 8 millimetres and 18 millimetres. The mouthpiece element may have a length of between 8 millimetres and 16 millimetres. The mouthpiece element may have a length of between 8 millimetres and 14 millimetres.

[0254] The mouthpiece element may have a length of between 10 millimetres and 20 millimetres. The mouthpiece element may have a length of between 10 millimetres and 18 millimetres. Themouthpiece element may have a length of between 10 millimetres and 16 millimetres. The mouthpiece element may have a length of between 10 millimetres and 14 millimetres.

[0255] Preferably, the length of the mouthpiece element is 12 millimetres.

[0256] The mouthpiece element may have an external diameter which is substantially constant along the entire length of the mouthpiece element.

[0257] The mouthpiece element may have an external diameter that is approximately equal to the external diameter of the aerosol-generating article. The mouthpiece element may have an external diameter that is approximately equal to the external diameter of the substrate element. The mouthpiece element may have an external diameter that is approximately equal to the external diameter of the first hollow tubular element. The mouthpiece element may have an external diameter that is approximately equal to the external diameter of the second hollow tubular element.

[0258] The mouthpiece may have an external diameter of between 5 millimetres and 12 millimetres. The mouthpiece may have an external diameter of between 5 millimetres and 10 millimetres. The mouthpiece may have an external diameter of between 6 millimetres and 8 millimetres. The mouthpiece may have an external diameter of between 7 millimetres and 8 millimetres. The mouthpiece may have an external diameter of about 7.2 millimetres.

[0259] A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be at least 0.18. A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be at least 0.2. A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be at least 0.22. A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be at least 0.25.

[0260] A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be less than or equal to 0.4. A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be less than or equal to 0.35. A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be less than or equal to 0.3.

[0261] A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be between 0.18 and 0.4. A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be between 0.18 and 0.35. A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be between 0.18 and 0.3.

[0262] A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be between 0.2 and 0.4. A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be between 0.2 and 0.35. A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be between 0.2 and 0.3.

[0263] A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be between 0.22 and 0.4. A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be between 0.22 and 0.35. A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be between 0.22 and 0.3.A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be between 0.25 and 0.4. A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be between 0.25 and 0.35. A ratio of the length of the mouthpiece element to the length of the aerosol-generating article may be between 0.25 and 0.3.

[0264] The mouthpiece element may comprise an internal tubular element. The internal tubular element may be an internal hollow tubular element. The internal tubular element may be a tube.

[0265] The internal tubular element may comprise a hollow cylindrical tube. The internal tubular element may be a hollow cylindrical tube. The internal tubular element may define a hollow section of the aerosol-generating article. The internal tubular element may define a hollow section of the downstream section. The internal tubular element may define a hollow section of the mouthpiece element.

[0266] The internal tubular element may be located within the internal cavity of the tubular portion. The internal tubular element tubular portion may define the internal cavity of the tubular portion.

[0267] The internal tubular element may be located inside of the mouthpiece element.

[0268] The internal tubular element may be located inside the tubular portion. The internal tubular element may be located concentrically inside of the tubular portion.

[0269] The internal tubular element may be attached to the mouthpiece element. The internal tubular element may be attached to an internal surface of the mouthpiece element. The internal tubular element may be attached to the mouthpiece element by any suitable means such as an adhesive.

[0270] The internal tubular element may be attached to the tubular portion. The internal tubular element may be attached to an internal surface of the tubular portion. The internal tubular element may be attached to the tubular portion by any suitable means such as an adhesive.

[0271] The internal tubular element and the tubular portion may be provided as two discrete elements. The internal tubular element and the tubular portion may be two discrete elements. The internal tubular element may be a discrete element. The internal tubular element may be a discrete tube.

[0272] The internal tubular element may comprise cellulose acetate, paper, carboard, viscose, or lyocell.

[0273] The internal tubular element may be made from or comprise a cellulosic material. The internal tubular element may be made entirely from a cellulosic material. The cellulosic material may comprise a sheet of cellulosic material. The cellulosic material may comprise cellulose fibres.

[0274] The cellulosic material may be paper. The internal tubular element may comprise at least one layer of paper. The paper may be very rigid paper. The paper may be crimped paper, such as crimped heat resistant paper or crimped parchment paper.

[0275] The cellulosic material may be cardboard. The internal tubular element may be a cardboard tube. Advantageously, cardboard is a cost-effective material that provides a balance between being deformable in order to provide ease of insertion of the article into an aerosol-generating deviceand being sufficiently stiff to provide suitable engagement of the article with the interior of the device. A cardboard tube may therefore provide suitable resistance to deformation or compression during use.

[0276] The internal tubular element may be a tube formed from spirally wound paper. The internal tubular element may be formed from a plurality of layers of paper. For example, the internal tubular element may be a cardboard tube formed from spirally wound paper.

[0277] The cellulosic material may be paperboard.

[0278] The cellulosic material may comprise natural fibres. The cellulosic material may comprise artificial fibres.

[0279] The internal tubular element may extend from an upstream end of the tubular portion to a downstream end of the tubular portion. The internal tubular element may extend between an upstream end of the tubular portion and a downstream end of the tubular portion.

[0280] The internal tubular element may have an internal dimeter which is substantially constant along the entire length of internal tubular element. The internal tubular element may comprise an internal cavity. The internal cavity of the internal tubular element may be hollow. The internal cavity of the internal tubular element may be substantially empty.

[0281] The internal tubular element may have an internal diameter which varies along the length of the internal tubular element.

[0282] The internal tubular element may have an internal diameter which decreases along the length of the internal tubular element. The internal tubular element may have an internal diameter which decreases from the upstream end of the internal tubular element to the downstream end of the internal tubular element.

[0283] The internal tubular element may have an internal diameter which increases along the length of the internal tubular element. The internal tubular element may have an internal diameter which increases from the upstream end of the internal tubular element to the downstream end of the internal tubular element.

[0284] The internal tubular element may have the same length as the tubular portion.

[0285] The internal tubular element may have a length of greater than 3.5 millimetres. The internal tubular element may have a length of greater than 4 millimetres. The internal tubular element may have a length of greater than 4.5 millimetres. The internal tubular element may have a length of greater than 5 millimetres. The internal tubular element may have a length of greater than 5.5 millimetres. The internal tubular element may have a length of greater than 6 millimetres. The internal tubular element may have a length of greater than 6.5 millimetres.

[0286] The internal tubular element may have a length of less than or equal to 7.5 millimetres. The internal tubular element may have a length of less than or equal to 7 millimetres. The internal tubular element may have a length of less than or equal to 6.5 millimetres. The internal tubular element may have a length of less than or equal to 6 millimetres. The internal tubular element mayhave a length of less than or equal to 5.5 millimetres. The internal tubular element may have a length of less than or equal to 5 millimetres.

[0287] The internal tubular element may have a length of between 4 millimetres and 7 millimetres. The internal tubular element may have a length of between 4 millimetres and 6.5 millimetres. The internal tubular element may have a length of between 4 millimetres and 6 millimetres. The internal tubular element may have a length of between 4 millimetres and 5.5 millimetres. The internal tubular element may have a length of between 4 millimetres and 5 millimetres.

[0288] The internal tubular element may have a length of between 4 millimetres and 7 millimetres. The internal tubular element may have a length of between 4.5 millimetres and 7 millimetres. The internal tubular element may have a length of between 5 millimetres and 7 millimetres. The internal tubular element may have a length of between 5.5 millimetres and 7 millimetres. The internal tubular element may have a length of between 6 millimetres and 7 millimetres.

[0289] The internal tubular element may have an external diameter which is the same as the internal diameter of the tubular portion.

[0290] The internal tubular element may have an external diameter of greater than 2 millimetres. The internal tubular element may have an external diameter of greater than 2.5 millimetres. The internal tubular element may have an external diameter of greater than 3 millimetres. The internal tubular element may have an external diameter of greater than 3.5 millimetres. The internal tubular element may have an external diameter of greater than 4 millimetres.

[0291] The internal tubular element may have an external diameter of less than or equal to 5 millimetres. The internal tubular element may have an external diameter of less than or equal to 4.5 millimetres. The internal tubular element may have an external diameter of less than or equal to 4 millimetres. The internal tubular element may have an external diameter of less than or equal to 3.5 millimetres. The internal tubular element may have an external diameter of less than or equal to 3 millimetres.

[0292] The internal tubular element may have an external diameter of between 2.5 millimetres and 5 millimetres. The internal tubular element may have an external diameter of between 2.5 millimetres and 4.5 millimetres. The internal tubular element may have an external diameter of between 2.5 millimetres and 4 millimetres. The internal tubular element may have an external diameter of between 2.5 millimetres and 3.5 millimetres. The internal tubular element may have an external diameter of between 2.5 millimetres and 3 millimetres.

[0293] The internal tubular element may have an external diameter of between 2 millimetres and 4.5 millimetres. The internal tubular element may have an external diameter of between 2.5 millimetres and 4.5 millimetres. The internal tubular element may have an external diameter of between 3 millimetres and 4.5 millimetres. The internal tubular element may have an external diameter of between 3.5 millimetres and 4.5 millimetres. The internal tubular element may have an external diameter of between 4 millimetres and 4.5 millimetres.The internal tubular element may have an external diameter of between 3 millimetres and 4.5 millimetres. The internal tubular element may have an external diameter of between 3 millimetres and 4 millimetres.

[0294] The aerosol-generating article may comprise a capsule. The capsule may be located inside the mouthpiece element.

[0295] The capsule may be a flavour capsule containing a flavourant. The capsule may be a breakable capsule.

[0296] A user may apply force to the mouthpiece element which breaks the capsule to release a flavourant. The mouthpiece element having a length as described below may be particularly advantageous to accommodate a capsule.

[0297] The capsule may be located centrally within the mouthpiece element. The capsule may be located centrally with respect to the longitudinal axis of the mouthpiece element. The capsule may be located centrally with respect to the axial axis of the mouthpiece element.

[0298] The capsule may be located in the tubular portion. The capsule may be located in the plug portion.

[0299] The capsule may have a diameter of greater than 2 millimetres. The capsule may have a diameter of greater than 2.5 millimetres. The capsule may have a diameter of greater than 3 millimetres. The capsule may have a diameter of greater than 3.5millimetres. The capsule may have a diameter of greater than 4 millimetres.

[0300] The capsule may have a diameter of less than or equal to 5 millimetres. The capsule may have a diameter of less than or equal to 4.5 millimetres. The capsule may have a diameter of less than or equal to 4 millimetres. The capsule may have a diameter of less than or equal to 3.5 millimetres. The capsule may have a diameter of less than or equal to 3 millimetres.

[0301] The capsule may have a diameter of between 2 millimetres and 5 millimetres. The capsule may have a diameter of between 2 millimetres and 4.5 millimetres. The capsule may have a diameter of between 2 millimetres and 4 millimetres. The capsule may have a diameter of between 2 millimetres and 3.5 millimetres. The capsule may have a diameter of between 2 millimetres and 3 millimetres.

[0302] The capsule may have a diameter of between 2.5 millimetres and 5 millimetres. The capsule may have a diameter of between 3 millimetres and 5 millimetres. The capsule may have a diameter of between 3.5 millimetres and 5 millimetres. The capsule may have a diameter of between 4 millimetres and 5 millimetres. The capsule may have a diameter of between 4.5 millimetres and 5 millimetres.

[0303] The capsule may have a diameter of between 3 millimetres and 4.5 millimetres. The capsule may have a diameter of between 3 millimetres and 4 millimetres.

[0304] The tubular portion and the plug portion may be formed separately. The tubular portion and the plug portion may be formed separately and subsequently attached to one another. The tubular portion may be attached to the plug portion. The tubular portion may abut the plug portion.Alternatively, the tubular portion and the plug portion may be formed as a unitary element. The mouthpiece element may be formed as a unitary element. The tubular portion may be provided by drilling out a portion of a solid mouthpiece element.

[0305] The tubular portion may have an external circumferential surface. The plug portion may have an external circumferential surface. The external circumferential surface of the tubular portion and the external circumferential surface of the plug portion may provide a single continuous external circumferential surface. The single continuous external circumferential surface does not have a joint between the tubular portion and the plug portion.

[0306] The tubular portion may be located downstream of the plug portion. A downstream end of the tubular portion may abut an upstream end of the plug portion. A downstream end of the tubular portion may be attached to an upstream end of the plug portion.

[0307] The tubular portion may be located at a downstream end of the second hollow tubular element. The tubular portion may abut a downstream end of the second hollow tubular element. An upstream end of the tubular portion may abut a downstream end of the second hollow tubular element.

[0308] The plug portion may be located at a downstream end of the aerosol-generating article. A downstream end of the plug portion may define the downstream end of the aerosol-generating article.

[0309] Alternatively, the plug portion may be located downstream of the tubular portion. A downstream end of the plug portion may abut an upstream end of the tubular portion. A downstream end of the plug portion may be attached to an upstream end of the tubular portion.

[0310] The plug portion may be located at a downstream end of the second hollow tubular element. The plug portion may abut a downstream end of the second hollow tubular element. An upstream end of the plug portion may abut a downstream end of the second hollow tubular element.

[0311] The tubular portion may be located at a downstream end of the aerosol-generating article. A downstream end of the tubular portion may define the downstream end of the aerosol-generating article.

[0312] A downstream end of the tubular portion may abut an upstream end of the plug portion. Alternatively, a downstream end of the plug portion may abut an upstream end of the tubular portion.

[0313] A ratio of the length of the plug portion to the length of the tubular portion may be greater than 1. A ratio of the length of the plug portion to the length of the tubular portion may be greater than 1.1. A ratio of the length of the plug portion to the length of the tubular portion may be greater than 1.2. A ratio of the length of the plug portion to the length of the tubular portion may be greater than 1.3. A ratio of the length of the plug portion to the length of the tubular portion may be greater than 1.4. A ratio of the length of the plug portion to the length of the tubular portion may be greater than 1.5.A ratio of the length of the plug portion to the length of the tubular portion may be less than or equal to 2. A ratio of the length of the plug portion to the length of the tubular portion may be less than or equal to 1.75. A ratio of the length of the plug portion to the length of the tubular portion may be less than or equal to 1.5.

[0314] A ratio of the length of the plug portion to the length of the tubular portion may be between 1 and 2. A ratio of the length of the plug portion to the length of the tubular portion may be between 1 and 1.75. A ratio of the length of the plug portion to the length of the tubular portion may be between 1 and 1.5.

[0315] A ratio of the length of the plug portion to the length of the tubular portion may be between 1.2 and 2. A ratio of the length of the plug portion to the length of the tubular portion may be between 1.2 and 1.75. A ratio of the length of the plug portion to the length of the tubular portion may be between 1.2 and 1.5.

[0316] The tubular portion may be a hollow cylindrical tube. The tubular portion may define a hollow section of the aerosol-generating article. The tubular portion may define a hollow section of the downstream section. The tubular portion may define a hollow section of the mouthpiece element.

[0317] The tubular portion may define an internal cavity. The internal cavity may extend from an upstream end of the tubular portion to a downstream end of the tubular portion. The internal cavity may have an internal dimeter which is substantially constant along the entire length of the tubular portion. The internal cavity may be hollow. The internal cavity may be substantially empty. The internal cavity may contain an internal tubular element.

[0318] The tubular portion may be in longitudinal alignment with the plug portion. The tubular portion may be in longitudinal alignment with the first hollow tubular element. The tubular portion may be in longitudinal alignment with the second hollow tubular element.

[0319] The tubular portion may have a length of greater than 3.5 millimetres. The tubular portion may have a length of greater than 4 millimetres. The tubular portion may have a length of greater than 4.5 millimetres. The tubular portion may have a length of greater than 5 millimetres. The tubular portion may have a length of greater than 5.5 millimetres. The tubular portion may have a length of greater than 6 millimetres. The tubular portion may have a length of greater than 6.5 millimetres.

[0320] The tubular portion may have a length of less than or equal to 7.5 millimetres. The tubular portion may have a length of less than or equal to 7 millimetres. The tubular portion may have a length of less than or equal to 6.5 millimetres. The tubular portion may have a length of less than or equal to 6 millimetres. The tubular portion may have a length of less than or equal to 5.5 millimetres. The tubular portion may have a length of less than or equal to 5 millimetres.

[0321] The tubular portion may have a length of between 4 millimetres and 7 millimetres. The tubular portion may have a length of between 4 millimetres and 6.5 millimetres. The tubular portion may have a length of between 4 millimetres and 6 millimetres. The tubular portion may have alength of between 4 millimetres and 5.5 millimetres. The tubular portion may have a length of between 4 millimetres and 5 millimetres.

[0322] The tubular portion may have a length of between 4 millimetres and 7 millimetres. The tubular portion may have a length of between 4.5 millimetres and 7 millimetres. The tubular portion may have a length of between 5 millimetres and 7 millimetres. The tubular portion may have a length of between 5.5 millimetres and 7 millimetres. The tubular portion may have a length of between 6 millimetres and 7 millimetres.

[0323] The tubular portion may have a length that is greater than the length of the plug portion. The tubular portion may have a length that is the same as the length of the plug portion. The tubular portion may have a length that is less than the length of the plug portion.

[0324] The tubular portion may have an internal diameter which is substantially constant along the entire length of the tubular portion.

[0325] The tubular portion may have an internal diameter which varies along the length of the tubular portion.

[0326] The tubular portion may have an internal diameter which decreases along the length of the tubular portion. The tubular portion may have an internal diameter which decreases from the upstream end of the tubular portion to the downstream end of the tubular portion.

[0327] The tubular portion may have an internal diameter which increases along the length of the tubular portion. The tubular portion may have an internal diameter which increases from the upstream end of the tubular portion to the downstream end of the tubular portion.

[0328] The tubular portion may have an internal diameter of greater than 2 millimetres. The tubular portion may have an internal diameter of greater than 2.5 millimetres. The tubular portion may have an internal diameter of greater than 3 millimetres. The tubular portion may have an internal diameter of greater than 3.5 millimetres. The tubular portion may have an internal diameter of greater than 4 millimetres.

[0329] The tubular portion may have an internal diameter of less than or equal to 5 millimetres. The tubular portion may have an internal diameter of less than or equal to 4.5 millimetres. The tubular portion may have an internal diameter of less than or equal to 4 millimetres. The tubular portion may have an internal diameter of less than or equal to 3.5 millimetres. The tubular portion may have an internal diameter of less than or equal to 3 millimetres.

[0330] The tubular portion may have an internal diameter of between 2.5 millimetres and 5 millimetres. The tubular portion may have an internal diameter of between 2.5 millimetres and 4.5 millimetres. The tubular portion may have an internal diameter of between 2.5 millimetres and 4 millimetres. The tubular portion may have an internal diameter of between 2.5 millimetres and 3.5 millimetres. The tubular portion may have an internal diameter of between 2.5 millimetres and 3 millimetres.

[0331] The tubular portion may have an internal diameter of between 2 millimetres and 4.5 millimetres. The tubular portion may have an internal diameter of between 2.5 millimetres and 4.5millimetres. The tubular portion may have an internal diameter of between 3 millimetres and 4.5 millimetres. The tubular portion may have an internal diameter of between 3.5 millimetres and 4.5 millimetres. The tubular portion may have an internal diameter of between 4 millimetres and 4.5 millimetres.

[0332] The tubular portion may have an internal diameter of between 3 millimetres and 4.5 millimetres. The tubular portion may have an internal diameter of between 3 millimetres and 4 millimetres.

[0333] The tubular portion may have an external diameter which is substantially constant along the entire length of the tubular portion.

[0334] The tubular portion may have an external diameter of greater than 5.5 millimetres. The tubular portion may have an external diameter of greater than 6 millimetres. The tubular portion may have an external diameter of greater than 6.5 millimetres. The tubular portion may have an external diameter of greater than 7 millimetres.

[0335] The tubular portion may have an external diameter of less than or equal to 7.5 millimetres. The tubular portion may have an external diameter of less than or equal to 8 millimetres. The tubular portion may have an external diameter of less than or equal to 8.5 millimetres. The tubular portion may have an external diameter of less than or equal to 9 millimetres.

[0336] The tubular portion may have an external diameter of between 5.5 millimetres and 9 millimetres. The tubular portion may have an external diameter of between 6 millimetres and 9 millimetres. The tubular portion may have an external diameter of between 6 millimetres and 8.5 millimetres. The tubular portion may have an external diameter of between 6.5 millimetres and 8.5 millimetres. The tubular portion may have an external diameter of between 6.5 millimetres and 8 millimetres. The tubular portion may have an external diameter of between 7 millimetres and 8 millimetres. The tubular portion may have an external diameter of between 7 millimetres and 7.5 millimetres.

[0337] The plug portion may be solid. The plug portion may be plain.

[0338] The plug portion may be formed of a fibrous material. The plug portion may be formed of a fibrous filtration material. The plug portion may be formed from a bundle of fibres having a denier per filament of between about 10 and about 15.

[0339] The fibrous filtration material may be for filtering the aerosol that is generated from the aerosol-generating substrate. The plug portion may be formed of cellulose acetate tow.

[0340] The plug portion may comprise cellulose acetate, paper, viscose, or lyocell. The plug portion may comprise paper, viscose, or lyocell. The plug portion may comprise viscose or lyocell.

[0341] The plug portion may have a length of greater than 4.5 millimetres. The plug portion may have a length of greater than 5 millimetres. The plug portion may have a length of greater than 5.5 millimetres. The plug portion may have a length of greater than 6 millimetres. The plug portion may have a length of greater than 6.5 millimetres. The plug portion may have a length of greater than7 millimetres. The plug portion may have a length of greater than 7.5 millimetres. The plug portion may have a length of greater than 8 millimetres.

[0342] The plug portion may have a length of less than or equal to 10 millimetres. The plug portion may have a length of less than or equal to 9 millimetres. The plug portion may have a length of less than or equal to 8.5 millimetres. The plug portion may have a length of less than or equal to 8 millimetres. The plug portion may have a length of less than or equal to 7.5 millimetres. The plug portion may have a length of less than or equal to 7 millimetres. The plug portion may have a length of less than or equal to 6.5 millimetres. The plug portion may have a length of less than or equal to 6 millimetres.

[0343] The plug portion may have a length of between 5 millimetres and 9 millimetres. The plug portion may have a length of between 5 millimetres and 8.5 millimetres. The plug portion may have a length of between 5 millimetres and 8 millimetres. The plug portion may have a length of between 5 millimetres and 7.5 millimetres. The plug portion may have a length of between 5 millimetres and 7 millimetres. The plug portion may have a length of between 5 millimetres and 6.5 millimetres. The plug portion may have a length of between 5 millimetres and 6 millimetres.

[0344] The plug portion may have a length of between 5.5 millimetres and 9 millimetres. The plug portion may have a length of between 6 millimetres and 9 millimetres. The plug portion may have a length of between 6.5 millimetres and 9 millimetres. The plug portion may have a length of between 7 millimetres and 9 millimetres. The plug portion may have a length of between 7.5 millimetres and 9 millimetres. The plug portion may have a length of between 8 millimetres and 9 millimetres.

[0345] The plug portion may have a length that is greater than the length of the tubular portion. The plug portion may have a length that is the same as the length of the tubular portion. The plug portion may have a length that is less than the length of the tubular portion.

[0346] The plug portion may have an external diameter of greater than 5.5 millimetres. The plug portion may have an external diameter of greater than 6 millimetres. The plug portion may have an external diameter of greater than 6.5 millimetres. The plug portion may have an external diameter of greater than 7 millimetres.

[0347] The plug portion may have an external diameter of less than or equal to 7.5 millimetres. The plug portion may have an external diameter of less than or equal to 8 millimetres. The plug portion may have an external diameter of less than or equal to 8.5 millimetres. The plug portion may have an external diameter of less than or equal to 9 millimetres.

[0348] The plug portion may have an external diameter of between 5.5 millimetres and 9 millimetres. The plug portion may have an external diameter of between 6 millimetres and 9 millimetres. The plug portion may have an external diameter of between 6 millimetres and 8.5 millimetres. The plug portion may have an external diameter of between 6.5 millimetres and 8.5 millimetres. The plug portion may have an external diameter of between 6.5 millimetres and 8 millimetres. The plug portion may have an external diameter of between 7 millimetres and 8millimetres. The plug portion may have an external diameter of between 7 millimetres and 7.5 millimetres.

[0349] The aerosol-generating article may comprise one or more wrappers circumscribing one or more of the upstream element, the substrate element, the one or more hollow tubular elements (the first hollow tubular element, the second hollow tubular element, or both) and the mouthpiece element so as to assemble them into the aerosol-generating article.

[0350] The expression “one or more wrappers” is used herein to encompass different possible arrangements wherein one or more of the components forming the aerosol-generating article may be individually wrapped, and some combination of wrappers and tipping paper are used to attach the various individually wrapped or unwrapped components so as to form the aerosol-generating article.

[0351] The aerosol-generating article may comprise a wrapper circumscribing the substrate element and the downstream section. The aerosol-generating article may comprise a wrapper circumscribing the substrate element along the entire length of the substrate element and the downstream section along the entire length of the downstream section.

[0352] The aerosol-generating article may comprise a wrapper circumscribing the upstream element along the entire length of the upstream element, the substrate element along the entire length of the substrate element, and the downstream section along the entire length of the downstream section.

[0353] The wrapper may extend from the upstream end of the aerosol-generating article to the downstream end of the aerosol-generating article.

[0354] The wrapper may have a length of at least 30 millimetres. The wrapper may have a length of at least 35 millimetres. The wrapper may have a length of at least 40 millimetres.

[0355] The wrapper may have a length of less than or equal to 55 millimetres. The wrapper may have a length of less than or equal to 50 millimetres. The wrapper may have a length of less than or equal to 45 millimetres.

[0356] The wrapper may have a length of between 35 millimetres and 55 millimetres. The wrapper may have a length of between 35 millimetres and 50 millimetres. The wrapper may have a length of between 35 millimetres and 45 millimetres.

[0357] The wrapper may have a length of between 40 millimetres and 55 millimetres. The wrapper may have a length of between 40 millimetres and 50 millimetres. The wrapper may have a length of between 40 millimetres and 45 millimetres.

[0358] The wrapper preferably has a length of 45 millimetres.

[0359] The ventilation zone may comprise a plurality of openings or perforations through the wrapper.

[0360] The aerosol-generating article may comprise a tipping wrapper circumscribing the second hollow tubular element and the mouthpiece element. The aerosol-generating article may comprise a tipping wrapper circumscribing the second hollow tubular element along at least a portion of thelength of the second hollow tubular element and the mouthpiece element along the entire length of the mouthpiece element. The tipping wrapper may circumscribe the second hollow tubular element along a portion of the length of the second hollow tubular element and the mouthpiece element along the entire length of the mouthpiece element. In this way, the tipping wrapper joins the mouthpiece element to the second hollow tubular element.

[0361] The tipping wrapper may extend from the downstream end of the mouthpiece element to a location along the second hollow tubular element.

[0362] Where the downstream section comprises only one hollow tubular element, which may be the first hollow tubular element, the aerosol-generating article may comprise a tipping wrapper circumscribing the first hollow tubular element and the mouthpiece element. The aerosolgenerating article may comprise a tipping wrapper circumscribing the first hollow tubular element along at least a portion of the length of the first hollow tubular element and the mouthpiece element along the entire length of the mouthpiece element. The tipping wrapper may circumscribe the first hollow tubular element along a portion of the length of the first hollow tubular element and the mouthpiece element along the entire length of the mouthpiece element. In this way, the tipping wrapper joins the mouthpiece element to the first hollow tubular element. The tipping wrapper may extend from the downstream end of the mouthpiece element to a location along the first hollow tubular element.

[0363] The tipping wrapper may have a length of at least 14 millimetres. The tipping wrapper may have a length of at least 16 millimetres. The tipping wrapper may have a length of at least 18 millimetres.

[0364] The tipping wrapper may have a length of less than or equal to 30 millimetres. The tipping wrapper may have a length of less than or equal to 26 millimetres. The tipping wrapper may have a length of less than or equal to 22 millimetres.

[0365] The tipping wrapper may have a length of between 14 millimetres and 30 millimetres. The tipping wrapper may have a length of between 14 millimetres and 26 millimetres. The tipping wrapper may have a length of between 14 millimetres and 22 millimetres.

[0366] The tipping wrapper may have a length of between 16 millimetres and 30 millimetres. The tipping wrapper may have a length of between 16 millimetres and 26 millimetres. The tipping wrapper may have a length of between 16 millimetres and 22 millimetres.

[0367] The tipping wrapper may have a length of between 18 millimetres and 30 millimetres. The tipping wrapper may have a length of between 18 millimetres and 26 millimetres. The tipping wrapper may have a length of between 18 millimetres and 22 millimetres.

[0368] The tipping wrapper preferably has a length of 20 millimetres.

[0369] The ventilation zone may be provided at a location along the tipping wrapper. Where the ventilation zone is at a location along the tipping wrapper, the ventilation zone may comprise a plurality of openings or perforations through the tipping wrapper.Where the ventilation zone is at a location along both the tipping wrapper and the second hollow tubular element, the ventilation zone may comprise a plurality of openings or perforations through the tipping wrapper and the peripheral wall of the second hollow tubular element, the plurality of openings or perforations through the tipping wrapper being aligned with the perforations through the peripheral wall of the second hollow tubular element.

[0370] The aerosol-generating article may comprise a mouthpiece wrapper circumscribing the mouthpiece element. The aerosol-generating article may comprise a mouthpiece wrapper circumscribing the mouthpiece element along the entire length of the mouthpiece element.

[0371] The aerosol-generating article may comprise a mouthpiece wrapper circumscribing the plug portion and the tubular portion. The aerosol-generating article may comprise a mouthpiece wrapper circumscribing the plug portion along the entire length of the plug portion, and circumscribing the tubular portion along the entire length of the tubular portion

[0372] The mouthpiece wrapper may extend from the upstream end of the mouthpiece element to the downstream end of the mouthpiece element.

[0373] The mouthpiece wrapper may extend from the upstream end of the plug portion to the downstream end of the tubular portion.

[0374] The mouthpiece wrapper may extend from the upstream end of the tubular portion to the downstream end of the plug portion.

[0375] The mouthpiece wrapper may have a length of at least 8 millimetres. The mouthpiece wrapper may have a length of at least 10 millimetres. The mouthpiece wrapper may have a length of at least 12 millimetres.

[0376] The mouthpiece wrapper may have a length of less than or equal to 16 millimetres. The mouthpiece wrapper may have a length of less than or equal to 14 millimetres. The mouthpiece wrapper may have a length of less than or equal to 12 millimetres.

[0377] The mouthpiece wrapper may have a length of between 8 millimetres and 16 millimetres. The mouthpiece wrapper may have a length of between lOmillimetres and 14 millimetres.

[0378] The mouthpiece wrapper may have a length that is the same length as the mouthpiece element.

[0379] The present disclosure also relates to an aerosol-generating system comprising an aerosol-generating article as described above and an aerosol-generating device, wherein the aerosol-generating device comprises a heating arrangement configured to heat at least a portion of the aerosol-generating substrate to generate an aerosol.

[0380] The heating arrangement may be a resistive heating arrangement or an inductive heating arrangement.

[0381] Below, there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, or embodiment, or aspect described herein.

[0382] EX1. An aerosol-generating article comprising:a substrate element comprising an aerosol-generating substrate, the aerosolgenerating substrate comprising one or more aerosol formers; and

[0383] a downstream section provided downstream of the substrate element, the downstream section comprising:

[0384] a mouthpiece element, the mouthpiece element comprising a tubular portion and a plug portion,

[0385] wherein the aerosol-generating substrate has an aerosol former content of greater than 30 percent by weight,

[0386] wherein the mouthpiece element is provided at a downstream end of the aerosolgenerating article.

[0387] EX2. An aerosol-generating article according to example EX1, wherein the tubular portion and the plug portion are formed separately.

[0388] EX3. An aerosol-generating article according to example EX1 or example EX2, wherein the tubular portion abuts the plug portion.

[0389] EX4. An aerosol-generating article according to example EX3, wherein a downstream end of the tubular portion abuts an upstream end of the plug portion.

[0390] EX5. An aerosol-generating article according to example EX3, wherein a downstream end of the plug portion abuts an upstream end of the tubular portion.

[0391] EX6. An aerosol-generating article according to any preceding example, wherein the tubular portion is attached to the plug portion.

[0392] EX7. An aerosol-generating article according to example EX3, wherein a downstream end of the tubular portion is attached to an upstream end of the plug portion.

[0393] EX8. An aerosol-generating article according to example EX3, wherein a downstream end of the plug portion is attached to an upstream end of the tubular portion.

[0394] EX9. An aerosol-generating article according to example EX1 , wherein the mouthpiece element is formed as a unitary element.

[0395] EX10. An aerosol-generating article according to any preceding example, wherein the mouthpiece element has a length of less than or equal to 20 millimetres.

[0396] EX11. An aerosol-generating article according to any preceding example, wherein the mouthpiece element has a length of less than or equal to 15 millimetres.

[0397] EX12. An aerosol-generating article according to any preceding example, wherein the mouthpiece element has a length of greater than 8 millimetres.

[0398] EX13. An aerosol-generating article according to any preceding example, wherein the mouthpiece element has a length of greater than 10 millimetres.

[0399] EX14. An aerosol-generating article according to any preceding example, wherein the mouthpiece element has a length of between 8 millimetres and 20 millimetres.

[0400] EX15. An aerosol-generating article according to any preceding example, wherein the tubular portion has a length of greater than 4 millimetres.EX16. An aerosol-generating article according to any preceding example, wherein the tubular portion has a length of greater than 4.5 millimetres.

[0401] EX17. An aerosol-generating article according to any preceding example, wherein the tubular portion has a length of less than or equal to 7 millimetres.

[0402] EX18. An aerosol-generating article according to any preceding example, wherein the tubular portion has a length of less than or equal to 6.5 millimetres.

[0403] EX19. An aerosol-generating article according to any preceding example, wherein the tubular portion has a length of between 4 millimetres and 7 millimetres.

[0404] EX20. An aerosol-generating article according to any preceding example, wherein the plug portion has a length of greater than 5 millimetres.

[0405] EX21. An aerosol-generating article according to any preceding example, wherein the plug portion has a length of greater than 5.5 millimetres.

[0406] EX22. An aerosol-generating article according to any preceding example, wherein the plug portion has a length of less than or equal to 9 millimetres.

[0407] EX23. An aerosol-generating article according to any preceding example, wherein the plug portion has a length of less than or equal to 8.5 millimetres.

[0408] EX24. An aerosol-generating article according to any preceding example, wherein the plug portion has a length of between 5 millimetres and 9 millimetres.

[0409] EX25. An aerosol-generating article according to any preceding example, wherein the tubular portion has a length that is greater than the length of the plug portion.

[0410] EX26. An aerosol-generating article according to any preceding example, wherein the tubular portion has an internal diameter of greater than 2.5 millimetres.

[0411] EX27. An aerosol-generating article according to any preceding example, wherein the tubular portion has an internal diameter of less than or equal to 4.5 millimetres.

[0412] EX28. An aerosol-generating article according to any preceding example, wherein the tubular portion has an internal diameter of less than or equal to 3.5 millimetres.

[0413] EX29. An aerosol-generating article according to any preceding example, wherein the tubular portion has an internal diameter of between 2.5 millimetres and 4.5 millimetres.

[0414] EX30. An aerosol-generating system comprising an aerosol-generating article according to any preceding example and an aerosol-generating device, wherein the aerosol-generating device comprises a heating arrangement configured to heat at least a portion of the aerosol-generating substrate to generate an aerosol.

[0415] Examples will now be further described with reference to the figures in which:

[0416] Figure 1 shows a schematic side sectional view of an aerosol-generating article according to a first example of the present disclosure;

[0417] Figure 2 shows a schematic side sectional view of an aerosol-generating article according to a second example of the present disclosure;Figure 3 shows a schematic side sectional view of an aerosol-generating article according to a third example of the present disclosure;

[0418] Figure 4 shows a schematic side sectional view of an aerosol-generating article according to a fourth example of the present disclosure;

[0419] Figure 5 shows a schematic side sectional view of an aerosol-generating article according to a fifth example of the present disclosure;

[0420] Figure 6 shows a schematic side sectional view of an aerosol-generating article according to a sixth example of the present disclosure;

[0421] Figure 7 shows a schematic side sectional view of an aerosol-generating article according to a seventh example of the present disclosure; and

[0422] Figure 8 shows a schematic side sectional view of an aerosol-generating system including the aerosol-generating article of Figure 1.

[0423] Figure 1 shows an aerosol-generating article 100 comprising a substrate element and a downstream section 14 at a location downstream of the substrate element. In the example of Figure 1, the substrate element is a rod of aerosol-generating substrate 12.

[0424] The aerosol-generating article 100 comprises an upstream section at a location upstream of the rod of aerosol-generating substrate 12.

[0425] The aerosol-generating article 100 extends from an upstream or distal end 16 to a downstream or proximal end 18. The downstream section 14 extends from the downstream end of the rod of aerosol-generating substrate 12 to the downstream end 18 of the aerosol-generating article 100. The upstream section extends from the upstream end 16 of the aerosol-generating article 100 to the upstream end of the rod of aerosol-generating substrate 12.

[0426] The aerosol-generating article has an overall length of about 45 millimetres and an external diameter of about 7.3 millimetres.

[0427] The aerosol-generating substrate in the rod of aerosol-generating substrate 12 is a solid aerosol-generating substrate. In the example of Figure 1, the aerosol-generating substrate comprises 50.37 percent by weight of glycerine, 22.39 percent by weight of hydroxypropylmethyl cellulose, 16.79 percent by weight of cellulose fibres, 5.6 percent by weight of sodium carboxymethyl cellulose, 3.45 percent by weight of lactic acid, and 1.4 percent by weight of nicotine.

[0428] The rod of aerosol-generating substrate 12 has a length of about 12 millimetres and an external diameter of about 7.1 millimetres.

[0429] The aerosol-generating article 100 includes a susceptor 60. The susceptor 60 is positioned within the rod of aerosol-generating substrate 12 and extends all the way from the upstream end of the rod of aerosol-generating substrate 12 to the downstream end of the rod of aerosolgenerating substrate 12. In effect, the susceptor 60 has substantially the same length as the rod of aerosol-generating substrate 12.The susceptor 60 is provided in the form of a strip and has a length of about 12 millimetres, a thickness of about 60 micrometres, and a width of about 4 millimetres.

[0430] The downstream section 14 includes a first hollow tubular element 20 and a second hollow tubular element 22. The second hollow tubular element 22 is located downstream of the first hollow tubular element 20. The downstream section 14 also includes a mouthpiece element 24 located downstream of the second hollow tubular element 22.

[0431] The first hollow tubular element 20 is in longitudinal alignment with the rod of aerosolgenerating substrate 12 and extends from the downstream end of the rod of aerosol-generating substrate 12 to the upstream end of the second hollow tubular element 22. The first hollow tubular element 20 abuts the downstream end of the rod of aerosol-generating substrate 12 and the upstream end of the second hollow tubular element 22.

[0432] The first hollow tubular element 20 is provided in the form of a hollow cylindrical tube and defines a hollow section of the aerosol-generating article 100. The first hollow tubular element 20 defines an internal cavity 26 that extends all the way from the upstream end of the first hollow tubular element 20 to the downstream end of the first hollow tubular element 20. The internal diameter of the first hollow tubular element 20 is substantially constant along the entire length of the first hollow tubular element 20. Accordingly, the internal cavity 26 of the first hollow tubular element 20 has a substantially constant diameter along the entire length of the first hollow tubular element 20.

[0433] The internal cavity 26 is substantially empty, and so substantially unrestricted airflow is enabled along the internal cavity 26. The first hollow tubular element 20 does not substantially contribute to the overall resistance to draw of the aerosol-generating article 100.

[0434] The first hollow tubular element 20 has a length of about 8 millimetres, an external diameter of about 7.2 millimetres, and a wall thickness of about 1.5 millimetres.

[0435] In the example of Figure 1, the first hollow tubular element 20 is formed from cellulose acetate.

[0436] The second hollow tubular element 22 is in longitudinal alignment with the rod of aerosolgenerating substrate 12 and extends from the downstream end of the first hollow tubular element 20 to the upstream end of the mouthpiece element 24. The second hollow tubular element 22 abuts the downstream end of the first hollow tubular element 20 to the upstream end of the mouthpiece element 24.

[0437] The second hollow tubular element 22 is provided in the form of a hollow cylindrical tube and defines a hollow section of the aerosol-generating article 100. The second hollow tubular element 22 defines an internal cavity 28 that extends all the way from the upstream end of the second hollow tubular element 22 to the downstream end of the second hollow tubular element 22. The internal diameter of the second hollow tubular element 22 is substantially constant along the entire length of the second hollow tubular element 22. Accordingly, the internal cavity 28 of thesecond hollow tubular element 22 has a substantially constant diameter along the entire length of the second hollow tubular element 22.

[0438] The internal cavity 28 is substantially empty, and so substantially unrestricted airflow is enabled along the internal cavity 28. The second hollow tubular element 22 does not substantially contribute to the overall resistance to draw of the aerosol-generating article 100.

[0439] The second hollow tubular element 22 has a length of about 8 millimetres, an external diameter of about 7.2 millimetres, and a wall thickness of about 240 micrometres.

[0440] In the example of Figure 1 , the second hollow tubular element 22 is formed from cellulose acetate.

[0441] The aerosol-generating article 100 has a ventilation zone 30 provided at a location along the second hollow tubular element 22. In more detail, the ventilation zone 30 is provided at about 18 millimetres from the downstream end 18 of the aerosol-generating article 100. The ventilation zone 30 is provided at about 6 millimetres upstream from the downstream end of the second hollow tubular element 22 and about 10 millimetres downstream from the upstream end of the first hollow tubular element 20. The ventilation zone 30 comprises a circumferential row of openings or perforations circumscribing the second hollow tubular element 22. The perforations of the ventilation zone 30 extend through the wall of the second hollow tubular element 22 in order to allow fluid ingress into the internal cavity 28 from the exterior of the aerosol-generating article 100.

[0442] The mouthpiece element 24 is in longitudinal alignment with the second hollow tubular element 22 and abuts the downstream end of the second hollow tubular element 22. In particular, the mouthpiece element 24 extends from the downstream end of the second hollow tubular element 22 to the downstream end 18 of the aerosol-generating article 100.

[0443] The mouthpiece element 24 has a length of about 12 millimetres and an external diameter of about 7.2 millimetres.

[0444] The mouthpiece element 24 has a tubular portion 32 and a plug portion 34.

[0445] The tubular portion 32 is hollow and cylindrical defines an internal cavity 36 that extends all the way from the upstream end of the tubular portion 32 to the downstream end of the tubular portion 32. The internal diameter of the tubular portion 32 is substantially constant along the entire length of the tubular portion 32. Accordingly, the internal cavity 36 of the tubular portion 32 has a substantially constant diameter along the entire length of the tubular portion 32.

[0446] The internal cavity 36 is substantially empty, and so substantially unrestricted airflow is enabled along the internal cavity 36. The tubular portion 32 does not substantially contribute to the overall resistance to draw of the aerosol-generating article 100.

[0447] The tubular portion 32 has a length of about 5 millimetres, an external diameter of about 7.2 millimetres, and a wall thickness of about 750 micrometres.

[0448] The plug portion 34 is not tubular and is instead solid. The plug portion 34 acts as a filter segment. In this example, the plug portion 34 is formed of a fibrous filtration material.The plug portion 34 does substantially contribute to the overall resistance to draw of the aerosol-generating article 100.

[0449] The plug portion 34 has a length of about 7 millimetres and an external diameter of about 7.0 millimetres.

[0450] The plug portion 34 is in longitudinal alignment with the tubular portion 32.

[0451] In the example shown in Figure 1 , the tubular portion 32 and the plug portion 34 are formed as separate elements and are then attached together to form the mouthpiece element 24. A mouthpiece element wrapper (not shown) may be provided to assist the connection between the tubular portion 32 and the plug portion 34.

[0452] In the aerosol-generating article 100 shown in Figure 1, the plug portion 34 is located downstream of the tubular portion 32. An upstream end of the plug portion 34 abuts a downstream end of the tubular portion 32.

[0453] The upstream section comprises an upstream element 38. The upstream element 38 is in longitudinal alignment with the rod of aerosol-generating substrate 12 and abuts the upstream end of the rod of aerosol-generating substrate 12. In particular, the upstream element 38 extends from the upstream end 16 of the aerosol-generating article 100 to the upstream end of the rod of aerosolgenerating substrate 12.

[0454] The upstream element 38 is in the form of a solid plug. The upstream element 38 has a length of about 5 millimetres and an external diameter of about 7.1 millimetres.

[0455] The aerosol-generating article 100 also includes a wrapper 40 circumscribing components of the aerosol-generating article 100. The wrapper 40 circumscribes the upstream element 38 along the entire length of the upstream element 38, the rod of aerosol-generating substrate 12 along the entire length of the rod of aerosol-generating substrate 12, the first hollow tubular element 20 along the entire length of the first hollow tubular element 20, and the second hollow tubular element 22 along the entire length of second hollow tubular element 22. In this way, the wrapper 40 joins the upstream element 38, the rod of aerosol-generating substrate 12, the first hollow tubular element 20 and the second hollow tubular element 22 together.

[0456] The wrapper 40 extends from the upstream end 16 of the aerosol-generating article 100 to a downstream end of the second hollow tubular element 22.

[0457] The wrapper 40 has a length of about 45 millimetres.

[0458] The aerosol-generating article 100 also comprises a tipping wrapper 42 circumscribing the second hollow tubular element 22 along the entire length of the second hollow tubular element 22 and the mouthpiece element 24 along the entire length of the mouthpiece element 24. In this way, the tipping wrapper 42 joins the mouthpiece element 24 to the second hollow tubular element 22. The tipping wrapper 42 extends from the downstream end of the mouthpiece element 24 (which corresponds to the downstream end 18 of the aerosol-generating article 100) to an upstream end of the second hollow tubular element 22.

[0459] The tipping wrapper 42 has a length of about 20 millimetres.The tipping wrapper 42 overlies the wrapper 40 over the second hollow tubular element 22. In the example of Figure 1, the tipping wrapper 42 overlies the wrapper 40 over the entire length of the second hollow tubular element 22.

[0460] In some examples, the ventilation zone 30 may have a circumferential row of perforations provided on the wrapper 40 and the tipping wrapper 42. The perforations of the wrapper 40 and the tipping wrapper 42 overlap the perforations provided on the second hollow tubular element 22. Accordingly, the wrapper 40 and the tipping wrapper 42 overlie the perforations of the ventilation zone 30 provided on the second hollow tubular element 22.

[0461] Advantageously, providing the plug portion 34 downstream of the tubular portion 32 may provide structural resistance to deformation of the mouth end of the article during use, for example, by a user’s lips. A mouthpiece element being formed from separate tubular and plug portions may more readily ensure the use of existing manufacturing and assembly processes as well as existing components in order to form such a mouthpiece element having different portions and maintain manufacturing uniformity.

[0462] Figure 2 shows an aerosol-generating article 200 in accordance with a second example of the present disclosure.

[0463] The aerosol-generating article 200 shown in Figure 2 is substantially similar to the aerosolgenerating article 100 shown in Figure 1 and the same reference numerals are used to designate like parts.

[0464] The aerosol-generating article 200 shown in Figure 2 differs from the aerosol-generating article 100 shown in Figure 1 in that instead of the plug portion 34 being located downstream of the tubular portion 32, the tubular portion 32 is located downstream of the plug portion 34. An upstream end of the tubular portion 32 abuts a downstream end of the plug portion 34.

[0465] Advantageously, providing the tubular portion 32 downstream of the plug portion 34 may provide a cooler mouth end of the aerosol-generating article during use and reduce the risk of a user’s sensitive tissues, such as their lips, entering into contact with a mouth end that may be uncomfortably warm or hot. A mouthpiece element being formed from separate tubular and plug portions may more readily ensure the use of existing manufacturing and assembly processes as well as existing components in order to form such a mouthpiece element having different portions and maintain manufacturing uniformity.

[0466] Figure 3 shows an aerosol-generating article 300 in accordance with a third example of the present disclosure.

[0467] The aerosol-generating article 300 shown in Figure 3 is substantially similar to the aerosolgenerating article 100 shown in Figure 1 and the same reference numerals are used to designate like parts.

[0468] The aerosol-generating article 300 shown in Figure 3 differs from the aerosol-generating article 100 shown in Figure 1 in that instead of the tubular portion 32 and the plug portion 34 beingformed separately and attached to one another, the tubular portion 32 and the plug portion 34 are formed as a single element.

[0469] In one example, the mouthpiece element 24 is initially formed as complete cylinder and then the internal cavity 36 is formed by drilling into the mouthpiece element 24.

[0470] Advantageously, forming the tubular portion and the plug portion together as a unitary or single mouthpiece element 24 (as shown in Figures 3, 4 and 5) may minimise the risk of airflow or aerosol leakage along the mouthpiece element 24, while also rendering the assembly process of the aerosol-generating article more efficient by reducing the number of separate components required.

[0471] Figure 4 shows an aerosol-generating article 400 in accordance with a fourth example of the present disclosure.

[0472] The aerosol-generating article 400 shown in Figure 4 is substantially similar to the aerosolgenerating articles 200, 300 shown in Figures 2 and 3 and the same reference numerals are used to designate like parts.

[0473] The aerosol-generating article 400 shown in Figure 4 differs from the aerosol-generating article 200 shown in Figure 2 in that instead of the tubular portion 32 and the plug portion 34 being formed separately and attached to one another, the tubular portion 32 and the plug portion 34 are formed as a single element. The aerosol-generating article 400 shown in Figure 4 differs from the aerosol-generating article 300 shown in Figure 3 in that instead of the plug portion 34 being located downstream of the tubular portion 32, the tubular portion 32 is located downstream of the plug portion 34. An upstream end of the tubular portion 32 abuts a downstream end of the plug portion 34.

[0474] Advantageously, forming the tubular portion and the plug portion together as a unitary or single mouthpiece element 24 (as shown in Figures 3, 4 and 5) may minimise the risk of airflow or aerosol leakage along the mouthpiece element 24, while also rendering the assembly process of the aerosol-generating article more efficient by reducing the number of separate components required. As mentioned in the context of Figure 2, providing the tubular portion 32 downstream of the plug portion 34 may provide a cooler mouth end of the aerosol-generating article during use and reduce the risk of a user’s sensitive tissues, such as their lips, entering into contact with a mouth end that may be uncomfortably warm or hot.

[0475] Figure 5 shows an aerosol-generating article 500 in accordance with a fifth example of the present disclosure.

[0476] The aerosol-generating article 500 shown in Figure 5 is substantially similar to the aerosolgenerating article 300 shown in Figure 3 and the same reference numerals are used to designate like parts.

[0477] The aerosol-generating article 500 shown in Figure 5 differs from the aerosol-generating article 300 shown in Figure 3 in that the downstream section 14 comprises a single hollow tubular element 20 or first hollow tubular element 20 extending from the rod of aerosol-generatingsubstrate 12 to the mouthpiece element 24. Similarly, the first hollow tubular element 20 is provided in the form of a hollow cylindrical tube and defines a hollow section of the aerosol-generating article 100. The first hollow tubular element 20 defines an internal cavity 26 that extends all the way from the upstream end of the first hollow tubular element 20 to the downstream end of the first hollow tubular element 20. The internal diameter of the first hollow tubular element 20 is substantially constant along the entire length of the first hollow tubular element 20. Accordingly, the internal cavity 26 of the first hollow tubular element 20 has a substantially constant diameter along the entire length of the first hollow tubular element 20.

[0478] The internal cavity 26 is substantially empty, and so substantially unrestricted airflow is enabled along the internal cavity 26. The first hollow tubular element 20 does not substantially contribute to the overall resistance to draw of the aerosol-generating article 100.

[0479] The first hollow tubular element 20 has a length of about 16 millimetres, an external diameter of about 7.2 millimetres, and a wall thickness of about 240 micrometres.

[0480] In the example of Figure 5, the first hollow tubular element 20 is formed from cardboard. The ventilation zone 30 is instead provided at a location along the first hollow tubular element 20. In more detail, the ventilation zone 30 is provided at about 18 millimetres from the downstream end 18 of the aerosol-generating article 100. The ventilation zone 30 is provided at about 6 millimetres upstream from the downstream end of the first hollow tubular element 20 (or upstream end of the mouthpiece element 24) and about 10 millimetres downstream from the upstream end of the first hollow tubular element 20. The ventilation zone 30 comprises a circumferential row of openings or perforations circumscribing the first hollow tubular element 20. The perforations of the ventilation zone 30 extend through the wall of the first hollow tubular element 20 in order to allow fluid ingress into the internal cavity 26 from the exterior of the aerosolgenerating article 100.

[0481] The mouthpiece element 24 abuts the downstream end of the first hollow tubular element 20. In particular, the mouthpiece element 24 extends from the downstream end of the first hollow tubular element 20 to the downstream end 18 of the aerosol-generating article 100.

[0482] The wrapper 40 circumscribes the upstream element 38 along the entire length of the upstream element 38, the rod of aerosol-generating substrate 12 along the entire length of the rod of aerosol-generating substrate 12, and the first hollow tubular element 20 along the entire length of the first hollow tubular element 20. In this way, the wrapper 40 joins the upstream element 38, the rod of aerosol-generating substrate 12, and the first hollow tubular element 20 together.

[0483] The wrapper 40 extends from the upstream end 16 of the aerosol-generating article 100 to a downstream end of the first hollow tubular element 20.

[0484] The tipping wrapper 42 instead circumscribes the first hollow tubular element 20 along a portion of the length of the first hollow tubular element 20 and the mouthpiece element 24 along the entire length of the mouthpiece element 24. In this way, the tipping wrapper 42 joins the mouthpiece element 24 to the first hollow tubular element 22. The tipping wrapper 42 extends fromthe downstream end of the mouthpiece element 24 (which corresponds to the downstream end 18 of the aerosol-generating article 100) to a location along the hollow tubular element 20, between its upstream and downstream ends.

[0485] Advantageously, the aerosol-generating article 500 shown in Figure 5 provides the same advantages as the aerosol-generating article 300 shown in Figure 3, while improving on its biodegradability and manufacturing efficiency by providing one single, relatively long, cardboard hollow tubular element 20.

[0486] Although not shown in the figures, the single, relatively long, cardboard hollow tubular element 20 shown in Figure 5 can also replace the dual hollow tubular element arrangements shown in Figures 1 , 2 and 4.

[0487] Figure 6 shows an aerosol-generating article 600 in accordance with a sixth example of the present disclosure.

[0488] The aerosol-generating article 600 shown in Figure 6 is substantially similar to the aerosolgenerating article 100 shown in Figure 1 and the same reference numerals are used to designate like parts.

[0489] The aerosol-generating article of Figure 5 differs from the aerosol-generating article 100 shown in Figure 1 in that the mouthpiece element 24 comprises an internal hollow tubular element 44.

[0490] The internal hollow tubular element 44 is located within the internal cavity 36 of the tubular portion 32 of the mouthpiece element 24 and extends from an upstream end of the tubular portion 32 to a downstream end of the tubular portion 32. The internal hollow tubular element 44 may be attached to the internal surface of the tubular portion 32, for example by use of an adhesive.

[0491] Advantageously, the aerosol-generating article 600 shown in Figure 6 provides the same advantages as the aerosol-generating article 100 shown in Figure 1 , while improving the structural integrity of the tubular portion 32.

[0492] Figure 7 shows an aerosol-generating article 700 in accordance with a seventh example of the present disclosure.

[0493] The aerosol-generating article 700 shown in Figure 7 is substantially similar to the aerosolgenerating article 300 shown in Figure 3 and the same reference numerals are used to designate like parts.

[0494] The aerosol-generating article of Figure 7 differs from the aerosol-generating article 300 shown in Figure 3 in that the mouthpiece element 24 comprises an internal hollow tubular element 44.

[0495] The internal hollow tubular element 44 is located within the internal cavity 36 of the tubular portion 32 of the mouthpiece element 24 and extends from an upstream end of the tubular portion 32 to a downstream end of the tubular portion 32. The internal hollow tubular element 44 may be attached to the internal surface of the tubular portion 32, for example by use of an adhesive.Advantageously, the aerosol-generating article 700 shown in Figure 7 provides the same advantages as the aerosol-generating article 300 shown in Figure 3, while improving the structural integrity of the tubular portion 32.

[0496] Although not shown in the figures, the aerosol-generating articles 200, 400 shown in Figures 2 and 4 may also include a mouthpiece hollow tubular element 44 located within their tubular portion 32.

[0497] Figure 8 shows an aerosol-generating system 900 comprising the aerosol-generating article 100 shown in Figure 1 and an aerosol-generating device 800. Although Figure 8 shows aerosol-generating article 100 of Figure 1, any of aerosol-generating article derivable from the present disclosure, including aerosol-generating articles 100, 200, 300, 400, 500, 600, 700 shown in Figures 1 to 7, can be used in the aerosol-generating system 900 and with the aerosolgenerating device 800.

[0498] The aerosol-generating device 800 comprises a housing (or body) 801 , extending between a downstream end and an upstream end. The housing 801 defines a heating chamber 802 for receiving an aerosol-generating article 100. The heating chamber 802 is defined by a closed, upstream end and an open, downstream end. The downstream end of the heating chamber 802 is located at the downstream end of the aerosol-generating device 800. The aerosol-generating article 100 is configured to be received through the open, downstream end of the heating chamber 802 and is configured to abut a closed, upstream end of the heating chamber 802, when the aerosol-generating article 100 is fully received in the heating chamber 802.

[0499] The aerosol-generating device 800 further comprises a heater arrangement 803 and a power source 803 for supplying power to the heater arrangement 803. A controller (not shown) is also provided to control such supply of power to the heater arrangement 803. The heater arrangement 803 is configured to controllably heat the aerosol-generating article 100 during use, when the aerosol-generating article 100 is fully received within the heating chamber 802.

[0500] The heater arrangement 803 extends from an upstream end to a downstream end defining a heating zone. The heater arrangement 803 is substantially the same length as the rod of aerosolgenerating substrate 12 such that when the aerosol-generating article 100 is received within the heating chamber 802, the entire length of the rod of aerosol-generating substrate 12 is received within the heating zone to provide optimal heating of the rod of aerosol-generating substrate 12.

[0501] The ventilation zone 30 of the aerosol-generating article 100 is arranged to be exposed when the aerosol-generating article 100 is received within the heating chamber 802 of the aerosolgenerating device 800.

[0502] In the example of Figure 8, the heater arrangement 803 comprises an induction element. In use, the aerosol-generating article 100 is received within the heating chamber 802 of the aerosol-generating device 800. The heater arrangement 803 is activated by the controller and the induction element cooperates, as described previously, with the susceptor 60 in the aerosolgenerating article 100 to generate heat which is transferred directly to the aerosol-generatingsubstrate which is thermally coupled with the susceptor 60. This causes aerosol species to be released from the aerosol-generating substrate.

[0503] In other examples in which the aerosol-generating article does not comprise a susceptor, the heating arrangement 803 may be, for example, a resistive heating arrangement.

[0504] When a pressure drop is applied to the downstream end 18 of the aerosol-generating article 100, air is drawn into the heating chamber 802 via an air inlet 812 of the aerosol-generating device 800 and into the rod of aerosol-generating substrate 12 of the aerosol-generating article 100. The aerosol species released upon heating are entrained in the airflow which then passes through the downstream section 14 of the aerosol-generating article 100 before leaving through the downstream end 18 of the aerosol-generating article 100.

[0505] The specific embodiments and examples described above illustrate, but do not limit, the invention. It is to be understood that other embodiments of the invention may be made and the specific embodiments and examples described herein are not exhaustive.

[0506] 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 ± 5% 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.

Claims

-57- CLAIMS1. An aerosol-generating article comprising:a substrate element comprising an aerosol-generating substrate, the aerosolgenerating substrate comprising one or more aerosol formers; anda downstream section provided downstream of the substrate element, the downstream section comprising:a mouthpiece element, the mouthpiece element comprising a tubular portion and a plug portion,wherein the aerosol-generating substrate has an aerosol former content of greater than 30 percent by weight,wherein the mouthpiece element is provided at a downstream end of the aerosolgenerating article,wherein the tubular portion and the plug portion are formed as a unitary element.

2. An aerosol-generating article according to any preceding claim, wherein the mouthpiece element has a length of less than or equal to 20 millimetres.

3. An aerosol-generating article according to any preceding claim, wherein the mouthpiece element has a length of greater than 8 millimetres.

4. An aerosol-generating article according to any preceding claim, wherein the tubular portion has a length of greater than 4 millimetres.

5. An aerosol-generating article according to any preceding claim, wherein the tubular portion has a length of less than or equal to 7 millimetres.

6. An aerosol-generating article according to any preceding claim, wherein the plug portion has a length of greater than 5 millimetres.

7. An aerosol-generating article according to any preceding claim, wherein the plug portion has a length of less than or equal to 9 millimetres.

8. An aerosol-generating article according to any preceding claim, wherein the tubular portion has a length that is greater than the length of the plug portion.

9. An aerosol-generating article according to any preceding claim, wherein the tubular portion has an internal diameter of greater than 2.5 millimetres.

10. An aerosol-generating article according to any preceding claim, wherein the tubular portion has an internal diameter of less than or equal to 4.5 millimetres.

11. An aerosol-generating article according to any preceding claim, wherein the mouthpiece element comprises an internal tubular element.

12. An aerosol-generating article according to claim 11, wherein the internal tubular element comprises a hollow cylindrical tube.

13. An aerosol-generating article according to claim 11 or claim 12, wherein the internal tubular element comprises a cellulosic material.

14. An aerosol-generating article according to any one of claims 11 to 13, wherein the tubular portion defines an internal cavity and the internal tubular element is located within the internal cavity of the tubular portion.

15. An aerosol-generating article according to any one of claims 11 to 14, wherein the internal tubular element is attached to an internal surface of the mouthpiece element.

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