Aerosol-generating article with upstream element

Abstract

An aerosol-generating article (100) for producing an inhalable aerosol upon heating, the aerosol-generating article comprising an aerosol-forming substrate (101). The aerosol-forming substrate comprises a gel composition comprising at least one gelling agent, an alkaloid compound, and an aerosol former. The aerosol-generating article further comprises an upstream element (102) located upstream of the aerosol-forming substrate. The aerosol-generating article further comprises a recess (103) extending from an upstream end of the aerosol-generating article through the upstream element and through at least a portion of the aerosol-forming substrate.

Description

Technical Field

[0001] This disclosure relates to an aerosol generating article for generating an inhalable aerosol upon heating. Specifically, the invention relates to an aerosol generating article for generating an inhalable aerosol upon heating, the aerosol generating article comprising an aerosol forming matrix containing a gel composition and upstream elements. Background Technology

[0002] Aerosol-generating articles are known in the art in which an aerosol-forming matrix, such as a tobacco-containing matrix, is heated rather than burned. Typically, in such heated smoking articles, an aerosol is generated by transferring heat from a heat source to a physically separated aerosol-forming 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-forming 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 or nucleate 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 forming matrix of the heated aerosol generating article.

[0004] Aerosol-generating articles in which the tobacco-containing matrix is ​​heated without combustion present several challenges not encountered in 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 section at the mouthpiece of the cigarette) may have undesirable effects in aerosol-generating articles in which the tobacco-containing matrix is ​​heated without combustion, as they can reduce nicotine delivery.

[0005] Furthermore, in some existing aerosol-generating articles, the aerosol-forming matrix is ​​heated from the outside by means of an external heater. However, this can be inefficient because the center of the aerosol-forming matrix may be heated to a lesser extent than the periphery. Therefore, it is desirable to provide an aerosol-generating article that can be heated more efficiently.

[0006] Furthermore, some existing aerosol-generating articles are constructed to allow air to pass through the aerosol-forming matrix. This can lead to variations in the suction resistance (RTD) of the aerosol-generating article during use. For example, an aerosol-forming matrix may have a higher RTD during first use than a partially depleted aerosol-forming matrix.

[0007] In view of the aforementioned shortcomings of the prior art, it is also recognized that any improved aerosol-generating article also requires an effective airflow management device. Such airflow management must enable air to enter the article, entrain aerosols from the aerosol-forming matrix, and exit the aerosol-generating article, while providing satisfactory RTD and low RTD variability from one article to another.

[0008] In addition, there is a general consensus that there is a need for aerosol-generating products that are easy to use and have improved practicality.

[0009] Therefore, it is desirable to provide a new and improved aerosol-generating article suitable for achieving at least one of the aforementioned desired results. Furthermore, it is desirable to provide such an aerosol-generating article that can be manufactured efficiently and at high speed. Summary of the Invention

[0010] This disclosure relates to an aerosol generating article for producing an inhalable aerosol upon heating. The aerosol generating article may include an aerosol forming matrix comprising a gel composition including at least one gelling agent, an alkaloid compound, and an aerosol forming agent.

[0011] Providing an aerosol-forming matrix comprising a gel composition is desirable because it provides a homogeneous matrix capable of generating highly consistent aerosols. Additionally, a gel aerosol-forming matrix can generate aerosols at lower temperatures than a tobacco-containing aerosol-forming matrix. This allows for a more efficient combination of aerosol-generating systems, aerosol-generating devices, and aerosol-generating articles. Furthermore, this advantageously reduces the need to cool the aerosol before it reaches the consumer.

[0012] Aerosol-generating articles may include upstream components. These upstream components may be located upstream of the aerosol-forming matrix.

[0013] The upstream element advantageously protects the aerosol-forming matrix and prevents direct user contact with the gel composition within it. The upstream element can separate the aerosol-forming matrix from the upstream end of the aerosol-generating article. This can be advantageous when the aerosol-generating article is configured for use with a heater that cannot heat the upstream end of the article. This is because, when the aerosol-generating article is inserted into the aerosol-generating apparatus, the upstream element advantageously allows the aerosol-forming matrix to be positioned optimally for heating. Additionally, the upstream element can be used to prevent or reduce air entry into the aerosol-generating article through its upstream end. This helps prevent air from passing through the aerosol-forming matrix, which advantageously prevents changes in the RTD during use of the aerosol-generating article. In this way, the upstream element can also act as an RTD buffer to control the RTD of the article, independent of the RTD of other individual components of the article.

[0014] The aerosol generating article may include a recess extending from the upstream end of the aerosol generating article through the upstream element and through at least a portion of the aerosol forming matrix.

[0015] The recessed design advantageously allows for the use of an internal heater, such as a pin or blade heater, to heat the article. This facilitates more efficient heating of the aerosol-forming matrix. The recess is particularly advantageous because aerosol-forming matrices containing gels typically have a higher density than those containing tobacco. Therefore, it is less practical to directly insert a pin or blade heater into a gel-containing aerosol-forming matrix compared to a tobacco-containing aerosol-forming matrix. Furthermore, the recessed design prevents the heater from contacting the gel aerosol-forming matrix, which helps keep the heater clean.

[0016] According to the present invention, an aerosol generating article is provided for generating an inhalable aerosol upon heating, the aerosol generating article comprising an aerosol forming matrix comprising a gel composition comprising at least one gelling agent, an alkaloid compound, and an aerosol forming agent. The aerosol generating article further includes an upstream element upstream of the aerosol forming matrix and a recess extending from the upstream end of the aerosol generating article through the upstream element and through at least a portion of the aerosol forming matrix.

[0017] The aerosol generating article according to the present invention overcomes many disadvantages of prior art aerosol generating articles. Firstly, it is advantageous to provide an aerosol forming matrix comprising a gel composition, as it provides a homogeneous matrix capable of generating highly consistent aerosols. Additionally, the gel aerosol forming matrix can generate aerosols at temperatures lower than those of a tobacco-containing aerosol forming matrix. This provides a more efficient combination of aerosol generating systems, aerosol generating devices, and aerosol generating articles. Furthermore, this advantageously reduces the need to cool the aerosol before it reaches the consumer.

[0018] The recessed design advantageously allows for the use of an internal heater, such as a pin or blade heater, to heat the article. This helps to heat the aerosol-forming matrix more effectively. It also helps prevent the outer surface of the aerosol-generating device used with the aerosol-forming matrix from becoming too hot. As mentioned above, providing an aerosol-forming matrix comprising a gel composition lowers the temperature required to generate aerosols compared to an aerosol-forming matrix comprising tobacco. This, combined with the recess extending from the upstream end, synergistically helps to heat the aerosol-forming matrix more effectively and lowers the temperature of the aerosol-generating device using the aerosol-generating article.

[0019] The upstream components are positioned to advantageously protect the aerosol forming matrix and prevent users from directly contacting the gel composition within the aerosol forming matrix.

[0020] Furthermore, upstream elements can be used to provide better control over the total suction resistance (RTD) of aerosol-generating articles. Specifically, upstream elements can advantageously compensate for potential reductions in RTD due to evaporation of the gel composition during use or due to the inclusion of other elements in aerosol-generating articles with relatively low suction resistance. For example, in embodiments of the invention that include an intermediate hollow section that does not actually contribute to the overall RTD of the article, upstream elements can be used to add RTD to the aerosol-generating article while still providing an acceptable level.

[0021] Advantageously, because the upstream element is located upstream of the aerosol-forming matrix, it can increase the total RTD without affecting the properties of the aerosol. If the desired RTD level is largely provided by the upstream element, this allows the use of downstream elements to provide minimal aerosol filtration. Therefore, aerosol-generating articles can optimize aerosol delivery from the gel composition to the consumer while maintaining optimal RTD levels throughout the smoking process.

[0022] Alternatively or additionally, the upstream element may be advantageously adapted to compensate for the reduction in length of other elements of the aerosol-generating article, thereby maintaining a generally consistent length of the aerosol-generating article. This advantageously allows the aerosol-forming matrix to be positioned optimally for heating when the aerosol-generating article is inserted into the aerosol-generating apparatus. This length compensation can be provided without affecting the properties of the aerosol.

[0023] Furthermore, upstream components can advantageously provide a more uniform appearance at the upstream end of the aerosol-generated article.

[0024] As used herein with respect to the invention, the term "aerosol-generating article" is used herein to mean an article in which an aerosol-forming matrix is ​​heated to generate an inhalable aerosol and deliver it to a consumer. As used herein, the term "aerosol-forming matrix" means a matrix capable of releasing volatile compounds upon heating to generate an aerosol.

[0025] 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 air inhaled through the cigarette 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 an aerosol-forming 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 an internal heater adapted to be inserted into a recess in the aerosol-generating matrix.

[0026] As used herein with respect to the invention, the term "aerosol generating apparatus" refers to an apparatus including a heater element that interacts with an aerosol forming matrix of an aerosol generating article to generate an aerosol.

[0027] As used herein with respect to the invention, the term "longitudinal" refers to the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. During use, air is drawn through the aerosol-generating article in the longitudinal direction.

[0028] As used herein with respect to the invention, the terms “upstream” and “front” and “downstream” and “rear” are used to describe the relative position of a component or part of an aerosol-generating article with respect to the direction of air flow through it during use of the aerosol-generating article. An aerosol-generating article according to the invention includes a proximal end through which, in use, aerosols exit the article. The proximal end of the aerosol-generating article may also be referred to as an orifice or downstream end. The orifice is downstream of the distal end. The distal end of the aerosol-generating article may also be referred to as an upstream end. A component or part of an aerosol-generating article may be described as being upstream or downstream of each other based on its relative position between the proximal end and the distal end of the aerosol-generating article. The front portion of a component or part of an aerosol-generating article is the portion closest to the upstream end of the aerosol-generating article. The rear portion of a component or part of an aerosol-generating article is the portion closest to the downstream end of the aerosol-generating article.

[0029] As used herein with respect to the invention, the term "transverse" refers to a direction perpendicular to the longitudinal axis. Unless otherwise stated, any reference to the "cross section" of an aerosol-generating article or a component of an aerosol-generating article refers to a transverse cross section.

[0030] As used herein with respect to the invention, the term "length" refers to the dimension of a component of an aerosol-generating article in the longitudinal direction. For example, it can be used to refer to the dimension of an aerosol-forming matrix or upstream element in the longitudinal direction.

[0031] According to the present invention, the aerosol-forming matrix comprises a gel composition containing an alkaloid compound. In a particularly preferred embodiment, the aerosol-forming matrix comprises a gel composition containing nicotine.

[0032] The aerosol-forming matrix includes a longitudinal opening for receiving the recess, extending from the upstream end of the aerosol-generating article through at least a portion of the aerosol-forming matrix. The longitudinal opening may extend along the entire length of the aerosol-forming matrix. Alternatively, the longitudinal opening may extend only through the upstream portion of the aerosol-forming matrix. The aerosol-forming matrix may include an annular mandrel containing a porous medium loaded with a gel composition. The porous medium may include at least one of cellulose acetate tow, crimped viscose fibers, and crimped cotton.

[0033] 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.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] The gel composition contains an alkaloid compound. The gel composition may include one or more alkaloids.

[0038] 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.

[0039] The gel composition may preferably include an alkaloid compound selected from nicotine, anaphylabine, and combinations thereof.

[0040] Preferably, the gel composition contains nicotine.

[0041] The term "nicotine" refers to nicotine and nicotine derivatives, such as free nicotine base and nicotine salts.

[0042] 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.

[0043] Preferably, the gel composition includes nicotine. Nicotine may be added to the composition in free alkali form or salt form. The gel composition contains 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 contains 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.

[0044] The gel composition optionally 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.

[0045] 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.

[0046] 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.

[0047] The gel composition optionally includes at least one gelling agent. Preferably, the gel composition contains 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.

[0048] 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.

[0049] Gelling agents may include one or more biopolymers. Biopolymers may be formed from polysaccharides.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] The gel composition may include a low-acyl gellan gum in the range of about 0.2% to about 5% by weight. Preferably, the low-acyl gellan gum may be in the range of about 0.5% to about 3% by weight. Preferably, the low-acyl gellan gum may be in the range of about 0.5% to about 2% by weight. Preferably, the low-acyl gellan gum may be in the range of about 1% to about 2% by weight.

[0064] 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.

[0065] The gel composition may include κ-carrageenan in the range of about 0.2% to about 5% by weight. Preferably, κ-carrageenan may be in the range of about 0.5% to about 3% by weight. Preferably, κ-carrageenan may be in the range of about 0.5% to about 2% by weight. Preferably, κ-carrageenan may be in the range of about 1% to about 2% by weight.

[0066] 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.

[0067] The gel composition may include alginate in the range of about 0.2% to about 5% by weight. Preferably, the alginate may be in the range of about 0.5% to about 3% by weight. Preferably, the alginate may be in the range of about 0.5% to about 2% by weight. Preferably, the alginate may be in the range of about 1% to about 2% by weight.

[0068] 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.

[0069] 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 contains high levels of glycerol.

[0070] The term "thickening agent" refers to a compound that, when homogenized in an amount of 0.3% by weight to a mixture of 50% by weight water and 50% by weight glycerol at 25°C, increases viscosity without causing gel formation, and the mixture retains or preserves fluidity. Preferably, a thickening agent is a compound that, when homogenized in an amount of 0.3% by weight to a mixture of 50% by weight water and 50% by weight glycerol at 25°C, increases viscosity to at least 50 cPs, preferably at least 200 cPs, preferably at least 500 cPs, preferably at least 1000 cPs at a shear rate of 0.1 s⁻¹, without causing gel formation, and the mixture retains or preserves fluidity. Preferably, the thickener is a compound that, when homogeneously added in an amount of 0.3% by weight to a mixture of 50% by weight water and 50% by weight glycerol at 25°C, increases the viscosity by at least 2 times, at least 5 times, at least 10 times, or at least 100 times compared to before addition at a shear rate of 0.1 s⁻¹, without causing gel formation, or causing the mixture to retain or hold fluid.

[0071] 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).

[0072] The gel composition preferably includes a tackifier ranging from about 0.2% by weight to about 5% by weight. Preferably, the composition includes a tackifier ranging from about 0.5% by weight to about 3% by weight. Preferably, the composition includes a tackifier ranging from about 0.5% by weight to about 2% by weight. Preferably, the composition includes a tackifier ranging from about 1% by weight to about 2% by weight.

[0073] 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.

[0074] The gel composition may include xanthan gum in the range of about 0.2% to about 5% by weight. Preferably, the xanthan gum may be in the range of about 0.5% to about 3% by weight. Preferably, the xanthan gum may be in the range of about 0.5% to about 2% by weight. Preferably, the xanthan gum may be in the range of about 1% to about 2% by weight.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] The gel composition may include gum arabic in the range of about 0.2% to about 5% by weight. Preferably, gum arabic may be in the range of about 0.5% to about 3% by weight. Preferably, gum arabic may be in the range of about 0.5% to about 2% by weight. Preferably, gum arabic may be in the range of about 1% to about 2% by weight.

[0079] 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.

[0080] The gel composition may include λ-carrageenan in the range of about 0.2% to about 5% by weight. Preferably, λ-carrageenan may be in the range of about 0.5% to about 3% by weight. Preferably, λ-carrageenan may be in the range of about 0.5% to about 2% by weight. Preferably, λ-carrageenan may be in the range of about 1% to about 2% by weight.

[0081] 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.

[0082] 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 to about 1% by weight.

[0083] 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.

[0084] The gel composition may include a carboxylic acid ranging from about 0.1% to about 5% by weight. Preferably, the carboxylic acid may range from about 0.5% to about 3% by weight. Preferably, the carboxylic acid may range from about 0.5% to about 2% by weight. Preferably, the carboxylic acid may range from about 1% to about 2% by weight.

[0085] 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.

[0086] 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.

[0087] The gel composition preferably includes some water. The gel composition is more stable when it contains some water. Preferably, the gel composition contains 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 contains at least about 10% by weight or at least about 15% by weight of water.

[0088] Preferably, the gel composition contains between about 8% by weight and 32% by weight of water. Preferably, the gel composition contains between about 15% by weight and about 25% by weight of water. Preferably, the gel composition contains between about 18% by weight and about 22% by weight of water. Preferably, the gel composition contains about 20% by weight of water.

[0089] Preferably, the aerosol forming matrix comprises a gel composition in the range of about 150 mg to about 350 mg.

[0090] As described above, the aerosol generating article of the present invention further includes an upstream element located upstream of the aerosol forming matrix.

[0091] The upstream component may be adjacent to the aerosol forming matrix. The downstream end of the upstream component may be adjacent to the upstream end of the aerosol forming matrix.

[0092] As used herein with respect to the invention, the term "abutting" is used to describe a component or part of a component that is in direct contact with another component or part of a component.

[0093] Since a recess extending from the upstream end of the aerosol-generating article through the upstream element is provided, the upstream element will include a longitudinal opening for receiving the recess. For example, the upstream element may have an annular shape.

[0094] The upstream element may be a porous rod element. 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, excluding the longitudinal opening in the upstream element for accommodating the recess.

[0095] 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.

[0096] The porosity or permeability of upstream components can be advantageously varied in order to provide the desired overall suction resistance for aerosol-generated articles.

[0097] When discussing the RTD of the upstream element, or when giving the RTD value of the upstream element, it is assumed that air cannot pass through the longitudinal opening of the upstream element. In practice, this may be true, because when using an aerosol-generating article, the longitudinal opening may be occupied by a heater. As explained in more detail below, in the aerosol-generating article according to the invention, it may not be desirable for air to be able to enter the aerosol-generating article through the recess and pass through the aerosol-generating article to reach the user. Therefore, when considering the RTD of the upstream element, it should be assumed that the longitudinal opening is blocked, and any air passing through the upstream element only passes through the material surrounding the longitudinal opening.

[0098] 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.

[0099] The upstream element of the RTD, which provides at least about 20 mm H2O, advantageously restricts airflow through the upstream end into the aerosol-generated article. Therefore, the airflow through the aerosol-generated article can be controlled simply by configuring a ventilation system, which will be described in more detail below. This advantageously simplifies manufacturing.

[0100] Furthermore, as mentioned above, providing an upstream element with a relatively high RTD can prevent or reduce the ingress of air through the upstream end of the aerosol-generating article. This helps prevent air from passing through the aerosol-forming matrix, which advantageously prevents changes in RTD during use of the aerosol-generating article. In this way, the upstream element can also act as an RTD buffer to control the RTD of the article, independent of the RTD of other individual components of the article. Specifically, the upstream element can advantageously be used to compensate for potential reductions in RTD due to evaporation of the gel composition during use or due to the inclusion of other elements in an aerosol-generating article with relatively low suction resistance.

[0101] Preferably, 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.

[0102] 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.

[0103] Preferably, the RTD of the upstream element is greater than the RTD of the mouthpiece element (if present). More preferably, the RTD of the upstream element is at least 1.5 times the RTD of the mouthpiece element, more preferably at least 2 times the RTD of the mouthpiece element, and even more preferably at least 2.5 times the RTD of the mouthpiece element. This advantageously provides a larger proportion of the total RTD of the aerosol-generating article upstream of the aerosol-forming matrix strip. This minimizes the RTD of the mouthpiece element, thereby minimizing the filtration effect on the aerosol if necessary.

[0104] The upstream components may be formed of an impermeable material. In such embodiments, the aerosol-generating article may be configured such that air flows into the aerosol-forming matrix through a suitable ventilation device disposed within the packaging.

[0105] The upstream element can be made of any material suitable for use in an aerosol-generating article. The upstream element can be made, for example, of the same material used for one of the other components of the aerosol-generating article (e.g., a mouthpiece or cooling element). Suitable materials for forming the upstream element include filter materials, ceramics, polymer materials, cellulose acetate, cardboard, high-density crimped cotton, viscose fiber, zeolite, or aerosol-forming matrix.

[0106] The upstream element may include an annular mandrel containing fibrous filter material. Suitable fibrous filter materials will be known to those skilled in the art. Particularly preferably, the upstream element includes a cellulose acetate filter tip section formed from cellulose acetate tow.

[0107] 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-forming matrix.

[0108] Preferably, the diameter of the upstream element is approximately equal to the diameter of the aerosol-generated product.

[0109] For example, upstream components may have a diameter between approximately 5 mm and approximately 15 mm, or between approximately 6 mm and approximately 9 mm.

[0110] 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, or to ensure that the aerosol-forming matrix is ​​located in an optimal position for heating when the aerosol-generating article is inserted into the aerosol-generating apparatus. 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.

[0111] 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.

[0112] The upstream component is preferably defined by packaging. The packaging defining the upstream component is preferably a rigid rod package, for example, a mandrel 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. This provides structural stiffness to the upstream component.

[0113] As described above, the aerosol generating article of the present invention further includes a recess extending from the upstream end of the aerosol generating article through the upstream element and through at least a portion of the aerosol forming matrix.

[0114] The recess may be defined by a longitudinal opening extending through the upstream element and a longitudinal opening extending through at least a portion of the aerosol-forming matrix. The longitudinal opening extending through the upstream element and the longitudinal opening extending through at least a portion of the aerosol-forming matrix may have substantially the same diameter and be substantially aligned.

[0115] The recess can have any cross-sectional shape. The recess can have a constant cross-sectional shape. The shape of the recess can be configured to correspond to the shape of the heater in an aerosol generating apparatus used with the aerosol generating article. The recess can have a circular cross-sectional shape. A recess with a circular cross-sectional shape may be suitable when the heater is a pin heater. The recess can have an elliptical or rectangular shape. A recess with an elliptical or rectangular cross-sectional shape may be suitable when the heater is a blade heater. Preferably, the recess has a circular cross-sectional shape.

[0116] The recess can be centrally positioned along the longitudinal axis of the aerosol-generating article. This advantageously simplifies the insertion of the aerosol-generating article into the aerosol-generating apparatus, since the orientation of the aerosol-generating apparatus may be irrelevant. Furthermore, centrally positioning the recess advantageously ensures uniform heating of the aerosol-forming matrix.

[0117] The recess can have any diameter. Preferably, the diameter of the recess is equal to or slightly larger than the diameter of the heater of the aerosol generating apparatus used with the aerosol generating article.

[0118] The diameter of the recess can be between approximately 0.5 mm and approximately 10 mm. For example, the diameter of the recess can be between approximately 1 mm and approximately 8 mm, or between approximately 2 mm and approximately 6 mm.

[0119] The recess can have any length. Preferably, the length of the recess is equal to or slightly greater than the length of the heater of the aerosol generating apparatus used with the aerosol generating article.

[0120] The length of the recess can be between approximately 5 mm and approximately 30 mm. For example, the length of the recess can be between approximately 10 mm and approximately 25 mm, or between approximately 15 mm and approximately 20 mm.

[0121] The recess may extend through the entire length of the aerosol-forming matrix. In this case, the recess may further extend downstream of the downstream end of the aerosol-forming matrix. Alternatively, in this case, the recess may extend to the downstream end of the aerosol-forming matrix, but not further downstream.

[0122] The inner surface of the recess may be provided with packaging. For example, the longitudinal inner surface of the recess may be provided with packaging. When the recess has a circular cross-sectional shape, the packaging may be provided on the curved longitudinal inner surface of the recess. Therefore, the packaging may be located between the upstream element and the recess, and between the aerosol forming matrix and the recess.

[0123] Providing a packing material on the longitudinal inner surface of the recess advantageously helps to hold components of the aerosol-generating article in place. For example, the packing material advantageously prevents portions of upstream elements and the aerosol-forming matrix from entering the recess, which would otherwise prevent the heating element of the aerosol-generating device from being inserted into the recess. Furthermore, the packing material acts as a barrier between the aerosol-forming matrix and the recess. This prevents direct contact between the aerosol-forming matrix and the heater of the aerosol-generating article, which advantageously helps to keep the heater clean.

[0124] The inventors have confirmed that when the aerosol-forming matrix is ​​a gel, as in the case of this invention, the package can readily adhere to the aerosol-forming matrix on the inner surface of the recess, thereby advantageously retaining the package within the recess. This is likely due to the relatively high moisture content of the gel aerosol-forming matrix. This synergistic effect may not be observed when the aerosol-forming matrix contains, for example, tobacco.

[0125] The packaging design reduces or prevents air from entering the aerosol-generating article through the recesses. This advantageously improves control over airflow through the aerosol-generating article. As explained in more detail below, in aerosol-generating articles according to some aspects of the invention, it is not desirable for air to be able to enter the aerosol-generating article through the recesses and pass through the aerosol-generating article to reach the user.

[0126] The packaging can extend along the full length of the longitudinal inner surface of the recess. In other words, the packaging can extend from the upstream end of the recess to the downstream end of the recess.

[0127] The packaging material can be disposed on the entire longitudinal inner surface of the recess. In other words, the entire longitudinal inner surface of the recess can be covered by the packaging material. This advantageously helps to completely separate the aerosol-forming matrix and the recess.

[0128] The packaging can be formed from any suitable material. For example, the packaging may include paper, preferably cellulose-based paper.

[0129] Packaging materials can be hydrophobic. The term "hydrophobic" means that the surface exhibits 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 the 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 TAPPI T558 test method, and the results are presented as interfacial contact angles and reported in "degrees," ranging from near zero degrees to near 180 degrees.

[0130] 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.

[0131] 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.

[0132] In cases where the gel aerosol forming matrix has a high moisture content, providing hydrophobic packaging materials may be particularly advantageous, as it helps maintain the structural integrity of the aerosol-generated article.

[0133] The packaging may include a metal layer. This metal layer may be bonded to another layer. For example, the metal layer may be used in conjunction with a paper layer. In this case, the metal layer may be positioned between the aerosol forming matrix or upstream element and the paper layer. This separates the paper from the aerosol forming matrix, which advantageously prevents direct contact between the gel aerosol forming matrix and the paper. Alternatively, the paper layer may be positioned between the aerosol forming matrix or upstream element and the metal layer. This prevents the paper layer from directly contacting or being near the heater of the aerosol generating device, which advantageously prevents paper combustion.

[0134] The packaging may include multiple metal layers. The packaging may include multiple paper layers.

[0135] The metal layer of the packaging can have any thickness. For example, the metal layer can have a thickness between about 2 micrometers and about 40 micrometers, or between about 5 micrometers and about 30 micrometers. The metal layer may include aluminum foil. The metal layer may be co-laminated with the paper layer.

[0136] The packaging can have any total thickness. For example, the packaging can have a thickness between about 30 micrometers and about 200 micrometers, between about 50 micrometers and about 180 micrometers, or between about 60 micrometers and about 150 micrometers.

[0137] The downstream end of the recess may be defined by a packaging material. The downstream end of the recess refers to the end face at the most downstream end of the recess, opposite to the longitudinal inner surface of the recess. The packaging material may be formed of any material described above related to the packaging material disposed on the longitudinal inner surface of the recess. Providing packaging material defining the downstream end of the recess can advantageously reduce or prevent air from entering the aerosol-forming article through the recess.

[0138] The packaging at the downstream end of the recess can be formed from the same material sheet as the packaging disposed on the longitudinal inner surface of the recess.

[0139] In this configuration, the package, positioned on the longitudinal inner surface of the recess, also extends above the downstream end of the recess. The package can be mechanically closed at the downstream end of the recess. This can be achieved by folding or twisting the package. An adhesive can be used to close the downstream end of the recess.

[0140] This provision advantageously simplifies the manufacture of aerosol-generating articles because it may require only a single piece of packaging material. Furthermore, using a single piece of packaging material eliminates the need for seams connecting two pieces of packaging material. This advantageously simplifies manufacturing. The absence of seams also advantageously prevents or reduces leakage of any aerosol-forming matrix from the aerosol-generating article.

[0141] At least one of the aerosol forming matrix and upstream components may be surrounded by packaging.

[0142] As used herein with respect to the invention, the term "circumscribe / circumscribing" means that the first feature extends around the entire circumference of the second feature. For example, in the invention, the packaging may surround at least one of the aerosol forming matrix and the upstream element. This means that at one or more points along the longitudinal length of at least one of the aerosol forming matrix and the upstream element, the packaging paper extends around the entire circumference of at least one of the aerosol forming matrix and the upstream element.

[0143] The packaging may be formed from any of the materials described above related to the packaging disposed on the longitudinal inner surface of the recess.

[0144] The packaging material can be advantageously used to secure the aerosol-forming matrix to upstream components. When the packaging material surrounds the aerosol-forming matrix, it advantageously prevents the user from coming into contact with the aerosol-forming matrix. Additionally, the packaging material can surround other components of the aerosol-generating article, such as a mouthpiece assembly.

[0145] The packaging can extend over the entire length of the aerosol-generating article. In other words, the packaging can extend from the upstream end to the downstream end of the aerosol-generating article.

[0146] The packaging surrounding at least one of the aerosol forming matrix and the upstream element may be formed of a sheet of the same material as the packaging disposed on the longitudinal inner surface of the recess. In this case, the packaging is disposed on the longitudinal inner surface of the recess and extends from the upstream end of the recess, across the upstream end face of the aerosol generating article, and around at least a portion of at least one of the aerosol forming matrix and the upstream element, such that at least one of the aerosol forming matrix and the upstream element is surrounded by the packaging.

[0147] This provision advantageously simplifies the manufacture of aerosol-generating articles because it may require only a single piece of packaging material. Furthermore, using a single piece of packaging material eliminates the need for seams connecting two pieces of packaging material. This advantageously simplifies manufacturing. The absence of seams also advantageously prevents or reduces leakage of any aerosol-forming matrix from the aerosol-generating article.

[0148] The packaging material may be disposed on at least a portion of the upstream end of the aerosol generating article. When the upstream element is the most upstream component of the aerosol generating article, the packaging material may be disposed on the upstream end of the upstream element. The packaging material may be disposed on only a portion of the upstream end face of the aerosol generating article. Preferably, the packaging material may be disposed on the entire upstream end face of the aerosol generating article. In this case, it should be understood that the upstream end of the recess remains open and uncovered.

[0149] The downstream end of the recess may be defined by a downstream element. The downstream element may include a material core rod. The material core rod may have a suction resistance of at least 20 mm H2O.

[0150] Providing a downstream element at the downstream end of the recess can advantageously reduce or prevent air from entering the aerosol-forming article through the recess. Furthermore, the downstream element can advantageously reinforce the downstream end of the recess. This may be particularly evident when compared to embodiments of the invention where the downstream end of the recess is defined by packaging.

[0151] The packaging material disposed on the longitudinal inner surface of the recess can surround at least a portion of the downstream element. This can thus advantageously help maintain the structure of the recess.

[0152] Downstream components may have any of the material properties mentioned above that are related to upstream components.

[0153] Specifically, the downstream element can be a porous mandrel element. Preferably, the porous mandrel element does not alter the suction resistance of the aerosol-generating article. Preferably, the downstream element has at least about 50% porosity in the longitudinal direction of the aerosol-generating article. More preferably, the downstream element has a porosity between about 50% and about 90% in the longitudinal direction. The porosity of the downstream element in the longitudinal direction is defined by the ratio of the cross-sectional area of ​​the material forming the downstream element to the internal cross-sectional area of ​​the aerosol-generating article at the location of the downstream element.

[0154] The downstream 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 downstream element.

[0155] The porosity or permeability of downstream components can be advantageously varied in order to provide the desired total suction resistance for aerosol-generated articles.

[0156] The downstream element of the RTD with at least about 20 mm H2O advantageously restricts airflow through the downstream end into the aerosol-generated article. Therefore, the airflow through the aerosol-generated article can be controlled simply by configuring a ventilation system, which will be described in more detail below. This advantageously simplifies manufacturing.

[0157] Preferably, the RTD of the downstream element is less than or equal to about 80 mmH2O. More preferably, the RTD of the downstream element is less than or equal to about 60 mmH2O. Even more preferably, the RTD of the downstream element is less than or equal to about 40 mmH2O.

[0158] Downstream components may be formed of an impermeable material. In such embodiments, the aerosol-generating article may be configured such that air flows into the aerosol-forming matrix through a suitable ventilation device disposed within the packaging.

[0159] Downstream elements can be made of any material suitable for use in aerosol-generating articles. For example, downstream elements can be made of the same material as one of the other components used in an aerosol-generating article (e.g., a mouthpiece or cooling element). Suitable materials for forming downstream elements include filter materials, ceramics, polymer materials, cellulose acetate, cardboard, high-density crimped cotton, viscose fiber, zeolite, or aerosol-forming matrices.

[0160] In some embodiments, the downstream element is formed of the same material as the upstream element. This can advantageously simplify the manufacture of aerosol-generated articles.

[0161] Preferably, the diameter of the downstream element is approximately equal to the diameter of the recess. For example, the downstream end of the downstream element may be between about 0.5 mm and about 10 mm. For example, the diameter of the downstream element may be between about 1 mm and about 8 mm, or between about 2 mm and about 6 mm.

[0162] Preferably, the downstream element has a length between about 1 mm and about 10 mm, more preferably between about 3 mm and about 8 mm, and even more preferably between about 4 mm and about 6 mm. In a particularly preferred embodiment, the downstream element has a length of about 5 mm.

[0163] The aerosol-generating article may also include a mouthpiece assembly. The mouthpiece assembly is disposed downstream of the aerosol-forming matrix. The mouthpiece assembly may include a single component. The mouthpiece assembly may include multiple components. The mouthpiece assembly may include one or more of a cooling element, a filtering element, or a spacer element.

[0164] The mouthpiece assembly may include a first tube. The mouthpiece assembly may include a second tube. The mouthpiece assembly may include a third tube. The first tube may be adjacent to the downstream end face of the second tube. The third tube may be adjacent to the upstream end face of the second tube. The inner diameter of the second tube may be smaller than the inner diameter of the first tube. The inner diameter of the second tube may be smaller than the inner diameter of the third tube. The inner diameter of the first tube may be at least about 3 mm.

[0165] An aerosol-generating article includes a mouthpiece assembly formed of multiple tubes, wherein the diameter of the second tube is narrower than the diameters of the first and third tubes, which can result in an increase in the amount of aerosol that can be extracted from the aerosol-generating article. The increased aerosol volume can improve the user experience.

[0166] The first tube may have an inner diameter between about 3 mm and about 8 mm. For example, the first tube may have an inner diameter between about 3.3 mm and about 6 mm, or between about 3.5 mm and about 5 mm, or between about 3.7 mm and about 4.5 mm. For example, the first tube may have an inner diameter of about 4 mm.

[0167] The first tube may have a length between approximately 4 mm and approximately 6 mm. For example, the first tube may have a length between approximately 4.5 mm and approximately 5.5 mm. The first tube may have a length of approximately 5 mm.

[0168] The second tube may have an inner diameter between about 1 mm and about 3 mm. For example, the second tube may have an inner diameter between about 1.3 mm and about 2.7 mm, or between about 1.5 mm and about 2.5 mm, or between about 1.8 mm and about 2.2 mm. For example, the second tube may have an inner diameter of about 2 mm.

[0169] The second tube may have a length between approximately 4 mm and approximately 6 mm. For example, the second tube may have a length between approximately 4.5 mm and approximately 5.5 mm. The second tube may have a length of approximately 5 mm.

[0170] The third tube may have an inner diameter between about 3 mm and about 8 mm. For example, the third tube may have an inner diameter between about 3.3 mm and about 6 mm, or between about 3.5 mm and about 5 mm, or between about 3.7 mm and about 4.5 mm. For example, the third tube may have an inner diameter of about 4 mm.

[0171] The third tube may have a length between approximately 4 mm and approximately 8 mm. For example, the third tube may have a length between approximately 4.5 mm and approximately 7.5 mm, or between approximately 5 mm and approximately 7 mm. The third tube may have a length of approximately 5 mm. The third tube may have a length of approximately 6 mm.

[0172] The ratio of the inner diameter of the first tube to the inner diameter of the second tube can be between about 1.2 and about 5. For example, the ratio can be between about 1.4 and about 4, or between about 1.6 and about 3, or between about 1.8 and about 2.5. The ratio can also be about 2.

[0173] The ratio of the inner diameter of the first tube to the inner diameter of the third tube can be between about 0.5 and about 2. For example, the ratio can be between about 0.7 and about 1.3, or between about 0.8 and about 1.2, or between about 0.9 and about 1.1, or between about 0.95 and about 1.05. The ratio can also be about 1.

[0174] The ratio of the inner diameter of the third tube to the inner diameter of the second tube can be between about 1.2 and about 5. For example, the ratio can be between about 1.4 and about 4, or between about 1.6 and about 3, or between about 1.8 and about 2.5. The ratio can also be about 2.

[0175] The first tube may be located at the downstream end of the mouthpiece assembly. The first tube may have a uniform inner diameter. In other words, the inner diameter of the first tube may be the same along its entire length.

[0176] Alternatively, the first tube may have a varying inner diameter. In other words, the inner diameter of the first tube may vary along its length. For example, the inner diameter of the first tube may increase from one end to the other. Or the inner diameter of the first tube may decrease from one end to the other.

[0177] In a specific instance, the inner diameter of the first tube may increase from its upstream end to its downstream end. In other words, the inner diameter of the first tube at its downstream end is larger than its inner diameter at its upstream end. Advantageously, this "funnel-shaped outflow" of the inner diameter of the first tube improves the taste of the aerosol.

[0178] In the instance of a first tube with a varying inner diameter, the inner diameter of the first tube is considered to be the average diameter of the first tube.

[0179] The inner diameter of the first tube can be larger than the inner diameter of the third tube.

[0180] Advantageously, the fact that the inner diameter of the first tube is larger than that of the third tube can also improve the user's filling sensation.

[0181] The second tube can have a uniform inner diameter. In other words, the inner diameter of the second tube can be the same along its entire length.

[0182] In the example of a second tube with a uniform inner diameter, the inner diameter of the second tube is considered to be the fixed diameter of the second tube.

[0183] Alternatively, the second tube may have a varying inner diameter. In other words, the inner diameter of the second tube may vary along its length. For example, the inner diameter of the second tube may increase from one end to the other. Or the inner diameter of the second tube may decrease from one end to the other.

[0184] The third tube can have a uniform inner diameter. In other words, the inner diameter of the third tube can be the same along its entire length.

[0185] In the example of a third tube with a uniform inner diameter, the inner diameter of the third tube is considered to be the fixed diameter of the third tube.

[0186] Alternatively, the third tube may have a varying inner diameter. In other words, the inner diameter of the third tube may vary along its length. For example, the inner diameter of the third tube may decrease from one end to the other. Or the inner diameter of the third tube may increase from one end to the other.

[0187] One or more of the first, second, and third tubes can be cellulose acetate tubes. In other words, one or more of the first, second, and third tubes can be formed of cellulose acetate. For example, the first tube can be a cellulose acetate tube. The second tube can be a cellulose acetate tube. The third tube can be a cellulose acetate tube.

[0188] Cellulose acetate tubes can also be called "hollow cellulose acetate tubes" or HAT.

[0189] Advantageously, forming the first tube from cellulose acetate also improves the rigidity and flexibility of the mouthpiece assembly, which enhances the user experience. Furthermore, because cellulose acetate is essentially waterproof, forming the first tube from cellulose acetate produces a mouthpiece assembly that is less sensitive to the moisture in the user's mouth.

[0190] The mouthpiece assembly may be adjacent to the downstream end of the aerosol forming matrix. Alternatively, the mouthpiece assembly may be spaced apart from the aerosol forming matrix.

[0191] The mouthpiece assembly, spaced apart from the aerosol-forming matrix, advantageously provides downstream space for the aerosol-forming matrix, in which aerosols can be cooled, condensed, and nucleated.

[0192] The portion between the aerosol-forming matrix and the mouthpiece may include a tube. The tube can advantageously enhance the aerosol-generating article while still providing cooling space for the aerosol.

[0193] The distance between the upstream end of the mouthpiece assembly and the downstream end of the aerosol forming matrix can be between 1 mm and 20 mm. For example, the distance between the upstream end of the mouthpiece assembly and the downstream end of the aerosol forming matrix can be between 2 mm and 10 mm.

[0194] Aerosol-generating articles may include at least one ventilation zone to allow air to enter the aerosol-generating articles.

[0195] Providing at least one ventilation zone can advantageously allow air to enter the aerosol-forming article and entrain aerosols from the aerosol-forming matrix.

[0196] At least one ventilation zone may include multiple perforations. Preferably, at least one ventilation zone includes at least one circumferential row of perforations around the longitudinal surface of the aerosol-generating article. In some embodiments, the ventilation zone may include two rows of circumferential perforations. For example, the perforations may be formed on a production line during the manufacture of the aerosol-generating article. Preferably, each row of circumferential perforations includes 8 to 30 perforations. The perforations can be provided by any means. For example, the perforations can be provided by laser perforation technology.

[0197] At least one ventilation zone may be located downstream of the aerosol forming matrix. For example, at least one ventilation zone may be located around the mouthpiece assembly. In the case where at least one ventilation zone is located around the mouthpiece assembly, it is preferable that at least one ventilation zone is located around the upstream end of the mouthpiece assembly. It should be understood that the "upstream end" of the mouthpiece assembly refers to any location within the upstream half of the mouthpiece assembly. This advantageously helps to maximize the aerosol entrainment in the airflow passing through the article, as air will enter the aerosol-generating article near the aerosol forming matrix. For example, at least one ventilation zone may be located around a third tube of the mouthpiece assembly.

[0198] Alternatively or additionally, at least one ventilation zone may be arranged around the space between the mouthpiece assembly and the aerosol forming matrix.

[0199] At least one ventilation zone may be set around the aerosol forming matrix.

[0200] At least one ventilation zone may be located at the downstream end of the recess. In this case, the perforation may be provided through the packaging defining the downstream end of the recess, or, if present, through a downstream element defining the downstream end of the recess. This allows air to enter the aerosol-generated article from the recess.

[0201] Aerosol-generating articles can have any size. Aerosol-generating articles can have a diameter between about 5 mm and about 15 mm or between about 6 mm and about 9 mm. Aerosol-generating articles can have a length between about 20 mm and about 80 mm, or between about 30 mm and about 60 mm, or between about 40 mm and about 50 mm.

[0202] The aerosol generating article according to the invention is intended for use in conjunction with an aerosol generating apparatus. The aerosol generating apparatus may be an electrically heated aerosol generating apparatus. In this case, the aerosol generating apparatus may include a power source, such as a battery, control electronics, and an electric heater. The electric heater may be a resistance heater and may take the form of a blade or a pin. Alternatively, the electric heater may be an induction heater, comprising an elongated sensor configured to be received by a recess in the aerosol generating article of the invention and at least one induction coil configured to inductively heat the sensor.

[0203] According to the present invention, an aerosol generation system is also provided, the aerosol generation system comprising an aerosol generation article according to the present invention and an aerosol generation apparatus as described above.

[0204] The invention is defined in the claims. However, a non-exhaustive list of non-limiting embodiments is provided below. Any one or more features of these embodiments may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0205] Example Ex1. An aerosol generating article for producing an inhalable aerosol upon heating, the aerosol generating article comprising:

[0206] An aerosol forming matrix comprising a gel composition comprising at least one gelling agent, an alkaloid compound, and an aerosol forming agent;

[0207] Upstream element, the upstream element being located upstream of the aerosol forming matrix; and

[0208] A recess that extends from the upstream end of the aerosol-generating article through the upstream element and through at least a portion of the aerosol-forming matrix.

[0209] Example Ex2. An aerosol generating article according to Example 1, wherein the upstream element comprises an annular mandrel containing fiber filter material.

[0210] Example Ex3. The aerosol generating article according to Example 2, wherein the suction resistance of the upstream element is at least 20 mmH2O.

[0211] Example Ex4. An aerosol-generating article according to any of the foregoing examples, wherein the longitudinal inner surface of the recess is provided with packaging.

[0212] Example Ex5. An aerosol-generating article according to Example 4, wherein at least one of the aerosol-forming matrix and the upstream element is surrounded by packaging.

[0213] Example Ex6. An aerosol generating article according to Example 5, wherein the package surrounding at least one of the aerosol forming matrix and the upstream element is formed of a sheet of the same material as the package disposed on the longitudinal inner surface of the recess.

[0214] Example Ex7. An aerosol-generated article according to any one of Examples 4 to 6, wherein the downstream end of the recess is defined by a packaging material.

[0215] Example Ex8. An aerosol-generating article according to Example 7, wherein the package defining the downstream end of the recess is formed of a sheet of the same material as the package disposed on the longitudinal inner surface of the recess.

[0216] Example Ex9. An aerosol-generating article according to any of the foregoing examples, wherein the downstream end of the recess is defined by a downstream element comprising a material core rod.

[0217] Example Ex10. An aerosol generating article according to any of the foregoing examples, further comprising a mouthpiece assembly located downstream of the aerosol forming matrix.

[0218] Example Ex11. An aerosol-generating article according to Example 10, wherein the mouthpiece assembly is spaced apart from the aerosol-forming matrix.

[0219] Example Ex12. An aerosol-generating article according to Example 11, wherein the upstream end of the mouthpiece assembly is between 1 mm and 20 mm from the downstream end of the aerosol-forming matrix.

[0220] Example Ex13. An aerosol generating article according to any of the foregoing examples further includes at least one ventilation zone to allow air to enter the aerosol generating article.

[0221] Example Ex14. The aerosol generating article according to Example 13, wherein the at least one ventilation zone is disposed around at least one of the aerosol forming matrix and the mouthpiece assembly.

[0222] Example Ex15. The aerosol generating article according to Example 14, wherein the at least one ventilation zone is disposed around the upstream end of the mouthpiece assembly.

[0223] Example Ex16. An aerosol generating article according to any of the foregoing examples, wherein the aerosol forming matrix comprises an annular mandrel loaded with a porous medium of the gel composition.

[0224] Example Ex17. An aerosol-generated article according to Example 16, wherein the porous medium is in the form of a rolled sheet.

[0225] Example Ex18. An aerosol-generated article according to Example 16 or 17, wherein the porous medium comprises cotton fibers.

[0226] Example Ex19. An aerosol-generating article according to any one of Examples 16 to 18, wherein the mandrel containing the porous medium of the gel composition is surrounded by a waterproof packaging.

[0227] Example Ex20. An aerosol-generating article according to any of the foregoing examples, wherein the gel composition contains at least 0.5% by weight of nicotine.

[0228] Example Ex21. An aerosol generation system comprising an aerosol generating article and an aerosol generating apparatus according to any of the foregoing examples. Attached Figure Description

[0229] Several examples will now be described further with reference to the accompanying drawings, in which:

[0230] Figure 1 A schematic side sectional view of the aerosol-generating article according to the present invention is shown; and

[0231] Figure 2 A schematic side sectional view of another aerosol-generating article according to the present invention is shown. Detailed Implementation

[0232] like Figure 1 As shown, the aerosol generating article 100 includes an upstream element 102 and a downstream aerosol forming matrix 101.

[0233] The aerosol forming matrix 101 comprises an annular mandrel containing a porous medium loaded with a gel composition as defined above. Examples of suitable gel compositions are shown in Table 1 below. The proportions of each component in each exemplary gel composition are given as a weight percentage:

[0234] Table 1

[0235]

[0236] The aerosol forming matrix 101 has a length of approximately 10 millimeters.

[0237] The upstream element 102 is positioned directly upstream of and adjacent to the aerosol forming matrix 101. The upstream element 102 includes an annular mandrel comprising fibrous filter material. In this exemplary embodiment, the upstream element 102 includes a cellulose acetate annular mandrel surrounded by a rigid packaging. The upstream element 102 has a length of approximately 5 mm. The RTD of the upstream element 102 is approximately 30 mm H2O.

[0238] The aerosol generating article 100 also includes a recess 103 extending from the upstream end of the aerosol generating article 100 through the upstream element 102 and through at least a portion of the aerosol forming matrix 101.

[0239] The recess 103 is positioned along the central axis of the aerosol-forming article 100. The recess 103 has a circular cross-sectional shape. In the example shown, the recess 103 extends the full length of both the upstream element 102 and the aerosol-forming matrix 101 by passing through both the annular mandrel comprising the fibrous filter material of the upstream element 102 and the annular mandrel comprising the porous medium of the aerosol-forming matrix 101. The recess 103 has a length of approximately 15 mm, corresponding to the combined length of the upstream element 102 and the aerosol-forming matrix 101. The recess has a diameter of approximately 4 mm.

[0240] The aerosol generating article 100 of the present invention also includes a packaging 104. The packaging 104 is disposed on the longitudinal inner surface of the recess. The packaging 104 extends the entire length of the recess 103 and is disposed on the entire longitudinal inner surface of the recess 103.

[0241] exist Figure 1 In the illustrated embodiment, the downstream end of the recess 103 is defined by a package. This is achieved by mechanically folding the package at the downstream end of the recess.

[0242] The package 104 extends upstream of the recess 103 and beyond the upstream end of the aerosol generating article 100. The package 104 also extends over the entire outer surface of the aerosol generating article 100. In this way, the package 104 is used to connect various components of the aerosol generating article 100.

[0243] The packaging 104 includes a cellulose-based paper layer co-laminated with the aluminum foil layer. The packaging 104 is arranged such that the paper layer is located on the outer surface of the aerosol-generating article 100.

[0244] The aerosol-generating product 100 also includes a multi-segment mouthpiece assembly 105.

[0245] The multi-segment mouthpiece assembly 105 includes a first tube 110, a second tube 109, and a third tube 108. The downstream end of the third tube 108 is adjacent to the upstream end of the second tube 109, while the downstream end of the second tube 109 is adjacent to the upstream end of the first tube 110.

[0246] The inner diameter of the first tube 110 is approximately 4 mm. The inner diameter of the second tube 109 is approximately 2 mm. The inner diameter of the third tube 108 is approximately 3.5 mm.

[0247] The first tube 110, the second tube 109, and the third tube 108 are cellulose acetate tubes.

[0248] The first tube 110 and the second tube 109 each have a length of approximately 5 mm. The third tube 108 has a length of approximately 6 mm.

[0249] An air inlet 107 is disposed around a third tube 108. The air inlet 107 extends through the packaging 104 to allow air to enter the aerosol-generating article 100.

[0250] The mouthpiece assembly 105 is spaced approximately 5 mm from the aerosol forming matrix 101.

[0251] In use, the aerosol generating article 100 is inserted into the aerosol generating device. The heating element of the aerosol generating device is sequentially inserted into the recess 103 of the aerosol generating article 100. The aerosol generating device is activated, and the heating element becomes hot. The heating element heats the aerosol forming matrix 101 of the aerosol generating article 100. The gel composition of the aerosol forming matrix 101 generates vapor, which cools and nucleates into aerosols in the space 106 between the mouthpiece assembly 105 and the aerosol forming matrix 101.

[0252] The pressure drop at the downstream end of the aerosol generating article 100 draws air into the aerosol generating article 100 through the air inlet 107. The air drawn in through the air inlet 107 carries vapor from the aerosol forming matrix 101. This vapor-laden air then passes through the nozzle 105 and exits from the downstream end of the aerosol generating article 100.

[0253] Another aerosol generating article 200 according to the present invention is shown in Figure 2 middle. Figure 2 The aerosol generating article 200 shown is similar to Figure 1 The aerosol-generating article 100 is shown, and the same reference numerals are used to indicate the same features.

[0254] Figure 2 Aerosol-generating products 200 and Figure 1 The difference in the aerosol-generating article 100 is that the downstream end of the recess 103 is defined by a downstream element 111. The downstream element 111 includes a core rod containing fibrous filter material. In this exemplary embodiment, the downstream element 111 includes a cellulose acetate core rod. The downstream element 111 has a length of approximately 5 mm. The RTD of the downstream element 111 is approximately 30 mm H2O.

[0255] Figure 2 The aerosol-generating product 200 is packaged in a way that surrounds the downstream component 111, rather than as in... Figure 1 The aerosol-generating product 100 is mechanically folded at the downstream end of the recess 103, as in the case of the aerosol-generating product 100.

[0256] For the purposes of this specification and the appended claims, unless otherwise indicated, all figures expressing quantities, quantities, percentages, etc., shall be understood to be modified by the term "about" in all cases. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein. Thus, in this document, the number A is understood to be ±10% of A. In this document, the number A may be considered to include a value within the general standard error of the measurement of the property modified by the number A. In some cases as used in the appended claims, the number A may deviate from the percentages listed above, provided that the amount of deviation from A does not significantly affect the fundamental and novel features of the claimed invention. Additionally, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein.

Claims

1. An aerosol generating article for producing an inhalable aerosol upon heating, the aerosol generating article comprising: An aerosol forming matrix comprising a gel composition comprising at least one gelling agent, an alkaloid compound, and an aerosol forming agent; An upstream element, the upstream element being located upstream of the aerosol forming matrix; as well as A recess extending from the upstream end of the aerosol-generating article through the upstream element and through at least a portion of the aerosol-forming matrix. The longitudinal inner surface of the recess is provided with packaging material.

2. The aerosol generating article according to claim 1, wherein the upstream element comprises an annular mandrel containing fiber filter material.

3. The aerosol generating article according to claim 2, wherein the suction resistance of the upstream element is at least 20 mmH2O.

4. The aerosol generating article according to any one of claims 1 to 3, wherein at least one of the aerosol forming matrix and the upstream element is surrounded by packaging.

5. The aerosol generating article according to claim 4, wherein the package surrounding at least one of the aerosol forming matrix and the upstream element is formed of a sheet of the same material as the package disposed on the longitudinal inner surface of the recess.

6. The aerosol generating article according to any one of claims 1 to 3, wherein the downstream end of the recess is defined by packaging.

7. The aerosol generating article of claim 6, wherein the package defining the downstream end of the recess is formed of a sheet of the same material as the package disposed on the longitudinal inner surface of the recess.

8. The aerosol generating article according to any one of claims 1 to 3, wherein the downstream end of the recess is defined by a downstream element comprising a material core rod.

9. The aerosol generating article according to any one of claims 1 to 3, further comprising a mouthpiece assembly located downstream of the aerosol forming matrix.

10. The aerosol generating article according to claim 9, wherein the mouthpiece assembly is spaced apart from the aerosol forming matrix.

11. The aerosol-generating article of claim 10, wherein the upstream end of the mouthpiece assembly is between 1 mm and 20 mm from the downstream end of the aerosol-forming matrix.

12. The aerosol generating article of claim 11, further comprising at least one ventilation zone to allow air to enter the aerosol generating article.

13. The aerosol generating article of claim 12, wherein the at least one ventilation zone is disposed around at least one of the aerosol forming matrix and the mouthpiece assembly.

14. The aerosol generating article of claim 13, wherein the at least one ventilation zone is disposed around the upstream end of the mouthpiece assembly.

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