Hybrid aerosol-generating element and method for manufacturing hybrid aerosol-generating element

Abstract

The present disclosure relates to a mixed aerosol-generating element and a method for manufacturing a mixed aerosol-generating element. In particular, the invention relates to a mixed aerosol-generating element for use in an aerosol-generating article, the mixed aerosol-generating element comprising: a liquid retention material holding an aerosol-forming liquid in the form of glycerol; and a solid aerosol-forming substrate comprising tobacco. The tobacco-containing solid aerosol-forming substrate is disposed proximate to the liquid retention material.

Description

[0001] This application is a divisional application of a Chinese patent application with international application number PCT / EP2017 / 059217, Chinese application number 201780024068.5, filing date April 19, 2017, and title "Hybrid aerosol generating element and method for manufacturing a hybrid aerosol generating element". Technical Field

[0002] The present invention relates to a hybrid aerosol generating element and a method for manufacturing a hybrid aerosol generating element. Specifically, the present invention relates to an aerosol generating element and article which includes a solid aerosol forming matrix, specifically a solid aerosol forming tobacco matrix, and an aerosol forming liquid. Background Art

[0003] Electronic smoking systems that combine the use of an e-liquid and a heated tobacco flavorant are known. However, there is a desire to use a hybrid aerosol generating element in an electronic device designed for an electronic cigarette. There is also a desire for an effective method for manufacturing a hybrid aerosol generating element, particularly for manufacturing a hybrid aerosol generating element used in a bar-shaped aerosol generating article. Summary of the Invention

[0004] According to the present invention, there is provided a hybrid aerosol generating element for use in an aerosol generating article such as an electronic cigarette. The hybrid aerosol generating element includes a liquid retention material for holding an aerosol forming liquid and includes a solid aerosol forming matrix disposed adjacent to the liquid retention material. Preferably, the solid aerosol forming matrix is a solid aerosol forming matrix containing tobacco.

[0005] In such a hybrid element, the user obtains not only the flavor or smoking experience of the heated solid aerosol forming matrix or only the flavor or smoking experience of the heated aerosol forming liquid, but also a combination of the aerosol formed by heating the solid aerosol forming matrix and the aerosol formed by evaporating the aerosol forming liquid. In such a hybrid element, the aerosol forming liquid contained in the liquid retention material can, for example, continuously flow or be drawn into the solid aerosol forming matrix. Thereby, only the solid aerosol forming matrix or the region of the solid matrix must be heated, which can reduce the energy required in the aerosol generating system. In addition, the provision of the aerosol forming liquid can significantly extend the consumption experience of the aerosol generating element or the aerosol generating article containing such an element. For example, a single tobacco matrix plug used in an aerosol generating article can provide aerosol for several puffs, such as 5 to 10 puffs. Providing a liquid retention material having the ability to hold a certain amount of aerosol forming liquid can extend the consumption experience to dozens of times the puffs, for example, to about 50 to 100 puffs.

[0006] While a solid aerosol-forming substrate is preferably used to deliver tobacco flavorants to the aerosol delivered to the user, an aerosol-forming liquid is preferably used to provide nicotine or non-tobacco flavorants to the aerosol generated in a corresponding device using a hybrid aerosol-generating element.

[0007] The liquid retention material can hold a predetermined amount of aerosol-forming liquid. Preferably, the predetermined amount of liquid corresponds to a predefined number of puffs obtainable when using the hybrid aerosol-generating element.

[0008] The hybrid aerosol-generating element has a longitudinal axis, and the extension of the element can be greater in the longitudinal direction than in a direction perpendicular to the longitudinal direction. The hybrid aerosol-generating element can be, for example, cylindrical or substantially cylindrical in shape. The aerosol-generating element can be substantially elongated.

[0009] The aerosol-generating element can have a length between 8 and 14 millimeters, such as 10 mm or 12 mm. The diameter of the aerosol-generating element can be between 5 millimeters and 12 millimeters, such as approximately 8 millimeters.

[0010] In the hybrid aerosol-generating element, the liquid retention material and the solid aerosol-forming substrate can be arranged adjacent to each other and successively along the longitudinal axis of the element.

[0011] Alternatively, the liquid retention material and the solid aerosol-forming substrate can be arranged at least partially at the same longitudinal position of the hybrid aerosol-generating element. In such embodiments, the liquid retention material and the solid aerosol-forming substrate are arranged at least partially adjacent to each other transversely across the length of the hybrid aerosol-generating element. The liquid retention material and the solid aerosol-forming substrate can be arranged at the same longitudinal position across the entire length of the hybrid aerosol-generating element. Preferably, the liquid retention material and the solid aerosol-forming substrate are arranged preferably parallel to each other across the entire length of the element.

[0012] The liquid retention material can at least partially surround the solid aerosol-forming substrate. The liquid retention material can completely surround the solid aerosol-forming substrate in the longitudinal direction. For example, the solid aerosol-forming substrate can be a cylindrical solid aerosol-forming substrate disposed within a tubular-shaped liquid retention material.

[0013] The hybrid aerosol-generating element can include a liquid-impermeable wrapper that wraps the hybrid aerosol-generating element. The liquid-impermeable wrapper can prevent the liquid in the liquid retention material from leaking out of the retention material in a direction other than towards the solid aerosol-forming substrate, such as in a direction opposite to the solid aerosol-forming substrate or outside the aerosol-generating element.

[0014] For aerosol generation, the hybrid aerosol - generating element can be heated by a heating element suitable for and known from any kind of aerosol - generating system, for example. For example, the hybrid aerosol - generating element can be used in an aerosol - generating system or device for inductive or resistive heating. Thus, the aerosol - generating device can be equipped with one or more resistively - heatable heating elements or with one or more inductively - heatable heating elements. If used in an inductive - heating system, the heating portion of the heating element can be incorporated into the hybrid aerosol - generating element. The hybrid aerosol - generating element can include susceptor material for inductively heating at least a portion of the element. The susceptor material can be disposed within a solid aerosol - forming matrix. The susceptor material can be introduced into the solid aerosol - forming matrix before, during, or after the manufacture of the hybrid aerosol - generating element.

[0015] The liquid - retaining material is a high - retention or high - release material (HRM) for storing liquid. The liquid - retaining material reduces the risk of spillage, for example, compared to a cartridge or reservoir system. In the case of a housing failure or rupture of the reservoir or cartridge, the spilled liquid may cause an undesired contact with active electrical components and biological tissue. The liquid - retaining material will inherently retain at least a portion of the liquid, which cannot be used for aerosolization before leaving the retaining material.

[0016] The liquid - retaining material can be of a substantially cylindrical shape. The liquid - retaining material can have the form of a hollow cylinder. The liquid - retaining material can be substantially elongated. The length and (outer) diameter of the liquid - retaining material can correspond to the length and diameter of the hybrid aerosol - generating element.

[0017] The aerosol - forming liquid to be stored in the retaining material can include at least one aerosol - forming agent and a liquid additive. The aerosol - forming agent can be, for example, propylene glycol or glycerol.

[0018] The aerosol - forming liquid can include water.

[0019] The liquid additive can be any one or combination of a liquid flavorant or a liquid stimulant. The liquid flavorant can include, for example, tobacco flavorants, tobacco extracts, fruit flavorants, or coffee flavorants. The liquid additive can be, for example: sweet liquids such as vanilla, caramel, and cocoa, herbal liquids, spicy liquids, or stimulant liquids containing, for example, caffeine, taurine, nicotine, or other stimulants known in the food industry.

[0020] The solid aerosol - forming matrix can include a tobacco - containing material that contains volatile tobacco flavor compounds released from the matrix upon heating. Alternatively, the aerosol - forming matrix can include a non - tobacco material. The aerosol - forming matrix can further include an aerosol - forming agent. Examples of suitable aerosol - forming agents are glycerol and propylene glycol.

[0021] The aerosol-forming substrate may comprise, for example, one or more of powders, granules, pellets, flakes, strips, bands or sheets, which contain one or more of herb leaves, tobacco leaves, tobacco vein fragments, reconstituted tobacco, homogenized tobacco, extruded tobacco and expanded tobacco. The aerosol-forming substrate may be in a loose form or may be provided in a suitable container or cartridge. For example, the aerosol-forming material of the aerosol-forming substrate may be contained within paper or other wrapper paper and have the form of a plug.

[0022] Optionally, the aerosol-forming substrate may contain additional tobacco or non-tobacco volatile flavor compounds to be released upon heating the aerosol-forming substrate. The solid aerosol-forming substrate may also contain a casing, such as one containing additional tobacco or non-tobacco volatile flavor compounds, and such a casing may melt during heating of the solid aerosol-forming substrate.

[0023] The aerosol-forming substrate may comprise one or more sheets of homogenized tobacco material that have been aggregated into a strip and cut to provide individual plugs of the aerosol-forming substrate. The susceptor material may be introduced into this or these aggregated strip sheets before, during or after the sheets are aggregated into a strip. Preferably, the aerosol-forming substrate comprises curled and aggregated sheets of homogenized tobacco material.

[0024] The shape of the solid aerosol-forming substrate may be substantially cylindrical. The aerosol-forming substrate may be substantially elongated. The length of the solid aerosol-forming substrate may correspond to the length of the hybrid aerosol-generating element. The diameter of the aerosol-forming substrate may be between 3 mm and 7 mm, for example 5.6 mm.

[0025] The tobacco slurry and the tobacco sheet forming the aerosol-forming substrate made from the tobacco slurry comprise tobacco particles, fiber particles, aerosol-forming agents, binders and, for example, flavorants.

[0026] Preferably, the aerosol-forming tobacco substrate is a tobacco sheet, preferably curled, comprising tobacco material, fibers, a binder and an aerosol-forming agent. Preferably, the tobacco sheet is a cast leaf. The cast leaf is a form of reconstituted tobacco formed from a slurry comprising tobacco particles, fiber particles, aerosol-forming agents, binders and, for example, flavorants.

[0027] Depending on the desired sheet thickness and casting gap, the tobacco particles may have the form of tobacco dust having particles of about 30 microns to 250 microns, preferably about 30 microns to 80 microns or 100 microns to 250 microns, where the casting gap generally defines the thickness of the sheet.

[0028] The fibrous particles may comprise tobacco stem material, stalks or other tobacco plant material, and other cellulosic fibers such as wood fibers having a low lignin content, for example. The fibrous particles may be selected based on the desire for sufficient tensile strength of the sheet produced at a relatively low inclusion rate, such as an inclusion rate between about 2% and 15%. Alternatively, fibers such as vegetable fibers, for example, may be used in combination with the above fibrous particles or in an alternative comprising bamboo material.

[0029] The aerosol former included in the slurry forming the cast leaf may be selected based on one or more characteristics. Functionally, the aerosol former provides a mechanism that allows the aerosol former to volatilize and convey nicotine or flavor or both in an aerosol when heated above a specific volatilization temperature of the aerosol former. Different aerosol formers typically evaporate at different temperatures. The aerosol former may be selected based on its ability to remain stable, for example, at or near room temperature but be able to volatilize at higher temperatures, such as between about 40 degrees Celsius and 450 degrees Celsius. The aerosol former may also have wetting agent type characteristics that help maintain a desired level of moisture in the aerosol forming matrix when the matrix consists of a tobacco product containing tobacco particles. Specifically, some aerosol formers are hygroscopic materials that act as wetting agents, i.e., materials that help keep the matrix containing the wetting agent moist.

[0030] One or more aerosol formers may be combined to take advantage of one or more characteristics of the combined aerosol formers. For example, triacetin may be combined with glycerol and water to take advantage of the ability of triacetin to transport active components and the wetting agent characteristics of glycerol.

[0031] The aerosol former may be selected from polyols, ethylene glycol ethers, polyol esters, esters, and fatty acids, and may include one or more of the following compounds: glycerol, erythritol, 1,3 - butanediol, tetraethylene glycol, triethylene glycol, triethyl citrate, propylene carbonate, ethyl laurate, triacetin, meso - erythritol, glycerol diacetate mixture, diethyl suberate, triethyl citrate, benzyl benzoate, phenylmethyl phenylacetate, ethyl vanillate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene glycol.

[0032] The solid aerosol - forming matrix or the aerosol - forming slurry forming the matrix may contain wax or oil added to release the aerosol - forming substance from the solid aerosol - forming matrix at a low temperature. Some waxes and oils are known for their ability to lower the temperature at which the aerosol former is released from the solid matrix containing the wax or oil.

[0033] Preferably, the tobacco-containing slurry comprises homogenized tobacco material and comprises glycerol or propylene glycol as an aerosol-forming agent. Preferably, the aerosol-forming substrate is made of the tobacco-containing slurry as described above.

[0034] Preferably, the solid aerosol-forming substrate has a capillary effect for a liquid. Preferably, the solid aerosol-forming substrate provides a capillary effect for the aerosol-forming liquid retained in the liquid-retaining material. Preferably, the solid aerosol-forming substrate enables the aerosol-forming liquid to be transported from the liquid-retaining material into the solid aerosol-forming substrate. The solid aerosol-forming substrate thus consists of or comprises a capillary material such that the aerosol-forming liquid is transported by capillary action.

[0035] A capillary material is a material that actively transports a liquid from one part of the material to another part. The capillary material is advantageously oriented in the solid aerosol-forming substrate to transport the aerosol-forming liquid into the solid aerosol-forming substrate.

[0036] The solid aerosol-forming substrate may have a fibrous structure or may have a spongy structure. The solid aerosol-forming substrate may comprise a bundle of capillaries, a plurality of fibers, a plurality of filaments, or may comprise a porous tube. The solid aerosol-forming substrate may comprise a combination of fibers, filaments, and porous tubes. The fibers, filaments, and porous tubes may be generally aligned to transport the liquid into the solid aerosol-forming substrate. The solid aerosol-forming substrate may comprise a spongy material or may comprise a foamy material. The structure of the solid aerosol-forming substrate may form a plurality of small holes or small tubes through which the liquid can be transported by capillary action. The capillary effect may cause the liquid to be transported to the location of a sensor or another heating element disposed in the solid aerosol-forming substrate, for example, to the center of the substrate.

[0037] The sensor material that can be used for the hybrid aerosol-generating element, in particular the sensor material that can be incorporated into the solid aerosol-forming substrate, may be a plurality of sensor particles, such as sensor granules or sensor sheets.

[0038] The sensor particles may be uniformly distributed in the hybrid aerosol-generating element, preferably in the solid aerosol-forming substrate. The sensor particles may also be located in a specific region of the hybrid aerosol-generating element, in particular in a specific region of the solid aerosol-forming substrate.

[0039] The sensor material may be an elongate sensor that is longitudinally disposed in the hybrid aerosol-generating element, in particular within the solid aerosol-forming substrate. Preferably, such an elongate sensor is radially centered within the hybrid aerosol-generating element, preferably radially centered within the solid aerosol-forming substrate.

[0040] The length dimension of the elongating sensor is greater than its width dimension or its thickness dimension, for example, greater than twice its width dimension or its thickness dimension. The elongating sensor can be arranged substantially longitudinally within the element. This means that the length dimension of the elongating sensor is arranged to be generally parallel to the longitudinal direction of the element, for example, within plus or minus 10 degrees of the longitudinal direction of the element. In a preferred embodiment, the elongating sensor is located in a radially central position within the element and extends along the longitudinal axis of the hybrid aerosol-generating element.

[0041] The elongating sensor is preferably in the form of a needle, strip, ribbon or blade. Preferably, the length of the elongating sensor is between 5 millimeters (mm) and 15 mm, for example, between 6 mm and 12 mm or between 8 mm and 10 mm. The lateral extension of the sensor material can be, for example, between 0.5 mm and 8 mm, preferably between 1 mm and 6 mm, for example, 4 mm. Preferably, the width of the elongating sensor is between 1 mm and 5 mm, and its thickness can be between 0.01 mm and 2 mm, for example, between 0.5 mm and 2 mm. In a preferred embodiment, the thickness of the elongating sensor can be between 10 micrometers and 500 micrometers, or even more preferably between 10 micrometers and 100 micrometers. If the elongating sensor has a constant cross-section, such as a circular cross-section, then its width or diameter is preferably between 1 mm and 5 mm. If the elongating sensor is in the form of a ribbon or blade, for example, if the sensor is made of sheet-like sensor material, then preferably, the ribbon or blade has a rectangular shape, its width is preferably between 2 millimeters (mm) and 8 mm, more preferably between 3 mm and 5 mm, for example, 4 mm, and its thickness is preferably between 0.03 mm and 0.15 mm, more preferably between 0.05 mm and 0.09 mm, for example, 0.07 mm.

[0042] Preferably, the length of the elongating sensor is the same as or shorter than the length of the hybrid aerosol-generating element or the solid aerosol-forming substrate. Preferably, the length of the elongating sensor is the same as the length of the aerosol-generating element or the solid aerosol-forming substrate.

[0043] As used herein, the term'receptor' refers to a material that can convert electromagnetic energy into heat. When located within a fluctuating electromagnetic field, eddy currents are typically induced and hysteresis losses occur in the receptor, causing heating of the receptor. Since the receptor material is in direct physical and thermal contact with the aerosol-forming substrate or the aerosol-forming liquid or both, the aerosol-forming substrate or liquid is heated by the receptor material.

[0044] The susceptor can be formed of any material capable of being inductively heated to a temperature sufficient to generate an aerosol from a solid aerosol-forming substrate and an aerosol-forming liquid. Preferred susceptors include metals or carbon. Preferred susceptors can include or be composed of ferromagnetic materials, such as ferromagnetic alloys, ferritic iron, or ferromagnetic steel or stainless steel. Suitable susceptors can be aluminum or include aluminum. Preferred susceptors can be made of 400 series stainless steel, such as grade 410 or grade 420 or grade 430 stainless steel. Different materials will consume different amounts of energy when positioned within an electromagnetic field having similar frequency and field strength values. Thus, the parameters of the susceptor, such as material type, length, width, and thickness, can be varied within a known electromagnetic field to provide the desired power consumption.

[0045] Preferred susceptors can be heated to a temperature in excess of 250 degrees Celsius. Suitable susceptors can include a non-metallic core having a metal layer disposed thereon, such as metal traces formed on the surface of a ceramic core. The susceptor can have an outer protective layer, such as a ceramic protective layer or a glass protective layer encapsulating the susceptor. The susceptor can include a protective coating formed of glass, ceramic, or an inert metal, the protective coating being formed on the core of the susceptor material.

[0046] The susceptor can be a multi-material susceptor and can include a first susceptor material and a second susceptor material. The first susceptor material is arranged in intimate physical contact with the second susceptor material. The first susceptor material is preferably mainly used for heating the susceptor when the susceptor is placed in a fluctuating electromagnetic field. For example, the first susceptor material can be aluminum or can be an iron-containing material, such as stainless steel. The second susceptor material is preferably mainly used for indicating when the susceptor has reached a specific temperature, which is likely the Curie temperature of the second susceptor material. The Curie temperature of the second susceptor material can be used to regulate the temperature of the entire susceptor during operation. Thus, the Curie temperature of the second susceptor material should be below the ignition point of the solid aerosol-forming substrate. Suitable materials for the second susceptor material can include nickel and certain nickel alloys.

[0047] By providing a susceptor having at least a first and a second susceptor material, wherein the second susceptor material has a Curie temperature and the first susceptor material does not have a Curie temperature, or the first and second susceptor materials have first and second Curie temperatures that are different from each other, heating of the aerosol-forming substrate and temperature control of the heating can be separated. Preferably, the second susceptor material is a magnetic material selected to have a second Curie temperature that is substantially the same as the desired maximum heating temperature. That is, preferably, the second Curie temperature is approximately the same as the temperature to which the susceptor should be heated in order to generate an aerosol from the aerosol-forming substrate. The second Curie temperature of the second susceptor material can be selected, for example, such that after heating by a susceptor at a temperature equal to the second Curie temperature, the overall average temperature of the aerosol-generating element does not exceed 240 °C.

[0048] Alternatively or additionally, in order to control the heating process of the hybrid aerosol-generating element, the evaporation temperature of the aerosol-forming liquid can also be used, as outlined in more detail below.

[0049] According to the present invention, there is also provided a hybrid aerosol-generating article comprising a plurality of elements assembled in a strip form. The strip has a mouth end and a distal end upstream of the mouth end. The plurality of elements includes a hybrid aerosol-generating element according to the present invention and as described herein. The advantages and features of the aerosol-generating article in relation to the hybrid aerosol-generating element have been described with respect to the hybrid aerosol-generating element and will not be repeated.

[0050] The plurality of elements can include at least one sealing element arranged in an end-to-end relationship with the hybrid aerosol-generating element. The at least one sealing element seals at least a portion of the distal end of the hybrid aerosol-generating element. Preferably, the at least one sealing element seals the portion of the distal end of the aerosol-generating element that includes the liquid retention material. Thereby, the at least one sealing element prevents liquid from leaving the liquid retention material in the upstream longitudinal direction of the aerosol-generating article.

[0051] The plurality of elements can include other sealing elements, wherein another sealing element is arranged immediately downstream of the hybrid aerosol-generating element.

[0052] Another sealing element seals at least a portion of the proximal end of the hybrid aerosol-generating element. Preferably, another sealing element seals the portion of the proximal end of the aerosol-generating element that includes the liquid retention material. Thereby, another sealing element prevents liquid from leaving the liquid retention material in the downstream longitudinal direction of the aerosol-generating article.

[0053] The plurality of components may include two sealing elements, one sealing element being arranged upstream of the hybrid aerosol-generating element and a second sealing element being arranged downstream of the hybrid aerosol-generating element. Preferably, the two sealing elements are arranged directly adjacent to the hybrid aerosol-generating element.

[0054] In some embodiments, at least one sealing element may prevent a susceptor arranged in the aerosol-generating element from shifting or falling out of the aerosol-generating element during transportation or handling of the article.

[0055] At least one sealing element may be a hollow sealing element. All sealing elements may be hollow sealing elements. The hollow sealing element may seal a distal or proximal end of a hollow tubular retention material and allow air to pass through the sealing element or, in the case of a sealing element arranged downstream, allow aerosol to pass through the sealing element. Preferably, the sealing element does not change the draw resistance of the aerosol-generating article.

[0056] The sealing element may be made of any material suitable for use in an aerosol-generating article. The sealing element may be made, for example, of the same material as that used in conventional mouthpiece filters, aerosol cooling elements or support elements. Exemplary materials are filter materials, ceramics, polymers, cellulose acetate, cardboard, non-inductively heatable metals or zeolites.

[0057] Preferably, the sealing element is made of a heat-resistant material. A heat-resistant material for the sealing element means herein that the sealing element can withstand temperatures of up to about 350 degrees Celsius. Advantageously, the sealing element is not affected by a heated aerosol-generating element or a potential heating element arranged in the aerosol-generating element.

[0058] Preferably, the sealing element does not change its consistency, geometry or optics after use of the article.

[0059] Preferably, the sealing element does not generate substances other than the generated aerosol during use of the article.

[0060] The (outer) diameter of the sealing element is substantially equal to the diameter of the aerosol-generating article. The sealing element has a length that may be defined as a dimension along the longitudinal axis of the aerosol-generating article. The length of the sealing element may be between 1 millimeter (mm) and 10 mm, for example between 4 mm and 8 mm or between 5 mm and 7 mm. Preferably, the sealing element is substantially cylindrical. Preferably, the sealing element is less than 8 mm. Preferably, the length of the sealing element is at least 2 millimeters to facilitate assembly of the aerosol-generating article, preferably at least 3 mm or at least 5 mm.

[0061] The minimum size of the length of the sealing element facilitates or allows the use of a conventional combiner to assemble a plurality of components into a strip.

[0062] Generally, whenever a value is mentioned throughout this application, this should be understood as meaning that the value is explicitly disclosed. However, for technical considerations, the value should also be understood as not necessarily being exactly the specific value.

[0063] The plurality of elements may also include, for example, one or more of the following elements: a mouthpiece element, a support element, or an aerosol cooling element.

[0064] The mouthpiece element may be located at the mouth end or the downstream end of the aerosol-generating article.

[0065] The mouthpiece element may include at least one filter segment. The filter segment may be a cellulose acetate filter plug made of cellulose acetate tow. The filter segment may have a low particle filtration efficiency or a very low particle filtration efficiency. The filter segment may be longitudinally spaced apart from the mixed aerosol-generating element. The length of the filter segment may be between 5 millimeters and 14 millimeters, for example 7 millimeters.

[0066] The user contacts the mouthpiece element so that the aerosol generated by the aerosol-generating article passes through the mouthpiece element to reach the user. Thus, the mouthpiece element is arranged downstream of the mixed aerosol-generating element.

[0067] Preferably, the outer diameter of the mouthpiece element is substantially equal to the outer diameter of the aerosol-generating article. The length of the mouthpiece element may be between 5 millimeters (mm) and 25 mm, preferably between 10 mm and 17 mm. In a preferred embodiment, the length of the mouthpiece element is 12 mm or 14 mm. In another preferred embodiment, the length of the mouthpiece element is 7 mm.

[0068] The support element may be located immediately downstream of the mixed aerosol-generating element and may abut against the mixed aerosol-generating element.

[0069] The support element may be formed of any suitable material or combination of materials. For example, the support element may be formed of one or more materials selected from the group consisting of: cellulose acetate; cardboard; crimped paper, such as crimped heat-resistant paper or crimped parchment paper; and polymeric materials, such as low density polyethylene (LDPE). In a preferred embodiment, the support element is formed of cellulose acetate.

[0070] The support element may include a hollow tubular element. In a preferred embodiment, the support element includes a hollow cellulose acetate tube. Accordingly, the sealing element that seals the proximal end of the mixed aerosol-generating element may be the support element, or the support element may be designed as a sealing element.

[0071] Preferably, the outer diameter of the support element is substantially equal to the outer diameter of the aerosol-generating article.

[0072] The length of the support element may be between 5 mm and 15 mm. In a preferred embodiment, the length of the support element is 8 mm.

[0073] The aerosol-cooling element may be located downstream of the hybrid aerosol-generating element, for example immediately downstream of the support element or the sealing element, and may abut the support element or the sealing element.

[0074] As used herein, the term 'aerosol-cooling element' is used to describe an element having a large surface area and low resistance to draw. In use, an aerosol formed from volatile compounds released from an aerosol-forming substrate is drawn through the aerosol-cooling element before being delivered to the mouth end of the aerosol-generating article. Aerosol-cooling elements have a low resistance to draw compared to high-resistance filters, such as filters formed from fiber bundles. Chambers and cavities within an aerosol-generating article, such as expansion chambers and support elements, are also not considered to be aerosol-cooling elements.

[0075] Preferably, the aerosol-cooling element has a porosity in the longitudinal direction of greater than 50%. Preferably, the airflow path through the aerosol-cooling element is relatively uninhibited. The aerosol-cooling element may be a gathered sheet or a rolled and gathered sheet. The aerosol-cooling element may comprise a sheet selected from the group consisting of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), and aluminum foil, or any combination thereof.

[0076] In a preferred embodiment, the aerosol-cooling element comprises a gathered sheet of biodegradable material, for example, a gathered sheet of non-porous paper or a gathered sheet of a biodegradable polymeric material, such as polylactic acid or Mater-Bi® grades (a range of commercially available starch-based copolyesters).

[0077] Preferably, the aerosol-cooling element comprises a sheet of PLA, more preferably a rolled, aggregated sheet of PLA. The aerosol-cooling element may be formed from a sheet having a thickness between 10 microns and 250 microns, for example 50 microns. The aerosol-cooling element may be formed from an aggregated sheet having a width between 150 mm and 250 mm. The specific surface area of the aerosol-cooling element may be 300 mm per mm of length. 2 Up to 1000 mm per mm length 2 Between 10 mm per mg weight 2 to 100 mm per mg weight 2 In some embodiments, the aerosol-cooling element may be formed from a gathered sheet of material having a specific surface area of about 35 mm2 per milligram of weight. 2The outer diameter of the aerosol cooling element can be between 5 mm and 10 mm, for example 7 mm.

[0078] The length of the aerosol cooling element can be between 10 mm and 15 mm, for example 13 mm, or in an alternative embodiment can be between 15 mm and 25 mm, preferably between 16 mm and 20 mm, for example 18 mm.

[0079] Depending on the desired or required cooling effect, the length of the aerosol cooling element can even be shorter. For example, wax or grease for the low-temperature release of aerosol-forming substances from a solid aerosol-forming matrix can be included in the solid matrix. In such an embodiment, the aerosol cooling element can be shortened to a few millimeters, for example 5 to 10 mm, or can be omitted.

[0080] The plurality of elements of the aerosol-forming article can be surrounded by a wrapper. The wrapper can be formed from any suitable material or combination of materials. Preferably, the wrapper is cigarette paper.

[0081] According to the present invention, there is also provided an aerosol generation system comprising a hybrid aerosol-forming article according to the present invention and as described herein. The system further comprises a heating element for heating at least a portion of the hybrid aerosol-forming element of the hybrid aerosol-forming article, a power source for supplying energy to the heating element, and an electronic control device configured to control the heating of the hybrid aerosol-forming element.

[0082] The electronic control device can be programmed to determine the temperature of at least a portion of the hybrid aerosol-forming element, the temperature being used to control the heating of at least a portion of the hybrid aerosol-forming element.

[0083] For a resistive heating element, the ohmic resistance of the heating element can be related to the temperature of the heating element. In an inductive heating system, the temperature of the susceptor can be determined based on the apparent ohmic resistance (R a ) of the inductive "heating circuit". Such inductive heating circuits and the determination of the apparent resistance and its correlation with the susceptor temperature are described in detail in International Patent Publication WO2015 / 177256.

[0084] In the aerosol generation system, the evaporation temperature of the aerosol-forming liquid provided in the liquid retention material of the aerosol-forming element can be used to control the heating of at least a portion of the hybrid aerosol-forming element, or to control the heating of, for example, the solid aerosol-forming matrix of the element. The evaporation temperature of the aerosol-forming liquid can correspond to a predefined maximum heating temperature.

[0085] The aerosol-forming liquid can be heated to its evaporation temperature at which the liquid evaporates. As long as, for example, the aerosol-forming liquid is present in the solid aerosol-generating substrate, the substrate may not be heated above the evaporation temperature of the liquid until all of the liquid has evaporated. As long as the liquid can penetrate into the solid substrate, the solid substrate will not be heated above the evaporation temperature, and thus the evaporation temperature corresponds to the maximum heating temperature.

[0086] The aerosol-generating system may include an aerosol-generating device, which includes a device housing and a chamber disposed in the device housing. The chamber has an inner surface shaped to receive at least a portion of the hybrid aerosol-generating article. The chamber is arranged such that when at least a portion of the hybrid aerosol-generating article is received in the chamber, a heating element is arranged such that at least a portion of the hybrid aerosol-generating element is heated during operation of the device.

[0087] Preferably, the entire aerosol-generating element of the article is received in the chamber.

[0088] In a resistive heating device, the heating elements are typically inserted separately into the aerosol-generating article or the aerosol-generating element.

[0089] In an inductive heating device, the chamber is arranged such that when at least a portion of the aerosol-generating element is received in the chamber, an inductor included in the device can be inductively coupled to a susceptor arranged in thermal contact with the hybrid aerosol-generating element, for example, coupled to a susceptor arranged in the aerosol-generating element, preferably a susceptor arranged in the solid aerosol-forming substrate.

[0090] According to the present invention, there is also provided a method for manufacturing a hybrid aerosol-generating element for use in an aerosol-generating article. The method includes the steps of: providing a continuous solid aerosol-forming substrate and a continuous liquid-retaining material, and guiding the continuous liquid-retaining material parallel to the continuous solid aerosol-forming substrate. Further steps include forming the continuous solid aerosol-forming substrate and the continuous liquid-retaining material into a continuous strip and cutting the continuous strip into individual hybrid aerosol-generating elements.

[0091] Thus, the continuous retaining material may be arranged along one longitudinal side (e.g., the first half) of the continuous strip, and the continuous solid aerosol-forming substrate may be arranged along the other longitudinal side (e.g., the other half) of the continuous strip.

[0092] The continuous retention material may also be arranged to at least partially or completely surround the continuous solid aerosol-forming substrate. In these embodiments, the method preferably further comprises the steps of: at least partially forming the solid continuous aerosol-forming substrate into a continuous strip, then arranging the continuous liquid retention material around the continuous strip of the at least partially formed solid aerosol-forming substrate, and then forming the continuous liquid retention material arranged around the continuous strip of the at least partially formed aerosol-forming substrate into a continuous strip. Thereby, a continuous strip having a core of a solid aerosol-forming substrate and a shell of a retention material can be formed.

[0093] The method may further comprise the step of wrapping the continuous strip with a fluid-impermeable wrapper before cutting the continuous strip.

[0094] The liquid may be present in the continuous retention material before forming the continuous strip, or may be provided to the retention material after forming the continuous strip. However, the liquid is provided to the liquid retention material before wrapping the continuous strip with a liquid-impermeable wrapper.

[0095] In order to manufacture a hybrid aerosol-generating element for inductive heating applications, a susceptor may be incorporated into the element during manufacture. In these embodiments, the method may further comprise the steps of: introducing a susceptor material, preferably a continuous susceptor material, into the solid continuous aerosol-forming substrate. Preferably, before forming the strip, a susceptor material such as a tape or filament is inserted into the element, preferably into the continuous solid aerosol-forming substrate. Preferably, the susceptor is incorporated into the continuous strip of the partially formed solid aerosol-forming substrate.

[0096] Preferably, the solid continuous aerosol-forming substrate is provided in the form of a sheet-like continuous matrix.

[0097] Preferably, the continuous liquid retention material is provided in the form of a sheet-like continuous web, preferably a porous web.

[0098] Then, the hybrid aerosol-generating elements cut from the continuous strip can be assembled with other elements in an end-to-end position to form a strip. The assembled elements can then be wrapped with an outer wrapper to form a hybrid aerosol-generating article. BRIEF DESCRIPTION OF THE DRAWINGS

[0099] The present invention is further described with reference to embodiments, which are illustrated by the following drawings, wherein:

[0100] Figure 1 is a schematic illustration of a hybrid aerosol-generating article;

[0101] Figure 2 is a schematic illustration of a method of manufacturing a hybrid aerosol-generating element and an article including a susceptor. DETAILED DESCRIPTION

[0102] Figure 1 An aerosol-generating article is shown. The aerosol-generating article comprises five elements arranged in coaxial alignment: a first sealing element 1, a mixing aerosol-forming element 2, a second sealing element 3 which also acts as a support element, an aerosol-cooling element 4 and a mouthpiece 5. Each of the five elements is a substantially cylindrical element and all have substantially the same diameter. The five elements are arranged in sequence and are surrounded by an outer wrapper (not shown) to form a cylindrical rod.

[0103] The first sealing element 1 is located at the most distal or upstream end 80 of the aerosol-generating article. The first sealing element 1 is shown as a hollow tube, such as a hollow cellulose acetate tube. The hollow tube allows air to pass through the first sealing element 1 and enter the mixing aerosol-forming element 2 disposed nearby and downstream of the first sealing element 1. The inner diameter of the hollow tube of the first sealing element 1 is smaller than the inner diameter of the liquid-retaining material tube 22 of the mixing aerosol-generating matrix element 2. The material of the first sealing element is impermeable to the liquid held in the liquid-retaining material tube 22. Thus, the first sealing element 1 prevents the liquid from leaving the distal end of the retaining material tube 22 in the upstream direction.

[0104] The mixing aerosol-generating element 2 comprises a tobacco plug 21 of solid aerosol-forming matrix material, which comprises an aggregated sheet of crimped homogeneous tobacco material. The crimped sheet of homogeneous tobacco material comprises glycerol or propylene glycol as an aerosol-forming agent. The diameter of the tobacco plug 21 may be about 5.6 mm

[0105] A susceptor blade 23 is positioned along the radial central axis of the aerosol-forming element 2. The susceptor has a length approximately the same as the length of the aerosol-forming element 2. The susceptor may be a ferritic iron material having a length of 10 mm to 12 mm, a width of 3 mm and a thickness of 1 mm.

[0106] The diameter of the susceptor blade 23 is larger than the inner diameter of the first sealing element 1. Thus, the susceptor blade 23 is prevented from moving out of or falling out of the aerosol-generating element 2 by the first sealing element 1.

[0107] A liquid-retaining material tube 22 is disposed around the tobacco plug 21. The liquid-retaining material is a porous material, such as a plastic material, and is adapted to retain a certain amount of aerosol-forming liquid. The aerosol-forming liquid comprises glycerol or propylene glycol as an aerosol-forming agent, and nicotine. The thickness of the wall of the liquid-retaining material tube is about 0.8 mm.

[0108] The mixing aerosol-forming element 2 is packaged with an impermeable wrapper 24. The wrapper 24 is impermeable to the aerosol-forming liquid in the retaining material 22.

[0109] The second sealing element 3 or the support element is located immediately downstream of the aerosol-forming element 2 and abuts against the aerosol-forming element 2. In Figure 1 , the second sealing element 3 is the same as the first sealing element 1. The second sealing element is shown as a hollow tube, such as a hollow cellulose acetate tube.

[0110] The second sealing element 3 positions the aerosol-forming element 2 within the aerosol-generating article.

[0111] The second sealing element 3 allows substances evaporated from the mixed aerosol-forming element 2 or the aerosol formed in the mixed aerosol-forming element 2 to pass through the second sealing element 3 and further downstream into the aerosol cooling element 4 disposed near and downstream of the second sealing element 3. The inner diameter of the hollow tube of the second sealing element 3 is smaller than the inner diameter of the liquid retention material tube 22 of the mixed aerosol-generating element 2. The material of the second sealing element 3 is impermeable to the liquid held in the liquid retention material tube 22. Thus, the second sealing element 3 prevents the liquid from leaving the proximal end of the retention material tube 22 in the downstream direction.

[0112] Thus, the liquid in the retention material 22 can only leave the retention material towards the direction of the tobacco plug 21. If the tobacco plug 21 is also heated by the sensor 23, the aerosol-forming substances in the tobacco plug 21 are evaporated, and the aerosol-forming liquid is inhaled into the tobacco plug 21 from the retention material.

[0113] The second sealing element 3 also serves as a spacer to space apart the aerosol cooling element 4 from the aerosol-forming element 2.

[0114] The aerosol cooling element 4 is located immediately downstream of the second sealing element 3 and abuts against the second sealing element 3. In use, the volatile substances released from the aerosol-forming element 2 pass along the aerosol cooling element 4 towards the mouth end 81 of the aerosol-generating article. The volatile substances can be cooled within the aerosol cooling element 4 to form an aerosol inhaled by the user. The aerosol cooling element includes a curled and aggregated polylactic acid sheet surrounded by a wrapper paper (not shown). The curled and aggregated polylactic acid sheet defines a plurality of longitudinal channels extending along the length of the aerosol cooling element 4.

[0115] The mouthpiece 5 is located immediately downstream of the aerosol cooling element 4 and abuts against the aerosol cooling element . In Figure 1 , the mouthpiece 5 includes a conventional cellulose acetate tow filter with a low filtration efficiency.

[0116] To assemble the aerosol-generating article, the above five cylindrical elements are aligned and tightly packaged within an outer wrapper paper. The outer wrapper paper can be a conventional cigarette paper.

[0117] The aerosol-generating article has a proximal or mouth end 81 that a user inserts into his or her mouth during use, and a distal end 80 located at an end of the aerosol-generating article opposite the mouth end 81. After assembly, the total length of the aerosol-generating article 10 is about 45 mm to 53 mm, and the diameter is about 7.2 mm.

[0118] In use, air is drawn by the user from the distal end 80, as indicated by arrow 7, through the aerosol-generating article to the mouth end 81. The distal end 80 of the aerosol-generating article may also be described as the upstream end of the aerosol-generating article, and the mouth end 81 of the aerosol-generating article may also be described as the downstream end of the aerosol-generating article.

[0119] In manufacturing the article, the five elements are prepared, assembled and packaged with an outer wrapper.

[0120] The susceptor 23 may be inserted into the tobacco plug 21 and then the elements are assembled to form a strip. Alternatively, all the elements except the first sealing element 1 may be assembled. The susceptor may then be inserted into the distal end of the assembly, passing through the tobacco plug 21.

[0121] Figure 1 The aerosol-generating article is designed to engage with an electrically-operated aerosol-generating device preferably including an induction coil or inductor, for inhalation or consumption by a user.

[0122] In Figure 2 embodiments of a method of manufacturing a hybrid aerosol-generating substrate element and an article including such elements are shown.

[0123] Continuous tobacco material 25, such as a cast tobacco leaf, is provided on a reel 44. The tobacco sheet 25 is curled between curling rollers 60.

[0124] Continuous susceptor material 54, such as susceptor tape material, is provided on another reel. The curled tobacco sheet and the susceptor tape 54 are together guided into a fitting tongue 61 where a continuous strip is formed that includes tobacco material surrounding the susceptor tape.

[0125] The continuous tobacco strip is wrapped with a high-retention material 64, such as a retention material web, which is provided on yet another reel. The retention material 64 may contain a liquid before being wrapped around the tobacco strip. The liquid may also be provided to the retention material after wrapping the retention material around the tobacco strip.

[0126] The continuous strip is further provided with a liquid-impermeable wrapper, which may be provided on another reel (not shown). The final continuous strip 9 is cut into strip segments 90 or directly into aerosol-generating substrate elements 2 of final length by a cutter 62. In Figure 2Also shown is a cross-section 20 through the strip section 90 or through the aerosol-generating substrate element 2.

[0127] After the continuous strip 9 or strip section 90 has been cut into aerosol-generating substrate elements 2, the elements 2 can be provided to an article assembly machine.

[0128] The elements of the article are aligned on the wrapper 74 together with the aerosol-generating substrate element 2. The elements or segments are then assembled and wrapped with the wrapper 74 to form a hybrid aerosol-generating article adapted to be inductively heated.

[0129] In the embodiment shown in the figures, the susceptor material is depicted or shown as being disposed within the solid aerosol-forming substrate or tobacco plug such that the tobacco plug and the liquid infiltrated into the plug are heated. Thus, the heating can be mainly limited to the tobacco plug, and the aerosol-forming liquid in the reservoir material is not heated or is not significantly heated. However, the susceptor material can alternatively or additionally be disposed within the liquid reservoir material, such as incorporated into the liquid reservoir material. By heating the liquid in the reservoir material, an increased delivery of the aerosol-forming liquid can be achieved.

[0130] The following clauses are also disclosed herein:

[0131] 1. A hybrid aerosol-generating element for use in an aerosol-generating article, the hybrid aerosol-generating element comprising a liquid reservoir material for holding an aerosol-forming liquid and a solid aerosol-forming substrate disposed adjacent to the liquid reservoir material, wherein the liquid reservoir material and the solid aerosol-forming substrate are at least partially disposed at the same longitudinal position within the hybrid aerosol-generating element.

[0132] 2. The hybrid aerosol-generating element according to any one of the preceding clauses, wherein the liquid reservoir material at least partially surrounds the solid aerosol-forming substrate.

[0133] 3. The hybrid aerosol-generating element according to any one of the preceding clauses, which comprises a liquid-impermeable wrapper.

[0134] 4. The hybrid aerosol-generating element according to any one of the preceding clauses, which further comprises a susceptor material.

[0135] 5. The hybrid aerosol-generating element according to any one of the preceding clauses, wherein the liquid reservoir material holds a predetermined amount of aerosol-forming liquid.

[0136] 6. A hybrid aerosol-generating article comprising a plurality of elements assembled in strip form, the plurality of elements comprising a hybrid aerosol-generating element according to any one of clauses 1 to 5.

[0137] 7. The hybrid aerosol-generating article according to clause 6, wherein the plurality of elements further includes at least one sealing element arranged in an end-to-end relationship with the hybrid aerosol-generating element, and the at least one sealing element seals at least a portion of the distal end of the hybrid aerosol-generating element.

[0138] 8. An aerosol-generating system comprising the hybrid aerosol-generating article according to any one of clauses 6 to 7, the system further comprising:

[0139] A heating element for heating at least a portion of the hybrid aerosol-generating element of the hybrid aerosol-generating article;

[0140] A power source for supplying energy to the heating element;

[0141] An electronic control device configured to control the heating of the hybrid aerosol-generating element.

[0142] 9. The aerosol-generating system according to clause 8, wherein the evaporation temperature of the aerosol-forming liquid provided in the liquid retention material of the aerosol-generating element corresponds to a predefined maximum heating temperature.

[0143] 10. The aerosol-generating system according to any one of clauses 8 to 9, wherein the electronic control device is programmed to determine the temperature of at least a portion of the hybrid aerosol-generating element for controlling the heating of at least a portion of the hybrid aerosol-generating element.

[0144] 11. A method for manufacturing a hybrid aerosol-generating element for use in an aerosol-generating article, the method comprising the steps of:

[0145] Providing a continuous solid aerosol-forming matrix and a continuous liquid retention material;

[0146] Guiding the continuous liquid retention material parallel to the continuous solid aerosol-forming matrix;

[0147] Forming the continuous solid aerosol-forming matrix and the continuous liquid retention material into a continuous strip, whereby

[0148] At least partially forming the solid continuous aerosol-forming matrix into a continuous strip;

[0149] Arranging the continuous liquid retention material around the continuous strip of the at least partially formed solid aerosol-forming matrix;

[0150] Forming the continuous liquid retention material arranged around the continuous strip of the at least partially formed aerosol-forming matrix into a continuous strip; and

[0151] Cut the continuous strip into individual mixed aerosol generating elements.

[0152] 12. The method according to clause 11, further comprising the step of wrapping the continuous strip with a fluid-impermeable wrapper before cutting the continuous strip.

[0153] 13. The method according to any one of clauses 11 to 12, further comprising the step of introducing a sensor material into the solid continuous aerosol-forming matrix.

Claims

1. A hybrid aerosol-generating element for use in an aerosol-generating article, the hybrid aerosol-generating element comprising: A liquid retention material for maintaining an aerosol-forming liquid in the form of glycerol; and a tobacco-containing solid aerosol-forming substrate, the solid aerosol-forming substrate comprising particles, wherein the tobacco-containing solid aerosol-forming substrate is disposed adjacent to the liquid retention material, and the tobacco-containing solid aerosol-forming substrate comprises a capillary material in contact with the liquid retention material, and wherein the capillary material enables glycerol to be transported into the tobacco-containing solid aerosol-forming substrate.

2. The hybrid aerosol generating element according to claim 1, wherein, The tobacco-containing solid aerosol-forming substrate comprises homogeneous tobacco.

3. The hybrid aerosol-generating element according to claim 1, further comprising a liquid-impermeable wrapper wrapping the hybrid aerosol-generating element.

4. The hybrid aerosol-generating element according to claim 1, having a diameter between 5 mm and 12 mm.

5. The hybrid aerosol generating element according to claim 1, wherein, The liquid retention material is a sheet.

6. The hybrid aerosol generating element according to claim 1, wherein, The liquid retention material and the tobacco-containing solid aerosol-forming substrate are successively disposed along the longitudinal axis of the hybrid aerosol-generating element.

7. The hybrid aerosol-generating element according to claim 1, wherein, The liquid retention material and the tobacco-containing solid aerosol-forming substrate are at least partially disposed at the same longitudinal position of the hybrid aerosol-generating element.

8. The hybrid aerosol generating element according to claim 7, wherein, The liquid retention material and the tobacco-containing solid aerosol-forming substrate are disposed at the same longitudinal position across the entire length of the hybrid aerosol-generating element.

9. The hybrid aerosol-generating element according to claim 1, having a length between 8 mm and 14 mm.

10. The hybrid aerosol generating element according to claim 1, wherein, The tobacco-containing solid aerosol-forming substrate is contained within a paper.

11. A hybrid aerosol-generating article comprising a plurality of elements assembled in the form of a strip, the plurality of elements including the hybrid aerosol-generating element according to claim 1.

12. The hybrid aerosol-generating article according to claim 11, wherein, The plurality of elements includes at least one of a mouthpiece element, a support element, a sealing element, or an aerosol cooling element.

13. The hybrid aerosol-generating article according to claim 12, wherein, The mouthpiece element is located at the mouth end of the hybrid aerosol-generating article, and the mouthpiece element includes at least one filter segment.

14. The hybrid aerosol-generating article according to claim 13, wherein, The filter segment is longitudinally spaced from the hybrid aerosol-generating element.

15. The hybrid aerosol-generating article according to claim 11, wherein, The plurality of elements includes a support element, the support element being a hollow element disposed downstream of the hybrid aerosol-generating element.

16. The hybrid aerosol-generating article according to claim 15, wherein, The support element comprises cellulose acetate.

17. The hybrid aerosol-generating article according to claim 11, wherein, The plurality of elements includes at least one sealing element disposed in an end-to-end relationship with the hybrid aerosol-generating element, the at least one sealing element sealing at least a portion of the distal end of the hybrid aerosol-generating element.

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