Aerosol generating articles with a predetermined insertion direction

Abstract

An aerosol generating article (10) is provided extending from a mouth end to a distal end upstream of the mouth end. The aerosol generating article includes an aerosol generating matrix strip (12), a downstream section (14) located downstream of the aerosol generating matrix strip, and an upstream section (16) located upstream of the aerosol generating matrix strip. The downstream section includes a mouthpiece element (42) positioned downstream of the strip and aligned longitudinally with the strip, extending to the mouth end of the aerosol generating article. The upstream section includes an upstream element extending to the distal end of the article. The diameter (D) of the aerosol generating article at the mouth end is... ME The diameter of the aerosol-generated product at the distal end is greater than the diameter of the product at the distal end (D). DE The ratio between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end (D) ME / D DE The value is at least approximately 1.005.

Description

[0001] The present invention relates to an aerosol generating article comprising an aerosol generating matrix and adapted to generate an inhalable aerosol upon heating.

[0002] Aerosol-generating articles that heat, rather than burn, an aerosol-generating matrix, such as a tobacco-containing matrix, are known in the art. Typically, in such heated smoking articles, an aerosol is generated by transferring heat from a heat source to a physically separated aerosol-generating matrix or material, which may be positioned 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 matrix through heat transfer from the heat source and entrained in the air drawn through the aerosol-generating article. When the released compounds cool, they condense to form an aerosol.

[0003] Numerous prior art documents disclose aerosol generating apparatuses for consuming aerosol generating articles. Such apparatuses include, for example, electrically heated aerosol generating apparatuses, wherein aerosols are generated by transferring heat from one or more electrically heated elements of the aerosol generating apparatus to the aerosol generating matrix of the heated aerosol generating article. For example, electrically heated aerosol generating apparatuses comprising an internal heating element adapted to be inserted into the aerosol generating matrix have been proposed. Alternatively, WO2015 / 176898 discloses an inductively heated aerosol generating article comprising an aerosol generating matrix and a sensor disposed within the aerosol generating matrix.

[0004] Aerosol-generating articles in which the tobacco-containing matrix is ​​heated without combustion present several challenges not encountered with conventional smoking articles. First, the tobacco-containing matrix is ​​typically heated to significantly lower temperatures compared to the combustion front temperatures reached in conventional cigarettes. This can affect nicotine release from the tobacco-containing matrix and its delivery to the consumer. Simultaneously, if the heating temperature is increased in an attempt to enhance nicotine delivery, the generated aerosol typically needs to cool more extensively and rapidly before reaching the consumer. However, technological solutions commonly used to cool the mainstream smoke in conventional smoking articles (such as providing a highly efficient filtration segment at the mouthpiece of the cigarette) may have undesirable effects in aerosol-generating articles where the tobacco-containing matrix is ​​heated without combustion, as they can reduce nicotine delivery. Second, there is a general consensus on the need for aerosol-generating articles that are easy to use and have improved practicality.

[0005] Furthermore, it is desirable to provide an aerosol-generated article that can be manufactured efficiently and at high speed, preferably with a satisfactory RTD and low RTD variability from one article to another.

[0006] Therefore, it is desirable to provide new and improved aerosol-generating articles suitable for achieving at least one of the aforementioned desired results.

[0007] This disclosure relates to an aerosol generating article comprising an aerosol generating matrix strip, wherein the aerosol generating article extends from an opening end to a distal end upstream of the opening end. The aerosol generating article may include a downstream section located downstream of the aerosol generating matrix strip. The downstream section may include a mouthpiece segment positioned downstream of the strip and aligned longitudinally with the strip. The mouthpiece segment may extend all the way to the opening end of the aerosol generating article. The diameter (D) of the aerosol generating article at the opening end is... ME It can be larger than the diameter of the aerosol-generated product at the distal end (D). DE The ratio between the diameter of the aerosol-generating article at the distal end and the diameter of the aerosol-generating article at the inlet end (D). ME / D DE It can be at least about 1.005.

[0008] According to the present invention, an aerosol generating article is provided extending from a mouth end to a distal end upstream of the mouth end, the aerosol generating article comprising: an aerosol generating matrix strip; and a downstream section located downstream of the aerosol generating matrix strip. The downstream section includes a mouthpiece segment positioned downstream of the strip and aligned longitudinally with the strip, the mouthpiece segment extending to the mouth end of the aerosol generating article. The diameter (D) of the aerosol generating article at the mouth end is... ME The diameter of the aerosol-generated product at the distal end is greater than the diameter of the product at the distal end (D). DE The ratio between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end (D) ME / D DE The value is at least approximately 1.005.

[0009] Providing an aerosol-generating article in which the outer diameter of the article is larger at one end than at the other has the advantage that consumers can more easily identify the end to be inserted into the aerosol-generating device for supplying heat to the aerosol-generating matrix. This is particularly advantageous in embodiments where the distal and inlet ends of the aerosol-generating article might otherwise be difficult for consumers to distinguish (e.g., because they are visually nearly identical, or because they both comprise similar elements). For example, the invention is particularly advantageous in those embodiments that include an upstream section located upstream of the aerosol-generating matrix strip, wherein the upstream section includes an upstream element comprising a filter material segment, and a downstream section located downstream of the aerosol-generating matrix, wherein the downstream section includes a mouthpiece segment extending to the inlet end of the article. With such an article design, consumers might otherwise have difficulty distinguishing the inlet end (where the mouthpiece segment is provided) from the distal end (where the upstream element is provided). The invention allows consumers to easily detect a decrease in diameter toward the distal end, which is the end inserted into the cavity of the device.

[0010] According to the present invention, an aerosol generating article is provided for generating an inhalable aerosol upon heating. The aerosol generating article includes an aerosol generating matrix strip.

[0011] The term "aerosol-generating article" is used herein to refer to an article in which an aerosol-generating matrix is ​​heated to produce an inhalable aerosol for delivery to a consumer. As used herein, the term "aerosol-generating matrix" refers to a matrix capable of releasing volatile compounds upon heating to generate an aerosol.

[0012] A conventional cigarette is ignited when a user applies a flame to one end and inhales air through the other end. The localized heat provided by the flame and oxygen in the inhaled air ignites the end of the cigarette, and the resulting combustion produces inhalable smoke. In contrast, in heated aerosol-generating articles, aerosols are generated by heating a flavor-generating matrix, such as tobacco. Heated aerosol-generating articles include, for example, electrically heated aerosol-generating articles, and aerosol-generating articles in which aerosols are generated by heat transfer from a combustible fuel element or heat source to a physically separate aerosol-forming material. For example, the aerosol-generating articles according to the invention find particular application in aerosol-generating systems that include electrically heated aerosol-generating devices having internal heating elements adapted to be inserted into a strip of aerosol-generating matrix. This type of aerosol-generating article is described in the prior art (e.g., in European patent application EP0822670).

[0013] As used herein, the term "aerosol generating apparatus" refers to an apparatus that includes a heater element that interacts with an aerosol generating matrix of an aerosol generating article to generate an aerosol.

[0014] As used herein with reference to the invention, the term "strip" is used to refer to a generally cylindrical element with a substantially circular, oval, or elliptical cross-section.

[0015] 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. As used herein, the terms "upstream" and "downstream" describe the relative positions of an element or portion of an element of the aerosol-generating article with respect to the direction in which the aerosol is transported through the aerosol-generating article during use.

[0016] During use, air is drawn through the aerosol-generating article in the longitudinal direction. The term "transverse" refers to the direction perpendicular to the longitudinal axis. Unless otherwise stated, any reference to the "cross section" of the aerosol-generating article or a component of the aerosol-generating article refers to the transverse cross section.

[0017] The term "length" refers to the longitudinal dimension of a component of an aerosol-generating article. For example, it can be used to describe the longitudinal dimension of a strip or elongated tubular element.

[0018] The aerosol generation matrix can be a solid aerosol generation matrix.

[0019] In some preferred embodiments, the aerosol generating matrix comprises homogenized plant material, preferably homogenized tobacco material.

[0020] As used herein, the term "homogenized plant material" encompasses any plant material formed by the agglomeration of plant particles. For example, sheets or webs of homogenized tobacco material used as the aerosol-generating matrix of the present invention can be formed by agglomerating particles of tobacco material obtained by crushing, grinding, or grinding plant material, and optionally one or more of tobacco leaf blades and tobacco stems. Homogenized plant materials can be produced by casting, extrusion, papermaking processes, or any other suitable processes known in the art.

[0021] Homogenized plant material can be provided in any suitable form. For example, homogenized plant material can be in the form of one or more sheets. As used herein with reference to the invention, the term "sheet" describes a layered element whose width and length are substantially greater than its thickness.

[0022] Alternatively, or otherwise, homogenized plant material may be in the form of multiple pellets or granules.

[0023] Alternatively or additionally, homogenized plant material may be in the form of multiple strips, bands, or fragments. As used herein, the term "strip" describes an elongated element of material whose length is substantially greater than its width and thickness. The term "strip" should be considered to include bands, fragments, and any other homogenized plant material of similar form. Bundles of homogenized plant material may be formed from sheets of homogenized plant material, for example by cutting or shredding, or by other methods, such as extrusion.

[0024] In some embodiments, strips may be formed in situ within the aerosol-generating matrix due to the splitting or cracking of the homogenized plant material sheet during the formation of the aerosol-generating matrix, for example, due to curling. The homogenized plant material strips within the aerosol-generating matrix may be separable from each other. Alternatively, each strip of homogenized plant material within the aerosol-generating matrix may be at least partially connected to one or more adjacent strips along its length. For example, adjacent strips may be connected by one or more fibers. This can occur, for example, due to the formation of strips as described above, caused by the splitting of the homogenized plant material sheet during the production of the aerosol-generating matrix.

[0025] Preferably, the aerosol generating matrix is ​​in the form of one or more sheets of homogenized plant material. In various embodiments of the invention, the one or more sheets of homogenized plant material may be produced by a casting process. In various embodiments of the invention, the one or more sheets of homogenized plant material may be produced by a papermaking process. The one or more sheets described herein may each individually have a thickness between 100 micrometers and 600 micrometers, preferably between 150 micrometers and 300 micrometers, and most preferably between 200 micrometers and 250 micrometers. Individual thickness refers to the thickness of a single sheet, while combined thickness refers to the total thickness of all sheets constituting the aerosol generating matrix. For example, if the aerosol generating matrix is ​​formed from two individual sheets, the combined thickness is the sum of the thicknesses of the two individual sheets or, in the case of two sheets stacked in the aerosol generating matrix.

[0026] One or more sheets as described herein may each individually have a weight between approximately 100 grams per square meter and approximately 300 grams per square meter.

[0027] One or more sheets as described herein may each individually have a density from about 0.3 g / cm² to about 1.3 g / cm², and preferably from about 0.7 g / cm² to about 1.0 g / cm².

[0028] In embodiments of the invention in which the aerosol-generating matrix comprises one or more sheets of homogenized plant material, the sheets are preferably in the form of one or more aggregated sheets. As used herein, the term “aggregate” means that the homogenized plant material sheet is rolled, folded, or otherwise compressed or contracted into a cylindrical shape substantially transverse to the axis of the rod or strip.

[0029] One or more sheets of homogenized plant material may be stacked laterally relative to its longitudinal axis and wrapped with packaging to form continuous strips or rods.

[0030] One or more sheets of homogenized plant material may be advantageously curled or similarly treated. As used herein, the term “curled” means that the sheet has a plurality of substantially parallel ridges or corrugations. Alternatively, or in addition to curling, one or more sheets of homogenized plant material may be embossed, debossed, perforated, or otherwise deformed to provide texture on one or both sides of the sheet.

[0031] Preferably, each sheet of homogenized plant material can be curled such that it has multiple ridges or corrugations substantially parallel to the cylindrical axis of the rod. This treatment advantageously promotes the aggregation of the curled sheets of homogenized plant material to form the rod. Preferably, one or more sheets of homogenized plant material can be aggregated. It is understood that the curled sheets of homogenized plant material may alternatively or additionally have multiple substantially parallel ridges or corrugations arranged at acute or obtuse angles to the cylindrical axis of the rod. The sheets can be curled to such an extent that the integrity of the sheets is disrupted at the multiple parallel ridges or corrugations, causing material separation and resulting in the formation of fragments, strips, or bands of homogenized plant material.

[0032] Alternatively, one or more sheets of homogenized plant material can be cut into strips as described above. In such embodiments, the aerosol-generating matrix comprises multiple strips of homogenized plant material. These strips can be used to form rods. Typically, the width of these strips is about 5 mm, or about 4 mm, or about 3 mm, or about 2 mm or less. The length of the strips can be greater than about 5 mm, between about 5 mm and about 15 mm, about 8 mm to about 12 mm, or about 12 mm. Preferably, the strips have substantially the same length as each other. The length of the strips can be determined by the manufacturing process, thereby cutting the strips into shorter rods, and the length of the strips corresponds to the length of the rods. The strips may be brittle, which can lead to breakage, especially during transportation. In this case, some strips may be shorter than the length of the rods.

[0033] The multiple strips preferably extend substantially longitudinally, aligned with the longitudinal axis along the length of the aerosol-generating matrix. Preferably, the multiple strips are thus aligned substantially parallel to each other.

[0034] The homogenized plant material may comprise up to about 95% by weight of plant particles on a dry weight basis. Preferably, the homogenized plant material comprises up to about 90% by weight of plant particles on a dry weight basis, more preferably up to about 80% by weight of plant particles, more preferably up to about 70% by weight of plant particles, more preferably up to about 60% by weight of plant particles, and more preferably up to about 50% by weight of plant particles.

[0035] For example, homogenized plant material may include plant particles of about 2.5% to about 95% by weight, or about 5% to about 90% by weight, or about 10% to about 80% by weight, or about 15% to about 70% by weight, or about 20% to about 60% by weight, or about 30% to about 50% by weight, on a dry weight basis.

[0036] In some embodiments of the invention, the homogenized plant material is a homogenized tobacco material comprising tobacco particles. Sheets of the homogenized tobacco material used in such embodiments of the invention may have a tobacco content of at least about 40% by weight, more preferably at least about 50% by weight, more preferably at least about 70% by weight, and most preferably at least about 90% by weight, based on dry weight.

[0037] Referring to this invention, the term "tobacco pellet" describes the pellets of any plant member of the genus Nicotiana. The term "tobacco pellet" includes ground or pulverized tobacco leaves, ground or pulverized tobacco stems, tobacco dust, tobacco debris, and other particulate tobacco byproducts formed during the processing, handling, and transportation of tobacco. In a preferred embodiment, the tobacco pellets are substantially entirely derived from tobacco leaves. In contrast, isolated nicotine and nicotine salts are compounds derived from tobacco but are not considered tobacco pellets for the purposes of this invention and are not included in the percentage of particulate plant material.

[0038] Tobacco pellets can be prepared from one or more tobacco plants. Any type of tobacco can be used in the blend. Examples of tobacco types that can be used include, but are not limited to, sun-cured tobacco, flue-cured tobacco, Burley tobacco, Maryland tobacco, Oriental tobacco, Virginia tobacco, and other specialty tobaccos.

[0039] Flue-curing is a method of drying tobacco, particularly Virginia tobacco. During the curing process, heated air circulates through densely packed tobacco leaves. In the first stage, the leaves turn yellow and wilt. In the second stage, the leaf blades are completely dried. In the third stage, the stems are completely dried.

[0040] Burley tobacco plays an important role in many tobacco blends. It has a distinctive flavor and aroma and is also capable of absorbing large amounts of casing.

[0041] Oriental tobacco is a type of tobacco characterized by small leaves and high aromatic quality. However, its flavor is milder than that of other tobaccos, such as Burley tobacco. Therefore, a relatively small proportion of Oriental tobacco is typically used in tobacco blends.

[0042] Kasturi, Madura, and Jatim are all usable subtypes of sun-cured tobacco. Preferably, Kasturi tobacco and flue-cured tobacco can be used in a mixture to produce tobacco pellets. Therefore, tobacco pellets in granular plant material can include a mixture of Kasturi tobacco and smoked tobacco.

[0043] The tobacco pellets may have a nicotine content of at least about 2.5% by weight on a dry weight basis. More preferably, the tobacco pellets may have a nicotine content of at least about 3% by weight on a dry weight basis, even more preferably at least about 3.2% by weight, even more preferably at least about 3.5% by weight, and most preferably at least about 4% by weight.

[0044] In certain other embodiments of the invention, the homogenized plant material comprises tobacco particles combined with non-tobacco plant flavor particles. Preferably, the non-tobacco plant flavor particles are selected from one or more of the following: ginger particles, eucalyptus particles, clove particles, and star anise particles. Preferably, in such embodiments, the homogenized plant material comprises at least about 2.5% by weight of non-tobacco plant flavor particles on a dry weight basis, wherein the remainder of the plant particles is tobacco particles. Preferably, the homogenized plant material comprises at least about 4% by weight of non-tobacco plant flavor particles on a dry weight basis, more preferably at least about 6% by weight, more preferably at least about 8% by weight, and more preferably at least about 10% by weight. Preferably, the homogenized plant material comprises up to about 20% by weight of non-tobacco plant flavor particles, more preferably up to about 18% by weight, and more preferably up to about 16% by weight.

[0045] The weight ratio of non-tobacco plant flavor particles to tobacco particles in the granular plant material forming the homogenized plant material can vary depending on the desired flavor characteristics and composition of the aerosols generated by the aerosol-generating matrix during use. Preferably, the homogenized plant material comprises, on a dry weight basis, a non-tobacco plant flavor particle to tobacco particle ratio of at least 1:30, more preferably at least 1:20, even more preferably at least 1:10, and most preferably at least 1:5.

[0046] The homogenized plant material preferably comprises no more than 95% by weight of granular plant material on a dry weight basis. Therefore, the granular plant material is usually combined with one or more other components to form the homogenized plant material.

[0047] The homogenized plant material may also include an adhesive to modify the mechanical properties of the granular plant material, wherein the adhesive is incorporated into the homogenized plant material during the manufacturing process as described herein. Suitable exogenous adhesives are known to those skilled in the art and include, but are not limited to: gums, such as guar gum, xanthan gum, gum arabic, and locust bean gum; cellulose adhesives, 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. Preferably, the adhesive comprises guar gum.

[0048] The adhesive may be present in an amount from about 1% to about 10% by weight based on the dry weight of the homogenized plant material, preferably in an amount from about 2% to about 5% by weight based on the dry weight of the homogenized plant material.

[0049] Alternatively or additionally, the homogenized plant material may further comprise one or more lipids to facilitate the diffusion of volatile components (e.g., aerosol forming agents, gingerol, and nicotine), wherein the lipids are included in the homogenized plant material during manufacturing as described herein. Suitable lipids included in the homogenized plant material include, but are not limited to: medium-chain triglycerides, cocoa butter, palm oil, palm kernel oil, mango oil, shea butter, soybean oil, cottonseed oil, coconut oil, hydrogenated coconut oil, candelilla wax, carnauba wax, shellac, sunflower wax, sunflower oil, rice bran, and RevelA; and combinations thereof.

[0050] Alternatively, homogenized plant materials may further include pH adjusters.

[0051] Alternatively or additionally, the homogenized plant material may further include fibers to modify the mechanical properties of the homogenized plant material, wherein the fibers are incorporated into the homogenized plant material during the manufacturing process as described herein. Suitable exogenous fibers for inclusion in the homogenized plant material are known in the art and include fibers formed from non-tobacco and non-ginger materials, including but not limited to: cellulose fibers; cork fibers; hardwood fibers; jute fibers; and combinations thereof. Exogenous fibers derived from tobacco and / or ginger may also be added. Any fibers added to the homogenized plant material are not considered to form part of the “granular plant material” as defined above. Prior to inclusion in the homogenized plant material, the fibers may be treated by suitable processes known in the art, including but not limited to: mechanical pulping; refining; chemical pulping; bleaching; sulfate pulping; and combinations thereof. The fibers typically have a length greater than their width.

[0052] Suitable fibers typically have a length greater than 400 micrometers and less than or equal to 4 millimeters, preferably in the range of 0.7 millimeters to 4 millimeters. Preferably, the fibers are present in an amount of about 2% to about 15% by weight, most preferably about 4% by weight, based on the dry weight of the matrix.

[0053] Alternatively or additionally, the homogenized plant material may further include one or more aerosol forming agents. Upon evaporation, the aerosol forming agent can transport other vaporized compounds, such as nicotine and flavorings, released from the aerosol-generating matrix upon heating within the aerosol. Suitable aerosol forming agents included in the homogenized plant material are known in the art and include, but are not limited to: polyols, such as triethylene glycol, 1,3-butanediol, and glycerol; esters of polyols, such as mono, di, or triacetic acid esters of glycerol; and fatty acid esters of mono, di, or polycarboxylic acids, such as dimethyl dodecanoate and dimethyl tetradecanoate.

[0054] The homogenized plant material may have an aerosol forming agent content of between about 5% and about 30% by weight on a dry weight basis, for example, between about 10% and about 25% by weight on a dry weight basis, or between about 15% and about 20% by weight on a dry weight basis.

[0055] For example, if the matrix is ​​intended for use in an aerosol-generating article of an electrically operated aerosol-generating system with a heating element, it may preferably include an aerosol-forming agent content of between about 5% and about 30% by weight on a dry weight basis. If the matrix is ​​intended for use in an aerosol-generating article of an electrically operated aerosol-generating system with a heating element, the aerosol-forming agent is preferably glycerol.

[0056] In other embodiments, the homogenized plant material may have an aerosol forming agent content of about 1% to about 5% by weight on a dry weight basis. For example, if the matrix is ​​intended for use in an aerosol-generating article, wherein the aerosol forming agent is held in a separate reservoir from the matrix, the matrix may have an aerosol forming agent content greater than 1% and less than about 5%. In such embodiments, the aerosol forming agent volatilizes upon heating, and the flow of the aerosol forming agent contacts the aerosol-generating matrix to entrain flavor compounds from the aerosol-generating matrix in the aerosol.

[0057] In other embodiments, the homogenized plant material may have an aerosol forming agent content of about 30% to about 45% by weight. This relatively high level of aerosol forming agent is particularly suitable for aerosol-generating matrices intended to be heated at temperatures below 275 degrees Celsius. In such embodiments, the homogenized plant material preferably further comprises between about 2% and about 10% by weight of cellulose ether and between about 5% and about 50% by weight of additional cellulose by dry weight. It has been found that the combination of cellulose ether and additional cellulose provides particularly effective aerosol delivery when used for aerosol-generating matrices having an aerosol forming agent content of between 30% and 45% by weight.

[0058] Suitable cellulose ethers include, but are not limited to, methylcellulose, hydroxypropyl methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, ethyl hydroxyethylcellulose, and carboxymethylcellulose (CMC). In a particularly preferred embodiment, the cellulose ether is carboxymethylcellulose.

[0059] As used herein, the term "added cellulose" encompasses any cellulose material incorporated into the homogenized plant material that is not derived from non-tobacco plant particles or tobacco particles provided in the homogenized plant material. Thus, in addition to non-tobacco plant material or tobacco material, added cellulose is incorporated into the homogenized plant material as a separate and distinct cellulose source from any cellulose inherently provided within the non-tobacco plant particles or tobacco particles. Added cellulose typically originates from plants different from those in the non-tobacco plant particles or tobacco particles. Preferably, the added cellulose is in the form of an inert cellulose material that is sensorily inert and therefore does not substantially affect the sensory properties of the aerosols generated by the aerosol-generating matrix. For example, the added cellulose is preferably a tasteless and odorless material.

[0060] Additional cellulose may include cellulose powder, cellulose fibers, or a combination thereof.

[0061] Aerosol forming agents can act as wetting agents in aerosol generation matrices.

[0062] The packaging for the homogenized plant material strips can be paper or non-paper. Suitable paper packaging for specific embodiments of the invention is known in the art and includes, but is not limited to, cigarette paper and filter tip packaging. Suitable non-paper packaging for specific embodiments of the invention is known in the art and includes, but is not limited to, sheets of homogenized tobacco material. In some preferred embodiments, the packaging may be formed of a laminated material comprising multiple layers. Preferably, the packaging is formed of an aluminum co-laminated sheet. The use of an aluminum co-laminated sheet advantageously prevents the combustion of the aerosol-generating matrix when it should be ignited rather than heated in the intended manner.

[0063] In some preferred embodiments of the invention, the aerosol-generating matrix comprises a gel composition comprising an alkaloid compound. In a particularly preferred embodiment, the aerosol-generating matrix comprises a gel composition comprising nicotine.

[0064] Preferably, the gel composition comprises an alkaloid compound; an aerosol forming agent; and at least one gelling agent. Preferably, at least one gelling agent forms a solid medium, and glycerol is dispersed in the solid medium, wherein the alkaloid is dispersed in the glycerol. Preferably, the gel composition is a stable gel phase.

[0065] Advantageously, nicotine-containing stable gel compositions provide a predictable compositional form during storage or shipment from manufacturer to consumer. Nicotine-containing stable gel compositions substantially retain their shape. Nicotine-containing stable gel compositions substantially do not release the liquid phase during storage or shipment from manufacturer to consumer. Nicotine-containing stable gel compositions allow for simple consumable design. The consumable does not need to be designed to contain liquid, thus allowing for a wider range of material and container constructions to be considered.

[0066] The gel composition described herein can be combined with an aerosol generating device to deliver nicotine aerosol to the lungs at an inhalation rate or airflow rate within the range of conventional smoking inhalation rates or airflow rates. The aerosol generating device can continuously heat the gel composition. The consumer can take multiple inhalations or "puffs," with each "puff" delivering a certain amount of nicotine aerosol. When preferably heated in a continuous manner, the gel composition is capable of delivering a high nicotine / low total particulate matter (TPM) aerosol to the consumer.

[0067] The phrase "stable gel phase" or "stable gel" refers to a gel that substantially retains its shape and quality when exposed to a variety of environmental conditions. When exposed to standard temperature and pressure while the relative humidity changes from about 10% to about 60%, a stable gel will substantially not release (sweat) or absorb moisture. For example, when exposed to standard temperature and pressure while the relative humidity changes from about 10% to about 60%, a stable gel can substantially maintain its shape and quality.

[0068] The gel composition includes an alkaloid compound. The gel composition may include one or more alkaloids.

[0069] The term "alkaloid compound" refers to any of a class of naturally occurring organic compounds containing one or more basic nitrogen atoms. Typically, alkaloids contain at least one nitrogen atom in an amine-type structure. This or other nitrogen atom in the alkaloid compound molecule can function as a base in acid-base reactions. In most alkaloid compounds, one or more of the nitrogen atoms are part of a cyclic system, such as a heterocycle. In nature, alkaloid compounds are primarily found in plants, particularly in certain flowering plant families. However, some alkaloid compounds are found in animal species and fungi. In this disclosure, the term "alkaloid compound" refers to alkaloid compounds of natural origin and synthetically produced alkaloid compounds.

[0070] The gel composition may preferably include an alkaloid compound selected from nicotine, anaphylabine, and combinations thereof.

[0071] Preferably, the gel composition includes nicotine.

[0072] The term "nicotine" refers to nicotine and nicotine derivatives, such as free nicotine base and nicotine salts.

[0073] The gel composition preferably comprises about 0.5% to about 10% by weight of an alkaloid compound. The gel composition may include about 0.5% to about 5% by weight of an alkaloid compound. Preferably, the gel composition comprises about 1% to about 3% by weight of an alkaloid compound. The gel composition may preferably include about 1.5% to about 2.5% by weight of an alkaloid compound. The gel composition may preferably include about 2% by weight of an alkaloid compound. The alkaloid compound component of the gel formulation may be the most volatile component of the gel formulation. In some aspects, water may be the most volatile component of the gel formulation, and the alkaloid compound component of the gel formulation may be the second most volatile component of the gel formulation. In some aspects, water may be the most volatile component of the gel formulation, and the alkaloid compound component of the gel formulation may be the second most volatile component of the gel formulation.

[0074] Preferably, the gel composition includes nicotine. Nicotine may be added to the composition in free alkali form or salt form. The gel composition comprises about 0.5% to about 10% by weight of nicotine, or about 0.5% to about 5% by weight of nicotine. Preferably, the gel composition comprises about 1% to about 3% by weight of nicotine, or about 1.5% to about 2.5% by weight of nicotine, or about 2% by weight of nicotine. The nicotine component of the gel formulation may be the most volatile component of the gel formulation. In some aspects, water may be the most volatile component of the gel formulation, and the nicotine component of the gel formulation may be the second most volatile component of the gel formulation.

[0075] The gel composition includes an aerosol forming agent. Ideally, the aerosol forming agent is substantially resistant to thermal degradation at the operating temperature of the associated aerosol generating device. Suitable aerosol forming agents include, but are not limited to: polyols, such as triethylene glycol, 1,3-butanediol, and glycerol; esters of polyols, such as mono-, di-, or triacetic acid esters of glycerol; and aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanoate and dimethyl tetradecanoate. The polyol or mixture thereof may be one or more of triethylene glycol, 1,3-butanediol, glycerol (glycerol or propane-1,2,3-triol), or polyethylene glycol. The aerosol forming agent is preferably glycerol.

[0076] The gel composition may include a majority aerosol forming agent. The gel composition may include a mixture of water and an aerosol forming agent, wherein the aerosol forming agent forms the majority (by weight) of the gel composition. The aerosol forming agent may form at least about 50% by weight of the gel composition. The aerosol forming agent may form at least about 60% by weight, at least about 65% by weight, or at least about 70% by weight of the gel composition. The aerosol forming agent may form about 70% by weight to about 80% by weight of the gel composition. The aerosol forming agent may form about 70% by weight to about 75% by weight of the gel composition.

[0077] The gel composition may comprise a majority of glycerol. The gel composition may comprise a mixture of water and glycerol, wherein glycerol forms the majority (by weight) of the gel composition. Glycerol may form at least about 50% by weight of the gel composition. Glycerol may form at least about 60% by weight, at least about 65% by weight, or at least about 70% by weight of the gel composition. Glycerol may form about 70% by weight to about 80% by weight of the gel composition. Glycerol may form about 70% by weight to about 75% by weight of the gel composition.

[0078] The gel composition preferably includes at least one gelling agent. Preferably, the gel composition includes a gelling agent in a total amount ranging from about 0.4% to about 10% by weight. More preferably, the composition includes a gelling agent in a total amount ranging from about 0.5% to about 8% by weight. More preferably, the composition includes a gelling agent in a total amount ranging from about 1% to about 6% by weight. More preferably, the composition includes a gelling agent in a total amount ranging from about 2% to about 4% by weight. More preferably, the composition includes a gelling agent in a total amount ranging from about 2% to about 3% by weight.

[0079] The term "gelling agent" refers to a compound that, when added in an amount of about 0.3% by weight to a mixture of 50% by weight water and 50% by weight glycerol, homogeneously forms a solid medium or supporting matrix that results in gelation. Gelling agents include, but are not limited to, hydrogen-bonded crosslinking gelling agents and ionic crosslinking gelling agents.

[0080] Gelling agents may include one or more biopolymers. Biopolymers may be formed from polysaccharides.

[0081] Biopolymers include, for example, gellan gum (natural, low-acyl gellan gum, high-acyl gellan gum, preferably low-acyl gellan gum), xanthan gum, alginate (alginic acid), agar, guar gum, etc. The composition may preferably include xanthan gum. The composition may include two biopolymers. The composition may include three biopolymers. The composition may include two biopolymers in substantially equal weight. The composition may include three biopolymers in substantially equal weight.

[0082] Preferably, the gel composition comprises at least about 0.2% by weight of a hydrogen-bonded crosslinking gelling agent. Alternatively or additionally, the gel composition preferably comprises at least about 0.2% by weight of an ionic crosslinking gelling agent. Most preferably, the gel composition comprises at least about 0.2% by weight of both a hydrogen-bonded crosslinking gelling agent and at least about 0.2% by weight of an ionic crosslinking gelling agent. The gel composition may comprise about 0.5% to about 3% by weight of a hydrogen-bonded crosslinking gelling agent and about 0.5% to about 3% by weight of an ionic crosslinking gelling agent, or about 1% to about 2% by weight of a hydrogen-bonded crosslinking gelling agent and about 1% to about 2% by weight of an ionic crosslinking gelling agent. The hydrogen-bonded crosslinking gelling agent and the ionic crosslinking gelling agent may be present in substantially equal amounts by weight in the gel composition.

[0083] The term "hydrogen-bonded crosslinking gelling agent" refers to a gelling agent that forms non-covalent or physical crosslinking bonds via hydrogen bonds. Hydrogen bonds are a type of electrostatic dipole-dipole attraction between molecules, rather than covalent bonds with hydrogen atoms. They arise from the attractive force between a hydrogen atom covalently bonded to a highly negatively charged atom (such as N, O, or F) and another highly negatively charged atom.

[0084] Hydrogen-bonded crosslinking gelling agents may include one or more of galactomannan, gelatin, agarose, konjac gum, or agar. Preferably, hydrogen-bonded crosslinking gelling agents include agar.

[0085] The gel composition preferably includes a hydrogen-bonded crosslinking gelling agent ranging from about 0.3% to about 5% by weight. Preferably, the composition includes a hydrogen-bonded crosslinking gelling agent ranging from about 0.5% to about 3% by weight. Preferably, the composition includes a hydrogen-bonded crosslinking gelling agent ranging from about 1% to about 2% by weight.

[0086] The gel composition may include galactomannan in the range of about 0.2% to about 5% by weight. Preferably, the galactomannan may be in the range of about 0.5% to about 3% by weight. Preferably, the galactomannan may be in the range of about 0.5% to about 2% by weight. Preferably, the galactomannan may be in the range of about 1% to about 2% by weight.

[0087] The gel composition may include gelatin in the range of about 0.2% by weight to about 5% by weight. Preferably, the gelatin may be in the range of about 0.5% by weight to about 3% by weight. Preferably, the gelatin may be in the range of about 0.5% by weight to about 2% by weight. Preferably, the gelatin may be in the range of about 1% by weight to about 2% by weight.

[0088] The gel composition may include agarose ranging from about 0.2% by weight to about 5% by weight. Preferably, the agarose ranges from about 0.5% by weight to about 3% by weight. Preferably, the agarose ranges from about 0.5% by weight to about 2% by weight. Preferably, the agarose ranges from about 1% by weight to about 2% by weight.

[0089] The gel composition may include konjac gum in the range of about 0.2% to about 5% by weight. Preferably, the konjac gum may be in the range of about 0.5% to about 3% by weight. Preferably, the konjac gum may be in the range of about 0.5% to about 2% by weight. Preferably, the konjac gum may be in the range of about 1% to about 2% by weight.

[0090] The gel composition may include agar in the range of about 0.2% by weight to about 5% by weight. Preferably, the agar may be in the range of about 0.5% by weight to about 3% by weight. Preferably, the agar may be in the range of about 0.5% by weight to about 2% by weight. Preferably, the agar may be in the range of about 1% by weight to about 2% by weight.

[0091] The term "ionic crosslinking gelling agent" refers to a gelling agent that forms non-covalent or physical crosslinking bonds through ionic bonds. Ionic crosslinking involves the association of polymer chains through non-covalent interactions. A crosslinked network is formed when multivalent molecules with opposite charges attract each other electrostatically to form a crosslinked polymer network.

[0092] Ionic crosslinking gelling agents may include low-acyl gellan gum, pectin, κ-carrageenan, ι-carrageenan, or alginate. Ionic crosslinking gelling agents may preferably include low-acyl gellan gum.

[0093] The gel composition may include an ionic crosslinking gelling agent ranging from about 0.3% to about 5% by weight. Preferably, the composition includes an ionic crosslinking gelling agent ranging from about 0.5% to about 3% by weight. Preferably, the composition includes an ionic crosslinking gelling agent ranging from about 1% to about 2% by weight.

[0094] The gel composition may include a low-acyl gellan gum in the range of about 0.2 wt% to about 5 wt%. Preferably, the low-acyl gellan gum may be in the range of about 0.5 wt% to about 3 wt%. Preferably, the low-acyl gellan gum may be in the range of about 0.5 wt% to about 2 wt%. Preferably, the low-acyl gellan gum may be in the range of about 1 wt% to about 2 wt%.

[0095] The gel composition may include pectin in the range of about 0.2% by weight to about 5% by weight. Preferably, the pectin may be in the range of about 0.5% by weight to about 3% by weight. Preferably, the pectin may be in the range of about 0.5% by weight to about 2% by weight. Preferably, the pectin may be in the range of about 1% by weight to about 2% by weight.

[0096] The gel composition may include κ-carrageenan in the range of about 0.2 wt% to about 5 wt%. Preferably, κ-carrageenan may be in the range of about 0.5 wt% to about 3 wt%. Preferably, κ-carrageenan may be in the range of about 0.5 wt% to about 2 wt%. Preferably, κ-carrageenan may be in the range of about 1 wt% to about 2 wt%.

[0097] The gel composition may include 1-carrageenan in the range of about 0.2% to about 5% by weight. Preferably, 1-carrageenan may be in the range of about 0.5% to about 3% by weight. Preferably, 1-carrageenan may be in the range of about 0.5% to about 2% by weight. Preferably, 1-carrageenan may be in the range of about 1% to about 2% by weight.

[0098] The gel composition may include alginate in the range of about 0.2 wt% to about 5 wt%. Preferably, the alginate may be in the range of about 0.5 wt% to about 3 wt%. Preferably, the alginate may be in the range of about 0.5 wt% to about 2 wt%. Preferably, the alginate may be in the range of about 1 wt% to about 2 wt%.

[0099] The gel composition may comprise a hydrogen-bonded crosslinking gelling agent and an ionic crosslinking gelling agent in a ratio of about 3:1 to about 1:3. Preferably, the gel composition may comprise a hydrogen-bonded crosslinking gelling agent and an ionic crosslinking gelling agent in a ratio of about 2:1 to about 1:2. Preferably, the gel composition may comprise a hydrogen-bonded crosslinking gelling agent and an ionic crosslinking gelling agent in a ratio of about 1:1.

[0100] The gel composition may also include a thickener. Thickeners combined with hydrogen-bonded crosslinking gelling agents and ionic crosslinking gelling agents appear to unexpectedly support the solid medium and maintain the gel composition, even when the gel composition includes high levels of glycerol.

[0101] The term "thickening agent" refers to a compound that, when homogenized in an amount of 0.3% by weight at 25°C, increases viscosity without causing gel formation, and the mixture retains or preserves fluidity. Preferably, the thickening agent refers to a compound that, when homogenized in an amount of 0.3% by weight at 25°C, increases viscosity at a rate of 0.1s... -1 The shear rate increases the viscosity to at least 50 cPs, preferably at least 200 cPs, preferably at least 500 cPs, preferably at least 1000 cPs, without causing gel formation, and the mixture retains or preserves fluidity. Preferably, the thickener refers to a compound that, when homogeneously added in an amount of 0.3 wt% to a mixture of 50 wt% water / 50 wt% glycerol at 25°C, increases the viscosity at a rate of 0.1 s⁻¹. -1 The shear rate causes the viscosity to increase by at least 2, 5, 10, or 100 times compared to before addition, without causing gel formation, the mixture retains or preserves the fluidity of the compound.

[0102] The viscosity values ​​described herein can be measured using a Brookfield RVT viscometer at 25°C by rotating the disc-type RV#2 spindle at a speed of 6 revolutions per minute (rpm).

[0103] The gel composition preferably includes a tackifier ranging from about 0.2 wt% to about 5 wt%. Preferably, the composition includes a tackifier ranging from about 0.5 wt% to about 3 wt%. Preferably, the composition includes a tackifier ranging from about 0.5 wt% to about 2 wt%. Preferably, the composition includes a tackifier ranging from about 1 wt% to about 2 wt%.

[0104] The thickener may include one or more of xanthan gum, carboxymethyl cellulose, microcrystalline cellulose, methyl cellulose, gum arabic, guar gum, λ-carrageenan, or starch. Xanthan gum is a preferred thickener.

[0105] The gel composition may include xanthan gum in the range of about 0.2% to about 5% by weight. Preferably, xanthan gum may be in the range of about 0.5% to about 3% by weight. Preferably, xanthan gum may be in the range of about 0.5% to about 2% by weight. Preferably, xanthan gum may be in the range of about 1% to about 2% by weight.

[0106] The gel composition may include carboxymethyl cellulose in the range of about 0.2% to about 5% by weight. Preferably, the carboxymethyl cellulose may be in the range of about 0.5% to about 3% by weight. Preferably, the carboxymethyl cellulose may be in the range of about 0.5% to about 2% by weight. Preferably, the carboxymethyl cellulose may be in the range of about 1% to about 2% by weight.

[0107] The gel composition may include microcrystalline cellulose in the range of about 0.2% to about 5% by weight. Preferably, the microcrystalline cellulose may be in the range of about 0.5% to about 3% by weight. Preferably, the microcrystalline cellulose may be in the range of about 0.5% to about 2% by weight. Preferably, the microcrystalline cellulose may be in the range of about 1% to about 2% by weight.

[0108] The gel composition may include methylcellulose in the range of about 0.2% to about 5% by weight. Preferably, the methylcellulose may be in the range of about 0.5% to about 3% by weight. Preferably, the methylcellulose may be in the range of about 0.5% to about 2% by weight. Preferably, the methylcellulose may be in the range of about 1% to about 2% by weight.

[0109] The gel composition may include gum arabic in the range of about 0.2 wt% to about 5 wt%. Preferably, gum arabic may be in the range of about 0.5 wt% to about 3 wt%. Preferably, gum arabic may be in the range of about 0.5 wt% to about 2 wt%. Preferably, gum arabic may be in the range of about 1 wt% to about 2 wt%.

[0110] The gel composition may include guar gum in the range of about 0.2% to about 5% by weight. Preferably, the guar gum may be in the range of about 0.5% to about 3% by weight. Preferably, the guar gum may be in the range of about 0.5% to about 2% by weight. Preferably, the guar gum may be in the range of about 1% to about 2% by weight.

[0111] The gel composition may include λ-carrageenan in the range of about 0.2 wt% to about 5 wt%. Preferably, λ-carrageenan may be in the range of about 0.5 wt% to about 3 wt%. Preferably, λ-carrageenan may be in the range of about 0.5 wt% to about 2 wt%. Preferably, λ-carrageenan may be in the range of about 1 wt% to about 2 wt%.

[0112] The gel composition may include starch in the range of about 0.2% by weight to about 5% by weight. Preferably, the starch may be in the range of about 0.5% by weight to about 3% by weight. Preferably, the starch may be in the range of about 0.5% by weight to about 2% by weight. Preferably, the starch may be in the range of about 1% by weight to about 2% by weight.

[0113] The gel composition may also include divalent cations. Preferably, the divalent cations include calcium ions, such as calcium lactate in solution. For example, divalent cations (such as calcium ions) can help form a gel in a composition including a gelling agent such as an ionic crosslinking gelling agent. Ionic effects can aid gel formation. Divalent cations may be present in the gel composition in the range of about 0.1% by weight to about 1% by weight or about 0.5% by weight.

[0114] The gel composition may also include an acid. The acid may include a carboxylic acid. The carboxylic acid may include a ketone group. Preferably, the carboxylic acid may include a ketone group having less than about 10 carbon atoms, less than about 6 carbon atoms, or less than about 4 carbon atoms, such as levulinic acid or lactic acid. Preferably, the carboxylic acid has three carbon atoms (such as lactic acid). Lactic acid surprisingly improves the stability of the gel composition even more than similar carboxylic acids. Carboxylic acids can aid in gel formation. During storage, carboxylic acids can reduce changes in the concentration of alkaloid compounds in the gel composition. During storage, carboxylic acids can reduce changes in the concentration of nicotine in the gel composition.

[0115] The gel composition may include a carboxylic acid ranging from about 0.1 wt% to about 5 wt%. Preferably, the carboxylic acid may range from about 0.5 wt% to about 3 wt%. Preferably, the carboxylic acid may range from about 0.5 wt% to about 2 wt%. Preferably, the carboxylic acid may range from about 1 wt% to about 2 wt%.

[0116] The gel composition may include lactic acid in the range of about 0.1% to about 5% by weight. Preferably, the lactic acid may be in the range of about 0.5% to about 3% by weight. Preferably, the lactic acid may be in the range of about 0.5% to about 2% by weight. Preferably, the lactic acid may be in the range of about 1% to about 2% by weight.

[0117] The gel composition may include levulinic acid in the range of about 0.1% to about 5% by weight. Preferably, levulinic acid may be in the range of about 0.5% to about 3% by weight. Preferably, levulinic acid may be in the range of about 0.5% to about 2% by weight. Preferably, levulinic acid may be in the range of about 1% to about 2% by weight.

[0118] The gel composition preferably includes some water. When the gel composition includes some water, the gel composition is more stable. Preferably, the gel composition includes at least about 1% by weight, or at least about 2% by weight, or at least about 5% by weight of water. Preferably, the gel composition includes at least about 10% by weight or at least about 15% by weight of water.

[0119] Preferably, the gel composition comprises between about 8% and 32% by weight of water. Preferably, the gel composition comprises from about 15% to about 25% by weight of water. Preferably, the gel composition comprises from about 18% to about 22% by weight of water. Preferably, the gel composition comprises about 20% by weight of water.

[0120] Preferably, the aerosol generating matrix comprises a gel composition of between about 150 mg and about 350 mg.

[0121] Preferably, the aerosol-generating matrix comprises a porous medium loaded with a gel composition. The advantage of a porous medium loaded with a gel composition is that the gel composition is retained within the porous medium, which facilitates the manufacture, storage, or transport of the gel composition. It helps maintain the desired shape of the gel composition, particularly during manufacture, transport, or use.

[0122] The porous medium can be any suitable porous material capable of containing or retaining the gel composition. Ideally, the porous medium allows the gel composition to move within it. In certain embodiments, the porous medium includes natural materials, synthetic or semi-synthetic materials, or combinations thereof. In certain embodiments, the porous medium includes sheet materials, foams, or fibers, such as loose fibers; or combinations thereof. In certain embodiments, the porous medium includes woven, nonwoven, or extruded materials, or combinations thereof. Preferably, the porous medium includes cotton, paper, viscose fibers, PLA, or cellulose acetate, or combinations thereof. Preferably, the porous medium includes sheet materials, such as cotton or cellulose acetate. In a particularly preferred embodiment, the porous medium includes a sheet made of cotton fibers.

[0123] The porous medium used in this invention can be coiled or shredded. In a preferred embodiment, the porous medium is coiled. In an alternative embodiment, the porous medium comprises shredded porous medium. The coiling or shredding process can be performed before or after loading the gel composition.

[0124] Curling the sheet material has the benefit of improving the structure to allow pathways through it. The passages through the curled sheet material help load and retain the gel, and also facilitate fluid flow through the curled sheet material. Therefore, using curled sheet materials as porous media has advantages.

[0125] Chopping allows for easy absorption of the gel due to the high surface area to the volume ratio of the culture medium.

[0126] In certain embodiments, the sheet is a composite material. Preferably, the sheet is porous. The sheet can aid in the fabrication of tubular elements comprising a gel. The sheet can aid in the introduction of surfactants into tubular elements comprising a gel. The sheet can help stabilize the structure of tubular elements comprising a gel. The sheet can aid in the transport or storage of the gel. Using the sheet can enable or facilitate the addition of structures to porous media, for example, by curling the sheet.

[0127] The porous medium can be a thread. This thread can include, for example, cotton, paper, or acetate filaments. The thread can also be loaded with gel, as with any other porous medium. An advantage of using threads as a porous medium is that it facilitates ease of manufacture.

[0128] The filament can be loaded with gel by any known method. The filament can be simply coated with gel, or it can be impregnated with gel. In manufacturing, the filament can be impregnated with gel and stored in preparation for inclusion in the assembly of tubular elements.

[0129] The porous medium containing the gel composition is preferably disposed within a tubular element that forms part of an aerosol-generating article. The term "tubular element" is used to describe a component suitable for an aerosol-generating article. Ideally, the longitudinal length of the tubular element may be longer than its width, but this is not necessary, as it can be part of a multi-component article where its longitudinal length is ideally longer than its width. Typically, the tubular element is cylindrical, but this is not mandatory. For example, the tubular element may have an elliptical, triangular, or rectangular polygonal or irregular cross-section.

[0130] The tubular element preferably includes a first longitudinal passage. The tubular element is preferably formed from a package defining the first longitudinal passage. The package is preferably a waterproof package. This waterproof property of the package can be achieved by using a waterproof material or by treating the material of the package. This can be achieved by treating one or both sides of the package. Waterproofing helps to maintain structure, rigidity, or stiffness. This also helps to prevent leakage of gels or liquids, especially when using gels with a fluid structure.

[0131] Preferably, in embodiments where the aerosol generating matrix strip comprises the gel composition as described above, the downstream section of the aerosol generating article includes an aerosol cooling element with a length of less than 10 mm. It has been found that combining relatively short aerosol cooling elements with the gel composition optimizes aerosol delivery to consumers. Further details regarding the provision of aerosol cooling elements are provided below.

[0132] In embodiments of the invention where the aerosol generating matrix strip comprises the gel composition as described above, an upstream element is preferably included upstream of the aerosol generating matrix strip. In this case, the upstream element advantageously prevents physical contact with the gel composition. The upstream element can also advantageously compensate for any potential reduction in RTD, for example due to evaporation of the gel composition during heating of the aerosol generating matrix strip during use. Further details regarding the provision of such an upstream element will be described below.

[0133] In some embodiments, in the aerosol generating article according to the invention, the receptor is arranged within the aerosol generating matrix strip and is in thermal contact with the aerosol generating matrix. Preferably, the receptor is an elongated receptor. More preferably, the elongated receptor is arranged substantially longitudinally within the aerosol generating matrix strip.

[0134] As used herein with reference to this invention, the term "receptor" refers to a material that can convert electromagnetic energy into heat. When located within a fluctuating electromagnetic field, eddy currents induced in the receptor cause heating of the receptor. When an elongated receptor is in thermal contact with an aerosol-generating matrix, the aerosol-generating matrix is ​​heated by the receptor.

[0135] When used to describe receptors, the term "elongated" means that the length of the receptor is greater than its width or thickness, for example, twice as large as its width or thickness.

[0136] The receptors can be arranged generally longitudinally within the strip. This means that the length of the elongated receptors is arranged approximately parallel to the longitudinal direction of the strip, for example, within + / - 10 degrees of the longitudinal direction of the strip. In a preferred embodiment, the elongated receptors can be located at the radial center within the strip and extend along the longitudinal axis of the strip.

[0137] Preferably, the receptor extends to the downstream end of the aerosol-generating article strip. In some embodiments, the receptor may extend to the upstream end of the aerosol-generating article strip. In a particularly preferred embodiment, the receptor has substantially the same length as the aerosol-generating matrix strip and extends from the upstream end of the strip to the downstream end.

[0138] The receptor is preferably in the form of a needle, strip, band or blade.

[0139] The receptor preferably has a length from about 5 mm to about 15 mm, for example from about 6 mm to about 12 mm, or from about 8 mm to about 10 mm.

[0140] The ratio between the length of the receptor and the total length of the aerosol-generated article matrix can be from about 0.2 to about 0.35.

[0141] Preferably, the ratio between the length of the receptor and the total length of the aerosol-generating article matrix is ​​at least about 0.22, more preferably at least about 0.24, and even more preferably at least about 0.26. The ratio between the length of the receptor and the total length of the aerosol-generating article matrix is ​​preferably less than about 0.34, more preferably less than about 0.32, and even more preferably less than about 0.3.

[0142] In some embodiments, the ratio between the length of the receptor and the total length of the aerosol-generating article matrix is ​​preferably from about 0.22 to about 0.34, more preferably from about 0.24 to about 0.34, and even more preferably from about 0.26 to about 0.34. In other embodiments, the ratio between the length of the receptor and the total length of the aerosol-generating article matrix is ​​preferably from about 0.22 to about 0.32, more preferably from about 0.24 to about 0.32, and even more preferably from about 0.26 to about 0.32. In yet another embodiment, the ratio between the length of the receptor and the total length of the aerosol-generating article matrix is ​​preferably from about 0.22 to about 0.3, more preferably from about 0.24 to about 0.3, and even more preferably from about 0.26 to about 0.3.

[0143] In a particularly preferred embodiment, the ratio between the length of the receptor and the total length of the aerosol-generated article matrix is ​​approximately 0.27.

[0144] The receptor preferably has a width from about 1 mm to about 5 mm.

[0145] The receptor may have a thickness generally from about 0.01 mm to about 2 mm, for example from about 0.5 mm to about 2 mm. In some embodiments, the receptor preferably has a thickness from about 10 micrometers to about 500 micrometers, more preferably from about 10 micrometers to about 100 micrometers.

[0146] If the receptor has a constant cross-section, such as a circular cross-section, its preferred width or diameter is from about 1 mm to about 5 mm.

[0147] If the receptor is in the form of a strip or leaf, the strip or leaf preferably has a rectangular shape, the rectangular shape having a width preferably from about 2 mm to about 8 mm, more preferably from about 3 mm to about 5 mm. For example, a receptor in the form of a strip or leaf may have a width of about 4 mm.

[0148] If the receptor is in the form of a strip or leaf, the strip or leaf preferably has a rectangular shape and a thickness from about 0.03 mm to about 0.15 mm, more preferably from about 0.05 mm to about 0.09 mm. For example, a receptor in the form of a strip or leaf may have a thickness of about 0.07 mm.

[0149] In a preferred embodiment, the elongated receptor (in the form of a strip or leaf, preferably having a rectangular shape, and) has a thickness from about 55 micrometers to about 65 micrometers.

[0150] More preferably, the elongated receptor has a thickness from about 57 micrometers to about 63 micrometers. Even more preferably, the elongated receptor has a thickness from about 58 micrometers to about 62 micrometers. In a particularly preferred embodiment, the elongated receptor has a thickness of about 60 micrometers.

[0151] Without being bound by theory, the inventors believe that, overall, the selection of a given thickness of the receptor is also influenced by constraints imposed by the selected length and width of the receptor, as well as the geometry and dimensions of the aerosol-generating matrix strip. For example, the length of the receptor is preferably selected to match the length of the aerosol-generating matrix strip. Preferably, the width of the receptor should be selected to prevent displacement of the receptor within the matrix, while also allowing for easy insertion during manufacturing.

[0152] The inventors have discovered that it is advantageously possible, in a particularly effective and efficient manner, to generate and distribute heat throughout the aerosol-generating matrix in a sensor having a thickness within the aforementioned range, for use in supplying induction heating during use. Without wishing to be bound by theory, the inventors believe this is because such a sensor is suited to providing optimal heat generation and transfer by means of the sensor surface area and induction power. In contrast, thinner sensors may be too easily deformed and may not be able to maintain the desired shape and orientation within the aerosol-generating matrix strip during the manufacture of the aerosol-generating article, potentially leading to a less uniform and finely tunable heat distribution during use. Simultaneously, thicker sensors may be more difficult to cut to a precise and consistent length, and this may also affect how precisely longitudinally aligned sensors can be provided within the aerosol-generating matrix strip, thus potentially affecting the uniformity of heat distribution within the strip. These advantageous effects are felt particularly when the sensor extends to the downstream end of the aerosol-generating article strip. This is believed to be because the suction resistance (RTD) downstream of the receptor can be substantially minimized, since there is no aerosol-generating matrix within the strip at the downstream location of the receptor that could contribute to the RTD. This is achieved particularly effectively in some preferred embodiments, which will be described in more detail below, wherein the aerosol-generating article includes a downstream section comprising a hollow intermediate section. Such a hollow intermediate section substantially does not contribute to the overall RTD of the aerosol-generating article and does not directly contact the downstream end of the receptor.

[0153] Without being bound by theory, the inventors believe that the downstream portion of the aerosol generating matrix strip can, to some extent, act as a filter relative to the upstream portion of the aerosol generating matrix strip. Therefore, the inventors believe it is desirable to homogeneously heat the downstream portion of the aerosol generating matrix strip, enabling it to actively participate in the release of volatile aerosols and contributing to the overall aerosol generation and delivery. Any potential filtering effect (which might hinder aerosol delivery to the consumer) is actively offset by the release of volatile aerosols throughout the aerosol generating matrix.

[0154] Preferably, the elongated receptor has a length that is the same as or shorter than the length of the aerosol-generating matrix. Preferably, the elongated receptor has the same length as the aerosol-generating matrix.

[0155] The receptor can be formed from any material capable of being inductively heated to a temperature sufficient to generate aerosols from the aerosol-generating matrix. Preferred receptors include metals or carbon.

[0156] Preferred sensors may comprise or be composed of ferromagnetic materials, such as ferromagnetic alloys, ferritic iron, ferromagnetic steel, or stainless steel. Suitable sensors may be aluminum or include aluminum. Preferred sensors may be made of 400 series stainless steel, such as grade 410, 420, or 430 stainless steel. Different materials will consume different amounts of energy when positioned within an electromagnetic field with similar frequency and field strength.

[0157] Therefore, the parameters of the sensor, such as material type, length, width, and thickness, can be varied within a known electromagnetic field to provide the required power consumption. Preferably, the sensor can be heated to temperatures exceeding 250 degrees Celsius.

[0158] Suitable receptors may include a non-metallic core having a metallic layer disposed on the non-metallic core, such as metallic traces formed on the surface of a ceramic core. The receptor may have an outer protective layer, such as a ceramic or glass protective layer encapsulating the receptor. The receptor may include a protective coating formed of glass, ceramic, or an inert metal on the core of the receptor material.

[0159] The receptor is arranged in thermal contact with the aerosol-generating matrix. Therefore, when the receptor heats up, the aerosol-generating matrix is ​​heated and forms an aerosol. Preferably, the receptor is arranged in direct physical contact with the aerosol-generating matrix, for example, within the aerosol-generating matrix.

[0160] The receptor can be a multi-material receptor and may include a first receptor material and a second receptor material. The first receptor material is disposed in close physical contact with the second receptor material. The second receptor material preferably has a Curie temperature below 500 degrees Celsius. The first receptor material is preferably primarily used to heat the receptor when it is placed in a fluctuating electromagnetic field. Any suitable material can be used. For example, the first receptor material may be aluminum, or it may be an iron-containing material, such as stainless steel. The second receptor material is preferably primarily used to indicate when the receptor has reached a specific temperature, which is the Curie temperature of the second receptor material. The Curie temperature of the second receptor material can be used to regulate the temperature of the entire receptor during operation. Therefore, the Curie temperature of the second receptor material should be below the ignition point of the aerosol-generating matrix. Suitable materials for the second receptor material may include nickel and certain nickel alloys.

[0161] By providing a sensor having at least first and second sensor materials, wherein the second sensor material has a Curie temperature and the first sensor material does not have a Curie temperature, or the first and second sensor materials have first and second Curie temperatures different from each other, the heating of the aerosol generating matrix and the temperature control of the heating can be separated. The first sensor material is preferably a magnetic material having a Curie temperature of 500 degrees Celsius or higher. From the viewpoint of heating efficiency, it is desirable that the Curie temperature of the first sensor material is above any maximum temperature to which the sensor should be heated. The second Curie temperature can preferably be selected as below 400 degrees Celsius, more preferably below 380 degrees Celsius, or below 360 degrees Celsius. Preferably, the second sensor material is a selected magnetic material having a second Curie temperature substantially the same as the desired maximum heating temperature. That is, preferably, the second Curie temperature is substantially the same as the temperature to which the sensor should be heated in order to generate aerosols from the aerosol generating matrix. The second Curie temperature can, for example, be in the range of 200 degrees Celsius to 400 degrees Celsius, or between 250 degrees Celsius and 360 degrees Celsius. The second Curie temperature of the second receptor material can be selected, for example, such that after being heated by a receptor at a temperature equal to the second Curie temperature, the overall average temperature of the aerosol-generating matrix does not exceed 240 degrees Celsius.

[0162] As briefly described above, the aerosol generating article according to the invention further includes a downstream section located downstream of the aerosol generating matrix strip. As will be apparent from the following description of various embodiments of the aerosol generating article of the invention, the downstream section may include one or more downstream elements.

[0163] According to the present invention, the downstream section of the aerosol generating article particularly includes a mouthpiece element positioned downstream of the aerosol generating matrix strip and longitudinally aligned with the aerosol generating matrix strip.

[0164] Preferably, the mouthpiece element is located at the downstream end or mouth end of the aerosol generating article and extends all the way to the mouth end of the aerosol generating article.

[0165] Preferably, the mouthpiece element includes at least one mouthpiece filter segment of a fibrous filter material for filtering aerosols generated from the aerosol generating matrix. Suitable fibrous filter materials will be known to those skilled in the art. Particularly preferably, at least one mouthpiece filter segment comprises a cellulose acetate filter segment formed from cellulose acetate tow.

[0166] In some preferred embodiments, the mouthpiece element comprises a single mouthpiece filter segment. In alternative embodiments, the mouthpiece element includes two or more mouthpiece filter segments aligned axially with each other in an adjacent-end-to-end relationship.

[0167] In some embodiments of the invention, the downstream section may include an end cavity at a downstream end of the mouthpiece element as described above. The end cavity may be defined by a hollow tubular element located at the downstream end of the mouthpiece. Alternatively, the end cavity may be defined by an outer casing of the mouthpiece element, wherein the outer casing extends from the mouthpiece element in a downstream direction.

[0168] The mouthpiece element may optionally include a flavoring agent, which may be provided in any suitable form. For example, the mouthpiece element may include one or more capsules, beads or granules of flavoring agent, or one or more strands or filaments loaded with flavoring agent.

[0169] In the aerosol generating article according to the invention, the mouthpiece element forms part of the downstream section and is therefore located downstream of the aerosol generating matrix strip.

[0170] In some preferred embodiments, the downstream section of the aerosol generating article further includes a support element located immediately downstream of the aerosol generating matrix strip. The mouthpiece element is preferably located downstream of the support element. Preferably, the downstream section further includes an aerosol cooling element located immediately downstream of the support element. The mouthpiece element is preferably located downstream of both the support element and the aerosol cooling element. Particularly preferably, the mouthpiece element is located immediately downstream of the aerosol cooling element. For example, the mouthpiece element may be adjacent to the downstream end of the aerosol cooling element.

[0171] Preferably, the mouthpiece element has a low particle filtration efficiency.

[0172] Preferably, the mouthpiece is formed from segments of fibrous filter material.

[0173] Preferably, the mouthpiece element is defined by a filter segment package. Preferably, the mouthpiece element is non-ventilated, preventing air from entering the aerosol-forming article along the mouthpiece element.

[0174] The mouthpiece element is preferably connected to one or more adjacent upstream components of the aerosol generating article by means of a sputtering package. For example, the mouthpiece element may be connected to an adjacent aerosol cooling element by means of a sputtering paper tape.

[0175] Preferably, the mouthpiece element has an RTD of less than about 25 mm H2O. More preferably, the mouthpiece element has an RTD of less than about 20 mm H2O. Even more preferably, the mouthpiece element has an RTD of less than about 15 mm H2O.

[0176] An RTD value of about 10 mm H2O to about 15 mm H2O is particularly preferred because a mouthpiece element with such an RTD is expected to contribute minimally to the overall RTD of the aerosol-generating article and essentially does not exert a filtering effect on the aerosol delivered to the consumer.

[0177] Preferably, the mouthpiece element has an outer diameter approximately equal to the outer diameter of the aerosol-generating article. The mouthpiece element may have an outer diameter between about 5 mm and about 10 mm, or between about 6 mm and about 8 mm. In a preferred embodiment, the mouthpiece element has an outer diameter of about 7.2 mm.

[0178] The mouthpiece element preferably has a length of at least about 5 mm, more preferably at least about 8 mm, and even more preferably at least about 10 mm. Alternatively or additionally, the mouthpiece element preferably has a length of less than about 25 mm, more preferably less than about 20 mm, and even more preferably less than about 15 mm.

[0179] In some embodiments, the mouthpiece element preferably has a length from about 5 mm to about 25 mm, more preferably from about 8 mm to about 25 mm, and even more preferably from about 10 mm to about 25 mm. In other embodiments, the mouthpiece element preferably has a length from about 5 mm to about 10 mm, more preferably from about 8 mm to about 20 mm, and even more preferably from about 10 mm to about 20 mm. In still other embodiments, the mouthpiece element preferably has a length from about 5 mm to about 15 mm, more preferably from about 8 mm to about 15 mm, and even more preferably from about 10 mm to about 15 mm.

[0180] For example, the mouthpiece element may have a length between about 5 mm and about 25 mm, or between about 8 mm and about 20 mm, or between about 10 mm and about 15 mm. In a preferred embodiment, the mouthpiece element has a length of about 12 mm.

[0181] In some preferred embodiments of the invention, the mouthpiece element has a length of at least 10 mm. Therefore, in such embodiments, the mouthpiece element is relatively long compared to mouthpiece elements provided in prior art articles. Providing a relatively long mouthpiece element in the aerosol-generating article of the present invention offers several benefits to the consumer. Compared to other elements (such as aerosol cooling elements or support elements) that may be disposed downstream of the aerosol-generating matrix strip, the mouthpiece element is generally more resilient to deformation or better adapted to returning to its initial shape after deformation. Therefore, increasing the length of the mouthpiece element is found to provide an improved grip for the consumer and facilitates insertion of the aerosol-generating article into a heating device. A longer mouthpiece can also be used to provide a higher level of filtration and removal of unwanted aerosol components, such as phenol, resulting in the delivery of higher quality aerosols. Additionally, using a longer mouthpiece element allows for the provision of more complex mouthpieces, as there is more space for incorporating mouthpiece components such as capsules, threads, and limiters.

[0182] In a particularly preferred embodiment of the invention, a mouthpiece having a length of at least 10 mm is combined with a relatively short aerosol cooling element, for example, an aerosol cooling element having a length of less than 10 mm. This combination has been found to provide a more rigid mouthpiece, which reduces the risk of deformation of the aerosol cooling element during use and facilitates more efficient inhalation by the consumer.

[0183] The ratio between the length of the mouthpiece element and the length of the aerosol-generating matrix strip can be from about 0.5 to about 1.5.

[0184] Preferably, the ratio between the length of the mouthpiece element and the length of the aerosol generating matrix strip is at least about 0.6, more preferably at least about 0.7, and even more preferably at least about 0.8. In a preferred embodiment, the ratio between the length of the mouthpiece element and the length of the aerosol generating matrix strip is less than about 1.4, more preferably less than about 1.3, and even more preferably less than about 1.2.

[0185] In some embodiments, the ratio between the length of the mouthpiece element and the length of the aerosol generating matrix strip is from about 0.6 to about 1.4, preferably from about 0.7 to about 1.4, and more preferably from about 0.8 to about 1.4. In other embodiments, the ratio between the length of the mouthpiece element and the length of the aerosol generating matrix strip is from about 0.6 to about 1.3, preferably from about 0.7 to about 1.3, and more preferably from about 0.8 to about 1.3. In still other embodiments, the ratio between the length of the mouthpiece element and the length of the aerosol generating matrix strip is from about 0.6 to about 1.2, preferably from about 0.7 to about 1.2, and more preferably from about 0.8 to about 1.2.

[0186] In a particularly preferred embodiment, the ratio between the length of the mouthpiece element and the length of the aerosol-generating matrix strip is approximately 1.

[0187] The ratio between the length of the mouthpiece element and the total length of the aerosol-generated article matrix can be from about 0.2 to about 0.35.

[0188] Preferably, the ratio between the length of the mouthpiece element and the total length of the aerosol-generating article matrix is ​​at least about 0.22, more preferably at least about 0.24, and even more preferably at least about 0.26. The ratio between the length of the mouthpiece element and the total length of the aerosol-generating article matrix is ​​preferably less than about 0.34, more preferably less than about 0.32, and even more preferably less than about 0.3.

[0189] In some embodiments, the ratio between the length of the mouthpiece element and the overall length of the aerosol-generating article matrix is ​​preferably from about 0.22 to about 0.34, more preferably from about 0.24 to about 0.34, and even more preferably from about 0.26 to about 0.34. In other embodiments, the ratio between the length of the mouthpiece element and the overall length of the aerosol-generating article matrix is ​​preferably from about 0.22 to about 0.32, more preferably from about 0.24 to about 0.32, and even more preferably from about 0.26 to about 0.32. In yet another embodiment, the ratio between the length of the mouthpiece element and the overall length of the aerosol-generating article matrix is ​​preferably from about 0.22 to about 0.3, more preferably from about 0.24 to about 0.3, and even more preferably from about 0.26 to about 0.3.

[0190] In a particularly preferred embodiment, the ratio between the length of the mouthpiece element and the total length of the aerosol-generated article matrix is ​​approximately 0.27.

[0191] Aerosol-generated articles, as a whole, can have a length ranging from about 35 mm to about 100 mm.

[0192] Preferably, the overall length of the aerosol-generating article according to the present invention is at least about 38 mm. More preferably, the overall length of the aerosol-generating article according to the present invention is at least about 40 mm. Even more preferably, the overall length of the aerosol-generating article according to the present invention is at least about 42 mm.

[0193] The overall length of the aerosol-generating article according to the present invention is preferably less than or equal to 70 mm. More preferably, the overall length of the aerosol-generating article according to the present invention is preferably less than or equal to 60 mm. Even more preferably, the overall length of the aerosol-generating article according to the present invention is preferably less than or equal to 50 mm.

[0194] In some embodiments, the overall length of the aerosol-generating article is preferably from about 38 mm to about 70 mm, more preferably from about 40 mm to about 70 mm, and even more preferably from about 42 mm to about 70 mm. In other embodiments, the overall length of the aerosol-generating article is preferably from about 38 mm to about 60 mm, more preferably from about 40 mm to about 60 mm, and even more preferably from about 42 mm to about 60 mm. In yet another embodiment, the overall length of the aerosol-generating article is preferably from about 38 mm to about 50 mm, more preferably from about 40 mm to about 50 mm, and even more preferably from about 42 mm to about 50 mm. In an exemplary embodiment, the overall length of the aerosol-generating article is about 45 mm.

[0195] The aerosol-generating article has an outer diameter of at least 5 mm. Preferably, the aerosol-generating article has an outer diameter of at least 6 mm. More preferably, the aerosol-generating article has an outer diameter of at least 7 mm.

[0196] Preferably, the aerosol-generating article has an outer diameter of about 12 mm or less. More preferably, the aerosol-generating article has an outer diameter of about 10 mm or less. Even more preferably, the aerosol-generating article has an outer diameter of about 8 mm or less.

[0197] In some embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 12 mm, preferably from about 6 mm to about 12 mm, and more preferably from about 7 mm to about 12 mm. In other embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 10 mm, preferably from about 6 mm to about 10 mm, and more preferably from about 7 mm to about 10 mm. In still other embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 8 mm, preferably from about 6 mm to about 8 mm, and more preferably from about 7 mm to about 8 mm.

[0198] According to the present invention, the diameter (D) of the aerosol-generating article at the mouth end ME The diameter of the aerosol-generated product at the distal end is greater than the diameter of the product at the distal end (D). DE The ratio between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end (D) ME / D DE The value is at least approximately 1.005.

[0199] Preferably, the ratio (D) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is... ME / D DE (Preferably) is at least about 1.01. More preferably, the ratio (D) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is... ME / D DE The ratio is at least about 1.02. Even more preferably, the ratio between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end (D) is... ME / D DE The value is at least approximately 1.05.

[0200] The ratio between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end (D) ME / D DE Preferably, the ratio (D) is less than or equal to about 1.30. More preferably, the ratio between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is... ME / D DE The ratio (D) is less than or equal to about 1.25. Even more preferably, the ratio between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end (D) is... ME / D DE The ratio (D) is less than or equal to about 1.20. In a particularly preferred embodiment, the ratio between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end (D) is... ME / D DE (less than or equal to 1.15 or 1.10)

[0201] In some preferred embodiments, the ratio (D) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is... ME / D DE The value is from about 1.01 to 1.30, more preferably from 1.02 to 1.30, and even more preferably from 1.05 to 1.30.

[0202] In other embodiments, the ratio (D) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is... ME / D DE The ratio (D) is from about 1.01 to 1.25, more preferably from 1.02 to 1.25, and even more preferably from 1.05 to 1.25. In another embodiment, the ratio (D) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is... ME / D DE The ratio (D) is from about 1.01 to 1.20, more preferably from 1.02 to 1.20, and even more preferably from 1.05 to 1.20. In other embodiments, the ratio (D) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is... ME / D DE The value is from about 1.01 to 1.15, more preferably from 1.02 to 1.15, and even more preferably from 1.05 to 1.15.

[0203] The diameter (D) of the aerosol-generated product at the mouth end ME The diameter of the aerosol-generated product at the distal end (D) DE The difference between the diameters can be at least about 25 micrometers. Preferably, the diameter (D) of the aerosol-generating article at the mouth end is... ME The diameter of the aerosol-generated product at the distal end (D) DE The difference between them is at least about 50 micrometers. More preferably, the diameter (D) of the aerosol-generating article at the mouth end is... ME The diameter of the aerosol-generated product at the distal end (D) DE The difference between them is at least about 100 micrometers. Even more preferably, the diameter (D) of the aerosol-generating article at the mouth end is... ME The diameter of the aerosol-generated product at the distal end (D) DEThe difference between the diameters is at least about 150 micrometers. In a particularly preferred embodiment, the diameter (D) of the aerosol-generating article at the mouth end is... ME The diameter of the aerosol-generated product at the distal end (D) DE The difference between them is at least about 200 micrometers, more preferably at least about 300 micrometers, and even more preferably at least about 500 micrometers.

[0204] To avoid being bound by theory, the expected diameter (D) of the aerosol-generated product at the mouth tip is... ME The diameter of the aerosol-generated product at the distal end (D) DE One such difference between the two is sufficient to establish an interference fit between the mouth of the aerosol-generating article and the inlet opening of the cavity of the heating device suitable for receiving the aerosol-generating article during use, while ensuring that the distal end of the aerosol-generating article can be easily and quickly received into the cavity.

[0205] For example, the outer diameter of the article may be substantially constant on the distal portion of the article extending at least about 5 mm or at least about 10 mm from the distal end of the aerosol-generated article. Alternatively, the outer diameter of the article may taper gradually on the distal portion of the article extending at least about 5 mm or at least about 10 mm from the distal end.

[0206] As briefly described above, in some preferred embodiments, the mouthpiece element is secured to one or more adjacent upstream components of the aerosol-generating article by means of a splicing package. For example, the mouthpiece element may be connected to an adjacent aerosol cooling element by means of a splicing paper tape.

[0207] In some embodiments, the aerosol generating article includes a first spout tape that at least partially defines a mouthpiece element and secures the mouthpiece to an adjacent upstream component of the aerosol generating article, and a second spout tape that defines the first spout tape. This provides an effective and relatively convenient way to ensure that the mouth and distal ends of the aerosol generating article have different diameters according to the invention, because the combined thickness of two or more spout tapes effectively contributes to the diameter (D) of the aerosol generating article at the mouth end. ME ).

[0208] In some of these embodiments, the mouthpiece element is at least partially defined by two or more splice paper tapes, while the upstream element at the distal end of the aerosol-generating article is not defined by splice paper. This advantageously helps to maximize the diameter (D) of the aerosol-generating article at the mouthpiece end. ME The diameter of the aerosol-generated product at the distal end (D) DE The difference between them.

[0209] In other embodiments of these examples, the mouthpiece element is at least partially defined by two or more splice paper tapes, while the upstream element at the distal end of the aerosol-generating article is defined by a single splice paper tape. This helps control how the weight is distributed along the length of the aerosol-generating article.

[0210] In some embodiments, the downstream section may include an intermediate hollow section between the mouthpiece element and the aerosol generating matrix strip. The intermediate hollow section may include one or more of a support element and an aerosol cooling element. One or more of the support element and the aerosol cooling element may include hollow tubular segments. In such embodiments, the support element and one or more of the aerosol cooling elements comprising one or more hollow tubular segments can thus form the intermediate hollow section of the aerosol generating article.

[0211] As used herein, the term "hollow tubular element" is used to refer to a generally elongated element that defines an internal cavity or airflow passage along its longitudinal axis. Specifically, the term "tubular" will be used below to refer to a tubular element having a generally cylindrical cross-section and defining at least one airflow conduit that establishes uninterrupted fluid communication between an upstream end and a downstream end of the tubular element. However, it should be understood that alternative geometries (e.g., alternative cross-sectional shapes) of the tubular element may be possible.

[0212] In the context of this invention, the hollow tubular segment provides a non-restrictive flow channel. This means that the hollow tubular segment provides a negligible level of suction resistance (RTD). Therefore, the flow channel should not contain any components that would impede the flow of air in the longitudinal direction. Preferably, the flow channel is substantially empty.

[0213] When used to describe another component of an aerosol cooling element, support element, or downstream section, the term "elongated" means that the aerosol cooling element, support element, or other component of the downstream section has a length dimension greater than its width dimension or its diameter dimension, for example, two or more times its width dimension or its diameter dimension.

[0214] The support element can be formed from any suitable material or combination of materials. For example, the support element can be formed from one or more materials selected from the group consisting of: cellulose acetate, cardboard, crimped paper such as crimped heat-resistant paper or crimped parchment, and polymeric materials such as low-density polyethylene (LDPE). In a preferred embodiment, the support element is formed from cellulose acetate. Other suitable materials include polyhydroxyalkanoate (PHA) fibers.

[0215] The support element may include a first hollow tubular segment. In a preferred embodiment, the support element includes a hollow cellulose acetate tube.

[0216] The support element is substantially arranged to align with the strip. This means that the length dimension of the support element is arranged approximately parallel to the longitudinal direction of the strip and the article, for example, within + / - 10 degrees parallel to the longitudinal direction of the strip. In a preferred embodiment, the support element extends along the longitudinal axis of the strip.

[0217] The support element preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol-generating matrix strip and the outer diameter of the aerosol-generating article.

[0218] The support element may have an outer diameter between 5 mm and 12 mm, for example between 5 mm and 10 mm, or between 6 mm and 8 mm. In a preferred embodiment, the support element has an outer diameter of 7.2 mm + / - 10%.

[0219] The peripheral wall of the support element may have a thickness of at least 1 mm, preferably at least about 1.5 mm, and more preferably at least about 2 mm.

[0220] The support element may have a length between approximately 5 mm and approximately 15 mm.

[0221] Preferably, the support element has a length of at least about 6 mm, more preferably at least about 7 mm.

[0222] In a preferred embodiment, the support element has a length of less than about 12 mm, more preferably less than about 10 mm.

[0223] In some embodiments, the support element has a length from about 5 mm to about 15 mm, preferably from about 6 mm to about 15 mm, and more preferably from about 7 mm to about 15 mm. In other embodiments, the support element has a length from about 5 mm to about 12 mm, preferably from about 6 mm to about 12 mm, and more preferably from about 7 mm to about 12 mm. In still other embodiments, the support element has a length from about 5 mm to about 10 mm, preferably from about 6 mm to about 10 mm, and more preferably from about 7 mm to about 10 mm.

[0224] In a preferred embodiment, the support element has a length of approximately 8 millimeters.

[0225] Preferably, the total length of the hollow section in the middle does not exceed about 18 mm, more preferably not more than about 17 mm, and even more preferably not more than 16 mm.

[0226] The ratio of the length of the support element to the length of the aerosol-generating matrix strip can range from about 0.25 to about 1.

[0227] Preferably, the ratio between the length of the support element and the length of the aerosol generating matrix strip is at least about 0.3, more preferably at least about 0.4, and even more preferably at least about 0.5. In a preferred embodiment, the ratio between the length of the support element and the length of the aerosol generating matrix strip is less than about 0.9, more preferably less than about 0.8, and even more preferably less than about 0.7.

[0228] In some embodiments, the ratio between the length of the support element and the length of the aerosol generating matrix strip is from about 0.3 to about 0.9, preferably from about 0.4 to about 0.9, and more preferably from about 0.5 to about 0.9. In other embodiments, the ratio between the length of the support element and the length of the aerosol generating matrix strip is from about 0.3 to about 0.8, preferably from about 0.4 to about 0.8, and more preferably from about 0.5 to about 0.8. In still other embodiments, the ratio between the length of the support element and the length of the aerosol generating matrix strip is from about 0.3 to about 0.7, preferably from about 0.4 to about 0.7, and more preferably from about 0.5 to about 0.7.

[0229] In a particularly preferred embodiment, the ratio between the length of the support element and the length of the aerosol-generating matrix strip is approximately 0.66.

[0230] The ratio between the length of the support element and the total length of the aerosol-generated article matrix can range from about 0.125 to about 0.375.

[0231] Preferably, the ratio between the length of the support element and the total length of the aerosol-generated article matrix is ​​at least about 0.13, more preferably at least about 0.14, and even more preferably at least about 0.15. The ratio between the length of the support element and the total length of the aerosol-generated article matrix is ​​preferably less than about 0.3, more preferably less than about 0.25, and even more preferably less than about 0.20.

[0232] In some embodiments, the ratio between the length of the support element and the overall length of the aerosol-generated article matrix is ​​preferably from about 0.13 to about 0.3, more preferably from about 0.14 to about 0.3, and even more preferably from about 0.15 to about 0.3. In other embodiments, the ratio between the length of the support element and the overall length of the aerosol-generated article matrix is ​​preferably from about 0.13 to about 0.25, more preferably from about 0.14 to about 0.25, and even more preferably from about 0.15 to about 0.25. In yet another embodiment, the ratio between the length of the support element and the overall length of the aerosol-generated article matrix is ​​preferably from about 0.13 to about 0.2, more preferably from about 0.14 to about 0.2, and even more preferably from about 0.15 to about 0.2.

[0233] In a particularly preferred embodiment, the ratio between the length of the support element and the total length of the aerosol-generated article matrix is ​​approximately 0.18.

[0234] Preferably, in the aerosol-generating article according to the invention, the support element has an average radial hardness of at least about 80%, more preferably at least about 85%, and even more preferably at least about 90%. Therefore, the support element is able to provide the desired hardness level for the aerosol-generating article.

[0235] If desired, the radial stiffness of components (such as support elements) in the downstream section of the aerosol-generating article according to the invention can be further increased by defining the aerosol cooling element with a rigid rod package (e.g., a rod package having a basis weight of at least about 80 grams per square meter (gsm), or at least about 100 gsm, or at least about 110 gsm).

[0236] As used herein, the term "radial hardness" refers to compressive resistance in a direction transverse to the longitudinal axis of the support element. The radial hardness of an aerosol-generated article around the support element can be determined by applying a load across the article at the location of the support element, transverse to the longitudinal axis of the article, and measuring the average (mean) indentation diameter of the article. The radial hardness is given by the following formula:

[0237]

[0238] Where D S It is the original (un-dimpled) diameter, and D d It is the diameter of the indentation after a set load is applied within a set duration. The harder the material, the closer the hardness is to 100%.

[0239] To determine the hardness of a portion of an aerosol-generating article (such as a support element provided in the form of a hollow tubular segment), the aerosol-generating articles should be aligned parallel in a plane, and the same portion of each aerosol-generating article to be tested should be subjected to a set load for a set duration. This test is performed using a known DD60A densitometer device (manufactured and commercially available by Heinr. Borgwaldt GmbH, Germany), which is equipped with a measuring head for aerosol-generating articles (such as cigarettes) and an aerosol-generating article container.

[0240] The load is applied using two load-applying cylindrical strips that extend simultaneously across the diameter of all aerosol-generating articles. According to the standard testing method for this instrument, the test should be performed such that twenty contact points appear between the aerosol-generating articles and the load-applying cylindrical strips. In some cases, the hollow tube segment to be tested may be long enough that only ten aerosol-generating articles are needed to form twenty contact points, with each smoking article contacting both load-applying strips (because they are long enough to extend between these strips). In other cases, if the support element is too short to achieve this, twenty aerosol-generating articles should be used to form twenty contact points, with each aerosol-generating article contacting only one of the load-applying strips, as discussed further below.

[0241] Two additional fixed cylindrical bars are located below the aerosol-generating article to support the aerosol-generating article and counteract the load applied by each of the cylindrical bars by these loads.

[0242] For the standard operating procedure for such equipment, a total load of 2 kg is applied for a duration of 20 seconds. After 20 seconds (while the smoking article is still under load), the indentation in the load-applied cylindrical strip is determined and then used to calculate the hardness according to the above formula. The temperature is maintained in the range of 22 degrees Celsius ± 2 degrees. The above test is known as the DD60A test. The standard way to measure filter hardness is when the aerosol-generated article has not yet been consumed. Additional information regarding the measurement of average radial hardness can be found, for example, in U.S. Patent Application Publication No. 2016 / 0128378.

[0243] During the insertion of the aerosol generating article according to the invention into the aerosol generating apparatus to heat the aerosol generating matrix, the user may need to apply force to overcome the resistance of the aerosol generating matrix to insertion. This can damage one or both of the aerosol generating article and the aerosol generating apparatus. Additionally, the force applied during insertion of the aerosol generating article into the aerosol generating apparatus can cause displacement of the aerosol generating matrix within the aerosol generating article. This may result in the heating element of the aerosol generating apparatus not being properly aligned with the sensors disposed within the aerosol generating matrix, potentially leading to uneven and inefficient heating of the aerosol generating matrix of the aerosol generating article. The support element is advantageously configured to prevent downstream movement of the aerosol generating matrix during insertion of the article into the aerosol generating apparatus.

[0244] Preferably, the hollow tubular segment of the support element is suitable for generating an RTD between about 0 mm H2O (about 0 Pa) and about 20 mm H2O (about 100 Pa), more preferably between about 0 mm H2O (about 0 Pa) and about 10 mm H2O (about 100 Pa). Therefore, the support element preferably does not contribute to the overall RTD of the aerosol-generating article.

[0245] Preferably, the aerosol cooling element in the downstream section of the aerosol generating article according to the invention is in the form of a second hollow tubular segment, the second hollow tubular segment defining a cavity extending from the upstream end of the aerosol cooling element to the downstream end of the aerosol cooling element, and a ventilation area is provided along the hollow tubular segment.

[0246] The inventors have discovered that satisfactory cooling of the aerosol flow generated during the heating of the aerosol-generating matrix and drawn by such an aerosol cooling element can be achieved by providing a ventilation zone at a location along a hollow tubular segment. Furthermore, the inventors have discovered, as will be described in more detail below, that by arranging the ventilation zone at a precisely defined location along the length of the aerosol cooling element, and by preferably utilizing a hollow tubular segment having a predetermined peripheral wall thickness or internal volume, it is possible to offset the increased aerosol dilution caused by allowing ventilation air into the article.

[0247] Without being bound by theory, it is assumed that the temperature of the aerosol flow rapidly decreases due to the introduction of ventilation air as the aerosol travels towards the nozzle segment. Therefore, the ventilation air is allowed to enter the aerosol flow relatively close to the upstream end of the aerosol cooling element (i.e., sufficiently close to the receptors extending within the aerosol generation matrix strip, which serve as a heat source during use), achieving significant cooling of the aerosol flow. This has a favorable effect on the condensation and nucleation of aerosol particles. Thus, compared to existing non-ventilated aerosol generation products, the overall ratio of aerosol particulate phase to aerosol gas phase can be increased.

[0248] Simultaneously, maintaining a relatively low thickness of the peripheral wall of the hollow tubular element ensures the total internal volume of the element (allowing aerosols to begin nucleation once the aerosol components leave the aerosol-generating matrix strip), and effectively maximizes the cross-sectional surface area of ​​the hollow tubular segment. This ensures the segment possesses the necessary structural strength to prevent collapse of the aerosol-generating article and provides some support for the aerosol-generating matrix strip, while minimizing the RTD of the hollow tubular segment. The larger cross-sectional surface area of ​​the cavity in the hollow tubular segment should be understood as being associated with a decreasing velocity of the aerosol flow traveling along the aerosol-generating article, which is also expected to favor aerosol nucleation. Furthermore, it appears that by using relatively low-thickness hollow tubular segments, it is possible to substantially prevent the diffusion of the ventilation air before it comes into contact with and mixes with the aerosol flow, which is also understood to further favor nucleation. In practice, the effect of cooling on the formation of new aerosol particles can be enhanced by providing more controlled localized cooling to the volatile material flow.

[0249] The outer diameter of the aerosol cooling element is preferably approximately equal to the outer diameter of the aerosol generating matrix strip and the outer diameter of the aerosol generating product.

[0250] The aerosol cooling element may have an outer diameter between 5 mm and 12 mm, for example between 5 mm and 10 mm, or between 6 mm and 8 mm. In a preferred embodiment, the aerosol cooling element has an outer diameter of 7.2 mm + / - 10%.

[0251] Preferably, the second hollow tubular segment of the aerosol cooling element has an inner diameter of at least about 1.5 mm. More preferably, the second hollow tubular segment of the aerosol cooling element has an inner diameter of at least about 2 mm. Even more preferably, the second hollow tubular segment of the aerosol cooling element has an inner diameter of at least about 2.5 mm. In a particularly preferred embodiment, the second hollow tubular segment of the aerosol cooling element has an inner diameter of at least about 3 mm.

[0252] The peripheral wall of the second hollow tubular segment of the aerosol cooling element may have a thickness of less than about 2.5 mm, preferably less than about 1.5 mm, more preferably less than about 1250 micrometers, and even more preferably less than about 1000 micrometers. In a particularly preferred embodiment, the peripheral wall of the second hollow tubular segment of the aerosol cooling element has a thickness of less than about 900 micrometers, preferably less than about 800 micrometers.

[0253] In one embodiment, the peripheral wall of the second hollow tubular segment of the aerosol cooling element has a thickness of approximately 2 millimeters.

[0254] Aerosol cooling elements can have a length between 5 mm and 15 mm.

[0255] Preferably, the aerosol cooling element has a length of at least about 6 mm, more preferably at least about 7 mm.

[0256] In a preferred embodiment, the aerosol cooling element has a length of less than about 12 mm, more preferably less than about 10 mm.

[0257] In some embodiments, the aerosol cooling element has a length from about 5 mm to about 15 mm, preferably from about 6 mm to about 15 mm, and more preferably from about 7 mm to about 15 mm. In other embodiments, the aerosol cooling element has a length from about 5 mm to about 12 mm, preferably from about 6 mm to about 12 mm, and more preferably from about 7 mm to about 12 mm. In still other embodiments, the aerosol cooling element has a length from about 5 mm to about 10 mm, preferably from about 6 mm to about 10 mm, and more preferably from about 7 mm to about 10 mm.

[0258] In a particular preferred embodiment of the invention, the aerosol cooling element has a length of less than 10 mm. For example, in one particular preferred embodiment, the aerosol cooling element has a length of 8 mm. In such embodiments, the aerosol cooling element thus has a relatively short length compared to aerosol cooling elements of prior art aerosol-generating articles. The reduction in the length of the aerosol cooling element is possible due to the optimized effectiveness of the hollow tubular segments forming the aerosol cooling element in the cooling and nucleation of the aerosol. The reduction in the length of the aerosol cooling element advantageously reduces the risk of deformation of the aerosol-generating article due to compression during use, as the aerosol cooling element typically has lower deformation resistance than a mouthpiece. Furthermore, reducing the length of the aerosol cooling element can provide cost benefits to manufacturers, as the cost per unit length of hollow tubular segments is typically higher than that of other elements such as mouthpiece elements.

[0259] The ratio between the length of the aerosol cooling element and the length of the aerosol generating matrix strip can range from about 0.25 to about 1.

[0260] Preferably, the ratio between the length of the aerosol cooling element and the length of the aerosol generating matrix strip is at least about 0.3, more preferably at least about 0.4, and even more preferably at least about 0.5. In a preferred embodiment, the ratio between the length of the aerosol cooling element and the length of the aerosol generating matrix strip is less than about 0.9, more preferably less than about 0.8, and even more preferably less than about 0.7.

[0261] In some embodiments, the ratio between the length of the aerosol cooling element and the length of the aerosol generating matrix strip is from about 0.3 to about 0.9, preferably from about 0.4 to about 0.9, and more preferably from about 0.5 to about 0.9. In other embodiments, the ratio between the length of the aerosol cooling element and the length of the aerosol generating matrix strip is from about 0.3 to about 0.8, preferably from about 0.4 to about 0.8, and more preferably from about 0.5 to about 0.8. In still other embodiments, the ratio between the length of the aerosol cooling element and the length of the aerosol generating matrix strip is from about 0.3 to about 0.7, preferably from about 0.4 to about 0.7, and more preferably from about 0.5 to about 0.7.

[0262] In a particularly preferred embodiment, the ratio between the length of the aerosol cooling element and the length of the aerosol generating matrix strip is approximately 0.66.

[0263] The ratio between the length of the aerosol cooling element and the total length of the aerosol-generated article matrix can be from about 0.125 to about 0.375.

[0264] Preferably, the ratio between the length of the aerosol cooling element and the total length of the aerosol-generated article matrix is ​​at least about 0.13, more preferably at least about 0.14, and even more preferably at least about 0.15. The ratio between the length of the aerosol cooling element and the total length of the aerosol-generated article matrix is ​​preferably less than about 0.3, more preferably less than about 0.25, and even more preferably less than about 0.20.

[0265] In some embodiments, the ratio between the length of the aerosol cooling element and the overall length of the aerosol-generated article matrix is ​​preferably from about 0.13 to about 0.3, more preferably from about 0.14 to about 0.3, and even more preferably from about 0.15 to about 0.3. In other embodiments, the ratio between the length of the aerosol cooling element and the overall length of the aerosol-generated article matrix is ​​preferably from about 0.13 to about 0.25, more preferably from about 0.14 to about 0.25, and even more preferably from about 0.15 to about 0.25. In yet another embodiment, the ratio between the length of the aerosol cooling element and the overall length of the aerosol-generated article matrix is ​​preferably from about 0.13 to about 0.2, more preferably from about 0.14 to about 0.2, and even more preferably from about 0.15 to about 0.2.

[0266] In a particularly preferred embodiment, the ratio between the length of the aerosol cooling element and the total length of the aerosol-generated article matrix is ​​approximately 0.18.

[0267] Preferably, the length of the mouthpiece element is at least 1 mm longer than the length of the aerosol cooling element, more preferably at least 2 mm longer, and even more preferably at least 3 mm longer. As mentioned above, reducing the length of the aerosol cooling element advantageously allows for an increase in the length of other components of the aerosol-generating article, such as the mouthpiece element. The potential technical benefits of providing a relatively long mouthpiece element have been described above.

[0268] Preferably, in the aerosol-generating article according to the invention, the aerosol cooling element has an average radial hardness of at least about 80%, more preferably at least about 85%, and even more preferably at least about 90%. Therefore, the aerosol cooling element is capable of providing the desired hardness level to the aerosol-generating article.

[0269] If desired, the radial stiffness of the aerosol cooling element of the aerosol generating article according to the invention can be further increased by defining the aerosol cooling element with a rigid rod package, for example, a rod package having a basis weight of at least about 80 grams per square meter (gsm), or at least about 100 gsm, or at least about 110 gsm.

[0270] Aerosol cooling elements can be formed from any suitable material or combination of materials. For example, aerosol cooling elements can be formed from one or more materials selected from the group consisting of: cellulose acetate, cardboard, curled paper such as curled heat-resistant paper or curled parchment, and polymeric materials such as low-density polyethylene (LDPE). Other suitable materials include polyhydroxyalkanoate (PHA) fibers.

[0271] In a preferred embodiment, the aerosol cooling element is formed of cellulose acetate.

[0272] The ventilation zone includes multiple perforations in the peripheral wall of the aerosol cooling element. Preferably, the ventilation zone includes at least one row of circumferential perforations. In some embodiments, the ventilation zone may include two rows of circumferential perforations. For example, the perforations may be formed on the production line during the manufacture of the aerosol-generated article. Preferably, each row of circumferential perforations includes 8 to 30 perforations.

[0273] In cases where the aerosol-generating article includes a combi bar for securing an aerosol cooling element to one or more other components of the aerosol-generating article, the ventilation zone preferably includes at least one row of corresponding circumferential perforations provided through a portion of the combi bar packaging. These can be formed on the production line during the manufacture of the smoking article. Preferably, the row or more rows of circumferential perforations provided through a portion of the combi bar packaging are substantially aligned with the row or more rows of perforations through the peripheral wall of the aerosol cooling element.

[0274] In cases where the aerosol-generating article includes a spout tape for attaching an aerosol cooling element to the mouthpiece element of the aerosol-generating article, wherein the spout tape extends above one or more rows of circumferential perforations in the peripheral wall of the aerosol cooling element, the ventilation area preferably includes at least one corresponding row of circumferential perforations provided by the spout tape. These can be formed on the production line during the manufacture of the smoking article. Preferably, the one or more rows of circumferential perforations provided by the spout tape are substantially aligned with one or more rows of perforations in the peripheral wall of the aerosol cooling element.

[0275] In some embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is at least about 1 mm. Preferably, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is at least about 2 mm. More preferably, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is at least about 3 mm.

[0276] In some embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is less than or equal to about 6 mm. Preferably, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is less than or equal to about 5 mm. More preferably, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is less than or equal to about 4 mm.

[0277] In some embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is from about 1 mm to about 6 mm, preferably from about 1 mm to about 5 mm, and more preferably from about 1 mm to about 4 mm. In other embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is from about 2 mm to about 6 mm, preferably from about 2 mm to about 5 mm, and more preferably from about 2 mm to about 4 mm. In yet another embodiment, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is from about 3 mm to about 6 mm, preferably from about 3 mm to about 5 mm, and more preferably from about 3 mm to about 4 mm.

[0278] The distance between the ventilation zone and the opening of the aerosol-generating article is preferably at least about 10 mm. More preferably, the distance between the ventilation zone and the opening of the aerosol-generating article is at least about 12 mm. Even more preferably, the distance between the ventilation zone and the opening of the aerosol-generating article is at least about 16 mm.

[0279] The distance between the ventilation zone and the opening of the aerosol-generating article is preferably less than or equal to about 26 mm. More preferably, the distance between the ventilation zone and the opening of the aerosol-generating article is less than or equal to about 24 mm. Even more preferably, the distance between the ventilation zone and the opening of the aerosol-generating article is less than or equal to about 22 mm. In a particularly preferred embodiment, the distance between the ventilation zone and the opening of the aerosol-generating article is less than or equal to about 20 mm.

[0280] In some embodiments, the distance between the venting area and the opening of the aerosol-generating article is from about 10 mm to about 26 mm, preferably from about 10 mm to about 24 mm, more preferably from about 10 mm to about 22 mm, and even more preferably from about 10 mm to about 20 mm. In other embodiments, the distance between the venting area and the opening of the aerosol-generating article is from about 12 mm to about 26 mm, preferably from about 12 mm to about 24 mm, more preferably from about 12 mm to about 22 mm, and even more preferably from about 12 mm to about 20 mm. In yet another embodiment, the distance between the venting area and the opening of the aerosol-generating article is from about 14 mm to about 26 mm, preferably from about 14 mm to about 24 mm, more preferably from about 14 mm to about 22 mm, and even more preferably from about 14 mm to about 20 mm. In other embodiments, the distance between the venting zone and the opening of the aerosol-generating article is from about 16 mm to about 26 mm, preferably from about 16 mm to about 24 mm, more preferably from about 16 mm to about 22 mm, and even more preferably from about 16 mm to about 20 mm.

[0281] The distance between the ventilation zone and the upstream end of the downstream section is preferably at least about 6 mm. More preferably, the distance between the ventilation zone and the upstream end of the downstream section is at least about 8 mm. Even more preferably, the distance between the ventilation zone and the upstream end of the downstream section is at least about 10 mm.

[0282] The distance between the ventilation zone and the upstream end of the downstream section is preferably less than or equal to about 20 mm. More preferably, the distance between the ventilation zone and the upstream end of the downstream section is less than or equal to about 18 mm. Even more preferably, the distance between the ventilation zone and the upstream end of the downstream section is less than or equal to about 16 mm.

[0283] In some embodiments, the distance between the ventilation zone and the upstream end of the downstream section is preferably from about 6 mm to about 20 mm, more preferably from about 8 mm to about 20 mm, and even more preferably from about 10 mm to about 20 mm. In other embodiments, the distance between the ventilation zone and the upstream end of the downstream section is preferably from about 6 mm to about 18 mm, more preferably from about 8 mm to about 18 mm, and even more preferably from about 10 mm to about 18 mm. In yet another embodiment, the distance between the ventilation zone and the upstream end of the downstream section is preferably from about 6 mm to about 16 mm, more preferably from about 8 mm to about 16 mm, and even more preferably from about 10 mm to about 16 mm.

[0284] The distance between the ventilation zone and the downstream end of the sensor is preferably at least about 6 mm. More preferably, the distance between the ventilation zone and the downstream end of the sensor is at least about 8 mm. Even more preferably, the distance between the ventilation zone and the downstream end of the sensor is at least about 10 mm.

[0285] The distance between the ventilation zone and the downstream end of the sensor is preferably less than or equal to about 20 mm. More preferably, the distance between the ventilation zone and the downstream end of the sensor is less than or equal to about 18 mm. Even more preferably, the distance between the ventilation zone and the downstream end of the sensor is less than or equal to about 16 mm.

[0286] In some embodiments, the distance between the ventilation zone and the downstream end of the sensor is preferably from about 6 mm to about 20 mm, more preferably from about 8 mm to about 20 mm, and even more preferably from about 10 mm to about 20 mm. In other embodiments, the distance between the ventilation zone and the downstream end of the sensor is preferably from about 6 mm to about 18 mm, more preferably from about 8 mm to about 18 mm, and even more preferably from about 10 mm to about 18 mm. In yet another embodiment, the distance between the ventilation zone and the downstream end of the sensor is preferably from about 6 mm to about 16 mm, more preferably from about 8 mm to about 16 mm, and even more preferably from about 10 mm to about 16 mm.

[0287] The aerosol-generating articles according to the present invention can have a ventilation level of at least about 5%.

[0288] Throughout this specification, the term "ventilation level" is used to indicate the volume ratio of the airflow entering the aerosol-generating article via a ventilated zone (ventilation airflow) to the sum of the aerosol airflow and the ventilation airflow. A higher ventilation level results in a higher dilution of the aerosol stream delivered to the consumer.

[0289] Aerosol-generating articles typically have a ventilation level of at least about 10%, preferably at least about 15%, and more preferably at least about 20%.

[0290] In a preferred embodiment, the aerosol-generating article has a ventilation level of at least about 25%.

[0291] Aerosol-generating articles preferably have a ventilation level of less than about 60%.

[0292] The aerosol-generating article according to the invention preferably has a ventilation level of less than or equal to about 45%. More preferably, the aerosol-generating article according to the invention has a ventilation level of less than or equal to about 40%, and even more preferably a ventilation level of less than or equal to about 35%.

[0293] In a particularly preferred embodiment, the aerosol-generating article has a ventilation level of approximately 30%.

[0294] In some embodiments, the aerosol generating article has a ventilation level of from about 20% to about 60%, preferably from about 20% to about 45%, and more preferably from about 20% to about 40%. In other embodiments, the aerosol generating article has a ventilation level of from about 25% to about 60%, preferably from about 25% to about 45%, and more preferably from about 25% to about 40%. In still other embodiments, the aerosol generating article has a ventilation level of from about 30% to about 60%, preferably from about 30% to about 45%, and more preferably from about 30% to about 40%.

[0295] In particularly preferred embodiments, the aerosol-generating article has a ventilation level of from about 28% to about 42%. In some particularly preferred embodiments, the aerosol-generating article has a ventilation level of about 30%.

[0296] Without being bound by theory, the inventors have discovered that the temperature drop caused by cooler external air entering the hollow tubular segment through the ventilation zone can have a favorable effect on the nucleation and growth of aerosol particles.

[0297] The formation of aerosols from gaseous mixtures containing various chemical substances depends on the subtle interactions between nucleation, evaporation and condensation, and coalescence, while taking into account variations in vapor concentration, temperature, and velocity fields. The so-called classical nucleation theory is based on the assumption that a portion of the molecules in the gas phase are large enough to remain coherent for a sufficient period (e.g., 50% probability). These molecules represent some kind of critical, threshold molecular cluster in transient molecular aggregates, meaning that, on average, smaller clusters are likely to disintegrate quickly into the gas phase, while larger clusters are likely to grow. Such critical clusters are considered key nucleation nucleation cores from which droplets are expected to grow due to the condensation of molecules in the vapor. It is assumed that newly nucleated pristine droplets appear with a certain initial diameter and can then grow by several orders of magnitude. This process is facilitated and enhanced by condensation caused by rapid cooling of the surrounding vapor. In this regard, it should be remembered that evaporation and condensation are two aspects of the same mechanism: gas-liquid mass transfer. While evaporation involves a net mass transfer from droplets to the gas phase, condensation is a net mass transfer from the gas phase to the droplet phase. Evaporation (or condensation) will cause droplets to shrink (or grow), but will not change the number of droplets.

[0298] In situations that can be further complicated by coalescence, the temperature and rate of cooling play a crucial role in determining how the system responds. Generally, different cooling rates can lead to significantly different temporal behaviors associated with liquid phase (droplet) formation, since nucleation processes are typically nonlinear. Without being bound by theory, it is assumed that cooling leads to a rapid increase in droplet number concentration, followed by a strong, brief surge in this growth (nucleation burst). This nucleation burst appears to be more pronounced at lower temperatures. Furthermore, higher cooling rates seem to favor earlier initiation of nucleation. In contrast, decreasing cooling rates appear to have a favorable effect on the final size eventually reached by aerosol droplets.

[0299] Therefore, the rapid cooling caused by outside air entering the hollow tubular segment through the ventilation zone can be advantageously used to promote the nucleation and growth of aerosol droplets. However, at the same time, the entry of outside air into the hollow tubular segment has the direct disadvantage of diluting the aerosol stream delivered to the consumer.

[0300] The inventors have surprisingly discovered how the beneficial effect of enhanced nucleation, promoted by rapid cooling caused by introducing ventilated air into the article, can significantly offset the less desirable dilution effect. Thus, articles generated using the aerosol according to the invention consistently achieve satisfactory aerosol delivery values.

[0301] The inventors also surprisingly discovered that when the ventilation level is within the aforementioned range, the dilution effect on the aerosol (which can be particularly assessed by measuring the effect on the delivery of aerosol-forming agents (such as glycerol) included in the aerosol-generating matrix) is advantageously minimized. In particular, ventilation levels between 25% and 50%, and even more preferably between 28% and 42%, have been found to produce particularly satisfactory glycerol delivery values. Simultaneously, the degree of nucleation and therefore the delivery of nicotine and aerosol-forming agents (e.g., glycerol) are enhanced.

[0302] This is particularly advantageous for "short" aerosol-generating articles, such as those in which the length of the aerosol-generating matrix strip is less than about 40 mm, preferably less than 25 mm, even more preferably less than 20 mm, or in which the overall length of the aerosol-generating article is less than about 70 mm, preferably less than about 60 mm, even more preferably less than 50 mm. It will be understood that in such aerosol-generating articles, there is almost no time or space available for aerosol formation and the aerosol particle phase transition to be delivered to the consumer.

[0303] Furthermore, since the ventilated hollow tubular segments contribute virtually nothing to the overall RTD of the aerosol-generating article, the overall RTD of the article can be advantageously finely adjusted in the aerosol-generating article according to the invention by adjusting the length and density of the aerosol-generating matrix strip, or the length and optional length and density of the filter material segments forming part of the mouthpiece, or the length and density of the filter material segments located upstream of the aerosol-generating matrix and the sensor. Therefore, aerosol-generating articles with a predetermined RTD can be manufactured consistently and with high precision, providing consumers with a satisfactory RTD level even in the presence of ventilation.

[0304] In some embodiments, the intermediate hollow section includes both a support element comprising a first hollow tubular section and an aerosol cooling element comprising a second hollow tubular section, wherein the inner diameter (D) of the second hollow tubular section is... STS Preferably, it is larger than the inner diameter (D) of the first hollow tubular segment. FTS ).

[0305] More specifically, the inner diameter (D) of the second hollow tubular segment STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between the two is preferably at least about 1.25. More preferably, the inner diameter (D) of the second hollow tubular segment is... STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between the two is preferably at least about 1.3. Even more preferably, the inner diameter (D) of the second hollow tubular segment is... STS ) and the inner diameter (D) of the first hollow tubular segment FTSThe ratio between the two is preferably at least about 1.4. In a particularly preferred embodiment, the inner diameter (D) of the second hollow tubular segment is... STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between () is at least about 1.5, more preferably at least about 1.6.

[0306] The inner diameter (D) of the second hollow tubular segment STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between the two is preferably less than or equal to about 2.5. More preferably, the inner diameter (D) of the second hollow tubular segment is... STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between the two is preferably less than or equal to about 2.25. Even more preferably, the inner diameter (D) of the second hollow tubular segment is... STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between () is preferably less than or equal to about 2.

[0307] In some embodiments, the inner diameter (D) of the second hollow tubular segment STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between them is from about 1.25 to about 2.5. Preferably, the inner diameter (D) of the second hollow tubular segment is... STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between them is from about 1.3 to about 2.5. More preferably, the inner diameter (D) of the second hollow tubular segment STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between them is from about 1.4 to about 2.5. In a particularly preferred embodiment, the inner diameter (D) of the second hollow tubular segment is... STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between them is from about 1.5 to about 2.5.

[0308] In other embodiments, the inner diameter (D) of the second hollow tubular segment STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between them is from about 1.25 to about 2.25. Preferably, the inner diameter (D) of the second hollow tubular segment is... STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between them is from about 1.3 to about 2.25. More preferably, the inner diameter (D) of the second hollow tubular segment is... STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between them is from about 1.4 to about 2.25. In a particularly preferred embodiment, the inner diameter (D) of the second hollow tubular segment is... STS) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between them is from about 1.5 to about 2.25.

[0309] In another embodiment, the inner diameter (D) of the second hollow tubular segment STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between them is from about 1.25 to about 2. Preferably, the inner diameter (D) of the second hollow tubular segment is... STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between them is from about 1.3 to about 2. More preferably, the inner diameter (D) of the second hollow tubular segment is... STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between them is from about 1.4 to about 2. In a particularly preferred embodiment, the inner diameter (D) of the second hollow tubular segment is... STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between them is from about 1.5 to about 2.

[0310] In embodiments in which the article of manufacture further includes elongated receptors arranged longitudinally within the aerosol-generating matrix, as described below, the inner diameter (D) of the first hollow tubular segment... FTS The ratio between the inner diameter (D) of the first hollow tubular segment and the width of the receptor is preferably at least about 0.2. More preferably, the inner diameter (D) of the first hollow tubular segment is... FTS The ratio between the diameter of the first hollow tubular segment and the width of the receptor is at least about 0.3. Even more preferably, the inner diameter (D) of the first hollow tubular segment... FTS The ratio between the width of the sensor and the width of the receptor is at least about 0.4.

[0311] Alternatively, or as an alternative, the inner diameter (D) of the second hollow tubular segment STS The ratio between the inner diameter (D) of the second hollow tubular segment and the width of the receptor is preferably at least about 0.2. More preferably, the inner diameter (D) of the second hollow tubular segment is... STS The ratio between the inner diameter (D) of the second hollow tubular segment and the width of the receptor is at least about 0.5. Even more preferably, the inner diameter (D) of the second hollow tubular segment... STS The ratio between the width of the sensor and the width of the receptor is at least about 0.8.

[0312] Preferably, the ratio between the volume of the cavity of the first hollow tubular segment and the volume of the cavity of the second hollow tubular segment is at least about 0.1. More preferably, the ratio between the volume of the cavity of the first hollow tubular segment and the volume of the cavity of the second hollow tubular segment is at least about 0.2. Even more preferably, the ratio between the volume of the cavity of the first hollow tubular segment and the volume of the cavity of the second hollow tubular segment is at least about 0.3.

[0313] The ratio between the volume of the cavity of the first hollow tubular segment and the volume of the cavity of the second hollow tubular segment is preferably less than or equal to about 0.9. More preferably, the ratio between the volume of the cavity of the first hollow tubular segment and the volume of the cavity of the second hollow tubular segment is preferably less than or equal to about 0.7. Even more preferably, the ratio between the volume of the cavity of the first hollow tubular segment and the volume of the cavity of the second hollow tubular segment is preferably less than or equal to about 0.5.

[0314] In some embodiments, the aerosol generating article may further include an additional cooling element, such as at a location downstream of an aerosol cooling element comprising a hollow tubular segment as described above, wherein the additional aerosol cooling element defines a plurality of longitudinally extending channels to allow a high surface area to be used for heat exchange. In other words, one such additional cooling element is adapted to essentially function as a heat exchanger. The plurality of longitudinally extending channels may be defined by a sheet material that has been pleated, gathered, or folded to form the channels. The plurality of longitudinally extending channels may be defined by a single sheet that has been pleated, gathered, and folded to form the plurality of channels. The sheet may have been rolled up prior to pleating, gathering, or folding. Alternatively, the plurality of longitudinally extending channels may be defined by a plurality of sheets that have been rolled up, pleated, gathered, or folded together, i.e., defined by two or more sheets that have entered the overlay arrangement and then rolled up, pleated, gathered, or folded into one. As used in this article, the term "sheet" refers to a layered element having a width and a length significantly greater than its thickness.

[0315] As used herein, the term "longitudinal direction" refers to the direction extending along or parallel to the cylindrical axis of the strip. As used herein, the term "curled" indicates that the sheet has a plurality of substantially parallel ridges or wrinkles. Preferably, when the aerosol-generating article has been assembled, the substantially parallel ridges or wrinkles extend relative to the strip in the longitudinal direction. As used herein, the terms "aggregated," "pleated," or "folded" indicate that the sheet of material is wrapped, folded, or otherwise compressed or contracted substantially transversely to the cylindrical axis of the strip. The sheet may be curled before being aggregated, pleated, or folded. The sheet may be aggregated, pleated, or folded without prior curling.

[0316] One such additional cooling element may have a total surface area between approximately 300 square millimeters per millimeter of length and approximately 1000 square millimeters per millimeter of length.

[0317] The auxiliary cooling element preferably provides low resistance to airflow through it. Preferably, the auxiliary cooling element has virtually no impact on the suction resistance of the aerosol-generating article. To achieve this, it is preferable that the porosity in the longitudinal direction is greater than 50% and that the airflow path through the auxiliary cooling element is relatively unrestricted. The longitudinal porosity of the auxiliary cooling element can be defined by the ratio of the cross-sectional area of ​​the material forming the auxiliary cooling element to the internal cross-sectional area of ​​the aerosol-generating article at the portion containing the auxiliary cooling element.

[0318] The additional cooling element preferably comprises a sheet material selected from metal foil, polymer sheets, and substantially non-porous paper or cardboard. In some embodiments, the aerosol cooling element may comprise a sheet 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. In a particularly preferred embodiment, the additional cooling element comprises a PLA sheet.

[0319] In other embodiments, alternatively, the aerosol cooling element may be provided as a single cooling element comprising a plurality of longitudinally extending channels.

[0320] In a preferred embodiment, the aerosol generating article further includes an upstream section located upstream of the aerosol generating matrix strip. The upstream section may include one or more upstream elements. In particular, the upstream section may include upstream elements arranged immediately upstream of the aerosol generating matrix strip.

[0321] The upstream element advantageously prevents direct physical contact with the upstream end of the aerosol-generating matrix. In particular, where the aerosol-generating matrix includes receptor elements, the upstream element prevents direct physical contact with the upstream end of the receptor elements. This helps prevent displacement or deformation of the receptor elements during handling or transport of the aerosol-generating article. This, in turn, helps to maintain the shape and position of the receptor elements. Furthermore, the presence of the upstream element helps prevent any loss of the matrix, which may be advantageous, for example, if the matrix contains granular plant material.

[0322] Upstream components can also provide an improved appearance for the upstream end of the aerosol-generating article. Furthermore, if desired, upstream components can be used to provide information about the aerosol-generating article, such as the brand, flavor, contents, or details of the aerosol-generating apparatus to which the article is intended to be used.

[0323] The upstream element may be a porous rod element. Preferably, the porous rod element does not alter the suction resistance of the aerosol-generating article. Preferably, the upstream element has at least about 50% porosity in the longitudinal direction of the aerosol-generating article. More preferably, the upstream element has between about 50% and about 90% porosity 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 ​​the material forming the upstream element to the internal cross-sectional area of ​​the aerosol-generating article at the location of the upstream element.

[0324] The upstream element may be made of a porous material or may include multiple openings. For example, this can be achieved by laser perforation. Preferably, the multiple openings are homogeneously distributed across the cross-section of the upstream element.

[0325] The porosity or permeability of upstream components can be advantageously varied in order to provide the desired overall suction resistance for aerosol-generated articles.

[0326] Preferably, the RTD of the upstream element is at least about 5 mm H2O. More preferably, the RTD of the upstream element is at least about 10 mm H2O. Even more preferably, the RTD of the upstream element is at least about 15 mm H2O. In a particularly preferred embodiment, the RTD of the upstream element is at least about 20 mm H2O.

[0327] The RTD of the upstream element is less than or equal to about 80 mmH2O. More preferably, the RTD of the upstream element is less than or equal to about 60 mmH2O. Even more preferably, the RTD of the upstream element is less than or equal to about 40 mmH2O.

[0328] In some embodiments, the RTD of the upstream element is from about 5 mm H2O to about 80 mm H2O, preferably from about 10 mm H2O to about 80 mm H2O, more preferably from about 15 mm H2O to about 80 mm H2O, and even more preferably from about 20 mm H2O to about 80 mm H2O. In other embodiments, the RTD of the upstream element is from about 5 mm H2O to about 60 mm H2O, preferably from about 10 mm H2O to about 60 mm H2O, more preferably from about 15 mm H2O to about 60 mm H2O, and even more preferably from about 20 mm H2O to about 60 mm H2O. In yet another embodiment, the RTD of the upstream element is from about 5 mm H2O to about 40 mm H2O, preferably from about 10 mm H2O to about 40 mm H2O, more preferably from about 15 mm H2O to about 40 mm H2O, and even more preferably from about 20 mm H2O to about 40 mm H2O.

[0329] In an alternative embodiment, the upstream element may be formed of an air-impermeable material. In such embodiments, the aerosol-generating article may be configured to allow air to flow into the aerosol-generating matrix strip through a suitable ventilation device disposed in the packaging.

[0330] The upstream element can be made of any material suitable for use in aerosol-generating articles. The upstream element can be made, for example, of the same material as one of the other components used in the aerosol-generating article (e.g., a mouthpiece, cooling element, or support element). Suitable materials for forming the upstream element include filter materials, ceramics, polymer materials, cellulose acetate, cardboard, zeolite, or aerosol-generating matrices. Preferably, the upstream element is formed from cellulose acetate rods.

[0331] Preferably, the upstream element is formed of a heat-resistant material. For example, preferably, the upstream element is formed of a material that can withstand temperatures up to 350 degrees Celsius. This ensures that the upstream element is not adversely affected by the heating device used to heat the aerosol generation matrix.

[0332] Preferably, the diameter of the upstream element is approximately equal to the diameter of the aerosol-generated product.

[0333] Preferably, the upstream element has a length between about 1 mm and about 10 mm, more preferably between about 3 mm and about 8 mm, and more preferably between about 4 mm and about 6 mm. In a particularly preferred embodiment, the upstream element has a length of about 5 mm. The length of the upstream element can be advantageously varied to provide the desired overall length of the aerosol-generating article. For example, in cases where it is desirable to reduce the length of one of the other components of the aerosol-generating article, the length of the upstream element can be increased to maintain the same overall length of the article.

[0334] The upstream element preferably has a substantially homogeneous structure. For example, the upstream element may be substantially homogeneous in texture and appearance. The upstream element may, for example, have a continuous, regular surface over its entire cross-section. For example, the upstream element may lack identifiable symmetry.

[0335] The upstream component is preferably defined by packaging. The packaging defining the upstream component is preferably a rigid bar package, for example, a bar package having a basis weight of at least about 80 grams per square meter (gsm), at least about 100 gsm, or at least about 110 gsm. This provides structural stiffness to the upstream component.

[0336] In certain preferred embodiments of the invention, the elements of the aerosol generating article described above are arranged such that the center of mass of the aerosol generating article extends from the downstream end along at least about 60% of the length of the aerosol generating article. More preferably, the elements of the aerosol generating article are arranged such that the center of mass of the aerosol generating article extends from the downstream end along at least about 62% of the length of the aerosol generating article, and more preferably, from the downstream end along at least about 65% of the length of the aerosol generating article.

[0337] Preferably, the center of mass does not exceed approximately 70% of the length of the aerosol-generated article from the downstream end.

[0338] Providing an arrangement of components with a center of mass closer to the upstream end than the downstream end results in an aerosol-generating article with a weight imbalance, where the upstream end is heavier. This weight imbalance can advantageously provide tactile feedback to the consumer, enabling them to distinguish between the upstream and downstream ends and thus insert the correct end into the aerosol-generating device. This can be particularly beneficial when the upstream components are provided in such a way that the upstream and downstream ends of the aerosol-generating article are visually similar to each other.

[0339] In embodiments of the aerosol-generating article according to the invention, both an aerosol cooling element and a support element are present, which are preferably packaged together in a modular package. The modular package defines the aerosol cooling element and the support element, but does not define another downstream element (such as a mouthpiece).

[0340] In these embodiments, the aerosol cooling element and the support element are assembled before being defined by the modular packaging, and then they are further assembled with the mouthpiece segment.

[0341] From a manufacturing point of view, this is advantageous because it enables the assembly of shorter aerosol-generated products.

[0342] Generally, processing individual elements with a length less than their diameter can be difficult. For example, for an element with a diameter of 7 mm, a length of approximately 7 mm represents a threshold, which is preferably not approached. However, a 10 mm aerosol cooling element can be combined with a pair of support elements (7 mm on each side) (and potentially with other elements such as aerosol generating matrix strips) to provide a 24 mm hollow section, which is then cut into two intermediate 12 mm hollow sections.

[0343] In a particularly preferred embodiment, the other components of the aerosol-generating article are individually defined by their own packaging. In other words, the upstream element, the aerosol-generating matrix strip, the support element, and the aerosol cooling element are all individually packaged. The support element and the aerosol cooling element are combined to form an intermediate hollow section. This is achieved by packaging the support element and the aerosol cooling element with a modular packaging. Then, the upstream element, the aerosol-generating matrix strip, and the intermediate hollow section are combined with the outer packaging. Subsequently, they are combined with a mouthpiece element having its own packaging by means of a tipping paper.

[0344] Preferably, at least one component of the aerosol-generating article is packaged in a hydrophobic packaging.

[0345] The term "hydrophobic" refers to a surface exhibiting water-repellent properties. A useful method for determining this is to measure the water contact angle. The water contact angle is the angle through which a liquid passes when a liquid / vapor interface encounters a solid surface, as conventionally measured. It quantifies the wettability of a solid surface by a liquid via Young's equation. Hydrophobicity, or the water contact angle, can be determined using the TAPPIT 558 test method, and the results are presented as interfacial contact angles and reported in degrees, ranging from near zero to near 180 degrees.

[0346] In a preferred embodiment, the hydrophobic packaging is a packaging comprising a paper layer having a water contact angle of about 30 degrees or greater, and preferably about 35 degrees or greater, or about 40 degrees or greater, or about 45 degrees or greater.

[0347] For example, the paper layer may include PVOH (polyvinyl alcohol) or silicone. PVOH may be applied to the paper layer as a surface coating, or the paper layer may include a surface treatment containing PVOH or silicone.

[0348] In a particularly preferred embodiment, the aerosol generating article according to the invention comprises, in a linear sequence, an upstream element, an aerosol generating matrix strip located immediately downstream of the upstream element, a support element located immediately downstream of the aerosol generating matrix strip, an aerosol cooling element located immediately downstream of the support element, a mouthpiece element located immediately downstream of the aerosol cooling element, and an outer packaging defining the upstream element, the support element, the aerosol cooling element, and the mouthpiece element.

[0349] More specifically, the aerosol generating matrix strip may be adjacent to the upstream element. The support element may be adjacent to the aerosol generating matrix strip. The aerosol cooling element may be adjacent to the support element. The nozzle element may be adjacent to the aerosol cooling element.

[0350] The aerosol-generated product has a generally cylindrical shape and an outer diameter of about 7.25 mm.

[0351] The upstream component has a length of approximately 5 mm, the aerosol-generating strip has a length of approximately 12 mm, the support component has a length of approximately 8 mm, and the mouthpiece component has a length of approximately 12 mm. Therefore, the total length of the aerosol-generating article is approximately 45 mm.

[0352] The upstream components are in the form of cellulose acetate rods packaged in rigid rod packaging.

[0353] The aerosol generating article includes an elongated receptor arranged substantially longitudinally within an aerosol generating matrix strip and in thermal contact with the aerosol generating matrix. The receptor is in the form of a strip or blade, having a length substantially equal to the length of the aerosol generating matrix strip and a thickness of approximately 60 micrometers.

[0354] The support element is in the form of a hollow cellulose acetate tube and has an inner diameter of approximately 1.9 mm. Therefore, the thickness of the peripheral wall of the support element is approximately 2.675 mm.

[0355] The aerosol cooling element is in the form of a thin hollow cellulose acetate tube with an inner diameter of approximately 3.25 mm. Therefore, the thickness of the peripheral wall of the aerosol cooling element is approximately 2 mm.

[0356] The mouthpiece is in the form of a low-density cellulose acetate filter segment.

[0357] The aerosol generating matrix strip includes at least one of the types of aerosol generating matrices described above, such as homogenized tobacco, gel formulations, or homogenized plant materials, wherein the homogenized plant materials include particles of plants other than tobacco.

[0358] The invention will now be further described below with reference to the following drawings, in which:

[0359] Figure 1 A schematic side cross-sectional view of the aerosol-generated article according to the present invention is shown; and

[0360] Figure 2 A schematic side cross-sectional view of another aerosol-generated article according to the present invention is shown.

[0361] In the following text, reference will be made to the appendix. Figure 1 The figure further illustrates the invention, showing a schematic side cross-sectional view of an aerosol-generated article according to the invention.

[0362] Figure 1 The aerosol generating article 10 shown includes a strip 12 of an aerosol generating matrix 12 and a downstream section 14 located downstream of the aerosol generating matrix strip 12. Furthermore, the aerosol generating article 10 includes an upstream section 16 located upstream of the aerosol generating matrix strip 12. Therefore, the aerosol generating article 10 extends from an upstream end or distal end 18 to a downstream end or port end 20.

[0363] The aerosol-generated product has an overall length of approximately 45 millimeters.

[0364] The downstream section 14 includes a support element 22 located immediately downstream of the aerosol generating matrix strip 12, the support element 22 being longitudinally aligned with the strip 12. Figure 1 In this embodiment, the upstream end of the support element 18 is adjacent to the downstream end of the aerosol generating matrix strip 12. Additionally, the downstream section 14 includes an aerosol cooling element 24 located immediately downstream of the support element 22, the aerosol cooling element 24 being longitudinally aligned with the strip 12 and the support element 22. Figure 1In one embodiment, the upstream end of the aerosol cooling element 24 is adjacent to the downstream end of the support element 22.

[0365] As will be apparent from the following description, the support element 22 and the aerosol cooling element 24 together define the intermediate hollow section 50 of the aerosol generating article 10. Overall, the intermediate hollow section 50 contributes essentially no to the overall RTD of the aerosol generating article. The overall RTD of the intermediate hollow section 26 is essentially 0 mmH2O.

[0366] The support element 22 includes a first hollow tubular segment 26. The first hollow tubular segment 26 is provided in the form of a hollow cylindrical tube made of cellulose acetate. The first hollow tubular segment 26 defines an inner cavity 28 extending from the upstream end 30 of the first hollow tubular segment 20 to the downstream end 32 of the first hollow tubular segment 20. The inner cavity 28 is substantially empty, and thus allows for substantially unrestricted airflow along the inner cavity 28. The first hollow tubular segment 26, and therefore the support element 22, substantially does not contribute to the overall RTD of the aerosol-generating article 10. More specifically, the RTD of the first hollow tubular segment 26 (which is substantially the RTD of the support element 22) is substantially 0 mmH2O.

[0367] The first hollow tubular segment 26 has a length of approximately 8 mm, an outer diameter of approximately 7.25 mm, and an inner diameter of approximately 1.9 mm (D). FTS Therefore, the thickness of the peripheral wall of the first hollow tubular segment 26 is approximately 2.67 mm.

[0368] The aerosol cooling element 24 includes a second hollow tubular segment 34. The second hollow tubular segment 34 is provided in the form of a hollow cylindrical tube made of cellulose acetate. The second hollow tubular segment 34 defines an inner cavity 36 extending from an upstream end 38 of the second hollow tubular segment to a downstream end 40 of the second hollow tubular segment 34. The inner cavity 36 is substantially empty, and therefore allows for substantially unrestricted airflow along the inner cavity 36. The second hollow tubular segment 28, and therefore the aerosol cooling element 24, substantially does not contribute to the overall RTD of the aerosol generating article 10. More specifically, the RTD of the second hollow tubular segment 34 (which is substantially the RTD of the aerosol cooling element 24) is substantially 0 mmH2O.

[0369] The second hollow tubular segment 34 has a length of approximately 8 mm, an outer diameter of approximately 7.25 mm, and an inner diameter of approximately 3.25 mm (D). FTS Therefore, the thickness of the peripheral wall of the second hollow tubular segment 34 is approximately 2 mm. Therefore, the inner diameter (D) of the first hollow tubular segment 26 is... FTS ) and the inner diameter (D) of the second hollow tubular segment 34 STS The ratio between them is approximately 0.75.

[0370] The aerosol-generating article 10 includes a ventilation zone 60 located along the second hollow tubular segment 34. More specifically, the ventilation zone is located approximately 2 mm upstream of the second hollow tubular segment 34. The ventilation level of the aerosol-generating article 10 is approximately 25%.

[0371] exist Figure 1 In this embodiment, the downstream section 14 further includes a mouthpiece element 42 located downstream of the intermediate hollow section 50. More specifically, the mouthpiece element 42 is positioned immediately downstream of the aerosol cooling element 24. Figure 1 As shown in the figure, the upstream end of the mouthpiece element 42 is adjacent to the downstream end 40 of the aerosol cooling element 18.

[0372] The mouthpiece element 42 is provided in the form of a cylindrical rod of low-density cellulose acetate.

[0373] The mouthpiece element 42 has a length of approximately 12 mm and an outer diameter of approximately 7.25 mm. The RTD of the mouthpiece element 42 is approximately 12 mm H2O.

[0374] Section 12 includes aerosol-generating matrices of one of the types mentioned above.

[0375] The aerosol generating matrix strip 12 has an outer diameter of approximately 7.25 mm and a length of approximately 12 mm.

[0376] The aerosol generating article 10 further includes an elongated receptor 44 within the aerosol generating matrix strip 12. More specifically, the receptor 44 is arranged substantially longitudinally within the aerosol generating matrix so as to be generally parallel to the longitudinal direction of the strip 12. Figure 1 As shown in the figure, the receptor 44 is located in the radial center position within the strip and extends effectively along the longitudinal axis of the strip 12.

[0377] The receptor 44 extends from the upstream end of the strip 12 to the downstream end. In fact, the receptor 44 has a length that is substantially the same as that of the aerosol generating matrix strip 12.

[0378] exist Figure 1 In one embodiment, the receptor 44 is provided in the form of a strip and has a length of approximately 12 mm, a thickness of approximately 60 micrometers, and a width of approximately 4 mm. The upstream segment 16 includes an upstream element 46 located immediately upstream of the aerosol-generating matrix strip 12, the upstream element 46 being longitudinally aligned with the strip 12. Figure 1 In this embodiment, the downstream end of the upstream element 46 is adjacent to the upstream end of the aerosol generating matrix strip 12. This advantageously prevents the receptor 44 from being removed. Furthermore, this ensures that the consumer will not accidentally come into contact with the heated receptor 44 after use.

[0379] The upstream element 46 is provided in the form of a cylindrical cellulose acetate rod defined by a rigid packaging. The upstream element 46 has a length of approximately 5 mm. The RTD of the upstream element 46 is approximately 30 mm H2O.

[0380] Figure 2 The aerosol generating article 110 shown has the same characteristics as... Figure 1 The aerosol generating article 10 has essentially the same overall structure, and the differences between it and the aerosol generating article 10 will be described below only.

[0381] like Figure 2 As shown, the aerosol generating article 110 includes a strip 12 of an aerosol generating matrix 12 and a modified downstream section 114 located downstream of the aerosol generating matrix strip 12. Furthermore, the aerosol generating article 10 includes an upstream section 16 located upstream of the aerosol generating matrix strip 12.

[0382] Similar to the downstream section 14 of the aerosol generating article 10, the modified downstream section 114 of the aerosol generating article 110 includes a support element 22 adjacent to the downstream of the aerosol generating matrix strip 12, the support element 22 being longitudinally aligned with the strip 12, wherein the upstream end of the support element 22 is adjacent to the downstream end of the aerosol generating matrix strip 12.

[0383] Additionally, the modified downstream section 114 includes an aerosol cooling element 124 located immediately downstream of the support element 22, the aerosol cooling element 124 being longitudinally aligned with the strip 12 and the support element 22. More specifically, the upstream end of the aerosol cooling element 124 is adjacent to the downstream end of the support element 22.

[0384] Compared to the downstream section 14 of the aerosol generating article 10, the modified downstream section 114's aerosol cooling element 124 includes multiple longitudinally extending channels that provide low or substantially no resistance to airflow. More specifically, the cooling element 124 is preferably formed of a non-porous sheet material selected from metal foil, polymer sheets, and substantially non-porous paper or cardboard. In particular, in Figure 2 In the embodiment shown, the aerosol cooling element 124 is provided in the form of a rolled and aggregated sheet of polylactic acid (PLA). The aerosol cooling element 124 has a length of about 8 mm and an outer diameter of about 7.25 mm.

Claims

1. An aerosol generating article for generating an inhalable aerosol upon heating, the aerosol generating article extending from an opening to a distal end upstream of the opening, and comprising: Aerosol-generated matrix strips; A downstream section located downstream of the aerosol generating matrix strip, wherein the downstream section includes a mouthpiece element positioned downstream of the aerosol generating matrix strip and longitudinally aligned with the aerosol generating matrix strip, the mouthpiece element extending to the mouth end of the aerosol generating article; as well as An upstream section located upstream of the aerosol generating matrix strip, the upstream section including an upstream element containing a filter material segment and extending to the distal end of the article; The diameter (D) at the mouth end of the aerosol-generating article therein ME The diameter (D) at the distal end of the aerosol-generating article is greater than that of the article. DE The ratio (D) between the diameter at the mouth end of the aerosol generating article and the diameter at the distal end of the aerosol generating article. ME / D DE The value is at least 1.

005. The aerosol generating article includes a first tipping paper tape and a second tipping paper tape surrounding the first tipping paper tape, the first tipping paper tape at least partially defining the mouthpiece element and securing the mouthpiece element to a portion of the aerosol generating article adjacent to and upstream of the mouthpiece element.

2. The aerosol generating article according to claim 1, wherein the ratio (D) between the diameter at the mouth end of the aerosol generating article and the diameter at the distal end of the aerosol generating article is... ME / D DE The value is at least 1.

05.

3. The aerosol generating article according to claim 1 or claim 2, wherein the diameter (D) at the mouth end of the aerosol generating article is... ME ) and the diameter (D) at the distal end of the aerosol-generating article. DE The difference between them is at least 100 micrometers.

4. The aerosol generating article according to claim 1 or claim 2, the article further comprising elongated receptors arranged longitudinally within the aerosol generating matrix strip.

5. The aerosol generating article according to claim 1 or claim 2, wherein the diameter of the upstream section is larger than the diameter of the aerosol generating matrix strip.

6. The aerosol generating article according to claim 1 or claim 2, wherein the downstream section further includes a support element positioned adjacent to and longitudinally aligned with the aerosol generating matrix strip.

7. The aerosol generating article of claim 6, wherein the downstream section further includes an aerosol cooling element positioned immediately downstream of the support element, the aerosol cooling element including a hollow tubular segment defining a cavity extending from an upstream end of the hollow tubular segment to a downstream end of the hollow tubular segment.

8. The aerosol-generating article of claim 7, further comprising a ventilation zone along the location of the hollow tubular segment.

9. The aerosol generating article according to claim 8, wherein the aerosol generating article has a ventilation level of at least 10%.

10. The aerosol-generating article according to claim 1 or claim 2, wherein the diameter of the aerosol-generating article is substantially constant over a distal portion of the aerosol-generating article extending at least 5 mm from the distal end.

11. The aerosol generating article according to claim 1 or claim 2, wherein the diameter of the aerosol generating article tapers over a distal portion of the aerosol generating article extending at least 5 mm from the distal end.

12. The aerosol-generating article according to claim 1 or claim 2, wherein the aerosol-generating matrix comprises at least 10% by weight of an aerosol forming agent on a dry weight basis.

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