Aerosol-generating article comprising hollow tubular element with balloon and ventilation

Abstract

An aerosol-generating article (10) for generating an inhalable aerosol upon heating comprises a hollow tubular element (101) and a bladder (102) mounted within the hollow tubular element (101) at an upstream end of the hollow tubular element (101). The capsule (102) contains an aerosol-generating substrate. The hollow tubular element (101) comprises a ventilation zone to allow external air to enter the aerosol-generating article (10). A ventilation zone is disposed downstream of the downstream end of the bladder (102).

Description

Technical Field

[0001] The present invention relates to an aerosol - generating article, which comprises an aerosol - generating substrate and is adapted to generate an inhalable aerosol upon heating. In particular, the present invention relates to an aerosol - generating article which comprises an aerosol - generating substrate housed within a capsule, and the aerosol - generating article further comprises a ventilation zone. Background Art

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

[0003] Many prior - art documents disclose aerosol - generating devices for consuming aerosol - generating articles. Such devices include, for example, electrically heated aerosol - generating devices, in which an aerosol is generated by transferring heat from one or more electrical heater elements of the aerosol - generating device to the aerosol - generating substrate of the heated aerosol - generating article. For example, electrically heated aerosol - generating devices have been proposed that include internal heater blades adapted to be inserted into the aerosol - generating substrate.

[0004] It is also known to use an aerosol - generating article in combination with an external heating system. For example, WO2020 / 115151 describes the provision of one or more heating elements arranged around the perimeter of an aerosol - generating article when the aerosol - generating article is received in a cavity of an aerosol - generating device. As an alternative, WO2015 / 176898 proposes an inductively heatable aerosol - generating article which comprises an aerosol - generating substrate and a susceptor arranged within the aerosol - generating substrate.

[0005] Certain types of aerosol - forming substrates containing nicotine and a relatively high content of aerosol - forming agents are known, for example, gels and membranes containing nicotine. Such substrates are generally very stable during storage and advantageously provide very consistent nicotine delivery to the consumer upon heating. They can also advantageously generate an aerosol at a lower temperature than other solid substrates. However, the use of this type of aerosol - forming substrate can also pose problems. The relatively high content of aerosol - forming agents increases the risk of leakage of the aerosol - forming agent from the substrate during storage and during use. Leakage of the aerosol - forming agent from the aerosol - generating article is undesirable because it can leak into the heating chamber of the aerosol - generating device and potentially contaminate the aerosol - generating device. Leakage of the aerosol - forming agent or gel composition can also be unpleasant for the consumer.

[0006] Accordingly, it is desirable to provide a novel aerosol - generating article having an arrangement that provides improved retention of the aerosol - forming substrate within the aerosol - generating article during storage and use.

[0007] In addition, it is desirable to provide a novel aerosol - generating article having an arrangement that maximizes the generation and delivery of aerosol from the aerosol - forming substrate. Summary of the Invention

[0008] The present disclosure relates to an aerosol - generating article for generating an inhalable aerosol upon heating. The aerosol - generating article may include a hollow tubular element. The aerosol - generating article may include a capsule mounted within the hollow tubular element. The capsule may be located at an upstream end of the hollow tubular element. The capsule may contain an aerosol - forming substrate. The hollow tubular element may include a ventilation zone to allow external air to enter the aerosol - generating article. The ventilation zone may be provided downstream of the downstream end of the capsule.

[0009] According to a first aspect of the invention, there is provided an aerosol - generating article for generating an inhalable aerosol upon heating, the article comprising a hollow tubular element and a capsule mounted within the hollow tubular element at an upstream end thereof. The capsule contains an aerosol - forming substrate. The hollow tubular element includes a ventilation zone to allow external air to enter the aerosol - generating article. The ventilation zone is provided downstream of the downstream end of the capsule.

[0010] An aerosol - generating substrate contained within a capsule can advantageously provide an efficient way to keep the aerosol - generating substrate in place within the aerosol - generating article during storage and use. The configuration of the present invention may be particularly advantageous for aerosol - generating substrates having a relatively high aerosol - forming agent content. Containing the aerosol - generating substrate within a capsule prevents the aerosol - forming agent from leaking from the aerosol - generating substrate during storage or use. Additionally, in the case where the aerosol - generating substrate melts upon heating, the molten substrate can be effectively retained within the capsule. Thus, leakage of the aerosol - forming agent or the aerosol - generating substrate from the aerosol - generating article during use can be substantially prevented, advantageously minimizing the risk of contamination of the aerosol - generating device.

[0011] The arrangement of the capsule within the hollow tubular element is relatively simple and, thus, can advantageously reduce the amount of material required to produce the aerosol - generating article compared to existing aerosol - generating articles with more complex structures. In particular, in the case of using an aerosol - generating substrate that can generate an aerosol at a relatively low temperature, it is possible to produce an aerosol - generating article according to the present invention with a minimum amount of filter material downstream of the capsule.

[0012] Providing a ventilation zone downstream of the downstream end of the capsule can allow ambient air to be drawn into the hollow tubular element. Providing ambient air can advantageously improve the generation of an aerosol from the aerosol - generating substrate. Without wishing to be bound by theory, the cold ambient air provided by the ventilation zone can mix with the warmer air from the capsule. This mixing can advantageously promote the nucleation of the aerosol, which can then be delivered to the user through the downstream end of the aerosol - generating article. For example, in the case where the aerosol - generating substrate contains nicotine and an aerosol - forming agent such as glycerol, heating of the aerosol - generating substrate during use can generate free - base nicotine vapor and volatile organic acid vapor. When these vapors are cooled by the ambient air, acid droplets are formed in combination with the volatile free - base nicotine. In this way, nicotine can be delivered as a nicotine salt. Additionally, the nicotine salt can bind to larger condensed glycerol droplets to make the nicotine more readily adsorbed. Thus, the cooling effect of the ventilation zone can advantageously improve the aerosol generation and delivery of the aerosol - generating article.

[0013] In use, the aerosol - generating article of the present invention can be used with a corresponding aerosol - generating device. The aerosol - generating article can be inserted into the aerosol - generating device, which can heat at least a portion of the capsule containing the aerosol - generating article. This can heat the aerosol - generating substrate, thereby generating vapors. These vapors can leave the capsule and mix with the ambient air provided by the ventilation zone, at which point the vapors can condense and nucleate to form an aerosol that can be delivered to the user.

[0014] As discussed in more detail below, additional components may or may not be provided downstream of the ventilation zone. As discussed in more detail below, the capsule may include at least one air inlet and at least one air outlet.

[0015] The term "aerosol-generating article" is used herein to denote an article in which an aerosol-generating substrate is heated to produce an inhalable aerosol and the inhalable aerosol is delivered to a consumer. As used herein, the term "aerosol-generating substrate" denotes a substrate capable of releasing volatile compounds upon heating to generate an aerosol.

[0016] As used herein, the term "aerosol-generating device" refers to a device including a heater element that interacts with an aerosol-generating substrate of an aerosol-generating article to generate an aerosol.

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

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

[0019] The term "length" denotes the dimension of a component of the aerosol-generating article in the longitudinal direction. For example, it may be used to denote the dimension of a strip or an elongate tubular element in the longitudinal direction.

[0020] As used herein, the term "hollow tubular element" is used to denote a generally elongate element that defines a lumen or air flow passage along its longitudinal axis. In particular, the term "tubular" will be used hereinafter to refer to a tubular element having a substantially cylindrical cross-section and defining at least one air flow conduit that establishes unbroken fluid communication between the upstream end and the downstream end of the tubular element. However, it should be understood that alternative geometries (e.g., alternative cross-sectional shapes) of the tubular element may be possible.

[0021] In the context of the present invention, the hollow tubular element provides an unconstrained flow channel. This means that the hollow tubular element provides a negligible suction resistance (RTD) level. The term "negligible RTD level" is used to describe less than 1 mmHg 2A hollow tubular element with a length of 0 / 10 millimeters, preferably less than 0.4 mmH 2 A hollow tubular element with a length of 0 / 10 millimeters, more preferably less than 0.1 mmH 2 The RTD of a hollow tubular element with a length of 0 / 10 millimeters.

[0022] As described above, the hollow tubular element has a capsule for containing an aerosol - generating substrate mounted at the upstream end. In addition, the hollow tubular element defines a cavity downstream of the capsule, which extends along a part or all of the length of the hollow tubular element. In some embodiments, the cavity extends from the capsule to the downstream end of the aerosol - generating article. In such embodiments, the aerosol - generating article can thus be formed from only two elements: the capsule and the hollow tubular element. Alternatively, as described in more detail below, one or more filter segments can be disposed within the hollow tubular element at the downstream end thereof.

[0023] The cavity defined within the hollow tubular element downstream of the capsule preferably has a length of at least 10 millimeters, more preferably at least 12 millimeters, and even more preferably at least 14 millimeters. The length of the cavity can be up to 40 millimeters, or up to 30 millimeters, or up to 25 millimeters. For example, the cavity can have a length between 10 millimeters and 40 millimeters, or between 12 millimeters and 30 millimeters, or between 14 millimeters and 25 millimeters.

[0024] The hollow tubular element preferably has a total length of at least 25 millimeters, more preferably at least 28 millimeters, more preferably at least 30 millimeters, more preferably at least 32 millimeters, more preferably at least 34 millimeters. The length of the hollow tubular element can be less than 50 millimeters, or less than 48 millimeters, or less than 45 millimeters, or less than 42 millimeters, or less than 40 millimeters. For example, the total length of the hollow tubular element can be between 25 millimeters and 50 millimeters, or between 28 millimeters and 48 millimeters, or between 30 millimeters and 45 millimeters, or between 32 millimeters and 42 millimeters, or between 34 millimeters and 40 millimeters.

[0025] The hollow tubular element can have an outer diameter between about 5 millimeters and about 12 millimeters, for example between about 5 millimeters and about 10 millimeters or between about 6 millimeters and about 8 millimeters. In a preferred embodiment, the hollow tubular element has an external diameter of 7.2 millimeters ± 10%.

[0026] The internal diameter of the hollow tubular element is preferably constant along the length of the hollow tubular element. The lumen or cavity of the hollow tubular segment can have any cross - sectional shape. The lumen of the hollow tubular segment can have a circular cross - sectional shape.

[0027] Preferably, the inner diameter of the hollow tubular element is at least 5 millimeters, more preferably at least 5.5 millimeters, more preferably at least 6 millimeters, more preferably at least 6.5 millimeters. The inner diameter of the hollow tubular element is preferably less than 9 millimeters, more preferably less than 8.5 millimeters, more preferably less than 8 millimeters, more preferably less than 7.5 millimeters. For example, the inner diameter may be between 5 millimeters and 9 millimeters, or between 5.5 millimeters and 8.5 millimeters, or between 6 millimeters and 6 millimeters, or between 6.5 millimeters and 7.5 millimeters. The inner diameter may be about 7 millimeters.

[0028] The hollow tubular element preferably has a wall thickness of at least 100 micrometers, more preferably at least 150 micrometers, more preferably at least 200 micrometers, more preferably at least 250 micrometers, more preferably at least 500 micrometers. The wall thickness of the hollow tubular element may be less than 2 millimeters, preferably less than 1.5 millimeters, and even more preferably less than 1.25 millimeters. The wall thickness of the hollow tubular element may be less than 1 millimeter. For example, the wall thickness of the hollow tubular element may be between 100 micrometers and 2 millimeters, or between 150 micrometers and 1.5 millimeters, or between 200 micrometers and 1.25 millimeters, or between 250 micrometers and 1 millimeter, or between 500 micrometers and 1 millimeter.

[0029] The hollow tubular segment may comprise a paper-based material. The hollow tubular segment may comprise at least one paper layer. The paper may be very hard paper. The paper may be curled paper, such as curled heat-resistant paper or curled parchment paper. Advantageously, the curled paper may form one or more air flow channels extending around the exterior of the capsule. In embodiments where the capsule includes at least one of an air inlet and an air outlet in the cylindrical wall of the capsule, the one or more air flow channels may be particularly advantageous.

[0030] Preferably, the hollow tubular element is formed of cardboard. The hollow tubular element may be a cardboard tube. Advantageously, cardboard is a cost-effective material that provides a balance between being deformable to facilitate insertion of the article into the aerosol-generating device and being rigid enough to provide proper engagement of the article with the interior of the device. Thus, the cardboard tube may provide a suitable resistance to deformation or compression during use.

[0031] The hollow tubular segment may be a paper tube. The hollow tubular segment may be a tube formed by helically winding paper. The hollow tubular segment may be formed of multiple paper layers. The paper may have a basis weight of at least about 50 grams per square meter, at least about 60 grams per square meter, at least about 70 grams per square meter, or at least about 90 grams per square meter.

[0032] The hollow tubular segment may comprise a polymeric material. For example, the hollow tubular segment may comprise a polymeric film. The polymeric film may comprise a cellulose film. The hollow tubular segment may comprise low density polyethylene (LDPE) or polyhydroxyalkanoate (PHA) fibers. The hollow tube may comprise cellulose acetate tow.

[0033] In the case where the hollow tubular segment comprises a cellulose acetate tow, the cellulose acetate tow may have a denier per filament between about 2 and about 4 and a total denier between about 25 and about 40.

[0034] The capsule may be mounted within the hollow tubular element such that a portion of the capsule extends from the upstream end of the hollow tubular element, whereby at least one capsule air inlet is positioned outside the hollow tubular element. Preferably, at least 20% of the length of the capsule, more preferably at least 30% of the length of the capsule, protrudes from the hollow tubular element. Preferably, no more than 50% of the length of the capsule protrudes from the hollow tubular element. Thus, most of the capsule is within the hollow tubular element such that the capsule can be firmly held in place. In such embodiments, the hollow tubular element may include at least one stop, such as a flange or protrusion extending inwardly from the inner surface at the downstream end of the capsule, to prevent the capsule from being further pushed downstream into the hollow tubular element. For example, the hollow tubular element may include an annular flange extending from the inner surface. The arrangement of at least one stop is described in more detail below.

[0035] The ventilation zone may include at least one ventilation perforation.

[0036] As described above, at least one ventilation perforation may advantageously allow ambient air to enter the hollow tubular element to improve aerosol generation.

[0037] The ventilation zone may include a plurality of ventilation perforations passing through the hollow tubular element.

[0038] Providing a plurality of ventilation perforations may advantageously allow more ambient air to enter the hollow tubular element. Additionally, providing a plurality of perforations may provide a more uniform distribution of ambient air into the hollow tubular element. This may advantageously further improve aerosol generation.

[0039] The ventilation zone may include at least 2 ventilation perforations. For example, the ventilation zone may include at least 2, at least 3, at least 5, or at least 10 ventilation perforations passing through the hollow tubular element.

[0040] Providing a greater number of ventilation perforations than this may advantageously improve aerosol generation.

[0041] The ventilation zone may include no more than 35 ventilation perforations. For example, the ventilation zone may include no more than 30, no more than 25, no more than 20, or no more than 15 ventilation perforations passing through the hollow tubular element.

[0042] This limitation on the number of ventilation perforations may advantageously prevent the hollow tubular element from being weakened by the ventilation zone. This may also advantageously prevent the draw resistance from being reduced to an unacceptable level.

[0043] The ventilation area may include from 2 to 35 ventilation perforations. For example, the ventilation area may include from 3 to 30 ventilation perforations, from 5 to 25 ventilation perforations, from 5 to 20 ventilation perforations, or from 10 to 15 ventilation perforations. The ventilation area may include from 5 to 15 ventilation perforations.

[0044] The plurality of ventilation perforations may include at least one perforation having a width of no more than 200 micrometers.

[0045] For example, the plurality of ventilation perforations may include at least one perforation having a width of no more than 175 micrometers, no more than 150 micrometers, no more than 125 micrometers, or no more than 120 micrometers.

[0046] The plurality of ventilation perforations may include at least one perforation having a width of no more than 2 millimeters. For example, the plurality of ventilation perforations may include at least one perforation having a width of no more than 1.5 millimeters, no more than 1 millimeter, no more than 500 micrometers, or no more than 250 micrometers.

[0047] The plurality of ventilation perforations may include at least one perforation having a width of at least 50 micrometers. For example, the plurality of ventilation perforations may include at least one perforation having a width of at least 65 micrometers, at least 80 micrometers, at least 90 micrometers, or at least 100 micrometers.

[0048] The plurality of ventilation perforations may include at least one perforation having a length of at least 400 micrometers. For example, the plurality of ventilation perforations may include at least one perforation having a length of at least 425 micrometers, at least 450 micrometers, at least 475 micrometers, or at least 500 micrometers.

[0049] The plurality of ventilation perforations may include at least one perforation having a length of no more than 1 millimeter. For example, the plurality of ventilation perforations may include at least one perforation having a length of no more than 950 micrometers, no more than 900 micrometers, no more than 850 micrometers, or no more than 800 micrometers.

[0050] In the case where the ventilation area includes a plurality of ventilation perforations, each ventilation perforation among the plurality of ventilation perforations may have substantially the same size. This can advantageously ensure uniform supply of ambient air to the hollow tubular element.

[0051] The plurality of ventilation perforations may form a row of perforations defining the hollow tubular element.

[0052] The ventilation area may include a porous portion of the hollow tubular element.

[0053] This can prevent any perforations from being visible on the outer surface of the aerosol-generating article. This can advantageously improve the appearance of the aerosol-generating article. Additionally, providing a porous portion of the hollow tubular element can advantageously improve the strength of the hollow tubular element as it can eliminate the need for ventilation perforations.

[0054] The porous portion of the hollow tubular element that forms the ventilation zone may have a basis weight lower than that of the portion of the hollow tubular element that does not form part of the ventilation zone.

[0055] The upstream end of the ventilation zone may be positioned at least 20 millimeters from the upstream end of the aerosol-generating article.

[0056] For example, the upstream end of the ventilation zone may be positioned at least about 25 millimeters from the upstream end of the aerosol-generating article.

[0057] When the aerosol-generating article is used with an aerosol-generating device, positioning the ventilation zone as described above can ensure that the ventilation zone is located outside the corresponding aerosol-generating device. This can advantageously ensure that the ventilation zone is not blocked by the aerosol-generating device during use, and can also ensure that the ambient air entering the aerosol-generating device through the ventilation zone is not heated by the heater of the aerosol-generating device.

[0058] The upstream end of the ventilation zone may be positioned no more than 37 millimeters from the upstream end of the aerosol-generating article.

[0059] For example, the upstream end of the ventilation zone may be positioned no more than about 30 millimeters from the upstream end of the aerosol-generating article.

[0060] Positioning the ventilation zone as described above can advantageously prevent the ventilation zone from being blocked by the user's mouth or lips when the aerosol-generating article is in use.

[0061] The upstream end of the ventilation zone may be positioned between about 20 millimeters and about 37 millimeters, or between about 25 millimeters and about 30 millimeters, from the upstream end of the aerosol-generating article. The upstream end of the ventilation zone may be positioned about 27 millimeters from the upstream end of the aerosol-generating article.

[0062] The upstream end of the ventilation zone may be positioned no more than 10 millimeters from the downstream end of the capsule.

[0063] For example, the upstream end of the ventilation zone may be positioned no more than 8 millimeters, no more than 5 millimeters, no more than 3 millimeters, or no more than 1 millimeter from the downstream end of the capsule.

[0064] The upstream end of the ventilation zone may be longitudinally aligned with the downstream end of the capsule.

[0065] Positioning the ventilation zone close to the downstream end of the capsule can advantageously provide a rapid and sharp decrease in temperature as soon as the vapor leaves the capsule. This can advantageously promote the effective nucleation of the aerosol from the vapor.

[0066] The ventilation level of the aerosol-generating article provided by the ventilation zone may be at least 20%.

[0067] The aerosol-generating article may generally have a ventilation level of at least about 10%, preferably at least about 20%.

[0068] In a preferred embodiment, the aerosol-generating article has a ventilation level of at least about 20% or 25% or 30%. More preferably, the aerosol-generating article has a ventilation level of at least about 35%.

[0069] The aerosol-generating article preferably has a ventilation level of less than about 80%. More preferably, the aerosol-generating article has a ventilation level of less than about 60% or less than about 50%.

[0070] The aerosol-generating article can generally have a ventilation level between about 10% and about 80%.

[0071] In some embodiments, the aerosol-generating article has a ventilation level of from about 20% to about 80%, preferably from about 20% to about 60%, more preferably from about 20% to about 50%. In other embodiments, the aerosol-generating article has a ventilation level of from about 25% to about 80%, preferably from about 25% to about 60%, more preferably from about 25% to about 50%. In further embodiments, the aerosol-generating article has a ventilation level of from about 30% to about 80%, preferably from about 30% to about 60%, more preferably from about 30% to about 50%.

[0072] In a particularly preferred embodiment, the aerosol-generating article has a ventilation level of from about 40% to about 50%. In some particularly preferred embodiments, the aerosol-generating article has a ventilation level of about 45%.

[0073] The aerosol-generating article may further comprise at least one stop, the at least one stop protruding from the inner surface of the hollow tubular element to prevent the capsule from moving downstream beyond the at least one stop.

[0074] Providing at least one stop can advantageously help to hold the capsule in place within the hollow tubular element. In particular, the at least one stop can advantageously prevent the capsule from moving too far downstream, in which case the capsule may block the ventilation zone, thereby preventing ambient air from entering the hollow tubular element.

[0075] The at least one stop can be located upstream of the ventilation zone.

[0076] Positioning the at least one stop upstream of the ventilation zone can further advantageously prevent the capsule from moving too far downstream and blocking the ventilation zone.

[0077] The at least one stop can be any type of stop. The at least one stop can limit the inner diameter of the hollow tubular element at a point. The inner diameter of the hollow tubular element at the at least one stop can be less than the outer diameter of the capsule, thereby preventing the capsule from moving downstream beyond the at least one stop.

[0078] The at least one stop can include a raised portion of the hollow tubular element extending into the interior of the hollow tubular element.

[0079] At least one stop may include a thicker portion of the hollow tubular element, which reduces the inner diameter of the hollow tubular element to prevent the capsule from moving further downstream than the thicker portion.

[0080] At least one stop may include a flange that is within and attached to the hollow tubular element, the flange preventing the capsule from moving further downstream.

[0081] The hollow tubular element may include at least one flap formed from a portion of the hollow tubular element that is partially separated from the remainder of the hollow tubular element, thereby forming a gap between the flap and the remainder of the hollow tubular element, the flap remaining attached to the remainder of the hollow tubular element along an attachment line, wherein the flap extends into the interior or the hollow tubular element such that: the at least one stop includes the at least one flap, and the at least one ventilation perforation includes the gap between the flap and the remainder of the hollow tubular element.

[0082] In other words, at least one ventilation perforation may be formed by piercing a hole in the hollow tubular element from the outside of the hollow tubular element to form a hole. In doing so, a portion of the hollow tubular element is pushed into the interior of the hollow tubular element. The piercing is performed such that this portion of the hollow tubular element remains attached to the hollow tubular element along the attachment line, thereby forming a flap. This flap extending into the interior of the hollow tubular element is the at least one stop.

[0083] Forming at least one stop in this way may advantageously allow both a ventilation zone and at least one stop to be formed during a single process, thereby simplifying the manufacture of the aerosol-generating article.

[0084] The attachment line may be located at the upstream end of the flap. Positioning the attachment line at the upstream end of the flap may advantageously mean that the flap acting as at least one stop is upstream of the ventilation perforation formed by the manufacture of the flap. As described above, this may advantageously prevent the capsule from blocking the ventilation perforation, which would disadvantageously prevent ambient air from entering the hollow tubular element.

[0085] The capsule may include a capsule outer wall that defines a lumen for containing an aerosol-generating substrate.

[0086] The capsule outer wall may be formed of any suitable material. Preferably, the capsule outer wall is formed of an air-impermeable material, most preferably an air-impermeable polymeric material. This ensures that air does not pass through the capsule outer wall except through the holes specifically provided for the airflow during use. Thus, the airflow through the capsule during use can be effectively controlled.

[0087] The outer wall of the capsule may comprise a polymeric material or a cellulose-based material. For example, the outer wall of the capsule may be made of one or more polymers compatible with nicotine, including medical-grade polymers such as the medical resin polymethyl methacrylate (PMMA), Chevron Phillips K- styrene-butadiene copolymer (SBC), Arkema specialty polymers and Clear, DOW (Health+ TM ) low density polyethylene (LDPE), DOW TM LDPE 91003, DOW TM LDPE 91020 (MFI 2.0; density 923), ExxonMobil TM polypropylene (PP) PP1013H1, PP1014H1 and PP9074MED, Trinseo CALIBRE TM polycarbonate (PC) 2060-SERIES.

[0088] The outer wall of the capsule may alternatively be formed from one or more materials selected from: polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), gelatin, and hydroxypropyl methylcellulose (HPMC).

[0089] In embodiments where it is contemplated that the outer wall of the capsule is pierced by a heating element or a piercing element in an aerosol generating device, as described below, the outer wall of the capsule should be formed from a pierceable or fragile material. The upstream end wall of the capsule may optionally include one or more weakened lines or weakened areas positioned to facilitate insertion of the heating element through the outer wall of the capsule during use.

[0090] The capsule is preferably of a capsule shape in the form of a sphere-cylinder, having a cylindrical portion defined by a cylindrical wall and rounded hemispherical end walls at each end of the cylindrical portion. This type of capsule is commonly used in the pharmaceutical industry. Alternatively, the capsule may be spherical or oval.

[0091] Preferably, the capsule is a two-part capsule having two separate parts that fit together to enclose the capsule and retain the contents. The two separate parts may fit together by friction fit without the need for an adhesive. Alternatively, an adhesive may be used to seal the two parts together.

[0092] Preferably, the capsule comprises a first part and a second part, wherein the second part has a smaller diameter than the first part such that the end of the second part can be inserted into the open end of the first part to enclose the capsule.

[0093] In such embodiments, the outer diameters of the first and second portions of the bladder may be adapted such that only the second portion of the bladder can be received within the hollow tubular element. The outer diameter of the first portion of the bladder is adapted to be greater than the inner diameter of the hollow tubular element such that the first portion of the bladder cannot be received within the hollow tubular element and remains outside the hollow tubular element. Preferably, the second portion of the bladder is retained within the hollow tubular element by a friction fit.

[0094] Alternatively, the bladder may be fully inserted into the hollow tubular element, and the outer diameters of the first and second portions of the bladder may be adapted such that the outer diameter of the second portion is less than the inner diameter of the hollow tubular element. This provides a space between the second portion of the bladder and the wall of the hollow tubular element such that an air flow can pass around the second portion of the bladder. As described below, such an arrangement may be beneficial in embodiments where it is desired to locate an air outlet on the cylindrical wall of the bladder.

[0095] The inner cavity of the bladder has a volume of at least 250 cubic millimeters corresponding to 0.25 millimeters. This corresponds to the internal volume, or capacity, of the bladder. Preferably, the inner cavity of the bladder has a volume of at least 400 cubic millimeters (0.4 milliliters), more preferably at least 500 cubic millimeters (0.5 milliliters), more preferably at least 600 cubic millimeters (0.6 milliliters). The inner cavity of the bladder may be less than 2000 cubic millimeters (2 milliliters), or less than 1500 cubic millimeters (1.5 milliliters) or less than 1000 cubic millimeters (1 milliliter). For example, standard bladder sizes 000, 00, 0, 0, 1, 2, and 3 may be suitable.

[0096] The bladder preferably has a length of at least 10 millimeters, more preferably at least 12 millimeters, more preferably at least 15 millimeters, more preferably at least 18 millimeters. The length of the bladder is preferably less than 30 millimeters, more preferably less than 28 millimeters, more preferably less than 25 millimeters. For example, the bladder length may be between 10 millimeters and 30 millimeters, or between 12 millimeters and 28 millimeters, or between 15 millimeters and 25 millimeters, or between 18 millimeters and 25 millimeters. The bladder length may be approximately 20 millimeters.

[0097] The bladder preferably has a maximum diameter of at least 5 millimeters, more preferably at least 5.5 millimeters, more preferably at least 6 millimeters, more preferably at least 6.5 millimeters. The maximum diameter of the bladder is preferably less than 9 millimeters, more preferably less than 8.5 millimeters, more preferably less than 8 millimeters, more preferably less than 7.5 millimeters. For example, the bladder maximum diameter may be between 5 millimeters and 9 millimeters, or between 5.5 millimeters and 8.5 millimeters, or between 6 millimeters and 6 millimeters, or between 6.5 millimeters and 7.5 millimeters. The bladder maximum diameter may be approximately 7 millimeters.

[0098] The outer diameter of the bladder may be substantially the same as the inner diameter of the hollow tubular element.

[0099] In this way, air is substantially prevented from passing from the upstream end of the hollow tubular element to the downstream end thereof without passing through the capsule.

[0100] Without wishing to be bound by theory, it is expected that once air leaves the capsule through at least one capsule air outlet and enters the interior of the hollow tubular element, the airflow through the aerosol-generating article will be significantly slowed down. This is because the diameter of the hollow tubular element is larger than the diameter of at least one capsule air outlet. This slowing down of the airflow also results in a pressure drop, which can additionally facilitate the desired nucleation of the aerosol. Additionally, the slowing down of the airflow can also improve the cooling of the airflow by ambient air entering through the ventilation zone. This can further advantageously promote aerosol generation.

[0101] The lumen of the capsule preferably contains at least 50 mg of the solid aerosol-generating substrate, more preferably at least 100 mg of the solid aerosol-generating substrate, and even more preferably at least 150 mg of the solid aerosol-generating substrate. The lumen can contain up to 1000 mg of the solid aerosol-generating substrate, or up to 750 mg of the solid aerosol-generating substrate, or up to 500 mg of the solid aerosol-generating substrate, or up to 250 mg of the solid aerosol-generating substrate. For example, the lumen of the capsule can contain a solid aerosol-generating substrate between 50 mg and 1000 mg, or between 100 mg and 750 mg, or between 150 mg and 500 mg, or between 150 mg and 250 mg.

[0102] According to the present invention, the density of the solid aerosol - forming substrate within the capsule corresponds to a lumen of at least 0.1 mg / mm³. This corresponds to the total weight of the solid aerosol - forming substrate divided by the total volume of the lumen. Preferably, the density of the solid aerosol - forming substrate within the capsule corresponds to a lumen of at least 0.12 mg / mm³, more preferably at least 0.15 mg / mm³, more preferably at least 0.18 mg / mm³, more preferably at least 0.2 mg / mm³, more preferably at least 0.22 mg / mm³, more preferably at least 0.25 mg / mm³, more preferably at least 0.28 mg / mm³, more preferably at least 0.3 mg / mm³, more preferably at least 0.32 mg / mm³, more preferably at least 0.35 mg / mm³, more preferably at least 0.38 mg / mm³, more preferably at least 0.4 mg / mm³. Preferably, the density of the solid aerosol - forming substrate within the capsule corresponds to a lumen of less than 2 mg / mm³, more preferably less than 1.9 mg / mm³, more preferably less than 1.8 mg / mm³, more preferably less than 1.7 mg / mm³, more preferably less than 1.6 mg / mm³, more preferably less than 1.5 mg / mm³, more preferably less than 1.4 mg / mm³, more preferably less than 1.3 mg / mm³, more preferably less than 1.2 mg / mm³, more preferably less than 1.1 mg / mm³, more preferably less than 1 mg / mm³. For example, the density of the solid aerosol - forming substrate within the capsule may correspond to a lumen between 0.1 mg / mm³ and 2 mg / mm³, or between 0.12 mg / mm³ and 1.9 mg / mm³, or between 0.15 mg / mm³ and 1.8 mg / mm³, or between 0.18 mg / mm³ and 1.7 mg / mm³, or between 0.2 mg / mm³ and 1.6 mg / mm³, or between 0.22 mg / mm³ and 1.5 mg / mm³, or between 0.25 mg / mm³ and 1.4 mg / mm³, or between 0.28 mg / mm³ and 1.3 mg / mm³, or between 0.3 mg / mm³ and 1.2 mg / mm³, or between 0.32 mg / mm³ and 1.1 mg / mm³, or between 0.35 mg / mm³ and 1 mg / mm³, or between 0.38 mg / mm³ and 1 mg / mm³, or between 0.4 mg / mm³ and 1 mg / mm³.

[0103] The filling percentage of the solid aerosol - generating substrate in the capsule is preferably at least 50%, more preferably at least 60%, and even more preferably at least 70%. The filling percentage is preferably less than 90%. The filling percentage corresponds to the percentage of the inner cavity of the capsule occupied by the solid aerosol - generating substrate. It may be advantageous to maintain some empty space within the inner cavity to allow air flow through the inner cavity and to allow the solid aerosol - generating substrate to be uniformly heated.

[0104] The capsule may be adapted to provide one or more air flow paths through the capsule during heating. This enables the aerosol generated from the aerosol - generating substrate to be drawn through the aerosol - generating article and delivered to the consumer. The capsule may be initially sealed and airtight, but is adapted to create an air flow path when the aerosol - generating article is inserted into the aerosol - generating device, for example, by the insertion of an internal heating element or by means of a piercing element that pierces the outer wall of the capsule.

[0105] Alternatively and preferably, the capsule includes at least one capsule air inlet and at least one capsule air outlet in the capsule outer wall. The at least one capsule air inlet and the at least one capsule air outlet define one or more air flow paths through the inner cavity of the capsule. The at least one capsule air outlet is disposed downstream of the at least one capsule air inlet.

[0106] The capsule may include at least one capsule air inlet located at the upstream end of the capsule and at least one capsule air outlet located at the downstream end of the capsule.

[0107] The capsule may include a plurality of capsule air inlets. For example, the capsule may include between 2 and 6 capsule air inlets.

[0108] The capsule may include a plurality of capsule air outlets. For example, the capsule may include between 2 and 6 capsule air outlets. The number of capsule air outlets may be the same as or different from the number of capsule air inlets. It may be advantageous to provide a greater number of capsule air outlets than capsule air inlets, as the capsule air outlets need to allow the aerosol generated within the capsule to flow out of the capsule into the hollow tubular element.

[0109] The number and size of the capsule air inlets and capsule air outlets can be adjusted in order to control the air flow through the capsule and also to control the draw resistance (RTD) of the aerosol - generating article. In some embodiments, the capsule will provide the main RTD source within the article, and thus the overall RTD of the aerosol - generating article may be highly dependent on the RTD of the capsule.

[0110] Each capsule air inlet and each capsule air outlet is preferably in the form of a hole through the capsule outer wall. Preferably, each hole is spherical, but other shapes may also be suitable. The diameter of each hole should be large enough such that the hole cannot be easily blocked, for example, by dust. However, the diameter of each hole should also be adjusted depending on the form and nature of the solid aerosol - generating substrate such that the solid aerosol - generating substrate does not escape from the inner cavity through the hole.

[0111] Preferably, each hole forming an air inlet or an air outlet has a diameter of at least 0.2 mm, more preferably at least 0.25 mm, more preferably at least 0.3 mm, more preferably at least 0.35 mm, more preferably at least 0.4 mm, more preferably at least 0.5 mm. The diameter of each hole can be less than 2 mm, or less than 1.8 mm, or less than 1.6 mm, or less than 1.4 mm, or less than 1.2 mm, or less than 1 mm, or less than 0.9 mm, or less than 0.8 mm. For example, the diameter of each hole can be between 0.2 mm and 2 mm, or between 0.25 mm and 1.8 mm, or between 0.3 mm and 1.6 mm, or between 0.35 mm and 1.4 mm, or between 0.4 mm and 1.2 mm, or between 0.45 mm and 1 mm, or between 0.5 mm and 0.9 mm, or between 0.5 mm and 0.8 mm.

[0112] In the case of providing a plurality of bladder air inlets or bladder air outlets, the corresponding holes should be sufficiently spaced apart such that the presence of the holes does not adversely affect the structural integrity of the bladder. For example, the holes are preferably spaced apart from each other by at least 1 mm.

[0113] At least one bladder air outlet is preferably at least 5 mm downstream of at least one air inlet, more preferably at least 8 mm downstream of at least one air inlet, and more preferably at least 10 mm downstream of at least one air inlet. This spacing enables maximizing the length of the air flow path through the bladder.

[0114] At least one bladder air outlet is preferably located at the downstream end of the bladder. In the case where the bladder has a conventional bladder shape (the conventional bladder shape has an elongated cylindrical body and rounded end walls), at least one bladder air outlet is preferably provided on the downstream end wall.

[0115] At least one bladder air inlet can be located at the upstream end of the bladder. For example, in the case where the bladder has the conventional bladder shape as described above, at least one bladder air inlet can be provided on the upstream end wall. However, in some embodiments, it may be advantageous to locate at least one bladder air inlet a certain distance downstream of the upstream end. For example, at least one bladder air inlet can be provided at least 2 mm downstream of the upstream end of the bladder, or at least 3 mm downstream of the upstream end of the bladder, or at least 4 mm downstream of the upstream end of the bladder, or at least 5 mm downstream of the upstream end of the bladder. In the case of providing a plurality of bladder air inlets, all air inlets should be set at least this distance from the upstream end, even when the position of the bladder air inlets along the length of the bladder varies.

[0116] In a preferred embodiment, the capsule comprises a cylindrical wall and rounded end walls at the upstream and downstream ends of the cylindrical wall (such as in a conventional capsule shape), and at least one capsule air inlet may advantageously be provided in the cylindrical wall downstream of the upstream end wall.

[0117] When the solid aerosol-forming substrate is in the form of a gel composition or any other substrate type that melts or becomes more viscous upon heating, this positioning of at least one capsule air inlet away from the upstream end of the capsule may be particularly beneficial. By having at least one capsule air inlet away from the upstream end of the chamber (where the molten substrate can accumulate), this ensures that the risk of leakage of the aerosol-forming substrate from the capsule is minimized. The risk of blockage of the capsule air inlet by the aerosol-forming substrate is also reduced.

[0118] At least one capsule air outlet may comprise a plurality of air outlets located at the downstream end of the capsule, the plurality of air outlets being arranged on the circumference of a circle centered on the longitudinal axis of the capsule, the circle having a diameter smaller than the diameter of the aerosol-generating article.

[0119] The plurality of capsule air outlets may be arranged on the circle such that each of the capsule air outlets radially overlaps at least a portion of a ventilation perforation.

[0120] As used herein, the term "radially overlap" means that the plurality of capsule air outlets and the plurality of ventilation perforations are arranged such that a straight line extending radially from the center of the aerosol-generating article can intersect both the capsule air outlet and at least one ventilation perforation.

[0121] The plurality of capsule air outlets may further comprise a capsule air outlet located at the center of the circle.

[0122] This arrangement may mean that the ambient air provided by at least one ventilation perforation is directly provided into the path of the vapor exiting the capsule through the capsule air outlet. This can advantageously improve aerosol generation.

[0123] The aerosol-generating article may comprise the same number of ventilation perforations and capsule air outlets such that each capsule air outlet may have a corresponding ventilation perforation, each capsule air outlet being radially aligned with the corresponding ventilation perforation.

[0124] The arrangement of the plurality of capsule air outlets may be arranged on the circle such that each of the capsule air outlets radially overlaps at least a portion of a ventilation perforation and such that each capsule air outlet radially overlaps the same sized portion of the ventilation perforation. This can advantageously improve the consistency of aerosol generation since the vapor passing through each capsule air outlet will encounter a similar amount of ambient cooling air.

[0125] The angular diameter (θ) of each of the capsule air outlets measured from the center of the circle C) can be greater than the angular distance (θ S ) between adjacent ventilation perforations. In other words:

[0126] θ C > θ S

[0127] This can advantageously ensure that each capsule air outlet radially overlaps a portion of the ventilation perforation, regardless of the orientation of the capsule within the hollow tubular element. This is advantageous because it can simplify manufacturing, as it is not necessary to carefully control the orientation of the capsule during manufacturing to achieve the desired radial overlap.

[0128] The angular diameter (θ C ) of each capsule air outlet measured from the center of the circle can be greater than the angular diameter (θ V ) of each ventilation perforation plus the angular distance (θ S ) between adjacent ventilation perforations. In other words:

[0129] θ C > θ V + θ S

[0130] This can advantageously ensure that the total radial overlap between each capsule air outlet and the ventilation perforation remains constant, regardless of the orientation of the capsule within the hollow tubular element. This is advantageous because it can simplify manufacturing, as it is not necessary to carefully control the orientation of the capsule during manufacturing to achieve the desired radial overlap.

[0131] The aerosol-generating article of the present invention includes an aerosol-generating substrate. The aerosol-generating substrate can be a solid aerosol-generating substrate contained within a capsule. The solid aerosol-generating substrate can contain nicotine and an aerosol-forming agent, but can take various different forms.

[0132] The aerosol-generating substrate can contain at least 15% by weight of an aerosol-forming agent based on dry weight. Preferably, the aerosol-generating substrate contains at least 20% by weight of an aerosol-forming agent based on dry weight. More preferably, the aerosol-generating substrate contains at least 25% by weight of an aerosol-forming agent based on dry weight. More preferably, the aerosol-generating substrate contains at least 30% by weight of an aerosol-forming agent based on dry weight. More preferably, the aerosol-generating substrate contains at least 35% by weight of an aerosol-forming agent based on dry weight. More preferably, the aerosol-generating substrate contains at least 40% by weight of an aerosol-forming agent based on dry weight. More preferably, the aerosol-generating substrate contains at least 45% by weight of an aerosol-forming agent based on dry weight. More preferably, the aerosol-generating substrate contains at least 50% by weight of an aerosol-forming agent based on dry weight.

[0133] Preferably, the aerosol - forming substrate comprises no more than 80% by weight on a dry weight basis. More preferably, the second aerosol - forming substrate comprises no more than 75% by weight on a dry weight basis. More preferably, the second aerosol - forming substrate comprises no more than 70% by weight on a dry weight basis.

[0134] For example, the aerosol - forming substrate can provide an aerosol - forming agent content between 15% and 80% by weight on a dry weight basis, or between 20% and 80% by weight on a dry weight basis, or between 25% and 80% by weight on a dry weight basis, or between 30% and 75% by weight on a dry weight basis, or between 35% and 75% by weight on a dry weight basis, or between 40% and 70% by weight on a dry weight basis, or between 45% and 70% by weight on a dry weight basis, or between 50% and 70% by weight on a dry weight basis.

[0135] In certain preferred embodiments, the aerosol - forming agent content of the aerosol - forming substrate can be between 40% and 80% by weight on a dry weight basis, or between 45% and 75% by weight on a dry weight basis, or between 50% and 70% by weight on a dry weight basis. In such embodiments, the aerosol - forming agent content of the aerosol - forming substrate is thus relatively high.

[0136] Suitable aerosol - forming agents included in the aerosol - forming substrate 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 mono -, di - or tri - acetate; and aliphatic esters of mono -, di - or poly - carboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0137] Preferably, the aerosol - forming substrate includes glycerol as the aerosol - forming agent.

[0138] The aerosol - forming substrate further comprises nicotine. As used herein in reference to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salts. In embodiments where the aerosol - forming substrate comprises nicotine base or nicotine salts, the amount of nicotine described herein is the amount of free - base nicotine or protonated nicotine, respectively.

[0139] The aerosol - forming substrate can comprise natural nicotine or synthetic nicotine. The nicotine can include one or more nicotine salts. The one or more nicotine salts can be selected from the following list: nicotine lactate, nicotine citrate, nicotine pyruvate, nicotine hydrogen tartrate, nicotine benzoate, nicotine pectinate, nicotine alginate, and nicotine salicylate.

[0140] The nicotine can include tobacco extracts.

[0141] Preferably, the aerosol - generating substrate comprises at least 0.5% by weight of nicotine on a dry - weight basis. More preferably, the aerosol - generating substrate comprises at least 1% by weight of nicotine on a dry - weight basis. Even more preferably, the aerosol - generating substrate comprises at least 2% by weight of nicotine on a dry - weight basis. Additionally, or alternatively, the aerosol - generating substrate preferably comprises less than 10% by weight of nicotine on a dry - weight basis. More preferably, the aerosol - generating substrate comprises less than 8% by weight of nicotine on a dry - weight basis. Even more preferably, the aerosol - generating substrate comprises less than 6% by weight of nicotine on a dry - weight basis.

[0142] For example, the aerosol - generating substrate may comprise nicotine between 0.5% and 10% by weight on a dry - weight basis, or between 1% and 8% by weight on a dry - weight basis, or between 2% and 6% by weight on a dry - weight basis.

[0143] The aerosol - generating substrate may comprise one or more carboxylic acids. Advantageously, the inclusion of one or more carboxylic acids in the aerosol - generating substrate can produce nicotine salts.

[0144] The one or more carboxylic acids include one or more of lactic acid and levulinic acid. Advantageously, the inventors have found that lactic acid and levulinic acid are particularly good carboxylic acids for producing nicotine salts.

[0145] Preferably, the aerosol - generating substrate comprises at least 0.5% by weight of carboxylic acid on a dry - weight basis. More preferably, the aerosol - generating substrate comprises at least 1% by weight of carboxylic acid on a dry - weight basis. Even more preferably, the aerosol - generating substrate comprises at least 2% by weight of carboxylic acid on a dry - weight basis.

[0146] Additionally, or alternatively, the aerosol - generating substrate preferably comprises less than 15% by weight of carboxylic acid on a dry - weight basis. More preferably, the aerosol - generating substrate preferably comprises less than 10% by weight of carboxylic acid on a dry - weight basis. Even more preferably, the aerosol - generating substrate preferably comprises less than 5% by weight of carboxylic acid on a dry - weight basis. For example, the aerosol - generating substrate may comprise carboxylic acid between 0.5% and 15% by weight, or between 1% and 10% by weight, or between 2% and 5% by weight.

[0147] In certain preferred embodiments, the aerosol - generating substrate is in the form of an aerosol - generating film comprising a cellulose - based film - forming agent, nicotine, and an aerosol - forming agent. The aerosol - generating film may further comprise a cellulose - based reinforcing agent. The aerosol - generating film may also include water, preferably 30% by weight or less of water.

[0148] As used herein, the term "membrane" is used to describe a solid, layer-like element whose thickness is less than its width or length. The membrane can be self-supporting. In other words, the membrane can have cohesive and mechanical properties such that the membrane can be separated from the support surface even if it is obtained by casting a membrane formulation on the support surface. Alternatively, the membrane can be disposed on a support or sandwiched between other materials. This can enhance the mechanical stability of the membrane.

[0149] The solid aerosol-generating substrate can be provided in any suitable form. Preferably, the capsule contains a plurality of particles of the solid aerosol-generating substrate. For example, the capsule can include a plurality of beads, pellets, microparticles, strips, filaments or flakes of the aerosol-generating substrate.

[0150] In certain embodiments, the maximum size of each particle is preferably at least 0.05 mm, more preferably at least 0.1 mm, more preferably at least 0.15 mm, more preferably at least 0.2 mm, more preferably at least 0.25 mm, more preferably at least 0.5 mm, more preferably at least 0.75 mm, more preferably at least 1 mm. Preferably, the maximum size of each particle does not exceed 10 mm, more preferably does not exceed 9 mm, more preferably does not exceed 8 mm, more preferably does not exceed 6 mm, more preferably does not exceed 5 mm. As described below, it may be preferred to provide relatively large particles within these ranges when the capsule wall is provided with holes to form air inlets and outlets. The relatively large maximum size of the particles will then ensure that the particles do not escape through the holes in the capsule wall.

[0151] The maximum size of a particle corresponds to the maximum external diameter of that particle. In the case where the particle is substantially spherical, the maximum size of the particle will correspond to the diameter of that particle.

[0152] In such embodiments, the capsule preferably includes at least 2 particles of the aerosol-generating substrate, more preferably at least 5 particles of the aerosol-generating substrate, more preferably at least 10 particles of the aerosol-generating substrate, more preferably at least 20 particles of the aerosol-generating substrate, more preferably at least 30 particles. The capsule can accommodate up to 200 particles.

[0153] In other embodiments, the solid aerosol-generating substrate can be in the form of a powder having a much larger number of much smaller particles. For example, in such embodiments, the powder can be formed of particles having a D50 size between 50 microns and 80 microns, between 50 microns and 75 microns, between 55 microns and 75 microns, between 55 microns and 70 microns, or between 60 microns and 70 microns.

[0154] As used herein with reference to the present invention, the term "D50 size" refers to the median particle size of particulate material or powder. The D50 size is the particle size that divides the distribution in half, with half of the particles being larger than the D50 size and half being smaller than the D50 size. The particle size distribution can be determined by laser diffraction. For example, the particle size distribution can be determined by laser diffraction using a Malvern Mastersizer 3000 laser diffraction particle size analyzer according to the manufacturer's instructions.

[0155] The powder can be formed from particles having a D95 size between 80 microns and 130 microns, between 90 microns and 125 microns, between 100 microns and 120 microns, or between 110 microns and 120 microns.

[0156] As used herein with reference to the present invention, the term "D95 size" is the size below which 95% by mass of the particles are present.

[0157] The powder can be formed from particles having a maximum diameter between 50 microns and 250 microns, between 80 microns and 225 microns, or between 100 microns and 125 microns.

[0158] In embodiments where the capsule contains a plurality of particles, the mass of each particle is preferably at least 0.05 micrograms, more preferably at least 0.1 micrograms, more preferably at least 0.2 micrograms, more preferably at least 0.3 micrograms, more preferably at least 0.4 micrograms, more preferably at least 0.5 micrograms, more preferably at least 0.6 micrograms, more preferably at least 0.7 micrograms, more preferably at least 0.8 micrograms, more preferably at least 0.9 micrograms, more preferably at least 1 microgram, more preferably at least 10 micrograms, more preferably at least 100 micrograms, more preferably at least 200 micrograms, more preferably at least 500 micrograms, more preferably at least 1 milligram. The mass of each particle is preferably not more than 600 milligrams, more preferably not more than 500 milligrams, more preferably not more than 400 milligrams, more preferably not more than 300 milligrams, more preferably not more than 200 milligrams, more preferably not more than 100 milligrams, more preferably not more than 50 milligrams, more preferably not more than 10 milligrams.

[0159] Alternatively, the solid aerosol - generating substrate can be in the form of one or more sheets. As used herein with reference to the present invention, the term "sheet" describes a layered element whose width and length are significantly greater than its thickness.

[0160] One or more sheets as described herein can be one or more of curled, folded, aggregated, and pleated. One or more sheets can be cut into strands.

[0161] The aerosol - generating article according to the present invention may further include a downstream filter segment mounted within the hollow tubular element at the downstream end of the hollow tubular element. The downstream filter segment may extend to the downstream end of the hollow tubular element. The downstream end of the downstream filter segment may define the downstream end of the aerosol - generating article. It may be useful to include a downstream filter segment within the hollow tubular element to provide a desired level of RTD for the aerosol - generating article.

[0162] The downstream filter segment is located downstream of the capsule, and preferably, the capsule and the downstream filter segment are spaced apart in the longitudinal direction such that a cavity is defined between the capsule and the downstream filter segment. Preferably, the downstream filter segment is located at least 5 mm downstream of the downstream end of the capsule, more preferably at least 8 mm downstream of the downstream end of the capsule, more preferably at least 10 mm downstream of the downstream end of the capsule, more preferably at least 15 mm downstream of the downstream end of the capsule. Preferably, the downstream filter segment is located less than 30 mm downstream of the downstream end of the capsule, more preferably less than 25 mm downstream of the downstream end of the capsule. The distance defined between the downstream end of the capsule and the downstream filter segment corresponds to the length of the cavity between the capsule and the downstream filter segment.

[0163] The downstream filter segment is preferably a solid rod, which may also be described as a "plain" rod and is non - tubular. Thus, the filter segment preferably has a substantially uniform cross - section.

[0164] The downstream filter segment is preferably formed of a fibrous filter material. The fibrous filter material can be used to filter the aerosol generated from the aerosol - generating substrate. Suitable fibrous filter materials will be known to the person skilled in the art. Particularly preferably, at least one downstream filter segment includes a cellulose acetate filter segment formed from a cellulose acetate tow.

[0165] The downstream filter segment may optionally include a flavorant, which may be provided in any suitable form. For example, the downstream filter segment may include one or more capsules, beads or microparticles of the flavorant, or one or more lines or filaments carrying the flavor.

[0166] Preferably, the downstream filter segment has a low particle filtration efficiency.

[0167] The downstream filter segment preferably has an outer diameter that is approximately equal to the inner diameter of the hollow tubular element, such that the downstream filter segment is held within the hollow tubular element by a friction fit.

[0168] Preferably, the outer diameter of the downstream filter segment is between 5 mm and 12 mm, more preferably between 6 mm and 10 mm, more preferably between 7 mm and 8 mm.

[0169] Unless otherwise stated, the draw resistance (RTD) of the component or the aerosol - generating article is measured according to ISO 6565 - 2015. The RTD refers to the pressure required to force air through the entire length of the component. The terms "pressure drop" or "draw resistance" of the component or article may also refer to "resistance to draw". Such terms generally refer to measurements according to ISO 6565 - 2015, which are typically carried out in a test at a temperature of 22 degrees Celsius, a pressure of 101 kPa (about 760 Torr), and a relative humidity of 60% at a volumetric flow rate of 17.5 mL / s at the output or downstream end of the measured component. The conditions for smoking and the specifications of the smoking machine are described in ISO standard 3308 (ISO 3308:2000). The atmosphere for conditioning and testing is described in ISO standard 3402 (ISO 3402:1999).

[0170] The draw resistance (RTD) of the downstream filter segment can be at least 0 mmHg, 2 or at least 3 mmHg, 2 or at least 6 mmHg. 2 mmHg.

[0171] The RTD of the downstream filter segment can be no greater than 12 mmHg, 2 or no greater than 11 mmHg, 2 or no greater than 10 mmHg. 2 mmHg.

[0172] As described above, the downstream filter segment can be formed from a fibrous filter material. The downstream filter segment can be formed from a porous material. The downstream filter segment can be formed from a biodegradable material. The downstream filter segment can be formed from a cellulose material such as cellulose acetate. For example, the downstream filter segment can be formed from a bundle of cellulose acetate fibers with a denier between 10 and 15. For example, the downstream filter segment is formed from a relatively low - density cellulose acetate tow (such as a cellulose acetate tow including fibers with a denier of 12).

[0173] The downstream filter segment can be formed from a polylactic - acid - based material. The downstream filter segment can be formed from a bioplastic material (preferably a starch - based bioplastic material). The downstream filter segment can be manufactured by injection molding or by extrusion. The bioplastic - based material is advantageous because it can provide a downstream filter segment structure that is simple and inexpensive to manufacture, has a specific and complex cross - sectional profile, which can include a plurality of relatively large air - flow channels extending through the downstream filter segment material, and provides suitable RTD characteristics.

[0174] The length of the downstream filter segment can be at least 5 mm, or at least 8 mm, or at least 10 mm. The length of the downstream filter segment can be less than 20 mm, or less than 15 mm, or less than 12 mm. For example, the length of the downstream filter segment can be between 5 mm and 20 mm, or between 8 mm and 15 mm, or between 8 mm and 12 mm, or between 10 mm and 12 mm.

[0175] In an alternative embodiment of the present invention, the downstream filter segment can be provided downstream of the hollow tubular element. The downstream filter segment can extend between the hollow tubular element and the downstream end of the aerosol generating article. In such embodiments, the downstream filter segment can be connected to the hollow tubular element by means of a tipping wrapper.

[0176] The overall RTD of the aerosol generating article can be at least 1 mm H 2 O. For example, the overall RTD of the aerosol generating article can be at least 2 mm H 2 O, at least 3 mm H 2 O, at least 4 mm H 2 O, at least 5 mm H 2 O, at least 6 mm H 2 O, at least 7 mm H 2 O, at least 8 mm H 2 O, at least 9 mm H 2 O, at least 10 mm H 2 O, at least 15 mm H 2 O, at least 20 mm H 2 O, at least 30 mm H 2 O, at least 40 mm H 2 O or at least 50 mm H 2 O.

[0177] The overall RTD of the aerosol generating article can be not more than 180 mm H 2 O. For example, the overall RTD of the aerosol generating article can be not more than 170 mm H 2 O, not more than 160 mm H 2 O, not more than 150 mm H 2 O or not more than 140 mm H 2 O.

[0178] The overall RTD of the aerosol generating article can be between 1 mm H 2 O and 180 mm H 2 O. For example, the overall RTD of the aerosol generating article can be between 5 mm H 2 O and 170 mm H 2 O, between 10 mm H 2 O and 160 mm H 2between O and 20 millimeters H 2 between O and 150 millimeters H 2 between O and 50 millimeters H 2 between O and 140 millimeters H 2 between them.

[0179] The aerosol-generating article according to the present invention may have a total length of at least 40 millimeters, or at least 50 millimeters, or at least 60 millimeters.

[0180] The total length of the aerosol-generating article according to the present invention may be less than or equal to 90 millimeters, or less than or equal to 85 millimeters, or less than or equal to 80 millimeters.

[0181] In some embodiments, the total length of the aerosol-generating article is preferably from 40 millimeters to 70 millimeters, more preferably from 45 millimeters to 70 millimeters. In other embodiments, the total length of the aerosol-generating article is preferably from 40 millimeters to 60 millimeters, more preferably from about 45 millimeters to about 60 millimeters. In further embodiments, the total length of the aerosol-generating article is preferably from 40 millimeters to 50 millimeters, more preferably from 45 millimeters to 50 millimeters. In an exemplary embodiment, the total length of the aerosol-generating article is about 45 millimeters.

[0182] The aerosol-generating article may have an outer diameter of at least 5 millimeters, or at least 6 millimeters, or at least 7 millimeters.

[0183] The aerosol-generating article may have an outer diameter of less than or equal to about 12 millimeters, or less than or equal to about 10 millimeters, or less than or equal to about 8 millimeters.

[0184] In some embodiments, the aerosol-generating article has an outer diameter of from about 5 millimeters to about 12 millimeters, preferably from about 6 millimeters to about 12 millimeters, more preferably from about 7 millimeters to about 12 millimeters. In other embodiments, the aerosol-generating article has an outer diameter of from about 5 millimeters to about 10 millimeters, preferably from about 6 millimeters to about 10 millimeters, more preferably from about 7 millimeters to about 10 millimeters. In further embodiments, the aerosol-generating article has an outer diameter of from about 5 millimeters to about 8 millimeters, preferably from about 6 millimeters to about 8 millimeters, more preferably from about 7 millimeters to about 8 millimeters. In other embodiments, the aerosol-generating article has an outer diameter of less than 7 millimeters.

[0185] The outer diameter of the aerosol-generating article may be substantially constant over the entire length of the article. As an alternative, different portions of the aerosol-generating article may have different outer diameters.

[0186] According to a second aspect of the present invention, there is also provided an aerosol generating system, which comprises an aerosol generating article according to the first aspect of the present invention; and an aerosol generating device, the aerosol generating device comprising a heating chamber for receiving the aerosol generating article, and a heating element disposed in the heating chamber or disposed around the periphery of the heating chamber.

[0187] The aerosol generating device may include an upstream end and a downstream end. The aerosol generating device may include a body. The body or housing of the aerosol generating device may define a heating chamber for removably receiving the aerosol generating article at the downstream end of the device. The aerosol generating device includes a heating element or heater for heating the aerosol generating substrate when the aerosol generating article is received in the heating chamber.

[0188] The heating chamber may extend between the upstream end and the downstream end. The upstream end of the heating chamber may be a closed end, and the downstream end of the heating chamber may be an open end. The aerosol generating article may be inserted into the heating chamber via the open end of the heating chamber. The shape of the heating chamber may be cylindrical to conform to the same shape of the aerosol generating article.

[0189] The expression "received within..." may refer to the fact that a component or element is received completely or partially within another component or element. For example, the expression "the aerosol generating article is received in the heating chamber" means that the aerosol generating article is received completely or partially within the heating chamber of the aerosol generating article. When the aerosol generating article is received in the heating chamber, the aerosol generating article may abut the upstream end of the heating chamber. When the aerosol generating article is received in the heating chamber, the aerosol generating article may be substantially close to the upstream end of the heating chamber. The upstream end of the heating chamber may be defined by an end wall.

[0190] The length of the heating chamber may be between 15 millimeters and 80 millimeters, or between 20 millimeters and 70 millimeters, or between 25 millimeters and 60 millimeters, or between 25 millimeters and 50 millimeters.

[0191] The length of the heating chamber may be between 25 millimeters and 29 millimeters, or between 26 millimeters and 29 millimeters, or between 27 millimeters or 28 millimeters.

[0192] When the aerosol generating article is received in the heating chamber, the capsule is preferably entirely within the device cavity to optimize heating of the solid aerosol generating substrate within the capsule. Accordingly, the length of the device cavity is preferably greater than the length of the capsule.

[0193] The diameter of the heating chamber may be between 4 millimeters and 10 millimeters. The diameter of the heating chamber may be between 5 millimeters and 9 millimeters. The diameter of the heating chamber may be between 6 millimeters and 8 millimeters. The diameter of the heating chamber may be between 6 millimeters and 7 millimeters.

[0194] The diameter of the heating chamber may be substantially equal to or greater than the diameter of the aerosol-generating article. The diameter of the heating chamber may be the same as the diameter of the aerosol-generating article to establish a tight fit with the aerosol-generating article.

[0195] The heating chamber may be configured to establish a tight fit with the aerosol-generating article received within the heating chamber. A tight fit may refer to a snug fit. The aerosol-generating device may include an outer peripheral wall. Such an outer peripheral wall may define the heating chamber. The outer peripheral wall defining the heating chamber may be configured to engage the aerosol-generating article received within the heating chamber in a tight fit such that when the aerosol-generating article is received within the device, there is substantially no gap or void space between the outer peripheral wall defining the heating chamber and the aerosol-generating article.

[0196] Such a tight fit may establish an airtight fit or configuration between the heating chamber and the aerosol-generating article received therein.

[0197] With such an airtight configuration, there is substantially no gap or void space for air to flow through between the outer peripheral wall defining the heating chamber and the aerosol-generating article.

[0198] The tight fit with the aerosol-generating article may be established along the entire length of the heating chamber or along a portion of the length of the heating chamber.

[0199] The aerosol-generating device may include an air flow channel extending between an inlet and an outlet. The air flow channel may be configured to establish fluid communication between the interior of the heating chamber and the exterior of the aerosol-generating device. The air flow channel of the aerosol-generating device may be defined within the housing of the aerosol-generating device to effect fluid communication between the interior of the heating chamber and the exterior of the aerosol-generating device. When the aerosol-generating article is received within the heating chamber, the air flow channel may be configured to supply an air flow to the article in order to deliver the generated aerosol to a user who sucks from the downstream end of the article.

[0200] The air flow channel of the aerosol-generating device may be defined within or by the outer peripheral wall of the housing of the aerosol-generating device. In other words, the air flow channel of the aerosol-generating device may be defined within the thickness of the outer peripheral wall or by the inner surface of the outer peripheral wall, or a combination of both. The air flow channel may be partially defined by the inner surface of the outer peripheral wall and may be partially defined within the thickness of the outer peripheral wall. The inner surface of the outer peripheral wall defines the outer perimeter of the device cavity.

[0201] The air flow channel of the aerosol-generating device may extend from an inlet located at the downstream end of the aerosol-generating device to an outlet located away from the downstream end of the device. The air flow channel may extend in a direction parallel to the longitudinal axis of the aerosol-generating device.

[0202] The heater can be any suitable type of heater. Preferably, in the present invention, the heater is an external heater that heats the capsule and its contents from the outside. When the aerosol-generating article is inserted into or received within the aerosol-generating device, such an external heater can define the aerosol-generating article.

[0203] Alternatively, the heater can be an elongate heater blade adapted to be inserted into the capsule to heat the capsule and its contents from the inside.

[0204] The heater can include at least one heating element. The at least one heating element can be any suitable type of heating element. In some embodiments, the device includes only one heating element. In some embodiments, the device includes a plurality of heating elements.

[0205] The heating element can be a resistive heating element.

[0206] Suitable materials for forming the resistive heating element include, but are not limited to: semiconductors (such as doped ceramics), electro-“conductive” ceramics (such as molybdenum disilicide, for example), carbon, graphite, metals, metal alloys, and composite materials made of ceramic materials and metal materials. Such composite materials can 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, cobalt-based superalloys, stainless steel, and iron-manganese-aluminum-based alloys.

[0207] In some embodiments, the resistive heating element includes one or more embossed portions of a resistive material (such as stainless steel). Alternatively, the at least one resistive heating element can include a heating wire or filament, such as Ni-Cr (nickel-chromium), platinum, tungsten, or alloy wire.

[0208] In some embodiments, the heating element includes an electrically insulating substrate on which at least one resistive heating element is disposed.

[0209] The electrically insulating substrate can include any suitable material. For example, the electrically insulating substrate can include one or more of paper, glass, ceramics, anodized metal, coated metal, and polyimide. The ceramics can include mica, alumina (Al 2 O 3 ) or zirconia (ZrO 2) Preferably, the electrically insulating substrate has a thermal conductivity less than or equal to about 40 W / m·K, preferably less than or equal to about 20 W / m·K, and ideally less than or equal to about 2 W / m·K.

[0210] The heater may include a heating element, which includes a rigid electrically insulating substrate having one or more conductive tracks or wires disposed on its surface. The size and shape of the electrically insulating substrate may allow it to be directly inserted into the aerosol - generating substrate. If the electrically insulating substrate is not rigid enough, the heating element may include additional strengthening means. An electric current may pass through one or more conductive tracks to heat the heating element and the aerosol - generating substrate.

[0211] In some embodiments, the heater includes inductive heating means. The inductive heating means may include an inductor coil and a power source configured to supply a high - frequency oscillating current to the inductor coil. As used herein, a high - frequency oscillating current means an oscillating current having a frequency between about 500 kHz and about 30 MHz. Advantageously, the heater may include a DC / AC inverter for converting the DC current supplied by a DC power source into an alternating current. The inductor coil may be arranged to generate a high - frequency oscillating electromagnetic field when receiving the high - frequency oscillating current from the power source. The inductor coil may be arranged to generate a high - frequency oscillating electromagnetic field in the device cavity. In some embodiments, the inductor coil may substantially define the device cavity. The inductor coil may at least partially extend along the length of the device cavity.

[0212] The heater may include an inductive heating element. The inductive heating element may be a susceptor element. The susceptor element may be arranged such that when the aerosol - generating article is received in the cavity of the aerosol - generating device, the oscillating electromagnetic field generated by the inductor coil induces a current in the susceptor element, causing the susceptor element to heat up. In these embodiments, the aerosol - generating device preferably can generate a fluctuating electromagnetic field having a magnetic field strength (H - field strength) between 1 kiloampere per meter and 5 kiloamperes per meter (kA / m), preferably between 2 kA / m and 3 kA / m, for example about 2.5 kA / m. Preferably, the electrically - operated aerosol - generating device can generate a fluctuating electromagnetic field having a frequency between 1 MHz and 30 MHz, for example between 1 MHz and 10 MHz, for example between 5 MHz and 7 MHz.

[0213] In these embodiments, the susceptor element is preferably positioned in contact with the solid aerosol - generating substrate. In some embodiments, the susceptor element is located in the aerosol - generating device. In these embodiments, the susceptor element may be located in the cavity. The aerosol - generating device may include only one susceptor element. The aerosol - generating device may include a plurality of susceptor elements. In some embodiments, the susceptor elements are preferably arranged to heat the outer surface of the aerosol - generating substrate.

[0214] The sensor element can include any suitable sensor element.

[0215] In some embodiments, the aerosol generating device can include at least one resistive heating element and at least one inductive heating element. In some embodiments, the aerosol generating device can include a combination of a resistive heating element and an inductive heating element.

[0216] During use, the heater can be controlled to operate within a defined operating temperature range below the maximum operating temperature. An operating temperature range between about 150 degrees Celsius and about 300 degrees Celsius in the heating chamber (or device cavity) is preferred. The operating temperature range of the heater can be between about 150 degrees Celsius and about 250 degrees Celsius.

[0217] The aerosol generating device can include a power source. The power source can be a DC power source. In some embodiments, the power source is a battery. The power source can 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. However, in some embodiments, the power source can be another form of charge storage device, such as, for example, a capacitor. The power source may need to be recharged and can have a capacity that allows for the storage of sufficient energy for one or more user operations (e.g., one or more aerosol generation experiences).

[0218] The aerosol generating device can include a piercing device for piercing the capsule when the aerosol generating article is inserted into the device cavity. As described above, it may be necessary to pierce the capsule in order to establish one or more air flow paths through the capsule.

[0219] A non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples can be combined with any one or more features of another example, embodiment, or aspect described herein.

[0220] Example 1: An aerosol generating article for generating an inhalable aerosol upon heating, the article comprising:

[0221] A hollow tubular element, and

[0222] A capsule mounted within the hollow tubular element at an upstream end thereof, the capsule containing an aerosol generating substrate,

[0223] The hollow tubular element includes a ventilation zone to allow external air to enter the aerosol generating article, the ventilation zone being provided downstream of a downstream end of the capsule.

[0224] Example 2: The aerosol generating article according to Example 1, wherein the ventilation zone includes at least one ventilation perforation.

[0225] Example 3: The aerosol-generating article according to Example 2, wherein the ventilation zone includes a plurality of ventilation perforations passing through the hollow tubular element.

[0226] Example 4: The aerosol-generating article according to Example 3, wherein the ventilation zone includes at least 5 ventilation perforations passing through the hollow tubular element.

[0227] Example 5: The aerosol-generating article according to Example 3 or Example 4, wherein the ventilation zone includes no more than 15 ventilation perforations passing through the hollow tubular element.

[0228] Example 6: The aerosol-generating article according to any one of Examples 3 to 5, wherein the plurality of ventilation perforations includes at least one perforation having a width of no more than 200 micrometers.

[0229] Example 7: The aerosol-generating article according to any one of Examples 3 to 6, wherein the plurality of ventilation perforations includes at least one perforation having a width of at least 50 micrometers.

[0230] Example 8: The aerosol-generating article according to any one of Examples 3 to 7, wherein the plurality of ventilation perforations includes at least one perforation having a length of at least 400 micrometers.

[0231] Example 9: The aerosol-generating article according to any one of Examples 3 to 8, wherein the plurality of ventilation perforations includes at least one perforation having a length of no more than 1 millimeter.

[0232] Example 10: The aerosol-generating article according to any one of Examples 3 to 9, wherein the plurality of ventilation perforations forms a row of perforations defining the hollow tubular element.

[0233] Example 11: The aerosol-generating article according to any one of Examples 3 to 10, further comprising at least one stop member that projects from an inner surface of the hollow tubular element to prevent the capsule from moving further downstream than the at least one stop member.

[0234] Example 12: The aerosol-generating article according to Example 11, wherein the at least one stop member is located upstream of the ventilation zone.

[0235] Example 13: The aerosol-generating article according to Example 11 or Example 12, wherein the at least one stop member includes a raised portion of the hollow tubular element that extends into the interior of the hollow tubular element.

[0236] Example 14: An aerosol-generating article according to any one of Examples 11 to 13, wherein the hollow tubular element includes at least one flap formed from a portion of the hollow tubular element that is partially separated from the remainder of the hollow tubular element, thereby forming a gap between the flap and the remainder of the hollow tubular element, the flap remaining attached to the remainder of the hollow tubular element along an attachment line, wherein the flap extends into the interior or the hollow tubular element such that:

[0237] the at least one stop includes the at least one flap, and

[0238] the at least one ventilation aperture includes the gap between the flap and the remainder of the hollow tubular element.

[0239] Example 15: An aerosol-generating article according to Example 14, wherein the attachment line is located at the upstream end of the flap.

[0240] Example 16: An aerosol-generating article according to any one of Examples 3 to 15, wherein the capsule includes at least one capsule air inlet located at the upstream end of the capsule and at least one capsule air outlet located at the downstream end of the capsule.

[0241] Example 17: An aerosol-generating article according to Example 16, wherein the at least one capsule air outlet includes a plurality of air outlets located at the downstream end of the capsule, the plurality of air outlets being arranged on the circumference of a circle centered on the longitudinal axis of the capsule, the circle having a diameter less than the diameter of the aerosol-generating article.

[0242] Example 18: An aerosol-generating article according to Example 17, wherein the plurality of capsule air outlets are arranged on the circle such that each of the capsule air outlets radially overlaps at least a portion of the ventilation aperture.

[0243] Example 19: An aerosol-generating article according to Example 18, wherein the angular diameter of each of the plurality of capsule air outlets measured from the center of the circle is greater than the angular distance between adjacent ventilation apertures in the ventilation zone.

[0244] Example 20: An aerosol-generating article according to Example 19, wherein the angular diameter of each of the plurality of capsule air outlets measured from the center of the circle is greater than the angular diameter of each ventilation aperture plus the angular distance between adjacent ventilation apertures in the ventilation zone.

[0245] Example 21: An aerosol-generating article according to any one of the preceding examples, wherein the ventilation zone includes a porous portion of the hollow tubular element.

[0246] Example 22: An aerosol-generating article according to any of the preceding examples, wherein an outer diameter of the capsule is substantially the same as an inner diameter of the hollow tubular element.

[0247] Example 23: An aerosol-generating article according to any of the preceding examples, wherein an upstream end of the ventilation zone is positioned at least 20 millimeters from an upstream end of the aerosol-generating article.

[0248] Example 24: An aerosol-generating article according to any of the preceding examples, wherein an upstream end of the ventilation zone is positioned no more than 37 millimeters from an upstream end of the aerosol-generating article.

[0249] Example 25: An aerosol-generating article according to any of the preceding examples, wherein an upstream end of the ventilation zone is positioned no more than 8 millimeters from a downstream end of the capsule.

[0250] Example 26: An aerosol-generating article according to any of the preceding examples, wherein a ventilation level of the aerosol-generating article provided by the ventilation zone is at least 20%.

[0251] Example 27: An aerosol-generating system, the aerosol-generating system comprising:

[0252] An aerosol-generating article according to any one of Examples 1 to 26; and

[0253] An aerosol-generating device, the aerosol-generating device comprising a heating chamber for receiving the aerosol-generating article and a heating element disposed in or around a perimeter of the heating chamber. Description of the Drawings

[0254] Hereinafter, the present invention will be further described with reference to the figures of the drawings, wherein:

[0255] Figure 1 A schematic side cross-sectional view of an aerosol-generating article according to an embodiment of the present invention is shown;

[0256] Figure 2 A close-up schematic side cross-sectional view of a part of an aerosol-generating article according to an embodiment of the present invention is shown;

[0257] Figure 3 A schematic cross-sectional view along a longitudinal axis of a first aerosol-generating article according to an embodiment of the present invention is shown;

[0258] Figure 4 A schematic cross-sectional view along a longitudinal axis of a second aerosol-generating article according to an embodiment of the present invention is shown;

[0259] Figure 5shows a schematic cross - sectional view along the longitudinal axis of a third aerosol - generating article according to an embodiment of the present invention; and

[0260] Figure 6 shows a schematic side - cross - sectional view of an aerosol - generating system according to an embodiment of the present invention. Detailed description

[0261] Figure 1 The aerosol - generating article 10 shown in

[0262] includes a hollow tubular element 101 and a capsule 102 mounted within the hollow tubular element 101. The hollow tubular element 101 is formed of cardboard and has a cylindrical shape extending from an upstream end to a downstream end. The hollow tubular element 101 has a constant outer diameter of about 7.2 mm and a constant inner diameter of about 6.7 mm. Thus, the hollow tubular element 101 has a wall thickness of about 0.25 mm. The hollow tubular element 101 has a length of about 40 mm.

[0263] The capsule 102 includes an outer wall formed of an air - impermeable polymer such as HPMC. The capsule 102 has an elongated capsule (spherical - cylindrical) shape with a circular cross - section. The capsule includes a capsule outer wall defining an inner cavity that houses a plurality of beads of a solid aerosol - generating matrix ( Figure 1 not shown in

[0264] ). The solid aerosol - generating matrix contains nicotine and glycerol as an aerosol - forming agent. The capsule outer wall is defined by a cylindrical wall and opposing hemispherical end walls at the upstream and downstream ends of the capsule 102. The capsule 102 has a length of about 20 mm and an outer diameter of about 6.7 mm. Thus, the outer diameter of the capsule 102 is similar to the inner diameter of the hollow tubular element 101, such that the capsule 102 is held within the hollow tubular element 101 by a friction fit.

[0265] The capsule 102 has an internal volume of about 600 cubic millimeters and houses about 200 mg of the solid aerosol - generating matrix. Thus, the capsule houses an inner cavity with approximately 0.33 mg of aerosol - generating matrix per cubic millimeter.

[0266] The capsule 102 includes a plurality of capsule air inlets 105 at the upstream end of the capsule 102, on the hemispherical upstream end wall of the capsule 102. The capsule 102 includes a plurality of capsule air outlets 106 at the downstream end of the capsule 102, on the hemispherical downstream end wall of the capsule 102. The arrangement of the capsule air inlets 105 and the capsule air outlets 106 is described in more detail below.

[0267] The ventilation area includes 10 ventilation perforations 102 extending through the hollow tubular element 101. The ventilation perforations 102 are evenly spaced from each other and are arranged in rows defining the hollow tubular element 101. All the ventilation perforations 102 are of the same size. Each ventilation perforation 102 has a width of 100 microns and a length of 600 microns. The ventilation area provides a ventilation level of at least 20%.

[0268] The aerosol-generating article 10 also includes at least one stop 107 that projects from the inner surface of the hollow tubular element 101 to prevent the capsule 102 from moving further downstream than the at least one stop 107. In Figure 1 the aerosol-generating article 10 shown in, the at least one stop 107 includes an annular flange attached to and extending from the inner surface of the hollow tubular element 101. The inner diameter of the flange is less than the outer diameter of the capsule 102, thereby preventing the capsule from moving further downstream than the stop 107. The at least one stop 107 is located upstream of the ventilation area.

[0269] The aerosol-generating article 10 also includes a cavity 104 downstream of the capsule 102 and a downstream filter segment 108 downstream of the cavity 104. The cavity 104 extends from the downstream end of the capsule 102 to the upstream end of the downstream filter segment 108. The cavity 104 has a length of approximately 20 millimeters.

[0270] The downstream filter segment 108 extends from the downstream end of the cavity 104 to the downstream end of the aerosol-generating article. The downstream filter segment 108 is formed of cellulose acetate tow.

[0271] Figure 2 A portion of an alternative aerosol-generating article 10 according to the present invention is shown. As Figure 2 shown, the hollow tubular element 101 includes a plurality of flaps cut out from the hollow tubular element 101. The flaps are separated from the hollow tubular element 101 at the downstream end of the flaps but are attached to the hollow tubular element 101 at the upstream end. As Figure 2 can be seen, these flaps can be formed during manufacture by an angled piercing element 201 that cuts the hollow tubular element 101 and folds the flaps inwardly.

[0272] In this example, the holes in the hollow tubular element 101 formed by the piercing element 201 form ventilation perforations 103 to allow ambient air to enter the aerosol-generating article 10, and the flaps of material form at least one stop 107 to prevent any further downstream movement of the capsule 102.

[0273] Figure 3 A cross-sectional view of the aerosol-generating article 10 taken along the longitudinal axis of the article at the position 'A' marked in Figure 1 is shown. AsFigure 3 As shown in Figure 3 , the capsule 102 includes four capsule air outlets 106 arranged on the circle 301, and another capsule air outlet is arranged at the center of the downstream end of the capsule 102. Figure 3 The aerosol-generating article 10 shown in Figure 3 further includes a ventilation area, and the ventilation area includes four ventilation perforations 103 passing through the hollow tubular element 101. Each capsule air outlet 106 is arranged to radially overlap with the ventilation perforation 103. This radial overlap is represented by a radius line 302, and the radius line clearly intersects both the capsule air outlet 106 and the ventilation perforation 103.

[0274] Figure 4 Shown is Figure 1 a cross-sectional view of another aerosol-generating article 10 as viewed along the longitudinal axis of the article at the position 'A' marked in Figure 1 . Figure 4 The aerosol-generating article 10 shown in Figure 4 includes a ventilation area, and the ventilation area includes eight ventilation perforations 103 passing through the hollow tubular element 101. The angular diameter (θ C ) of the capsule air outlet and the angular distance (θ S ) between adjacent ventilation perforations are shown. The angular diameter (θ C ) of the capsule air outlet is greater than the angular distance (θ S ) between adjacent ventilation perforations.

[0275] Figure 5 Shown is Figure 1 a cross-sectional view of another aerosol-generating article 10 as viewed along the longitudinal axis of the article at the position 'A' marked in Figure 1 . Figure 5 The aerosol-generating article 10 shown in Figure 5 includes a ventilation area, and the ventilation area includes eighteen ventilation perforations 103 passing through the hollow tubular element 101. The angular diameter (θ C ) of the capsule air outlet is shown. The angular diameter (θ V ) of each ventilation perforation plus the angular distance (θ S ) between adjacent ventilation perforations are also shown. The angular diameter (θ C ) of the capsule air outlet is greater than the angular diameter (θ V ) of each ventilation perforation plus the angular distance (θ S ) between adjacent ventilation perforations.

[0276] Figure 6 Shown is an aerosol-generating system 20 according to the present invention. The system 20 includes the aerosol-generating article 10 as described above. The system 20 further includes an aerosol-generating device 30. The aerosol-generating device 30 includes a device housing 601. The housing 601 defines a heating chamber 602 for receiving the upstream end of the aerosol-generating article 20. The heating chamber 602 has an inner diameter substantially corresponding to the outer diameter of the aerosol-generating article 10. The heating chamber 602 has a length of about 30 millimeters.

[0277] The aerosol generating device 30 further includes a heating element or heater 603 for heating the aerosol - generating substrate when the aerosol - generating article 10 is received within the heating chamber 602. The heater 603 is an external heater that defines the heating chamber 602. The heater 603 is a resistive heater and is connected to a power source (not shown) and is controlled using control circuitry (not shown).

[0278] The aerosol generating device 30 further includes a plurality of device air inlets 604 to allow air to enter the heating chamber 602 of the device 30.

[0279] In use, the upstream end of the aerosol - generating article 10 is inserted into the heating chamber 602 of the aerosol generating device 30. The heater 603 is activated and the aerosol - generating substrate is heated within the capsule 102. The heated aerosol - generating substrate generates vapor. When a pressure drop is applied to the downstream end of the aerosol - generating article, ambient air is drawn through the device air inlets 604 and through the capsule air inlet 105 and into the capsule 102. Here, the air becomes entrained with vapor before it exits the capsule 102 through the capsule air outlet 106. Here, the air is mixed with ambient air that is drawn through the ventilation perforations 103, and the ambient air cools the vapor, thus promoting the nucleation and condensation of the aerosol. The aerosol then passes through the downstream filter section 108 and exits the downstream end of the aerosol - generating article.

[0280] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing quantities, amounts, percentages, etc. should be understood to be modified in all instances by the term "about". Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges that may be specifically enumerated or may not be enumerated herein. Thus, herein, a number A is understood to be A ± 10%. In this document, a number A may be considered to include values within the general standard error of the measurement of the property modified by the number A. In some cases used in the appended claims, the number A may deviate from the percentages recited above, provided that the amount by which A deviates does not materially affect the basic and novel features of the claimed invention. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges that may be specifically enumerated or may not be enumerated herein.

Claims

1. An aerosol - generating article for generating an inhalable aerosol upon heating, the article comprises: a hollow tubular element, and a capsule, which is mounted within the hollow tubular element at an upstream end thereof, the capsule containing an aerosol - generating substrate, the hollow tubular element includes a ventilation zone to allow external air to enter the aerosol - generating article, the ventilation zone being provided downstream of the downstream end of the capsule.

2. The aerosol - generating article according to claim 1, wherein the ventilation zone comprises at least one ventilation perforation.

3. The aerosol - generating article according to claim 2, wherein the ventilation zone comprises a plurality of ventilation perforations through the hollow tubular element.

4. The aerosol - generating article according to claim 3, wherein the ventilation zone comprises at least 5 ventilation perforations through the hollow tubular element.

5. The aerosol - generating article according to claim 3 or claim 4, wherein the ventilation zone comprises no more than 15 ventilation perforations through the hollow tubular element.

6. The aerosol - generating article according to any one of claims 3 to 5, wherein the plurality of ventilation perforations comprises at least one perforation having a width of no more than 200 micrometers.

7. The aerosol - generating article according to any one of claims 3 to 6, wherein the plurality of ventilation perforations comprises at least one perforation having a width of at least 50 micrometers.

8. The aerosol - generating article according to any one of claims 3 to 7, wherein the plurality of ventilation perforations comprises at least one perforation having a length of at least 400 micrometers.

9. The aerosol - generating article according to any one of claims 3 to 8, wherein the plurality of ventilation perforations comprises at least one perforation having a length of no more than 1 millimeter.

10. The aerosol - generating article according to any one of claims 3 to 9, wherein the plurality of ventilation perforations forms a first row of perforations defining the hollow tubular element.

11. The aerosol - generating article according to any one of claims 3 to 10, further comprising at least one stop member that projects from an inner surface of the hollow tubular element to prevent the capsule from moving downstream beyond the at least one stop member.

12. The aerosol - generating article according to claim 11, wherein the at least one stop member is located upstream of the ventilation zone.

13. The aerosol - generating article according to claim 11 or claim 12, wherein the hollow tubular element includes at least one flap, the at least one flap being formed by a portion of the hollow tubular element that is partially separated from the remainder of the hollow tubular element, thereby forming a gap between the flap and the remainder of the hollow tubular element, the flap remaining attached to the remainder of the hollow tubular element along an attachment line, wherein the flap extends into the interior or the hollow tubular element such that: the at least one stop member comprises the at least one flap, and the at least one ventilation perforation comprises the gap between the flap and the remainder of the hollow tubular element.

14. The aerosol-generating article according to any one of claims 3 to 13, wherein the capsule includes at least one capsule air inlet located at an upstream end of the capsule and at least one capsule air outlet located at a downstream end of the capsule.

15. An aerosol-generating system, the aerosol-generating system comprising: an aerosol-generating article according to any one of claims 1 to 14; and an aerosol-generating device including a heating chamber for receiving the aerosol-generating article and a heating element disposed in the heating chamber or disposed around a periphery of the heating chamber.

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