Aerosol-generating article having a tubular element

Abstract

An aerosol-generating article comprises a plurality of elements assembled in the form of a rod (11). The elements comprise a first element (100, 11) comprising an aerosol-generating substrate, and a tubular element (100, 200, 300, 500, 600, 700, 800) positioned upstream or downstream of the first element (100, 11). The tubular element (100, 200, 300, 500, 600, 700, 800) comprises a tubular body (103, 203) defining a cavity (106, 206, 606) extending from a first end (101) of the tubular body (103, 203) to a second end (102) of the tubular body (103, 203); and a folded end portion forming a first end wall (104, 105, 204A, 604, 804) at the first end (101) of the tubular body (103, 203). The first end wall (104, 105, 204A, 604, 804) delimits an opening (105, 205A, 205B, 605B, 605) for airflow between the cavity (106, 206, 606) of the tubular element (100, 200, 300, 500, 600, 700, 800) and the exterior.

Description

TECHNICAL FIELD

[0001] The present application relates to an aerosol-generating article comprising an aerosol- generating substrate and adapted to generate an inhalable aerosol upon heating. BACKGROUND

[0002] Aerosol-generating articles in which an aerosol-generating substrate, such as a tobacco- containing substrate, is heated rather than combusted are known in the art. Typically, in such heated smoking articles, an aerosol is generated by the transfer of heat from a heat source to a physically separate aerosol-generating substrate or material that can be positioned in contact with, inside, around or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[0003] Many prior art documents disclose aerosol-generating devices for consuming aerosol- generating articles. Such devices include, for example, electrically heated aerosol-generating devices in which an aerosol is generated by the transfer of heat from one or more electrically heated heater elements of the aerosol-generating device to an aerosol-generating substrate of a heated aerosol-generating article. For example, electrically heated aerosol-generating devices comprising an internal heating blade adapted to be inserted into an aerosol-generating substrate have been proposed. As an alternative, inductively heatable aerosol-generating articles comprising an aerosol-generating substrate and a susceptor element arranged within the aerosol-generating substrate have been proposed by WO 2015 / 176898.

[0004] Aerosol-generating articles in which a tobacco-containing substrate is heated rather than combusted present a number of challenges not encountered with conventional smoking articles. For example, it can be desirable to limit the movement of the aerosol-generating substrate within the aerosol-generating article while still ensuring that sufficient levels of airflow can pass through the aerosol-generating substrate and the aerosol-generating article. Limiting the potential movement of the aerosol-generating substrate is particularly desirable as this can, for example, help to improve the consistency of performance from one article to another by helping to increase the consistency of the interaction between the aerosol-generating substrate and the heater element. This can be particularly applicable to aerosol-generating articles adapted to receive a heater blade as the action of inserting the heater blade can otherwise increase the likelihood of displacement of the aerosol-generating substrate.

[0005] WO 2013 / 098405 proposes a support element comprising the aerosol- generating substrate immediately downstream. The support element is provided in the form of a ring-shaped tube of filter material, commonly referred to as a hollow acetate tube. The support element is configured to resist downstream movement of the aerosol-generating substrate during insertion of a heating blade of an aerosol-generating device into the aerosol-generating substrate. The empty space within the hollow support element provides an opening for the flow of aerosol from the aerosol-generating substrate towards the mouth end of the aerosol-generating article.

[0006] However, some support elements, such as hollow acetate tubes, can undesirably filter some volatile compounds released from the aerosol-generating substrate. Furthermore, some support elements can not provide the desired RTD characteristics for the aerosol-generating article. Prior art support elements, such as hollow acetate tubes, can also be expensive, or expensive and complex to manufacture. Prior art support elements, such as hollow acetate tubes, can also be undesirably suited to aerosol-generating articles in which a susceptor element is arranged within the aerosol-generating substrate. For example, because prior art support elements can be undesirably suited to the temperatures generated by the susceptor element. SUMMARY

[0007] It would therefore be desirable to provide a new and improved aerosol-generating article adapted to achieve at least one of the above-mentioned desirable results. Furthermore, it would be desirable to provide an aerosol-generating article of this kind which can be manufactured efficiently and at high speed, preferably with satisfactory RTD and low RTD variability from one article to another.

[0008] The present disclosure relates to an aerosol-generating article. The aerosol- generating article can comprise a plurality of elements assembled in the form of a rod. The plurality of elements can comprise a first element comprising an aerosol- generating substrate. The plurality of elements can comprise a tubular element positioned upstream or downstream of the first element. The tubular element can comprise a tubular body defining a cavity. The cavity can extend from a first end of the tubular body to a second end of the tubular body. The tubular element can further comprise a folded end portion forming a first end wall at the first end of the tubular body. The first end wall can delimit an opening for airflow between the cavity of the tubular element and the exterior. The first end wall can be adjacent to the aerosol-generating substrate.

[0009] According to a first aspect of the application, there is provided an aerosol-generating article comprising a plurality of elements assembled in the form of a rod, the elements comprising: a first element comprising an aerosol-generating substrate; and a tubular element positioned upstream or downstream of the first element, the tubular element comprising: a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body; and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall delimiting an opening for airflow between the cavity of the tubular element and the exterior. The first end wall can be adjacent to the aerosol-generating substrate.

[0010] According to a second aspect of the application, there is provided an aerosol-generating article comprising a plurality of elements assembled in the form of a rod, the elements comprising: a first element comprising an aerosol-generating substrate; and a tubular element positioned upstream or downstream of the first element, the tubular element comprising: a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body; and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall delimiting an opening for airflow between the cavity of the tubular element and the exterior; and wherein the aerosol-generating article further comprises an outer wrapper circumscribing at least the tubular element.

[0011] The outer wrapper can define an outer surface of the aerosol-generating article. The outer wrapper can also circumscribe the first element. The outer wrapper can circumscribe all of the plurality of elements of the aerosol-generating article assembled in the form of a rod. As described below, the outer wrapper can be a tipping wrapper. The outer wrapper circumscribing the tubular element can be a paper wrapper or a non-paper wrapper. Suitable paper wrappers for use in particular embodiments of the application are known in the art and include, but are not limited to: cigarette paper; and filter plug wrap. Suitable non-paper wrappers for use in particular embodiments of the application are known in the art and include, but are not limited to: sheets of homogenised tobacco material. In certain preferred embodiments, the wrapper can be formed from a laminate comprising a plurality of layers. Preferably, the wrapper is formed from an aluminium co-laminate sheet. The use of a co-laminate sheet comprising aluminium advantageously prevents combustion of the outer wrapper in the event that the aerosol-generating substrate is intended to be lit rather than heated in the intended manner.

[0012] According to a third aspect of the invention, an aerosol generating article is provided, the aerosol generating article comprising a plurality of elements assembled in the form of a strip, the elements comprising: a first element including an aerosol generating matrix; and a tubular element positioned entirely upstream of or entirely downstream of the first element, the tubular element comprising: a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body; and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall defining an opening for airflow between the cavity of the tubular element and the outside.

[0013] The term "aerosol-generating article" is used herein to refer to an article in which an aerosol-generating matrix is ​​heated to generate an inhalable aerosol and delivered to a consumer. As used herein, the term "aerosol-generating matrix" refers to a matrix capable of releasing volatile compounds upon heating to generate an aerosol.

[0014] A conventional cigarette is ignited when a user applies a flame to one end and inhales air through the other end. The localized heat provided by the flame and oxygen in the inhaled air ignites the cigarette end, and the resulting combustion produces inhalable smoke. In contrast, in heated aerosol-generating articles, aerosols are generated by heating a flavor-generating matrix, such as tobacco. Known 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 article according to the invention has a particular application in aerosol-generating systems including an electrically heated aerosol-generating device having internal heater blades adapted to be inserted into a strip of aerosol-generating matrix. This type of aerosol-generating article is described in the prior art (e.g., in European patent application EP0822670).

[0015] As used herein, the term "aerosol generating apparatus" refers to an apparatus that includes a heater element that interacts with an aerosol generating matrix of an aerosol generating article to generate an aerosol.

[0016] As used herein, the term "strip" is used to refer to a generally cylindrical element having a generally circular, oval, or elliptical cross-section.

[0017] As used herein, the term "longitudinal" refers to the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. As used herein, the terms "upstream" and "downstream" describe the relative positions of an element or portion of an element of the aerosol-generating article with respect to the direction in which the aerosol is transported through the aerosol-generating article during use.

[0018] During use, air is drawn through the aerosol-generating article in the longitudinal direction. The term "transverse" refers to the direction perpendicular to the longitudinal axis. Unless otherwise stated, any reference to the "cross section" of the aerosol-generating article or a component of the aerosol-generating article refers to the transverse cross section.

[0019] The term "length" refers to the longitudinal dimension of a component of an aerosol-generating article. For example, it can be used to describe the longitudinal dimension of a first element or hollow tubular element comprising an aerosol-generating matrix.

[0020] As used herein, the term "tubular element" is used to refer to a generally elongated element that defines an internal cavity or airflow passage along its longitudinal axis. Specifically, the term "tubular" will be used hereinafter to refer to a tubular element having a tubular body with a generally cylindrical cross-section and defining at least one airflow conduit that establishes uninterrupted fluid communication between an upstream end and a downstream end of the tubular body. However, it should be understood that alternative geometries (e.g., alternative cross-sectional shapes) of the tubular body may be possible.

[0021] As used herein, the term "slender" means that the length dimension of an element is greater than its width dimension or its diameter dimension, for example, twice or more of its width dimension or its diameter dimension.

[0022] In the context of this invention, the tubular body of the tubular element provides a non-restrictive flow channel. This means that the tubular body portion of the tubular element provides a negligible level of suction resistance (RTD). Therefore, the flow channel should not contain any components that would impede the flow of air in the longitudinal direction. Preferably, the flow channel is substantially empty. In this case, the tubular body of the tubular element defines a cavity.

[0023] The tubular element of the present invention provides an improved component for aerosol generation articles. By forming the tubular element from a tubular body defining a cavity (which extends from a first end of the tubular body to a second end of the tubular body), a relatively large proportion of the tubular element can be empty and allow unobstructed airflow. When the tubular element is downstream of the aerosol generation matrix, this can help improve aerosol cooling and nucleation. Furthermore, such a configuration can also help minimize the filtration of any compounds released from the aerosol generation matrix, particularly when compared to prior art hollow acetic acid tubes.

[0024] By providing a folded end portion at the first end of the tubular element, forming a first end wall at the first end of the tubular body, the tubular element can be configured to have a desired RTD through the arrangement of the size and shape of the first end wall. In particular, the tubular element and its first end wall can be manufactured efficiently and at high speed, with a satisfactory RTD and low RTD variability between different articles. Furthermore, the arrangement of the tubular element and its first end wall means that the RTD can be positioned at a specific longitudinal location of the tubular element, rather than being continuously distributed along the length of the tubular element.

[0025] When the first end wall of the tubular element is adjacent to the aerosol-generating matrix, the first end wall can provide a barrier that restricts the movement of the aerosol-generating matrix. This arrangement can also advantageously allow one or both of air and aerosols to flow through the opening into the cavity.

[0026] The barrier provided by the first end wall of the tubular element can be more effective than that provided by the end of the hollow acetate tube because the first end wall is less deformable than the end of the hollow acetate tube. The tubular element is also better suited to withstand the temperatures generated by heating blades or sensor elements.

[0027] The term "adjacent" as used herein with respect to tubular elements and first elements means that the tubular element is longitudinally positioned adjacent to the first element in the assembly element strip. In particular, the term means that no other assembly strip elements are arranged between the first element and the tubular element in the longitudinal direction.

[0028] The first element and the tubular element can be adjacent to and in contact with each other. For example, the first end wall of the tubular element can be adjacent to and in contact with the aerosol generating matrix.

[0029] The first element and the tubular element can be adjacent to each other but not in contact, because the small gap creates a space that separates the first element from the tubular element in the longitudinal direction of the aerosol-generating article. For example, the first end wall of the tubular element can be adjacent to the aerosol-generating matrix but not in contact with it. The gap can be 2 mm or less. The gap can be 1 mm or less.

[0030] The first element can be referred to as the aerosol generating element.

[0031] The tubular element can be positioned entirely upstream of the first element. In such an embodiment, the tubular element may be referred to as the upstream tubular element.

[0032] The tubular element can be positioned entirely downstream of the first element. In such an embodiment, the tubular element may be referred to as the downstream tubular element.

[0033] The aerosol-generating article may include two tubular elements, one of which is a first tubular element located entirely downstream of a first element, and the other of which is a second tubular element located entirely upstream of the first element. The first and second tubular elements may each have any feature or combination of features described above or below with respect to tubular elements of the present invention.

[0034] For example, the tubular element may be a first tubular element located downstream of the aerosol-forming matrix, wherein a first end wall of the first tubular element is adjacent to the downstream end of the aerosol-forming matrix. In such an embodiment, the aerosol-generating article may further include a second tubular element. The second tubular element may be located upstream of the first element. The second tubular element may include: a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body; and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall defining an opening for airflow between the cavity of the second tubular element and the outside. The first end wall of the second tubular element may be adjacent to the upstream end of the aerosol-forming matrix. Thus, in such an embodiment, a first element comprising the aerosol-forming matrix may be sandwiched between the first and second tubular elements, wherein each tubular element has a folded end portion providing a corresponding end wall adjacent to the upstream or downstream end of the first element. In such an embodiment, the second tubular element may be referred to as the upstream tubular element, and the first tubular element may be referred to as the downstream tubular element.

[0035] The second tubular element may further include a folded end portion that forms a second end wall at a second end of its tubular body. The second end wall of the second tubular element may define an opening for airflow between the cavity of the second tubular element and the outside. The opening defined by the second end wall of the second tubular element may be smaller than the opening defined by the first end wall of the second tubular element. For example, the size of the opening defined by the second end wall of the second tubular element may be between about 20% and about 80% of the size of the opening defined by the first end wall of the second tubular element. More preferably, the size of the opening defined by the second end wall of the second tubular element may be between about 40% and about 60% of the size of the opening defined by the first end wall of the second tubular element.

[0036] Generally, in the case where the tubular element of the present invention comprises two end walls each having a corresponding opening, the size of the opening defined by the second end wall of the tubular element can be between about 20% and about 80% of the size of the opening defined by the first end wall of the tubular element.

[0037] The second tubular element can be the upstream component of the aerosol-generating article. For example, the upstream end of the aerosol-generating article can be defined by the upstream end of the second tubular element.

[0038] As will be described in more detail below, the aerosol-generating article may also include a ventilation zone located along the tubular element. In the case where the aerosol-generating article includes the first and second tubular elements described above, the ventilation zone is preferably positioned along the first tubular element.

[0039] The first end wall may extend approximately transversely to the longitudinal direction of the aerosol-generating article. The first end wall may extend approximately transversely to the longitudinal direction of the tubular body.

[0040] The first end wall may extend partially into the cavity of the tubular body and form an angle of less than 90 degrees with the inner surface of the tubular body, more preferably less than 80 degrees, and even more preferably less than 70 degrees. This can be achieved by ensuring that a folding force is applied to the tubular element during manufacturing so that at least a portion of the first end portion of the tubular element is pushed into the cavity of the tubular body. Such an arrangement advantageously increases the likelihood that the first end wall will remain stationary relative to the tubular body after the tubular element has been manufactured. In particular, such an arrangement helps to overcome any natural elasticity in the material forming the tubular element, making it less likely that the folded end portion of the tubular element will return to its pre-folded state after manufacturing.

[0041] The opening defined by the first end wall may be the only opening in the first end wall. This opening may be located at the general radial center of the tubular element. The first end wall may be generally annular.

[0042] The first end wall may extend from the fold point on the tubular element and toward the radial center of the tubular element. The fold point may generally correspond to the first end of the tubular body of the tubular element.

[0043] Preferably, at least the first portion forming the first end wall of the tubular element is substantially air-impermeable. In other words, preferably, the first end wall is substantially non-porous. Preferably, the first end wall does not contain any perforations. The material forming the first end wall may have a porosity of less than 2000 coresta units. The material forming the first end wall may have a porosity of less than 1000 coresta units. The material forming the first end wall may have a porosity of less than 500 coresta units.

[0044] In cases where the first element comprises a receptor element within an aerosol-generating matrix, the opening in the first wall can be substantially aligned with the radial position of the receptor element. This advantageously helps maintain the distance between the first end wall of the tubular element and the receptor of the first element. Maintaining this distance helps mitigate any undesirable heating of the first end wall of the tubular element by the receptor element.

[0045] This disclosure also includes a method of forming a tubular element for aerosol generation articles of the present invention. The method may include the step of providing a tubular element precursor comprising: a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body; and a first end portion adjacent to and integrally formed with the first end of the tubular body. The method further includes the step of applying a folding force to the tubular element precursor to bend or fold the first end portion about a fold point corresponding to the first end of the tubular body, the applied folding force causing at least a portion of the first end portion of the tubular element to extend into the cavity of the tubular body. The method may further include the step of releasing the folding force such that the first end portion of the tubular element partially recovers along its folding path and reaches a position in which the first end portion extends substantially transversely to the longitudinal direction of the tubular body, thereby forming a first end wall at the first end of the tubular body, wherein the first end wall defines an opening for airflow between the cavity of the tubular element and the outside.

[0046] This disclosure also includes tubular elements for aerosol-generating articles. The tubular element may include: a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body; a first folded end portion forming a first end wall at the first end of the tubular body, the first end wall defining a first opening for airflow between the cavity of the tubular element and an exterior; and a second folded end portion forming a second end wall at the second end of the tubular body, the second end wall defining a second opening for airflow between the cavity of the tubular element and an exterior. The tubular element may include any feature or combination of features described above or below with respect to tubular elements of aerosol-generating articles of the present invention, or in combination with such features or combinations of features.

[0047] The outer diameter of the tubular element is preferably approximately equal to the outer diameter of the aerosol-generated article. When the first element is formed as a strip, the outer diameter of the tubular element is preferably approximately equal to the outer diameter of the first element.

[0048] The tubular element may have an outer diameter between 6 mm and 10 mm, for example between 7 mm and 9 mm, or between 7.5 mm and 8.5 mm. In a preferred embodiment, the tubular element has an outer diameter of 7.8 mm + / - 10%.

[0049] Preferably, the tubular element has an equivalent inner diameter of at least about 5.5 mm. More preferably, the tubular element has an equivalent inner diameter of at least about 6 mm. Even more preferably, the tubular element has an equivalent inner diameter of at least about 7 mm. The term "equivalent inner diameter" is used herein to refer to the diameter of a circle having the same surface area as the cross-section of the airflow duct defined by the interior of the hollow tubular segment. The cross-section of the airflow duct can have any suitable shape. However, as briefly described above, a circular cross-section is preferred, i.e., the hollow tubular segment is actually a cylindrical tube. In this case, the equivalent inner diameter of the hollow tubular segment effectively coincides with the inner diameter of the cylindrical tube.

[0050] The equivalent inner diameter of the hollow tubular segment is preferably less than about 10 mm. More preferably, the equivalent inner diameter of the hollow tubular segment is less than about 9.5 mm, or even more preferably less than 9 mm.

[0051] Preferably, the tubular element has a wall thickness of at least about 0.1 mm, more preferably at least about 0.2 mm.

[0052] Preferably, the tubular element has a wall thickness of less than about 1.5 mm, more preferably less than about 1.25 mm. In a preferred embodiment, the tubular element has a wall thickness of less than about 1 mm.

[0053] Therefore, the tubular element preferably has a wall thickness between about 0.1 mm and about 1.5 mm, or between about 0.2 mm and about 1.25 mm, or between about 0.5 mm and about 1 mm.

[0054] Providing such wall thickness to tubular elements can help improve the resistance of the tubular body to collapse or deformation, while still allowing the first end wall to be formed from the folded end portion of the tubular element.

[0055] The wall thickness of the tubular element can be the same as the wall thickness of one or both of the tubular body and the first end wall.

[0056] The length of the tubular element can be substantially the same as the length of the tubular body.

[0057] Preferably, the tubular element has a length of at least about 10 mm, more preferably at least about 15 mm.

[0058] Preferably, the tubular element has a length of less than about 30 mm, more preferably less than about 25 mm, and even more preferably less than about 20 mm.

[0059] The tubular element may have a length of about 10 mm to about 30 mm, preferably about 15 mm to about 25 mm, and more preferably about 15 mm to about 20 mm. For example, in a particularly preferred embodiment, the tubular element has a length of 18 mm. Such a length may be particularly preferred in embodiments where the tubular element is positioned downstream of the aerosol generating matrix and wherein the first end wall of the tubular element is adjacent to the downstream end of the aerosol generating matrix.

[0060] The tubular element may have a length of about 5 mm to about 20 mm, preferably about 8 mm to about 15 mm, and more preferably about 10 mm to about 13 mm. For example, in a particularly preferred embodiment, the tubular element has a length of 12 mm. Such a length may be particularly preferred in embodiments where the tubular element is positioned upstream of the aerosol generating matrix and wherein the first end wall of the tubular element is adjacent to the upstream end of the aerosol generating matrix.

[0061] Preferably, the tubular element is adapted to generate an RTD between about 0 mm H2O (about 0 Pa) and about 20 mm H2O (about 100 Pa), more preferably between about 0 mm H2O (about 0 Pa) and about 10 mm H2O (about 100 Pa).

[0062] The tubular element is preferably formed from a paper material, such as paper, cardboard, or cardboard. The tubular element can be formed from multiple overlapping layers of paper, such as multiple layers of parallel winding or multiple layers of spiral winding. Forming the tubular element from multiple overlapping layers of paper helps improve the tubular body's resistance to collapse or deformation, while still allowing the first end wall to be formed from the folded end portion of the tubular element.

[0063] A tubular element may include at least two layers of paper. A tubular element may include fewer than eleven layers of paper.

[0064] When the tubular element is formed of paper material, the paper material may have a basis weight of at least about 90 g / m². The paper material may have a basis weight of less than about 300 g / m². The paper material may have a basis weight of about 100 g / m² to about 200 g / m². Providing such a wall basis weight to the tubular element helps improve the tubular body's resistance to collapse or deformation, while still allowing the first end wall to be formed from the folded end portion of the tubular element.

[0065] The first end wall of the tubular element may include a hydrophobic region comprising hydrophobic groups covalently bonded to the first end wall. In cases where the tubular element includes a second end wall, the second end wall may also include a hydrophobic region.

[0066] On the other hand, the water contact angle of the hydrophobic region is at least about 90 degrees or at least about 100 degrees, and the Cobb measurement (at 60 seconds) is about 40 g / m³.2 Or smaller, or about 35g / m 2 Or smaller.

[0067] The hydrophobic region can be prepared by a method comprising the steps of applying a liquid composition containing a fatty acid halide to the surface of a first end wall and maintaining the surface at a temperature of about 120 degrees Celsius to about 180 degrees Celsius. The fatty acid halide reacts in situ with the native groups of the material in the hydrophobic region, thereby resulting in the formation of a fatty acid ester.

[0068] The term "hydrophobic" refers to a surface exhibiting water-repellent properties. A useful method for determining this is to measure the water contact angle. The water contact angle is the angle through which 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.

[0069] This hydrophobic region has a concentration of less than approximately 40 g / m³. 2 Less than approximately 35g / m 2 Less than approximately 30g / m 2 or less than about 25g / m 2 The Cobb water absorption rate (ISO 535:1991) value (at 60 seconds).

[0070] The hydrophobic region has a water contact angle of at least about 90 degrees, at least about 95 degrees, at least about 100 degrees, at least about 110 degrees, at least about 120 degrees, at least about 130 degrees, at least about 140 degrees, at least about 150 degrees, at least about 160 degrees, or at least about 170 degrees. Hydrophobicity is determined using the TAPPI T558om-97 test, and the results are presented as interfacial contact angles and reported in "degrees," ranging from near zero degrees to near 180 degrees. When the contact angle is not specified together with the term hydrophobic, the water contact angle is at least 90 degrees.

[0071] According to this disclosure, an aerosol generating article is provided for generating an inhalable aerosol upon heating. The aerosol generating article includes a first element comprising an aerosol generating matrix and a tubular element. The aerosol generating article includes a downstream section located downstream of the aerosol generating matrix. The downstream section may include one or more downstream elements, such as a tubular element.

[0072] The downstream section may include a mouthpiece element. The mouthpiece element may extend all the way to the mouth of the aerosol-generating article.

[0073] The mouthpiece element can extend all the way to the downstream end of the aerosol generating matrix. When the mouthpiece element extends from the downstream end of the aerosol generating matrix to the mouth end of the aerosol generating article, the mouthpiece element can be the only element in the downstream section of the aerosol generating article. Alternatively, when the tubular element is located downstream of the aerosol generating matrix, the mouthpiece element can be located downstream of the first tubular element. In such an embodiment, the mouthpiece element can extend all the way to the downstream end of the tubular element. In other words, the mouthpiece element is located immediately downstream of the tubular element. For example, the mouthpiece element may be adjacent to the downstream end of the tubular element.

[0074] The mouthpiece element is preferably located at the downstream end or mouth end of the aerosol-generating article. The mouthpiece element preferably includes at least one mouthpiece filter section for filtering aerosols generated from the aerosol-generating matrix. For example, the mouthpiece element may include one or more segments of fibrous filter material. Suitable fibrous filter materials will be known to those skilled in the art. Particularly preferably, at least one mouthpiece filter section includes a cellulose acetate filter section formed from cellulose acetate tow.

[0075] A mouthpiece element may consist of a single mouthpiece filter segment. In an alternative embodiment, the mouthpiece element includes two or more mouthpiece filter segments aligned axially with each other in an adjacent-end-to-end relationship.

[0076] The mouthpiece element may include a mouth end cavity. The mouth end cavity may be defined by a hollow tubular element located at the downstream end of the mouthpiece. Alternatively, the mouth end cavity may be defined by an outer packaging of an aerosol-generating article at the mouth end.

[0077] The mouthpiece element may optionally include a flavoring agent, which may be provided in any suitable form. For example, the mouthpiece element may include one or more capsules, beads or granules of flavoring agent, or one or more strands or filaments carrying flavoring.

[0078] Preferably, the mouthpiece element has a low particle filtration efficiency.

[0079] Preferably, the mouthpiece is formed from sections of fibrous filter material.

[0080] Preferably, the mouthpiece element is defined by a filter segment package. Preferably, the mouthpiece element is non-ventilated, preventing air from entering the aerosol-forming article along the mouthpiece element.

[0081] The mouthpiece element is preferably connected by means of a tipping package to one or more adjacent upstream components of the aerosol-generating article, such as one or more tubular elements.

[0082] Preferably, the mouthpiece element has an RTD of less than about 25 mm H2O. More preferably, the mouthpiece element has an RTD of less than about 20 mm H2O. Even more preferably, the mouthpiece element has an RTD of less than about 15 mm H2O.

[0083] An RTD value of about 10 mm H2O to about 15 mm H2O is particularly preferred because a mouthpiece element with such an RTD is expected to contribute minimally to the overall RTD of the aerosol-generating article and essentially does not exert a filtering effect on the aerosol delivered to the consumer.

[0084] Preferably, the mouthpiece element has an outer diameter approximately equal to the outer diameter of the aerosol-generating article. The mouthpiece element may have an outer diameter between about 5 mm and about 10 mm, or between about 6 mm and about 8 mm. In a preferred embodiment, the mouthpiece element has an outer diameter of about 7.2 mm.

[0085] The mouthpiece element may have a length of at least about 10 mm, more preferably at least about 11 mm, and even more preferably at least about 12 mm. The mouthpiece element may have a length of less than about 25 mm, more preferably less than about 20 mm, and even more preferably less than about 15 mm.

[0086] The mouthpiece element may have a length of about 10 mm to about 25 mm, more preferably about 10 mm to about 20 mm, and even more preferably about 10 mm to about 15 mm. The mouthpiece element may have a length of about 11 mm to about 25 mm, more preferably about 11 mm to about 20 mm, and even more preferably about 11 mm to about 15 mm. The mouthpiece element may have a length of about 12 mm to about 25 mm, more preferably about 12 mm to about 20 mm, and even more preferably about 12 mm to about 20 mm.

[0087] In a preferred embodiment, the mouthpiece element has a length of approximately 12 millimeters.

[0088] Providing a relatively long mouthpiece element in an aerosol-generating article may allow for the inclusion of a capsule, or may allow the article to be more rigid at the point where the user applies it to their lips, or both.

[0089] Aerosol-generating articles may include a ventilation zone located along a downstream section. If the downstream section includes a tubular element, the ventilation zone may be located along the tubular element.

[0090] The tubular element of the present invention may include a ventilation zone located along the tubular body of the tubular element. Features of the ventilation zone are described below with respect to aerosol-generating articles. However, it should be understood that they may also be applied directly to the tubular element itself.

[0091] The ventilation zone can be positioned between approximately 5 mm and approximately 15 mm from the folded end portion of the tubular element. The ventilation zone can be positioned at least 2 mm from the folded end portion of the tubular element, more preferably at least 3 mm from the folded end portion of the tubular element, and even more preferably at least 5 mm from the folded end portion of the tubular element.

[0092] The ventilation zone can be positioned less than 20 mm from the folded end portion of the tubular element, more preferably less than 15 mm from the folded end portion of the tubular element, and even more preferably less than 10 mm from the folded end portion of the tubular element.

[0093] When the tubular element is a first tubular element located downstream of the aerosol forming matrix, the ventilation zone is preferably located in the downstream section of the first tubular element. Preferably, the ventilation zone is positioned between about 1 mm and about 10 mm from the downstream end of the first tubular element, more preferably between about 2 mm and about 8 mm from the downstream end of the first tubular element, and even more preferably between about 3 mm and about 6 mm from the downstream end of the first tubular element.

[0094] Preferably, the ventilation zone is positioned at least 1 mm from the downstream end of the first tubular element; more preferably, the ventilation zone is positioned at least 2 mm from the downstream end of the first tubular element; and even more preferably, the ventilation zone is positioned at least 3 mm from the downstream end of the first tubular element.

[0095] Preferably, the ventilation zone is positioned less than 10 mm from the downstream end of the first tubular element; more preferably, the ventilation zone is positioned less than 8 mm from the downstream end of the first tubular element; and even more preferably, the ventilation zone is positioned less than 6 mm from the downstream end of the first tubular element.

[0096] The ventilation zone may include multiple perforations through the peripheral wall of a ventilation element, which may be a tubular element. Preferably, the ventilation zone includes at least one row of circumferential perforations, or the ventilation zone may include two rows of circumferential perforations. For example, the perforations may be formed on the production line during the manufacture of the aerosol-generating article. Preferably, each row of circumferential perforations includes 8 to 30 perforations.

[0097] The aerosol-generating articles according to the present invention can have a ventilation level of at least about 5%.

[0098] Throughout this specification, the term "ventilation level" is used to indicate the volume ratio of the airflow entering the aerosol-generating article via a ventilated zone (ventilation airflow) to the sum of the aerosol airflow and the ventilation airflow. A higher ventilation level results in a higher dilution of the aerosol stream delivered to the consumer.

[0099] Aerosol-generating articles can typically have a ventilation level of at least about 10%, preferably at least about 15%, and more preferably at least about 20%.

[0100] In a preferred embodiment, the aerosol-generating article has a ventilation level of at least about 25%. Preferably, the aerosol-generating article has a ventilation level of less than about 60%. The aerosol-generating article may have a ventilation level of less than or equal to about 45%. More preferably, the aerosol-generating article has a ventilation level of less than or equal to about 40%, and even more preferably, a ventilation level of less than or equal to about 35%.

[0101] In a particularly preferred embodiment, the aerosol generating article has a ventilation level of about 30%. The aerosol generating article may have a ventilation level of about 20% to about 60%, preferably about 20% to about 45%, more preferably about 20% to about 40%. The aerosol generating article may have a ventilation level of about 25% to about 60%, preferably about 25% to about 45%, more preferably about 25% to about 40%. In another embodiment, the aerosol generating article has a ventilation level of about 30% to about 60%, preferably about 30% to about 45%, more preferably about 30% to about 40%.

[0102] In some particularly preferred embodiments, the aerosol generating article has a ventilation level of about 28% to about 42%. In some particularly preferred embodiments, the aerosol generating article has a ventilation level of about 30%.

[0103] Embodiments in which the aerosol-generating article includes a first tubular element downstream of the aerosol-generating matrix and a ventilation zone is provided along the location of the first tubular element offer numerous advantages. For example, and without wishing to be bound by theory, the inventors have discovered that the temperature drop caused by cooler outside air entering the first tubular element through the ventilation zone can have a favorable effect on the nucleation and growth of aerosol particles.

[0104] The formation of aerosols from gaseous mixtures containing various chemicals depends on the delicate interactions between nucleation, evaporation and condensation, and coalescence, while taking into account variations in vapor concentration, temperature, and velocity fields. The so-called classical nucleation theory is based on the assumption that a subset of molecules in the gas phase is large enough to remain coherent for a sufficient period (e.g., 50% probability). These molecules represent some kind of critical, threshold molecular cluster in transient molecular aggregates, meaning that, on average, smaller clusters are likely to disintegrate quickly into the gas phase, while larger clusters are likely to grow. Such critical clusters are considered key nucleation nuclei from which droplets are expected to grow due to the condensation of molecules in the vapor. It is assumed that newly nucleated pristine droplets appear with a certain initial diameter and can then grow by several orders of magnitude. This process is facilitated and reinforced by condensation caused by rapid cooling of the surrounding vapor. In this regard, it should be remembered that evaporation and condensation are two aspects of the same mechanism: gas-liquid mass transfer. While evaporation involves a net mass transfer from the droplet to the gas phase, condensation is a net mass transfer from the gas phase to the droplet phase. Evaporation (or condensation) will cause droplets to shrink (or grow), but will not change the number of droplets.

[0105] In situations that can be further complicated by coalescence, the temperature and rate of cooling play a crucial role in determining how the system responds. Generally, different cooling rates can lead to significantly different temporal behaviors associated with liquid phase (droplet) formation, since nucleation processes are typically nonlinear. Without being bound by theory, it is assumed that cooling leads to a rapid increase in droplet number concentration, followed by a strong, brief surge in this growth (nucleation burst). This nucleation burst appears to be more pronounced at lower temperatures. Furthermore, higher cooling rates seem to favor earlier initiation of nucleation. In contrast, lower cooling rates appear to have a favorable effect on the final size that aerosol droplets eventually reach.

[0106] Therefore, the rapid cooling caused by the influx of outside air into the first tubular element via the ventilation zone can be advantageously used to promote the nucleation and growth of aerosol droplets. However, at the same time, the influx of outside air into the first tubular element has the direct disadvantage of diluting the aerosol stream delivered to the consumer.

[0107] The inventors have surprisingly discovered that when the ventilation level is within the aforementioned range, the dilution effect on the aerosol (which can be assessed, in particular, by measuring the effect on the delivery of aerosol-forming agents (such as glycerol) included in the aerosol-generating matrix) is advantageously minimized. Specifically, ventilation levels between 25% and 50%, and even more preferably between 28% and 42%, have been found to produce particularly satisfactory glycerol delivery values. Simultaneously, the degree of nucleation and therefore the delivery of nicotine and aerosol-forming agents (e.g., glycerol) are enhanced.

[0108] The inventors have surprisingly discovered how the beneficial effect of enhanced nucleation promoted by rapid cooling caused by introducing ventilated air into the article can significantly offset the less desirable dilution effect. Thus, satisfactory aerosol delivery values ​​are consistently achieved with the aerosol-generated articles according to this disclosure.

[0109] This is particularly advantageous for "short" aerosol-generating articles, such as those comprising a first element of an aerosol-generating matrix with a length of less than about 40 mm, preferably less than 25 mm, or even more preferably less than 20 mm, or wherein the overall length of the aerosol-generating article is less than about 70 mm, preferably less than about 60 mm, or even more preferably less than 50 mm. It will be understood that in such aerosol-generating articles, there is virtually no time or space available for aerosol formation and the microparticle phase transition of the aerosol to be delivered to the consumer.

[0110] Furthermore, because the first tubular element for ventilation can be configured to contribute substantially no to the overall RTD of the aerosol-generating article, the overall RTD of such an aerosol-generating article can be advantageously finely adjusted by adjusting the length and density of the first element comprising the aerosol-generating matrix, or the length and optional length and density of the filter material segment forming part of the mouthpiece, or the length and density of the element located upstream of the first element comprising the aerosol-generating matrix. Therefore, aerosol-generating articles with a predetermined RTD can be manufactured consistently and with high precision, providing consumers with a satisfactory RTD level even in the presence of ventilation.

[0111] Furthermore, the inventors have discovered that when ventilation is provided to a tubular element having a folded end portion forming a first end wall at a first end of the tubular body, wherein the first end wall defines an opening for airflow between the cavity of the tubular element and the outside. In particular, and without wishing to be bound by theory, it is believed that the combination of partial airflow restriction created by the first end wall and the presence of incoming air from the ventilation can particularly effectively promote the mixing of hot air drawn through the aerosol-forming matrix and fresh air drawn through the ventilation holes.

[0112] The aerosol generating matrix may also include an upstream section located upstream of the aerosol generating matrix. The upstream section may include one or more upstream elements, such as the tubular element according to the invention. The upstream section may include upstream elements arranged immediately upstream of the aerosol generating matrix. The upstream element may be a tubular element according to the invention, such as the second tubular element described above.

[0113] The first element comprising the aerosol generating matrix may further include a receptor element located within the aerosol generating matrix. The receptor element may be an elongated receptor element. The receptor element may extend longitudinally within the aerosol generating matrix. The receptor element is configured to be in thermal contact with the aerosol generating matrix.

[0114] As used herein, the term "receptor element" refers to a material that can convert electromagnetic energy into heat. When located in a fluctuating electromagnetic field, eddy currents induced in the receptor element cause it to heat up. When an elongated receptor element is positioned in thermal contact with an aerosol-generating matrix, the aerosol-generating matrix is ​​heated by the receptor element.

[0115] When used to describe a receptor element, the term "elongated" means that the length of the receptor element is greater than its width or thickness, for example, twice as large as its width or thickness.

[0116] The receptor elements are arranged substantially longitudinally within the strip. This means that the length of the elongated receptor elements is arranged approximately parallel to the longitudinal direction of the strip, for example, within plus or minus 10 degrees. In a preferred embodiment, the elongated receptor elements may be located at the radial center within the strip and extend along the longitudinal axis of the strip.

[0117] Preferably, the receptor element extends downstream of the first element. The receptor element may also extend upstream of the first element. In a particularly preferred embodiment, the receptor element has substantially the same length as the first element and extends from upstream to downstream of the first element.

[0118] The receptor element is preferably in the form of a pin, strip, strip, or blade.

[0119] The receptor element preferably has a length of about 5 mm to about 15 mm, for example about 6 mm to about 12 mm, or about 8 mm to about 10 mm.

[0120] The ratio of the length of the receptor element to the total length of the aerosol-generated article matrix can be from about 0.2 to about 0.35.

[0121] Preferably, the ratio between the length of the receptor element and the total length of the aerosol-generating article matrix is ​​at least about 0.22, more preferably at least about 0.24, and even more preferably at least about 0.26. The ratio between the length of the receptor element and the total length of the aerosol-generating article matrix is ​​preferably less than about 0.34, more preferably less than about 0.32, and even more preferably less than about 0.3.

[0122] The ratio between the length of the receptor element and the total length of the aerosol-generating article matrix can be from about 0.22 to about 0.34, more preferably from about 0.24 to about 0.34, and even more preferably from about 0.26 to about 0.34. The ratio between the length of the receptor element and the total length of the aerosol-generating article matrix can be from about 0.22 to about 0.32, more preferably from about 0.24 to about 0.32, and even more preferably from about 0.26 to about 0.32. In another embodiment, the ratio between the length of the receptor element and the total length of the aerosol-generating article matrix is ​​preferably from about 0.22 to about 0.3, more preferably from about 0.24 to about 0.3, and even more preferably from about 0.26 to about 0.3.

[0123] In a particularly preferred embodiment, the ratio of the length of the receptor element to the total length of the aerosol-generated article matrix is ​​approximately 0.27.

[0124] The receptor element preferably has a width of about 1 mm to about 5 mm.

[0125] Receptor elements can typically have a thickness of about 0.01 mm to about 2 mm, for example, about 0.5 mm to about 2 mm. Receptor elements can have a thickness of about 10 micrometers to about 500 micrometers, more preferably about 10 micrometers to about 100 micrometers.

[0126] If the receptor element has a constant cross-section, such as a circular cross-section, then it preferably has a width or diameter of about 1 mm to about 5 mm.

[0127] If the receptor element is in the form of a strip or blade, the strip or blade preferably has a rectangular shape, the rectangular shape having a width preferably from about 2 mm to about 8 mm, more preferably from about 3 mm to about 5 mm. For example, a receptor element in the form of a strip or blade may have a width of about 4 mm.

[0128] If the receptor element is in the form of a strip or blade, the strip or blade preferably has a rectangular shape and a thickness of about 0.03 mm to about 0.15 mm, more preferably about 0.05 mm to about 0.09 mm. For example, a receptor element in the form of a strip or blade may have a thickness of about 0.07 mm.

[0129] In a preferred embodiment, the elongated receptor element is in the form of a strip or blade, preferably having a rectangular shape, and having a thickness of about 55 micrometers to about 65 micrometers.

[0130] More preferably, the elongated receptor element has a thickness of about 57 micrometers to about 63 micrometers. Even more preferably, the elongated receptor element has a thickness of about 58 micrometers to about 62 micrometers. In a particularly preferred embodiment, the elongated receptor element has a thickness of about 60 micrometers.

[0131] Preferably, the elongated receptor element has a length that is the same as or shorter than the length of the aerosol-generating matrix. Preferably, the elongated receptor element has the same length as the aerosol-generating matrix.

[0132] The sensor element can be formed from any material capable of being inductively heated to a temperature sufficient to generate aerosols from the aerosol-generating matrix. Preferred sensor elements include metals or carbon.

[0133] Preferred sensor elements may comprise or be composed of ferromagnetic materials, such as ferromagnetic alloys, ferritic iron, ferromagnetic steel, or stainless steel. Suitable sensor elements may be aluminum or include aluminum. Preferred sensor elements may be formed of 400 series stainless steel, such as grade 410, 420, or 430 stainless steel. Different materials will consume different amounts of energy when positioned within an electromagnetic field with similar frequency and field strength.

[0134] Therefore, parameters such as the material type, length, width, and thickness of the sensor element can all be changed to achieve the desired power dissipation within a known electromagnetic field. Preferably, the sensor element can be heated to temperatures exceeding 250 degrees Celsius.

[0135] Suitable receptor elements may include a non-metallic core having a metallic layer disposed on the non-metallic core, such as metallic traces formed on the surface of a ceramic core. The receptor element may have an outer protective layer, such as a ceramic or glass protective layer encapsulating the receptor element. The receptor element may include a protective coating formed of glass, ceramic, or an inert metal on the core of the receptor element material.

[0136] The receptor element is arranged in thermal contact with the aerosol-generating matrix. Therefore, when the receptor element is heated, the aerosol-generating matrix is ​​heated and forms an aerosol. Preferably, the receptor element is arranged in direct physical contact with the aerosol-generating matrix, for example, within the aerosol-generating matrix.

[0137] The receptor element can be a multi-material receptor element and can include a first receptor element material and a second receptor element material. The first receptor element material is arranged in close physical contact with the second receptor element material. The second receptor element material preferably has a Curie temperature below 500 degrees Celsius. The first receptor element material is preferably primarily used to heat the receptor element when it is placed in a fluctuating electromagnetic field. Any suitable material can be used. For example, the first receptor element material can be aluminum, or it can be an iron-containing material such as stainless steel. The second receptor element material is preferably primarily used to indicate when the receptor element reaches a specific temperature, which is the Curie temperature of the second receptor element material. The Curie temperature of the second receptor element material can be used to regulate the temperature of the entire receptor element during operation. Therefore, the Curie temperature of the second receptor element material should be below the ignition point of the aerosol-generating matrix. Suitable materials for the second receptor element material can include nickel and certain nickel alloys.

[0138] By providing a sensor element having at least a first sensor element material and a second sensor element material, wherein the second sensor element material has a Curie temperature and the first sensor element material does not have a Curie temperature, or the first sensor element material and the second sensor element material have different first and second Curie temperatures, the heating of the aerosol generating matrix and the temperature control of the heating can be separated. The first sensor element material is preferably a magnetic material having a Curie temperature of 500 degrees Celsius or higher. From the viewpoint of heating efficiency, it is desirable that the Curie temperature of the first sensor element material is above any maximum temperature to which the sensor element should be heated. The second Curie temperature may preferably be selected as below 400 degrees Celsius, more preferably below 380 degrees Celsius, or below 360 degrees Celsius. Preferably, the second sensor element material is a selected magnetic material having a second Curie temperature that is substantially the same as the desired maximum heating temperature. That is, preferably, the second Curie temperature is substantially the same as the temperature to which the sensor element should be heated in order to generate aerosols from the aerosol generating matrix. The second Curie temperature may, for example, be in the range of 200 to 400 degrees Celsius, or between 250 and 360 degrees Celsius. The second Curie temperature of the second receptor element material may, for example, be selected such that after being heated by a receptor element at a temperature equal to the second Curie temperature, the overall average temperature of the aerosol-generating matrix does not exceed 240 degrees Celsius.

[0139] As described above, the aerosol generating article of the present invention includes an aerosol generating matrix strip. The aerosol generating matrix may be a solid aerosol generating matrix.

[0140] In some preferred embodiments, the aerosol generating matrix comprises homogenized plant material, preferably homogenized tobacco material.

[0141] As used herein, the term "homogenized plant material" encompasses any plant material formed by the agglomeration of plant particles. For example, sheets or webs of homogenized tobacco material used as the aerosol-generating matrix of the present invention can be formed by agglomerating particles of tobacco material obtained by crushing, grinding, or grinding plant material, and optionally one or more of tobacco leaves and tobacco stems. Homogenized plant materials can be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0142] Homogenized plant material can be provided in any suitable form. For example, homogenized plant material can be in the form of one or more sheets. As used herein, the term "sheet" describes a sheet-like element whose width and length are substantially greater than its thickness. Homogenized plant material can be in the form of multiple pellets or granules. Homogenized plant material can be in the form of multiple strips, strips, or fragments. As used herein, the term "strip" describes an elongated element of material whose length is substantially greater than its width and thickness. The term "strip" should be considered to include strips, fragments, and any other homogenized plant material having similar forms. Strips of homogenized plant material can be formed from sheets of homogenized plant material, for example by cutting or shredding, or by other methods, such as extrusion.

[0143] Due to the splitting or cracking of the homogenized plant material sheet during the formation of the aerosol-generating matrix, such as due to curling, thin strips can be formed in situ within the aerosol-generating matrix. These homogenized plant material strips within the aerosol-generating matrix can separate from each other. At least some of these strips can be at least partially connected along their length to one or more adjacent strips. For example, adjacent strips can be connected by one or more fibers. This can occur, for example, due to the formation of strips as described above, during the production of the aerosol-generating matrix, when the homogenized plant material sheet is split.

[0144] Preferably, the aerosol generating matrix is ​​in the form of one or more sheets of homogenized plant material. The one or more sheets of homogenized plant material can be produced by a casting process. The one or more sheets of homogenized plant material can be produced by a papermaking process. Each of the one or more sheets described herein may individually have a thickness between 100 micrometers and 600 micrometers, preferably between 150 micrometers and 300 micrometers, and most preferably between 200 micrometers and 250 micrometers. Individual thickness refers to the thickness of a single sheet, while combined thickness refers to the total thickness of all sheets constituting the aerosol generating matrix. For example, if the aerosol generating matrix is ​​formed from two separate sheets, the combined thickness is the sum of the thicknesses of the two separate sheets, or, in the case of two sheets stacked in the aerosol generating matrix, the measured thickness of the two sheets.

[0145] One or more sheets as described herein may each individually have approximately 100 g / m³ 2 Approximately 300g / m 2 The weight per square meter.

[0146] The one or more sheets described herein may each individually have approximately 0.3 g / cm³. 3 Approximately 1.3 g / cm³ 3 The preferred concentration is approximately 0.7 g / cm³. 3 To approximately 1.0 g / cm³ 3 The density.

[0147] In embodiments where the aerosol-generating matrix comprises one or more sheets of homogenized plant material, the sheets are preferably in the form of one or more aggregated sheets. As used herein, the term "aggregate" means that the homogenized plant material sheet is rolled, folded, or otherwise compressed or contracted into a cylindrical shape substantially transverse to the axis of the rod or strip.

[0148] One or more sheets of homogenized plant material may be aggregated laterally relative to its longitudinal axis and defined by packaging to form continuous strips or rods.

[0149] One or more sheets of homogenized plant material may be advantageously curled or similarly treated. As used herein, the term “curled” means that the sheet has a plurality of substantially parallel ridges or corrugations. Alternatively, or in addition to curling, one or more sheets of homogenized plant material may be embossed, debossed, perforated, or otherwise deformed to provide texture on one or both sides of the sheet.

[0150] Preferably, each sheet of homogenized plant material can be curled such that it has multiple ridges or corrugations substantially parallel to the cylindrical axis of the rod. This treatment advantageously promotes the aggregation of the curled sheets of homogenized plant material to form the rod. Preferably, one or more sheets of homogenized plant material can be aggregated. It is understood that the curled sheets of homogenized plant material may alternatively or additionally have multiple substantially parallel ridges or corrugations arranged at acute or obtuse angles to the cylindrical axis of the rod. The sheets can be curled to such an extent that the integrity of the sheets is disrupted at the multiple parallel ridges or corrugations, causing material separation and resulting in the formation of fragments, strips, or bands of homogenized plant material.

[0151] One or more sheets of homogenized plant material can be cut into strips as described above. The aerosol-generating matrix may include multiple strips of homogenized plant material. The strips can be used to form rods. Typically, these strips are about 5 mm wide, or about 4 mm, or about 3 mm, or about 2 mm or less. The length of the strips may be greater than about 5 mm, between about 5 mm and about 15 mm, about 8 mm to about 12 mm, or about 12 mm. Preferably, the strips have substantially the same length as each other. The length of the strips may be determined by the manufacturing process, thereby cutting the strips into shorter rods, and the length of the strips corresponds to the length of the rods. The strips may be brittle, which may lead to breakage, especially during transportation. In this case, some strips may be shorter than the length of the rods.

[0152] The multiple strips preferably extend substantially longitudinally, aligned with the longitudinal axis along the length of the aerosol-generating matrix. Preferably, the multiple strips are thus aligned substantially parallel to each other.

[0153] The homogenized plant material may comprise up to about 95% by weight of plant particles on a dry weight basis. Preferably, the homogenized plant material comprises up to about 90% by weight of plant particles on a dry weight basis, more preferably up to about 80% by weight of plant particles, more preferably up to about 70% by weight of plant particles, more preferably up to about 60% by weight of plant particles, and more preferably up to about 50% by weight of plant particles.

[0154] For example, homogenized plant material may include plant particles of about 2.5% to about 95% by weight, or about 5% to about 90% by weight, or about 10% to about 80% by weight, or about 15% to about 70% by weight, or about 20% to about 60% by weight, or about 30% to about 50% by weight, on a dry weight basis.

[0155] The homogenized plant material can be a homogenized tobacco material containing tobacco particles. The sheet of homogenized tobacco material used in such embodiments can have a tobacco content of at least about 40% by weight, more preferably at least about 50% by weight, more preferably at least about 70% by weight, and most preferably at least about 90% by weight, based on dry weight.

[0156] The term "tobacco pellet" describes the pellets of any plant member of the genus Nicotiana. The term "tobacco pellet" includes ground or pulverized tobacco leaves, ground or pulverized tobacco stems, tobacco dust, tobacco debris, and other particulate tobacco byproducts formed during the processing, handling, and transportation of tobacco. In a preferred embodiment, the tobacco pellets are substantially entirely derived from tobacco leaves. In contrast, isolated nicotine and nicotine salts are compounds derived from tobacco but are not considered tobacco pellets for the purposes of this invention and are not included in the percentage of particulate plant material.

[0157] Tobacco pellets can be prepared from one or more tobacco plants. Any type of tobacco can be used in the blend. Examples of tobacco types that can be used include, but are not limited to, sun-cured tobacco, flue-cured tobacco, Burley tobacco, Maryland tobacco, Oriental tobacco, Virginia tobacco, and other specialty tobaccos.

[0158] Flue-curing is a method of drying tobacco, particularly Virginia tobacco. During the curing process, heated air circulates through densely packed tobacco leaves. In the first stage, the leaves turn yellow and wilt. In the second stage, the leaf blades are completely dried. In the third stage, the stems are completely dried.

[0159] Burley tobacco plays an important role in many tobacco blends. It has a distinctive flavor and aroma and is also capable of absorbing large amounts of casing.

[0160] Oriental tobacco is a type of tobacco characterized by small leaves and high aromatic quality. However, its flavor is milder than that of other tobaccos, such as Burley tobacco. Therefore, a relatively small proportion of Oriental tobacco is typically used in tobacco blends.

[0161] Kasturi, Madura, and Jatim are all usable subtypes of sun-cured tobacco. Preferably, Kasturi tobacco and flue-cured tobacco can be used in a mixture to produce tobacco pellets. Therefore, tobacco pellets in granular plant material can include a mixture of Kasturi tobacco and smoked tobacco.

[0162] The tobacco pellets may have a nicotine content of at least about 2.5% by weight based on dry weight. More preferably, the tobacco pellets may have a nicotine content of at least about 3% by weight, even more preferably at least about 3.2% by weight, even more preferably at least about 3.5% by weight, and most preferably at least about 4% by weight based on dry weight.

[0163] The homogenized plant material may include a combination of tobacco particles and non-tobacco plant flavoring particles. Preferably, the non-tobacco plant flavoring particles are selected from one or more of the following: ginger particles, rosemary particles, eucalyptus particles, clove particles, and star anise particles. Preferably, in such embodiments, the homogenized plant material includes at least about 2.5% by weight of non-tobacco plant flavoring particles on a dry weight basis, wherein the remainder of the plant particles is tobacco particles. Preferably, the homogenized plant material includes at least about 4% by weight of non-tobacco plant flavoring particles on a dry weight basis, more preferably at least about 6% by weight, more preferably at least about 8% by weight, and more preferably at least about 10% by weight. Preferably, the homogenized plant material includes up to about 20% by weight of non-tobacco plant flavoring particles, more preferably up to about 18% by weight, and more preferably up to about 16% by weight.

[0164] The weight ratio of non-tobacco plant flavor particles to tobacco particles in the granular plant material forming the homogenized plant material can vary depending on the desired flavor characteristics and composition of the aerosols generated by the aerosol-generating matrix during use. Preferably, the homogenized plant material comprises, on a dry weight basis, a non-tobacco plant flavor particle to tobacco particle ratio of at least 1:30, more preferably at least 1:20, even more preferably at least 1:10, and most preferably at least 1:5.

[0165] The homogenized plant material preferably comprises no more than 95% by weight of granular plant material on a dry weight basis. Therefore, the granular plant material is usually combined with one or more other components to form the homogenized plant material.

[0166] The homogenized plant material may also include an adhesive to modify the mechanical properties of the granular plant material, wherein the adhesive is incorporated into the homogenized plant material during the manufacturing process as described herein. Suitable exogenous adhesives are known to those skilled in the art and include, but are not limited to: gums, such as guar gum, xanthan gum, gum arabic, and locust bean gum; cellulose adhesives, such as hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose, and ethyl cellulose; polysaccharides, such as starch; organic acids, such as alginic acid; conjugate base salts of organic acids, such as sodium alginate, agar, and pectin; and combinations thereof. Preferably, the adhesive comprises guar gum.

[0167] The adhesive may be present in an amount of about 1% to about 10% by weight based on the dry weight of the homogenized plant material, preferably in an amount of about 2% to about 5% by weight based on the dry weight of the homogenized plant material.

[0168] The homogenized plant material may further include one or more lipids to facilitate the diffusion of volatile components (e.g., aerosol forming agents, gingerol, and nicotine), wherein the lipids are included in the homogenized plant material during manufacturing as described herein. Suitable lipids included in the homogenized plant material include, but are not limited to: medium-chain triglycerides, cocoa butter, palm oil, palm kernel oil, mango oil, shea butter, soybean oil, cottonseed oil, coconut oil, hydrogenated coconut oil, candelilla wax, carnauba wax, shellac, sunflower wax, sunflower oil, rice bran, and RevelA; and combinations thereof.

[0169] Homogenized plant materials may also contain pH modifiers.

[0170] The homogenized plant material may also contain fibers to modify the mechanical properties of the homogenized plant material, wherein said fibers are included in the homogenized plant material during the manufacturing process as described herein. Suitable exogenous fibers for inclusion in the homogenized plant material are known in the art and include fibers formed from non-tobacco and non-ginger materials, including but not limited to: cellulose fibers; cork fibers; hardwood fibers; jute fibers, and combinations thereof. Exogenous fibers derived from tobacco and / or ginger may also be added. Any fibers added to the homogenized plant material are not considered to form part of the “granular plant material” as defined above. Prior to inclusion in the homogenized plant material, the fibers may be treated by suitable methods known in the art, including but not limited to: mechanical pulping; refining; chemical pulping; bleaching; sulfate pulping; and combinations thereof. The fibers typically have a length greater than their width.

[0171] Suitable fibers typically have a length greater than 400 micrometers and less than or equal to 4 millimeters, preferably in the range of 0.7 millimeters to 4 millimeters. Preferably, the fibers are present in an amount of about 2% to about 15% by weight, most preferably about 4% by weight, based on the dry weight of the matrix.

[0172] Homogenized plant materials may also include one or more aerosol forming agents. Upon evaporation, the aerosol forming agent can transport other volatile compounds, such as nicotine and flavorings, released from the aerosol matrix upon heating. Suitable aerosol forming agents included in homogenized plant materials are known in the art and include, but are not limited to: polyols, such as triethylene glycol, propylene 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.

[0173] The homogenized plant material may have an aerosol forming agent content of between about 5% and about 30% by weight on a dry weight basis, for example, between about 10% and about 25% by weight on a dry weight basis, or between about 15% and about 20% by weight on a dry weight basis.

[0174] For example, if the matrix is ​​intended for use in an aerosol-generating article of an electrically operated aerosol-generating system with a heating element, it may preferably include an aerosol-forming agent content of between about 5% and about 30% by weight on a dry weight basis. If the matrix is ​​intended for use in an aerosol-generating article of an electrically operated aerosol-generating system with a heating element, the aerosol-forming agent is preferably glycerol.

[0175] The homogenized plant material may have an aerosol forming agent content of about 1% to about 5% by weight on a dry weight basis. For example, if the matrix is ​​intended for use in an aerosol-generating article, wherein the aerosol forming agent is held in a separate reservoir from the matrix, the matrix may have an aerosol forming agent content greater than 1% and less than about 5%. In such embodiments, the aerosol forming agent volatilizes upon heating, and the flow of the aerosol forming agent contacts the aerosol-generating matrix to entrain flavor compounds from the aerosol-generating matrix in the aerosol.

[0176] The homogenized plant material may have an aerosol forming agent content of about 30% to about 45% by weight. This relatively high level of aerosol forming agent is particularly suitable for aerosol-generating matrices intended to be heated at temperatures below 275 degrees Celsius. In such embodiments, the homogenized plant material preferably further comprises between about 2% and about 10% by weight of cellulose ether and between about 5% and about 50% by weight of additional cellulose by dry weight. It has been found that the combination of cellulose ether and additional cellulose provides particularly effective aerosol delivery when used for aerosol-generating matrices having an aerosol forming agent content of between 30% and 45% by weight.

[0177] Suitable cellulose ethers include, but are not limited to, methylcellulose, hydroxypropyl methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, ethyl hydroxyethylcellulose, and carboxymethylcellulose (CMC). In a particularly preferred embodiment, the cellulose ether is carboxymethylcellulose.

[0178] As used herein, the term "added cellulose" encompasses any cellulose material incorporated into the homogenized plant material that is not derived from non-tobacco plant particles or tobacco particles provided in the homogenized plant material. Thus, in addition to non-tobacco plant material or tobacco material, added cellulose is incorporated into the homogenized plant material as a separate and distinct cellulose source from any cellulose inherently provided within the non-tobacco plant particles or tobacco particles. Added cellulose typically originates from plants different from those in the non-tobacco plant particles or tobacco particles. Preferably, the added cellulose is in the form of an inert cellulose material that is sensorily inert and therefore does not substantially affect the sensory properties of the aerosols generated by the aerosol-generating matrix. For example, the added cellulose is preferably a tasteless and odorless material.

[0179] Additional cellulose may include cellulose powder, cellulose fibers, or a combination thereof.

[0180] Aerosol forming agents can act as wetting agents in aerosol generation matrices.

[0181] The packaging for the homogenized plant material strips can be paper or non-paper. Suitable paper packaging for specific embodiments of the invention is known in the art and includes, but is not limited to, cigarette paper and filter tip packaging. Suitable non-paper packaging for specific embodiments of the invention is known in the art and includes, but is not limited to, sheets of homogenized tobacco material. In some preferred embodiments, the packaging may be formed of a laminated material comprising multiple layers. Preferably, the packaging is formed of an aluminum co-laminated sheet. The use of an aluminum co-laminated sheet advantageously prevents the combustion of the aerosol-generating matrix when it should be ignited rather than heated in the intended manner.

[0182] In some preferred embodiments, the aerosol-generating matrix comprises a gel composition containing an alkaloid compound. In a particularly preferred embodiment, the aerosol-generating matrix comprises a gel composition containing nicotine.

[0183] 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.

[0184] 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.

[0185] 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.

[0186] 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.

[0187] The gel composition may include alkaloid compounds. The gel composition may include one or more alkaloids.

[0188] 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.

[0189] The gel composition may preferably include an alkaloid compound selected from nicotine, anaphylabine, and combinations thereof.

[0190] Preferably, the gel composition includes nicotine.

[0191] The term "nicotine" refers to nicotine and nicotine derivatives, such as free nicotine base and nicotine salts.

[0192] 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.

[0193] Preferably, the gel composition contains nicotine. Nicotine may be added to the composition in free alkali form or salt form. The gel composition comprises about 0.5% to about 10% by weight of nicotine, or about 0.5% to about 5% by weight of nicotine. Preferably, the gel composition comprises about 1% to about 3% by weight of nicotine, or about 1.5% to about 2.5% by weight of nicotine, or about 2% by weight of nicotine. The nicotine component of the gel formulation may be the most volatile component of the gel formulation. In some aspects, water may be the most volatile component of the gel formulation, and the nicotine component of the gel formulation may be the second most volatile component of the gel formulation.

[0194] The gel composition preferably 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.

[0195] 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.

[0196] 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.

[0197] The gel composition preferably includes at least one gelling agent. Preferably, the gel composition includes a gelling agent in a total amount ranging from about 0.4% to about 10% by weight. More preferably, the composition includes a gelling agent in a total amount ranging from about 0.5% to about 8% by weight. More preferably, the composition includes a gelling agent in a total amount ranging from about 1% to about 6% by weight. More preferably, the composition includes a gelling agent in a total amount ranging from about 2% to about 4% by weight. More preferably, the composition includes a gelling agent in a total amount ranging from about 2% to about 3% by weight.

[0198] 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.

[0199] Gelling agents may include one or more biopolymers. Biopolymers may be formed from polysaccharides.

[0200] 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.

[0201] Preferably, the gel composition comprises at least about 0.2% by weight of a hydrogen-bonded crosslinking gelling agent. 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 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.

[0202] 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.

[0203] 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.

[0204] The gel composition preferably includes a hydrogen-bonded crosslinking gelling agent in the range of about 0.3% to about 5% by weight. Preferably, the composition includes a hydrogen-bonded crosslinking gelling agent in the range of about 0.5% to about 3% by weight. Preferably, the composition includes a hydrogen-bonded crosslinking gelling agent in the range of about 1% to about 2% by weight.

[0205] 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.

[0206] The gel composition may include gelatin in the range of about 0.2% to about 5% by weight. Preferably, the gelatin may be in the range of about 0.5% to about 3% by weight. Preferably, the gelatin may be in the range of about 0.5% to about 2% by weight. Preferably, the gelatin may be in the range of about 1% to about 2% by weight.

[0207] The gel composition may include agarose in the range of about 0.2% to about 5% by weight. Preferably, the agarose may be in the range of about 0.5% to about 3% by weight. Preferably, the agarose may be in the range of about 0.5% to about 2% by weight. Preferably, the agarose may be in the range of about 1% to about 2% by weight.

[0208] 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.

[0209] The gel composition may include agar in the range of about 0.2% to about 5% by weight. Preferably, the agar may be in the range of about 0.5% to about 3% by weight. Preferably, the agar may be in the range of about 0.5% to about 2% by weight. Preferably, the agar may be in the range of about 1% to about 2% by weight.

[0210] 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.

[0211] 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.

[0212] The gel composition may include an ionic crosslinking gelling agent in the range of about 0.3% to about 5% by weight. Preferably, the composition includes an ionic crosslinking gelling agent in the range of about 0.5% to about 3% by weight. Preferably, the composition includes an ionic crosslinking gelling agent in the range of about 1% to about 2% by weight.

[0213] The gel composition may include a low-acyl gellan gum in the range of about 0.2 wt% to about 5 wt%. Preferably, the low-acyl gellan gum may be in the range of about 0.5 wt% to about 3 wt%. Preferably, the low-acyl gellan gum may be in the range of about 0.5 wt% to about 2 wt%. Preferably, the low-acyl gellan gum may be in the range of about 1 wt% to about 2 wt%.

[0214] 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.

[0215] The gel composition may include κ-carrageenan in the range of about 0.2 wt% to about 5 wt%. Preferably, κ-carrageenan may be in the range of about 0.5 wt% to about 3 wt%. Preferably, κ-carrageenan may be in the range of about 0.5 wt% to about 2 wt%. Preferably, κ-carrageenan may be in the range of about 1 wt% to about 2 wt%.

[0216] 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.

[0217] The gel composition may include alginate in the range of about 0.2 wt% to about 5 wt%. Preferably, the alginate may be in the range of about 0.5 wt% to about 3 wt%. Preferably, the alginate may be in the range of about 0.5 wt% to about 2 wt%. Preferably, the alginate may be in the range of about 1 wt% to about 2 wt%.

[0218] 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.

[0219] The gel composition may also include a thickener. Thickeners combined with hydrogen-bonded crosslinking gelling agents and ionic crosslinking gelling agents appear to unexpectedly support the solid medium and maintain the gel composition, even when the gel composition includes high levels of glycerol.

[0220] The term "thickening agent" refers to a compound that, when homogenized in an amount of 0.3% by weight at 25°C, increases viscosity without causing gel formation, and the mixture retains or preserves fluidity. Preferably, the thickening agent refers to a compound that, when homogenized in an amount of 0.3% by weight at 25°C, increases viscosity at a rate of 0.1s... -1 The shear rate increases the viscosity to at least 50 cPs, preferably at least 200 cPs, preferably at least 500 cPs, preferably at least 1000 cPs, without causing gel formation, and the mixture retains or preserves fluidity. Preferably, the thickener refers to a compound that, when homogeneously added in an amount of 0.3 wt% to a mixture of 50 wt% water / 50 wt% glycerol at 25°C, increases the viscosity at a rate of 0.1 s⁻¹. -1The shear rate increases the viscosity to at least 2, 5, 10, or 100 times that before addition, without causing gel formation, the mixture retains or preserves the fluidity of the compound.

[0221] 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).

[0222] The gel composition preferably includes a tackifier in the range of about 0.2 wt% to about 5 wt%. Preferably, the composition includes a tackifier in the range of about 0.5 wt% to about 3 wt%. Preferably, the composition includes a tackifier in the range of about 0.5 wt% to about 2 wt%. Preferably, the composition includes a tackifier in the range of about 1 wt% to about 2 wt%.

[0223] 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.

[0224] The gel composition may include xanthan gum in the range of about 0.2 wt% to about 5 wt%. Preferably, xanthan gum may be in the range of about 0.5 wt% to about 3 wt%. Preferably, xanthan gum may be in the range of about 0.5 wt% to about 2 wt%. Preferably, xanthan gum may be in the range of about 1 wt% to about 2 wt%.

[0225] 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.

[0226] The gel composition may include microcrystalline cellulose in the range of about 0.2 wt% to about 5 wt%. Preferably, the microcrystalline cellulose may be in the range of about 0.5 wt% to about 3 wt%. Preferably, the microcrystalline cellulose may be in the range of about 0.5 wt% to about 2 wt%. Preferably, the microcrystalline cellulose may be in the range of about 1 wt% to about 2 wt%.

[0227] 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.

[0228] The gel composition may include gum arabic in the range of about 0.2 wt% to about 5 wt%. Preferably, gum arabic may be in the range of about 0.5 wt% to about 3 wt%. Preferably, gum arabic may be in the range of about 0.5 wt% to about 2 wt%. Preferably, gum arabic may be in the range of about 1 wt% to about 2 wt%.

[0229] 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.

[0230] The gel composition may include λ-carrageenan in the range of about 0.2 wt% to about 5 wt%. Preferably, λ-carrageenan may be in the range of about 0.5 wt% to about 3 wt%. Preferably, λ-carrageenan may be in the range of about 0.5 wt% to about 2 wt%. Preferably, λ-carrageenan may be in the range of about 1 wt% to about 2 wt%.

[0231] The gel composition may include starch in the range of about 0.2% to about 5% by weight. Preferably, the starch may be in the range of about 0.5% to about 3% by weight. Preferably, the starch may be in the range of about 0.5% to about 2% by weight. Preferably, the starch may be in the range of about 1% to about 2% by weight.

[0232] 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.

[0233] 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.

[0234] The gel composition may include a carboxylic acid in the range of about 0.1 wt% to about 5 wt%. Preferably, the carboxylic acid may be in the range of about 0.5 wt% to about 3 wt%. Preferably, the carboxylic acid may be in the range of about 0.5 wt% to about 2 wt%. Preferably, the carboxylic acid may be in the range of about 1 wt% to about 2 wt%.

[0235] 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.

[0236] The gel composition may include levulinic acid in the range of about 0.1 wt% to about 5 wt%. Preferably, levulinic acid may be in the range of about 0.5 wt% to about 3 wt%. Preferably, levulinic acid may be in the range of about 0.5 wt% to about 2 wt%. Preferably, levulinic acid may be in the range of about 1 wt% to about 2 wt%.

[0237] The gel composition preferably includes some water. When the gel composition includes some water, the gel composition is more stable. Preferably, the gel composition includes at least about 1% by weight, or at least about 2% by weight, or at least about 5% by weight of water. Preferably, the gel composition includes at least about 10% by weight or at least about 15% by weight of water.

[0238] Preferably, the gel composition comprises between about 8% by weight and 32% by weight of water. Preferably, the gel composition comprises between about 15% by weight and about 25% by weight of water. Preferably, the gel composition comprises between about 18% by weight and about 22% by weight of water. Preferably, the gel composition comprises about 20% by weight of water.

[0239] Preferably, the aerosol generating matrix comprises a gel composition of between about 150 mg and about 350 mg.

[0240] Preferably, in embodiments comprising a gel composition, the aerosol-generating matrix comprises a porous medium loaded with the gel composition. The advantage of a porous medium loaded with the gel composition is that the gel composition is retained within the porous medium, which facilitates the manufacture, storage, or transport of the gel composition. It helps maintain the desired shape of the gel composition, particularly during manufacture, transport, or use.

[0241] The term “porous” is used herein to refer to a material that provides multiple holes or openings that allow air to pass through the material.

[0242] The porous medium can be any suitable porous material capable of containing or retaining the gel composition. Ideally, the porous medium allows the gel composition to move within it. In certain embodiments, the porous medium includes natural materials, synthetic or semi-synthetic materials, or combinations thereof. In certain embodiments, the porous medium includes sheet materials, foams, or fibers, such as loose fibers; or combinations thereof. In certain embodiments, the porous medium includes woven, nonwoven, or extruded materials, or combinations thereof. Preferably, the porous medium includes cotton, paper, viscose fibers, PLA, or cellulose acetate, or combinations thereof. Preferably, the porous medium includes sheet materials, such as cotton or cellulose acetate. In a particularly preferred embodiment, the porous medium includes a sheet made of cotton fibers.

[0243] The porous medium can be coiled or shredded. In a preferred embodiment, the porous medium is coiled. In an alternative embodiment, the porous medium includes shredded porous medium. The coiling or shredding process can be performed before or after loading the gel composition.

[0244] Curling the sheet material has the benefit of improving the structure to allow pathways through it. The passages through the curled sheet material help load and retain the gel, and also facilitate fluid flow through the curled sheet material. Therefore, using curled sheet materials as porous media has advantages.

[0245] Chopping allows for easy absorption of the gel due to the high surface area to volume ratio of the culture medium.

[0246] In some embodiments, the sheet is a composite material. Preferably, the sheet is porous. The sheet can aid in the fabrication of tubular elements comprising a gel. The sheet can aid in the introduction of surfactants into tubular elements comprising a gel. The sheet can help stabilize the structure of tubular elements comprising a gel. The sheet can aid in the transport or storage of the gel. Using the sheet can enable or facilitate the addition of structures to porous media, for example, by curling the sheet.

[0247] The porous medium can be a thread. This thread can include, for example, cotton, paper, or acetate filaments. The thread can also carry a gel, as with any other porous medium. An advantage of using threads as a porous medium is that it facilitates manufacturing.

[0248] The filament can be loaded with gel by any known method. The filament can be simply coated with gel, or it can be impregnated with gel. In manufacturing, the filament can be impregnated with gel and stored in preparation for inclusion in the assembly of tubular elements.

[0249] Preferably, in embodiments where the first element comprises the gel composition as described above, the downstream section of the aerosol-generating article includes a first tubular element according to the invention, wherein the first tubular element has a length of less than 10 mm. Combining such a relatively short tubular element with the gel composition can optimize aerosol delivery to consumers.

[0250] In embodiments of the invention where the aerosol-generating matrix comprises the gel composition as described above, an upstream element is preferably located upstream of the first element comprising the aerosol-generating matrix. In this case, the upstream element advantageously prevents physical contact with the gel composition. The upstream element can also advantageously compensate for any potential reduction in RTD, for example due to evaporation of the gel composition during use when the first element comprising the aerosol-generating matrix is ​​heated.

[0251] The features described with respect to one embodiment or implementation can also be applied to other embodiments and implementations.

[0252] The following is a non-exhaustive list of non-limiting examples. Any one or more features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0253] EX1. A tubular element for an aerosol-generating article, the tubular element comprising: a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body; a folded end portion forming a first end wall at the first end of the tubular body, the first end wall defining an opening for airflow between the cavity of the tubular element and the outside; and a ventilation zone along the tubular body of the tubular element.

[0254] EX2. The tubular element according to EX1, wherein the ventilation zone includes a plurality of perforations through the tubular body.

[0255] EX3. The tubular element according to EX1 or EX2, wherein the ventilation zone is positioned between approximately 5 mm and approximately 15 mm from the folded end portion of the tubular element.

[0256] EX4. The tubular element according to any one of EX1 to EX3, wherein the ventilation zone includes at least one circumferential perforation row extending around the tubular portion.

[0257] EX5. A tubular element according to any one of EX1 to EX4, wherein the tubular element has a ventilation level of about 20% to about 70%.

[0258] EX6. A tubular element according to any one of EX1 to EX5, wherein the tubular element is formed of paper material.

[0259] EX7. A tubular element according to any one of EX1 to EX6, wherein at least the first portion forming the first end wall of the tubular element is air impermeable.

[0260] EX8. The tubular element according to any one of EX1 to EX7, wherein the first end wall extends partially into the cavity of the tubular body and forms an angle of less than 90 degrees with the inner surface of the tubular body.

[0261] EX9. An aerosol generating article comprising: a first element including an aerosol generating matrix; and a tubular element according to any one of EX1 to EX8, the tubular element being located upstream or downstream of the first element.

[0262] EX10. The aerosol-generating article according to EX9, wherein the tubular element is adjacent to the first element.

[0263] EX11. The aerosol generating article according to EX10, wherein the first end wall of the tubular element is adjacent to the tubular element.

[0264] EX12. The aerosol generating article according to EX11, wherein the first end wall of the tubular element is in contact with the aerosol generating matrix.

[0265] EX13. An aerosol generating article according to any one of EX9 to EX12, wherein the aerosol generating matrix is ​​an aerosol generating matrix strip, and wherein the first element further includes a receptor element disposed within the aerosol generating matrix strip.

[0266] EX14. The aerosol generating article according to EX13, wherein the sensor element is an elongated sensor arranged longitudinally within the aerosol generating matrix.

[0267] EX15. An aerosol generating article according to any one of EX9 to EX14, wherein the tubular element is a first tubular element and is located downstream of the aerosol generating matrix, wherein a first end wall of the first tubular element is adjacent to the downstream end of the aerosol generating matrix.

[0268] EX16. The aerosol generating article according to EX15, wherein the ventilation zone is located in the downstream section of the first tubular element.

[0269] EX17. The aerosol generating article according to EX15 or EX16 further includes a second tubular element comprising: a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body; and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall defining an opening for airflow between the cavity of the second tubular element and the outside, wherein the second tubular element is positioned upstream of the aerosol generating matrix, wherein the first end wall of the second tubular element is adjacent to the upstream end of the aerosol generating matrix.

[0270] EX18. The aerosol generating article according to EX17, wherein the second tubular element further includes a folded end portion forming a second end wall at a second end of the tubular body, the second end wall defining an opening for airflow between the cavity of the second tubular element and the outside.

[0271] EX19. The aerosol generating article according to EX18, wherein the opening defined by the second end wall of the second tubular element is smaller than the opening defined by the first end wall of the second tubular element.

[0272] EX20. An aerosol generating article according to any one of EX17 to EX19, wherein the second tubular element is the upstream component of the aerosol generating article.

[0273] EX21. An aerosol-generating article according to any one of EX15 to EX20, further comprising a ventilation zone along the location of the first tubular element.

[0274] EX22. The aerosol-generating article according to any one of EX15 to EX22, further comprising a mouthpiece element located downstream of the first tubular element.

[0275] EX23. The aerosol-generating article according to EX22, wherein the mouthpiece element includes a filter material segment.

[0276] EX24. An aerosol-generated article according to any one of EX1 to EX23, wherein the cavity in the tubular body is a hollow cavity.

[0277] It should be understood that features described with respect to one example or embodiment may also be applicable to other examples and embodiments. For example, it should be understood that features described to date with respect to one or more of the components of a device, its use, and its configuration for performing a particular function are also equivalent to the disclosure of a method of operating the device. For example, the disclosure of a winding apparatus configured to wind a strip of material is also equivalent to the disclosure of method steps for winding a strip of material using the winding apparatus. Attached Figure Description

[0278] The invention will now be further described by way of example only, with reference to the accompanying drawings, in which:

[0279] Figure 1 A schematic side cross-sectional view of an aerosol-generated article according to a first embodiment of the present invention is shown;

[0280] Figure 2 A schematic side cross-sectional view of an aerosol-generated article according to a second embodiment of the present invention is shown;

[0281] Figure 2 A schematic side cross-sectional view of an aerosol-generated article according to a third embodiment of the present invention is shown;

[0282] Figure 4 A perspective view of a tubular element of an aerosol-generating article according to a first embodiment of the present invention is shown; and

[0283] Figures 5A to 5D The illustration depicts Figure 1 A schematic side cross-sectional view of the formation stage of a tubular element in an aerosol-generated product;

[0284] Figure 6 A schematic side cross-sectional view of an aerosol-generated article according to a fourth embodiment of the present invention is shown;

[0285] Figure 7 A schematic side cross-sectional view of an aerosol-generating article according to a fifth embodiment of the present invention is shown; and

[0286] Figure 8 A schematic side cross-sectional view of an aerosol-generated article according to a sixth embodiment of the present invention is shown. Detailed Implementation

[0287] Figure 1 An aerosol generating article 1 according to a first embodiment of the present invention is shown. The aerosol generating article 1 includes a first element 11 having an aerosol generating matrix 12 and a downstream section 14 located downstream of the first element 11. Furthermore, the aerosol generating article 1 includes an upstream section 16 located upstream of the first element 11. Therefore, the aerosol generating article 1 extends from an upstream end or distal end 18 to a downstream end or port end 20.

[0288] The aerosol-generated product has an overall length of approximately 45 millimeters.

[0289] The downstream section 14 includes a tubular element 100 located immediately downstream of the first element 11, the tubular element 100 being longitudinally aligned with the first element 11. Figure 1In one embodiment, the upstream end of the tubular element 100 abuts against the downstream end of the first element 11, and in particular against the downstream end of the aerosol generating matrix 12.

[0290] Additionally, downstream section 14 includes a mouthpiece element 42 located downstream of tubular element 100. More specifically, mouthpiece element 42 is positioned immediately downstream of tubular element 100. Figure 1 As shown, the upstream end of the mouthpiece element 42 is adjacent to the downstream end 40 of the tubular element 100.

[0291] The mouthpiece element 42 is provided in the form of a cylindrical filter segment of low-density cellulose acetate. The mouthpiece element 42 has a length of approximately 12 mm and an outer diameter of approximately 7.25 mm. The RTD of the mouthpiece element 42 is approximately 12 mm H2O.

[0292] The aerosol generating article 1 includes a ventilation zone 60 located along the tubular element 100. More specifically, the ventilation zone is located approximately 4 mm downstream of the tubular element 100. The ventilation level of the aerosol generating article 10 is approximately 40%.

[0293] The first element 11 is in the form of a strip, which includes an aerosol generating matrix 12 of one of the types described above. The aerosol generating matrix 12 substantially defines the structure and dimensions of the strip 11. The strip 11 may also include a package (not shown) surrounding the aerosol generating matrix 12. The strip 11 including the aerosol generating matrix has an outer diameter of about 7.25 mm and a length of about 12 mm.

[0294] The first element 11 also includes an elongated receptor element 44 within the aerosol generating matrix 12. More specifically, the receptor element 44 is arranged substantially longitudinally within the aerosol generating matrix 12 so as to be generally parallel to the longitudinal direction of the strip 11. Figure 1 As shown in the figure, the receptor element 44 is positioned at the radial center within the strip and extends effectively along the longitudinal axis of the strip 11.

[0295] The receptor element 44 extends from the upstream end of the aerosol generating matrix 12 to the downstream end. In fact, the receptor element 44 has a length that is substantially the same as that of the first element 11 that includes the aerosol generating matrix 12.

[0296] exist Figure 1 In one embodiment, the receptor element 44 is provided in the form of a strip and has a length of about 12 mm, a thickness of about 60 micrometers, and a width of about 4 mm.

[0297] The upstream segment 16 includes an upstream element 46 located immediately upstream of the first element 11, and the upstream element 46 is longitudinally aligned with the first element 11. Figure 1In this embodiment, the downstream end of the upstream element 46 abuts against the upstream end of the first element 11, and in particular against the upstream end of the aerosol generating matrix 12. This advantageously prevents the receptor element 44 from being removed. Furthermore, this ensures that the consumer will not accidentally come into contact with the heated receptor element 44 after use.

[0298] The upstream element 46 is provided in the form of a cylindrical cellulose acetate rod defined by a rigid packaging. The upstream element 46 has a length of approximately 5 mm. The RTD of the upstream element 46 is approximately 30 mm H2O.

[0299] The aerosol-generating article 1 also includes at least an outer packaging 109 surrounding the tubular element. For example... Figure 1 As shown, the outer packaging also surrounds the first element 11, the mouthpiece element 42, and the upstream element 46. The outer packaging 109 extends from the upstream or distal end 18 to the downstream or mouth end 20.

[0300] The tubular element 100 includes a tubular body 103 defining a cavity 106 extending from a first end 101 of the tubular body 103 to a second end 102 of the tubular body 103. The tubular element 100 also includes a folded end portion forming a first end wall 104 at the first end 101 of the tubular body 103. The first end wall 104 defines an opening 105 that allows airflow between the cavity 106 of the tubular element 100 and the outside. Specifically, Figure 1 The embodiments are configured such that aerosols can flow from the first element 11 through the opening 105 into the cavity 106.

[0301] The cavity 106 of the tubular body 103 is substantially empty, and therefore allows for substantially unrestricted airflow along the cavity 106. Thus, the RTD of the tubular element 100 can be located at a specific longitudinal position of the tubular element 100, namely at the first end wall 104, and can be controlled by a selected configuration of the first end wall 104 and its corresponding opening 105. Figure 1 In one embodiment, the RTD of the tubular element 100 (which is essentially the RTD of the first end wall 104) is essentially 10 mm H2O. Figure 1 In one embodiment, the tubular element 100 has a length of about 16 mm, an outer diameter of about 7.25 mm, and an inner diameter of about 6.5 mm (D). FTS Therefore, the thickness of the peripheral wall of the tubular body 103 is approximately 0.75 mm.

[0302] like Figure 4 As shown, and even more in Figures 5A-5DIn the perspective view, the first end wall 104 extends substantially transversely to the longitudinal direction of the aerosol-generating article 1 and the longitudinal direction of the tubular element 100. The opening 105 is the only opening in the first end wall 104, and is located at approximately the radial center of the tubular element 100. Therefore, the first end wall 104 is generally annular.

[0303] The combination of the first end wall 104 and its corresponding opening 105 provides an effective barrier arrangement that restricts the movement of the aerosol-generating matrix while allowing one or both of air and aerosol to flow from the first element 11 and into the cavity 106 through the opening 105. The opening 105 is generally aligned with the radial center of the receptor element 44 of the first element 11. This can be advantageous because it helps maintain the distance between the first end wall 105 and the receptor, and thus reduces undesirable heating of the first end wall 105. It can also be advantageous because it allows for a direct, unobstructed downstream flow of aerosols generated by the portion of the aerosol-generating matrix immediately adjacent to the receptor element 44.

[0304] As will be discussed below Figure 2 In more detail, the first end wall 104 is formed by folding the end portion of the tubular element 100 around a fold point. The fold point generally corresponds to the first end of the tubular body 103 of the tubular element 100.

[0305] Figure 2 An aerosol generating article 2 according to a second embodiment of the present invention is shown. The aerosol generating article 2 of the second embodiment is substantially the same as the aerosol generating article 1 of the first embodiment, except that the aerosol generating article 2 of the second embodiment does not include an upstream element 46 provided in the form of a cylindrical cellulose acetate filter segment defined by a rigid packaging. Instead, the aerosol generating article 2 of the second embodiment includes a second tubular element 200 located immediately upstream of the first element 11. Therefore, in this second embodiment, the tubular element 100 located immediately downstream of the first element 11 is referred to as the first tubular element 100.

[0306] The second tubular element 200 includes a tubular body 203 defining a cavity 206 extending from a first end of the tubular body 203 to a second end of the tubular body 203. The tubular element 200 also includes a folded end portion forming a first end wall 204a at the first end of the tubular body 203. The first end wall 204a defines an opening 205a that allows airflow between the cavity 206 of the second tubular element 200 and the outside. Specifically, Figure 2 An embodiment is configured such that air can flow from cavity 206 through opening 205a and into first element 11.

[0307] Therefore, the second tubular element 200 is similar to the first tubular element 100 because the end portion of the tubular element 200 is folded to form an end wall 205a, which extends substantially transversely to the longitudinal direction of the aerosol-generating article and is disposed adjacent to the end of the aerosol-generating matrix 12. In this case, the second tubular element 200 is disposed upstream of, rather than downstream of, the first element 11 containing the aerosol-generating matrix 12, meaning that the end wall 204a is disposed adjacent to the upstream end of the aerosol-generating matrix 12.

[0308] However, unlike the first tubular element, the second tubular element 200 also includes a second end wall 204b at a second end of its tubular body 203. This second end wall 204b is formed by folding the end portion of the second tubular element 200 at the second end of its tubular body. The second end wall 204b defines an opening 205b that allows airflow between the cavity 206 of the second tubular element 200 and the outside. In the case of the second end wall 204b, the opening 205b is configured to allow air to flow from the outside of the aerosol-generating article 2 through the opening 205b and into the cavity 206. Thus, the opening 205b provides a conduit through which air can be drawn into the aerosol-generating article 2 and through the aerosol-generating matrix 12. Figure 3 In the embodiments, the first end wall 204a of the second tubular element 200 may be referred to as the downstream end wall of the second tubular element 200. Similarly, the second end wall 204b of the second tubular element 200 may be referred to as the upstream end wall of the second tubular element 200.

[0309] Figures 5A to 5D An aerosol generating article 3 according to a third embodiment of the present invention is shown. The aerosol generating article 3 of the third embodiment is substantially the same as the aerosol generating article 1 of the first embodiment, except that the aerosol generating article 3 of the third embodiment does not include any form of upstream element 46 upstream of the first element 11. Therefore, the upstream end or distal end 18 of the aerosol generating article 3 is defined by the first element 11. Furthermore, in the third embodiment of the invention, the first element 11 does not include a receptor element 44 located within the aerosol generating matrix 12. Therefore, such an aerosol generating article 3 can be an aerosol generating article configured to receive heater blades of an aerosol generating device. The heater blades can be inserted into the aerosol generating matrix 12 through the upstream end 18 of the aerosol generating article 3.

[0310] The tubular element 300 of the aerosol generating article 3 of the third embodiment is substantially the same as the tubular element 100 of the aerosol generating article 1 of the first embodiment, except that the tubular element 300 is longer than the tubular element 100.

[0311] Figure 1The tubular element for aerosol generation articles according to the invention is shown through different stages of its formation. Thus, these figures illustrate methods for forming the tubular element, for example... Figure 5A 100 tubular elements.

[0312] like Figure 5A As shown, the method begins by providing a tubular element 500, which includes a first end portion 504 and a tubular body 103 adjacent to and integral with the first end portion 504. In order to form the first end wall 104, a folding force is applied to the tubular element 500 to bend the first end portion 504 around a folding point 501 corresponding to the first end of the tubular body 103.

[0313] The folding force causes the first end portion 504 to fold inward relative to the tubular body 103 (e.g.) Figure 5C , 5B (As indicated by the dashed curved arrow in 5C) it deflects and turns toward the cavity 106 of the tubular body 103. As measured relative to the wall of the tubular body 103, the folding force continues to be applied until the first end portion 504 has been folded at an angle greater than 90 degrees. Figure 5C Such a location is described in the text. For example, from... Figure 5C As can be seen, in this position, at least a portion of the first end portion 504 of the tubular element 500 extends into the cavity 106 of the tubular body 103. In other words, at least a portion of the first end portion 504 of the tubular element 500 has a longitudinal position between the position of the first end of the tubular body 103 and the position of the second end of the tubular body 103.

[0314] Once the first end portion 504 arrives Figure 5D When the tubular element 500 reaches its folding position, the folding force is stopped. At this point, the inherent elastic properties of the paper material (e.g., paper, cardboard, or hardboard) of the tubular element 500 will cause the first end portion 504 to partially recover along its folding path, such that the first end portion 504 reaches a position where it extends substantially transversely to the longitudinal direction of the tubular body 103. This position is determined by... Figures 5A to 5D The figure depicts a fully formed tubular element 100. Specifically, a folded first end portion 504 forms a first end wall 104 at the first end of the tubular body 103, the first end wall 104 defining an opening 105 for airflow between the cavity 106 of the tubular element 100 and the outside.

[0315] exist Figure 6 In the arrangement, the second end of the tubular element 500 is not folded; however, it should be understood that similar method steps can be applied to the second end of the tubular element 500 to obtain a tubular element with two folded end portions, each folded end portion forming a corresponding first end wall and second end wall of the tubular element.

[0316] Figure 6 An aerosol generating article 6 according to a fourth embodiment of the present invention is shown. The aerosol generating article 6 of the fourth embodiment is substantially the same as the aerosol generating article 3 of the third embodiment, and similar reference numerals are used where appropriate. However, the aerosol generating article 6 of the fourth embodiment does not include a mouthpiece element 42 located downstream of the tubular element 600. Instead, Figure 6 The tubular element 600 extends from the downstream end of the aerosol forming matrix 12 to the orifice 20 of the aerosol generating article 6. Therefore, Figure 6 The downstream section 14 of the aerosol-generating product 6 is entirely formed by tubular elements 600.

[0317] In addition, Figure 7 In this embodiment, the first end wall 604 of the tubular element 600 is not positioned adjacent to the downstream end of the aerosol forming matrix 12. Instead, the first end wall 604 of the tubular element 600 is positioned at the port end 20 of the aerosol generating article 6. The first end wall 604 defines an opening 605 that allows airflow between the cavity 606 of the tubular element 600 and the outside. The opening 605 is configured to allow one or both of air and aerosol to flow from the cavity 606 through the opening 605b to the outside of the aerosol generating article 6.

[0318] Figure 7 An aerosol generating article 7 according to a fifth embodiment of the present invention is shown. The aerosol generating article 7 of the fifth embodiment is substantially the same as the aerosol generating article 6 of the fourth embodiment, and similar reference numerals are used where appropriate. However, the aerosol generating article 7 of the fifth embodiment now includes a mouthpiece element in the form of a hollow tube 742 located downstream of the tubular element 700. Therefore, Figure 6 The tubular element 700 extends all the way to the upstream end of the hollow tube 742. Therefore, Figure 8 The downstream section 14 of the aerosol-generating article 6 is defined by the tubular element 700 and the hollow tube 742.

[0319] Figure 8 An aerosol generating article 8 according to a sixth embodiment of the present invention is shown. The aerosol generating article 8 of the sixth embodiment is substantially the same as the aerosol generating article 1 of the first embodiment, and similar reference numerals are used where appropriate.

[0320] However, in Figure 8 In this embodiment, the tubular element 800 does not contact the first element 11, which includes the aerosol-generating matrix 12. Instead, a gap 850 exists between the downstream end of the first element 11 and the first end wall 804 at the upstream end 801 of the tubular element 800. Therefore, in ​In this embodiment, the first end wall 804 of the tubular element 800 does not provide a barrier that contacts the aerosol generating matrix 12 to limit its movement. However, the blank space 850 does provide an area where any loose particles or debris from the aerosol generating matrix 12 may accumulate during use of the aerosol generating article 8. The first end wall 804 can, with the aid of gravity, prevent such loose particles or debris from moving further downstream within the aerosol generating article 8.

Claims

1. An aerosol generating article, the aerosol generating article comprising a plurality of elements assembled in the form of strips, the plurality of elements comprising: Including the first element of the aerosol generation matrix; as well as A tubular element positioned upstream or downstream of the first element, the tubular element comprising: A tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body; and A folded end portion, wherein the folded end portion forms a first end wall at a first end of the tubular body, the first end wall defining an opening for airflow between the cavity of the tubular element and the outside; and The aerosol-generating article further includes an outer packaging that defines at least the tubular element.

2. The aerosol generating article according to claim 1, wherein the tubular element is adjacent to the first element.

3. The aerosol generating article according to claim 2, wherein the first end wall of the tubular element is adjacent to the first element.

4. The aerosol generating article according to claim 3, wherein the first end wall of the tubular element is in contact with the aerosol generating matrix.

5. The aerosol generating article according to claim 1, wherein the aerosol generating matrix is ​​an aerosol generating matrix strip, and The first element further includes a receptor element disposed within the aerosol generating matrix strip.

6. The aerosol generating article according to claim 5, wherein the receptor element is an elongated receptor arranged longitudinally within the aerosol generating matrix.

7. The aerosol generating article according to claim 1, wherein the tubular element is a first tubular element and is positioned downstream of the aerosol generating matrix, wherein a first end wall of the first tubular element is adjacent to the downstream end of the aerosol generating matrix.

8. The aerosol-generating article according to claim 7, further comprising a second tubular element, the second tubular element comprising: A tubular body, wherein the tubular body of the second tubular element defines a cavity extending from a first end of the tubular body of the second tubular element to a second end of the tubular body of the second tubular element; as well as In the folded end portion, a first end wall is formed at the first end of the tubular body of the second tubular element, and the first end wall of the second tubular element defines an opening for airflow between the cavity of the second tubular element and the outside. The second tubular element is positioned upstream of the aerosol generating matrix, wherein the first end wall of the second tubular element is adjacent to the upstream end of the aerosol generating matrix.

9. The aerosol generating article of claim 8, wherein the second tubular element further includes a folded end portion forming a second end wall at a second end of the tubular body of the second tubular element, the second end wall defining an opening for airflow between the cavity of the second tubular element and the outside.

10. The aerosol-generating article of claim 9, wherein the opening defined by the second end wall of the second tubular element is smaller than the opening defined by the first end wall of the second tubular element.

11. The aerosol generating article according to claim 8, wherein the second tubular element is the upstream component of the aerosol generating article.

12. The aerosol-generating article of claim 8, further comprising a ventilation zone along the location of the first tubular element.

13. The aerosol-generating article according to claim 8, further comprising a mouthpiece element located downstream of the first tubular element.

14. The aerosol generating article of claim 12, wherein the ventilation zone is located in the downstream section of the first tubular element.

15. The aerosol generating article of claim 1, wherein the first end wall of the tubular element extends partially into the cavity of the tubular body and forms an angle of less than 90 degrees with the inner surface of the tubular body.

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