An aerosol-generating article comprising a wrapper having an overlap region

Abstract

An aerosol-generating article (10) comprising an aerosol-forming substrate (11) and a wrapper (30) defining the aerosol-forming substrate. The wrapper defines an overlap region (41) in which the wrapper overlaps itself, the overlap region comprising a first section (42) and a second section (43) disposed externally on the first section. The second section comprises a fold (44) defining a folded section (45) at one end of the wrapper, and the folded section is sandwiched between the first section and the second section. An external adhesive is disposed between the folded section and the second section.

Description

Technical Field

[0001] This invention relates to aerosol generating articles comprising an aerosol forming matrix. The aerosol generating articles can be used to generate inhalable aerosols when heated. Background Technology

[0002] Aerosol-generating articles are known in the art in which an aerosol-forming matrix (such as a tobacco-containing matrix) is heated rather than burned. The purpose of such heatable aerosol-generating articles is to reduce potentially harmful byproducts generated by the combustion and pyrolytic degradation of tobacco in conventional cigarettes.

[0003] In heatable aerosol-generating articles, inhalable aerosols are typically generated via heat transfer from a heater to an aerosol-forming matrix. During heating, volatile compounds are released from the aerosol-forming matrix and become entrained in the air. For example, volatile compounds can be entrained in air drawn in through, above, around, or otherwise near the aerosol-generating article. As the released volatile compounds cool, they condense to form an aerosol. The aerosol can be inhaled by a user. The aerosol may contain fragrances, flavors, nicotine, and other desired ingredients.

[0004] Heating elements may be included in the aerosol generating apparatus. The combination of the aerosol generating article and the aerosol generating apparatus forms an aerosol generating system.

[0005] Heated aerosol-generating articles may include one or more packages defining at least a portion of the aerosol-generating article. Advantageously, the one or more packages can prevent the user from handling the aerosol-forming matrix, which can help maintain a high level of hygiene. The provision of one or more packages can also help hold the components of the aerosol-generating article together.

[0006] However, when the packaging defines at least a portion of the aerosol-generating article, the packaging may include at least one free end disposed on a section of the packaging where the free ends overlap. This arrangement may be detrimental to the mechanical stability of the aerosol-generating article. It may also hinder the manufacture and handling of the aerosol-generating article.

[0007] Therefore, it is desirable to provide an aerosol-generating article that includes one or more packaging materials and has improved mechanical stability. Summary of the Invention

[0008] An aerosol-generating article may be provided. The aerosol-generating article may include packaging defining an aerosol-forming matrix. The packaging may define an overlapping region in which the packaging overlaps itself, the overlapping region including a first segment and a second segment externally disposed on the first segment. The second segment may include a fold or pleat defining a folded segment at one end of the packaging. The folded segment may be sandwiched between the first segment and the second segment.

[0009] An aerosol-generating article may be provided, the aerosol-generating article comprising:

[0010] Aerosol forming matrix; and

[0011] Packaging material that defines the aerosol forming matrix;

[0012] The packaging defines an overlapping area of ​​itself, the overlapping area including a first segment and a second segment externally disposed on the first segment;

[0013] The second section includes a fold or pleat that defines a folded section at one end of the package; and

[0014] The folded section is sandwiched between the first section and the second section.

[0015] The term "aerosol-generating article" is used herein to refer to an article in which an aerosol-forming matrix can be heated to generate an inhalable aerosol and delivered to a consumer. As used herein, the term "aerosol-forming matrix" refers to a matrix capable of releasing volatile compounds that can form aerosols. Such volatile compounds can be released by heating the aerosol-forming matrix. An aerosol-forming matrix is ​​typically part of an aerosol-generating article.

[0016] The aerosol-forming matrix may include nicotine. Nicotine-containing aerosol-forming matrix may be a nicotine salt matrix.

[0017] The aerosol forming matrix may include a liquid. The aerosol forming matrix may include both solid and liquid components. Preferably, the aerosol forming matrix may include a solid.

[0018] Aerosol forming matrices can include plant-based materials. Aerosol forming matrices can include tobacco. Aerosol forming matrices can include tobacco-containing materials, which include volatile tobacco aroma compounds released from the aerosol forming matrix upon heating. Aerosol forming matrices can include non-tobacco materials. Aerosol forming matrices can include homogenized plant-based materials.

[0019] As used herein, the term "aerosol generating apparatus" typically includes a heater that interacts with an aerosol-forming matrix of an aerosol generating article to generate an aerosol.

[0020] 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.

[0021] 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 aerosols are transported through the aerosol-generating article during use.

[0022] 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 "section" of an aerosol-generating article or a component of an aerosol-generating article refers to a cross-section.

[0023] The term "length" refers to the longitudinal dimension of a component of an aerosol-generated article.

[0024] By providing a folded section at one end of the packaging, with the folded section sandwiched between the first and second sections of the packaging, the end of the packaging is not positioned overlapping the free end of the second section on the first section of the packaging. Therefore, the folded section can improve the mechanical stability of the aerosol-generating article comprising the packaging.

[0025] Because the folded section is sandwiched between the first and second sections, it does cause significant irregularities on the outer surface of the packaging. This may be advantageous for handling aerosol-generating articles during manufacturing and transportation.

[0026] Compared to other packaging configurations that include folded sections, a configuration where the folded sections are defined by folds or pleats included in a second section of the packaging may be desirable because this configuration avoids the formation of irregular recesses within the internal space defined by the packaging or minimizes the size of such irregular recesses. Since the internal space defined by the packaging is expected to contain an aerosol-forming matrix, this arrangement allows for a reduction in the amount of aerosol-forming matrix required for manufacturing aerosol-generating articles. It can also improve the manufacturing process, as irregular recesses can make the insertion of the aerosol-forming matrix more difficult and time-consuming.

[0027] An internal adhesive may be disposed between the folded section and the first section. An external adhesive may be disposed between the folded section and the second section. Providing either an internal or external adhesive can help improve the mechanical stability of the aerosol-generated article. A greater improvement in mechanical stability can be achieved when both internal and external adhesives are provided.

[0028] The internal and external adhesives can be the same adhesive.

[0029] The folded section may extend at least about 0.75 mm around the periphery of the aerosol-forming matrix, or at least about 1 mm around the periphery of the aerosol-forming matrix.

[0030] The folded section may extend up to about 2.5 mm around the aerosol-forming matrix or up to about 2 mm around the aerosol-forming matrix.

[0031] Preferably, the folded section extends between about 0.75 mm and about 2.5 mm around the periphery of the aerosol-forming matrix, or between about 0.75 mm and about 2 mm around the periphery of the aerosol-forming matrix, or between about 1 mm and 2.5 mm around the periphery of the aerosol-forming matrix. More preferably, the folded section extends between about 1 mm and about 2 mm around the periphery of the aerosol-forming matrix.

[0032] The folded section may extend at least about 3% of the periphery of the aerosol-forming matrix, or at least about 4% of the periphery of the aerosol-forming matrix.

[0033] The folded section may extend over up to about 12% of the periphery of the aerosol-forming matrix, or up to about 10% of the periphery of the aerosol-forming matrix.

[0034] Preferably, the folded section extends between about 3% and about 12% of the periphery of the aerosol-forming matrix, or between about 3% and about 10% of the periphery of the aerosol-forming matrix, or between about 4% and about 12% of the periphery of the aerosol-forming matrix. More preferably, the folded section extends between about 4% and about 10% of the periphery of the aerosol-forming matrix.

[0035] The second section may extend at least about 0.75 mm around the aerosol-forming matrix, or at least about 1 mm around the aerosol-forming matrix.

[0036] The second section may extend up to about 2.5 mm around the aerosol-forming matrix or up to about 2 mm around the aerosol-forming matrix.

[0037] Preferably, the second segment extends between about 0.75 mm and about 2.5 mm around the periphery of the aerosol-forming matrix, or between about 0.75 mm and about 2 mm around the periphery of the aerosol-forming matrix, or between about 1 mm and 2.5 mm around the periphery of the aerosol-forming matrix. More preferably, the second segment extends between about 1 mm and about 2 mm around the periphery of the aerosol-forming matrix.

[0038] The second section may extend over at least about 3% of the periphery of the aerosol-forming matrix, or at least about 4% of the periphery of the aerosol-forming matrix.

[0039] The second section may extend over up to about 12% of the periphery of the aerosol-forming matrix, or up to about 10% of the periphery of the aerosol-forming matrix.

[0040] Preferably, the second section extends between about 3% and about 12% of the periphery of the aerosol-forming matrix, or between about 3% and about 10% of the periphery of the aerosol-forming matrix, or between about 4% and about 12% of the periphery of the aerosol-forming matrix. More preferably, the second section extends between about 4% and about 10% of the periphery of the aerosol-forming matrix.

[0041] The periphery of the aerosol forming matrix can also be referred to as the circumference of the aerosol forming matrix.

[0042] The packaging material may have a basis weight between approximately 10 g / m² and 28 g / m². Preferably, the packaging material may have a basis weight between approximately 10 g / m² and 16 g / m².

[0043] This range of basis weights may be advantageous in allowing for the formation of folded sections within the packaging.

[0044] The packaging material can have a porosity between about 30 and about 80 Coresta units. Preferably, the packaging material can have a porosity between about 30 and about 50 Coresta units. Most preferably, the packaging material can have a porosity between 30 and 40 Coresta units.

[0045] The packaging material can have a roughness between about 50 kek seconds and about 1000 kek seconds. More preferably, the packaging material can have a roughness between about 100 kek seconds and about 200 kek seconds.

[0046] Roughness, expressed in Bekk seconds, is measured using a standard test employing the BEKK smoothness tester, which generates a vacuum and measures the time it takes for the vacuum to decrease from 50.66 kPa to 48.00 kPa. This test is accredited by the international standard ISO 5627.

[0047] The internal adhesive may include one or more of the following: gum arabic, natural or synthetic resins, starch, and varnish. The external adhesive may include one or more of the following: gum arabic, natural or synthetic resins, starch, and varnish. This adhesive can be used to provide a strong adhesion in overlapping areas of packaging.

[0048] Heating elements can be embedded within an aerosol-forming matrix. Embedded heating elements are internal heating elements. As used herein, the term "internal heating element" refers to a heating element configured to be inserted into or disposed within an aerosol-forming matrix or fragrance matrix.

[0049] Aerosol generating articles, including heating elements embedded in an aerosol forming matrix, can be advantageous because when the aerosol generating articles are in use, enhanced heat distribution from the heating element to the aerosol forming matrix can be achieved.

[0050] The heating element can be a sensor.

[0051] As used herein, the term "sensor" refers to an element comprising materials capable of converting magnetic energy into heat. When a sensor is placed in a changing magnetic field, such as one generated by a sensor coil, the sensor is heated.

[0052] Heating of the sensor can result from hysteresis losses and / or eddy currents induced within the sensor, depending on the electrical and magnetic properties of the sensor material. In ferromagnetic or ferrimagnetic sensor materials, hysteresis losses occur due to the switching of magnetic domains within the material under the influence of a changing electromagnetic field. If the sensor material is conductive, eddy currents can be induced. In the case of conductive ferromagnetic or ferrimagnetic sensor materials, heat can be generated due to both eddy currents and hysteresis losses. Therefore, the sensor can be heated due to at least one of hysteresis losses or eddy currents, depending on the electrical and magnetic properties of the sensor material.

[0053] The heating element can be completely surrounded by the aerosol forming matrix and extend along the entire length of the aerosol forming matrix. This provides optimized heat distribution within the aerosol forming matrix when the heating element is heated.

[0054] The receptor can have a thickness of about 35 micrometers to about 85 micrometers. The receptor can have a thickness of about 45 micrometers to about 75 micrometers. The receptor can have a thickness of about 55 micrometers to about 65 micrometers.

[0055] It has been found that in aerosol-generating articles in which a receptor with the thickness described above is provided, heat generation and distribution throughout the aerosol-forming matrix can be achieved in a particularly effective and efficient manner. Without wishing to be bound by theory, the inventors believe this is likely because such a receptor is suited to provide optimal heat generation and heat transfer by means of the receptor surface area and inductive power. In contrast, thinner receptors may be too easily deformed and may not maintain the desired shape and orientation within the aerosol-forming matrix during the manufacture of the aerosol-generating article, potentially leading to a less uniform and finely tuned heat distribution during use. Simultaneously, thicker receptors may be more difficult to cut to a precise and consistent length, and this may also affect how accurately the receptor can be longitudinally aligned within the aerosol-forming matrix, thus potentially affecting the uniformity of heat distribution within the aerosol-forming matrix. These advantageous effects are particularly felt when the receptor extends to the downstream end of the aerosol-forming matrix. This is thought to be because the suction resistance (RTD) downstream of the receptor can therefore be substantially minimized, since there is no aerosol-forming matrix that can contribute to the RTD at the location downstream of the receptor within the aerosol-forming matrix.

[0056] The receptors can be elongated receptors arranged substantially longitudinally within the aerosol-forming matrix.

[0057] When used to describe receptors, the term "elongated" means that the receptor has a length dimension greater than its width or thickness dimension, for example, more than twice its width or thickness dimension.

[0058] The receptors can be arranged substantially longitudinally within the aerosol-forming matrix. This means that the length dimension of the elongated receptors is arranged approximately parallel to the longitudinal direction of the aerosol-forming matrix, for example, within plus or minus 10 degrees. The elongated receptors can be located at the radial center within the aerosol-forming matrix and extend along the longitudinal axis of the aerosol-forming matrix.

[0059] The receptor can have essentially the same length as the aerosol-forming matrix.

[0060] Receptors can take the form of needles, strips, bands, or sheets.

[0061] The receptor may have a length of about 5 mm to about 15 mm, for example about 6 mm to about 12 mm, more preferably about 8 mm to about 10 mm.

[0062] The receptor may have a width of at least about 1 mm, more preferably at least about 2 mm. Typically, the receptor may have a width of up to 8 mm, preferably less than or equal to about 6 mm.

[0063] When the receptor has a constant cross-section, such as a circular cross-section, it can have a width or diameter of about 1 mm to about 5 mm.

[0064] When the receptor is in the form of a strip or sheet, the strip or sheet may have a rectangular cross-section, preferably about 2 mm to about 8 mm, more preferably about 3 mm to about 6 mm wide. Receptors in strip or sheet form may have a width of about 4 mm.

[0065] The elongated receptor can have a thickness of about 57 micrometers to about 63 micrometers. More preferably, the elongated receptor can have a thickness of about 58 micrometers to about 62 micrometers. Most preferably, the elongated receptor has a thickness of about 60 micrometers.

[0066] The diameter of aerosol-generated articles can be between approximately 3 mm and approximately 8 mm.

[0067] The packaging material may have a thickness between about 60 micrometers and about 200 micrometers, preferably between about 78 micrometers and about 160 micrometers, more preferably between 78 micrometers and about 140 micrometers, even more preferably between about 100 micrometers and about 140 micrometers, and most preferably between about 125 micrometers and about 140 micrometers.

[0068] This range of packaging thickness can create a proper balance between the total thickness of the overlapping area and the thickness of the remaining portion of the packaging.

[0069] Aerosol forming matrix may include one or more of the following: tobacco, nicotine, gel components, and flavoring agents.

[0070] Advantageously, the gel component can be a solid at room temperature. In this context, "solid" means that the gel has a stable size and shape and does not flow. Room temperature in this context means 25 degrees Celsius. A gel can be defined as a substantially diluted cross-linked system that does not exhibit flowability at steady state. By weight, gels may be primarily liquid, but due to the three-dimensional cross-linked network within the liquid, they behave similarly to solids. It is the cross-linking within the fluid that gives the gel its structure (stiffness). Thus, a gel can be a dispersion of liquid molecules within a solid, where liquid particles are dispersed in a solid medium.

[0071] Aerosol-generating articles may include filters disposed in the longitudinal direction downstream of the aerosol-forming matrix.

[0072] The term "filter" is used to indicate a section of aerosol-generating articles configured to at least partially remove gaseous or particulate components, or both, from the mainstream aerosol drawn through the filter.

[0073] The length of aerosol-generated articles can be between approximately 30 mm and approximately 100 mm.

[0074] Aerosol-generating articles may include support elements disposed downstream of the aerosol-forming matrix.

[0075] Support elements are typically provided in the form of annular tubes of filter material, commonly referred to as hollow acetic acid tubes. These hollow tubular support elements are configured to resist downstream movement of the aerosol-forming matrix during processing of the aerosol-generating article, such as during the insertion of the heating element into the aerosol-forming matrix. The empty spaces within the hollow tubular support element can provide openings for the flow of aerosols from the aerosol-forming matrix toward the orifice of the aerosol-generating article.

[0076] The support element can be positioned immediately downstream of the aerosol forming matrix.

[0077] When an aerosol-generating article includes a filter and a support element, the filter may be positioned downstream of the support element in the longitudinal direction.

[0078] The filter can be positioned downstream of the support element in the longitudinal direction.

[0079] Since the support element can be useful and sufficient to provide customization of the formed aerosol according to user preferences, the filter can be positioned immediately downstream of the support element, i.e., without intermediate components such as aerosol cooling elements. Therefore, aerosol-generating articles can achieve a reduction in both gaseous and particulate phase components, while requiring fewer production steps and allowing for a more consistent experience.

[0080] However, the aerosol generating article may include an aerosol cooling element downstream of the support element. Preferably, the aerosol cooling element may be disposed between the support element and the filter.

[0081] As used herein, an "aerosol cooling element" refers to a component of an aerosol-generating article positioned downstream of the aerosol-forming matrix such that, during use, aerosols formed from volatile compounds released from the aerosol-forming matrix pass through and are cooled by the aerosol cooling element before being inhaled by the consumer. Preferably, the aerosol cooling element is positioned between the aerosol-forming matrix and the mouthpiece. Aerosol cooling elements have a large surface area but cause a low pressure drop. Filters and other mouthpieces that generate high pressure drops (e.g., filters formed from fiber bundles) are not considered aerosol cooling elements. Chambers and cavities within the aerosol-generating article are also not considered aerosol cooling elements.

[0082] The support element may include a first hollow tubular segment. The aerosol cooling element may include a second hollow tubular segment.

[0083] Aerosol generating articles may include a mouthpiece disposed at the downstream end of the aerosol generating article. It is desirable to provide a mouthpiece to facilitate the inhalation of aerosols by a user.

[0084] Aerosol generating articles may include upstream elements disposed at the upstream end of the aerosol generating article. When the aerosol generating article includes a sensor, this ensures that consumers do not accidentally come into contact with the heated sensor after use. When the aerosol generating article includes a sensor, the provision of the upstream element can advantageously prevent the sensor from being displaced.

[0085] The aerosol forming matrix can have any suitable cross-section. For example, the matrix can have a circular, oval, stadium-shaped, rectangular, or triangular cross-sectional shape. Preferably, the matrix has a circular cross-sectional shape.

[0086] Solid aerosol forming matrix may include tobacco sticks. Tobacco sticks may include one or more of the following: powder, granules, pellets, fragments, strands, strips, or sheets, containing one or more of the following: herbaceous leaves, tobacco leaves, tobacco ribs, expanded tobacco, and homogenized tobacco. As used herein, the term "homogenized tobacco material" refers to a material formed by agglomerating particulate tobacco. Providing homogenized tobacco material can improve aerosol generation, nicotine content, and aroma profile of aerosols generated during heating of aerosol-forming articles. Specifically, the process of manufacturing homogenized tobacco involves grinding tobacco leaves, which more effectively releases nicotine and aroma upon heating. When tobacco sticks include homogenized tobacco material, the homogenized tobacco material may be in the form of sheets. As used herein, the term "sheet" refers to a layered element having a width and a length significantly greater than its thickness.

[0087] Solid aerosol forming matrix may include homogenized tobacco material. Solid aerosol forming material may include fragments, strands, or strips of homogenized tobacco material. Solid aerosol forming matrix may include sheets of homogenized tobacco material.

[0088] The aerosol-forming matrix can have a substantially homogeneous composition. The aerosol-forming matrix can have a substantially homogeneous composition, at least in the longitudinal direction.

[0089] Homogenized tobacco material sheets can be formed by agglomerating particulate tobacco, which is obtained by grinding or otherwise pulverizing one or both of tobacco leaf blades and tobacco stems. Homogenized tobacco material sheets may include one or more of the following: tobacco dust, tobacco powder, and other particulate tobacco byproducts formed during, for example, the handling, processing, and transportation of tobacco. Homogenized tobacco material sheets are preferably formed by a casting process of the type typically comprising: casting a slurry comprising particulate tobacco and one or more binders onto a conveyor belt or other support surface; drying the cast slurry to form a homogenized tobacco material sheet; and removing the homogenized tobacco material sheet from the support surface.

[0090] Solid aerosol forming matrices may include aggregated sheets of homogenized tobacco material. As used herein, the term "aggregate" is used to describe sheets that are wound, folded, or otherwise compressed or shrunken substantially transverse to the longitudinal axis of the aerosol-generating article.

[0091] Aerosol-forming matrices comprise aggregated textured sheets of homogenized tobacco material. As used herein, the term "textured sheet" refers to a sheet that has been rolled, embossed, debossed, perforated, or otherwise deformed. Using textured sheets of homogenized tobacco material can advantageously facilitate the aggregation of homogenized tobacco material sheets to form an aerosol-forming matrix. An aerosol-forming matrix may comprise aggregated textured sheets of homogenized tobacco material comprising a plurality of spaced-apart recesses, protrusions, perforations, or combinations thereof.

[0092] Preferably, the aerosol-forming matrix comprises an aggregated curled sheet of homogenized tobacco material. As used herein, the term "curled sheet" refers to a sheet having a plurality of substantially parallel ridges or folds. Preferably, the substantially parallel ridges or folds extend along or parallel to the longitudinal axis of the aerosol-generating article. This advantageously facilitates the aggregation of the curled sheet of homogenized tobacco material to form the aerosol-generating article. However, it should be understood that the curled sheet of homogenized tobacco material included in the aerosol-generating article may have a plurality of substantially parallel ridges or folds arranged at acute or obtuse angles relative to the longitudinal axis of the aerosol-generating article.

[0093] Aerosol forming matrices may include tobacco-containing materials and tobacco-free materials.

[0094] The aerosol forming matrix may include aerosol forming agents. The aerosol forming matrix may include a single aerosol forming agent or a combination of two or more aerosol forming agents. As used herein, the term "aerosol forming agent" is used to describe any suitable known compound or mixture of compounds that facilitates aerosol formation in use and is substantially resistant to thermal degradation at the operating temperature of the aerosol-generating article. Suitable aerosol forming agents include, but are not limited to: polyols such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerol; esters of polyols such as mono, di, or triacetic acids of glycerol; and aliphatic esters of mono, di, or polycarboxylic acids such as dimethyl dodecanoate and dimethyl tetradecanoate. Preferred aerosol forming agents are polyols or mixtures thereof, such as propylene glycol, triethylene glycol, 1,3-butanediol, and most preferably glycerol. The aerosol forming matrix may have an aerosol forming agent content of greater than 5% on a dry weight basis. The aerosol forming matrix can have an aerosol forming agent content of about 5% to about 30% by dry weight. The aerosol forming matrix can have an aerosol forming agent content of about 20% by dry weight.

[0095] The aerosol forming matrix may include homogenized tobacco material, aerosol forming agent, and water.

[0096] The homogenized tobacco material can be provided in sheets, which are processed by folding, rolling, or cutting into strips. The sheets can be cut into strips having a width between about 0.2 mm and about 2 mm, more preferably between about 0.4 mm and about 1.2 mm. The width of the strips can be about 0.9 mm.

[0097] The aerosol forming matrix may include an inner cavity. In other words, the aerosol forming matrix may be a tubular matrix. The aerosol forming matrix may include an inner surface having an inner diameter, the inner surface defining an inner cavity extending longitudinally within the aerosol forming matrix. Providing an inner cavity into the aerosol forming matrix allows a heating element to be inserted into the aerosol forming matrix within the cavity without penetrating the matrix and without altering its structure. The provision of the inner cavity also facilitates a further reduction in the thickness of the aerosol forming matrix, thereby enhancing the heat transfer advantages explained above.

[0098] When the aerosol forming matrix includes an inner surface defining an inner cavity, the inner surface may have the same cross-sectional shape as the outer surface. Specifically, the inner surface may have a substantially circular, elliptical, or stadium-shaped cross-section.

[0099] Aerosol-forming articles may include a thermally conductive material layer. The thermally conductive material layer may cover at least a portion of the originally exposed aerosol-forming matrix. The thermally conductive material layer may be disposed at least on the outer surface of the matrix. The thermally conductive material layer may be disposed at least on the inner surface of the matrix. The thermally conductive material layer may be disposed at least on both the inner and outer surfaces of the matrix. Providing a thermally conductive material layer on the originally exposed matrix surface allows heat from heating elements received by or bonded to the matrix to be distributed over a wider area of ​​the aerosol-forming matrix, thereby improving the heat transfer efficiency between the heating elements and the aerosol-forming matrix. The thermally conductive material layer may also create a physical separation between the heating elements received within the cavity and the aerosol-forming matrix, which can reduce the risk of overheating of the aerosol-forming matrix in areas of the matrix near the heating elements. The thermally conductive material layer may also increase the stability of the tubular aerosol-forming matrix, which can be reduced by providing a cavity to decrease the thickness of the matrix.

[0100] As used herein, "thermal conductivity" means that a material has a thermal conductivity of at least 10 W / mK, preferably at least 40 W / mK, and more preferably at least 100 W / mK at 23 degrees Celsius and 50% relative humidity. Preferably, the thermally conductive material layer may comprise a material having a thermal conductivity of at least 40 W / mK, preferably at least 100 W / mK, more preferably at least 150 W / mK, and even more preferably at least 200 W / mK at 23 degrees Celsius and 50% relative humidity.

[0101] Examples of suitable conductive materials include, but are not limited to, aluminum, copper, zinc, nickel, silver, and combinations thereof.

[0102] The aerosol forming matrix may have a strip comprising multiple elongated tubular elements. These elongated tubular elements may contain tobacco material. The multiple elongated tubular elements included in the aerosol forming matrix must be consistent with the tubular elements positioned downstream of the aerosol forming matrix.

[0103] By adjusting the number, equivalent diameter, and thickness of the elongated tubular elements in the strip, the density and porosity of the strip can be advantageously adjusted. Generally speaking, an aerosol-forming matrix comprising multiple elongated tubular elements of homogenized tobacco can advantageously exhibit a more uniform density compared to an aerosol-forming matrix comprising fragments of tobacco material. The geometry of the elongated tubular elements allows for particularly stable channels to be provided for airflow along the strip. This can advantageously allow for consistent fine-tuning of the RTD, enabling the consistent and high-precision manufacture of an aerosol-forming matrix with a predetermined RTD.

[0104] The weight of an aerosol-forming matrix comprising elongated tubular elements of homogenized tobacco can be determined by the number, size, density, and spacing of the tubular elements. This reduces weight inconsistencies between aerosol-forming matrices of the same size and thus results in a lower scrap rate for aerosol-forming matrices whose weight falls outside the selected acceptable range compared to aerosol-forming matrices comprising tobacco material fragments.

[0105] Variations in the thickness of elongated tubular elements within a strip can also be advantageously used to adjust the content of homogenized tobacco within the strip. For example, in elongated tubular elements formed from rolled strips of homogenized tobacco web, the thickness of the elongated tubular element can be adjusted by changing the number of times the strip is wound around the longitudinal axis or by changing the thickness of the homogenized tobacco web itself. This allows for greater design flexibility in aerosol-generated articles compared to those containing tobacco material fragments.

[0106] The size, geometry, and arrangement of the elongated tubular elements in the strip can be easily adapted to facilitate the insertion of heating elements into the strip for aerosol generation. Because the elongated tubular elements are located substantially straight within the strip and extend longitudinally, the insertion of longitudinally extending internal heating elements, such as heater plates, is facilitated. The regular arrangement of the elongated tubular elements in the strip also advantageously optimizes heat transfer from the heating elements through the strip.

[0107] Inserting (and removing) the heater of an aerosol generating device into (and from) an aerosol forming matrix comprising tobacco material fragments may tend to remove the tobacco material fragments from the aerosol forming matrix. This may necessitate more frequent cleaning of the heater element and other parts of the aerosol generating device to remove the removed fragments. In contrast, inserting and removing the heater of the aerosol generating device into and from an aerosol forming matrix comprising multiple elongated tubular elements comprising homogenized tobacco material advantageously has a significantly reduced tendency to remove material.

[0108] Strips comprising multiple elongated tubular elements can be manufactured in a continuous process that can be performed at high speed and efficiency and can be easily integrated into existing production lines for manufacturing aerosol-generating products.

[0109] The strip of the aerosol forming matrix preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol-generated article.

[0110] The strip of the aerosol forming matrix can have an outer diameter of at least 5 mm. The strip of the aerosol forming matrix can have an outer diameter between about 5 mm and about 12 mm, for example between about 5 mm and about 10 mm, or between about 6 mm and about 8 mm. Preferably, the strip of the aerosol forming matrix can have an outer diameter of 7.2 mm to within 10%.

[0111] The strips of the aerosol-forming matrix can have a length between about 5 mm and about 100 mm. Preferably, the strips of the aerosol-forming matrix can have a length of at least about 5 mm, more preferably at least about 7 mm. The strips of the aerosol-forming matrix can preferably have a length of less than about 80 mm, more preferably less than about 65 mm, and even more preferably less than about 50 mm. Preferably, the strips of the aerosol-forming matrix can have a length of less than about 35 mm, more preferably less than 25 mm, and even more preferably less than about 20 mm. The strips of the aerosol-forming matrix can have a length of about 10 mm; the strips of the aerosol-forming matrix can have a length of about 12 mm.

[0112] The strips of the aerosol forming matrix can have a substantially uniform cross-section along the length of the strip. Preferably, the strips of the aerosol forming matrix have a substantially circular cross-section.

[0113] The strip, including the elongated tubular element, may be defined by the packaging. The elongated tubular element may be assembled such that the elongated tubular element extends in the longitudinal direction.

[0114] The multiple elongated tubular elements of the aerosol-generated article according to the invention can be formed from a homogeneous tobacco material, which may include particulate tobacco obtained by grinding. The multiple elongated tubular elements may all have substantially the same composition as each other. Similarly, the multiple elongated tubular elements may include tubular elements with at least two different compositions.

[0115] At least one elongated tubular element in the strip may comprise a rolled strip cut from a sheet or web of homogenized tobacco material.

[0116] The sheet or web of homogenized tobacco material may have a tobacco content of at least about 40% by weight, more preferably at least about 60% by weight, more preferably at least about 70% by weight, and most preferably at least about 90% by weight, based on dry weight.

[0117] Sheets or webs of homogenized tobacco material used in an aerosol-forming matrix may include one or more inherent binders (i.e., tobacco endogenous binders), one or more non-inherent binders (i.e., tobacco exogenous binders), or combinations thereof, to facilitate the agglomeration of particulate tobacco. Sheets of homogenized tobacco material used in an aerosol-forming matrix may include other additives, including but not limited to tobacco and non-tobacco fibers, aerosol forming agents, humectants, plasticizers, flavorings, fillers, aqueous solvents and non-aqueous solvents, and combinations thereof.

[0118] Suitable non-inherent binders, including but 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; conjugated base salts of organic acids such as sodium alginate, agar and pectin; and combinations thereof.

[0119] Suitable non-tobacco fibers included in sheets or webs of homogenized tobacco material used in an aerosol-forming matrix are known in the art, including, but not limited to: cellulose fibers; cork fibers; hardwood fibers; jute fibers; and combinations thereof. Prior to being included in sheets of homogenized tobacco material used in an aerosol-forming matrix, the non-tobacco fibers may be treated by suitable processes known in the art, including, but not limited to: mechanical pulping; refining; chemical pulping; bleaching; sulfate pulping; and combinations thereof.

[0120] Homogenized tobacco materials in sheets or webs may include aerosol forming agents.

[0121] Sheets or webs of homogenized tobacco for use in the aerosol-generating articles of the present invention can be manufactured by methods known in the art (e.g., the method disclosed in International Patent Application WO-A-2012 / 164009 A2). Sheets of homogenized tobacco material for use in aerosol-generating articles can be formed by a casting process from a slurry comprising particulate tobacco, guar gum, cellulose fibers, and glycerol.

[0122] Similarly, elongated tubular elements for use in the aerosol-forming matrix of the present invention can be formed by extrusion. For example, a slurry comprising particulate tobacco obtained by grinding or otherwise pulverizing tobacco leaves can be pushed through a die having a desired cross-section. Furthermore, additive manufacturing can also be used to manufacture tubular elements of homogenized tobacco material.

[0123] The elongated tubular element may have an equivalent diameter of about 0.03 mm to about 3 mm. Preferably, the elongated tubular element may have an equivalent diameter of at least about 0.1 mm. More preferably, the elongated tubular element may have an equivalent diameter of at least about 0.3 mm.

[0124] Similarly, the elongated tubular element may preferably have an equivalent diameter of less than about 2 mm. More preferably, the elongated tubular element may have an equivalent diameter of less than about 1 mm.

[0125] The elongated tubular element may have an equivalent diameter of about 0.7 mm to about 2.7 mm; the elongated tubular element may have an equivalent diameter of about 0.3 mm to about 1.1 mm.

[0126] When forming an elongated tubular element by rolling up a strip of homogenized tobacco material, the strip can have a width of at least about 1 mm. Preferably, the strip of homogenized tobacco material can have a width of at least about 2 mm. More preferably, the strip of homogenized material can have a width of at least about 3 mm.

[0127] The strips of homogenized tobacco material can have a width of about 1 mm to about 3.5 mm; the bars of homogenized tobacco material can have a width of about 2.4 mm to about 8.2 mm.

[0128] Strips of homogenized tobacco material can be cut from sheets or webs having a thickness of at least about 40 micrometers, more preferably at least about 60 micrometers, more preferably at least about 80 micrometers, and most preferably at least about 100 micrometers. Similarly, strips of homogenized tobacco material can be cut from sheets or webs having a thickness of no more than about 5000 micrometers, more preferably no more than about 2000 micrometers, more preferably no more than about 1000 micrometers, and most preferably no more than about 500 micrometers. For example, the thickness of the sheet or web can be between about 40 micrometers and about 5000 micrometers, more preferably between about 60 micrometers and about 2000 micrometers, more preferably between about 80 micrometers and about 1000 micrometers, and most preferably between about 100 micrometers and about 500 micrometers.

[0129] The thickness of the elongated tubular element may be at least about 40 micrometers, more preferably at least about 80 micrometers, more preferably at least about 120 micrometers, and most preferably at least about 160 micrometers. Similarly, the thickness of the elongated tubular element may be less than about 5000 micrometers, more preferably less than about 2500 micrometers, and most preferably less than about 1000 micrometers.

[0130] The elongated tubular element can be formed from a porous tobacco material, allowing airflow through the walls of the tubular element; that is, the airflow in the strip along the substantially radial direction is unimpeded. In the case where the elongated tubular element is formed by rolling up a strip of homogenized tobacco material, the strip itself can be formed from a porous tobacco material.

[0131] As used herein with respect to homogenized tobacco materials, the term "porous" can indicate that the tobacco material has been produced within its inherent porosity, providing sufficient pores or gaps within the structure of the sheet or web to allow air to flow through it in a direction transverse to the surface of the sheet or web. Similarly, the term "porous" can indicate that each sheet or web of tobacco material includes multiple airflow holes to provide the desired porosity. For example, a sheet of tobacco material can be punctured with an airflow hole pattern before a rolling operation is performed on an elongated tubular element that generates an aerosol-forming matrix. These airflow holes can be punctured randomly or uniformly across the sheet. The pattern of airflow holes can substantially cover the entire surface of the sheet, or it can cover one or more specific areas of the sheet, with the remaining areas lacking airflow holes.

[0132] Strips of homogenized tobacco material that can form elongated tubular elements can be textured. For example, sheets or webs from which strips are cut may include multiple spaced recesses, protrusions, perforations, or combinations thereof. Texture may be provided on one side or both sides of each sheet.

[0133] Including one or more elongated tubular elements formed by curled strips can help provide and maintain a certain spacing between adjacent tubular elements within the strip.

[0134] The additive may be applied to at least a portion of the surface of at least one of a plurality of tubular elements. The additive may be a solid additive, a liquid additive, or a combination of solid and liquid additives. Suitable solid and liquid additives for use in this invention are known in the art, including, but not limited to: fragrances, such as, for example, menthol; adsorbents, such as, for example, activated carbon; fillers, such as, for example, calcium carbonate; and plant-based additives.

[0135] To form a substantially elongated tubular element, the strip of homogenized tobacco material may be wound around the longitudinal axis at least about 345 degrees. Preferably, the strip of homogenized tobacco material may be wound around the longitudinal axis at least about 360 degrees. More preferably, the strip of homogenized tobacco material may be wound around the longitudinal axis at least about 540 degrees. Similarly, the strip of homogenized tobacco material may preferably be wound around the longitudinal axis less than about 1800 degrees. More preferably, the strip of homogenized tobacco material may be wound around the longitudinal axis less than about 900 degrees. Preferably, the strip of homogenized tobacco material may be wound around the longitudinal axis from about 345 degrees to about 540 degrees.

[0136] Each elongated tubular element may have a length substantially equal to the length of the aerosol-forming matrix strip. Each elongated tubular element may have a length of approximately 10 mm; each elongated tubular element may have a length of approximately 12 mm.

[0137] The aerosol-forming matrix strip may include fewer than about 200 elongated tubular elements of homogenized tobacco material. More preferably, the aerosol-forming matrix strip may include fewer than about 150 elongated tubular elements. Even more preferably, the aerosol-forming matrix strip may include fewer than about 100 elongated tubular elements.

[0138] Similarly, the aerosol-forming matrix strip may include at least about 15 elongated tubular elements of homogenized tobacco material. More preferably, the aerosol-forming matrix strip may include at least about 30 elongated tubular elements. Even more preferably, the aerosol-forming matrix strip may include at least about 40 elongated tubular elements. The aerosol-forming matrix strip may include about 15 to about 100 strands of non-tobacco material.

[0139] In the strips of the aerosol-forming matrix, slender tubular elements can be aligned substantially parallel to each other.

[0140] The elongated tubular element of the homogenized tobacco material can have a substantially oval cross-section; it can have a substantially elliptical cross-section; or it can have a substantially circular cross-section. As described above, the elongated tubular element for use in aerosol-generating articles can be effectively formed by winding a strip of homogenized tobacco material around its longitudinal axis by slightly less than 360 degrees. This allows the element to effectively have a C-shaped cross-section, wherein the slit extends longitudinally along the entire length of the elongated tubular element.

[0141] An aerosol generation system may be provided. The aerosol generation system may include any of the aerosol generation articles and aerosol generation apparatuses disclosed above. The aerosol generation apparatus may include a heating element or a portion thereof for heating the aerosol generation article.

[0142] As used herein, the term "aerosol generation system" refers to the combination of an aerosol generation device and an aerosol-generated product.

[0143] Since the aerosol generation system of this disclosure includes aerosol generation articles according to the previously disclosed aerosol generation articles, the advantages specified above for the aerosol generation articles also apply to the system itself.

[0144] The heating element can be any suitable type. The heating element can be an internal heating element. The heating element can be an elongated heating element. The elongated heating element can be plate-shaped. The elongated heating element can be needle-shaped. The elongated heating element can have a conical shape or at least a conical end. The elongated heating element can have a pointed tip. The heating element can be conical. The elongated heating element can have any suitable shape arranged to facilitate insertion of the heating element into the aerosol forming matrix. Advantageously, the elongated heating element can provide easier engagement or disengagement of the aerosol generating article and the heating element of the apparatus, or easier engagement and disengagement of both.

[0145] The heating element may be an external heating element. As used herein, the term "external heating element" refers to a heating element configured to heat the outer surface of the aerosol forming matrix. The external heating element may at least partially define a cavity for receiving the aerosol forming matrix.

[0146] The heating element may include at least one resistance heating element.

[0147] At least one resistance heating element may include an electrically insulating substrate and one or more conductive tracks on the electrically insulating substrate.

[0148] The electrically insulating matrix is ​​stable at the operating temperature of at least one heating element. The electrically insulating matrix is ​​stable at temperatures up to about 400 degrees Celsius, more preferably about 500 degrees Celsius, more preferably about 600 degrees Celsius, more preferably about 700 degrees Celsius, and most preferably about 800 degrees Celsius.

[0149] At least one resistance heating element may operate at a temperature of at least about 200 degrees Celsius during use. At least one resistance heating element may operate at a temperature of less than about 700 degrees Celsius during use. At least one resistance heating element may operate at a temperature of less than about 600 degrees Celsius during use. At least one resistance heating element may operate at a temperature of less than about 500 degrees Celsius during use. At least one resistance heating element may operate at a temperature of less than about 400 degrees Celsius during use.

[0150] The electrical insulating matrix can include any suitable material. For example, the electrical insulating matrix can include one or more of the following: paper, glass, ceramics, anodized metals, coated metals, and polyimide. Ceramics can include mica, alumina (Al2O3), or zirconium oxide (ZrO2). The electrical insulating matrix may have a thermal conductivity of less than or equal to about 40 W / m Kelvin, preferably less than or equal to about 20 W / m Kelvin, and ideally less than or equal to about 2 W / m Kelvin.

[0151] Suitable materials for forming resistance heating elements and, in particular, one or more conductive tracks, may include, but are not limited to: semiconductors, such as doped ceramics, electrically “conductive” ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys, and composite materials made of ceramic and metallic materials. Such composite materials may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, nickel-containing alloys, cobalt-containing alloys, chromium-containing alloys, aluminum-containing alloys, titanium-containing alloys, zirconium-containing alloys, hafnium-containing alloys, niobium-containing alloys, molybdenum-containing alloys, tantalum-containing alloys, tungsten-containing alloys, tin-containing alloys, gallium-containing alloys, manganese-containing alloys, and iron-containing alloys, and nickel-, iron-, and cobalt-based superalloys, stainless steel, Timetal ® And iron-manganese-aluminum based alloys.

[0152] The resistance heating element may include one or more stamped portions of a resistive material (such as stainless steel). At least one resistance heating element may include a heating wire or filament, such as Ni-Cr (nickel-chromium), platinum, tungsten, or alloy wire.

[0153] The heating element may include at least one induction heating device.

[0154] At least one induction heating device may include at least one inductor coil. The inductor coil is arranged to generate a changing magnetic field when it receives a changing current from a power source. This changing current may be between about 5 kHz and about 500 kHz. The changing current may be a high-frequency changing current. As used herein, the term "high-frequency changing current" refers to a changing current having a frequency between about 500 kHz and about 30 MHz. The high-frequency changing current may have a frequency between about 1 MHz and about 30 MHz (such as between about 1 MHz and about 10 MHz, or such as between about 5 MHz and about 8 MHz). The changing current may be an alternating current that generates an alternating magnetic field.

[0155] The sensor coil can have any suitable form. For example, the sensor coil can be a flat sensor coil. A flat sensor coil can be wound in a helical manner substantially in a plane. Preferably, the sensor coil can be a tubular sensor coil. Typically, a tubular sensor coil can be wound helically about a longitudinal axis. The sensor coil can be elongated. Particularly preferred is an elongated tubular sensor coil. The sensor coil can have any suitable cross-section. The sensor coil can have a circular, elliptical, square, rectangular, triangular, or other polygonal cross-section.

[0156] The inductor coil can be formed from any suitable material. The inductor coil can be formed from a conductive material. Preferably, the inductor coil can be formed from a metal or a metal alloy.

[0157] As used in this article, “conductivity” refers to an electrical conductivity of less than or equal to 1 x 10⁻⁶ at 20 degrees Celsius. -4 Materials with resistivity of ohm-meter (Ω·m).

[0158] At least one induction heating device may include at least one sensor. As discussed above, the sensor may also be included in an aerosol-generating article.

[0159] The sensor is arranged such that when the aerosol-generating article is received in the aerosol-generating apparatus, the oscillating electromagnetic field generated by the sensor coil induces a current in the sensor, thereby heating the sensor. Preferably, the aerosol-generating apparatus may be able to generate a fluctuating electromagnetic field with a magnetic field strength (H field strength) between 1 kA / m and 5 kA / m, preferably between 2 kA / m and 3 kA / m (e.g., about 2.5 kA / m). Preferably, the aerosol-generating apparatus may be able to generate a fluctuating electromagnetic field with a frequency between 1 MHz and 30 MHz, for example between 1 MHz and 10 MHz, for example between 5 MHz and 7 MHz.

[0160] The receptor may comprise any suitable material. The receptor may be formed from any material capable of being inductively heated to a temperature sufficient to release volatile compounds from the aerosol-forming matrix or aroma matrix. Preferred receptors may be heated to temperatures exceeding about 250 degrees Celsius. Preferred receptors may be formed from conductive materials. Suitable materials for receptors include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. Preferred receptors may comprise metals or carbon. Some preferred receptors may comprise ferromagnetic materials, such as ferritic iron, ferromagnetic alloys (such as ferromagnetic steel or stainless steel), ferromagnetic particles, and ferrites. Some preferred receptors may be composed of ferromagnetic materials. Suitable receptors may comprise aluminum. Suitable receptors may be composed of aluminum. The receptor may comprise at least about 5%, at least about 20%, at least about 50%, or at least about 90% ferromagnetic or paramagnetic material.

[0161] The receptor can be formed of a material that is essentially impermeable to gas. In other words, preferably, the receptor can be formed of a material that is impermeable to gas.

[0162] Receptors can have any suitable form. For example, a receptor can be elongated. A receptor can have any suitable cross-section. For example, a receptor can have a circular, elliptical, square, rectangular, triangular, or other polygonal cross-section. A receptor can be tubular.

[0163] The sensor may comprise a sensor layer disposed on a support. Arranging the sensor in a changing magnetic field induces eddy currents close to the sensor surface; this effect is known as the skin effect. Therefore, the sensor can be formed from a relatively thin layer of sensor material while ensuring that the sensor is effectively heated in the presence of a changing magnetic field. Manufacturing the sensor from a support and a relatively thin sensor layer facilitates the simple, inexpensive, and robust production of aerosol-generating articles.

[0164] The support can be formed of a material that is not easily heated by induction. Advantageously, this can reduce heating of the surface of the receptor that does not come into contact with the aerosol-forming matrix, wherein the surface of the support forms the surface of the receptor that does not come into contact with the aerosol-forming matrix.

[0165] The support structure may include electrically insulating material. As used herein, "electrically insulating" means having a strength of at least 1 x 10⁻⁶ at 20 degrees Celsius. 4 Materials with resistivity of ohm-meter (Ωm).

[0166] A support structure formed of thermal insulation material can provide a thermal insulation barrier between the sensor layer and other components of the induction heating device, such as the inductor coil defining the induction heating element. Advantageously, this can reduce heat transfer between the sensor and other components of the induction heating system.

[0167] Thermal insulation materials can also have a volumetric thermal diffusivity of less than or equal to about 0.01 cm² / s, as measured using a laser flash method. Providing a support with this thermal diffusivity can result in a support with high thermal inertia, which reduces heat transfer between the sensor layer and the support, and also reduces temperature changes in the support.

[0168] The receptor may have a protective outer layer, such as a protective ceramic layer or a protective glass layer. The protective outer layer improves the receptor's durability and facilitates cleaning. The protective outer layer may substantially surround the receptor. The receptor may include a protective coating formed of glass, ceramic, or inert metal.

[0169] When a receptor is included in an aerosol generating apparatus, the receptor may be located within the apparatus cavity. The receptor may extend into the apparatus cavity in the longitudinal direction. The receptor may be elongated. An elongated receptor may be plate-shaped. An elongated receptor may be needle-shaped. An elongated receptor may have a conical shape or at least a conical end. An elongated receptor may have a pointed tip. An elongated element may be conical.

[0170] When a sensor is included in an aerosol generating apparatus, the sensor may be an internal heating element configured to be at least partially inserted into the aerosol-forming matrix of the aerosol-generating article when it is received in the apparatus cavity. In cases where the aerosol-forming matrix includes an inner cavity, the sensor may be configured to be at least partially inserted into the inner cavity of the aerosol-forming matrix when it is received in the apparatus cavity.

[0171] The aerosol generating device may include a power source. The power source may be a DC voltage source. The power source may be a battery. For example, the power source may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery, such as a lithium-cobalt battery, a lithium-iron phosphate battery, or a lithium polymer battery. The power source may also be another form of charge storage device, such as a capacitor. The power source may require recharging and may have a capacity that allows for the storage of sufficient energy for use by the aerosol generating device.

[0172] A power source can be electrically connected to the heater to supply power to heating elements such as a matrix heating element and downstream heating elements. When the heating elements receive power from the power source, they can generate heat. The power source can be configured to supply sufficient power to the heating elements to heat the aerosol forming matrix to a temperature at which volatile compounds are released from the aerosol forming matrix.

[0173] An aerosol generating apparatus may include a housing. The housing may at least partially define a cavity for receiving the aerosol-generated article.

[0174] The aerosol generating apparatus may include at least one apparatus air inlet in fluid communication with a cavity. When the aerosol generating apparatus includes a housing, the housing may at least partially define at least one apparatus air inlet. It is desirable that the apparatus air inlet allows ambient air to be drawn into the upstream end of the aerosol forming matrix.

[0175] The aerosol generating apparatus may include a controller. The controller may be configured to control the power supply from a power source to a heating element. The controller can be any suitable controller. The controller may include any suitable circuitry and electrical components. The controller may include a processor and memory. The controller may include a microprocessor, which may be a programmable microprocessor.

[0176] The aerosol generating device may include a sensor that detects the airflow instructing the user to inhale. The airflow sensor may be an electromechanical device. The airflow sensor may be any of the following: mechanical, optical, optomechanical, or microelectromechanical system (MEMS) based sensors. The aerosol generating device may include a manually operable switch for the user to initiate inhalation.

[0177] The aerosol generating apparatus may include an indicator for indicating when at least one heating element is activated. The indicator may include a lamp that is activated when at least one heating element is activated.

[0178] The aerosol generating apparatus may include at least one electrical connector. The at least one electrical connector may be configured to charge a power source. The at least one electrical connector may be configured to connect to another electrical device. The at least one electrical connector may include an external plug or socket, which includes at least one external electrical contact, thereby allowing the aerosol generating apparatus to connect to another electrical device. For example, the aerosol generating apparatus may include a USB plug or USB socket to allow the aerosol generating apparatus to connect to another USB-enabled device. For example, the USB plug or socket may allow the aerosol generating apparatus to connect to a USB charging device, thereby charging a rechargeable power source within the aerosol generating apparatus. The USB plug or socket may support data transmission to or from the aerosol generating apparatus, or both data transmission to and from the aerosol generating apparatus. Similarly, the aerosol generating apparatus may be connected to a computer to transmit data to the apparatus, such as new heating profiles for new aerosol-generated articles.

[0179] When the aerosol generating device includes a USB plug or socket, the aerosol generating device may further include a removable cover that covers the USB plug or socket when not in use. When the USB plug or socket is a USB plug, the USB plug may selectively retract into the device.

[0180] 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 disclosure described herein.

[0181] Ex1. An aerosol-generating article, comprising:

[0182] Aerosol forming matrix; and

[0183] Packaging material that defines the aerosol forming matrix;

[0184] The packaging defines an overlapping area of ​​itself, the overlapping area including a first segment and a second segment externally disposed on the first segment;

[0185] The second section includes a fold or pleat that defines a folded section at one end of the package; and

[0186] The folded section is sandwiched between the first section and the second section.

[0187] Ex2. The aerosol-generated article according to Ex1, wherein an internal adhesive is disposed between the folded section and the first section.

[0188] Ex3. An aerosol-generated article according to any one of Ex1 to Ex2, wherein an external adhesive is disposed between the folded section and the second section.

[0189] Ex4. An aerosol-generated article according to any one of E2 to Ex3, wherein the binder comprises one or more of the following: gum arabic, natural or synthetic resin, starch, and varnish.

[0190] Ex5. The aerosol generating article according to any one of Ex1 to Ex4 further includes a heating element embedded in the aerosol forming matrix.

[0191] Ex6. The aerosol-generating article according to Ex5, wherein the heating element is a sensor.

[0192] Ex7. An aerosol-generating article according to any one of Ex5 to Ex6, wherein the heating element is completely surrounded by the aerosol-forming matrix and extends along the entire length of the aerosol-forming matrix.

[0193] Ex8. An aerosol-generating article according to any one of Ex1 to Ex7, wherein the diameter of the aerosol-generating article is between about 3 mm and about 8 mm.

[0194] Ex9. An aerosol-generated article according to any one of Ex1 to Ex8, wherein the packaging has a thickness between about 60 micrometers and about 200 micrometers, preferably between about 78 micrometers and about 160 micrometers, more preferably between 78 micrometers and about 140 micrometers, more preferably between about 100 micrometers and about 140 micrometers, and most preferably between about 125 micrometers and about 140 micrometers.

[0195] Ex10. An aerosol-forming article according to any one of Ex1 to Ex9, wherein the aerosol-forming matrix comprises one or more of tobacco, nicotine, a gel component, and a flavor matrix.

[0196] Ex11. An aerosol-generated article according to any one of Ex1 to Ex10, wherein the package has a basis weight between about 10 g / m² and 28 g / m², preferably between about 10 g / m² and 16 g / m².

[0197] Ex12. An aerosol-generated article according to any one of Ex1 to Ex11, wherein the packaging has a porosity between about 30 and about 80 Coresta units, preferably between about 30 and about 50 Coresta units, and most preferably between 30 and 40 Coresta units.

[0198] Ex13. An aerosol-generated article according to any one of Ex1 to Ex12, wherein the package has a roughness between about 50 kek seconds and about 1000 kek seconds, more preferably between about 100 kek seconds and about 200 kek seconds.

[0199] Ex14. The aerosol generating article according to any one of Ex1 to Ex13 further includes a filter disposed downstream of the aerosol forming matrix.

[0200] Ex15. The aerosol generating article according to any one of Ex1 to Ex14 further includes a support element disposed downstream of the aerosol forming matrix.

[0201] Ex16. The aerosol-generating article according to Ex15, wherein the support element comprises a first hollow tubular segment.

[0202] Ex17. An aerosol-generating article according to any one of Ex15 to Ex16, wherein the support element is disposed downstream of the aerosol-forming matrix in the longitudinal direction.

[0203] Ex18. An aerosol generating article according to any one of Ex15 to Ex17, which are subordinate to Ex14, wherein the filter is disposed downstream of the support element in the longitudinal direction.

[0204] Ex19. The aerosol generating article according to any one of Ex15 to Ex18 further includes an aerosol cooling element disposed in the longitudinal direction downstream of the support element.

[0205] Ex20. The aerosol generating article according to Ex19, wherein the aerosol cooling element includes a second hollow tubular segment.

[0206] Ex21. An aerosol generating article according to any one of Ex19 to Ex20, which are subordinate to Ex14, wherein the aerosol cooling element is disposed between the support element and the filter.

[0207] Ex22. The aerosol generating article according to any one of Ex1 to Ex21 further includes a mouthpiece disposed at the downstream end of the aerosol generating article.

[0208] Ex23. The aerosol generating article according to any one of Ex1 to Ex22 further includes an upstream element disposed at the upstream end of the aerosol generating article.

[0209] Ex24. An aerosol-forming article according to any one of Ex1 to Ex23, wherein the aerosol-forming matrix comprises a liquid component.

[0210] Ex25. An aerosol-forming article according to any one of Ex1 to Ex24, wherein the aerosol-forming matrix comprises a solid component.

[0211] Ex26. An aerosol-generating article according to any one of Ex1 to Ex25, wherein the aerosol-forming matrix comprises a plant-based material, preferably a homogenized plant-based material.

[0212] Ex27. An aerosol-generating article according to any one of Ex1 to Ex26, wherein the aerosol-forming matrix comprises a non-tobacco material.

[0213] Ex28. An aerosol-generating article according to any one of Ex1 to Ex27, wherein the aerosol-forming matrix comprises a solid homogenized tobacco material.

[0214] Ex29. The aerosol-forming article according to Ex29, wherein the aerosol-forming matrix comprises at least one aggregated sheet of solid homogenized tobacco material.

[0215] Ex30. An aerosol-generating article according to Ex29, wherein the at least one aggregated sheet comprises a textured sheet, a rolled sheet, or both.

[0216] Ex31. An aerosol-generated article according to any one of Ex28 to Ex30, wherein the solid homogenized tobacco material comprises strips of tobacco material.

[0217] Ex32. An aerosol generating article according to any one of Ex25 to Ex31, which are subordinate to Ex25, wherein the aerosol forming matrix has a strip comprising a plurality of elongated tubular elements.

[0218] Ex33. An aerosol-generating article according to Ex32, which is subordinate to Ex28, wherein the plurality of elongated tubular elements comprise solid homogenized tobacco material.

[0219] Ex34. An aerosol-generating article according to Ex33, wherein at least one elongated tubular material comprises a rolled strip cut from a sheet or web of solid homogenized tobacco material.

[0220] Ex35. An aerosol-forming article according to any one of Ex1 to Ex34, wherein the aerosol-forming matrix is ​​a hollow tubular matrix defining an inner cavity.

[0221] Ex36. An aerosol-generated article according to any one of Ex1 to Ex35 further comprises a layer of thermally conductive material.

[0222] Ex37. An aerosol-generating article according to any one of Ex1 to Ex36, wherein the aerosol-forming matrix comprises an aerosol-forming agent.

[0223] Ex38. An aerosol generating apparatus comprising a heating element or a portion thereof.

[0224] Ex39. The aerosol generating apparatus according to Ex38, wherein the heating element comprises at least one resistance heating element.

[0225] Ex40. The aerosol generating apparatus according to Ex39, wherein the at least one resistance heating element comprises an electrically insulating matrix and one or more conductive tracks on the electrically insulating matrix.

[0226] Ex41. An aerosol generating apparatus according to any one of Ex38 to Ex40, wherein the heating element comprises at least one induction heating device, each induction device comprising at least one inductor coil and optionally at least one sensor.

[0227] Ex42. The aerosol generating apparatus according to Ex41, wherein the at least one inductor coil is arranged to generate a changing magnetic field when receiving a changing current from a power source, the changing current being between about 5 kHz and about 500 kHz.

[0228] Ex43. The aerosol generating apparatus according to Ex41, wherein the at least one inductor coil is arranged to generate a changing magnetic field when receiving a changing current from a power source, the changing current being between about 500 kHz and about 5 MHz.

[0229] Ex44. An aerosol generating apparatus according to any one of Ex41 to Ex43, wherein the at least one sensor coil is a flat sensor coil, such as a flat sensor coil wound substantially in a spiral manner in a plane.

[0230] Ex45. An aerosol generating apparatus according to any one of Ex41 to Ex43, wherein the at least one sensor coil is a tubular sensor coil, such as a tubular sensor coil spirally wound around a longitudinal axis.

[0231] Ex46. The aerosol generating apparatus according to any one of Ex41 to Ex45, wherein the at least one sensor coil is formed of a conductive material.

[0232] Ex47. An aerosol generating apparatus according to any one of Ex41 to Ex46 when subordinate to Ex6 or when the aerosol generating apparatus includes at least one sensor, wherein the at least one sensor is formed of a conductive material.

[0233] Ex48. An aerosol generating apparatus according to any one of Ex41 to Ex47 when subordinate to Ex6 or when the aerosol generating apparatus includes at least one sensor, wherein the at least one sensor comprises a sensor layer disposed on a support, the support preferably comprising a thermally insulating material.

[0234] Ex49. An aerosol generating apparatus according to any one of Ex39 to Ex48, wherein the heating element comprises at least one resistance heating element and at least one induction heating device.

[0235] Ex50. An aerosol generating apparatus according to any one of Ex38 to Ex49, wherein the heating element comprises an internal heating element.

[0236] Ex51. An aerosol generating apparatus according to any one of Ex38 to Ex50, wherein the heating element comprises an external heating element.

[0237] Ex52. The aerosol generating apparatus according to any one of Ex38 to Ex51 further includes a power source.

[0238] Ex53. The aerosol generating apparatus according to Ex52, wherein the power supply is electrically connected to the heating element.

[0239] Ex54. The aerosol generating apparatus according to any one of Ex38 to Ex53 further includes a cavity for receiving the aerosol-generated article.

[0240] Ex55. The aerosol generating apparatus according to any one of Ex38 to Ex54 further includes an apparatus housing.

[0241] Ex56. The aerosol generating apparatus according to Ex54 and Ex55, wherein the apparatus housing at least partially defines the cavity for receiving the aerosol-generated article.

[0242] Ex57. The aerosol generating apparatus according to any one of Ex38 to Ex56 further includes at least one apparatus air inlet.

[0243] Ex58. An aerosol generating apparatus according to Ex57, which is subordinate to Ex55, wherein the apparatus housing includes the at least one apparatus air inlet.

[0244] Ex59. The aerosol generating article according to any one of Ex38 to Ex58 further includes a controller.

[0245] Ex60. The aerosol generating article according to any one of Ex38 to Ex59 further includes a sensor configured to detect an airflow instructing a user to inhale.

[0246] Ex61. An aerosol-generated article according to any one of Ex38 to Ex60, further comprising at least one electrical connector.

[0247] Ex62. The aerosol-generating article according to Ex61, wherein the at least one electrical connector includes an external plug or socket, such as a USB plug or USB socket.

[0248] Ex63. An aerosol generation system comprising an aerosol generation article according to any one of Ex1 to Ex37 and an aerosol generation apparatus according to any one of Ex38 to Ex62. Attached Figure Description

[0249] These and other features and advantages of the invention will become more apparent from the following detailed description of preferred embodiments with reference to the accompanying drawings, which are given by way of illustrative and non-limiting example only:

[0250] Figure 1 A longitudinal section of the aerosol-generating article, including embedded receptors and packaging, is depicted.

[0251] Figure 2a It shows Figure 1 The cross-section of the aerosol-generated product.

[0252] Figure 2b It shows Figure 2a The cross-section of the overlapping area defined by the packaging of the aerosol-generated product, circled in the center.

[0253] Figure 3 A longitudinal section of an aerosol-generating article, including tubular elements and filters, is shown.

[0254] Figure 4 A longitudinal section of an aerosol-generating article, including upstream components and aerosol cooling components, is shown.

[0255] Figure 5 The diagram shows an aerosol generating device and Figures 1 to 4 The longitudinal section of any aerosol generating system for aerosol-generating articles.

[0256] Figure 6 Depicting Figure 5 An external view of the aerosol generation system. Detailed Implementation

[0257] Figure 1 A longitudinal section of an aerosol-generating article 10 having an upstream end 13 and a downstream end 14 is depicted, the aerosol-generating article 10 defining a longitudinal direction between the upstream end 13 and the downstream end 14. The article 10 includes an aerosol-forming matrix 11 and a package 30 defining the aerosol-forming matrix 11.

[0258] exist Figure 1 In one embodiment, the heating element 40 is embedded within the aerosol forming matrix 11. The heating element 40 is a sensor 40. The sensor 40 extends along the entire length of the aerosol forming matrix 11.

[0259] Figure 2a It shows Figure 1 The figure shows a cross-section of the aerosol-generating article 10. This figure illustrates an overlapping region 41 defined by the packaging 30, in which the packaging 30 overlaps itself. The overlapping region 41 includes a first segment 42 and a second segment 43, the second segment externally disposed on the first segment 42. The second segment 43 includes a fold 44 (or pleat) defining a folded segment 45 at one end of the packaging 40. The folded segment 45 is sandwiched between the first segment 42 and the second segment 43.

[0260] An internal adhesive 50 is disposed between the folded section 45 and the first section 42. An external adhesive 51 is disposed between the folded section 45 and the second section 43.

[0261] For clarity, Figure 2a The overlapping area in Figure 2b It is shown in more detail in the middle.

[0262] Figure 3 An aerosol-generating article is shown, which is similar to Figure 1 and Figure 2a , 2b The aerosol-generating article 10 includes an aerosol-forming matrix 11 and a packaging 30. The aerosol-generating article 10 further includes a support element 12 disposed downstream of the aerosol-forming matrix 11. The support element 12 defines an opening extending in a longitudinal direction and adapted for the flow of matrix aerosols to a downstream end 14. In other words, the support element 12 comprises a hollow tubular segment. Figure 3 In one embodiment, the filter 17 is disposed downstream of the support element 12 in the longitudinal direction. The packaging 30 and... Figure 1 and 2a The packaging of aerosol-generating article 10 is the same as that of article 2b. The receptor 40 extends along the entire length of the aerosol-forming matrix 11.

[0263] Figure 4 An aerosol-generating article 10 is shown, which includes Figure 1 , 2a Packaging materials 30 for 2b and 3. The following will describe... Figure 4 Aerosol-generating products 10 and Figure 1 , 2a The differences between aerosol-generated products 10 of 2b and 3.

[0264] Figure 4 The aerosol-generating article 10 includes a support element 12 positioned downstream of the aerosol-forming matrix 11. Figure 4 In this embodiment, the upstream end of the support element 12 is adjacent to the downstream end of the aerosol forming matrix 11. Furthermore, the aerosol generating article 10 includes an aerosol cooling element 15 positioned immediately downstream of the support element 22. Figure 4 In one embodiment, the upstream end of the aerosol cooling element 15 is adjacent to the downstream end of the support element 12.

[0265] The support element 12 includes a first hollow tubular segment. The aerosol cooling element 15 includes a second hollow tubular segment. The hollow tubular segments are provided in the form of hollow cylindrical tubes made of cellulose acetate. Other constructions of the support element, aerosol cooling element, or both that do not include hollow tubular segments are also consistent with... Figure 4 The implementation is compatible.

[0266] exist Figure 4 In this configuration, the support element 12 and the aerosol cooling element 15 together define a central hollow section of the aerosol generation article 10. Overall, the central hollow section is suitable for the matrix aerosol to flow downstream to the downstream end 14 and does not substantially contribute to the overall suction resistance of the aerosol generation article 10.

[0267] exist Figure 4 In one embodiment, the filter 17 is disposed downstream of the aerosol cooling element 15 in the longitudinal direction. For example... Figure 4 As shown, the upstream end of filter 17 is adjacent to the downstream end of aerosol cooling element 15.

[0268] Filter 17 is provided in the form of a cylindrical filter tip segment of low-density cellulose acetate.

[0269] exist Figure 4 In this embodiment, the aerosol generating article 10 includes an upstream element 16. The upstream element 16 is adjacent to the upstream end of the aerosol forming matrix 11. This advantageously prevents the receptor 40 from being displaced. Furthermore, this ensures that consumers will not accidentally come into contact with the heated receptor 40 after use.

[0270] The upstream element 16 is provided in the form of a cylindrical filter tip segment of cellulose acetate.

[0271] exist Figure 3 and 4 In some embodiments not shown, the aerosol generating article 10 includes a mouthpiece disposed immediately downstream of the filter 17.

[0272] Figure 5 A schematic longitudinal section of an aerosol generation system, including an aerosol generation apparatus 200 and an aerosol generation article 10, is shown. The aerosol generation article 10 can be... Figures 1 to 4 Any product of the product.

[0273] The aerosol generating device 200 includes a generally cylindrical device housing 207 having a shape and size similar to that of a conventional cigar.

[0274] The aerosol generating apparatus 200 also includes a power supply 201 in the form of a rechargeable nickel-cadmium battery, a controller 202 in the form of a printed circuit board including a microprocessor, an electrical connector 203, and a heating element 204. The heating element 204 is configured to heat the aerosol forming matrix 11.

[0275] exist Figure 5In one embodiment, the heating element 204 is an induction heating device 204, which includes at least one inductor coil 206 designed to cooperate with the sensor 40 of the aerosol generating article 10. However, other forms of heating elements, such as resistance heating elements, may be used. Again, the induction heating device 204 may include a sensor. The latter device is preferably used with aerosol generating articles that do not include a sensor.

[0276] The power supply 201, controller 202, and sensor coil 206 are all housed within the device housing 207. The sensor coil 206 of the aerosol generating device 200 is located at the proximal end of the device 200. The electrical connector 203 is located at the distal end of the device housing 207.

[0277] As used herein, the term "proximal" refers to the user end or mouth end of an aerosol generating device or aerosol generating article. The proximal end of a component of an aerosol generating device or aerosol generating article is the end of the component closest to the user end or mouth end of the aerosol generating device or aerosol generating article. As used herein, the term "distal" refers to the end opposite the proximal end.

[0278] Controller 202 is configured to control the power supply from power source 201 to inductor coil 206. Controller 202 also includes a DC / AC inverter, including a Class D power amplifier. Controller 202 is further configured to control the recharging of power source 201 from electrical connector 203. Controller 202 also includes a suction sensor (not shown) configured to sense when a user inhales onto an aerosol-generating article received in device cavity 208.

[0279] The sensor coil 206 is connected to the controller 202 and the power supply 201, and the controller 202 is configured to supply a varying current to the matrix sensor coil 206. When the varying current is supplied to the sensor coil 206, the sensor coil generates a varying magnetic field, which heats the sensor 40 by induction.

[0280] like Figure 6 As shown, the device housing 207 also defines a device air inlet 213 adjacent to the distal end of the cavity 208 for receiving the aerosol-generating article 10. The device air inlet 213 is configured such that ambient air can be drawn into the device housing 207 toward the aerosol-generating matrix 11.

Claims

1. An aerosol-generating article, comprising: Aerosols form a matrix; as well as Packaging material that surrounds the aerosol to form a matrix; The packaging defines an overlapping area of ​​itself, the overlapping area including a first segment and a second segment externally disposed on the first segment; The second section includes a fold portion that defines a fold section at one end of the package; The folded section is sandwiched between the first section and the second section; and An external adhesive is disposed between the folded section and the second section.

2. The aerosol-generating article according to claim 1, wherein the internal adhesive is disposed between the folded section and the first section.

3. The aerosol generating article according to claim 1, wherein the adhesive comprises one or more of the following: gum arabic, natural or synthetic resin, starch, and varnish.

4. The aerosol generating article according to claim 1 further includes a heating element embedded in the aerosol forming matrix.

5. The aerosol generating article according to claim 4, wherein the heating element is a sensor.

6. The aerosol-generating article of claim 4, wherein the heating element is completely surrounded by the aerosol-forming matrix and extends along the entire length of the aerosol-forming matrix.

7. The aerosol-generating article according to claim 1, wherein the diameter of the aerosol-generating article is between 3 mm and 8 mm.

8. The aerosol-generating article of claim 1, wherein the packaging has a thickness between 60 micrometers and 200 micrometers.

9. The aerosol-generating article according to claim 1, wherein the aerosol-forming matrix comprises a fragrance matrix.

10. The aerosol-generating article according to claim 1, wherein the aerosol-forming matrix comprises one or more of tobacco, nicotine, and gel components.

11. The aerosol generating article according to claim 1, further comprising a filter disposed downstream of the aerosol forming matrix.

12. The aerosol-generating article according to claim 1, wherein the length of the aerosol-generating article is between 30 mm and 100 mm.

13. An aerosol generation system, comprising: Aerosol-generated articles according to any one of claims 1 to 12; and Aerosol generation device.

14. The aerosol generation system according to claim 13, wherein the aerosol generation device includes a resistance heating element.

15. The aerosol generation system according to claim 13, wherein the aerosol generation device includes a sensor coil.

Images