Aerosol-generating article for use with an aerosol-generating device

Abstract

An aerosol-generating article (10) comprises: an aerosol-forming substrate (20); a support element (30) arranged immediately downstream of the aerosol-forming substrate (20); an aerosol-cooling element (40) arranged downstream of the support element (30); and an outer wrapper (60) confining the aerosol-forming substrate (20), the support element (30), and the aerosol-cooling element (40). The support element (30) is adjacent to the aerosol-forming substrate (20). The aerosol-forming substrate (20) is penetrable by a heating element (110) of an aerosol-generating device (120).

Description

[0001] The present application is a divisional application of an invention patent application entitled “Aerosol-generating article for use with an aerosol-generating device”, with an international application date of December 28, 2012, an international application number of PCT / EP2012 / 077077, and a national application number of 201280061528.9. Technical Field

[0002] The present disclosure relates to an aerosol-generating article comprising an aerosol-forming substrate for generating an inhalable aerosol when heated by a heating element of an aerosol-generating device. The present disclosure also relates to a method of using such an aerosol-generating article. Background Art

[0003] A variety of smoking articles have been proposed in the art in which tobacco is heated rather than burned. One goal of such heated smoking articles is to reduce known harmful smoke components of the type produced by the combustion and pyrolytic degradation of tobacco in conventional cigarettes.

[0004] Typically in such heated smoking articles, an aerosol is generated by heat transfer from a heat source to a physically separate aerosol-forming substrate or material, which may be arranged within, around, or downstream of the heat source. During smoking, volatile compounds are released from the aerosol-forming substrate by heat transfer from the heat source and are entrained in the air drawn through the smoking article. As the released compounds cool, they condense to form an aerosol that is inhaled by the user.

[0005] Several prior art documents disclose aerosol-generating devices for consuming or smoking heated smoking articles. Such devices include, for example, electrically heated aerosol-generating devices, in which aerosol is generated by heat transfer from one or more electrical heating elements of the aerosol-generating device to an aerosol-forming substrate of the heated smoking article. One advantage of such electrically heated smoking systems is that they significantly reduce sidestream smoke while allowing users to selectively pause and resume smoking.

[0006] An example of an electrically heated cigarette used in an electrical smoking system is disclosed in US 2005 / 0172976 A1. The electrically heated cigarette is configured to be inserted into a cigarette receptacle of a reusable lighter in the electrical smoking system. The lighter includes an energy source that supplies energy to a heater fixture comprising a plurality of resistive heating elements arranged to slideably receive the cigarette, such that the heating elements are positioned adjacent to the cigarette. The electrically heated cigarette used in the electrical smoking system disclosed in US 2005 / 0172976 A1 can provide energy to the electrically heated cigarette by using pulse heating.

[0007] As described above, the electrically heated cigarette disclosed in US 2005 / 0172976 A1 is used in an electrical smoking system that includes multiple external heating elements. Electrical smoking systems that include an aerosol-generating device with an internal heating element are also known. During use, the internal heating element of the aerosol-generating device of such an electrical smoking system is inserted into the aerosol-forming substrate of the heated smoking article, so that the internal heating element is in direct contact with the aerosol-forming substrate.

[0008] Direct contact between the internal heating element of the aerosol-generating device and the aerosol-forming substrate of the heated smoking article can provide an efficient device for heating the aerosol-forming substrate to form an inhalable aerosol. In such a configuration, when the internal heating element is actuated, the heat from the internal heating element can be almost instantaneously transferred to at least a portion of the aerosol-forming substrate, and this can promote the rapid generation of aerosol. In addition, the overall heating energy required to generate aerosol can be lower than in a smoking system including an external heating element, in which the aerosol-forming substrate does not directly contact the external heating element, and the initial heating of the aerosol-forming substrate occurs by convection or radiation. In the case where the internal heating element of the aerosol-generating device is in direct contact with the aerosol-forming substrate, the initial heating of the parts of the aerosol-forming substrate will be achieved by conduction, which parts are in direct contact with the internal heating element. Summary of the Invention

[0009] The present disclosure relates to an aerosol-generating article and a method of using an aerosol-generating article. In particular, the present disclosure relates to an aerosol-generating article comprising an aerosol-forming substrate for generating an inhalable aerosol when heated by an internal heating element of an aerosol-generating device. The present disclosure also relates to a method of using such an aerosol-generating article with an aerosol-generating device comprising an internal heating element.

[0010] According to a first aspect, there is provided an aerosol-generating article for use in an aerosol-generating system, the aerosol-generating system comprising an electrically heated aerosol-generating device, the aerosol-generating device comprising an internal heating element. The aerosol-generating article comprises, arranged in a linear sequence, an aerosol-forming substrate; a support element disposed immediately downstream of the aerosol-forming substrate; an aerosol-cooling element disposed downstream of the support element; and an outer wrapper circumscribing the aerosol-forming substrate, the support element, and the aerosol-cooling element. The support element is adjacent to the aerosol-forming substrate. The aerosol-forming substrate is penetrable by the heating element of the aerosol-generating device.

[0011] According to a second aspect, there is provided a method of using an aerosol-generating article according to the first aspect via an aerosol-generating device, the aerosol-generating device comprising a heating element. The method comprises the steps of: inserting the heating element of the aerosol-generating device into an aerosol-forming substrate of the aerosol-generating article; increasing the temperature of the heating element of the aerosol-generating device to heat the aerosol-forming substrate of the aerosol-generating article to generate aerosol; and removing the heating element of the aerosol-generating device from the aerosol-forming substrate of the aerosol-generating article.

[0012] According to a third aspect, an aerosol-generating system is provided, comprising: an aerosol-generating device including a heating element; and an aerosol-generating article for use with the aerosol-generating device. The aerosol-generating article comprises: an aerosol-forming substrate; a support element disposed immediately downstream of the aerosol-forming substrate; an aerosol-cooling element disposed downstream of the support element; and an outer wrapper confining the aerosol-forming substrate, the support element, and the aerosol-cooling element. The support element is adjacent to the aerosol-forming substrate. The aerosol-forming substrate is penetrable by the heating element of the aerosol-generating device.

[0013] According to a fourth aspect, there is provided a method of using the aerosol-generating system according to the third aspect. The method comprises the steps of: inserting a heating element of an aerosol-generating device into an aerosol-forming substrate of an aerosol-generating article; increasing the temperature of the heating element of the aerosol-generating device to heat the aerosol-forming substrate of the aerosol-generating article to generate aerosol; and removing the heating element of the aerosol-generating device from the aerosol-forming substrate of the aerosol-generating article.

[0014] As used herein, the term 'aerosol-forming substrate' is used to describe a substrate that is capable of releasing volatile compounds upon heating, which volatile compounds can form an aerosol. The aerosol generated by the aerosol-forming substrate of the aerosol-generating articles described herein may be visible or invisible and may include vapor (e.g., fine particles of a substance that is typically liquid or solid at room temperature, in a gaseous state) as well as droplets of gas and condensed vapor.

[0015] As used herein, the terms 'upstream' and 'downstream' are used to describe the relative position of elements, or parts of elements, of an aerosol-generating article with respect to the direction in which a user draws on the aerosol-generating article during use thereof.

[0016] The aerosol-generating article comprises two ends: a proximal end and a distal end, through which the aerosol leaves the aerosol-generating article and is delivered to a user. In use, the user can draw suction on the proximal end in order to inhale the aerosol generated by the aerosol-generating article.

[0017] The proximal end may also be referred to as the mouth end or the downstream end, and is downstream of the distal end. The distal end may also be referred to as the upstream end, and is upstream of the proximal end.

[0018] As used herein, the term 'aerosol-cooling element' is used to describe an element having a large surface area and low resistance to draw. In use, an aerosol formed from volatile compounds released from an aerosol-forming substrate passes through the aerosol-cooling element before being inhaled by a user and is cooled by the aerosol-cooling element. In contrast to high-resistance-to-draw filters and other mouthpieces, aerosol-cooling elements have low resistance to draw. Chambers and cavities in aerosol-generating articles are not considered to be aerosol-cooling elements.

[0019] Preferably, the aerosol-generating article is a smoking article that generates an aerosol that is inhalable directly into the user's lungs through the user's mouth. More preferably, the aerosol-generating article is a smoking article that generates a nicotine-containing aerosol that is inhalable directly into the user's lungs through the user's mouth.

[0020] As used herein, the term 'aerosol-generating device' is used to describe a device that interacts with an aerosol-forming substrate of an aerosol-generating article to generate an aerosol. Preferably, the aerosol-generating device is a smoking device that interacts with the aerosol-forming substrate of an aerosol-generating article to generate an aerosol that is directly inhalable into the user's lungs through the user's mouth. The aerosol-generating device may be a mouthpiece (holder) for a smoking article.

[0021] For the avoidance of doubt, in the following description the term 'heating element' is used to refer to one or more heating elements.

[0022] In preferred embodiments, the aerosol-forming substrate is arranged at the upstream end of the aerosol-generating article.

[0023] In an alternative embodiment, the aerosol-generating article may comprise a front-plug upstream of the aerosol-forming substrate, wherein the front-plug is penetrable by the heating element of the aerosol-generating device.In such an alternative embodiment, the front-plug may be arranged at the upstream end of the aerosol-generating article.

[0024] In such an embodiment, the front plug may prevent the aerosol-forming substrate from exiting the upstream end of the aerosol-forming substrate during handling and shipping. The front plug may also help position the aerosol-forming substrate at a predetermined distance from the upstream end of the aerosol-forming substrate for optimal engagement with the heating element of the aerosol-generating device.

[0025] The front plug can be configured to prevent the aerosol-forming substrate from exiting the aerosol-generating article during use, for example when the heating element of the aerosol-generating device exits the aerosol-generating article. The aerosol-forming substrate of the aerosol-generating article can be contracted to contact the heating element of the aerosol-generating device during the heating of the aerosol-forming substrate to produce aerosol. The aerosol-forming substrate can also be contracted to reduce its contact with an external wrapper that limits the components of the aerosol-generating article. This may cause the aerosol-forming substrate in the aerosol-generating article to relax. The inclusion of the front plug can facilitate the removal of the heating element from the aerosol-generating article by preventing the aerosol-forming substrate from moving upstream during the withdrawal of the heating element of the aerosol-generating device from the aerosol-generating article.

[0026] Alternatively, or in addition, the front-plug may be configured to wipe the surface of the heating element of the aerosol-generating device as it is withdrawn from the aerosol-generating article.

[0027] The front-plug may define an aperture or slit through which the heating element of the aerosol-generating device may pass. In this case, in the methods according to the second and fourth aspects, the step of inserting the heating element of the aerosol-generating device into the aerosol-forming substrate of the aerosol-generating article may comprise passing the heating element of the aerosol-generating device through the aperture or slit of the front-plug of the aerosol-generating article.

[0028] The hole or slit defined in the front plug can be sized to engage the heating element of the aerosol-generating device passing therethrough. For example, the size of the hole or slit defined in the front plug can almost exactly match the cross-sectional dimensions of the heating element of the aerosol-generating device. Alternatively, the hole or slit can have dimensions smaller than the cross-sectional dimensions of the heating element of the aerosol-generating device. In such an embodiment, the heating element may need to deform the front plug in order to pass through the hole or slit.

[0029] One or more holes or slits may be defined in the front-plug. For example, an aerosol-generating article intended for use with an aerosol-generating device having three heating elements may comprise a front-plug having three holes or slits defined therein, each hole or slit being arranged to receive one of the three heating elements of the aerosol-generating device.

[0030] Alternatively, the front-plug may be formed from a pierceable material. In this case, in the methods according to the second and fourth aspects, the step of inserting the heating element of the aerosol-generating device into the aerosol-forming substrate of the aerosol-generating article may comprise piercing the front-plug of the aerosol-generating article with the heating element of the aerosol-generating device.

[0031] The front plug can be made of an air permeable material that allows air to be drawn through the front plug. In such an embodiment, a user can draw air downstream through the aerosol-generating article through the front plug.

[0032] The front plug may be made of an air-permeable filter material. The front plug may conveniently be formed from an air-permeable material used to form a mouth filter for a conventional lit-end cigarette. For example, the front plug may be formed from cellulose acetate tow. The permeability of the front plug may be varied to help control the draw resistance of the aerosol-generating article.

[0033] Alternatively, the front-plug may be made of an air permeable material.In such embodiments, the aerosol-generating article may further comprise one or more air inlets downstream of the front-plug through which air may be drawn into the aerosol-generating article.

[0034] The front-plug may be formed from a low strength material in order to reduce the force required to penetrate the front-plug with the heating element of the aerosol-generating device.

[0035] The front plug may be formed of a fibrous material or a foam material. Where the front plug is formed of a fibrous material, the fibres of the fibrous material may be substantially aligned in the longitudinal direction of the aerosol-generating article so as to reduce the force required to penetrate the front plug with a heating element of an aerosol-generating device.

[0036] In some embodiments, the front-plug may be formed at least in part from an aerosol-forming substrate.For example, the front-plug may be formed at least in part from an aerosol-forming substrate comprising tobacco.

[0037] As used herein, the term 'longitudinal' is used to describe the direction between the downstream end and the upstream end of the aerosol-generating article, and the term 'transverse' is used to describe the direction perpendicular to the longitudinal direction.

[0038] The front-plug may be formed from a pierceable material that can be deformed by the heating element of the aerosol-generating device when the heating element is inserted into the aerosol-generating article, and regain its shape when the heating element is withdrawn from the aerosol-generating article.

[0039] For example, the front plug may be formed from a pierceable elastic material that, when pierced by the heating element, deforms to allow the heating element of the aerosol-generating device to pass through the front plug. When the heating element is withdrawn from the aerosol-generating article, the hole or slit in the front plug pierced by the heating element may be fully or partially closed. In such an embodiment, the front plug may advantageously provide a cleaning function by wiping the heating element of the aerosol-generating device as the heating element is withdrawn from the aerosol-generating article.

[0040] However, it will be appreciated that the front-plug need not be formed of an elastic material in order to provide a cleaning function. For example, a cleaning function may also be provided when the heating element of the aerosol-generating device is withdrawn from the aerosol-generating article, wherein the front-plug defines a hole or aperture having a size that almost exactly matches or is smaller than the size of the cross-section of the heating element.

[0041] The front-plug preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol-generating article.

[0042] Preferably, the front plug has an outer diameter of at least 5 mm. The front plug base may have an outer diameter between approximately 5 mm and approximately 12 mm (e.g., between approximately 5 mm and approximately 10 mm, or between approximately 6 mm and approximately 8 mm). In a preferred embodiment, the front plug has an outer diameter of 7.2 mm + / - 10%.

[0043] Preferably the front plug has a length of at least 2 mm, more preferably at least 3 mm or at least 4 mm.The front plug may have a length of between approximately 2 mm and approximately 10 mm, for example between approximately 4 mm and approximately 8 mm.

[0044] As used herein, the term 'diameter' is used to describe the largest dimension in the transverse direction of an aerosol-generating article.As used herein, the term 'length' is used to describe the largest dimension in the longitudinal direction of an aerosol-generating article.

[0045] Preferably, the front plug is generally cylindrical.

[0046] Preferably, the aerosol-forming substrate is a solid aerosol-forming substrate.The aerosol-forming substrate may comprise both a solid component and a liquid component.

[0047] Preferably, the aerosol-forming substrate comprises nicotine. More preferably, the aerosol-forming substrate comprises tobacco.

[0048] Alternatively or additionally, the aerosol-forming substrate may comprise a non-tobacco comprising the aerosol-forming material.

[0049] If the aerosol-forming substrate is a solid aerosol-forming substrate, the solid aerosol-forming substrate may comprise, for example, one or more of: powders, granules, pellets, fragments, strands, ribbons or flakes comprising one or more of: grass leaves, tobacco leaves, tobacco main veins, expanded tobacco and homogenised tobacco.

[0050] Optionally, the solid aerosol-forming substrate may contain tobacco or non-tobacco volatile flavoring compounds that are released upon heating of the solid aerosol-forming substrate. The solid aerosol-forming substrate may also contain one or more capsules that, for example, include additional tobacco volatile flavoring compounds or non-tobacco volatile flavoring compounds, and such capsules may melt during heating of the solid aerosol-forming substrate.

[0051] Optionally, the solid aerosol-forming substrate may be provided on or embedded in a thermally stable carrier. The carrier may take the form of a powder, granules, pellets, chips, strands, strips, or flakes. The solid aerosol-forming substrate may be deposited on the surface of the carrier in the form of, for example, a flake, foam, glue, or paste. The solid aerosol-forming substrate may be deposited on the entire surface of the carrier, or alternatively, may be deposited in a pattern to provide non-uniform flavor delivery during use.

[0052] In preferred embodiments, the aerosol-forming substrate comprises homogenised tobacco material.

[0053] As used herein, the term 'homogenised tobacco material' means a material formed by agglomerating particulate tobacco.

[0054] Preferably, the aerosol-forming substrate comprises a gathered sheet of homogenised tobacco material.

[0055] As used herein, the term 'sheet' refers to a laminar element having a width and length that are significantly greater than its thickness.

[0056] As used herein, the term 'gathered' is used to describe a sheet that is convoluted, folded or otherwise compressed or contracted generally transversely to the longitudinal axis of the aerosol-generating article.

[0057] The use of an aerosol-forming substrate comprising a gathered sheet of homogenised tobacco material advantageously significantly reduces the risk of 'loose ends', which are the loss of fragments of tobacco material from the end of the rod, compared to an aerosol-forming substrate comprising fragments of tobacco material. Loose ends can disadvantageously result in the need for more frequent cleaning of aerosol-generating devices used with aerosol-generating articles and manufacturing equipment.

[0058] The aerosol-forming substrate comprising the aggregated thin slices of homogenized tobacco material also advantageously presents a significantly low weight standard deviation compared to the aerosol-forming substrate comprising the fragments of tobacco material. The weight of the aerosol-forming substrate comprising the aggregated thin slices of homogenized tobacco material of a specific length is determined by the density, width and thickness of the thin slice of homogenized tobacco material, and the homogenized tobacco material is gathered to form the aerosol-forming substrate. The weight of the aerosol-forming substrate comprising the aggregated thin slices of homogenized tobacco material of a specific length can thus be regulated by the density and size of the thin slice of the homogenized tobacco material. This reduces the inconsistency of the weight between the aerosol-forming substrates of the same size, and therefore, compared to the aerosol-forming substrate comprising the fragments of tobacco material, results in a lower scrap rate of the aerosol-forming substrate whose weight falls outside the selected acceptance range.

[0059] An aerosol-forming substrate comprising a gathered sheet of homogenised tobacco material also advantageously exhibits a more uniform density than an aerosol-forming substrate comprising shredded tobacco material.

[0060] Insertion of the heating element of the aerosol-generating device into an aerosol-generating substrate comprising fragments of tobacco material, and removal of the heating element of the aerosol-generating device from the aerosol-generating substrate comprising fragments of tobacco material, tends to dislodge fragments of tobacco material from the aerosol-generating substrate. This can disadvantageously result in the need for more frequent cleaning of the heating element and other parts of the aerosol-generating device to remove the dislodged fragments.

[0061] In contrast, insertion of the heating element of the aerosol-generating device into, and withdrawal of the heating element of the aerosol-generating device from, the aerosol-generating substrate comprising the gathered sheet of homogenised tobacco material advantageously does not tend to dislodge the tobacco material.

[0062] In preferred embodiments, the aerosol-forming substrate comprises a gathered textured sheet of homogenised tobacco material.

[0063] As used herein, the term 'textured sheet' means a sheet that has been corrugated, embossed, debossed, perforated or otherwise deformed. The aerosol-forming substrate may comprise a gathered textured sheet of homogenised tobacco material comprising a plurality of spaced-apart depressions, protrusions, perforations and combinations thereof.

[0064] In particularly preferred embodiments, the aerosol-forming substrate comprises a gathered crimped sheet of homogenised tobacco material.

[0065] The use of a textured sheet of homogenised tobacco material may advantageously facilitate gathering of the sheet of homogenised tobacco material to form the aerosol-forming substrate.

[0066] As used herein, the term ' wrinkled sheet ' means a sheet with a plurality of generally parallel ridges or ripples. Preferably, when the aerosol generating article is assembled, the generally parallel ridges or ripples extend along the longitudinal axis of the aerosol generating article or in parallel with the longitudinal axis of the aerosol generating article. This advantageously promotes the gathering of the wrinkled sheet of homogenized tobacco material to form aerosol forming a substrate. However, it will be appreciated that the wrinkled sheet for the homogenized tobacco material included in the aerosol generating article may alternatively or additionally have a plurality of generally parallel ridges or ripples, which, when the aerosol generating article is assembled, are arranged at an acute angle or an obtuse angle relative to the longitudinal axis of the aerosol generating article.

[0067] In some embodiments, the aerosol-forming substrate may comprise a gathered sheet of homogenized tobacco material having a generally uniform texture across substantially its entire surface. For example, the aerosol-forming substrate may comprise a gathered, corrugated sheet of homogenized tobacco material comprising a plurality of generally parallel ridges or corrugations that are generally evenly spaced across the width of the sheet.

[0068] The aerosol-forming substrate may be in the form of a plug comprising aerosol-forming material circumscribed by a paper or other wrapper.Where the aerosol-forming substrate is in the form of a plug, the entire plug including any wrapper is considered to be the aerosol-forming substrate.

[0069] In preferred embodiments, the aerosol-generating substrate comprises a plug comprising a gathered, textured sheet of homogenised tobacco material confined by a wrapper.In particularly preferred embodiments, the aerosol-generating substrate comprises a plug comprising a gathered, corrugated sheet of homogenised tobacco material confined by a wrapper.

[0070] In certain embodiments, sheets of homogenised tobacco material used in an aerosol-generating substrate may have a tobacco content of approximately 70% or greater by weight on a dry weight basis.

[0071] The sheet of homogenized tobacco material used in the aerosol generation substrate may include one or more inherent binders, one or more external binders, or combinations thereof, to help agglomerate granular tobacco, the one or more inherent binders being tobacco endogenous binders, the one or more external binders being tobacco exogenous binders. Alternatively or in addition, the sheet of homogenized tobacco material used in the aerosol generation substrate may include other additives including, but not limited to, tobacco and tobacco-free fibers, aerosol formers, humectants, plasticizers, flavorings, fillers, aqueous and anhydrous solvents, and combinations thereof.

[0072] Suitable external binders for inclusion in sheets of homogenized tobacco material for use in aerosol-generating substrates are known in the art and include, but are not limited to, gums such as guar gum, synthetic biopolymer gum, gum arabic and locust bean gum; cellulosic binders such as hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose and ethyl cellulose; polysaccharides such as starch, organic acids such as alginic acid, conjugate base salts of organic acids such as sodium alginate, agar, and pectin; and combinations thereof.

[0073] Suitable non-tobacco fibers for inclusion in a sheet of homogenized tobacco material for use in an aerosol-generating substrate are known in the art and include, but are not limited to, cellulose fibers; softwood fibers; hardwood fibers; jute fibers; and combinations thereof. Prior to inclusion in a sheet of homogenized tobacco material for use in an aerosol-generating substrate, the non-tobacco fibers may be treated by suitable processes known in the art, including, but not limited to, mechanical pulping; refining; chemical pulping; bleaching; kraft pulping; and combinations thereof.

[0074] The sheet of homogenized tobacco material used in the aerosol-generating substrate should have a sufficiently high tensile strength to remain gathered to form the aerosol-generating substrate. In some embodiments, non-tobacco fibers may be included in the sheet of homogenized tobacco material used in the aerosol-generating substrate to achieve appropriate tensile strength.

[0075] For example, a homogenised sheet of tobacco material for use in an aerosol-generating substrate may comprise between approximately 1% and approximately 5% by weight of non-tobacco fibres on a dry weight basis.

[0076] Preferably, the aerosol-forming substrate comprises an aerosol-former.

[0077] As used herein, the term 'aerosol former' is intended to describe any suitable known compound or mixture of compounds that, in use, promotes the formation of an aerosol and is substantially resistant to thermal degradation at the operating temperature of the aerosol-generating article.

[0078] Suitable aerosol formers are known in the art and include, but are not limited to, polyols such as propylene glycol, triethylene glycol, 1,3-butylene glycol, and glycerol; esters of polyols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecenedioate.

[0079] Preferred aerosol formers are polyols or mixtures thereof, such as propylene glycol, triethylene glycol, 1,3-butylene glycol, and most preferably glycerol.

[0080] The aerosol-forming substrate may comprise a single aerosol-forming agent. Alternatively, the aerosol-forming substrate may comprise a combination of two or more aerosol-forming agents.

[0081] Preferably, the aerosol-forming substrate may have an aerosol-forming agent content of greater than 5% on a dry weight basis.

[0082] The aerosol-forming substrate may have an aerosol-forming agent content of between approximately 5% and approximately 30% on a dry weight basis.

[0083] In a preferred embodiment, the aerosol-forming substrate has an aerosol-forming agent content of approximately 20% on a dry weight basis.

[0084] Aerosol-forming substrates comprising a gathered sheet of homogenised tobacco for use in aerosol-generating articles may be made by methods known in the art, for example as disclosed in WO 2012 / 164009 A2.

[0085] In a preferred embodiment, sheets of homogenised tobacco material for use in aerosol-generating articles are formed by a casting process from a slurry comprising particulate tobacco, guar gum, cellulose fibres and glycerol.

[0086] The aerosol-forming element preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol-generating article.

[0087] Preferably, the aerosol-forming substrate has an outer diameter of at least 5 mm. The aerosol-forming substrate may have an outer diameter of between approximately 5 mm and approximately 12 mm (e.g., between approximately 5 mm and approximately 10 mm, or between approximately 6 mm and approximately 8 mm). In a preferred embodiment, the aerosol-forming substrate has an outer diameter of 7.2 mm + / - 10%.

[0088] The aerosol-forming substrate may have a length of between approximately 7 mm and approximately 15 mm. In one embodiment, the aerosol-forming substrate may have a length of approximately 10 mm. In a preferred embodiment, the aerosol-forming substrate has a length of approximately 12 mm.

[0089] Preferably, the aerosol-forming substrate is generally cylindrical.

[0090] The support element is arranged immediately downstream of the aerosol-forming substrate and is adjacent to the aerosol-forming substrate.

[0091] The support element can be formed from any suitable material or combination of materials. For example, the support element is formed from one or more materials selected from the group consisting of: cellulose acetate; cardboard; corrugated paper, such as corrugated heat-resistant paper or corrugated sulfate paper; and polymeric materials, such as low-density polyethylene (LDPE). In a preferred embodiment, the support element is formed from cellulose acetate.

[0092] The support element may comprise a hollow tubular element.In a preferred embodiment, the support element comprises a hollow cellulose acetate tube.

[0093] The support element preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol-generating article.

[0094] Preferably, the support element may have an outer diameter between approximately 5 mm and approximately 12 mm, such as between approximately 5 mm and approximately 10 mm, or between approximately 6 mm and approximately 8 mm. In a preferred embodiment, the support element has an outer diameter of 7.2 mm + / - 10%.

[0095] The support element may have a length of between approximately 5 mm and approximately 15 mm. In a preferred embodiment, the support element has a length of approximately 8 mm.

[0096] During insertion of the heating element of the aerosol-generating device into the aerosol-forming substrate of the aerosol-generating article, the user may be required to apply some force in order to overcome the resistance of the aerosol-forming substrate of the aerosol-generating article to the insertion of the heating element of the aerosol-generating device. This may damage one or both of the aerosol-generating article and the heating element of the aerosol-generating device.

[0097] In addition, the application of force during the insertion of the heating element of the aerosol-generating device into the aerosol-forming substrate of the aerosol-generating article may cause the aerosol-forming substrate to move within the aerosol-generating article. This may result in insufficient insertion of the heating element of the aerosol-generating device into the aerosol-forming substrate, which may lead to uneven and inefficient heating of the aerosol-forming substrate of the aerosol-generating article.

[0098] In preferred embodiments, the support element is configured to prevent downstream movement of the aerosol-forming substrate during insertion of the heating element of the aerosol-generating device into the aerosol-forming substrate of the aerosol-generating article.

[0099] The insertion force experienced by an aerosol-generating article as it is inserted into an aerosol-generating device by a user can be divided into three components: friction force, penetration force and crush force.

[0100] As the aerosol-generating article is initially inserted into the aerosol-generating device, and before the heating element of the aerosol-generating device is inserted into the aerosol-forming substrate of the aerosol-generating article, the insertion force is controlled by the force required to overcome friction due to interference between the outer surface of the aerosol-generating article and the inner surface of the aerosol-generating device. As used herein, the term 'friction force' is used to describe the maximum insertion force prior to insertion of the heating element of the aerosol-generating device into the aerosol-forming substrate of the aerosol-generating article.

[0101] As the aerosol-generating article is inserted further into the aerosol-generating device, and before the aerosol-generating article reaches a maximum insertion position, the insertion force is controlled by the force required to overcome the resistance of the aerosol-forming substrate of the aerosol-generating article to insertion of the heating element of the aerosol-generating device.

[0102] As used herein, the term 'penetration force' is used to describe the maximum insertion force during insertion of the heating element into the aerosol-forming substrate of an aerosol-generating article and before the aerosol-generating article reaches a maximum insertion position.

[0103] Once the aerosol-generating article reaches the maximum insertion point, the insertion force is controlled by the force required to deform the aerosol-generating article. In the maximum insertion position, the farthest upstream end of the aerosol-generating article may contact a surface of the aerosol-generating device, such as the bottom or rear surface, which prevents further insertion of the aerosol-generating article into the aerosol-generating device.

[0104] As used herein, the term 'injection force' is used to describe the maximum insertion force after the aerosol-generating article reaches the point of maximum insertion.

[0105] The support element of the aerosol-generating article resists penetration forces experienced by the aerosol-generating article during insertion of the heating element of the aerosol-generating device into the aerosol-forming substrate.

[0106] In one embodiment, the support element is configured to resist a penetration force of at least 2.5 N during insertion of the heating element of the aerosol-generating device into the aerosol-forming substrate.

[0107] In another embodiment, the support element is configured to resist a penetration force of at least 4 N during insertion of the heating element of the aerosol-generating device into the aerosol-forming substrate.

[0108] The support element of the aerosol-generating article prevents downstream movement of the aerosol-forming substrate in the aerosol-generating article during insertion of the heating element of the aerosol-generating device into the aerosol-forming substrate.

[0109] This may help ensure that the heating element of the aerosol-generating device is sufficiently inserted into the aerosol-forming substrate and thereby avoid uneven and inefficient heating of the aerosol-forming substrate of the aerosol-generating article.

[0110] Preferably, the support element has a resistance to rupture of at least 40 N (eg at least 45 N or at least 50 N) as measured using a standard compression test.

[0111] The aerosol-cooling element may be arranged immediately downstream of the support element and adjacent to the support element.

[0112] The aerosol-cooling element may be arranged between the support element and the mouthpiece, the mouthpiece being arranged at the furthest downstream end of the aerosol-generating article.

[0113] The aerosol-cooling element may have a total surface area of ​​between approximately 300 square millimeters per millimeter of length and approximately 1000 square millimeters per millimeter of length. In a preferred embodiment, the aerosol-cooling element has a total surface area of ​​approximately 500 square millimeters per millimeter of length.

[0114] The aerosol-cooling element may alternatively be referred to as a heat exchanger.

[0115] The aerosol-cooling element preferably has a low resistance to draw. That is, the aerosol-cooling element preferably offers low resistance to the passage of air through the aerosol-generating article. Preferably, the aerosol-cooling element does not substantially affect the resistance to draw of the aerosol-generating article.

[0116] Preferably, the aerosol-cooling element has a porosity in the longitudinal direction of between 50% and 90%. The porosity of the aerosol-cooling element in the longitudinal direction is defined by the ratio of the cross-sectional area of ​​the material forming the aerosol-cooling element to the internal cross-sectional area of ​​the aerosol-generating article at the location of the aerosol-cooling element.

[0117] The aerosol-cooling element may alternatively be referred to as a heat exchanger.

[0118] The aerosol-cooling element may include a plurality of longitudinally extending channels. The plurality of longitudinally extending channels may be defined by a sheet material that has been one or more of corrugated, pleated, gathered, and folded to form the channels. The plurality of longitudinally extending channels may be defined by a single sheet that has been one or more of corrugated, pleated, gathered, and folded to form the plurality of channels. Alternatively, the plurality of longitudinally extending channels may be defined by a plurality of sheets that have been one or more of corrugated, pleated, gathered, and folded to form the plurality of channels.

[0119] Preferably, the air flow through the aerosol-cooling element does not deviate to a substantial extent between adjacent channels. In other words, preferably, the air flow through the aerosol-cooling element is in a longitudinal direction along the longitudinal channels without substantial radial deviation. In some embodiments, the aerosol-cooling element is formed from a material having low porosity or substantially no porosity other than the longitudinally extending channels. For example, the aerosol-cooling element may be formed from a sheet material having low porosity or substantially no porosity that has been one or more of corrugated, pleated, gathered, and folded to form the channels.

[0120] In some embodiments, the aerosol-cooling element may comprise a gathered sheet of material selected from the group consisting of: metal foil, polymeric material, and substantially non-porous paper or cardboard. In some embodiments, the aerosol-cooling element may comprise a gathered sheet of material selected from the group consisting of: polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), and aluminum foil.

[0121] In a preferred embodiment, the aerosol-cooling element comprises a gathered sheet of biodegradable material. For example, a gathered sheet of non-porous paper or a gathered sheet of biodegradable polymer material, such as polylactic acid or Mater- Grade (a family of commercially available starch-based copolyesters).

[0122] In particularly preferred embodiments, the aerosol-cooling element comprises a gathered sheet of polylactic acid.

[0123] The aerosol-cooling element may be formed from a gathered sheet of material having a specific surface area between approximately 10 square millimeters per milligram and approximately 100 square millimeters per milligram by weight. In some embodiments, the aerosol-cooling element may be formed from a gathered sheet of material having a specific surface area between approximately 10 square millimeters per milligram and approximately 100 square millimeters per milligram by weight. 2 / mg of specific surface area.

[0124] When an aerosol containing a proportion of water vapor is drawn through an aerosol-cooling element, some of the water vapor may condense on the surface of the aerosol-cooling element. In such cases, it is preferred that the condensed water remains in droplet form on the surface of the aerosol-cooling element rather than being absorbed into the aerosol-cooling element. Thus, it is preferred that the aerosol-cooling element be formed from a material that is substantially non-porous or substantially non-water-absorbing.

[0125] The aerosol-cooling element may act to cool the temperature of an aerosol stream drawn through the aerosol-cooling element by means of heat transfer. Components of the aerosol will interact with the aerosol-cooling element and lose thermal energy.

[0126] The aerosol-cooling element may function to cool the temperature of the aerosol stream as it is drawn through the aerosol-cooling element by undergoing a phase change that dissipates thermal energy from the aerosol stream. For example, the aerosol-cooling element may be formed from a material that undergoes an endothermic phase change, such as melting or a glass transition.

[0127] The aerosol-cooling element can function to lower the temperature of the aerosol stream by causing condensation of components (e.g., water vapor) from the aerosol stream as it is drawn through the aerosol-cooling element. Due to condensation, the aerosol stream may be drier after passing through the aerosol-cooling element. In some embodiments, the water vapor content of the aerosol drawn through the aerosol-cooling element can be reduced by between approximately 20% and approximately 90%. A user may perceive the drier aerosol as being cooler than a moister aerosol of the same actual temperature.

[0128] In some embodiments, the temperature of the aerosol stream may decrease by more than 10 degrees Celsius as it is drawn through the aerosol-cooling element. In some embodiments, the temperature of the aerosol stream may decrease by more than 15 degrees Celsius or more than 20 degrees Celsius as it is drawn through the aerosol-cooling element.

[0129] In some embodiments, the aerosol-cooling element removes a certain proportion of the water vapor content of the aerosol drawn through the aerosol-cooling element. In some embodiments, as the aerosol is drawn through the aerosol-cooling element, a certain proportion of other volatile substances can be removed from the aerosol stream. For example, in some embodiments, as the aerosol is drawn through the aerosol-cooling element, a certain proportion of phenolic compounds can be removed from the aerosol stream.

[0130] The phenolic compounds may be removed by interaction with the material forming the aerosol-cooling element.For example, the aerosol-cooling element may be formed from a material that absorbs phenolic compounds (eg, phenolic formaldehyde and cresol).

[0131] The phenolic compounds may be removed by interaction with water droplets which condense on the surface of the aerosol-cooling element.

[0132] As mentioned above, the aerosol-cooling element can be formed from a sheet of suitable material that has been one or more of corrugated, pleated, gathered, and folded to define a plurality of longitudinally extending channels. The cross-sectional profile of such an aerosol-cooling element can have randomly oriented channels. The aerosol-cooling element can be formed by other means. For example, the aerosol-cooling element can be formed from a bundle of longitudinally extending tubes. The aerosol-cooling element can be formed by extrusion, molding, lamination, injection, or comminution of suitable materials.

[0133] The aerosol-cooling element may comprise an outer tube or wrapper containing or arranged with a longitudinally extending channel. For example, a pleated, gathered or folded sheet material may be wrapped in a wrapper material (e.g., a plug wrapper) to form the aerosol-cooling element. In some embodiments, the aerosol-cooling element comprises a sheet of corrugated material gathered into a rod shape and constrained by a wrapper, such as a wrapper of filter paper.

[0134] The aerosol-cooling element preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol-generating article.

[0135] The aerosol-cooling element may have an outer diameter of between approximately 5 mm and approximately 10 mm, for example between approximately 6 mm and approximately 8 mm.In a preferred embodiment, the aerosol-cooling element has an outer diameter of 7.2 mm + / - 10%.

[0136] The aerosol-cooling element may have a length of between approximately 5 mm and approximately 25 mm. In a preferred embodiment, the aerosol-cooling element has a length of approximately 18 mm.

[0137] In some embodiments, the aerosol-cooling element may comprise a gathered sheet of material selected from the group consisting of: metal foil, polymeric material, and substantially non-porous paper or cardboard. In some embodiments, the aerosol-cooling element may comprise a gathered sheet of material selected from the group consisting of: polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), and aluminum foil.

[0138] In a preferred embodiment, the aerosol-cooling element comprises a gathered sheet of biodegradable polymeric material, such as polylactic acid or Mater- Grade (a family of commercially available starch-based copolyesters).

[0139] In particularly preferred embodiments, the aerosol-cooling element comprises a gathered sheet of polylactic acid.

[0140] The aerosol-generating article may comprise a volatile flavour-generating component disposed in the aerosol-cooling element. For example, the aerosol-generating article may comprise a volatile flavour-generating component disposed in a longitudinally extending channel of the aerosol-cooling element.

[0141] As used herein, the term 'volatile flavour-generating ingredient' is used to describe any volatile ingredient that is added to an aerosol-generating article in order to provide flavour.

[0142] The volatile flavor-generating ingredient may be in liquid or solid form. The volatile flavor-generating ingredient may be coupled to the support element or otherwise associated with the support element. The volatile flavor-generating ingredient may include menthol.

[0143] As used herein, the term 'menthol' is used to describe the compound 2-isopropyl-5-methylcyclohexanol in any of its isomeric forms.

[0144] Menthol can be used in solid or liquid form. In solid form, menthol can be provided as granules or particulates. The term 'solid menthol particulates' can be used to describe any granular or particulate solid material comprising at least approximately 80% menthol by weight.

[0145] Preferably, 1.5 mg or more of the volatile flavour-generating component is included in the aerosol-generating article.

[0146] The volatile flavor-producing component can be coupled to a fibrous support element. The fibrous support element can be any suitable substrate or support for positioning, clamping, or retaining the flavor-producing component. The fibrous support element can be, for example, a paper support. Such a paper support can be filled with a liquid component such as liquid menthol. The fibrous support can be, for example, a thread or twine. Such a thread or twine can be saturated with a liquid component such as liquid menthol. Alternatively, such a thread or twine can be threaded or otherwise coupled to a solid flavor-producing component. For example, solid particles of menthol can be coupled to the thread.

[0147] Preferably, the volatile flavor-generating component is supported by an elongate fibrous support element, such as a thread or twine. Preferably, the volatile flavor-generating component is arranged within the aerosol-generating article radially inwardly from the inner surface of the outer wrapper, with the longitudinal axis of the elongate fibrous support element arranged generally parallel to the longitudinal axis of the aerosol-generating article.

[0148] The aerosol-generating article may comprise a mouthpiece arranged at the downstream end of the aerosol-generating article.

[0149] The mouthpiece may be arranged immediately downstream of, and adjacent to, the aerosol-cooling element.

[0150] The mouthpiece may include a filter. The filter may be formed from one or more suitable filter materials. A variety of such filter materials are known in the art. In one embodiment, the mouthpiece may include a filter formed from cellulose acetate tow.

[0151] The mouthpiece preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol-generating article.

[0152] The nozzle may have an outer diameter of between approximately 5 mm and approximately 10 mm in diameter, for example between approximately 6 mm and approximately 8 mm. In a preferred embodiment, the nozzle has an outer diameter of 7.2 mm + / - 10%.

[0153] The mouth can have a length between approximately 5 mm and approximately 20 mm. In a preferred embodiment, the mouth has a length of approximately 14 mm.

[0154] The mouth can have a length between approximately 5 mm and approximately 14 mm. In a preferred embodiment, the mouth has a length of approximately 7 mm.

[0155] The aerosol-forming substrate, support element, aerosol-cooling element and any other elements of the aerosol-generating article (such as the front-plug and mouthpiece, where present) are confined by an outer wrapper.The outer wrapper may be formed from any suitable material or combination of materials.

[0156] Preferably, the outer wrapper is cigarette paper.

[0157] The downstream end portion of the outer wrapper may be constrained by a band of tipping paper.

[0158] The appearance of the aerosol-generating article may mimic the appearance of a conventional lit-end cigarette.

[0159] The aerosol-generating article may have an outer diameter of between approximately 5 mm and approximately 12 mm, for example between approximately 6 mm and approximately 8 mm.In preferred embodiments, the aerosol-generating article has an outer diameter of 7.2 mm + / - 10%.

[0160] The aerosol-generating article may have an overall length of between approximately 30 millimetres and approximately 100 millimetres.In a preferred embodiment, the aerosol-generating article has an overall length of approximately 45 millimetres.

[0161] The aerosol-generating device may comprise: a housing; a heating element; a power source connected to the heating element; and a control element configured to control the supply of power from the power source to the heating element.

[0162] The housing may define a cavity surrounding the heating element, the cavity being configured to receive the aerosol-generating article.

[0163] Preferably, the aerosol-generating device is a portable or handheld aerosol-generating device that is comfortable for a user to hold between the fingers of a single hand.

[0164] The aerosol-generating device may be generally cylindrical in shape.

[0165] The aerosol-generating device may have a length of between approximately 70 millimetres and approximately 120 millimetres.

[0166] The device may comprise further heaters in addition to the internal heating element, which is inserted into the aerosol-forming substrate of the aerosol-generating article.

[0167] The energy source can be any suitable energy source, for example, a DC voltage source such as a battery. In one embodiment, the power source is a lithium-ion battery. Alternatively, the energy source can be a nickel metal hydride battery, a nickel chromium battery, or a lithium-based battery, such as a lithium-cobalt, lithium-iron-phosphorus, lithium titanate, or lithium-polymer battery.

[0168] The control element may be a simple switch. Alternatively, the control element may be an electrical circuit and may include one or more microprocessors or microcontrollers.

[0169] An aerosol-generating system may comprise an aerosol-generating device and one or more aerosol-generating articles configured to be received in a cavity of the aerosol-generating device.

[0170] The heating element of the aerosol-generating device may be any suitable heating element that is insertable into the aerosol-forming substrate of the aerosol-generating article.For example, the heating element may be in the form of a pin or a blade.

[0171] The heating element may have a tapered, pointed or sharp end to facilitate insertion of the heating element into the aerosol-forming substrate of the aerosol-generating article.

[0172] The resistance to draw (RTD) of the aerosol-generating article after insertion of the heating element may be between approximately 80 mm WG and approximately 140 mm WG.

[0173] As used herein, resistance to suction is expressed in pressure units 'mm WG' or 'mm of water gauge' and is measured in accordance with ISO 6565:2002.

[0174] Features described with respect to one aspect or embodiment may also apply to other aspects or embodiments.For example, features described with respect to the aerosol-generating articles and aerosol-generating systems described above may also be used in conjunction with methods of using the aerosol-generating articles and aerosol-generating systems described above. BRIEF DESCRIPTION OF THE DRAWINGS

[0175] Specific embodiments will now be described with reference to the accompanying drawings, in which:

[0176] Figure 1 is a schematic cross-sectional view of an embodiment of an aerosol-generating article for use with an aerosol-generating device comprising a heating element;

[0177] Figure 2 is a schematic cross-sectional view of an embodiment of an aerosol generating system comprising an electrically heated aerosol generating device comprising a heating element and a Figure 1 The aerosol-generating article of the embodiment shown in ; and

[0178] Figure 3 is Figure 2 A schematic cross-sectional view of an electrically heated aerosol-generating device is shown. DETAILED DESCRIPTION

[0179] Figure 1 An aerosol-generating article 10 according to a preferred embodiment is shown. The aerosol-generating article 10 comprises four elements arranged in a coaxial arrangement: an aerosol-forming substrate 20, a support element 30, an aerosol-cooling element 40, and a mouthpiece 50. These four elements are arranged sequentially and bounded by an outer wrapper 60 to form the aerosol-generating article 10. The aerosol-generating article 10 has a proximal end or mouth end 70, which a user inserts into his or her mouth during use, and a distal end 80, which is arranged at the end of the aerosol-generating article 10 opposite the mouth end 70.

[0180] In use, air is drawn by a user through the aerosol-generating article from the distal end 80 to the mouth end 70. The distal end 80 of the aerosol-generating article may also be described as the upstream end of the aerosol-generating article 10, and the mouth end 70 of the aerosol-generating article 10 may also be described as the downstream end of the aerosol-generating article 10. Elements of the aerosol-generating article 10 arranged between the mouth end 70 and the distal end 80 may be described as being upstream of the mouth end 70, or alternatively, downstream of the distal end 80.

[0181] The aerosol-forming substrate 20 is arranged at the farthest distal or upstream end of the aerosol-generating article 10. Figure 1 In the embodiment shown in , the aerosol-forming substrate 20 comprises a crimped, gathered sheet of homogenised tobacco material circumscribed by a wrapper. The crimped, gathered sheet of homogenised tobacco material comprises glycerol as the aerosol-former.

[0182] The support element 30 is arranged immediately downstream of the aerosol-forming substrate 20 and is adjacent to the aerosol-forming substrate 20. Figure 1 In the embodiment shown in FIG, the support element is a hollow cellulose acetate tube. The support element 30 positions the aerosol-forming substrate 20 at the distal end 80 of the aerosol-generating article 10 so that it can be penetrated by the heating element of the aerosol-generating device. As described further below, when the heating element of the aerosol-generating device is inserted into the aerosol-forming substrate 20, the support element 30 prevents the aerosol-forming substrate 20 from being pushed downstream within the aerosol-generating article 10 toward the aerosol-cooling element 40. The support element 30 also acts as a spacer to separate the aerosol-cooling element 40 of the aerosol-generating article 10 from the aerosol-forming substrate 20.

[0183] The aerosol-cooling element 40 is arranged immediately downstream of the support element 30 and is adjacent to the support element 30. In use, volatile substance released from the aerosol-forming substrate 20 passes along the aerosol-cooling element 40 towards the mouth end 70 of the aerosol-generating article 10. The volatile substance may cool within the aerosol-cooling element 40 to form an aerosol that is inhaled by the user. Figure 1 In the embodiment shown in , the aerosol-cooling element comprises a corrugated and gathered sheet of polylactic acid circumscribed by a wrapper 90. The corrugated and gathered sheet of polylactic acid defines a plurality of longitudinal channels that extend along the length of the aerosol-cooling element 40.

[0184] The mouthpiece 50 is arranged immediately downstream of the aerosol-cooling element 40 and is adjacent to the aerosol-cooling element 40. Figure 1 In the embodiment shown in FIG. 5 , the mouthpiece 50 comprises a conventional cellulose acetate tow filter having low filtration efficiency.

[0185] To assemble the aerosol-generating article 10, the four elements described above are aligned and tightly wrapped within the outer wrapper 60. Figure 1 In the embodiment shown in FIG, the outer wrapper is a conventional cigarette paper. Figure 1 As shown, rows of perforations are selectively provided in the region of the outer wrapper 60 that circumscribes the support element 30 of the aerosol-generating article 10 .

[0186] exist Figure 1 In the embodiment shown in , the distal end portion of the outer wrapper 60 of the aerosol-generating article 10 is constrained by a tipping paper tape (not shown).

[0187] exist Figure 1 The aerosol-generating article 10 shown in FIG is designed to be engaged with an aerosol-generating device including a heating element for smoking or consumption by a user. In use, the heating element of the aerosol-generating device heats the aerosol-forming substrate 20 of the aerosol-generating article 10 to a sufficient temperature to form an aerosol, which is drawn downstream through the aerosol-generating article 10 and inhaled by the user.

[0188] Figure 2 1 shows a portion of an aerosol generating system 100 comprising an aerosol generating device 110 and a device according to the above description and in Figure 1 The aerosol-generating article 10 of the embodiment shown in FIG.

[0189] The aerosol generating device comprises a heating element 120. Figure 2As shown, the heating element 120 is mounted within the aerosol-generating article receiving chamber of the aerosol-generating device 110. In use, the user inserts the aerosol-generating article 10 into the aerosol-generating article receiving chamber of the aerosol-generating device 110, whereby the heating element 120 is directly inserted into the aerosol-forming substrate 20 of the aerosol-generating article 10, as shown in FIG. Figure 2 As shown. Figure 2 In the embodiment shown in FIG, the heating element 120 of the aerosol-generating device 110 is a heater blade.

[0190] The aerosol generating device 110 includes a power supply and electronics (shown in FIG. Figure 3 ), these electronic devices allow the heating element 120 to be actuated. Such actuation may be manually operated, or may occur automatically in response to a user drawing on an aerosol-generating article 10, which is inserted into an aerosol-generating article receiving chamber of the aerosol-generating device 110. A plurality of openings are provided in the aerosol-generating device to allow air to flow to the aerosol-generating article 10; the direction of air flow is in the Figure 2 Indicated by arrows.

[0191] The support element 40 of the aerosol-generating article 10 resists penetration forces experienced by the aerosol-generating article 10 during insertion of the heating element 120 of the aerosol-generating device 110 into the aerosol-forming substrate 20. The support element 40 of the aerosol-generating article 10 thereby prevents downstream movement of the aerosol-forming substrate within the aerosol-generating article 10 during insertion of the heating element 120 of the aerosol-generating device into the aerosol-forming substrate.

[0192] Once the internal heating element 120 is inserted into the aerosol-forming substrate 10, the aerosol-generating article 10 is actuated and the aerosol-forming substrate 20 of the aerosol-generating article 10 is heated to a temperature of approximately 375 degrees Celsius by the heating element 120 of the aerosol-generating device 110. At this temperature, volatile compounds are emitted from the aerosol-forming substrate 20 of the aerosol-generating article 10. As the user draws on the mouth end 70 of the aerosol-generating article 10, the volatile compounds emitted from the aerosol-forming substrate 20 are drawn downstream through the aerosol-generating article 10 and condense to form an aerosol that is drawn through the mouthpiece 50 of the aerosol-generating article 10 into the user's mouth.

[0193] As the aerosol passes downstream through the aerosol-cooling element 40, the temperature of the aerosol is reduced due to the transfer of heat energy from the aerosol to the aerosol-cooling element 40. When the aerosol enters the aerosol-cooling element 40, its temperature is approximately 60 degrees Celsius. Due to the cooling within the aerosol-cooling element 40, the temperature of the aerosol when it leaves the aerosol-cooling element is approximately 40 degrees Celsius.

[0194] exist Figure 3In the figure, the components of the aerosol generating device 110 are shown in a simplified manner. Specifically, the components of the aerosol generating device 110 are not shown in the figure. Figure 1 Parts not relevant to the understanding of the embodiments have been omitted to simplify Figure 3 .

[0195] like Figure 3 As shown, the aerosol generating device 110 includes a housing 130. The heating element 120 is mounted in an aerosol generating article receiving chamber within the housing 130. Figure 3 The heating element 120 is inserted into the aerosol-generating article receiving chamber within the housing 130 of the aerosol-generating device 110 (shown by dashed lines in FIG).

[0196] Within housing 130, an electrical energy source 140, such as a rechargeable lithium-ion battery, is located. A controller 150 is connected to heating element 120, electrical energy source 140, and a user interface 160, such as buttons or a display. Controller 150 controls the energy supplied to heating element 120 to regulate its temperature.

[0197] Although according to the above description and Figure 1 The support element of the aerosol-generating article of the embodiment shown in is formed from cellulose acetate, but it will be appreciated that this is not required and aerosol-generating articles according to other embodiments may comprise a support element formed from other suitable materials or combinations of materials.

[0198] Similarly, although according to the above description and in Figure 1 The aerosol-generating article of the embodiment shown in comprises an aerosol-cooling element comprising a corrugated and gathered sheet of polylactic acid, but it will be appreciated that this is not required and aerosol-generating articles according to other embodiments may comprise other aerosol-cooling elements.

[0199] Furthermore, despite the above description and Figure 1 The aerosol-generating article of the embodiment shown in has four elements circumscribed by an outer wrapper, but it will be appreciated that this is not required and aerosol-generating articles according to other embodiments may comprise additional elements or fewer elements.

[0200] It will also be appreciated that, despite the above description and in Figure 1 The four elements of the aerosol-generating article of the embodiment shown in are confined by an outer wrapper of conventional cigarette paper, but this is not required and elements of aerosol-generating articles according to other embodiments may be confined by other outer wrappers.

[0201] It will be further appreciated that for Figure 1 Elements of an aerosol-generating article according to the embodiment shown in Figure 2 The dimensions provided for the parts of the aerosol-generating device in the illustrated embodiment are exemplary only, and suitable alternative dimensions may be selected.

[0202] The exemplary embodiments described above are not limiting. Other embodiments consistent with the exemplary embodiments described above will be apparent to those skilled in the art.

Claims

1. An aerosol-generating article for use with an aerosol-generating device, the aerosol-generating device comprising a heating element, the aerosol-generating article comprising: an aerosol-forming substrate comprising a gathered sheet of homogenised tobacco material, wherein the aerosol-forming substrate is arranged at a furthest upstream end of the aerosol-generating article, and wherein the heating element is insertable into and retractable from the aerosol-forming substrate; a support element arranged immediately downstream of the aerosol-forming substrate; an aerosol-cooling element disposed downstream of the support element, wherein the aerosol-cooling element comprises a plurality of longitudinally extending channels defined by a sheet material that has been one or more of corrugated, pleated, gathered, and folded to form the plurality of longitudinally extending channels; and an outer wrapper surrounding the aerosol-forming substrate, the support element and the aerosol-cooling element, Therein, the support element is adjacent to the aerosol-forming substrate.

2. An aerosol-generating article for use with an aerosol-generating device, the aerosol-generating device comprising a heating element, the aerosol-generating article comprising: an aerosol-forming substrate comprising a gathered sheet of homogenised tobacco material, wherein the heating element is insertable into and retractable from the aerosol-forming substrate; a support element arranged immediately downstream of the aerosol-forming substrate; an aerosol-cooling element disposed downstream of the support element, wherein the aerosol-cooling element comprises a plurality of longitudinally extending channels, the plurality of longitudinally extending channels being defined by a sheet material that has been one or more of corrugated, pleated, gathered, and folded to form the plurality of longitudinally extending channels; a front-plug located upstream of the aerosol-forming substrate, wherein the front-plug is penetrable by a heating element of an aerosol-generating device; and an outer wrapper surrounding the aerosol-forming substrate, the support element, the aerosol-cooling element and the front-plug, Therein, the support element is adjacent to the aerosol-forming substrate.

3. An aerosol-generating article for use with an aerosol-generating device, the aerosol-generating device comprising a heating element, the aerosol-generating article comprising: an aerosol-forming substrate comprising a gathered sheet of homogenised tobacco material, wherein the heating element is insertable into and retractable from the aerosol-forming substrate; a support element arranged immediately downstream of the aerosol-forming substrate; an aerosol-cooling element disposed downstream of the support element, wherein the aerosol-cooling element comprises a gathered sheet of biodegradable polymer material, and wherein the aerosol-cooling element comprises a plurality of longitudinally extending channels, the plurality of longitudinally extending channels being defined by the sheet material that has been one or more of corrugated, pleated, gathered and folded to form the plurality of longitudinally extending channels; and an outer wrapper surrounding the aerosol-forming substrate, the support element and the aerosol-cooling element, Therein, the support element is adjacent to the aerosol-forming substrate.

4. An aerosol-generating article according to claim 3, wherein The aerosol-forming substrate is arranged at the furthest upstream end of the aerosol-generating article.

5. The aerosol-generating article of claim 3, further comprising: a front plug located upstream of the aerosol-forming substrate, The outer wrapper surrounds the front plug, and the front plug can be penetrated by the heating element of the aerosol generating device.

6. An aerosol-generating article according to any one of claims 1 to 5, wherein The sheet of homogenised tobacco material is crimped.

7. An aerosol-generating article according to any one of claims 1 to 5, wherein The support element comprises a hollow tubular element.

8. An aerosol-generating article according to claim 7, wherein The support element comprises a hollow cellulose acetate tube.

9. An aerosol-generating article according to any one of claims 1 to 5, wherein The aerosol-cooling element is arranged immediately downstream of the support element and is adjacent to the support element.

10. An aerosol-generating article according to claim 1, wherein The aerosol-cooling element comprises a gathered sheet of biodegradable polymeric material.

11. An aerosol-generating article according to claim 10, wherein The aerosol-cooling element comprises aggregated polylactic acid sheets.

12. An aerosol-generating article according to any one of claims 1 to 5, further comprising: a mouthpiece arranged at the furthest downstream end of the aerosol-generating article, Wherein, the outer wrapping member surrounds the mouth.

13. An aerosol-generating article according to claim 12, wherein The mouthpiece includes a plug of cellulose acetate tow.

14. An aerosol-generating article according to any one of claims 1 to 5, wherein The aerosol-forming substrate is penetrable by the heating element of the aerosol-generating device.

15. An aerosol-generating article according to any one of claims 1 to 5, wherein The support element is configured to resist a penetration force of at least 2.5 N during insertion of the heating element of the aerosol-generating device into the aerosol-forming substrate.

16. An aerosol generating system comprising: an aerosol-generating device, the aerosol-generating device comprising a heating element; and An aerosol-generating article according to any one of claims 1 to 15.

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