Aerosol-generating articles with coated sensor elements

Abstract

An aerosol generating article (10) is provided for generating an inhalable aerosol upon heating. The aerosol generating article (10) includes an aerosol generating element (12) comprising an aerosol generating matrix. The aerosol generating matrix comprises homogenized tobacco material containing an aerosol forming agent. The aerosol generating article also includes a receptor (44) disposed within the aerosol generating element (12) and configured to heat the homogenized tobacco material. The receptor (44) is coated with a coating composition comprising at least 20% by weight of the aerosol forming agent. The coating composition also comprises isolated nicotine or a monoproton nicotine salt, or both.

Description

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

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

[0003] Numerous prior art documents disclose aerosol generating apparatuses for consuming aerosol generating articles. Such apparatuses include, for example, electrically heated aerosol generating apparatuses, wherein aerosols are generated by transferring heat from one or more electrically heated elements of the aerosol generating apparatus to the aerosol generating matrix of the heated aerosol generating article. For example, electrically heated aerosol generating apparatuses comprising an internal heating element adapted to be inserted into the aerosol generating matrix have been proposed. Alternatively, WO 2015 / 176898 discloses an inductively heated aerosol generating article comprising an aerosol generating matrix and a sensor disposed within the aerosol generating matrix.

[0004] Aerosol-generating articles in which the tobacco-containing matrix is ​​heated without combustion present many challenges not encountered with conventional smoking products. First, the tobacco-containing matrix is ​​typically heated to a significantly lower temperature compared to the combustion front temperatures reached in conventional cigarettes. This can affect nicotine release from the tobacco-containing matrix and its delivery to the consumer. Furthermore, if the heating temperature is increased in an attempt to enhance nicotine delivery, the generated aerosol typically needs to cool to a greater extent and more rapidly before reaching the consumer.

[0005] Secondly, heating the tobacco-containing aerosol-generating matrix to even the temperature required for aerosol formation typically takes time, and therefore, there may be a delay in aerosol delivery to the consumer. This phenomenon, where the aerosol reaching the user when they initially inhale the product may have relatively low levels of flavor or nicotine, or both, is often referred to as the "cold spray" or "dry spray" effect.

[0006] Such a delay can be detected, for example, in aerosol-generating strips and articles in which the aerosol-generating matrix comprises homogenized tobacco material, because the aerosol forming agent and nicotine may not be readily available for release. In particular, this can occur in cases where cast leaf homogenized tobacco material prepared from a slurry containing an aerosol forming agent is used, as opposed to cases where the aerosol forming agent is applied (e.g., sprayed) onto the formed sheet.

[0007] It has been previously proposed to address this issue by providing two or more independent heating zones in the apparatus that heats the aerosol-generating strip or article. This helps to counteract the "cold spray" effect because it allows for different heating profiles to be applied to different portions of the aerosol-generating matrix.

[0008] However, there is a need for new and improved aerosol generating strips or articles suitable for addressing the initial "cold spray" or "dry spray" effect. For example, there is a need for novel and improved aerosol generating strips or articles that can provide users with satisfactory aerosol delivery more quickly overall and allow for more precise adjustment of aerosol delivery during use.

[0009] In particular, there is a desire to provide a novel and improved aerosol generating strip or article that can generate a satisfactory aerosol delivery to the user at a lower temperature while still heating the tobacco-containing matrix for regular consumption.

[0010] In general, the aim is to provide an aerosol generation article that is suitable for solving the initial "cold spray" or "air spray" effect, is easy to use, and can have improved practicality.

[0011] The aim is to provide an aerosol generating strip or product that can be manufactured efficiently and at high speed without requiring major modifications to existing equipment.

[0012] Therefore, it is desirable to provide new and improved aerosol-generating articles suitable for achieving at least one of the aforementioned desired results.

[0013] This disclosure relates to an aerosol generating article for generating an inhalable aerosol upon heating. The aerosol generating article may include an aerosol generating element comprising an aerosol generating matrix. The aerosol generating matrix may comprise homogenized tobacco material containing an aerosol forming agent. The aerosol generating article may further include a receptor disposed within the aerosol generating element and configured to heat the homogenized tobacco material. The receptor may be coated with a coating composition. The coating composition may contain at least 20% by weight of the aerosol forming agent. The coating composition may also contain isolated nicotine or a monoproton nicotine salt, or both.

[0014] According to the present invention, an aerosol generating article for generating an inhalable aerosol upon heating is provided, the aerosol generating article comprising: an aerosol generating element comprising an aerosol generating matrix, wherein the aerosol generating matrix comprises homogenized tobacco material, the homogenized tobacco material comprising an aerosol forming agent; and a receptor disposed within the aerosol generating element and configured to heat the homogenized tobacco material, the receptor being coated with a coating composition comprising at least 20% by weight of an aerosol forming agent, the coating composition further comprising isolated nicotine or a monoproton nicotine salt or both.

[0015] Compared to existing aerosol-generating articles, the aerosol-generating article according to the present invention comprises a receptor coated with a coating composition containing a predetermined amount of an aerosol forming agent and isolated nicotine or nicotine salt or both.

[0016] The inventors have discovered that by thermally coupling a receptor coated with such a composition to an aerosol generation matrix based on homogenized tobacco, it is advantageous to at least partially avoid the initial delays in aerosol generation and delivery commonly found in conventional aerosol generation articles.

[0017] Without being bound by theory, it should be understood that nicotine in the coating composition—whether in isolated form, as a salt of monoprotic acid, or both—and aerosol-forming agents are more readily available than nicotine and aerosol-forming agents contained within the homogenized tobacco material. Furthermore, during the initial heating cycle, the heat generated by induction via the receptors should be understood as being rapidly and directly transferred to the coating composition, thus providing the consumer with an initial burst of nicotine-containing aerosols while the temperature of the matrix containing the homogenized tobacco material surrounding the coated receptors continues to rise. Therefore, once the aerosols from the homogenized tobacco material begin to be released at a satisfactory rate and with the desired flavor and nicotine content, this flow provides a sustained release of aerosols for the remainder of the usage cycle.

[0018] By adjusting the content of aerosol forming agents and nicotine in the composition, and the ratio between the content of aerosol forming agents and nicotine in the composition and their corresponding content in the homogenized tobacco material, it is advantageous to fine-tune the transition from one aerosol source to another. In particular, this allows the transition to be made exceptionally smooth and imperceptible to the consumer.

[0019] Figure 1 The qualitative analysis demonstrates how aerosol delivery from each of the homogenized tobacco matrix and the coating composition provided on the receptors evolves over time. For example... Figure 1As shown by line A, aerosol release from the coating composition occurs rapidly at the start of heating the article, quickly reaching its maximum value, and then decreasing almost equally rapidly. The content of aerosol species in the coating composition is depleted relatively quickly, and therefore, the release of aerosols from the coating composition essentially ceases after a relatively short period. On the other hand, as shown by line B, the release of aerosols from the homogenized tobacco matrix is ​​initially less significant, and the amount of aerosol released from the homogenized tobacco matrix only reaches a comparable level after the release from the coating composition begins to decrease. By the time the release of aerosols from the coating composition has almost ceased, the intensity of the release from the homogenized tobacco matrix has more than doubled, and will only decrease smoothly over a longer period of time, during the remainder of the article's usage cycle.

[0020] At any point during use, the consumer actually receives the sum of the aerosol species streams released from the coating composition provided on the receptor and the aerosol species streams released from the homogenized tobacco matrix. Figure 1 Line C in the diagram illustrates this effect during the initial portion of the product's lifespan. As can be seen in the graph, the release of aerosol from the coating composition provided on the receptors compensates for the initial delay in the release of aerosol from the homogenized tobacco matrix until the latter essentially takes over. This is perceived by consumers as a generally faster, more uniform, and consistent aerosol delivery throughout the product's lifespan compared to existing aerosol-generating products.

[0021] The following will also describe methods that allow the manufacture of aerosol-generating articles that provide one or more of the benefits discussed above on existing production lines without requiring major reconfiguration.

[0022] As briefly described above, the present invention provides an aerosol generating article for generating inhalable aerosols upon heating. The aerosol generating article includes an aerosol generating element, which includes an aerosol generating matrix.

[0023] The term "aerosol-generating article" is used herein to refer to an article in which an aerosol-generating matrix is ​​heated to produce an inhalable aerosol for delivery to a consumer. As used herein, the term "aerosol-generating matrix" refers to a matrix capable of releasing volatile compounds upon heating to generate an aerosol.

[0024] A conventional cigarette is ignited when a user applies a flame to one end and inhales air through the other end. The localized heat provided by the flame and oxygen in the air inhaled through the cigarette ignites the end of the cigarette, and the resulting combustion produces inhalable smoke. In contrast, in heated aerosol-generating articles, aerosols are generated by heating a flavor-generating matrix, such as tobacco. Heated aerosol-generating articles include, for example, electrically heated aerosol-generating articles, and aerosol-generating articles in which aerosols are generated by heat transfer from a combustible fuel element or heat source to a physically separate aerosol-forming material. For example, the aerosol-generating articles according to the invention find particular application in aerosol-generating systems that include electrically heated aerosol-generating devices having internal heating elements adapted to be inserted into strips of the aerosol-generating matrix. This type of aerosol-generating article is described in the prior art (e.g., in European patent application EP 0822670).

[0025] 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.

[0026] Aerosol generating elements may be in the form of strips. As used herein with reference to the invention, the term "strip" is used to refer to a generally cylindrical element with a substantially circular, oval, or elliptical cross-section.

[0027] 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.

[0028] 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.

[0029] The term "length" refers to the longitudinal dimension of a component of an aerosol-generating article. For example, it can be used to describe the longitudinal dimension of a strip or elongated tubular element.

[0030] The aerosol generating matrix is ​​a solid aerosol generating matrix. More specifically, the aerosol generating matrix comprises homogenized tobacco material.

[0031] Homogenized tobacco material is an example of "homogenized plant material." 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 tobacco leaves and stems. Homogenized plant material can be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0032] Homogenized tobacco material can be provided in any suitable form. For example, homogenized tobacco material can be in the form of one or more sheets. As used herein with reference to the invention, the term "sheet" describes a layered element whose width and length are substantially greater than its thickness. Homogenized tobacco material can also be in the form of multiple pellets or granules.

[0033] Homogenized tobacco material can be in the form of multiple strips, bands, or fragments. As used herein, the term "strip" describes an elongated element of material whose length is substantially greater than its width and thickness. The term "strip" should be considered to include bands, fragments, and any other homogenized tobacco material having a similar form. Strips of homogenized tobacco material can be formed from sheets of homogenized tobacco material, for example by cutting or shredding, or by other methods, such as extrusion.

[0034] In some embodiments, strips may be formed in situ within the aerosol-generating matrix due to the splitting or cracking of the sheet of homogenized tobacco material during the formation of the aerosol-generating matrix, for example, due to curling. The homogenized tobacco material strips within the aerosol-generating matrix may be separable from each other. Alternatively, each strip of homogenized tobacco material within the aerosol-generating matrix may be at least partially connected along its length to one or more adjacent strips. For example, adjacent strips may be connected by one or more fibers. This can occur, for example, in cases where strips are formed due to the splitting of the sheet of homogenized tobacco material during the production of the aerosol-generating matrix, as described above.

[0035] Preferably, the aerosol generating matrix is ​​in the form of one or more sheets of homogenized tobacco material. In various embodiments of the invention, the one or more sheets of homogenized tobacco material may be produced by a casting process. In various embodiments of the invention, the one or more sheets of homogenized tobacco material may be produced by a papermaking process. The one or more sheets described herein may each individually have a thickness between 100 micrometers and 600 micrometers, preferably between 150 micrometers and 300 micrometers, and most preferably between 200 micrometers and 250 micrometers. Individual thickness refers to the thickness of a single sheet, while combined thickness refers to the total thickness of all sheets constituting the aerosol generating matrix. For example, if the aerosol generating matrix is ​​formed from two 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.

[0036] 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.

[0037] 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 / cm 3 The density.

[0038] In embodiments of the invention in which the aerosol-generating matrix comprises one or more sheets of homogenized tobacco material, the sheets are preferably in the form of one or more aggregated sheets. As used herein, the term "aggregate" means that a sheet of homogenized tobacco material is wound, folded, or otherwise compressed or contracted into a cylindrical shape substantially transverse to the axis of a rod or strip.

[0039] One or more sheets of homogenized tobacco material may be aggregated laterally relative to their longitudinal axis and surrounded by packaging to form a continuous strip or rod.

[0040] One or more sheets of homogenized tobacco material may be advantageously rolled or similarly treated. As used herein, the term “rolled” refers to a sheet having a plurality of substantially parallel ridges or folds. Alternatively or in addition to rolling, one or more sheets of homogenized tobacco material may be embossed, debossed, perforated or otherwise deformed to provide texture on one or both sides of the sheet.

[0041] Preferably, each sheet of homogenized tobacco material can be rolled up 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 rolled sheets of homogenized tobacco material to form a rod. Preferably, one or more sheets of homogenized tobacco material can be aggregated. It should be understood that the rolled sheets of homogenized tobacco 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 rolled up to such an extent that the integrity of the sheet is compromised at the multiple parallel ridges or corrugations, causing material separation and resulting in the formation of fragments, strips, or bands of homogenized tobacco material.

[0042] Alternatively, one or more sheets of homogenized tobacco material can be cut into strips as described above. In such embodiments, the aerosol-generating matrix comprises multiple strips of homogenized tobacco material. These strips can be used to form rods. Typically, the width of these strips is about 5 mm, or about 4 mm, or about 3 mm, or about 2 mm or less. The length of the strips can be greater than about 5 mm, between about 5 mm and about 15 mm, about 8 mm to about 12 mm, or about 12 mm. Preferably, the strips have substantially the same length as each other. The length of the strips can be determined by the manufacturing process, thereby cutting the strips into shorter rods, and the length of the strips corresponds to the length of the rods. The strips may be brittle, which can lead to breakage, especially during transport. In this case, some strips may be shorter than the length of the rod.

[0043] 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.

[0044] The homogenized tobacco material may contain up to about 95% by weight of plant particles on a dry weight basis. Preferably, the homogenized tobacco material contains 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.

[0045] For example, homogenized tobacco material may contain plant particles of about 2.5% to about 95% by weight on a dry weight basis, 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.

[0046] The sheet of homogenized tobacco material used in this invention may have a tobacco content of at least about 40% by weight, more preferably at least about 50% by weight, more preferably at least about 70% by weight, and most preferably at least about 90% by weight, based on dry weight.

[0047] Referring to this invention, the term "tobacco pellet" describes the pellets of any plant member of the genus Nicotiana. The term "tobacco pellet" includes ground or pulverized tobacco leaves, ground or pulverized tobacco stems, tobacco dust, tobacco debris, and other particulate tobacco byproducts formed during the processing, handling, and transportation of tobacco. In a preferred embodiment, the tobacco pellets are substantially entirely derived from tobacco leaves. In contrast, isolated nicotine and nicotine salts are compounds derived from tobacco but are not considered tobacco pellets for the purposes of this invention and are not included in the percentage of particulate plant material.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] The tobacco pellets may have a nicotine content of at least about 2.5% by weight on a dry weight basis. More preferably, the tobacco pellets may have a nicotine content of at least about 3% by weight on a dry weight basis, even more preferably at least about 3.2% by weight, even more preferably at least about 3.5% by weight, and most preferably at least about 4% by weight.

[0054] In some other embodiments of the invention, the homogenized tobacco material may comprise tobacco particles combined with non-tobacco plant flavor particles. Preferably, the non-tobacco plant flavor particles are selected from one or more of the following: ginger particles, eucalyptus particles, clove particles, and star anise particles. Preferably, in such embodiments, the homogenized tobacco material comprises at least about 2.5% by weight of non-tobacco plant flavor particles on a dry weight basis, wherein the remainder of the plant particles is tobacco particles. Preferably, the homogenized tobacco material comprises at least about 4% by weight of non-tobacco plant flavor particles on a dry weight basis, more preferably at least about 6% by weight, more preferably at least about 8% by weight, and more preferably at least about 10% by weight. Preferably, the homogenized tobacco material comprises up to about 20% by weight of non-tobacco plant flavor particles, more preferably up to about 18% by weight, and more preferably up to about 16% by weight.

[0055] The weight ratio of non-tobacco plant flavor particles to tobacco particles in the granular plant material forming the homogenized tobacco 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 tobacco material comprises a non-tobacco plant flavor particle to tobacco particle ratio of at least 1:30 by dry weight, more preferably at least 1:20 by weight, even more preferably at least 1:10 by weight, and most preferably at least 1:5 by weight.

[0056] Homogenized tobacco material preferably comprises no more than 95% by weight of granular plant material on a dry weight basis. Therefore, granular plant material is usually combined with one or more other components to form homogenized tobacco material.

[0057] The homogenized tobacco material may also include a binder to modify the mechanical properties of the granular plant material, wherein the binder is included in the homogenized tobacco material during the manufacturing process as described herein. Suitable exogenous binders 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 binders, such as hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose, and ethyl cellulose; polysaccharides, such as starch; organic acids, such as alginic acid; conjugate base salts of organic acids, such as sodium alginate, agar, and pectin; and combinations thereof. Preferably, the binder comprises guar gum.

[0058] The binder may be present in an amount of about 1% to about 10% by weight based on the dry weight of the homogenized tobacco material, preferably in an amount of about 2% to about 5% by weight based on the dry weight of the homogenized tobacco material.

[0059] Alternatively or additionally, the homogenized tobacco material may also contain 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 tobacco material during the manufacturing process as described herein. Suitable lipids included in the homogenized tobacco 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 Revel A; and combinations thereof.

[0060] Alternatively or additionally, homogenized tobacco materials may also contain pH adjusters.

[0061] Alternatively or additionally, the homogenized tobacco material may also contain fibers to modify the mechanical properties of the homogenized tobacco material, wherein said fibers are incorporated into the homogenized tobacco material during the manufacturing process as described herein. Suitable exogenous fibers for inclusion in the homogenized tobacco 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 tobacco material are not considered to form part of the “granular plant material” as defined above. Prior to inclusion in the homogenized tobacco material, the fibers may be treated by suitable processes known in the art, including but not limited to: mechanical pulping; refining; chemical pulping; bleaching; sulfate pulping; and combinations thereof. The fibers typically have a length greater than their width.

[0062] 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 based on the dry weight of the matrix, most preferably at least about 4% by weight.

[0063] In the context of this invention, the homogenized tobacco material further comprises 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-generating matrix upon heating within the aerosol. Suitable aerosol forming agents included in the homogenized tobacco material 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 glycerol monoacetate, glycerol diacetate, or glycerol triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanoate and dimethyl tetradecanoate.

[0064] The homogenized tobacco material may have an aerosol forming agent content of about 5% to about 30% by weight on a dry weight basis. Preferably, the homogenized tobacco material has an aerosol forming agent content of at least about 10% by weight on a dry weight basis, more preferably at least about 15% by weight on a dry weight basis.

[0065] The homogenized tobacco material preferably has an aerosol forming agent content of less than or equal to about 25% by weight, more preferably less than or equal to about 20% by weight, based on dry weight.

[0066] In some embodiments, the homogenized tobacco material has an aerosol forming agent content of 5% to 25% by weight, preferably 10% to 25% by weight, and more preferably 15% to 25% by weight, based on dry weight. In other embodiments, the homogenized tobacco material has an aerosol forming agent content of 5% to 20% by weight, preferably 10% to 20% by weight, and more preferably 15% to 20% by weight, based on dry weight.

[0067] In other embodiments, the homogenized tobacco 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 tobacco material preferably also comprises between about 2% and about 10% by weight of cellulose ether and between about 5% and about 50% by weight of additional cellulose, based on 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 between 30% and 45% by weight.

[0068] 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.

[0069] As used herein, the term "added cellulose" encompasses any cellulose material incorporated into homogenized tobacco material that is not derived from non-tobacco plant particles or tobacco particles provided in the homogenized tobacco material. Thus, in addition to non-tobacco plant material or tobacco material, added cellulose is incorporated into homogenized tobacco material as a separate and distinct cellulose source from any cellulose inherently provided within non-tobacco plant particles or tobacco particles. Added cellulose is typically derived from a plant different from 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.

[0070] Additional cellulose may include cellulose powder, cellulose fibers, or a combination thereof.

[0071] Aerosol forming agents can act as wetting agents in aerosol generation matrices.

[0072] The aerosol generating element comprising the aerosol generating matrix can be defined by a packaging material, which can be a paper packaging material or a non-paper packaging material. Suitable paper packaging materials for specific embodiments of the invention are known in the art and include, but are not limited to: cigarette paper; and filter tip packaging materials. Suitable non-paper packaging materials for specific embodiments of the invention are known in the art and include, but are not limited to, sheets of homogenized tobacco material. In some preferred embodiments, the packaging material may be formed of a laminated material comprising multiple layers. Preferably, the packaging material 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.

[0073] As briefly described above, in the aerosol generating article according to the invention, a receptor is arranged within an aerosol generating element and configured to heat the aerosol generating matrix, such as homogenized tobacco material. Furthermore, the receptor is coated with a coating composition, which will be described in more detail below.

[0074] As used herein with reference to this invention, the term "receptor" refers to a material that can convert electromagnetic energy into heat. When located within a fluctuating electromagnetic field, eddy currents induced in the receptor cause heating of the receptor. When an elongated receptor is thermally coupled to an aerosol-generating matrix, for example, when in thermal contact with the aerosol-generating matrix, the aerosol-generating matrix is ​​heated by the receptor.

[0075] Preferably, the coated receptor is surrounded by an aerosol-generating matrix. In a preferred embodiment, the coated receptor is surrounded by homogenized tobacco material, and in a particularly preferred embodiment, it is surrounded by homogenized tobacco material.

[0076] More preferably, the receptor is an elongated receptor. When used to describe a receptor, the term "elongated" means that the length dimension of the receptor is greater than its width dimension or its thickness dimension, for example, more than twice its width dimension or its thickness dimension.

[0077] The receptors are preferably arranged substantially longitudinally within the aerosol generating element. This means that the length of the elongated receptors is arranged approximately parallel to the longitudinal direction of the aerosol generating element, for example, within plus or minus 10 degrees. In a preferred embodiment, the elongated receptors may be positioned at a radial center within the aerosol generating element and extend along the longitudinal axis of the aerosol generating element, particularly when the aerosol generating element is provided in strip form.

[0078] For example, the coated elongated receptors can be arranged substantially longitudinally within a strip containing an aerosol-generating matrix of homogenized tobacco material, such that the receptors are thermally coupled to the aerosol-generating matrix.

[0079] Preferably, the receptor extends downstream of the aerosol generating element. In some embodiments, the receptor may extend upstream of the aerosol generating element. In a particularly preferred embodiment, the receptor has substantially the same length as the aerosol generating element and extends from the upstream end of the strip to the downstream end of the aerosol generating element.

[0080] The receptor is preferably in the form of a needle, strip, band or blade.

[0081] The receptor 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.

[0082] The ratio between the length of the receptor and the total length of the aerosol-generated article can be from about 0.2 to about 0.35.

[0083] Preferably, the ratio between the length of the receptor and the total length of the aerosol-generating article is at least about 0.22, more preferably at least about 0.24, and even more preferably at least about 0.26. The ratio between the length of the receptor and the total length of the aerosol-generating article is preferably less than about 0.34, more preferably less than about 0.32, and even more preferably less than about 0.3.

[0084] In some embodiments, the ratio between the length of the receptor and the overall length of the aerosol-generating article is preferably from about 0.22 to about 0.34, more preferably from about 0.24 to about 0.34, and even more preferably from about 0.26 to about 0.34. In other embodiments, the ratio between the length of the receptor and the overall length of the aerosol-generating article is preferably from about 0.22 to about 0.32, more preferably from about 0.24 to about 0.32, and even more preferably from about 0.26 to about 0.32. In yet another embodiment, the ratio between the length of the receptor and the overall length of the aerosol-generating article 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.

[0085] In a particularly preferred embodiment, the ratio between the length of the receptor and the overall length of the aerosol-generated article is about 0.27.

[0086] The receptor preferably has a width of about 1 mm to about 6 mm. More preferably, the receptor has a width of at least about 2 mm. Even more preferably, the receptor has a width of at least about 3 mm. In a particularly preferred embodiment, the receptor has a width of about 4 mm or 5 mm. This is believed to maximize the surface area available for heat transfer while ensuring that the receptor is completely surrounded by the aerosol-generating matrix.

[0087] The receptor may have a thickness of approximately 0.01 mm to approximately 2 mm, for example, approximately 0.5 mm to approximately 2 mm. In some embodiments, the receptor preferably has a thickness of approximately 10 micrometers to approximately 500 micrometers, more preferably approximately 10 micrometers to approximately 100 micrometers.

[0088] If the receptor 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.

[0089] If the receptor is in the form of a strip or leaf, the strip or leaf is preferably rectangular in shape, and the rectangular shape has a width of preferably about 2 mm to about 8 mm, more preferably about 3 mm to about 5 mm. For example, a receptor in the form of a strip or leaf may have a width of about 4 mm.

[0090] If the receptor is in the form of a strip or leaf, the strip or leaf 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 in the form of a strip or leaf may have a thickness of about 0.07 mm.

[0091] In a preferred embodiment, the elongated receptor (in the form of a strip or leaf, preferably having a rectangular shape, and) has a thickness from about 55 micrometers to about 65 micrometers.

[0092] More preferably, the elongated receptor has a thickness from about 57 micrometers to about 63 micrometers. Even more preferably, the elongated receptor has a thickness from about 58 micrometers to about 62 micrometers. In a particularly preferred embodiment, the elongated receptor has a thickness of about 60 micrometers.

[0093] Without being bound by theory, the inventors believe that, in general, the selection of a given thickness of the receptor is also influenced by constraints set by the selected length and width of the receptor and the geometry and dimensions of the strip of aerosol generating matrix. For example, it is preferable to select the length of the receptor to match the length of the aerosol generating element. Preferably, the width of the receptor should be selected to prevent displacement of the receptor within the matrix, while also allowing for easy insertion during manufacturing.

[0094] The inventors have discovered that it is advantageously possible, in a particularly effective and efficient manner, to generate and distribute heat throughout the aerosol-generating matrix in a sensor having a thickness within the aforementioned range, for use in supplying induction heating during use. Without wishing to be bound by theory, the inventors believe this is because such a sensor is suited to providing optimal heat generation and transfer by means of the sensor surface area and induction power. In contrast, thinner sensors may be too easily deformed and may not be able to maintain the desired shape and orientation within the strip of the aerosol-generating matrix during the manufacture of the aerosol-generating article, potentially leading to a less uniform and finely tunable heat distribution during use. Simultaneously, thicker sensors may be more difficult to cut to a precise and consistent length, and this may also affect how precisely longitudinally aligned sensors can be provided within the strip of the aerosol-generating matrix, thus potentially affecting the uniformity of heat distribution within the strip. These advantageous effects are felt particularly when the sensor extends to the downstream end of the strip of the aerosol-generating article. This is believed to be because the suction resistance (RTD) downstream of the receptor can be substantially minimized, since there is no aerosol-generating matrix that can contribute to the RTD at the location downstream of the receptor within the strip.

[0095] Not wanting to be bound by theory, the inventors believe that the downstream portion of the aerosol generating element can, to some extent, act as a filter for the upstream portion of the aerosol generating element. Therefore, the inventors believe it is desirable to also uniformly heat the downstream portion of the aerosol generating element, enabling it to actively participate in the release of volatile aerosol species and contribute to overall aerosol generation and delivery, and any potential filtration effect—which might hinder aerosol delivery to consumers—will be actively offset by the release of volatile aerosol species throughout the aerosol generating element.

[0096] The receptor can be formed from any material capable of being inductively heated to a temperature sufficient to generate aerosols from the aerosol-generating matrix. Preferred receptors include metals or carbon.

[0097] Preferred sensors may comprise or be composed of ferromagnetic materials, such as ferromagnetic alloys, ferritic iron, or ferromagnetic steel or stainless steel. Suitable sensors may be aluminum or include aluminum. Preferred sensors may be made of 400 series stainless steel, such as grade 410, 420, or 430 stainless steel. Different materials will consume different amounts of energy when positioned within an electromagnetic field with similar frequency and field strength.

[0098] Therefore, the parameters of the sensor, such as material type, length, width, and thickness, can be varied within a known electromagnetic field to provide the required power consumption. Preferably, the sensor can be heated to temperatures exceeding 250 degrees Celsius.

[0099] Suitable receptors may include a non-metallic core having a metallic layer disposed on the non-metallic core, such as metallic traces formed on the surface of a ceramic core. The receptor may have an outer protective layer, such as a ceramic or glass protective layer encapsulating the receptor. The receptor may include a protective layer formed of glass, ceramic, or inert metal and extending on a core of the receptor material.

[0100] The receptors are arranged to be thermally coupled to the aerosol-generating matrix. Therefore, when the receptors heat up, the aerosol-generating matrix is ​​heated and forms aerosols.

[0101] The sensor can be a multi-material sensor and may include a first sensor material and a second sensor material. The first sensor material is disposed in close physical contact with the second sensor material. The second sensor material preferably has a Curie temperature below 500 degrees Celsius. The first sensor material is preferably primarily used to heat the sensor when it is placed in a fluctuating electromagnetic field. Any suitable material can be used. For example, the first sensor material may be aluminum, or it may be an iron-containing material, such as stainless steel. The second sensor material is preferably primarily used to indicate when the sensor has reached a specific temperature, which is the Curie temperature of the second sensor material. The Curie temperature of the second sensor material can be used to regulate the temperature of the entire sensor during operation. Therefore, the Curie temperature of the second sensor material should be below the ignition point of the aerosol-generating matrix. Suitable materials for the second sensor material may include nickel and certain nickel alloys.

[0102] By providing a sensor having at least first and second sensor materials, wherein the second sensor material has a Curie temperature and the first sensor material does not have a Curie temperature, or the first and second sensor materials have first and second Curie temperatures different from each other, the heating of the aerosol generating matrix and the temperature control of the heating can be separated. The first sensor material is preferably a magnetic material having a Curie temperature of 500 degrees Celsius or higher. From the viewpoint of heating efficiency, it is desirable that the Curie temperature of the first sensor material is above any maximum temperature to which the sensor should be heated. The second Curie temperature can preferably be selected as below 400 degrees Celsius, more preferably below 380 degrees Celsius, or below 360 degrees Celsius. Preferably, the second sensor material is a selected magnetic material having a second Curie temperature substantially the same as the desired maximum heating temperature. That is, preferably, the second Curie temperature is substantially the same as the temperature to which the sensor should be heated in order to generate aerosols from the aerosol generating matrix. The second Curie temperature can, for example, be in the range of 200 degrees Celsius to 400 degrees Celsius, or between 250 degrees Celsius and 360 degrees Celsius. The second Curie temperature of the second receptor material can be selected, for example, such that after being heated by a receptor at a temperature equal to the second Curie temperature, the overall average temperature of the aerosol-generating matrix does not exceed 240 degrees Celsius.

[0103] In embodiments where the receptors are in the form of strips or blades, the weight per square meter (g / m²) of the receptors can be at least about 350 g / m², preferably at least about 400 g / m², and more preferably at least about 450 g / m². Preferably, in such embodiments, the weight per square meter of the receptors is less than or equal to about 650 g / m², more preferably less than or equal to about 600 g / m², and even more preferably less than or equal to about 550 g / m². In some preferred embodiments, the weight per square meter of the receptors is about 500 g / m².

[0104] In the aerosol-generating article according to the invention, the receptor may have a density of at least about 5 g / cm³, preferably at least about 6 g / cm³, and more preferably at least about 7 g / cm³. The receptor preferably has a density of less than or equal to about 11 g / cm³, more preferably less than or equal to about 10 g / cm³, and even more preferably less than or equal to about 9 g / cm³. In some preferred embodiments, the receptor has a density of about 8 g / cm³.

[0105] In the aerosol-generating article according to the invention, the receptor is coated with a coating composition. As used herein, the term "coated" means that a layer comprising the coating composition has been provided on the outer surface of the receptor. This is not limited to the mechanism or method of forming or applying a coating over the outer surface of the receptor. For example, the coating composition can be applied to the outer surface of the receptor by spraying, dipping, or extruding the coating composition onto the receptor.

[0106] In some embodiments, the entire outer surface of the receptor is coated. This can also be described as "continuous coating". In other embodiments, only a portion of the outer surface of the receptor is coated. This can also be described as "discontinuous coating" because the coating effectively creates covered and uncovered areas on the outer surface of the receptor.

[0107] Preferably, at least 50% of the surface area of ​​the outer surface of the receptor is coated with the coating composition. More preferably, at least 75% of the surface area of ​​the outer surface of the receptor is coated with the coating composition. Even more preferably, at least 90% of the surface area of ​​the outer surface of the receptor is coated with the coating composition. Most preferably, at least 95% of the surface area of ​​the outer surface of the receptor is coated with the coating composition. In some particularly preferred embodiments, substantially the entire surface area of ​​the outer surface of the receptor is coated with the coating composition.

[0108] The coating composition forms a layer on the outer surface of the receptor. The thickness of the coating composition layer can be controlled by adjusting parameters such as the viscosity of the slurry before the application process begins. Furthermore, different application techniques, such as dip coating and spray coating, can be selectively used to control the thickness of the coating composition layer.

[0109] The coating layer may have a thickness of at least 1 micrometer. Preferably, the coating layer has a thickness of at least 2 micrometers, more preferably at least 3 micrometers, and even more preferably at least 4 micrometers. In a particularly preferred embodiment, the coating layer has a thickness of at least about 5 micrometers, more preferably about 6 micrometers.

[0110] The coating composition layer can have a thickness of up to about 100 micrometers. Preferably, the coating composition layer has a thickness of less than or equal to about 50 micrometers, more preferably less than or equal to about 30 micrometers, and even more preferably less than or equal to about 15 micrometers. In a particularly preferred embodiment, the coating composition layer has a thickness of less than or equal to about 12 micrometers, more preferably less than or equal to about 10 micrometers.

[0111] In some embodiments, the coating composition layer has a thickness of about 2 micrometers to about 50 micrometers, preferably about 3 micrometers to about 50 micrometers, more preferably about 4 micrometers to about 50 micrometers, even more preferably about 5 micrometers to about 50 micrometers, and most preferably about 6 micrometers to about 50 micrometers. In other embodiments, the coating composition layer has a thickness of about 2 micrometers to about 30 micrometers, preferably about 3 micrometers to about 30 micrometers, more preferably about 4 micrometers to about 30 micrometers, even more preferably about 5 micrometers to about 30 micrometers, and most preferably about 6 micrometers to about 30 micrometers. In a further embodiment, the coating composition layer has a thickness of about 2 micrometers to about 15 micrometers, preferably about 3 micrometers to about 15 micrometers, more preferably about 4 micrometers to about 15 micrometers, even more preferably about 5 micrometers to about 15 micrometers, and most preferably about 6 micrometers to about 15 micrometers. In yet another embodiment, the coating composition layer has a thickness of about 2 micrometers to about 12 micrometers, preferably about 3 micrometers to about 12 micrometers, more preferably about 4 micrometers to about 12 micrometers, even more preferably about 5 micrometers to about 30 micrometers, and most preferably about 6 micrometers to about 12 micrometers. In a further embodiment, the coating composition layer has a thickness of about 2 micrometers to about 10 micrometers, preferably about 3 micrometers to about 10 micrometers, more preferably about 4 micrometers to about 10 micrometers, even more preferably about 5 micrometers to about 10 micrometers, and most preferably about 6 micrometers to about 10 micrometers.

[0112] The total weight of the coating composition present in the aerosol-generating article according to the invention can be from about 1 mg to about 4 mg, preferably from about 1 mg to about 3 mg, more preferably from about 1 mg to about 2 mg.

[0113] The sum of the total weight of the aerosol generating matrix in the aerosol generating element and the total weight of the coating composition in the aerosol generating article according to the invention can be from about 150 mg to about 500 mg, preferably from about 180 mg to about 400 mg, more preferably from about 200 mg to about 300 mg. In some preferred embodiments, the sum of the total weight of the aerosol generating matrix in the aerosol generating element and the total weight of the coating composition is about 250 mg.

[0114] As previously described, in the aerosol-generating article according to the invention, the coating composition comprises at least 20% by weight of an aerosol-forming agent. Additionally, the coating composition comprises isolated nicotine or a monoprotic nicotine salt, or both. When heated, the coating composition described herein is suitable for delivering a nicotine-containing aerosol to the lungs at inhalation rates or airflow rates within those of conventional smoking.

[0115] The coating composition preferably comprises about 0.5% by weight to about 10% by weight of isolated nicotine or monoproton nicotine salt, or both. More preferably, the coating composition comprises about 1% by weight to about 3% by weight of isolated nicotine or monoproton nicotine salt, or both. Even more preferably, the coating composition comprises about 1.5% by weight to about 2.5% by weight of isolated nicotine or monoproton nicotine salt, or both. In some preferred embodiments, the coating composition comprises about 1.5% by weight of isolated nicotine or monoproton nicotine salt, or both. The coating composition may comprise about 2% by weight of isolated nicotine or monoproton nicotine salt, or both.

[0116] The nicotine component of the coating composition may be the most volatile component in the coating composition. In some respects, water may be the most volatile component in the coating composition, and the nicotine component of the coating composition may be the second most volatile component in the coating composition.

[0117] As described above, the aerosol-generating matrix comprises homogenized tobacco material, which in turn comprises an aerosol-forming agent. Therefore, the total weight of nicotine in the aerosol-generating article will substantially correspond to the sum of the nicotine content in the coating composition and the nicotine content in the homogenized tobacco material. The nicotine content in the coating composition may account for at least about 0.1% by weight of the total nicotine content in the overall aerosol-generating article. Preferably, the nicotine content in the coating composition accounts for at least about 0.25% by weight of the total nicotine content in the overall aerosol-generating article. More preferably, the nicotine content in the coating composition accounts for at least about 0.5% by weight of the total nicotine content in the overall aerosol-generating article.

[0118] The nicotine content in the coating composition is preferably less than or equal to about 10% by weight of the total nicotine content in the overall aerosol-generating article. More preferably, the nicotine content in the coating composition is less than or equal to about 5% by weight of the total nicotine content in the overall aerosol-generating article. Even more preferably, the nicotine content in the coating composition is less than or equal to 2% by weight of the total nicotine content in the overall aerosol-generating article.

[0119] In some embodiments, the nicotine content in the coating composition preferably accounts for about 0.1% to about 10% by weight of the total nicotine content in the overall aerosol-generating article. Preferably, the nicotine content in the coating composition preferably accounts for about 0.25% to about 10% by weight of the total nicotine content in the overall aerosol-generating article. More preferably, the nicotine content in the coating composition preferably accounts for about 0.5% to about 10% by weight of the total nicotine content in the overall aerosol-generating article. In other embodiments, the nicotine content in the coating composition preferably accounts for about 0.1% to about 15% by weight of the total nicotine content in the overall aerosol-generating article. Preferably, the nicotine content in the coating composition preferably accounts for about 0.25% to about 5% by weight of the total nicotine content in the overall aerosol-generating article. More preferably, the nicotine content in the coating composition preferably accounts for about 0.5% to about 5% by weight of the total nicotine content in the overall aerosol-generating article. In a further embodiment, the nicotine content in the coating composition preferably accounts for about 0.1% to about 2% by weight of the total nicotine content in the overall aerosol-generating article. Preferably, the nicotine content in the coating composition preferably accounts for about 0.25% to about 2% by weight of the total nicotine content in the overall aerosol-generating article. More preferably, the nicotine content in the coating composition preferably accounts for about 0.5% to about 2% by weight of the total nicotine content in the overall aerosol-generating article.

[0120] The coating composition comprises 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. Glycerol is preferably the aerosol forming agent.

[0121] As briefly described above, the coating composition comprises at least 20% by weight of an aerosol forming agent. The coating composition may comprise from about 20% by weight to about 90% by weight of an aerosol forming agent, such as from about 30% by weight to about 80% by weight of an aerosol forming agent or from about 40% by weight to 70% by weight of an aerosol forming agent. In some preferred embodiments, the coating composition may comprise about 50% by weight of an aerosol forming agent.

[0122] Specifically, the composition may contain about 20% by weight of glycerol to about 90% by weight, such as about 30% by weight of glycerol to about 80% by weight, or about 40% by weight of glycerol to 70% by weight. In some preferred embodiments, the coating composition may contain about 50% by weight of glycerol.

[0123] The coating composition may comprise a majority of an aerosol forming agent. The coating composition may comprise a mixture of water and an aerosol forming agent, wherein the aerosol forming agent constitutes the majority (by weight) of the coating composition. The aerosol forming agent may form at least about 50% by weight of the coating 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 coating composition. The aerosol forming agent may form about 70% by weight to about 80% by weight of the coating composition. The aerosol forming agent may form about 70% by weight to about 75% by weight of the coating composition.

[0124] Specifically, the coating composition may contain a majority of glycerol. The coating composition may contain a mixture of water and glycerol, wherein glycerol forms the majority (by weight) of the coating composition. Glycerol may form at least about 50% by weight of the coating 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 coating composition. Glycerol may form about 70% by weight to about 80% by weight of the coating composition.

[0125] Glycerin can form about 70% to about 75% by weight of the coating composition.

[0126] As described above, the aerosol-generating matrix comprises homogenized tobacco material, and the homogenized tobacco material comprises an aerosol forming agent. Therefore, the total content of the aerosol forming agent in the aerosol-generating article will substantially correspond to the sum of the aerosol forming agent content in the coating composition and the aerosol forming agent content in the homogenized tobacco material.

[0127] The aerosol forming agent content in the coating composition can be at least about 0.1% by weight of the total aerosol forming agent content in the overall aerosol-generating article. Preferably, the aerosol forming agent content in the coating composition is at least about 0.25% by weight of the total aerosol forming agent content in the overall aerosol-generating article. More preferably, the aerosol forming agent content in the coating composition is at least about 0.5% by weight of the total aerosol forming agent content in the overall aerosol-generating article.

[0128] The aerosol forming agent content in the coating composition is preferably less than or equal to about 10% by weight of the total aerosol forming agent content in the overall aerosol-generating article. More preferably, the aerosol forming agent content in the coating composition is less than or equal to about 5% by weight of the total aerosol forming agent content in the overall aerosol-generating article. Even more preferably, the aerosol forming agent content in the coating composition is less than or equal to 2% by weight of the total aerosol forming agent content in the overall aerosol-generating article.

[0129] In some embodiments, the aerosol forming agent content in the coating composition preferably accounts for about 0.1% to about 10% by weight of the total aerosol forming agent content in the overall aerosol-generating article. Preferably, the aerosol forming agent content in the coating composition preferably accounts for about 0.25% to about 10% by weight of the total aerosol forming agent content in the overall aerosol-generating article. More preferably, the aerosol forming agent content in the coating composition preferably accounts for about 0.5% to about 10% by weight of the total aerosol forming agent content in the overall aerosol-generating article. In other embodiments, the aerosol forming agent content in the coating composition preferably accounts for about 0.1% to about 15% by weight of the total aerosol forming agent content in the overall aerosol-generating article. Preferably, the aerosol forming agent content in the coating composition preferably accounts for about 0.25% to about 5% by weight of the total aerosol forming agent content in the overall aerosol-generating article. More preferably, the aerosol forming agent content in the coating composition is from about 0.5% to about 5% by weight of the total aerosol forming agent content in the overall aerosol-generating article. In a further embodiment, the aerosol forming agent content in the coating composition is from about 0.1% to about 2% by weight of the total aerosol forming agent content in the overall aerosol-generating article. Preferably, the aerosol forming agent content in the coating composition is from about 0.25% to about 2% by weight of the total aerosol forming agent content in the overall aerosol-generating article. More preferably, the aerosol forming agent content in the coating composition is from about 0.5% to about 2% by weight of the total aerosol forming agent content in the overall aerosol-generating article.

[0130] In a preferred embodiment, the glycerol content in the coating composition may be at least about 0.1% by weight of the total aerosol forming agent content in the overall aerosol generating article. Preferably, the glycerol content in the coating composition is at least about 0.25% by weight of the total aerosol forming agent content in the overall aerosol generating article. More preferably, the glycerol content in the coating composition is at least about 0.5% by weight of the total aerosol forming agent content in the overall aerosol generating article.

[0131] The glycerol content in the coating composition is preferably less than or equal to about 10% by weight of the total aerosol forming agent content in the overall aerosol generating article. More preferably, the glycerol content in the coating composition is less than or equal to about 5% by weight of the total aerosol forming agent content in the overall aerosol generating article. Even more preferably, the glycerol content in the coating composition is less than or equal to 2% by weight of the total aerosol forming agent content in the overall aerosol generating article.

[0132] In some preferred embodiments, the glycerol content in the coating composition is preferably from about 0.1% by weight to about 10% by weight of the total aerosol forming agent content in the overall aerosol generating article. Preferably, the glycerol content in the coating composition is preferably from about 0.25% by weight to about 10% by weight of the total aerosol forming agent content in the overall aerosol generating article. More preferably, the glycerol content in the coating composition is preferably from about 0.5% by weight to about 10% by weight of the total aerosol forming agent content in the overall aerosol generating article. In other embodiments, the glycerol content in the coating composition is preferably from about 0.1% by weight to about 15% by weight of the total aerosol forming agent content in the overall aerosol generating article. Preferably, the glycerol content in the coating composition is preferably from about 0.25% by weight to about 5% by weight of the total aerosol forming agent content in the overall aerosol generating article. More preferably, the glycerol content in the coating composition is preferably from about 0.5% by weight to about 5% by weight of the total aerosol forming agent content in the overall aerosol generating article. In a further embodiment, the glycerol content in the coating composition preferably accounts for about 0.1% to about 2% by weight of the total aerosol forming agent content in the overall aerosol generating article. Preferably, the glycerol content in the coating composition preferably accounts for about 0.25% to about 2% by weight of the total aerosol forming agent content in the overall aerosol generating article. More preferably, the glycerol content in the coating composition preferably accounts for about 0.5% to about 2% by weight of the total aerosol forming agent content in the overall aerosol generating article.

[0133] In certain preferred embodiments of the invention, the coating composition further comprises at least one gelling agent. In other words, the coating composition is preferably a gel composition. Preferably, the at least one gelling agent forms a solid medium and an aerosol forming agent is dispersed in the solid medium, wherein the isolated nicotine or monoproton nicotine salt or both are dispersed in the aerosol forming agent.

[0134] 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.

[0135] Gelling agents may include one or more biopolymers. Biopolymers may be formed from polysaccharides.

[0136] 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.

[0137] Preferably, the gel composition is a stable gel phase. Advantageously, stable gel compositions containing nicotine provide a predictable compositional form during storage or shipment from manufacturer to consumer. Stable gel compositions containing nicotine substantially retain their shape. Stable gel compositions containing nicotine substantially do not release the liquid phase during storage or shipment from manufacturer to consumer. Stable gel compositions containing nicotine allow for simple consumable design. The consumable does not necessarily need to be designed to contain liquid, thus allowing for a wider range of materials and container constructions.

[0138] 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.

[0139] The coating composition preferably comprises one or more gelling agents. In some preferred embodiments, the gelling agent comprises carboxymethyl cellulose (CMC) or hydroxypropyl methyl cellulose (HPMC) or both. Preferably, in these embodiments, the aerosol forming agent comprises glycerol.

[0140] Preferably, the coating composition comprises a total amount of gelling agent ranging from about 0.4% to about 10% by weight. More preferably, the coating composition comprises a gelling agent ranging from about 0.5% to about 8% by weight. More preferably, the coating composition comprises a gelling agent ranging from about 1% to about 6% by weight. More preferably, the coating composition comprises a gelling agent ranging from about 2% to about 4% by weight. More preferably, the coating composition comprises a gelling agent ranging from about 2% to about 3% by weight.

[0141] The aerosol generating article of the present invention preferably further includes a downstream section located downstream of the aerosol generating element. As will be apparent from the following description of various embodiments of the aerosol generating article of the present invention, the downstream section may include one or more downstream elements.

[0142] The downstream section may include a support element arranged aligned with and downstream of the aerosol generating element. Specifically, the support element may be located immediately downstream of the aerosol generating element and may be adjacent to a strip of the aerosol generating matrix.

[0143] The support element can be formed from any suitable material or combination of materials. For example, the support element can be formed from one or more materials selected from the group consisting of: cellulose acetate, cardboard, crimped paper such as crimped heat-resistant paper or crimped parchment, and polymeric materials such as low-density polyethylene (LDPE). In a preferred embodiment, the support element is formed from cellulose acetate. Other suitable materials include polyhydroxyalkanoate (PHA) fibers.

[0144] The support element may include a hollow tubular segment. In a preferred embodiment, the support element includes a hollow cellulose acetate tube.

[0145] The support element is substantially arranged to align with the strip. This means that the length dimension of the support element is arranged approximately parallel to the longitudinal direction of the strip and the article, for example, within + / - 10 degrees parallel to the longitudinal direction of the strip. In a preferred embodiment, the support element extends along the longitudinal axis of the strip.

[0146] The support element preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol-generating matrix strip and the outer diameter of the aerosol-generating article.

[0147] The support element may have an outer diameter between 5 mm and 12 mm, for example between 5 mm and 10 mm, or between 6 mm and 8 mm. In a preferred embodiment, the support element has an outer diameter of 7.2 mm + / - 10%.

[0148] The peripheral wall of the support element may have a thickness of at least 1 mm, preferably at least about 1.5 mm, and more preferably at least about 2 mm.

[0149] The support element may have a length between approximately 5 mm and approximately 15 mm.

[0150] Preferably, the support element has a length of at least about 6 mm, more preferably at least about 7 mm.

[0151] In a preferred embodiment, the support element has a length of less than about 12 mm, more preferably less than about 10 mm.

[0152] In some embodiments, the support element has a length of about 5 mm to about 15 mm, preferably about 6 mm to about 15 mm, more preferably about 7 mm to about 15 mm. In other embodiments, the support element has a length of about 5 mm to about 12 mm, preferably about 6 mm to about 12 mm, more preferably about 7 mm to about 12 mm. In still other embodiments, the support element has a length of about 5 mm to about 10 mm, preferably about 6 mm to about 10 mm, more preferably about 7 mm to about 10 mm.

[0153] In a preferred embodiment, the support element has a length of approximately 8 millimeters.

[0154] Preferably, the intermediate hollow section has a total length of no more than about 18 mm, more preferably no more than about 17 mm, and even more preferably no more than 16 mm.

[0155] Preferably, in the aerosol-generating article according to the invention, the support element has an average radial hardness of at least about 80%, more preferably at least about 85%, and even more preferably at least about 90%. Therefore, the support element is able to provide the desired hardness level for the aerosol-generating article. If desired, the radial hardness of components (such as the support element) in the downstream section of the aerosol-generating article according to the invention can be further increased by defining an aerosol cooling element with a rigid rod package (e.g., a rod package having a basis weight of at least about 80 grams per square meter (gsm), or at least about 100 gsm, or at least about 110 gsm).

[0156] As used herein, the term "radial hardness" refers to compressive resistance in a direction transverse to the longitudinal axis of the support element. The radial hardness of an aerosol-generated article around the support element can be determined by applying a load across the article at the location of the support element, transverse to the longitudinal axis of the article, and measuring the average (mean) indentation diameter of the article. The radial hardness is given by the following formula:

[0157] Radial hardness (%) = (D d / D S )*100

[0158] Where D S It is the original (un-dimpled) diameter, and D d It is the diameter of the indentation after a set load is applied within a set duration. The harder the material, the closer the hardness is to 100%.

[0159] To determine the hardness of a portion of an aerosol-generating article (such as a support element provided in the form of a hollow tube segment), the aerosol-generating articles should be aligned parallel in a plane, and the same portion of each aerosol-generating article to be tested should be subjected to a set load for a set duration. This test is performed using a known DD60A densitometer device (manufactured and commercially available by Heinr. Borgwaldt GmbH, Germany), which is equipped with a measuring head for aerosol-generating articles (such as cigarettes) and an aerosol-generating article container.

[0160] The load is applied using two load-applying cylindrical strips that extend simultaneously across the diameter of all aerosol-generating articles. According to the standard testing method for this instrument, the test should be performed such that twenty contact points appear between the aerosol-generating articles and the load-applying cylindrical strips. In some cases, the hollow tube segment to be tested may be long enough that only ten aerosol-generating articles are needed to form twenty contact points, with each smoking article contacting both load-applying strips (because they are long enough to extend between these strips). In other cases, if the support element is too short to achieve this, twenty aerosol-generating articles should be used to form twenty contact points, with each aerosol-generating article contacting only one of the load-applying strips, as discussed further below.

[0161] Two additional fixed cylindrical bars are located below the aerosol-generating article to support the aerosol-generating article and counteract the load applied by each of the cylindrical bars by these loads.

[0162] For the standard operating procedure for such equipment, a total load of 2 kg is applied for a duration of 20 seconds. After 20 seconds (while the load is still applied to the smoking article), the indentation in the load-applied cylindrical strip is determined and then used to calculate the hardness according to the above formula. The temperature is maintained in the range of 22 degrees Celsius ± 2 degrees. The above test is known as the DD60A test. The standard way to measure the hardness of a filter tip is when the aerosol-generated article has not yet been consumed. Additional information regarding the measurement of average radial hardness can be found, for example, in U.S. Patent Application Publication No. 2016 / 0128378.

[0163] During the insertion of the aerosol generating article according to the invention into the aerosol generating apparatus to heat the aerosol generating matrix, the user may need to apply force to overcome the resistance of the aerosol generating matrix to insertion. This can damage one or both of the aerosol generating article and the aerosol generating apparatus. Additionally, the force applied during insertion of the aerosol generating article into the aerosol generating apparatus can cause displacement of the aerosol generating matrix within the aerosol generating article. This may result in the heating element of the aerosol generating apparatus not being properly aligned with the sensors disposed within the aerosol generating matrix, potentially leading to uneven and inefficient heating of the aerosol generating matrix of the aerosol generating article. The support element is advantageously configured to prevent downstream movement of the aerosol generating matrix during insertion of the article into the aerosol generating apparatus.

[0164] Preferably, the hollow tubular segments of the hollow tubular element are 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). The support element therefore preferably does not contribute to the total RTD of the aerosol-generating article.

[0165] In some preferred embodiments, the downstream section of the aerosol generating article includes a mouthpiece element located downstream of the aerosol generating element and longitudinally aligned with the aerosol generating element.

[0166] Preferably, the mouthpiece element is located at the downstream end or mouth end of the aerosol generating article and extends all the way to the mouth end of the aerosol generating article.

[0167] Preferably, the mouthpiece element includes at least one mouthpiece filter segment of a fibrous filter material for filtering aerosols generated from the aerosol generating matrix. Suitable fibrous filter materials will be known to those skilled in the art. Particularly preferably, at least one mouthpiece filter segment comprises a cellulose acetate filter segment formed from cellulose acetate tow.

[0168] A mouthpiece element may consist of a single mouthpiece filter segment. A mouthpiece element may include two or more mouthpiece filter segments aligned axially with each other in an adjacent-end-to-end relationship.

[0169] The downstream section may include an end cavity at the downstream end of the mouthpiece element as described above. The end cavity may be defined by a hollow tubular element located at the downstream end of the mouthpiece. The end cavity may be defined by an outer casing of the mouthpiece element, wherein the outer casing extends from the mouthpiece element in the downstream direction.

[0170] 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.

[0171] In the aerosol generating article according to the invention, the mouthpiece element forms part of the downstream section and is therefore located downstream of the aerosol generating element.

[0172] In some preferred embodiments, the downstream section of the aerosol generating article further includes a support element located immediately downstream of the aerosol generating element and a mouthpiece element located downstream of the support element.

[0173] Preferably, the mouthpiece element has a low particle filtration efficiency.

[0174] Preferably, the mouthpiece is formed from segments of fibrous filter material.

[0175] Preferably, the mouthpiece element is defined by a core packing. Preferably, the mouthpiece element is non-ventilated, preventing air from entering the aerosol-forming article along the mouthpiece element.

[0176] The mouthpiece element is preferably connected to one or more adjacent upstream components of the aerosol-generating article by means of a tipping package.

[0177] 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.

[0178] 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.

[0179] 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.

[0180] The mouthpiece element preferably has a length of at least about 5 mm, more preferably at least about 8 mm, and even more preferably at least about 10 mm. The mouthpiece element preferably has a length of less than about 25 mm, more preferably less than about 20 mm, and even more preferably less than about 15 mm.

[0181] In some embodiments, the mouthpiece element preferably has a length from about 5 mm to about 25 mm, more preferably from about 8 mm to about 25 mm, and even more preferably from about 10 mm to about 25 mm. In other embodiments, the mouthpiece element preferably has a length from about 5 mm to about 10 mm, more preferably from about 8 mm to about 20 mm, and even more preferably from about 10 mm to about 20 mm. In still other embodiments, the mouthpiece element preferably has a length from about 5 mm to about 15 mm, more preferably from about 8 mm to about 15 mm, and even more preferably from about 10 mm to about 15 mm.

[0182] For example, the mouthpiece element may have a length between about 5 mm and about 25 mm, or between about 8 mm and about 20 mm, or between about 10 mm and about 15 mm. In a preferred embodiment, the mouthpiece element has a length of about 12 mm.

[0183] In a particularly preferred embodiment, the downstream section may further include an aerosol cooling element located downstream of the support element, wherein the mouthpiece element is located downstream of both the support element and the aerosol cooling element. Particularly preferably, the mouthpiece element is located immediately downstream of the aerosol cooling element. For example, the mouthpiece element may be adjacent to the downstream end of the aerosol cooling element.

[0184] Aerosol cooling elements can, for example, define multiple longitudinally extending channels to provide a high surface area for heat exchange. The multiple longitudinally extending channels can be defined by a sheet material that has been pleated, gathered, or folded to form the channels. Alternatively, the multiple longitudinally extending channels can be defined by a single sheet that has been pleated, gathered, and folded to form multiple channels. The sheet may have been rolled up before pleating, gathering, or folding. Alternatively, the multiple longitudinally extending channels can be defined by multiple sheets that have been rolled up, pleated, gathered, and folded to form multiple channels. In some embodiments, the multiple longitudinally extending channels can be defined by multiple sheets that have been rolled up, pleated, gathered, or folded together, i.e., by two or more sheets that have been incorporated into the overlay arrangement and then rolled up, pleated, gathered, or folded into one.

[0185] Such an aerosol cooling element can have a total surface area between approximately 300 square millimeters per millimeter of length and approximately 1000 square millimeters per millimeter of length.

[0186] Such an aerosol cooling element preferably provides low resistance to airflow through the additional cooling element. Preferably, the aerosol cooling element substantially does not affect the suction resistance of the aerosol-generating article. The aerosol cooling element preferably comprises a sheet material selected from metal foil, polymer sheets, and substantially non-porous paper or paperboard. In some embodiments, the aerosol cooling element may comprise a sheet material selected from the group consisting of: polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), and aluminum foil. In a particularly preferred embodiment, the additional cooling element comprises a sheet of PLA.

[0187] The aerosol generating article may also include an upstream section located upstream of the aerosol generating element. The upstream section may include one or more upstream elements. In some embodiments, the upstream section may include an upstream element arranged immediately upstream of the aerosol generating element.

[0188] The aerosol generating article of the present invention preferably includes an upstream element located upstream of and adjacent to the aerosol generating element, wherein the upstream section includes at least one upstream element. The upstream element advantageously prevents direct physical contact with the upstream end of the aerosol generating matrix. In particular, the upstream element can prevent direct physical contact with the upstream end of a receptor element disposed within the aerosol generating element. This helps prevent displacement or deformation of the receptor element during handling or transport of the aerosol generating article. This, in turn, helps to maintain the shape and position of the receptor element. Furthermore, the presence of the upstream element helps to prevent any loss of the matrix.

[0189] Upstream components can also provide an improved appearance for the upstream end of the aerosol-generating article. Furthermore, if desired, upstream components can be used to provide information about the aerosol-generating article, such as the brand, flavor, contents, or details of the aerosol-generating apparatus to which the article is intended to be used.

[0190] The upstream element may be a porous rod element. Preferably, the porous rod element does not alter the suction resistance of the aerosol-generating article. Preferably, the upstream element has at least about 50% porosity in the longitudinal direction of the aerosol-generating article. More preferably, the upstream element has between about 50% and about 90% porosity in the longitudinal direction. The porosity of the upstream element in the longitudinal direction is defined by the ratio of the cross-sectional area of ​​the material forming the upstream element to the internal cross-sectional area of ​​the aerosol-generating article at the location of the upstream element.

[0191] The upstream element may be made of a porous material or may include multiple openings. For example, this can be achieved by laser perforation. Preferably, the multiple openings are homogeneously distributed across the cross-section of the upstream element.

[0192] The porosity or permeability of upstream components can be advantageously varied in order to provide the desired overall suction resistance for aerosol-generated articles.

[0193] Preferably, the RTD of the upstream element is at least about 5 mm H2O. More preferably, the RTD of the upstream element is at least about 10 mm H2O. Even more preferably, the RTD of the upstream element is at least about 15 mm H2O. In a particularly preferred embodiment, the RTD of the upstream element is at least about 20 mm H2O.

[0194] The RTD of the upstream element is preferably less than or equal to about 80 mmH2O. More preferably, the RTD of the upstream element is less than or equal to about 60 mmH2O. Even more preferably, the RTD of the upstream element is less than or equal to about 40 mmH2O.

[0195] In some embodiments, the RTD of the upstream element is from about 5 mm H2O to about 80 mm H2O, preferably from about 10 mm H2O to about 80 mm H2O, more preferably from about 15 mm H2O to about 80 mm H2O, and even more preferably from about 20 mm H2O to about 80 mm H2O. In other embodiments, the RTD of the upstream element is from about 5 mm H2O to about 60 mm H2O, preferably from about 10 mm H2O to about 60 mm H2O, more preferably from about 15 mm H2O to about 60 mm H2O, and even more preferably from about 20 mm H2O to about 60 mm H2O. In yet another embodiment, the RTD of the upstream element is from about 5 mm H2O to about 40 mm H2O, preferably from about 10 mm H2O to about 40 mm H2O, more preferably from about 15 mm H2O to about 40 mm H2O, and even more preferably from about 20 mm H2O to about 40 mm H2O.

[0196] The upstream components can be formed of an impermeable material. Aerosol-generating articles can be constructed such that air flows into the strips of the aerosol-generating matrix through suitable ventilation means provided in the packaging.

[0197] The upstream element can be made of any material suitable for use in aerosol-generating articles. The upstream element can be made, for example, of the same material as one of the other components used in the aerosol-generating article (e.g., a mouthpiece, cooling element, or support element). Suitable materials for forming the upstream element include filter materials, ceramics, polymer materials, cellulose acetate, cardboard, zeolite, or aerosol-generating matrices. Preferably, the upstream element is formed from cellulose acetate rods.

[0198] Preferably, the upstream element is formed of a heat-resistant material. For example, preferably, the upstream element is formed of a material that can withstand temperatures up to 350 degrees Celsius. This ensures that the upstream element is not adversely affected by the heating device used to heat the aerosol generation matrix.

[0199] Preferably, the diameter of the upstream element is approximately equal to the diameter of the aerosol-generated product.

[0200] Preferably, the upstream element has a length between about 1 mm and about 10 mm, more preferably between about 3 mm and about 8 mm, and more preferably between about 4 mm and about 6 mm. In a particularly preferred embodiment, the upstream element has a length of about 5 mm. The length of the upstream element can be advantageously varied to provide the desired overall length of the aerosol-generating article. For example, in cases where it is desirable to reduce the length of one of the other components of the aerosol-generating article, the length of the upstream element can be increased to maintain the same overall length of the article.

[0201] The upstream element preferably has a substantially homogeneous structure. For example, the upstream element may be substantially homogeneous in texture and appearance. The upstream element may, for example, have a continuous, regular surface over its entire cross-section. For example, the upstream element may lack identifiable symmetry.

[0202] The upstream component is preferably defined by packaging. The packaging defining the upstream component is preferably a rigid bar package, for example, a bar package having a basis weight of at least about 80 grams per square meter (gsm), at least about 100 gsm, or at least about 110 gsm. This provides structural stiffness to the upstream component.

[0203] Aerosol-generated articles can have a length of about 35 mm to about 100 mm.

[0204] Aerosol-generated articles can have a length of about 35 mm to about 100 mm.

[0205] Preferably, the overall length of the aerosol-generating article according to the invention is at least about 38 mm. More preferably, the overall length of the aerosol-generating article according to the invention is at least about 40 mm. Even more preferably, the overall length of the aerosol-generating article according to the invention is at least about 42 mm.

[0206] The overall length of the aerosol-generating article according to the present invention is preferably less than or equal to 70 mm. More preferably, the overall length of the aerosol-generating article according to the present invention is preferably less than or equal to 60 mm. Even more preferably, the overall length of the aerosol-generating article according to the present invention is preferably less than or equal to 50 mm.

[0207] In some embodiments, the overall length of the aerosol-generating article is preferably from about 38 mm to about 70 mm, more preferably from about 40 mm to about 70 mm, and even more preferably from about 42 mm to about 70 mm. In other embodiments, the overall length of the aerosol-generating article is preferably from about 38 mm to about 60 mm, more preferably from about 40 mm to about 60 mm, and even more preferably from about 42 mm to about 60 mm. In yet another embodiment, the overall length of the aerosol-generating article is preferably from about 38 mm to about 50 mm, more preferably from about 40 mm to about 50 mm, and even more preferably from about 42 mm to about 50 mm. In an exemplary embodiment, the overall length of the aerosol-generating article is about 45 mm.

[0208] The aerosol-generating article has an outer diameter of at least 5 mm. Preferably, the aerosol-generating article has an outer diameter of at least 6 mm. More preferably, the aerosol-generating article has an outer diameter of at least 7 mm.

[0209] Preferably, the aerosol-generating article has an outer diameter of about 12 mm or less. More preferably, the aerosol-generating article has an outer diameter of about 10 mm or less. Even more preferably, the aerosol-generating article has an outer diameter of about 8 mm or less.

[0210] In some embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 12 mm, preferably about 6 mm to about 12 mm, and more preferably about 7 mm to about 12 mm. In other embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 10 mm, preferably about 6 mm to about 10 mm, and more preferably about 7 mm to about 10 mm. In still other embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 8 mm, preferably about 6 mm to about 8 mm, and more preferably about 7 mm to about 8 mm.

[0211] Preferably, the aerosol generating article according to the invention comprises, in a linear sequence: an upstream element, an aerosol generating element located downstream of the upstream element, a support element located downstream of the aerosol generating element, a mouthpiece element located downstream of the support element, and an outer packaging defining the upstream element, the aerosol generating element, the support element, and the mouthpiece element.

[0212] More specifically, the aerosol generating element may be adjacent to the upstream element. The support element may be adjacent to the aerosol generating element. The aerosol cooling element may be adjacent to the support element. The nozzle element may be adjacent to the aerosol cooling element.

[0213] The aerosol-generated product has a generally cylindrical shape and an outer diameter of about 7.25 mm.

[0214] The upstream component has a length of approximately 5 mm, the aerosol generating component has a length of approximately 12 mm, the support component has a length of approximately 16 mm, and the mouthpiece component has a length of approximately 12 mm. Therefore, the overall length of the aerosol generating article is approximately 45 mm.

[0215] The upstream components are in the form of cellulose acetate core rods packaged in rigid core rod packaging.

[0216] The aerosol generating article includes an elongated receptor arranged substantially longitudinally within and thermally coupled to the aerosol generating matrix. The receptor is in the form of a strip or blade, having a length substantially equal to the length of the aerosol generating element and a thickness of approximately 60 micrometers.

[0217] The support element is in the form of a hollow cellulose acetate tube and has an inner diameter of approximately 1.9 mm. Therefore, the thickness of the peripheral wall of the support element is approximately 2.675 mm.

[0218] The mouthpiece is in the form of a low-density cellulose acetate filter segment.

[0219] The aerosol-generating matrix contains homogenized tobacco.

[0220] The coating composition covers most of the outer surface of the receptor, preferably substantially the entire outer surface of the receptor.

[0221] As briefly mentioned above, the aerosol-generated articles according to the present invention can be manufactured at high speed by implementing suitable methods on existing equipment without requiring major modifications.

[0222] In one such method, in a first step, an aerosol-generating matrix comprising homogenized tobacco material containing an aerosol-forming agent is provided. In a second step, a protected coated receptor is provided, wherein the protected coated receptor comprises a receptor element coated with a coating composition and a protective layer applied over the coating composition, the coating composition containing an aerosol-forming agent and isolated nicotine or a monoproton nicotine salt, or both. In a third step, the protective layer is removed to expose the coating composition and an unprotected coated receptor is provided. In a fourth step, the unprotected coated receptor and the aerosol-generating matrix form an aerosol-generating element, such that the unprotected coated receptor is arranged within the aerosol-generating element and configured to heat the homogenized tobacco material in the aerosol-generating matrix.

[0223] According to this method, the coated receptors can be advantageously stored in a protected state, in which the coating composition is effectively preserved. Because the protective layer is removed only just before the coated receptors are combined with the aerosol-generating matrix to form an aerosol-generating element, the coating composition is advantageously protected from dust or other potential contaminants, for example, during storage or transport. Furthermore, providing such a protective layer prevents the layers of the coated receptors from adhering to each other, for example, if the coated receptors are supplied wound in a spool. The protective layer can be, for example, in the form of a metal foil such as aluminum foil, and can be removed mechanically. In one embodiment, a continuous strip of the protected coated receptors can be supplied forward through a foil removal unit, in which the protective layer is removed, for example, by a wedge, and wound. The continuous strip of coated receptors exiting the foil removal unit can be supplied together with sheets of homogenized tobacco material and packaging material to be incorporated into the continuous strip into a cone or funnel, whereby the continuous strip can then be cut into segments of predetermined lengths.

[0224] In another suitable method, in the first step, an aerosol-generating matrix comprising homogenized tobacco material containing an aerosol-forming agent is provided. In the second step, a receptor element is provided. In the third step, the receptor element is coated with a coating composition comprising the aerosol-forming agent and isolated nicotine or monoproton nicotine salt, or both, to provide a coated receptor. In the fourth step, the coated receptor and the aerosol-generating matrix form an aerosol-generating element, such that the coated receptor is arranged within the aerosol-generating element and configured to heat the homogenized tobacco material.

[0225] According to this method, the coating composition can be applied to the outer surface of the receptor element at the same location where the receptor to be coated and the aerosol-generating matrix are combined. This can be achieved by dispensing the coating composition onto a metal strip forming the receptor element. The coated receptor thus formed can be fed together with sheets of homogenized tobacco material and sheets of packaging material into a cone or funnel to provide a continuous semi-finished strip, which can then be cut into segments of predetermined lengths.

[0226] The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. 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.

[0227] Example 1. An aerosol generating article for generating an inhalable aerosol upon heating, the aerosol generating article comprising: an aerosol generating element, the aerosol generating element including an aerosol generating matrix, wherein the aerosol generating matrix comprises homogenized tobacco material, the homogenized tobacco material comprising an aerosol forming agent; and a receptor disposed within the aerosol generating element and configured to heat the homogenized tobacco material, the receptor being coated with a coating composition comprising at least 20% by weight of an aerosol forming agent, the coating composition further comprising isolated nicotine or a monoproton nicotine salt or both.

[0228] Example 2. An aerosol-generated article according to Example 1, wherein the receptor is surrounded by homogenized tobacco material.

[0229] Example 3. An aerosol generating article according to Example 1 or 2, wherein the receptor is an elongated receptor extending longitudinally within the aerosol generating element.

[0230] Example 4. An aerosol-generating article according to any one of Examples 1 to 3, wherein the homogenized tobacco material is provided as an aggregated sheet of homogenized tobacco material.

[0231] Example 5. An aerosol generating article according to any of the foregoing examples, wherein the coating composition comprises at least one gelling agent forming a solid medium, the aerosol forming agent being dispersed in the solid medium, wherein isolated nicotine or monoproton nicotine salt or both are dispersed in the aerosol forming agent.

[0232] Example 6. An aerosol-generating article according to Example 5, wherein the gelling agent comprises carboxymethyl cellulose (CMC) or hydroxypropyl methyl cellulose (HPMC) or both and the aerosol forming agent comprises glycerol.

[0233] Example 7. An aerosol generating article according to any of the foregoing examples, wherein the aerosol forming agent accounts for at least about 50% by weight of the coating composition.

[0234] Example 8. An aerosol-generating article according to any of the foregoing examples, wherein the separated nicotine or nicotine salt or both constitute at least about 0.5% by weight of the coating composition.

[0235] Example 9. An aerosol-generating article according to any of the preceding examples, wherein the coating composition forms a layer on the outer surface of the receptor, the layer having a thickness of at least about 1 micrometer.

[0236] Example 10. An aerosol generating article according to any of the foregoing examples, wherein the aerosol forming agent content in the coating composition accounts for at least about 0.25% of the total aerosol forming agent content in the aerosol generating article.

[0237] Example 11. An aerosol generating article according to any of the preceding examples, comprising a downstream section located downstream of an aerosol generating element, wherein the downstream section includes a support element located immediately downstream of the aerosol generating element, the support element being longitudinally aligned with the aerosol generating element and comprising a hollow tubular segment.

[0238] Example 12. An aerosol-generating article according to Example 11, comprising a mouthpiece element located downstream of the support element.

[0239] Example 13. An aerosol generating article according to any of the preceding examples, comprising an upstream section located upstream of an aerosol generating element, the upstream section comprising an upstream element positioned immediately upstream of the aerosol generating element and having a suction resistance (RTD) of less than about 80 mm H2O.

[0240] Example 14. A method of manufacturing an aerosol-generating article for generating an inhalable aerosol upon heating, the method comprising: providing an aerosol-generating matrix comprising homogenized tobacco material, the homogenized tobacco material comprising an aerosol forming agent; providing a protected coated receptor, wherein the protected coated receptor comprises a receptor element coated with a coating composition and a protective layer applied over the coating composition, the coating composition comprising an aerosol forming agent and isolated nicotine or a monoproton nicotine salt or both; removing the protective layer to expose the coating composition and providing an unprotected coated receptor; combining the unprotected coated receptor with the aerosol-generating matrix to form an aerosol-generating element such that the unprotected coated receptor is arranged within the aerosol-generating element and configured to heat the homogenized tobacco material.

[0241] Example 15. A method of manufacturing an aerosol-generating article for generating an inhalable aerosol upon heating, the method comprising: providing an aerosol-generating matrix comprising homogenized tobacco material, the homogenized tobacco material comprising an aerosol forming agent; providing a receptor element; coating the receptor element with a coating composition comprising the aerosol forming agent and isolated nicotine or monoproton nicotine salt or both to provide a coated receptor; combining the coated receptor with the aerosol-generating matrix to form an aerosol-generating element such that the coated receptor is disposed within the aerosol-generating element and configured to heat the homogenized tobacco material.

[0242] In the following description, the invention will be further described with reference to the accompanying drawings, wherein:

[0243] Figure 1 The changes in aerosol delivery over time during the use of the aerosol-generated article according to the invention are qualitatively illustrated.

[0244] Figure 2A schematic side sectional view of the aerosol-generated article according to the present invention is shown; and

[0245] Figure 3 A schematic perspective view of a coated receptor for use in an aerosol-generating article according to the invention is shown.

[0246] Figure 2 The aerosol generating article 10 shown includes an aerosol generating element 12 comprising an aerosol generating matrix, and a downstream section 14 located downstream of the aerosol generating element 12. Furthermore, the aerosol generating article 10 includes an upstream section 16 located upstream of the aerosol generating element 12. Therefore, the aerosol generating article 10 extends from an upstream end or distal end 18 to a downstream end or port end 20.

[0247] The aerosol-generated product has an overall length of approximately 45 millimeters.

[0248] The downstream section 14 includes a support element 22 located immediately downstream of the aerosol generating element 12, the support element 22 being longitudinally aligned with the aerosol generating element 12. Figure 2 In one embodiment, the upstream end of the support element 18 is adjacent to the downstream end of the aerosol generating element 12.

[0249] The support element 22 includes a hollow tubular segment 24. The hollow tubular segment 24 is provided in the form of a hollow cylindrical tube made of cellulose acetate. The hollow tubular segment 24 defines an inner cavity 26 extending from the upstream end 30 of the hollow tubular segment 20 to the downstream end 32 of the hollow tubular segment 20. The inner cavity 26 is substantially empty, and therefore allows for substantially unrestricted airflow along the inner cavity 26. The hollow tubular segment 24, and therefore the support element 22, substantially does not contribute to the overall RTD of the aerosol-generating article 10. More specifically, the RTD of the first hollow tubular segment 24 (which is substantially the RTD of the support element 22) is substantially 0 mmH2O.

[0250] The hollow tubular segment 24 has a length of about 16 mm, an outer diameter of about 7.25 mm, and an inner diameter of about 1.9 mm. Therefore, the thickness of the peripheral wall of the first hollow tubular segment 26 is about 2.67 mm.

[0251] exist Figure 2 In one embodiment, the downstream section 14 further includes a mouthpiece element 42 located downstream of the support element 22. More specifically, the mouthpiece element 42 is positioned immediately downstream of the support element 22. Figure 2 As shown in the figure, the upstream end of the mouthpiece element 42 is adjacent to the downstream end 40 of the support element 22.

[0252] The mouthpiece element 42 is provided in the form of a cylindrical filter segment of low-density cellulose acetate.

[0253] 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.

[0254] The aerosol generating element 12 includes a sheet of homogenized tobacco material aggregated to form a strip having an outer diameter of about 7.25 mm and a length of about 12 mm.

[0255] The aerosol generating article 10 also includes an elongated receptor 44 within the aerosol generating matrix 12. More specifically, the receptor 44 is arranged substantially longitudinally within the aerosol generating matrix so as to be generally parallel to the longitudinal direction of the aerosol generating element 12. Figure 2 As shown in the figure, the receptor 44 is positioned at the radial center within the strip and extends effectively along the longitudinal axis of the aerosol generating element 12.

[0256] The receptor 44 extends from the upstream end of the aerosol generating element 12 to the downstream end. In fact, the receptor 44 has a length that is substantially the same as that of the aerosol generating element.

[0257] exist Figure 2 In one embodiment, the sensor 44 is provided in the form of a metal strip and has a length of about 12 mm, a thickness of about 60 micrometers, and a width of about 4 mm.

[0258] The upstream section 16 includes an upstream element 46 located immediately upstream of the aerosol generating element 12, the upstream element 46 being longitudinally aligned with the aerosol generating element 12. Figure 1 In this embodiment, the downstream end of the upstream element 46 is adjacent to the upstream end of the aerosol generating element 12. This advantageously prevents the sensor 44 from being removed. Furthermore, this ensures that the consumer will not accidentally come into contact with the heated sensor 44 after use.

[0259] 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.

[0260] Figure 3 The sensor 44 is shown in more detail. The outer surface of the metal strip is coated with a layer 48 of the coating composition, which has a thickness of about 30 micrometers.

[0261] Table 1 below shows an example of a suitable coating composition:

[0262] Table 1: Coating Compositions

[0263]

[0264] like Figure 3As shown, the top side 50 and bottom side 52 of the strip of receptor 44 are both coated with corresponding layers 54, 56 comprising a coating composition. Furthermore, Figure 3 The diagram illustrates how, according to one of the manufacturing methods described above, a protective layer 58, 60 can be applied to the receptor 44 over layers 54, 56 containing the coating composition.

[0265] For the purposes of this specification and the appended claims, unless otherwise indicated, all figures representing quantities, quantities, percentages, etc., shall be understood to be modified by the term "about" in all cases. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein. Thus, in this document, the number A is understood to be ±10% of A. In this document, the number A may be considered to include a value within the general standard error of the measurement of the property modified by the number A. In some cases as used in the appended claims, the number A may deviate from the percentage listed above, provided that the amount of deviation from A does not significantly affect the fundamental and novel features of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein.

Claims

1. An aerosol generating article for producing an inhalable aerosol upon heating, the aerosol generating article comprising: An aerosol generating element, the aerosol generating element comprising an aerosol generating matrix, wherein the aerosol generating matrix comprises homogenized tobacco material, and the homogenized tobacco material comprises an aerosol forming agent; and A receptor, disposed within the aerosol generating element and configured to heat the homogenized tobacco material, the receptor being coated with a coating composition comprising at least 20% by weight of an aerosol forming agent, the coating composition further comprising 0.5% to 10% by weight of isolated nicotine or a tobacco-derived monoproton nicotine salt or both.

2. The aerosol-generating article according to claim 1, wherein the receptor is surrounded by the homogenized tobacco material.

3. The aerosol generating article according to claim 1 or 2, wherein the receptor is an elongated receptor and extends longitudinally within the aerosol generating element.

4. The aerosol-generating article according to claim 1 or 2, wherein the homogenized tobacco material is provided as an aggregated sheet of homogenized tobacco material.

5. The aerosol generating article according to claim 1 or 2, wherein the coating composition comprises at least one gelling agent forming a solid medium, the aerosol forming agent being dispersed in the solid medium, wherein the isolated nicotine or monoproton nicotine salt or both are dispersed in the aerosol forming agent.

6. The aerosol generating article according to claim 5, wherein the gelling agent comprises carboxymethyl cellulose (CMC) or hydroxypropyl methyl cellulose (HPMC) or both and the aerosol forming agent comprises glycerol.

7. The aerosol generating article according to claim 1 or 2, wherein the aerosol forming agent accounts for at least 50% by weight of the coating composition.

8. The aerosol-generating article according to claim 1 or 2, wherein the coating composition forms a layer on the outer surface of the receptor, the layer having a thickness of at least 1 micrometer.

9. The aerosol generating article according to claim 1 or 2, wherein the aerosol forming agent content in the coating composition accounts for at least 0.25% of the total aerosol forming agent content in the aerosol generating article.

10. The aerosol generating article according to claim 1 or 2, wherein the aerosol generating article includes a downstream section located downstream of the aerosol generating element, wherein the downstream section includes a support element located immediately downstream of the aerosol generating element, the support element being longitudinally aligned with the aerosol generating element and including a hollow tubular segment.

11. The aerosol generating article according to claim 10, wherein the aerosol generating article includes a mouthpiece element located downstream of the support element.

12. The aerosol generating article according to claim 1 or 2, wherein the aerosol generating article includes an upstream section located upstream of the aerosol generating element, the upstream section including an upstream element positioned adjacent to the upstream of the aerosol generating element and having a suction resistance (RTD) of less than 80 mmH2O.

13. A method for manufacturing an aerosol-generating article for generating an inhalable aerosol upon heating, the method comprising: An aerosol-generating matrix comprising homogenized tobacco material, wherein the homogenized tobacco material comprises an aerosol-forming agent; Provided a protected coated receptor, wherein the protected coated receptor comprises a receptor element coated with a coating composition and a protective layer applied over the coating composition, the coating composition comprising an aerosol forming agent and 0.5% to 10% by weight of isolated nicotine or a tobacco-derived monoproton nicotine salt or both. Remove the protective layer to expose the coating composition and provide unprotected coated receptors; The unprotected coated receptor is combined with the aerosol generating matrix to form an aerosol generating element, such that the unprotected coated receptor is arranged within the aerosol generating element and configured to heat the homogenized tobacco material.

14. A method for manufacturing an aerosol-generating article for generating an inhalable aerosol upon heating, the method comprising: An aerosol-generating matrix comprising homogenized tobacco material, wherein the homogenized tobacco material comprises an aerosol-forming agent; Provide sensory elements; The receptor element is coated with a coating composition comprising an aerosol forming agent and 0.5% to 10% by weight of isolated nicotine or tobacco-derived monoproton nicotine salt or both to provide a coated receptor. The coated sensor is combined with the aerosol generating matrix to form an aerosol generating element, such that the coated sensor is arranged within the aerosol generating element and configured to heat the homogenized tobacco material.

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