Aerosol-generating article having a unitary tubular element

Abstract

An aerosol-generating article (1) comprising a substrate element (2) comprising an aerosol-generating substrate; and a tubular element (12) having an internal cavity (18, 24) defining at least one airflow conduit establishing uninterrupted fluid communication between an upstream end (20) of the tubular element and a downstream end (26) of the tubular element, the tubular element comprising a first tubular portion (14) and a second tubular portion (16); wherein the first tubular portion and the second tubular portion each constitute at least 10% of the length of the tubular element, the tubular element being formed as a unitary element; wherein the first tubular portion has a first internal diameter (D1 int ) and the second tubular portion has a second internal diameter (D2 int ), the first internal diameter being different from the second internal diameter; or wherein the first tubular portion has a first external diameter and the second tubular portion has a second external diameter, the first external diameter being different from the second external diameter; and wherein the aerosol-generating article further comprises a ventilation zone (28) provided at a location along the second tubular portion.

Description

Technical Field

[0001] This disclosure relates to an aerosol generating article comprising an aerosol generating matrix for generating, for example, an inhalable aerosol upon heating. This disclosure also relates to a method of manufacturing a tubular element for the aerosol generating article. Background Technology

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

[0003] Many aerosol generating apparatuses for consuming heated aerosol generating articles are known in the art. Such apparatuses include, for example, electrically heated aerosol generating apparatuses, in which aerosols are generated by transferring heat from one or more electrically heated elements of the aerosol generating apparatus to the aerosol generating matrix of the heated aerosol generating article. For example, electrically heated aerosol generating apparatuses have been proposed that include internal resistive heater blades adapted to be inserted into the aerosol generating matrix. Alternatively, inductively heated aerosol generating articles include sensor elements arranged within the aerosol generating matrix, which can be heated by an alternating magnetic field provided by the aerosol generating apparatus.

[0004] Heated aerosol generating articles are typically cigarette-shaped and include multiple elements or rods. For example, such articles typically include: a matrix rod comprising an aerosol generating matrix, a tubular rod downstream of the matrix rod, and a mouthpiece filter section at the mouth end of the article. The tubular rod has an inner cavity or hollow core defining an airflow path. It is known to have two tubular rods: a first tubular rod and a separate second tubular rod, the first tubular rod serving as a spacer between the matrix rod and other components of the aerosol generating article, and the second tubular rod serving as an air cooler to cool air as it passes through the aerosol generating article to facilitate aerosol formation. The second tubular rod is generally adjacent to the first tubular rod.

[0005] Aerosol-generating articles in the form of inhaler articles (e.g., dry powder inhalers) are known in the art. Some dry powder inhalers have a component for storing dry powder, such as a capsule. The capsule can be activated by puncturing a separate puncture element, such as the puncture element of a retainer. Once the capsule is activated, the consumer can inhale through the mouth of the inhaler to generate an airflow through the inhaler. Each airflow from each inhalation can deliver a portion of the dry powder from the capsule into the user's lungs. Such aerosol-generating articles generate aerosols without heating.

[0006] Aerosol-generating articles, such as those for dry powder inhalers, typically include a retainer rod or element having a cavity or hollow core that defines an airflow path and helps retain the capsule or otherwise resist capsule movement, allowing the capsule to be easily punctured. Such a retainer rod is typically formed of two tubular rods: a first tubular rod and a second, separate, smaller tubular rod. The first tubular rod extends across and is secured to the interior of the aerosol-generating article, while the second, smaller tubular rod is secured to the first tubular rod on the capsule-facing side. The smaller diameter of the second tubular rod provides an opening or groove between its outer tubular surface and the inner surface of the aerosol-generating article. This opening or groove collects the dry powder and reduces the likelihood of leakage after the capsule has been punctured (e.g., if the article is tilted).

[0007] Because airflow is confined to its internal cavity, it can be difficult to manufacture and assemble the first and second tubular rods of both heated and non-heated aerosol-generating articles (e.g., dry powder inhalers). The ability of the first and second tubular rods to perform their respective functions depends on the accuracy of their positioning and alignment. The quality and consistency of the consumer experience can depend on the internal air path through the aerosol-generating article, and therefore the adjacency and concentricity of the first and second tubular rods are important. Summary of the Invention

[0008] It is desirable to provide an aerosol-generating article that is easier to manufacture and reduces the need for precise positioning and alignment of tubular rods or components.

[0009] According to an example of this disclosure, an aerosol generating article is provided, comprising: a matrix element comprising an aerosol generating matrix. The aerosol generating article may further comprise a tubular element comprising a first tubular portion. The tubular element may further comprise a second tubular portion. The first tubular portion may constitute at least 10% of the length of the tubular element. The second tubular portion may constitute at least 10% of the length of the tubular element. The tubular element may be formed as an integral element.

[0010] In one example, the first tubular portion may have a first inner diameter. The second tubular portion may have a second inner diameter. The first inner diameter may be different from the second inner diameter.

[0011] In another example, the first tubular portion may have a first outer diameter. The second tubular portion may have a second outer diameter. The first outer diameter may be different from the second outer diameter.

[0012] According to an example of this disclosure, an aerosol generating article is provided, comprising: a matrix element comprising an aerosol generating matrix; and a tubular element comprising a first tubular portion and a second tubular portion. The first tubular portion and the second tubular portion each constitute at least 10% of the length of the tubular element. The tubular element is formed as an integral element. The first tubular portion has a first inner diameter, and the second tubular portion has a second inner diameter, wherein the first inner diameter is different from the second inner diameter. Alternatively or additionally, the first tubular portion has a first outer diameter, and the second tubular portion has a second outer diameter, wherein the first outer diameter is different from the second outer diameter.

[0013] The term "aerosol-generating article" is used herein to refer to an article in which inhalable aerosols are generated from an aerosol-generating matrix and delivered to a consumer. As used herein, the term "aerosol-generating matrix" refers to a matrix from which aerosols may be formed or generated. For example, an aerosol-generating matrix may be able to release volatile compounds to generate aerosols when heated. Alternatively, an aerosol-generating matrix may include particles that can be entrained in an airflow to generate aerosols.

[0014] As used herein, the term "tubular element" refers to a generally hollow, elongated element that defines a lumen or airflow passage along its longitudinal axis. Specifically, the term "tubular" will be used to refer to a tubular element having a substantially cylindrical cross-section and an inner lumen defining at least one airflow conduit that establishes uninterrupted fluid communication between an upstream end and a 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. The tubular element is a separate, discrete component of an aerosol-generating article.

[0015] The term "integral element" is used herein to refer to a tubular element formed as a single piece or individual component. This contrasts with aerosol-generating articles that may have a first tubular portion and a second tubular portion corresponding to the tubular element described herein and must be assembled. A tubular element can be formed as an integral element from a single piece of material (e.g., a single sheet of web material).

[0016] For the purposes of aerosol-generating articles, the term "length" refers to the dimension of a component of the aerosol-generating article in the longitudinal direction of the aerosol-generating article. The longitudinal direction of the aerosol-generating article is the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. As used herein, the terms "upstream" and "downstream" describe the relative position of an element or portion of an element of the aerosol-generating article with respect to the direction in which aerosols are transported through the aerosol-generating article during use.

[0017] By forming the tubular element as a single, integral component, it advantageously functions as a single piece. This helps alleviate any difficulties in positioning the first and second tubular portions relative to each other during the assembly of the aerosol-generating article, compared to forming the first and second tubular portions as separate components. Precise abutment engagement of the first and second tubular portions is not required during the assembly of the aerosol-generating article, as the integral tubular element is already assembled, automatically realizing the advantages of this construction. The integral nature of the tubular element also helps ensure axial alignment of the first and second tubular portions. This ensures smooth airflow through the tubular element and contributes to providing a consistent consumer experience.

[0018] Another advantage of forming the tubular element as a single unit is that it helps reduce aerosol leakage at the interface between the first and second tubular portions compared to aerosol-generating articles in which the first and second tubular portions are formed as separate units. In a single tubular element, there is no gap between the first and second portions through which aerosol can leak from the tubular element, and the first and second tubular portions are less likely to move relative to each other, creating a gap. Aerosol leakage between tubular elements can be problematic because hot vapor-carrying air leaks from the gas flow path before vaporization, which can adversely affect aerosolization. Furthermore, aerosol leakage also means heat leakage from the gas flow path, lowering the temperature of the remaining aerosol, which can reduce the overall downstream temperature drop and thus reduce the amount and quality of aerosol produced.

[0019] Another advantage of forming the tubular element as a single unit is that it allows for a reduction in the size of the first and second tubular portions compared to aerosol-generating articles where the first and second tubular portions are formed as separate units. If separate tubular elements were used, they would need to be larger to make them easier to handle during manufacturing. Therefore, a single tubular element helps reduce the overall length of the tubular element.

[0020] The first tubular portion and the second tubular portion may each constitute at least 20% of the length of the tubular element, preferably at least 30% of the length of the tubular element, and more preferably at least 40% of the length of the tubular element. In a preferred embodiment, the first tubular portion and the second tubular portion may each constitute about 50% of the length of the tubular element.

[0021] The first tubular portion may have a uniform or constant first inner diameter along its length. The second tubular portion may have a uniform or constant second inner diameter along its length.

[0022] The first tubular portion may have a uniform or constant first outer diameter along its length. The second tubular portion may have a uniform or constant second outer diameter along its length.

[0023] The difference between the inner and outer diameters can be formed by steps in the inner or outer surface of the tubular element. The difference between the first and second inner diameters can be formed by steps in the inner surface of the tubular element. The difference between the first and second outer diameters can be formed by steps in the outer surface of the tubular element.

[0024] The difference between the inner and outer diameters is at least 0.2 mm, optionally at least 0.5 mm, optionally at least 0.7 mm, optionally at least 1 mm, optionally at least 1.5 mm, optionally at least 2 mm, and further optionally at least 2.5 mm. The difference between the inner and outer diameters can be between about 0.2 mm and 2.5 mm, optionally between 0.5 mm and 2.0 mm, optionally between 0.7 mm and 2.0 mm, and optionally between 1 mm and 2 mm.

[0025] Tubular elements can be formed from individual wound sheets of web material. The advantage of forming tubular elements from individual wound sheets of web material is that it produces integral tubular elements.

[0026] The tubular element may comprise multiple wound layers of a single sheet of web material. The first tubular portion and the second tubular portion may each have a different number of wound layers. Advantageously, by winding multiple layers of a single sheet of web material, the thickness of the peripheral walls of the first and second tubular portions can be adjusted depending on the number of layers. A thicker peripheral wall can be achieved simply by winding more layers of web material. Advantageously, the first and second tubular portions have different numbers of layers to provide different inner or outer diameters. Furthermore, forming the first and second tubular portions from a single wound sheet of web material facilitates alignment of the first and second tubular portions, since the first and second tubular portions of the tubular element are wound on the same mandrel and thus share a common winding axis.

[0027] Web material sheets may include one or more of paper, cardboard, cellulose acetate tow, or polylactic acid (PLA). In a preferred embodiment, the web material sheet comprises paper or cardboard. Advantageously, paper and cardboard are relatively flexible materials and are therefore suitable for winding processes. They are also sufficiently strong for the purpose of forming tubular elements of aerosol-generating articles, especially if multiple layers of these materials are used.

[0028] The tubular element may also include a third tubular portion. The third tubular portion may constitute at least 10% of the length of the tubular element, optionally at least 20% of the length of the tubular element, and further optionally at least 30% of the length of the tubular element.

[0029] In one example, the first tubular portion and the second tubular portion may have different first inner diameters and second inner diameters, respectively, and the third tubular portion may have an outer diameter different from that of the first tubular portion and the second tubular portion.

[0030] Alternatively, the first tubular portion and the second tubular portion may have different first outer diameters and second outer diameters, respectively, and the third tubular portion may have an inner diameter different from that of the first tubular portion and the second tubular portion.

[0031] In an exemplary aerosol-generating article, the first tubular portion and the second tubular portion may have different first outer diameters and second outer diameters, respectively.

[0032] The matrix element may include a capsule containing an aerosol-generating matrix. The capsule may be positioned upstream of the tubular element.

[0033] The first outer diameter may be smaller than the second outer diameter. The outer surface of the first tubular portion of the tubular element having the smaller first outer diameter may at least partially define an annular space within the aerosol-generating article. Advantageously, the annular space may define grooves or pores for collecting excess aerosol-generating matrix released from the capsule. The annular space may also collect aerosol-generating matrix released from the capsule as the aerosol-generating article moves through the space between consumer inhalations.

[0034] The first outer diameter may be at least 1 mm smaller than the second outer diameter. Optionally, the first outer diameter may be at least 2 mm smaller than the second outer diameter. More optionally, the first outer diameter may be at least 3 mm smaller than the second outer diameter.

[0035] The difference between the first outer diameter and the second outer diameter can be between about 0.5 mm and about 3.5 mm, optionally between about 1 mm and about 3 mm, and further optionally between about 1.5 mm and about 2.5 mm. In a preferred embodiment, the difference between the first outer diameter and the second outer diameter can be about 2 mm.

[0036] The ratio between the second outer diameter and the first outer diameter can be between 1.2 and 1.8, preferably between 1.3 and 1.6, and more preferably between 1.3 and 1.5. In a preferred embodiment, the ratio between the second outer diameter and the first outer diameter can be about 1.4.

[0037] Tubular elements can be hollow. Tubular elements can be hollow along their entire length.

[0038] The tubular element may define an inner cavity extending from an upstream end to a downstream end of the tubular element. The inner cavity may define an airflow path through the tubular element. The inner cavity may be substantially empty to allow substantially unrestricted airflow along it.

[0039] The first tubular portion of the tubular element may have an outer diameter of at least about 4.0 mm, preferably at least about 4.5 mm, and more preferably at least about 5.0 mm. Alternatively or additionally, the first tubular portion of the tubular element may have an outer diameter of less than about 7.0 mm, preferably less than about 6.5 mm or less than about 6.0 mm.

[0040] The first tubular portion of the tubular element may have an outer diameter between about 4.0 mm and about 7.0 mm, preferably between about 4.0 mm and about 6.0 mm, and more preferably between about 4.5 mm and 5.5 mm. In a preferred embodiment, the first tubular portion of the tubular element may have an outer diameter of about 5.0 mm.

[0041] The peripheral wall of the first tubular portion may have a thickness of at least about 0.5 mm, preferably at least about 1.0 mm or at least about 2 mm. Alternatively or additionally, the peripheral wall of the first tubular portion may have a thickness of less than about 3.0 mm, preferably less than about 2.5 mm or less than about 2 mm.

[0042] The peripheral wall of the first tubular portion may have a thickness between about 0.5 mm and 3.0 mm, preferably between about 1.0 mm and 2.5 mm, and more preferably between about 1.0 mm and 2.0 mm. In a preferred embodiment, the peripheral wall of the first tubular portion may have a thickness of about 1.0 mm.

[0043] The first tubular portion of the tubular element may have a length of at least about 3 mm, preferably at least about 4 mm, and more preferably at least about 5 mm. The first tubular portion of the tubular element may have a length of less than about 10 mm, preferably less than about 8 mm, and more preferably less than about 7 mm.

[0044] The first tubular portion of the tubular element may have a length between about 3 mm and about 10 mm, preferably between about 4 mm and 8 mm, and more preferably between about 5 mm and 7 mm. In a preferred embodiment, the first tubular portion of the tubular element may have a length of about 6 mm.

[0045] The second tubular portion of the tubular element may have an outer diameter of at least about 5.0 mm, preferably at least about 6.0 mm, and more preferably at least about 7.0 mm. Alternatively or additionally, the second tubular portion of the tubular element may have an outer diameter of less than about 10.0 mm, preferably less than about 9.0 mm, and more preferably less than about 8.0 mm.

[0046] The second tubular portion of the tubular element may have an outer diameter between about 5.0 mm and about 10.0 mm, preferably between about 6.0 mm and about 9.0 mm, and more preferably between about 6.5 mm and 8.0 mm. In a preferred embodiment, the second tubular portion of the tubular element may have an outer diameter of about 7.0 mm.

[0047] The peripheral wall of the second tubular portion may have a thickness of at least 0.5 mm, preferably at least about 1.0 mm, and more preferably at least about 1.5 mm. Alternatively or additionally, the peripheral wall of the second tubular portion may have a thickness of less than about 3.5 mm, preferably less than about 3.0 mm, and more preferably less than about 2.5 mm.

[0048] The peripheral wall of the second tubular portion may have a thickness between about 0.5 mm and 3.5 mm, preferably between about 1.0 mm and 3.0 mm, and more preferably between about 1.5 mm and 2.5 mm. In a preferred embodiment, the peripheral wall of the second tubular portion may have a thickness of about 2.0 mm.

[0049] The second tubular portion of the tubular element may have a length of at least about 6 mm, preferably at least about 7 mm, and more preferably at least about 8 mm. The second tubular portion of the tubular element may have a length of less than about 12 mm, preferably less than about 11 mm, and more preferably less than about 10 mm.

[0050] The second tubular portion of the tubular element may have a length between about 6 mm and about 12 mm, preferably between about 7 mm and 11 mm, and more preferably between about 8 mm and 10 mm. In a preferred embodiment, the second tubular portion of the tubular element may have a length of about 9 mm.

[0051] The inner diameter of the tubular element can be smaller than the outer diameter of the bladder. Advantageously, this helps prevent the bladder from passing through the tubular element, i.e., through the lumen within the tubular element.

[0052] The inner diameter of the tubular element can be at least 1 mm smaller than the outer diameter of the bladder. Optionally, the inner diameter of the tubular element can be at least 2 mm smaller than the outer diameter of the bladder. More optionally, the inner diameter of the tubular element can be at least 3 mm smaller than the outer diameter of the bladder.

[0053] The inner diameter of the tubular element can be uniform along its entire length. The tubular element may have an inner diameter of less than 4.5 mm, preferably less than 4.0 mm, and more preferably less than 3.5 mm.

[0054] The upstream end of the tubular element can be arranged to engage the outer surface of the sac. The tubular element can act as a retaining rod or element for limiting the downstream movement of the sac. Advantageously, by providing a pressing surface, puncturing the sac to release its contents can be made easier by limiting the movement of the sac.

[0055] The aerosol-generating article may include a tubular body having a partially closed distal or upstream end and a partially closed downstream or inlet end. An upstream opening may be formed in the upstream end of the tubular body. The upstream opening may serve as an air inlet. A downstream opening may be formed in the inlet end of the tubular body. The downstream opening may serve as an air outlet. An airflow path may extend between the upstream and downstream openings and through the inner cavity of the tubular body. A second tubular portion of the tubular element may be attached to the inner surface of the tubular body.

[0056] The capsule may contain dry powder. The capsule may hold or contain at least about 5 mg of dry powder or at least about 10 mg of dry powder. The capsule may hold or contain less than or equal to about 900 mg of dry powder, less than or equal to about 30-300 mg of dry powder, or less than or equal to about 150 mg of dry powder. The capsule may hold or contain between about 5 mg and about 300 mg of dry powder, between about 10 mg and about 200 mg of dry powder, or between about 25 mg and about 100 mg of dry powder.

[0057] The capsule can contain pharmaceutically active particles, such as nicotine particles. As used herein, the term "nicotine" can refer to nicotine and nicotine derivatives, such as free nicotine bases, nicotine salts, etc.

[0058] The capsule may contain one or more nicotine salts.

[0059] Pharmaceutically active particles may have a median aerodynamic diameter of about 5 micrometers or less, or about 4 micrometers or less.

[0060] Pharmaceutically active particles may have a median aerodynamic diameter of at least about 0.5 micrometers or at least about 1 micrometer.

[0061] Pharmaceutically active particles may have a median aerodynamic diameter between approximately 0.5 micrometers and approximately 4 micrometers.

[0062] The capsule can hold enough nicotine particles to provide at least 2 inhalations or "puffs", at least 5 inhalations or "puffs", or at least 10 inhalations or "puffs".

[0063] Each inhalation or "inhalation" delivers approximately 0.1 mg to approximately 3 mg of nicotine particles to the user's lungs, approximately 0.2 mg to approximately 2 mg of nicotine particles to the user's lungs, or approximately 1 mg of nicotine particles to the user's lungs.

[0064] The capsule can hold or contain at least about 5 mg of nicotine particles or at least about 10 mg of nicotine particles.

[0065] The capsule can hold or contain nicotine particles of less than or equal to about 900 mg, less than or equal to about 300 mg, or less than or equal to about 150 mg.

[0066] The capsule can hold flavor particles.

[0067] In another exemplary aerosol-generating article, the first tubular portion and the second tubular portion may have different first inner diameters and second inner diameters, respectively. The second tubular portion may be disposed downstream of the first tubular portion.

[0068] The second inner diameter can be larger than the first inner diameter. Advantageously, the larger second inner diameter results in an expansion of the airflow path through the tubular element. This sudden increase in volume caused by the larger second inner diameter can help cool the airflow through the tubular element, which can contribute to the formation of aerosols.

[0069] The second inner diameter may be at least 1 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 1.2 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 1.4 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 1.6 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 1.8 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 2.0 mm larger than the first inner diameter.

[0070] The difference between the first inner diameter and the second inner diameter can be between about 0.5 mm and about 2.5 mm, optionally between about 1 mm and about 2.5 mm, and further optionally between about 1.5 mm and about 2.0 mm. In a preferred embodiment, the difference between the first inner diameter and the second inner diameter can be about 1.7 mm.

[0071] The ratio of the second inner diameter to the first inner diameter can be between 1.2 and 2.5, optionally between 1.2 and 2.0, further optionally between 1.3 and 1.7, and even more optionally between 1.4 and 1.6. In one example, the ratio of the second inner diameter to the first inner diameter can be about 1.4. In another example, the ratio of the second inner diameter to the first inner diameter can be between about 2.0 and about 2.5.

[0072] Tubular elements can be hollow. Tubular elements can be hollow along their entire length.

[0073] A first tubular portion of the tubular element may define a first inner cavity of the tubular element, the first inner cavity extending from an upstream end of the first tubular portion to a downstream end of the first tubular portion. A first inner diameter is the inner diameter of the first inner cavity. The first inner cavity may define at least a portion of an airflow path through the tubular element. The first inner cavity may be substantially empty to allow substantially unrestricted airflow along the first inner cavity. The suction resistance (RTD) of the first tubular portion may be substantially 0 mmH2O. Therefore, the first tubular portion does not substantially contribute to the overall RTD of the aerosol-generating article. The first tubular portion of the tubular element may be configured to act as a spacer or support element for the aerosol-generating article.

[0074] A second tubular portion of the tubular element may define a second inner cavity of the tubular element, the second inner cavity extending from an upstream end of the second tubular portion to a downstream end of the second tubular portion. The second inner cavity may define at least a portion of the airflow path through the tubular element. The second inner cavity may be substantially empty to allow substantially unrestricted airflow along the second inner cavity. The RTD of the second tubular portion may be substantially 0 mmH2O. Therefore, the second tubular portion does not substantially contribute to the overall RTD of the aerosol-generating article. The second tubular portion of the tubular element may be configured to act as an aerosol cooling element for the aerosol-generating article.

[0075] The tubular element can be arranged to align with and be downstream of the matrix element. In a preferred embodiment, the tubular element is positioned immediately downstream of the matrix element. The upstream end of the tubular element may be adjacent to the downstream end of the matrix element.

[0076] The tubular element preferably has an outer diameter that is approximately equal to the outer diameter of the matrix element and the outer diameter of the aerosol-generated article.

[0077] The tubular element may have an outer diameter between 5 mm and 12 mm, for example between 5 mm and 10 mm, or between 6 mm and 8 mm. In a preferred embodiment, the tubular element has an outer diameter of 7.1 mm + / - 10%.

[0078] The first tubular portion of the tubular element may have an inner diameter of at least about 2.5 mm, preferably at least about 3.0 mm, and more preferably at least about 3.5 mm. Alternatively or additionally, the first tubular portion of the tubular element may have an inner diameter of less than about 4.0 mm, preferably less than about 3.5 mm or less than about 3.0 mm.

[0079] The inner diameter of the first tubular portion of the tubular element may be between about 2.0 mm and about 4.0 mm, preferably between about 2.5 mm and about 3.5 mm, and more preferably between about 3.0 mm and 3.5 mm. In a preferred embodiment, the first tubular portion of the tubular element may have an inner diameter of about 3.3 mm.

[0080] The peripheral wall of the first tubular portion may have a thickness of at least about 1 mm, preferably at least about 1.5 mm or at least about 2 mm. Alternatively or additionally, the peripheral wall of the first tubular portion may have a thickness of less than about 3 mm, preferably less than about 2.5 mm or less than about 2 mm.

[0081] The peripheral wall of the first tubular portion may have a thickness between about 1 mm and about 3 mm, preferably between about 1.5 mm and about 2.5 mm, and more preferably between about 1.5 mm and 2.0 mm. In a preferred embodiment, the peripheral wall of the first tubular portion may have a thickness of about 1.9 mm.

[0082] The first tubular portion of the tubular element may have a length of at least about 5 mm, preferably at least about 6 mm, and more preferably at least about 7 mm. The first tubular portion of the tubular element may have a length of less than about 15 mm, preferably less than about 12 mm, and more preferably less than about 10 mm.

[0083] The first tubular portion of the tubular element may have a length between about 5 mm and about 15 mm, preferably between about 6 mm and 12 mm, and more preferably between about 7 mm and 10 mm. In a preferred embodiment, the first tubular portion of the tubular element may have a length of about 8 mm or about 9 mm.

[0084] The second tubular portion of the tubular element may have an inner diameter of at least about 4.0 mm, preferably at least about 4.5 mm, and more preferably at least about 5.0 mm. Alternatively or additionally, the second tubular portion of the tubular element may have an inner diameter of less than about 6.0 mm, preferably less than about 5.5 mm or less than about 5.0 mm.

[0085] The second tubular portion of the tubular element may have an inner diameter between about 4.0 mm and about 6.0 mm, preferably between about 4.5 mm and about 6.0 mm, and more preferably between about 4.5 mm and 5.5 mm. In a preferred embodiment, the second tubular portion of the tubular element may have an inner diameter of about 5.0 mm.

[0086] The peripheral wall of the second tubular portion may have a thickness of at least about 0.3 mm, preferably at least about 0.6 mm, and more preferably at least about 0.9 mm. Alternatively or additionally, the peripheral wall of the second tubular portion may have a thickness of less than about 2.5 mm, preferably less than about 2.0 mm, and more preferably less than about 1.5 mm.

[0087] The peripheral wall of the second tubular portion may have a thickness between about 0.3 mm and 2.5 mm, preferably between about 0.6 mm and 2.0 mm, and more preferably between about 0.9 mm and 1.5 mm. In a preferred embodiment, the peripheral wall of the second tubular portion may have a thickness of about 1.05 mm.

[0088] The second tubular portion of the tubular element may have a length of at least about 5 mm, preferably at least about 6 mm, and more preferably at least about 7 mm. The second tubular portion of the tubular element may have a length of less than about 15 mm, preferably less than about 12 mm, and more preferably less than about 10 mm.

[0089] The second tubular portion of the tubular element may have a length between about 5 mm and about 15 mm, preferably between about 6 mm and 12 mm, and more preferably between about 7 mm and 10 mm. In a preferred embodiment, the second tubular portion of the tubular element may have a length of about 8 mm.

[0090] The inner diameter of the first tubular portion may be continuously tapered along the length of the first tubular portion. The inner diameter of the second tubular portion may be continuously tapered along the length of the second tubular portion.

[0091] The aerosol generating article may also include a ventilation zone disposed along the second tubular portion. The inventors have discovered that by arranging the ventilation zone along the second tubular portion, satisfactory cooling of the aerosol flow generated when the aerosol generating matrix is ​​heated and the aerosol is drawn through the tubular element can be achieved. As mentioned above, a significant temperature reduction is desired at the location where aerosol generation is desired because sudden cooling facilitates aerosol generation. Advantageously, by providing a ventilation zone at the aerosol generation location, a suitable temperature reduction can be achieved. Furthermore, by limiting the ventilation to a specific area, i.e., the ventilation zone, cooling is concentrated in a limited area. This reduces the cooling of the airflow upstream of the ventilation zone, allowing more vapor to be delivered to the ventilation zone for aerosolization. Additionally, downstream cooling of the airflow is reduced, which decreases the likelihood of condensation of the generated aerosol on the downstream surface of the aerosol generating article, which may be undesirable.

[0092] The ventilation zone may include multiple ventilation holes or perforations through the peripheral wall of the second tubular portion. Preferably, the ventilation zone includes at least one row of circumferential perforations. In some instances, the ventilation zone may include multiple rows of circumferential perforations, such as two rows of circumferential perforations. Preferably, each row of circumferential perforations includes 8 to 30 perforations.

[0093] Aerosol-generating products can have a ventilation level of at least about 5%.

[0094] The term "ventilation level" is used herein to refer to the volume ratio between the airflow permitted to enter the aerosol-generating article via a ventilated area (ventilation airflow) and the sum of the aerosol airflow and the ventilation airflow. The higher the ventilation level, the higher the dilution of the aerosol stream delivered to the consumer.

[0095] The aerosol-generating article may have a ventilation level of at least about 10%, preferably at least about 15%, and more preferably at least about 20%. The aerosol-generating article may have a ventilation level of less than about 60%, preferably less than about 45%, and more preferably less than about 40%. In a preferred embodiment, the aerosol-generating article has a ventilation level of about 25% or 30%.

[0096] Aerosol-generated articles may include multiple components assembled in strip form.

[0097] The aerosol-generating article may include a downstream section located downstream of the matrix element. The downstream section may include one or more downstream elements. The downstream section may include a tubular element. The downstream section may include a mouthpiece element.

[0098] The mouthpiece element can be arranged to align with and be downstream of the tubular element. In a preferred embodiment, the mouthpiece element is positioned immediately downstream of the tubular element. The upstream end of the mouthpiece element may be adjacent to the downstream end of the tubular element.

[0099] The mouthpiece element is preferably located at the downstream end or mouth end of the aerosol-generating article. The mouthpiece element includes at least one mouthpiece filter segment of fibrous filter material for filtering aerosols generated from the aerosol-generating matrix. Suitable fibrous filter materials will be known to those skilled in the art. Particularly preferably, at least one mouthpiece filter segment comprises a cellulose acetate filter segment formed from cellulose acetate tow.

[0100] Preferably, the mouthpiece element has a low particle filtration efficiency.

[0101] Preferably, the mouthpiece element is defined by a rod package. Preferably, the mouthpiece element is non-ventilated, so that air does not enter the aerosol-forming article along the mouthpiece element.

[0102] The mouthpiece element is preferably connected to one or more adjacent upstream components of the aerosol-generating article by means of a tipping package.

[0103] Preferably, the mouthpiece element has an outer diameter approximately equal to the outer diameter of the aerosol-generating article. The mouthpiece element may have an outer diameter between about 5 mm and about 10 mm, or between about 6 mm and about 8 mm. In a preferred embodiment, the mouthpiece element has an outer diameter of about 7.1 mm.

[0104] The mouthpiece element preferably has a length of at least about 5 mm, preferably at least about 8 mm, and more preferably at least about 10 mm. Alternatively or additionally, the mouthpiece element preferably has a length of less than about 25 mm, preferably less than about 20 mm, and more preferably less than about 15 mm.

[0105] The mouthpiece element may have a length between about 5 mm and about 25 mm, or between about 8 mm and about 20 mm, or between about 10 mm and about 15 mm. In a preferred embodiment, the mouthpiece element has a length of about 12 mm.

[0106] The matrix element can be arranged to align with and be upstream of the tubular element. The matrix element can be adjacent to the tubular element. In a preferred embodiment, the matrix element is positioned immediately upstream of the tubular element. The downstream end of the matrix element can be adjacent to the upstream end of the tubular element.

[0107] Preferably, the matrix element is defined by a rod package.

[0108] Preferably, the outer diameter of the matrix element is approximately equal to the outer diameter of the aerosol-generated article. The matrix element may have an outer diameter between about 5 mm and about 10 mm, or between about 6 mm and about 8 mm. In a preferred embodiment, the matrix element has an outer diameter of about 7.1 mm.

[0109] The matrix element preferably has a length of at least about 5 mm, preferably at least about 8 mm, and more preferably at least about 10 mm. Alternatively or additionally, the matrix element preferably has a length of less than about 25 mm, preferably less than about 20 mm, and more preferably less than about 15 mm.

[0110] The matrix element may have a length between about 5 mm and about 25 mm, or between about 8 mm and about 20 mm, or between about 10 mm and about 15 mm. In a preferred embodiment, the matrix element has a length of about 11 mm or about 12 mm.

[0111] As described above, the matrix element includes an aerosol generation matrix. The aerosol generation matrix can be a solid aerosol generation matrix.

[0112] Preferably, the aerosol generating matrix contains an aerosol forming agent.

[0113] Aerosol forming agents can be any suitable known compound or mixture of compounds that contributes to the formation of a dense and stable aerosol during use. Aerosol forming agents promote substantially thermal degradation of the aerosol at temperatures applied during the normal use of the aerosol-generating article. Suitable aerosol forming agents include, for example: polyols, such as triethylene glycol, 1,3-butanediol, propylene glycol, and glycerol; esters of polyols, such as mono, di, or triacetic acid esters of glycerol; aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids, such as dimethyl dodecanoate and dimethyl tetradecanoate; and combinations thereof.

[0114] Preferably, the aerosol forming agent comprises one or more of glycerol and propylene glycol. The aerosol forming agent may consist of glycerol or propylene glycol, or a combination of glycerol and propylene glycol.

[0115] The aerosol generating matrix may contain at least about 5% by weight, at least about 10% by weight, or at least about 12% by weight of an aerosol forming agent based on the dry weight of the aerosol generating matrix.

[0116] The aerosol generating matrix may contain less than or equal to about 30% by weight, less than or equal to about 25% by weight, or less than or equal to about 20% by weight of the aerosol generating matrix on a dry weight basis.

[0117] The aerosol generating matrix may contain between about 5% to about 30% by weight, about 5% to about 25% by weight, or about 5% to about 20% by weight, based on the dry weight of the aerosol generating matrix.

[0118] The aerosol generating matrix may contain between about 10% to about 30% by weight, about 10% to about 25% by weight, or about 10% to about 20% by weight, based on the dry weight of the aerosol generating matrix.

[0119] The aerosol generating matrix may contain between about 12% to about 30% by weight, about 12% to about 25% by weight, or about 12% to about 20% by weight, based on the dry weight of the aerosol generating matrix.

[0120] The aerosol-generating matrix may include multiple fragments of tobacco material. Alternatively, the aerosol-generating matrix may include multiple thin strips of homogenized tobacco material.

[0121] As used in this article, the term "strip" refers to an element whose length is significantly greater than its width and thickness.

[0122] As used in this article, the term "homogenized tobacco material" is used to describe materials formed by agglomerating particulate tobacco material.

[0123] Homogenized tobacco strips can be formed from homogenized tobacco sheet, for example, by cutting or shredding. Homogenized tobacco strips can also be formed by other methods, such as extrusion.

[0124] The tobacco strips may have a width of at least about 0.3 mm, at least about 0.5 mm, or at least about 0.6 mm.

[0125] The tobacco strips may have a width of less than or equal to about 2 mm, less than or equal to about 1.2 mm, or less than about 0.9 mm.

[0126] The tobacco strips may have a width between about 0.3 mm and about 2 mm, between about 0.3 mm and about 1.2 mm, or between about 0.3 mm and about 0.9 mm.

[0127] The tobacco strips may have a width between about 0.5 mm and about 2 mm, between about 0.5 mm and about 1.2 mm, or between about 0.5 mm and about 0.9 mm.

[0128] The tobacco strips may have a width between about 0.6 mm and about 2 mm, between about 0.6 mm and about 1.2 mm, or between about 0.6 mm and about 0.9 mm.

[0129] The tobacco material strips can have a length of at least about 10 millimeters.

[0130] The tobacco material strips can have a length of less than or equal to about 40 millimeters.

[0131] Fragments of tobacco material can be between approximately 10 mm and approximately 40 mm in length.

[0132] At least about 20% by weight of the plurality of tobacco material fragments, based on dry weight, may extend along the entire length of the aerosol-generating matrix. At least about 20% by weight of the plurality of tobacco material fragments, based on dry weight, may have a length substantially the same as the length of the aerosol-generating matrix.

[0133] The plurality of tobacco material fragments, accounting for less than or equal to about 60% by dry weight, may extend along the entire length of the aerosol-generating matrix. The plurality of tobacco material fragments, accounting for less than or equal to about 60% by dry weight, may have a length substantially the same as the length of the aerosol-generating matrix.

[0134] The plurality of tobacco material fragments, comprising approximately 20% to 60% by dry weight, may extend along the entire length of the aerosol-generating matrix. The plurality of tobacco material fragments, comprising approximately 20% to 60% by dry weight, may have a length substantially the same as the length of the aerosol-generating matrix.

[0135] The size of the components of the aerosol-generating matrix (such as multiple tobacco material fragments) can affect the heat distribution within the aerosol-generating matrix. Furthermore, the size of the components of the aerosol-generating matrix can influence the raw material density (RTD) of the product.

[0136] The aerosol-generating matrix may include multiple pellets or particles of tobacco material. The aerosol-generating matrix may include multiple homogenized pellets or particles of tobacco material.

[0137] The aerosol generating matrix may include one or more tobacco material sheets.

[0138] The aerosol generating matrix may include one or more homogenized tobacco material sheets.

[0139] The one or more tobacco material sheets may each individually have a thickness of at least about 100 micrometers, at least about 150 micrometers, or at least about 300 micrometers.

[0140] As used herein, individual thickness refers to the thickness of a single tobacco material sheet, while combined thickness refers to the total thickness of all tobacco material sheets that constitute the aerosol-generating matrix. For example, if the aerosol-generating matrix is ​​formed from two individual tobacco material sheets, the combined thickness is the sum of the thicknesses of the two individual tobacco material sheets, or, in the case where two tobacco material sheets are stacked in the aerosol-generating matrix, the measured thickness of the two tobacco material sheets.

[0141] The one or more tobacco material sheets may each individually have a thickness of less than or equal to about 600 micrometers, less than or equal to about 300 micrometers, or less than or equal to about 250 micrometers.

[0142] The one or more tobacco material sheets may each individually have a thickness between about 100 micrometers and about 600 micrometers, between about 100 micrometers and about 300 micrometers, or between about 100 micrometers and about 250 micrometers.

[0143] The one or more tobacco material sheets may each individually have a thickness between about 150 micrometers and about 600 micrometers, between about 150 micrometers and about 300 micrometers, or between about 150 micrometers and about 250 micrometers.

[0144] The one or more tobacco material sheets may each individually have a thickness between about 250 micrometers and about 600 micrometers, between about 250 micrometers and about 300 micrometers, or between about 250 micrometers and about 250 micrometers.

[0145] The one or more tobacco material sheets may each individually have a length substantially the same as the length of the aerosol-generating matrix.

[0146] The one or more tobacco material sheets may be rolled, folded, gathered, and pleated in one or more ways.

[0147] The curling, folding, agglomeration, or pleating of the one or more tobacco material sheets can cause the one or more tobacco material sheets to split to form tobacco material fragments. For example, the one or more tobacco material sheets may be curled to such an extent that the integrity of the one or more tobacco material sheets is compromised at multiple parallel ridges or corrugations, causing material separation and resulting in the formation of tobacco material fragments.

[0148] Aerosol generating articles may include receptors disposed within an aerosol generating matrix. A first element may include a receptor disposed within the aerosol generating matrix.

[0149] 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 induced in the receptor cause the receptor to heat up.

[0150] The receptor is arranged in thermal contact with the aerosol-generating matrix. Therefore, when the receptor heats up, the aerosol-generating matrix is ​​heated by the receptor to generate aerosols. The receptor can be arranged in direct physical contact with the aerosol-generating matrix.

[0151] The receptor can be a long and thin receptor.

[0152] As used in this article, the term "slender" is used to describe a component of an aerosol-generated article whose length is greater than its width and thickness.

[0153] The elongated receptors can be arranged substantially longitudinally within the aerosol-generating matrix. That is, the longitudinal axis of the elongated receptors can be approximately parallel to the longitudinal axis of the aerosol-generating matrix. For example, the longitudinal axis of the elongated receptors can be within ±10 degrees of the longitudinal axis of the aerosol-generating matrix. The elongated receptors can be located at the radial center within the aerosol-generating matrix and extend along the longitudinal axis of the aerosol-generating matrix.

[0154] The receptor can extend from the downstream end of the aerosol generating matrix toward the upstream end of the aerosol generating matrix.

[0155] The receptor can extend from the upstream end of the aerosol generating matrix toward the downstream end of the aerosol generating matrix.

[0156] The receptor can extend from the upstream end of the aerosol-generating matrix to the downstream end of the aerosol-generating matrix. That is, the receptor can extend along the entire length of the aerosol-generating matrix.

[0157] The length of the receptor can be approximately the same as the length of the aerosol-generating matrix.

[0158] The receptors can extend partially along the length of the aerosol-generating matrix.

[0159] The receptor can be spaced apart from the downstream end of the aerosol-generating matrix.

[0160] The receptor can be spaced apart from the upstream end of the aerosol-generating matrix.

[0161] The receptor can be spaced apart from both the downstream and upstream ends of the aerosol-generating matrix.

[0162] The length of the receptor can be less than the length of the aerosol-generating matrix.

[0163] The receptor can be completely enclosed within the aerosol-generating matrix. In other words, the aerosol-generating matrix can completely surround the receptor.

[0164] Receptors can take the form of needles, strips, bands, or blades.

[0165] The receptor may have a length of at least about 5 mm, at least about 6 mm, or at least about 8 mm. The receptor may have a length of less than or equal to about 15 mm, less than or equal to about 12 mm, or less than or equal to about 10 mm.

[0166] The receptor may have a length between about 5 mm and about 15 mm, between about 5 mm and about 12 mm, or between about 5 mm and about 10 mm.

[0167] The receptor may have a length between about 6 mm and about 15 mm, between about 6 mm and about 12 mm, or between about 6 mm and about 10 mm.

[0168] The receptor may have a length between about 8 mm and about 15 mm, between about 8 mm and about 12 mm, or between about 8 mm and about 10 mm.

[0169] The receptor may have a width of at least about 1 millimeter.

[0170] The receptor can have a width of less than or equal to about 5 millimeters.

[0171] The receptor can have a width between about 1 mm and about 5 mm.

[0172] The receptor may have a thickness of at least about 0.01 mm or at least about 0.5 mm.

[0173] The receptor may have a thickness of less than or equal to about 2 millimeters, less than or equal to about 500 micrometers, or less than or equal to about 100 micrometers.

[0174] The receptor may have a thickness between about 10 micrometers and about 2 millimeters, between about 10 micrometers and about 500 micrometers, or between about 10 micrometers and about 100 micrometers.

[0175] The receptor can have a thickness between about 0.5 mm and about 2 mm.

[0176] Receptors can have a generally circular cross-section.

[0177] The receptor may have a cross section that is substantially constant along the length of the receptor.

[0178] If the receptor is in the form of a strip or leaf, the strip or leaf may have a rectangular shape with a width between about 2 mm and about 8 mm or between about 3 mm and about 5 mm. For example, a receptor in the form of a strip or leaf may have a width of about 4 mm.

[0179] If the receptor is in the form of a strip or a blade, the strip or blade may have a rectangular shape and a thickness between about 0.03 mm and about 0.15 mm or between about 0.05 mm and about 0.09 mm. For example, a receptor in the form of a strip or blade may have a thickness of about 0.07 mm or about 0.06 mm.

[0180] The receptor can be formed from any material that can be inductively heated to a temperature sufficient to generate aerosols from the aerosol-generating matrix. For example, the receptor can contain metal or carbon.

[0181] The sensor can contain or be composed of ferromagnetic materials, such as ferromagnetic alloys, ferritic iron, ferromagnetic steel, or stainless steel. Suitable sensors may be aluminum or contain aluminum. Sensors can be formed from 400 series stainless steel (e.g., grade 410, 420, or 430 stainless steel). When positioned within an electromagnetic field with similar frequency and field strength, different materials will dissipate different amounts of energy.

[0182] Therefore, parameters of the sensor, such as material type, length, width, and thickness, can all be changed to provide the desired power dissipation within a known electromagnetic field. The sensor can be heated to temperatures exceeding 250 degrees Celsius.

[0183] Suitable receptors may include a non-metallic core having a metallic layer disposed on the non-metallic core, such as a metallic trace formed on the surface of a ceramic core. The receptor may have an outer protective layer, such as a ceramic or glass protective layer encapsulating the receptor. The receptor may include a protective coating formed of glass, ceramic, or an inert metal on the core of the receptor material.

[0184] The receptor can be a multi-material receptor, and can include a first receptor material and a second receptor material.

[0185] The aerosol-generating article may also include an upstream section located upstream of the matrix element. The upstream section may include one or more upstream elements. In some instances, the upstream section may include an upstream element arranged immediately adjacent to the matrix element. The upstream element may be arranged to be aligned with the matrix element. The downstream end of the upstream element may be adjacent to the upstream end of the matrix element. The upstream element may help reduce the risk of damage to the matrix element or consumer contact with the thermal sensor.

[0186] The upstream element preferably has an outer diameter substantially equal to that of the matrix element and the aerosol-generated article. The upstream element may have an outer diameter between about 5 mm and about 10 mm, or between about 6 mm and about 8 mm. In a preferred embodiment, the upstream element has an outer diameter of approximately 7.1 mm.

[0187] The upstream element preferably has a length of at least about 2 mm, preferably at least about 3 mm, and more preferably at least about 4 mm. Alternatively or additionally, the upstream element preferably has a length of less than about 10 mm, preferably less than about 8 mm, and more preferably less than about 6 mm.

[0188] The upstream element may have a length between about 2 mm and about 10 mm, between about 3 mm and about 8 mm, or between about 4 mm and about 6 mm. In a preferred embodiment, the upstream element may have a length of about 5 mm.

[0189] The aerosol-generating article may also include packaging that defines at least one component of the aerosol-generating article. The packaging may define a tubular element and at least one other component of the aerosol-generating article. The packaging may define at least a portion of the tubular element and the component of the aerosol-generating article upstream of the tubular element. The packaging may define at least a portion of the tubular element and the component of the aerosol-generating article downstream of the tubular element.

[0190] In one example, the packaging may define upstream elements, matrix elements, and tubular elements to form a sub-assembly of the packaging. The sub-assembly of the packaging may be attached to a mouthpiece element via a splice paper. The splice paper may define a downstream portion of the mouthpiece element and the sub-assembly of the packaging.

[0191] In another example, the packaging may define all components of the aerosol-generating article. The packaging may extend along the entire length of the aerosol-generating article, that is, from the upstream end of the aerosol-generating article to the downstream end of the aerosol-generating article.

[0192] The packaging can be an outer packaging. The packaging can be the outermost packaging. The outer surface of the packaging can form the outer surface of the aerosol-generating article. Especially in areas with ventilation or areas covered by ventilation, the packaging can be porous or equipped with ventilation devices.

[0193] According to another embodiment of this disclosure, a method for manufacturing a tubular element for aerosol generation articles is provided. The tubular element may have a first tubular portion. The tubular element may have a second tubular portion. The method may include providing a web material sheet. The web material sheet may have a first sheet portion corresponding to the first tubular portion. The web material sheet may have a second sheet portion corresponding to the second tubular portion. The method may include cutting slits from the edge of the web material sheet to form discontinuous edges. The slits may be made from the first sheet portion. Alternatively or additionally, the slits may be made from the second sheet portion. The slits may cause the dimensions of the first sheet portion and the second sheet portion to differ in a direction substantially perpendicular to a winding axis. The discontinuous edges may be substantially parallel to the winding axis. The method may include winding the web material sheet around the winding axis to form the tubular element.

[0194] According to another embodiment of this disclosure, a method for manufacturing a tubular element for aerosol generation articles is provided. The tubular element has a first tubular portion and a second tubular portion. The method includes providing a web material sheet having a first sheet portion corresponding to the first tubular portion and a second sheet portion corresponding to the second tubular portion. The method further includes cutting slits from the edge of the web material sheet to form discontinuous edges. The slits are cut from either the first sheet portion or the second sheet portion such that the dimensions of the first sheet portion and the second sheet portion differ in a direction substantially perpendicular to a winding axis. The discontinuous edges are substantially parallel to the winding axis. The method further includes winding the web material sheet around the winding axis to form the tubular element.

[0195] Advantageously, by providing a cut sheet of web material comprising a first sheet portion and a second sheet portion having different dimensions in a direction substantially perpendicular to the winding axis, a tubular element having a first tubular portion and a second tubular portion with different inner or outer diameters can be formed.

[0196] The sheet material may include a polygon having at least one corner facing an interior angle of 270 degrees. As used herein, the term "interior angle" refers to an angle facing inside the shape of the sheet rather than outside the shape of the sheet.

[0197] The features described in one of the above examples can also be applied to other examples of this disclosure.

[0198] The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0199] Example Ex1: An aerosol generating article comprising: a matrix element comprising an aerosol generating matrix; and a tubular element comprising a first tubular portion and a second tubular portion.

[0200] Example Ex2: An aerosol-generated article according to Example Ex1, wherein the first tubular portion and the second tubular portion each constitute at least 10% of the length of the tubular element.

[0201] Example Ex3: An aerosol-generated article according to Example Ex1 or Ex2, wherein the tubular element is formed as an integral element.

[0202] Example Ex4: An aerosol-generated article according to any one of Examples Ex1 to Ex3, wherein the first tubular portion has a first inner diameter and the second tubular portion has a second inner diameter, the first inner diameter being different from the second inner diameter.

[0203] Example Ex5: An aerosol-generated article according to any one of Examples Ex1 to Ex3, wherein the first tubular portion has a first outer diameter and the second tubular portion has a second outer diameter, the first outer diameter being different from the second outer diameter.

[0204] Example Ex6: An aerosol-generated article according to any one of Examples Ex2 to Ex5, wherein the first tubular portion and the second tubular portion each constitute at least 20% of the length of the tubular element.

[0205] Example Ex7: An aerosol-generated article according to Example Ex6, wherein the first tubular portion and the second tubular portion each constitute at least 30% of the length of the tubular element.

[0206] Example Ex8: An aerosol-generated article according to Example Ex7, wherein the first tubular portion and the second tubular portion each constitute at least 40% of the length of the tubular element.

[0207] Example Ex9: An aerosol-generated article according to any one of Examples Ex2 to Ex8, wherein the first tubular portion and the second tubular portion each constitute approximately 50% of the length of the tubular element.

[0208] Example Ex10: An aerosol-generated article according to any of the foregoing examples, wherein the difference between the inner and outer diameters is formed by steps in the inner or outer surface of the tubular element.

[0209] Example Ex11: An aerosol-generated article according to any of the foregoing examples, wherein the difference between the inner diameter and the outer diameter is at least 1 mm.

[0210] Example Ex12: An aerosol-generated article according to Example Ex11, wherein the difference between the inner diameter and the outer diameter is at least 2 mm.

[0211] Example Ex13: An aerosol-generated article according to Example Ex12, wherein the difference between the inner diameter and the outer diameter is at least 2.5 mm.

[0212] Example Ex14: An aerosol-generated article according to any of the foregoing examples, wherein the tubular element is formed from a single wound sheet of web material.

[0213] Example Ex15: An aerosol-generated article according to Example Ex14, wherein the tubular element comprises multiple wound layers of a single sheet of the web material.

[0214] Example Ex16: An aerosol-generated article according to Example Ex15, wherein the first tubular portion and the second tubular portion each have a different number of winding layers.

[0215] Example Ex17: An aerosol-generated article according to any one of Examples Ex14 to Ex16, wherein the web material sheet includes one or more of paper, cardboard, cellulose acetate tow, or polylactic acid (PLA).

[0216] Example Ex18: An aerosol-generated article according to any of the foregoing examples, wherein the first tubular portion and the second tubular portion have different first outer diameters and second outer diameters, respectively.

[0217] Example Ex19: An aerosol generating article according to Example Ex18, wherein the matrix element includes a capsule containing an aerosol generating matrix.

[0218] Example Ex20: An aerosol-generated article according to Example Ex18 or Ex19, wherein the first outer diameter is smaller than the second outer diameter.

[0219] Example Ex21: An aerosol-generated article according to any one of Examples Ex18 to Ex20, wherein the ratio of the second outer diameter to the first outer diameter is between 1.2 and 1.8.

[0220] Example Ex22: An aerosol-generated article according to Example Ex21, wherein the ratio of the second outer diameter to the first outer diameter is between 1.3 and 1.6.

[0221] Example Ex23: An aerosol-generated article according to Example Ex22, wherein the ratio of the second outer diameter to the first outer diameter is between 1.3 and 1.5.

[0222] Example Ex24: An aerosol-generated article according to Example Ex23, wherein the ratio between the second outer diameter and the first outer diameter is about 1.4.

[0223] Example Ex25: An aerosol-generating article according to any one of Examples Ex19 to Ex23, wherein the inner diameter of the tubular element is smaller than the outer diameter of the bladder.

[0224] Example Ex26: An aerosol-generated article according to any one of Examples Ex1 to Ex17, wherein the first tubular portion and the second tubular portion have different first inner diameters and second inner diameters, respectively.

[0225] Example Ex27: An aerosol-generated article according to Example Ex26, wherein the second inner diameter is larger than the first inner diameter.

[0226] Example Ex28: An aerosol-generated article according to Example Ex27, wherein the ratio of the second inner diameter to the first inner diameter is between 1.2 and 1.8.

[0227] Example Ex29: An aerosol-generated article according to Example Ex28, wherein the ratio of the second inner diameter to the first inner diameter is between 1.3 and 1.7.

[0228] Example Ex30: An aerosol-generated article according to Example Ex29, wherein the ratio of the second inner diameter to the first inner diameter is between 1.4 and 1.6.

[0229] Example Ex31: An aerosol-generated article according to Example Ex30, wherein the ratio of the second inner diameter to the first inner diameter is about 1.4.

[0230] Example Ex32: An aerosol-generating article according to any of the foregoing examples, wherein the tubular element further comprises a third tubular portion constituting at least 10% of the length of the tubular element.

[0231] Example Ex33: An aerosol-generated article according to Example Ex32, wherein the third tubular portion constitutes at least 20% of the length of the tubular element.

[0232] Example Ex34: An aerosol-generated article according to Example Ex33, wherein the third tubular portion constitutes at least 30% of the length of the tubular element.

[0233] Example Ex35: An aerosol-generating article according to any one of Examples Ex32 to Ex34, wherein the first tubular portion and the second tubular portion have different first inner diameters and second inner diameters, respectively, and the third tubular portion has an outer diameter different from that of the first tubular portion and the second tubular portion.

[0234] Example Ex36: An aerosol-generating article according to any one of Examples Ex32 to Ex34, wherein the first tubular portion and the second tubular portion have different first outer diameters and second outer diameters, respectively, and the third tubular portion has an inner diameter different from that of the first tubular portion and the second tubular portion.

[0235] Example Ex36: An aerosol-generating article according to any of the foregoing examples further includes a ventilation zone disposed along the second tubular portion.

[0236] Example Ex37: An aerosol-generating article according to Example Ex36, wherein the ventilation zone includes a plurality of ventilation holes passing through the peripheral wall of the second tubular portion.

[0237] Example Ex38: An aerosol generating article according to Example Ex36 or Ex37, wherein the aerosol generating article has a ventilation level of about 30%.

[0238] Example Ex39: An aerosol-generated article according to any of the foregoing examples, wherein the matrix element is arranged upstream of the tubular element.

[0239] Example Ex40: An aerosol-generated article according to any of the foregoing examples,

[0240] The matrix element is adjacent to the tubular element.

[0241] Example Ex41: An aerosol-generated article according to any of the foregoing examples, wherein the matrix element includes a receptor.

[0242] Example Ex42: A method for manufacturing a tubular element for aerosol generation articles, the tubular element having a first tubular portion and a second tubular portion, the method comprising: providing a web material sheet having a first sheet portion corresponding to the first tubular portion and a second sheet portion corresponding to the second tubular portion; and winding the web material sheet about a winding axis to form the tubular element.

[0243] Example Ex43: The method according to Example Ex42 further includes cutting a slit from the edge of the web material sheet to form a discontinuous edge, the slit being cut from the first sheet portion or the second sheet portion such that the dimensions of the first sheet portion and the second sheet portion are different in a direction substantially perpendicular to the winding axis, and the discontinuous edge being substantially parallel to the winding axis.

[0244] Example Ex44: According to the method of Example Ex42 or Ex43, the web material sheet includes a polygon having at least one corner facing an interior angle of 270 degrees. Attached Figure Description

[0245] The examples will now be described further with reference to the accompanying drawings, in which:

[0246] Figure 1 This is a schematic longitudinal cross-sectional view of the aerosol-generated product.

[0247] Figure 1A yes Figure 1 A schematic longitudinal cross-sectional view of a tubular element of an aerosol-generated article, which shows the feature in more detail.

[0248] Figure 2 This is a schematic longitudinal cross-sectional view of another aerosol-generated product.

[0249] Figure 2A yes Figure 2 A schematic longitudinal cross-sectional view of a tubular element of an aerosol-generated article, which shows the feature in more detail.

[0250] Figure 3 This is a flowchart of a method for manufacturing tubular elements for aerosol generation articles from sheet material.

[0251] Figure 4 It is a schematic longitudinal cross-sectional view of a tubular subassembly that includes multiple tubular elements.

[0252] Figure 5 This is a schematic plan view of a cut sheet of web material used to form a tubular subassembly, which includes six tubular elements with different outer diameters.

[0253] Figures 6A to 6C A diagram showing the winding process is provided. Figure 5 Method steps for cutting web material into sheets to form tubular sub-assemblies.

[0254] Figure 7A A diagram showing the cutting process is provided. Figure 6C A perspective view of the cutting steps of the tubular sub-assembly.

[0255] Figure 7B yes Figure 6C A schematic longitudinal cross-sectional view of the tubular sub-assembly, showing the location of the cut sub-assembly.

[0256] Figure 8 This is a schematic plan view of a cut sheet of web material used to form a tubular subassembly, which includes six tubular elements with different inner diameters.

[0257] Figure 9A and 9B A diagram showing the winding process is provided. Figure 8 Method steps for cutting web material into sheets to form tubular sub-assemblies.

[0258] Figure 10A and 10B It is a schematic longitudinal cross-sectional view of a mandrel including multiple winding sections for winding tubular sub-assemblies, showing the mandrel in a disassembled state and an assembled state, respectively.

[0259] Figure 10C It shows the surrounding Figure 10B A schematic longitudinal cross-sectional view of the tubular sub-assembly wound with an assembly mandrel.

[0260] Figure 11A and 11B It is a schematic longitudinal cross-sectional view of another mandrel including multiple winding sections for winding tubular sub-assemblies, showing the mandrel in a disassembled state and an assembled state, respectively.

[0261] Figure 11C It shows the surrounding Figure 11BA schematic longitudinal cross-sectional view of the tubular sub-assembly wound with an assembly mandrel.

[0262] Figure 12 A diagram showing the cutting process is provided. Figure 10C and 11C A perspective view of the cutting steps of the tubular sub-assembly.

[0263] Figures 13A to 13D A series of steps for ejecting tubular elements with different inner diameters from a mandrel are shown.

[0264] Figure 14A This is a schematic longitudinal cross-sectional view of another tubular element used in aerosol generation products.

[0265] Figure 14B It shows the method for forming Figure 14A Cut sheets of tubular components.

[0266] Figure 15A This is a schematic longitudinal cross-sectional view of another tubular element used in aerosol generation products.

[0267] Figure 15B The cut sheet material used to form the tubular element of FIG19A is shown. Detailed Implementation

[0268] refer to Figure 1 The diagram illustrates an aerosol generating article 1 comprising multiple elements assembled in a strip configuration. The aerosol generating article 1 includes a matrix element 2 containing an aerosol generating matrix and a downstream section 4 located downstream of the matrix element 2. Furthermore, the aerosol generating article 1 includes an upstream section 6 located upstream of the matrix element 2. The aerosol generating article 1 extends from an upstream or distal end 8 to a downstream or inlet end 10. The aerosol generating article has an overall length of approximately 45 mm.

[0269] Downstream section 4 includes a tubular element 12 positioned downstream of matrix element 2, the tubular element 12 being longitudinally aligned with matrix element 2. Figure 1 In this example, the upstream end of the tubular element 12 is adjacent to the downstream end of the matrix element 2. The tubular element 12 includes a first tubular portion 14 and a second tubular portion 16, the second tubular portion 16 being downstream of the first tubular portion 14. The tubular element 12 is formed as an integral element, i.e., formed as a single piece. The first tubular portion 14 and the second tubular portion 16 each form a part of the entire tubular element.

[0270] The first tubular portion 14 of the tubular element 12 defines an inner cavity 18 that extends from an upstream end 20 to a downstream end 22 of the first tubular portion 14. The inner cavity 18 is substantially empty, and thus allows for substantially unrestricted airflow along the inner cavity 18. Therefore, the first tubular portion 14 does not substantially contribute to the overall RTD of the aerosol-generating article 1. More specifically, the RTD of the first tubular portion 14 is substantially 0 mmH2O. The first tubular portion 14 of the tubular element 12 is configured to act as a spacer or support element for the aerosol-generating article 1.

[0271] The second tubular portion 16 of the tubular element 12 defines an inner cavity 24 extending from an upstream end 22 to a downstream end 26 of the second tubular portion 16. The inner cavity 24 is substantially empty, and thus allows for substantially unrestricted airflow along it. The second tubular portion does not substantially contribute to the overall RTD of the aerosol-generating article 10. More specifically, the RTD of the second tubular portion 16 is substantially 0 mmH2O. The second tubular portion 16 of the tubular element 12 is configured to act as an aerosol cooling element for the aerosol-generating article 1.

[0272] The aerosol generating article 1 also includes a ventilation zone 28 disposed along the second tubular portion 16 of the tubular element 12. More specifically, the ventilation zone 28 is disposed approximately 2 mm from the upstream end 22 of the second tubular portion 16. The ventilation zone 28 includes a circumferential ring of ventilation holes extending through the wall of the second tubular portion 16. Air can be drawn through the ventilation holes and through the second tubular portion 16 to achieve cooling of the aerosol flow generated when the matrix element 2 is heated. The ventilation level of the aerosol generating article 1 is approximately 25%.

[0273] exist Figure 1 In this example, the downstream section 4 also includes a mouthpiece element 30 located downstream of the tubular element 12. More specifically, the mouthpiece element 30 is positioned downstream of the second tubular portion 16 of the tubular element 12. The upstream end of the mouthpiece element 30 is adjacent to the downstream end 26 of the second tubular portion 16 of the tubular element 12. The mouthpiece element 30 is provided in the form of a cylindrical rod of low-density cellulose acetate. The mouthpiece element 30 also includes a package or rod pack 35 defining the cellulose acetate rod. The mouthpiece element 30 has a length of about 12 mm and an outer diameter of about 7.1 mm.

[0274] Matrix element 2 comprises an aerosol-generating matrix of one of the types described above. Matrix element 2 is in the form of a strip comprising the aerosol-generating matrix. The aerosol-generating matrix may substantially define the structure and dimensions of strip 2. Strip 2 may also include packaging (not shown) defining the aerosol-generating matrix. Matrix element 2 has an outer diameter of approximately 7.1 mm and a length of approximately 12 mm. However, it should be understood that these dimensions may vary. For example, in another aerosol-generating article, matrix element 2 may have a length of approximately 11 mm.

[0275] The aerosol generating article 1 also includes an elongated receptor element 32 within a matrix element 2. More specifically, the receptor element 32 is arranged substantially longitudinally within the aerosol generating matrix, so as to be generally parallel to the longitudinal direction of the strip-shaped matrix element 2. The receptor element 32 is positioned at a radial center within the matrix element 2 and extends effectively along the longitudinal axis of the matrix element 2. The receptor element 32 extends from the upstream end to the downstream end of the matrix element 2. In practice, the receptor element 32 has substantially the same length as the matrix element 2. Figure 1 In one example, the receptor element 32 is provided in the form of a strip and has a length of about 12 mm, a thickness of about 60 micrometers, and a width of about 4 mm.

[0276] The upstream segment 6 includes an upstream element 34 positioned immediately upstream of the matrix element 2, which is longitudinally aligned with the matrix element 2. Figure 1 In this example, the downstream end of the upstream element 34 is adjacent to the upstream end of the matrix element 2. This advantageously prevents the receptor element 44 from being displaced. Furthermore, this ensures that the consumer will not accidentally come into contact with the heated receptor element 34 after use. The upstream element 34 is provided in the form of a cylindrical cellulose acetate rod defined by a rigid packaging (not shown). The upstream element 34 has a length of approximately 5 mm.

[0277] The aerosol generating article 1 also includes a package 36 defining the upstream element 34, the matrix element 2, and the tubular element 12. The package 36 extends from the upstream or distal end 8 of the aerosol generating article 1 to the downstream end 26 of the second tubular portion 16. Ventilation openings of the ventilation zone 28 extend through the package 36 to communicate with ventilation openings in the tubular element 12. A mouthpiece element 30 is connected to the aerosol generating article 1 via a splice paper 37 defining the mouthpiece element 30 and a portion of the downstream end of the second tubular portion 16 enclosed in the package 36.

[0278] Figure 1A Showing more details Figure 1The aerosol-generating article 1 has a tubular element 12. A first tubular portion 14 has a length L1 of about 8 mm, and a second tubular portion 16 has a length L2 of about 8 mm. Thus, the first tubular portion 14 and the second tubular portion 16 each constitute about 50% of the length of the tubular element. However, it should be understood that these lengths and their relative percentages can vary. For example, in another aerosol-generating article, the second tubular portion may have a length of 9 mm.

[0279] The first tubular portion 14 and the second tubular portion 16 have the same outer diameter D of approximately 7.1 mm. ext It is constant over the entire length (L1+L2) of the tubular element 12. The first tubular portion 14 and the second tubular portion 16 have different inner diameters. The first tubular portion 14 has a first inner diameter D1 of approximately 3.3 mm. int Therefore, the thickness of the peripheral wall of the first tubular portion 14 is approximately 1.9 mm. The second tubular portion 16 has a second inner diameter D2 of approximately 5.0 mm. int Therefore, the thickness of the peripheral wall of the second tubular portion 16 is approximately 1.05 mm. The first inner diameter D1 of the first tubular portion 14... int The length L1 of the first tubular portion 14 is uniform, and the second inner diameter D2 of the second tubular portion 16 is uniform. int The second tubular portion 16 is uniform along its length L2. The second inner diameter D2 of the second tubular portion 16 is... int With the first inner diameter D1 of the first tubular portion 14 int The ratio between them is approximately 1.52.

[0280] The tubular element 12 is formed from a single wound sheet of web material. The sheet is wound around itself such that the tubular element 12 comprises multiple wound layers 38 of the single wound sheet of web material. The first tubular portion 14 and the second tubular portion 16 each have a different number of wound layers 38 to provide their respective peripheral walls of different thicknesses. Forming the tubular element 12 from a single wound sheet of web material automatically ensures axial alignment of the first tubular portion 14 and the second tubular portion 16. It also produces an integral tubular element, i.e., a tubular element formed as a single piece, which alleviates any difficulties in positioning the first tubular portion 14 and the second tubular portion 16 relative to each other compared to forming the first tubular portion 14 and the second tubular portion 16 as separate elements.

[0281] Figure 2This is a schematic longitudinal cross-sectional view of another aerosol-generating article 100. The aerosol-generating article 100 is an inhaler article, such as a dry powder inhaler. The aerosol-generating article 100 includes a tubular body 102 having a partially closed distal or upstream end 104 and a partially closed downstream or inlet end 106. An upstream opening 108 is formed in the upstream end 104 of the tubular body 102, and a downstream opening 110 is formed in the inlet end 106 of the tubular body 102. The upstream opening 108 serves as an air inlet, and the downstream opening 110 serves as an air outlet. An airflow path extends between the upstream opening 108 and the downstream opening 110, and through the inner cavity 107 of the tubular body 102. An upstream portion 109 of the inner cavity of the tubular body 102 near the upstream end 104 houses a sac 111 containing nicotine particles.

[0282] The partially closed upstream end 104 of the tubular body 102 prevents the bladder 111 from falling out of the upstream end 104 of the tubular body 102. The diameter of the bladder 111 is larger than the diameter of the upstream opening 108 and therefore cannot pass through the upstream opening 108. A tubular element 112 is disposed downstream of the bladder 111. The tubular element 112 is fixed to the inner surface of the tubular body 102 and acts as a retaining rod to limit the downstream movement of the bladder 111 to retain the bladder 111 in the upstream region of the tubular body 102.

[0283] The tubular element 112 includes a first tubular portion 114 and a second tubular portion 116, the second tubular portion 116 being downstream of the first tubular portion 114. The tubular element 112 is formed as an integral element, that is, formed as a single piece. The first tubular portion 114 and the second tubular portion 116 each form a part of the entire tubular element 112.

[0284] The first tubular portion 114 has a first outer diameter smaller than the inner diameter of the tubular body 102. The second tubular portion 116 has a second outer diameter substantially the same as the inner diameter of the tubular body 102. Therefore, the first outer diameter of the first tubular portion 114 differs from the second outer diameter of the second tubular portion 116, specifically, the first outer diameter is smaller than the second outer diameter. The tubular element is fixed to the inner surface of the tubular body 102 in the region of the second tubular portion 116.

[0285] The tubular element 112 defines an inner cavity 118 that extends from the upstream end of the tubular element 112 to its downstream end. The inner cavity 118 is substantially empty, and thus allows for substantially unrestricted airflow along it. The inner diameter of the inner cavity 118 is smaller than the outer diameter of the bladder 111, and thus prevents the bladder from passing through the tubular element 112.

[0286] During use, the consumer uses an external piercing tool 120 (in... Figure 2(Shown in dashed outline) The sac 111 is punctured via an upstream opening 108. The puncture tool 120 is pushed through the upstream opening 108 and into the sac 111 to create a hole 122 in the sac 111 through which the nicotine particles can exit the sac 111. Significant downstream movement of the sac 111 is restricted by a tubular element 112. The upstream end of the tubular element 112 is in abutment contact with the sac 111 during puncture and holds the sac 111 in place to allow for easier puncture.

[0287] When a consumer inhales or inhales through the mouth end 106 of the aerosol-generating article 100, air is drawn through the upstream opening 108 and through the upstream portion 109 of the inner cavity 107 of the tubular body 102 containing the capsule 111. Nicotine particles exit the capsule and are entrained in the airflow passing through the tubular body 102. The airflow carrying nicotine particles passes through the inner cavity 118 of the tubular element 112 and enters the downstream portion 124 of the inner cavity 107 of the tubular body 102. The inner diameter of the downstream portion 124 of the inner cavity 107 of the tubular body 102 is larger than the inner diameter of the inner cavity 118 of the tubular element 112. As air is transferred from the tubular element 112 to the downstream portion 124 of the inner cavity 107 of the tubular body 102, the expansion of the cross-section of the airflow path causes a vortex effect, which helps to mix the nicotine particles with the airflow before the airflow is inhaled into the consumer's mouth via the downstream opening 110.

[0288] The smaller first outer diameter of the first tubular portion 114 of the tubular element 112 defines an annular space 126 between the outer surface of the first tubular portion 114 and the inner surface of the tubular body 102. The annular space 126 defines grooves or pores for collecting excess nicotine particles released from the capsule 111 when inhaled by a consumer on the aerosol-generating article 100, but not entrained in the airflow. The annular space 126 also collects nicotine particles released from the capsule as the aerosol-generating article 100 moves between consumer inhalations. The annular space 126 created by the tubular element 112 acts as a barrier reducing the likelihood of nicotine particles leaking from the aerosol-generating article 100 between consumer inhalations or between uses of the aerosol-generating article 100.

[0289] Figure 2A Showing more details Figure 2 The aerosol-generating article 100 has a tubular element 112. A first tubular portion 114 has a length L1 of about 6 mm, and a second tubular portion 116 has a length L2 of about 9 mm. Thus, the first tubular portion 114 and the second tubular portion 116 each constitute about 50% of the length of the tubular element. However, it should be understood that these lengths and their relative percentages may vary.

[0290] The first tubular portion 114 and the second tubular portion 116 have the same inner diameter D of approximately 3.0 mm. intIt is constant over the entire length (L1+L2) of the tubular element 112. The first tubular portion 114 and the second tubular portion 116 have different outer diameters. The first tubular portion 114 has a first outer diameter D1 of approximately 5.0 mm. ext Therefore, the thickness of the peripheral wall of the first tubular portion 114 is approximately 1.0 mm. The second tubular portion 116 has a second outer diameter D2 of approximately 7.0 mm. ext Therefore, the thickness of the peripheral wall of the second tubular portion 16 is approximately 2.0 mm. The first outer diameter D1 of the first tubular portion 114... ext The length L1 of the first tubular portion 114 is uniform, and the second outer diameter D2 of the second tubular portion 116 is uniform. ext The second tubular portion 116 is uniform along its length L2. The second outer diameter D2 of the second tubular portion 116 is... ext The first outer diameter D1 of the first tubular portion 114 ext The ratio between them is approximately 1.4.

[0291] The tubular element 112 is formed from a single wound sheet of web material. The sheet is wound around itself such that the tubular element 112 comprises multiple wound layers 138 of the single sheet of web material. The first tubular portion 114 and the second tubular portion 116 each have a different number of wound layers 138 to provide their respective peripheral walls of different thicknesses. Forming the tubular element 112 from a single wound sheet of web material automatically ensures axial alignment of the first tubular portion 114 and the second tubular portion 116. It also produces an integral tubular element, i.e., a single-piece tubular element, which alleviates any difficulties in positioning the first tubular portion 114 and the second tubular portion 116 relative to each other compared to forming the first tubular portion 114 and the second tubular portion 116 as separate elements.

[0292] Figure 3 Tubular elements (e.g.) for manufacturing articles for aerosol generation are shown. Figure 1A and 2A The flowchart illustrates a method for manufacturing tubular elements from a single wound sheet of web material. The web material sheet has a first sheet portion corresponding to a first tubular portion of the tubular element and a second sheet portion corresponding to a second tubular portion of the tubular element. The web material sheet can be sized such that multiple tubular elements can be made from a single sheet of web material.

[0293] In the first step S1, the method includes sheet cutting, wherein a cut is made from the edge of a web material sheet to form a discontinuous edge. The cut is made from a first sheet portion or a second sheet portion such that the dimensions of the first sheet portion and the second sheet portion differ in a direction substantially perpendicular to the winding axis. The discontinuous edge is arranged substantially parallel to the winding axis.

[0294] In the second step S2, the method includes gluing, wherein the cut sheet is coated with glue or adhesive to hold multiple layers of the web material together after winding.

[0295] In the third step S3, the method includes winding, wherein a cut and glued sheet is wound around a rotating central pin or mandrel to produce a tubular element. The sheet may be pressed onto the pin or mandrel by peripheral rollers or wheels.

[0296] In the fourth step S4, the method includes a drying step in which the adhesive or binder is cured or solidified. This step is optional and can be used to accelerate the manufacturing process. This drying step can be carried out by placing a heat source (such as a heating rod) close to the wound sheet of the web material.

[0297] When multiple tubular elements are made from a single sheet of web material, the method may include a fifth step S5 of tube cutting, wherein the individual tubular elements are cut to a certain length and separated from the wound sheet of web material. This can be accomplished by a plurality of knives or blades spaced apart by the length of the individual tubular elements. The knives or blades are configured to cut transversely to the winding axis of the central pin or mandrel.

[0298] In the final sixth step S6, the method includes ejecting the tubular element, that is, removing the tubular element from the center pin or mandrel.

[0299] As further described below, in the case where the tubular element has a first tubular portion and a second tubular portion with different inner diameters, the central pin or mandrel around which the web material sheet is wound may include multiple wound sections arranged along the longitudinal axis of the pin or mandrel. The multiple wound sections can be disassembled and reassembled, and have an outer diameter corresponding to the inner diameter of the tubular element.

[0300] The following sections will discuss each step of the above method in more detail with different examples of tubular elements.

[0301] Figure 4 A schematic longitudinal cross-sectional view of a tubular subassembly 200 comprising three tubular elements A, B, and C formed using the methods described herein is shown. The tubular subassembly is formed as a single piece from a single sheet of web material and is shown before the individual tubular elements are separated. Tubular element A is similar to... Figure 2A The tubular element 112 includes a first tubular portion A1 with a different outer diameter and a constant inner diameter, and a second tubular portion A2. The tubular element B is similar to... Figure 1AThe tubular element 12 includes a first tubular portion B1 and a second tubular portion B2 with different inner diameters and a constant outer diameter. The tubular element C includes a first tubular portion C1, a second tubular portion C2, and a third tubular portion C3. The first tubular portion C1 and the second tubular portion C2 have different first and second outer diameters, respectively, and the third tubular portion C3 has an inner diameter different from that of the first tubular portion C1 and the second tubular portion C2. The outer diameter of the third tubular portion is the same as that of the second tubular portion C2. Figure 4 The dashed lines in the diagram indicate the locations where the tubular subassemblies 200 are cut to separate the individual tubular elements.

[0302] Figure 4 The purpose is to illustrate only the types of tubular elements that can be formed using the methods described herein. Although Figure 4 The three different types of tubular elements can be formed around a single central mandrel with different outer diameters of winding sections, but it should be understood that the manufacturing station will usually be dedicated to producing only a single type of tubular element.

[0303] Figures 5 to 7B Various steps of a method for forming tubular elements with different outer diameters and a constant inner diameter are illustrated. The method produces six tubular elements, each having a length Lp and two different outer diameters: a first outer diameter D1 over a length L1 of a first tubular portion and a second outer diameter D2 over a length L2 of a second tubular portion. In this example, D2 is greater than D1. The length Lp of the tubular element is equal to L1 + L2, and the tubular element has an inner diameter d. The thickness of the web material sheet used to form the tubular elements is Ts, and the thickness of the adhesive layer between the continuous layers of the web material is Tg.

[0304] Figure 5 This is a schematic plan view of a cut sheet 300 of web material used to form a tubular subassembly comprising six tubular elements with different outer diameters. It should be understood that the cut sheet 300 is not drawn to scale. The portion of the cut sheet 300 corresponding to each of the tubular elements (i.e., the portion of the cut sheet 300 having a width Lp) each has a first sheet portion 300a with a width L1 corresponding to the length of a first tubular portion of the tubular element, and a second sheet portion 300b with a width L2 corresponding to the length of a second tubular portion of the tubular element. Figure 5 The cut sheet 300 is configured to produce three pairs of symmetrical tubular elements, each pair arranged back-to-back. That is, in each symmetrical pair, the second sheet portion 300b is arranged adjacent to each other. Figure 5 In this context, La is the length of each pair of symmetrical tubular elements and is equal to 2Lp. Ls is the total width of the sheet and is equal to 3La.

[0305] The cut sheet 300 has a continuous edge 302 on one side and a discontinuous edge 304 on the opposite side. A notch 306 has been made from each first sheet portion 300a of the cut sheet 300 to form the discontinuous edge 304. The continuous edge 302 has no notches and thus forms a straight, continuous edge of the cut sheet 300. To form a tubular element with a different outer diameter and a constant inner diameter, the continuous edge 302 of the cut sheet 300 is first fed to a rotating mandrel, causing the cut sheet 300 to begin winding around the mandrel with the continuous edge 302. The discontinuous edge 304 with the notch 306 is wound last, and the second sheet portion 300b will provide additional thickness to achieve a larger outer diameter D2. The cut sheet can be cut using various known techniques, including, for example, a paper cutter.

[0306] The cut sheet 300 is a polygon, wherein all interior angles are 90 degrees or 270 degrees. A notch 306 provides at least one interior angle of 270 degrees, such that the cut sheet 300 is not rectangular or square. The notch 306 in the cut sheet 300 causes the first sheet portion 300a and the second sheet portion 300b to have different dimensions in a direction substantially perpendicular to the winding axis. The winding axis is defined by the longitudinal axis of the mandrel. The cut sheet 300 is wound such that the continuous edge 302 and the discontinuous edge 304 are substantially parallel to the winding axis. Due to the notch 306, the first sheet portion 300a has a length H1 in a direction perpendicular to the winding axis or perpendicular to the continuous edge 302 and the discontinuous edge 304, and the second sheet portion 300b has a length H1+H2. Lengths H1 and H2 determine the thickness of the peripheral wall of the tubular element, and the difference between H1 and H1+H2 causes the tubular element to have different outer diameters in the first and second tubular portions.

[0307] Dimensions H1 and H2 can be determined as follows. If N1 is the number of layers of web material sheet required for the first outer diameter D1 of the first tubular portion of the tubular element, then N1 can be expressed as the variables discussed above:

[0308]

[0309] For the N1 rearrangement:

[0310] Equation (1)

[0311] H1 can then be calculated as follows:

[0312]

[0313]

[0314] Equation (2)

[0315] Similar calculations can also be used to determine N2 (which is the number of web material sheets required for the second outer diameter D2 of the second tubular portion of the tubular element) and H2.

[0316] In the gluing step of the manufacturing process, depending on the orientation of the paper relative to the rotation center pin or mandrel, glue can be applied to the cut sheet 300 via a nozzle or (multiple) glue rollers. For manufacturing methods where the sheet is fed to the bottom of the mandrel, the top surface of the cut sheet should be glued, and therefore a nozzle is a good solution. For manufacturing methods where the sheet is fed to the top of the mandrel, the bottom surface of the sheet should be glued, and therefore (multiple) glue rollers are a good solution.

[0317] Two types of adhesives have been found to be particularly advantageous for bonding cut sheets 300. First, fast-acting adhesives, such as ethylene-vinyl acetate (EVA) or poly(ethylene-vinyl acetate) (PEVA), are commonly used in paper because they bond well to cellulose materials to quickly fix the web material layers constituting the tubular element. Preferably, this adhesive should undergo a drying step to facilitate its rapid curing. Second, long-lasting adhesives, such as polyvinyl acetate (PVA), can be used to ensure that the multilayered structure of the tubular element remains in place over time. In particular, this type of adhesive can help reduce the likelihood of the edges of the tubular element layers collapsing into the central cavity over time. Both types of adhesives can be applied to the same cut sheet to ensure effective bonding. Alternatively, only one type of adhesive can be applied. In cases where only one type of adhesive is used, a fast-acting adhesive, such as EVA, is typically chosen.

[0318] It may be desirable to avoid applying adhesive to the portion of the cut sheet 300 that contacts the mandrel, in order to reduce the risk of the sheet adhering to the mandrel. Figure 5 Within a distance Hg from the continuous edge 302, adhesive is not applied across the width of the sheet. Hg is equal to the circumference of the first layer of sheet around the central axis, i.e., Hg equals π.d. Adhesive is applied to the remaining portion of the cut sheet 300.

[0319] Alternatively, adhesive can be applied to the portions of the cut sheet 300 that will come into direct contact with the center pin or mandrel. This has been found to help the cut sheet 300 begin to wind around the mandrel. Since the center pin or mandrel is typically made of metal (e.g., stainless steel) and the cut sheet 300 is tightly wound around it, the adhesive is removed from the center pin or mandrel when the resulting tubular structure is ejected, making it usable for new cut sheets.

[0320] Figures 6A to 6C A diagram showing the winding process is provided. Figure 5 Method steps for cutting web material into 300 sheets to form tubular sub-assemblies.

[0321] Figure 6A and 6B Perspective and cross-sectional views are shown, respectively, of the winding step, in which a cut sheet 300 is wound around a rotating central pin or mandrel 330 to produce a tubular subassembly 324 with different outer diameters. The central mandrel 330 has a constant outer diameter along its longitudinal or winding axis, which corresponds to a constant inner diameter of the tubular subassembly 324. The cut sheet 300 is driven to the rotating central mandrel 330 by rollers 331. The cut sheet 300 is first fed to the rotating mandrel with its continuous edges. The longitudinal dimension of the cut sheet 300 (i.e., the dimension between the continuous and discontinuous edges) is perpendicular to the winding or longitudinal axis of the central mandrel 330. The cut sheet 300 is wound around the mandrel 330 and pressed toward the central mandrel 330 by peripheral rollers 332. This facilitates winding the cut sheet 300 on the central mandrel with a desired amount of pressure. Figure 6A and 6B In this process, the cutting sheet 300 is fed to the bottom of the central spindle 330, but it should be understood that the cutting sheet can also be fed to the top of the central spindle 330.

[0322] Figure 6C A perspective view of the tubular subassembly 324 after being wound around a central mandrel 330 is shown. The tubular subassembly 324 has tubular portions with varying outer diameters and a constant inner diameter, the inner diameter corresponding to the outer diameter of the central mandrel. After the winding step, the wound tubular subassembly can be heated to dry or cure the adhesive.

[0323] Figure 7A A diagram showing the cutting process is provided. Figure 6C A perspective view of the cutting steps of the tubular subassembly 324. Figure 7A In this example, the tubular subassembly 324 is cut by a circular blade 340 fixed to a rotation axis 41, which moves toward a central spindle 330 to cut the tubular subassembly 324 and separate individual tubular elements from the tubular subassembly. It should be understood that other methods for cutting the tubular subassembly may be used.

[0324] Figure 7B It is arranged on the central spindle 330 Figure 6C A schematic longitudinal cross-sectional view of the tubular subassembly 324. The tubular subassembly 324 is shown at cut line 342 (at...). Figure 7B The tubes are cut at the locations shown as dashed lines to produce tubular elements 325, each with a length Lp.

[0325] The ejection step (not shown) in which the tubular element 325 ejects from the central spindle 330 is in Figure 7A and 7BFollowing the cutting step, the ejection can be performed by one or more mechanical actuators that push along the longitudinal axis of the central spindle 330. Given that the inner diameter d of the tubular element 325 is constant and smooth, all the rods can be pushed together along one or the other direction of the central spindle 330.

[0326] Figures 8 to 13D The steps of a method for forming tubular elements with different inner diameters and a constant outer diameter are illustrated. The method produces six tubular elements, each having a length Lp and two different inner diameters: a first inner diameter D1 over a first tubular portion of length L1 and a second inner diameter D2 over a second tubular portion of length L2. In this example, D2 is greater than D1. The length of the tubular element Lp is equal to L1 + L2, and the tubular element has an outer diameter D. ext The thickness of the web material sheet used to form the tubular element is Ts, and the thickness of the adhesive layer between the continuous layers of the web material is Tg.

[0327] Figure 8 This is a schematic plan view of a cut sheet 400 of web material used to form a tubular subassembly comprising six tubular elements with different inner diameters. It should be understood that the cut sheet 400 is not drawn to scale. The portion of the cut sheet 400 corresponding to each of the tubular elements (i.e., the portion of the cut sheet 300 having a length Lp) each has a first sheet portion 400a with a width L1 corresponding to the length of the first tubular portion of the tubular element, and a second sheet portion 400b with a width L2 corresponding to the length of the second tubular portion of the tubular element. Figure 8 The cut sheet 400 is configured to produce three pairs of symmetrical tubular elements, each pair arranged back-to-back. That is, in each symmetrical pair, the second sheet portion 400b is arranged adjacent to each other. Figure 8 In this context, La is the length of each pair of symmetrical tubular elements and is equal to 2Lp. Ls is the total width of the sheet and is equal to 3La.

[0328] The cut sheet 400 has a continuous edge 402 on one side and a discontinuous edge 404 on the opposite side. A cut 406 has been made from each first sheet portion 400a of the cut sheet 400 to form the discontinuous edge 404. The continuous edge 402 has no cuts and thus forms a straight, continuous edge of the cut sheet 400. To form a tubular element with a different inner diameter and a constant outer diameter, the discontinuous edge 404 of the cut sheet 400 is first fed to a rotating mandrel, causing the cut sheet 400 to begin winding around the mandrel with the discontinuous edge 404. A second sheet portion 400b with the discontinuous edge 404 will provide additional thickness to achieve a smaller inner diameter D1. The cut sheet can be cut using various known techniques, including, for example, a paper cutter.

[0329] The cut sheet 400 is a polygon, wherein all interior angles are 90 degrees or 270 degrees. A notch 406 provides at least one interior angle of 270 degrees, such that the cut sheet 400 is not rectangular or square. The notch 406 in the cut sheet 400 causes the first sheet portion 400a and the second sheet portion 400b to have different dimensions in a direction substantially perpendicular to the winding axis. The winding axis is defined by the longitudinal axis of the mandrel. The cut sheet 400 is wound such that the continuous edge 402 and the discontinuous edge 404 are substantially parallel to the winding axis. Due to the notch 406, the first sheet portion 400a has a length H1 in a direction perpendicular to the winding axis or perpendicular to the continuous edge 402 and the discontinuous edge 404, and the second sheet portion 400b has a length H1+H2. Lengths H1 and H2 determine the thickness of the peripheral wall of the tubular element, and the difference between H1 and H1+H2 causes the tubular element to have different inner diameters in the first and second tubular portions.

[0330] Dimensions H1 and H2 can be determined using equations similar to those in Equations 1 and 2 above, taking into account the fact that the tubular elements in this example have different inner diameters.

[0331] exist Figures 8 to 13D In the gluing step of the manufacturing method, it is applicable to and suitable for Figures 5 to 7B The gluing considerations in the manufacturing method are essentially the same. One difference is that adhesive is not applied to the portion of the cut sheet 400 that contacts the mandrel to reduce the risk of the sheet adhering to the mandrel, because in this exemplary method, the cut sheet is supplied to the mandrel with its discontinuous edges 404. Figure 8 In this process, the adhesive is not applied to the area of ​​the cut sheet 400 behind the discontinuous edge 404 at a distance Hg from the discontinuous edge 404. Hg is equal to the circumference of the first sheet around the central axis, that is, Hg is equal to π.d. The adhesive is applied to the rest of the cut sheet 300.

[0332] Figure 9A and 9B A diagram showing the winding process is provided. Figure 8 Method steps for cutting web material into sheets to form tubular sub-assemblies.

[0333] Figure 9A and 9BA perspective view of the winding process is shown, in which a cut sheet 400 is wound around a rotating center pin or mandrel 430 to produce tubular subassemblies 424 with different inner diameters. The center mandrel 430 has different outer diameters along its longitudinal direction or winding axis, which correspond to different inner diameters of the tubular subassemblies 424. Specifically, the center mandrel 430 has a plurality of alternating first diameter segments 430a and second diameter segments 430b arranged along its longitudinal axis. The plurality of first diameter segments 430a have a smaller outer diameter than the plurality of second diameter segments 430b. The smaller outer diameter of the plurality of first diameter segments 430a corresponds to a smaller inner diameter of the tubular subassemblies 424. The larger outer diameter of the plurality of second diameter segments 430b corresponds to a larger inner diameter of the tubular subassemblies 424. A recessed portion of the cut sheet 400 (i.e., having a notch 406 (see...)) is also shown. Figure 8 The first sheet portion 400a) will produce a smaller diameter portion of the tubular subassembly 424.

[0334] The cut sheet 400 is driven by roller 431 to a central spindle 430. The cut sheet 400 is initially fed to the spindle 430 with its discontinuous edges 404. The longitudinal dimension of the cut sheet 400 (i.e., the dimension between the continuous and discontinuous edges) is perpendicular to the winding or longitudinal axis of the central spindle 430. The cut sheet 400 is wound around the spindle 430, and due to the different outer diameters of the spindle 430, the cut sheet 400 is pressed toward the spindle 430 by peripheral short rollers or wheels 433. The peripheral wheels 433 may press the cut sheet in a region corresponding to a first diameter segment 430a of the smaller diameter, which first wound around a second sheet portion 400b of the cut sheet 400. This facilitates winding the cut sheet 400 with a desired amount of pressure on the central spindle 430. Figure 9A and 9B In this process, the cutting sheet 400 is fed to the bottom of the central spindle 430, but it should be understood that the cutting sheet can also be fed to the top of the central spindle 430.

[0335] After being wound around the central mandrel 430, the tubular subassembly 424 has tubular portions with varying inner diameters and a constant outer diameter. Following the winding step, the wound tubular subassembly 424 can be heated to dry or cure the adhesive.

[0336] Figure 10A and 10B This is a schematic longitudinal cross-sectional view of a mandrel 430, which includes multiple winding segments 434 for winding tubular subassemblies. This mandrel 430 can be used to form tubular elements with different inner diameters, for example, as... Figure 9A and 9B As shown. Figure 10A The mandrel 430 is shown in a disassembled state, and Figure 10BA mandrel 430 in an assembled state is shown. Each winding segment 434 is configured to form a single tubular element, but as discussed below, the winding segments can be configured to form more than one tubular element. Each winding segment 434 has a first diameter segment 430a and a second diameter segment 430b. As discussed above regarding... Figure 9A As discussed, the first diameter segment 430a has a smaller outer diameter than the second diameter segment 430b. Each winding segment 434 has a connector (not shown) so that multiple winding segments 434 can be connected together by a suitable connection (such as a male-female connection). The multiple winding segments 434 are connected at each end to an end piece 435 to form a complete mandrel 430. The multiple winding segments 434 are rotatable about the end piece 435.

[0337] Figure 10C It shows the surrounding Figure 10B A schematic longitudinal cross-sectional view of the tubular sub-assembly 424 wound around the assembly mandrel 430. The tubular sub-assembly 424 has been... Figure 9A and 9B The method shown is used to form it. Cutting line 442 (in) Figure 10C (shown as dashed lines) indicates the location where the tubular subassemblies 424 are cut to produce the tubular elements 425, each having a length Lp.

[0338] Figure 11A and 11B This is a schematic longitudinal cross-sectional view illustrating another example of a mandrel 430' including multiple winding sections 434' for winding tubular subassemblies. This mandrel 430' can be used to form tubular elements with different inner diameters, for example, such as... Figure 9A and 9B As shown. Figure 11A The mandrel 430' is shown in a disassembled state, and Figure 11B A mandrel 430' in an assembled state is shown. Each winding segment 434' is configured to form two tubular elements. Each winding segment 434' has two first diameter segments 430a and two second diameter segments 430b, the second diameter segments 430b being adjacent to each other and arranged between the two first diameter segments 430a. As mentioned above... Figure 9A As discussed, the first diameter segment 430a has a smaller outer diameter than the second diameter segment 430b. Each winding segment 434' has a connector (not shown) so that multiple winding segments 434' can be connected together by a suitable connection (such as a male-female connection). The multiple winding segments 434' are connected at each end to an end piece 435' to form a complete mandrel 430'. The multiple winding segments 434' are rotatable about the end piece 435'.

[0339] Figure 11C It shows the surrounding Figure 11BA schematic longitudinal cross-sectional view of the tubular sub-assembly 424' wound around the assembly mandrel 430'. The tubular sub-assembly 424' has been... Figure 9A and 9B The method shown is used to form it. Cutting line 442' (in Figure 11C (Seen as dashed lines) shows the locations where tubular subassemblies 424' are cut to produce tubular elements 425', each with a length Lp. Figure 11C As can be seen, each winding section 434' has formed two tubular elements 425'.

[0340] Figure 12 The method for cutting tubular sub-assemblies (such as in) is shown. Figure 10C and 11C A perspective view of the cutting steps shown (those illustrated). Although shown Figure 11C The mandrel 430' and tubular subassembly 424', but it should be understood that the same cutting steps can be used with Figure 10C The spindle 430 and tubular sub-assembly 424 are used together. Figure 12 The cutting steps are similar to Figure 7A The cutting steps have been adjusted to account for tubular sub-assemblies 424' with different inner diameters.

[0341] exist Figure 12 In one example, the tubular subassembly 424' is cut by circular blades 443 and 444 fixed on a rotating shaft 441, the circular blades moving toward a central spindle 430' to cut the tubular subassembly 424' and separate individual tubular elements from the tubular assembly. Figure 12 In the diagram, the central mandrel 430' is shown in dashed outline in conjunction with the tubular subassembly 424'. Due to the different outer diameters of the central mandrel 430', and in order to cut all layers of the wound web material forming the tubular subassembly 424' to the central mandrel 430', the circular cutters have different diameters: a smaller diameter cutter 444 aligned with the larger outer diameter section of the central mandrel 430'; and a larger diameter cutter 443 aligned with the smaller outer diameter section of the central mandrel 430'. It should be understood that other methods can be used to cut the tubular subassembly.

[0342] Figures 13A to 13D This illustrates tubular elements with different inner diameters (such as those in...) that are ejected from a mandrel. Figure 10C and 11C The process involves a series of steps for ejecting the tubular element (as shown in the diagram). When the tubular element has different inner diameters due to variations in the outer diameter of the central mandrel, and the wound web material is located between two sections of the mandrel with larger outer diameters, ejecting the tubular element from the central mandrel becomes more complex. Therefore, the tubular element cannot simply slide along the central mandrel. To facilitate the ejection of the tubular element, the central pin can be removed as described below. Although... Figures 13A to 13D It shows Figure 10C The spindle 430 and tubular subassembly 424, but it should be understood that similar steps can be taken with Figure 11C The spindle 430' and tubular sub-assembly 424' are used together.

[0343] Figure 13A It shows Figure 10C The mandrel 430 and tubular subassemblies 424 are described. In this example, each winding segment 434 of the mandrel 430 is configured to form a tubular element 425. The tubular subassemblies have been cut at a cutting line 442 so that the individual tubular elements 425 can be separated from the tubular subassemblies 424. To remove the tubular elements 425, the mandrel 430 is disassembled.

[0344] Figure 13B The image shows one of the end pieces 435 being removed from the mandrel.

[0345] Figure 13C The image shows the first tubular element 425 being removed from the tubular subassembly. With the first tubular element 425 removed, it is possible to remove the first winding section 434 from the mandrel 430 because the tubular portion of the first tubular element, having a smaller inner diameter, no longer obstructs the removal of the winding section 434.

[0346] Figure 13D This shows the first winding segment 434 being removed from the mandrel 430. Then it is repeated. Figure 13C and 13D The process continues until all tubular elements 425 have been removed from the mandrel 430. When the wound sections 434 are removed from the mandrel, they are reconnected... Figure 12 The removed end piece 435 in B forms a new mandrel in preparation for forming another tubular subassembly.

[0347] It should be understood that this relates to the combination and formation of tubular elements with different outer diameters. Figures 5 to 7B Methods and related to the formation of tubular elements with different inner diameters Figures 8 to 13D This method may produce tubular elements with different inner and outer diameters, for example... Figure 4 The tubular element C. In this case, the cut sheet will have two opposing discontinuous edges, and the cut sheet will begin to be wound from one of the discontinuous edges.

[0348] Example

[0349] The following examples illustrate in detail how to use the methods described herein to produce specific tubular elements, namely, Figure 14AThe diagram shows a tubular element 500 with different outer diameters and a constant inner diameter, illustrated in a schematic longitudinal section. The tubular element 500 has a first tubular portion 502 with a first outer diameter D1 of 5 mm and a length L1 of 6 mm. The tubular element 500 has a second tubular portion 504 with a second outer diameter D2 of 7 mm and a length L2 of 9 mm. Therefore, the overall length Lp of the tubular element 500 is 15 mm. The tubular element 500 has a constant inner diameter d of 3 mm along its entire length.

[0350] Figure 14B It shows the method for forming Figure 14A 500 tubular elements and 510 cut sheet. Figure 14B The structure of the 510 cutting sheet is similar to Figure 5 The cut sheet is 300, and Figure 14B The dimensions of the cut sheet 500 have been similarly marked. The cut sheet 510 is configured to produce a tubular subassembly of twelve tubular elements, each having a length Lp of 15 mm. The portion of the cut sheet 510 corresponding to each tubular element (i.e., the portion of the cut sheet 510 having a width Lp) each has a first sheet portion 510a with a width L1 of 6 mm and a second sheet portion 300b with a width L2 of 9 mm. Figure 14B The cut sheet 510 is configured to produce six pairs of symmetrical tubular elements, each pair being arranged back-to-back. That is, in each symmetrical pair, the second sheet portion 510b is arranged adjacent to each other. Each pair of symmetrical tubular elements has a length La (equal to 2Lp) of 30 mm, and the total width Ls (equal to 6La) of the sheet is 180 mm.

[0351] One side of the cut sheet 510 has a continuous edge 512, and the opposite side of the cut sheet 510 has a discontinuous edge 514. A notch 516 has been made from each first sheet portion 510a of the cut sheet 510 to form the discontinuous edge 514. Due to the notch 516, the first sheet portion 510a has a length H1 in a direction perpendicular to the winding axis or perpendicular to the continuous edge 512, and the second sheet portion 510b has a length H1+H2. To form a tubular element 500 with different outer diameters D1 and D2, the continuous edge 512 of the cut sheet 500 is first fed to a rotating mandrel, causing the cut sheet 500 to begin winding around the mandrel with the continuous edge 512. The discontinuous edge 514 with the notch 516 is wound last, and the second sheet portion 510b will be provided with additional thickness to achieve a larger outer diameter D2.

[0352] The web material chosen for manufacturing the tubular element 500 is uncoated 70 g / m² standard paper. The thickness (Ts) of this paper is approximately 90 micrometers. Before winding, one surface of the cut sheet is uniformly coated with a fast-acting adhesive, such as EVA, but a long-lasting adhesive, such as PVA, can be applied to the areas of the cut sheet that will define the ends of the tubular element to more firmly adhere the edges of the sheet in these areas and prevent them from collapsing into the central cavity of the tubular element. Assume the adhesive thickness (Tg) is 5 micrometers.

[0353] Applying Equations 1 and 2 above, the number of web material sheets N1 required for the first outer diameter D1 of the first tubular portion 502 of the tubular element 500 is 11, and the corresponding length H1 of the first sheet portion 510a is 130 mm. Applying Equations 1 and 2 again, the number of web material sheets N2 required for the second outer diameter D2 of the second tubular portion 504 of the tubular element 500 is 21, and the corresponding length H1 + H2 of the second sheet portion 510b is 325.5 mm. Therefore, the length H2 is equal to the difference between these two lengths, which is 195.5 mm.

[0354] In order to produce twelve tubular elements per second, or 720 tubular elements per minute, the winding speed of the central mandrel should be 21 revolutions per second (1260 revolutions per minute), which is the same as the number of layers for the maximum outer diameter D2 of the second tubular section 504.

[0355] Figure 15A This is a schematic longitudinal cross-sectional view of another tubular element 600 used for aerosol generation products. Figure 15A The tubular element 600, shown schematically in a longitudinal section, has a different inner diameter and a constant outer diameter. The tubular element 600 has a first tubular portion 602 having a first inner diameter d1 and a length L1. The tubular element 600 has a second tubular portion 604 having a second inner diameter d2 and a length L2. The second inner diameter d2 is smaller than the first inner diameter d1. The inner diameter of the tubular element 600 tapers inward along the length L1 of the first tubular portion 602, such that the inner diameter continuously decreases until it reaches the second inner diameter d2. The inner diameter of the tubular element 600 tapers outward along the length L2 of the second tubular portion 604, such that the inner diameter continuously increases until it again reaches the first inner diameter d1. Due to its tapered inner diameter, and particularly its smaller second inner diameter d2, the tubular element 600 can act as a venturi or throttling valve to accelerate the flow of air or aerosol through the tubular element 600. When air or aerosol flows through the tubular element 600, the reduced diameter creates a low-pressure area, which can help homogenize the aerosol and improve its quality.

[0356] The overall length Lp of the tubular element 600 is equal to L1 + L2. The tubular element 600 has a constant outer diameter D along its entire length. The tubular element 600 is formed from a single wound sheet of web material. The sheet is wound on itself such that the tubular element 600 comprises multiple wound layers 606 of a single sheet of web material.

[0357] Figure 15B It shows the method for forming Figure 15A The tubular element 600 is cut sheet 610. Figure 15B The configuration of the 610 cutting sheet is similar to Figure 5 The cut sheet is 300, and Figure 15B The dimensions of the cut sheet 610 have been similarly marked. The cut sheet 610 is configured to produce tubular subassemblies of three tubular elements, each having a length Lp. The portion of the cut sheet 610 corresponding to each of the tubular elements (i.e., the portion of the cut sheet 610 having a width Lp) each has a first sheet portion 610a with a width L1 and a second sheet portion 610b with a width L2.

[0358] One side of the cut sheet 610 has a continuous edge 612, and the opposite side of the cut sheet 610 has a discontinuous edge 614. A cut 616 has been made from each first sheet portion 610a of the cut sheet 610, and a cut 617 has been made from each second sheet portion 610b of the cut sheet 610a to form the discontinuous edge 614. Cuts 616 and 617 are triangular, i.e., the cut edges are formed at an angle to the winding axis. The triangular cuts 616 and 617 are formed. Figure 15A The tubular element 600 has a tapered inner diameter. To form the tubular element 600 with a tapered inner diameter, the discontinuous edges 614 of the cut sheet 610 are first fed to a rotating mandrel, causing the cut sheet 610 to begin winding around the mandrel with the discontinuous edges 614. To form individual tubular elements 600, tubular sub-assemblies formed by winding the cut sheet 610 can be cut along the cut line 618.

[0359] For the purposes of this specification and the appended claims, unless otherwise indicated, all figures representing quantities, quantities, percentages, etc., shall be understood to be modified by the term "about" in all cases. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein. Thus, in this context, the number A is understood to be 5 percent (5%) of A ± A. In this context, the number A can be considered to include a value within the general standard error for 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 listed above, provided that the amount of deviation from A does not materially affect the essential and novel features of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein.

Claims

1. An aerosol-generating article, said aerosol-generating article comprising: A matrix element, the matrix element comprising an aerosol-generating matrix; as well as A tubular element having an inner cavity defining at least one airflow conduit, the at least one airflow conduit establishing uninterrupted fluid communication between an upstream end and a downstream end of the tubular element, the tubular element comprising a first tubular portion and a second tubular portion. The first tubular portion and the second tubular portion each constitute at least 10% of the length of the tubular element, and the tubular element is formed as an integral element; The first tubular portion has a first inner diameter, and the second tubular portion has a second inner diameter, wherein the first inner diameter is different from the second inner diameter; or The first tubular portion has a first outer diameter, and the second tubular portion has a second outer diameter, wherein the first outer diameter is different from the second outer diameter; and The aerosol generating article further includes a ventilation zone disposed along the second tubular portion.

2. The aerosol generating article according to claim 1, wherein the difference between the inner and outer diameters is formed by steps in the inner or outer surface of the tubular element.

3. The aerosol-generating article according to claim 1 or 2, wherein the difference between the inner diameter and the outer diameter is at least 1 mm.

4. The aerosol generating article according to any one of claims 1 to 3, wherein the tubular element is formed from a single wound sheet of web material.

5. The aerosol generating article according to claim 4, wherein the tubular element comprises a plurality of wound layers of a single sheet of web material, the first tubular portion and the second tubular portion each having a different number of wound layers.

6. The aerosol-generating article according to claim 4 or 5, wherein the web material sheet comprises one or more of paper, cardboard, cellulose acetate tow, or polylactic acid (PLA).

7. The aerosol generating article according to any of the preceding claims, wherein the first tubular portion and the second tubular portion have different first outer diameters and second outer diameters, respectively, and the matrix element includes a capsule for containing the aerosol generating matrix.

8. The aerosol-generating article according to claim 7, wherein the first outer diameter is smaller than the second outer diameter.

9. The aerosol generating article according to claim 7 or 8, wherein the inner diameter of the tubular element is smaller than the outer diameter of the capsule.

10. The aerosol generating article according to any one of claims 1 to 6, wherein the first tubular portion and the second tubular portion have different first inner diameters and second inner diameters, and the second inner diameter is larger than the first inner diameter.

11. The aerosol-generating article according to claim 10, wherein the ratio of the second inner diameter to the first inner diameter is between 1.2 and 1.

8.

12. The aerosol generating article according to any preceding claim, wherein the tubular element further comprises a third tubular portion constituting at least 10% of the length of the tubular element; The first tubular portion and the second tubular portion have different first inner diameters and second inner diameters, respectively, and the third tubular portion has an outer diameter different from that of the first tubular portion and the second tubular portion; or The first tubular portion and the second tubular portion have different first outer diameters and second outer diameters, respectively, and the third tubular portion has an inner diameter different from that of the first tubular portion and the second tubular portion.

13. The aerosol generating article according to any of the preceding claims, wherein the ventilation zone includes a plurality of ventilation holes or perforations through the peripheral wall of the second tubular portion.

14. The aerosol-generating article of claim 13, wherein the ventilation zone comprises at least one row of circumferential perforations.

15. The aerosol-generating article of claim 14, wherein the ventilation zone comprises multiple rows of circumferential perforations.

16. The aerosol-generating article according to claim 14 or 15, wherein each row of circumferential perforations comprises 8 to 30 perforations.

17. The aerosol generating article according to any of the preceding claims, wherein the aerosol generating article has a ventilation level of at least about 5%.

18. The aerosol generating article according to any of the preceding claims, wherein the matrix element is disposed upstream of and adjacent to the tubular element.

19. The aerosol generating article according to any of the preceding claims, wherein the matrix element comprises a receptor.

Images