Aerosol-generating article having a tubular element

Abstract

An aerosol-generating article (10; 400) is provided, comprising a plurality of elements assembled in the form of a strip. The plurality of elements includes a matrix element (16; 416) comprising an aerosol-forming matrix (48), and a tubular element (18; 418). The tubular element (18; 418) is an integral element comprising a first tubular portion (22), a second tubular portion (24), and a folded portion (26). The first tubular portion (22) defines a cavity (32) extending from a first end (28) of the first tubular portion (22) to a second end (34) of the first tubular portion (22). The second tubular portion (24) is at least partially positioned within the cavity (32) defined by the first tubular portion (22), and the second tubular portion (24) forms an air inlet in fluid communication with the cavity (32). The folded portion (26) extends between the first end (28) of the first tubular portion (22) and the second tubular portion (24).

Description

Technical Field

[0001] The present invention relates to an aerosol generating article having a tubular element, the tubular element comprising a first tubular portion and a second tubular portion. Background Technology

[0002] Aerosol-forming articles in which an aerosol-forming matrix, such as a tobacco-containing matrix, is heated rather than burned, are known in the art. Typically, in such heated aerosol-forming articles, an aerosol is generated by transferring heat from a heat source to a physically separated aerosol-forming matrix or material, which may be positioned in contact with, within, around, or downstream of the heat source. During use of the aerosol-forming article, volatile compounds are released from the aerosol-forming matrix through heat transfer from the heat source and are entrained in the air drawn through the aerosol-forming article. When 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 forming matrix of the heated aerosol generating article. For example, electrically heated aerosol generating apparatuses have been proposed that include internal resistance heater blades adapted to be inserted into the aerosol forming matrix. Alternatively, inductively heated aerosol generating articles include sensor elements disposed within the aerosol forming 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-forming 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 separate second tubular rod serving as an air cooler for cooling 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 and has a different inner diameter compared to the first tubular rod. For example, the first tubular rod may have a smaller inner diameter to resist or prevent movement of the matrix rod within the article, for example, when internal resistance heater blades are inserted into the matrix rod.

[0005] Aerosol-generating articles in the form of inhaler articles (such as dry powder inhalers) are known in the art. Some dry powder inhalers have components (such as a capsule) for storing dry powder. 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 separate, smaller tubular rod is secured to the first tubular rod on the capsule-facing side. The smaller diameter of the second tubular rod provides a recess or groove between its outer tubular surface and the inner surface of the aerosol-generating article. This recess or groove collects the dry powder and reduces the likelihood of leakage after the capsule has been punctured (e.g., when the article is tilted).

[0007] Manufacturing and assembling the first and second tubular rods of both heated and unheated aerosol-generating articles (such as dry powder inhalers) can be challenging because airflow is confined within their internal cavities. 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 airflow path through the aerosol-generating article, and therefore, the adjacency and concentric alignment of the first and second tubular rods are crucial. 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 this disclosure, an aerosol-generating article is provided, comprising a plurality of elements assembled in the form of a strip. The plurality of elements may include: a matrix element comprising an aerosol-forming matrix, and a tubular element. The tubular element may include a first tubular portion defining a cavity extending from a first end of the first tubular portion to a second end of the first tubular portion. The tubular element may include a second tubular portion at least partially positioned within the cavity defined by the first tubular portion, the second tubular portion forming an air inlet in fluid communication with the cavity. The tubular element may include a folded portion extending between the first end of the first tubular portion and the second tubular portion.

[0010] According to an embodiment of this disclosure, an aerosol-generating article is provided, comprising a plurality of elements assembled in the form of a strip. The plurality of elements includes: a matrix element comprising an aerosol-forming matrix, and a tubular element. The tubular element includes a first tubular portion defining a cavity extending from a first end of the first tubular portion to a second end of the first tubular portion. The tubular element further includes a second tubular portion at least partially positioned within the cavity defined by the first tubular portion, the second tubular portion forming an air inlet in fluid communication with the cavity. The tubular element also includes a folded portion extending between the first end of the first tubular portion and the second tubular portion.

[0011] The term "aerosol-forming article" is used herein to refer to an article in which an aerosol-forming matrix is ​​heated to generate an inhalable aerosol and delivered to a consumer. As used herein, the term "aerosol-forming matrix" refers to a matrix that can form or generate an aerosol. An aerosol-forming matrix may be able to release volatile compounds to generate an aerosol when heated.

[0012] 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 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 the aerosol-generating article.

[0013] As used herein, the term "length" refers to the dimension of a component of an 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.

[0014] Aerosol-generating articles according to examples of this disclosure include tubular elements comprising a first tubular portion, a second tubular portion, and a folded portion. In other words, the tubular element is an integral element. The term "integral element" is used herein to refer to a tubular element formed as a single piece or a single component. In other words, the first tubular portion, the second tubular portion, and the folded portion are formed as a single piece or a single 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 together during the manufacture of the aerosol-generating article. The tubular element can be formed as an integral element by being made from a single piece of material (e.g., a single web material sheet).

[0015] By forming the tubular element as a single, integral component, it advantageously becomes a single piece. Advantageously, this eliminates any difficulties in positioning the first and second tubular portions relative to each other compared to forming the first and second tubular portions as separate components. For example, there is no need to precisely align the first and second tubular portions abutting each other, as the integral tubular element automatically achieves this construction advantage. The integral nature of the tubular element also ensures axial alignment of the first and second tubular portions. Advantageously, this ensures smooth airflow through the tubular element and contributes to providing a consistent consumer experience.

[0016] The first end may be the upstream end of the first tubular portion, wherein the folded portion extends between the upstream end of the first tubular portion and the downstream end of the second tubular portion. Advantageously, the folded portion extending between the downstream end of the second tubular portion and the upstream end of the first tubular portion can facilitate the formation of the tubular element by applying one or more folding steps only to the tubular precursor, wherein the tubular precursor may be a simple tubular body.

[0017] The downstream end of the second tubular portion can be positioned within the cavity. Advantageously, this arrangement can produce a tubular element in which the first tubular portion has a larger inner diameter compared to the second tubular portion. This may be particularly advantageous in embodiments in which the second tubular portion abuts a matrix element comprising an aerosol-forming matrix. For example, the smaller diameter of the second tubular portion can resist or prevent movement of the matrix element within the aerosol-forming article, for example, when the internal resistance heater blades are inserted into the matrix element.

[0018] In some instances, the folded portion extends between the upstream end of the first tubular portion and the downstream end of the second tubular portion, with the downstream end of the second tubular portion positioned within the cavity. Advantageously, in this arrangement, the folded portion can resist or prevent further movement of the second tubular portion into the cavity. Furthermore, in this arrangement, the folded portion can define an annular recess extending between the upstream end of the first tubular portion and the downstream end of the second tubular portion. In embodiments where the matrix element comprises a capsule containing an aerosol-forming matrix and the aerosol-forming matrix comprises powder, the annular recess can be particularly advantageous because it can collect the powder and reduce the likelihood of powder leaking out of the aerosol-generating article after the capsule has been punctured.

[0019] The upstream end of the second tubular portion can be positioned outside the cavity. The upstream end of the second tubular portion can be flush with the upstream end of the first tubular portion. The second tubular portion can be completely positioned inside the cavity.

[0020] Preferably, the angle between the folded portion and the inner surface of the first tubular portion is less than 90 degrees. For example, the angle between the folded portion and the inner surface of the first tubular portion may be less than 85 degrees, less than 80 degrees, less than 75 degrees, less than 70 degrees, less than 65 degrees, less than 60 degrees, less than 55 degrees, less than 50 degrees, or less than 45 degrees.

[0021] Preferably, the angle between the folded portion and the outer surface of the second tubular portion is less than 90 degrees. For example, the angle between the folded portion and the outer surface of the second tubular portion may be less than 85 degrees, less than 80 degrees, less than 75 degrees, less than 70 degrees, less than 65 degrees, less than 60 degrees, less than 55 degrees, less than 50 degrees, or less than 45 degrees.

[0022] Preferably, the angle between the inner surfaces of the folded portion and the first tubular portion is the same as the angle between the outer surfaces of the folded portion and the second tubular portion. Advantageously, this arrangement can provide a folded portion with a substantially linear cross-sectional profile, and coaxial alignment of the second tubular portion with the first tubular portion. Advantageously, this facilitates the formation of tubular elements from the tubular body precursor using simple folding steps.

[0023] The first tubular portion may have a first inner diameter, and the second tubular portion may have a second inner diameter. The first inner diameter may be uniform or constant along the length of the first tubular portion. The second inner diameter may be uniform or constant along the length of the second tubular portion.

[0024] The second inner diameter may be smaller than the first inner diameter. The difference between the first inner diameter and the second inner diameter may be at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, or at least 6 mm.

[0025] The first inner diameter may be at least 4 mm, at least 4.5 mm, at least 5 mm, at least 5.5 mm, at least 6 mm, at least 6.5 mm, at least 7 mm, at least 7.5 mm, at least 8 mm, or at least 8.5 mm. The first inner diameter may be less than 9 mm, less than 8.5 mm, less than 8 mm, less than 7.5 mm, less than 7 mm, less than 6.5 mm, less than 6 mm, less than 5.5 mm, less than 5 mm, or less than 4.5 mm. The first inner diameter may be between 4 mm and 9 mm, between 5 mm and 8.5 mm, between 6 mm and 8.5 mm, between 6.5 mm and 8 mm, or between 6.5 mm and 7.5 mm.

[0026] The second inner diameter may be at least 1 mm, at least 1.25 mm, at least 1.5 mm, at least 1.75 mm, at least 2 mm, at least 2.25 mm, at least 2.5 mm, at least 2.75 mm, at least 3 mm, at least 3.25 mm, at least 3.5 mm, or at least 3.75 mm. The second inner diameter may be less than 4 mm, less than 3.75 mm, less than 3.5 mm, less than 3.25 mm, less than 3 mm, less than 2.75 mm, less than 2.5 mm, less than 2.25 mm, less than 2 mm, less than 1.75 mm, less than 1.5 mm, or less than 1.25 mm. The second inner diameter may be between 1 mm and 4 mm, between 2 mm and 3 mm, or between 2.25 mm and 2.75 mm.

[0027] The first tubular portion may have a first length, and the second tubular portion may have a second length. The second length may be less than the first length.

[0028] Advantageously, providing a second tubular portion that is shorter than the first tubular portion can reduce the material required to form the tubular element. This may be particularly advantageous in instances where the second tubular portion has a smaller inner diameter than the first tubular portion and is only provided to resist or prevent movement of the matrix element within the aerosol-generating article.

[0029] The second length may be less than 50%, less than 45%, less than 40%, less than 35%, less than 30%, less than 25%, less than 20%, less than 15%, or less than 10% of the first length.

[0030] The first length may be at least 10 mm, at least 13 mm, at least 15 mm, at least 20 mm, at least 25 mm, at least 30 mm, or at least 35 mm. The first length may be less than 40 mm, less than 35 mm, less than 30 mm, less than 25 mm, less than 20 mm, less than 15 mm, or less than 13 mm. The first length may be between 10 mm and 40 mm, between 10 mm and 30 mm, or between 10 mm and 20 mm. The first length may be between 13 mm and 30 mm, between 16 mm and 27 mm, or between 18 mm and 23 mm.

[0031] The first tubular portion may have a first outer diameter, and the second tubular portion may have a second outer diameter. The first outer diameter may be uniform or constant along the length of the first tubular portion. The second outer diameter may be uniform or constant along the length of the second tubular portion.

[0032] The second outer diameter may be smaller than the first outer diameter. The difference between the first outer diameter and the second outer diameter may be at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, or at least 6 mm.

[0033] The first outer diameter may be at least 4 mm, at least 4.5 mm, at least 5 mm, at least 5.5 mm, at least 6 mm, at least 6.5 mm, at least 7 mm, at least 7.5 mm, at least 8 mm, or at least 8.5 mm. The first outer diameter may be less than 9 mm, less than 8.5 mm, less than 8 mm, less than 7.5 mm, less than 7 mm, less than 6.5 mm, less than 6 mm, less than 5.5 mm, less than 5 mm, or less than 4.5 mm. The first outer diameter may be between 4 mm and 9 mm, between 5 mm and 8.5 mm, between 6 mm and 8.5 mm, between 6.5 mm and 8 mm, or between 6.5 mm and 7.5 mm.

[0034] The second outer diameter may be at least 1 mm, at least 1.25 mm, at least 1.5 mm, at least 1.75 mm, at least 2 mm, at least 2.25 mm, at least 2.5 mm, at least 2.75 mm, at least 3 mm, at least 3.25 mm, at least 3.5 mm, or at least 3.75 mm. The second outer diameter may be less than 4 mm, less than 3.75 mm, less than 3.5 mm, less than 3.25 mm, less than 3 mm, less than 2.75 mm, less than 2.5 mm, less than 2.25 mm, less than 2 mm, less than 1.75 mm, less than 1.5 mm, or less than 1.25 mm. The second outer diameter may be between 1 mm and 4 mm, between 2 mm and 3 mm, or between 2.25 mm and 2.75 mm.

[0035] In an example where the downstream end of the second tubular portion is positioned within the cavity, the longitudinal distance between the upstream end of the first tubular portion and the downstream end of the second tubular portion may be referred to as the overlap length. The overlap length may be at least 0.5 mm, at least 0.75 mm, at least 1 mm, at least 1.25 mm, at least 1.5 mm, at least 1.75 mm, at least 2 mm, at least 2.25 mm, at least 2.5 mm, or at least 2.75 mm. The overlap length may be less than 3 mm, less than 2.75 mm, less than 2.5 mm, less than 2.25 mm, less than 2 mm, less than 1.75 mm, less than 1.5 mm, less than 1.25 mm, less than 1 mm, or less than 0.75 mm. The overlap length may be between 0.5 mm and 3 mm, between 0.75 mm and 1.5 mm, or between 0.9 mm and 1.1 mm.

[0036] The tubular element may have a length of at least 10 mm, at least 13 mm, at least 15 mm, at least 20 mm, at least 25 mm, at least 30 mm, or at least 35 mm. The length of the tubular element may be less than 40 mm, less than 35 mm, less than 30 mm, less than 25 mm, less than 20 mm, less than 15 mm, or less than 13 mm. The length of the tubular element may be between 10 mm and 40 mm, between 10 mm and 30 mm, or between 10 mm and 20 mm. The length of the tubular element may be between 13 mm and 30 mm, between 16 mm and 27 mm, or between 18 mm and 23 mm.

[0037] The tubular element may include at least one airflow orifice extending through the folded portion. Advantageously, the at least one airflow orifice may provide at least one additional path for air to flow into the cavity. In particular, airflow may enter the cavity through the second tubular portion and through the at least one airflow orifice.

[0038] At least one airflow orifice may include multiple airflow orifices. Multiple airflow orifices may include two, three, four, five, six, seven, eight, nine, or ten airflow orifices. Preferably, the airflow orifices are arranged symmetrically around the folded portion.

[0039] The tubular element can be formed from any suitable material. It can be formed from one or more of paper, cardboard, cellulose acetate tow, or polylactic acid (PLA). In a preferred embodiment, the tubular element is formed from at least one of paper and cardboard. Advantageously, forming tubular elements from at least one of paper and cardboard can provide one or more environmental and sustainability advantages compared to tubular segments formed from polymeric materials such as acetate.

[0040] The tubular element can be formed from a material with a basis weight between 100 g / m² and 700 g / m², preferably between 100 g / m² and 400 g / m².

[0041] Preferably, the tubular element is positioned adjacent to the matrix element. Preferably, the tubular element is adjacent to the matrix element. Preferably, the second tubular portion is adjacent to the matrix element.

[0042] The matrix element may have a maximum outer diameter. Preferably, the maximum outer diameter of the matrix element is greater than the inner diameter of the second tubular portion. The difference between the maximum outer diameter and the second inner diameter of the matrix element may be at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, or at least 6 mm.

[0043] Multiple components may include a mouthpiece element. The mouthpiece element may be positioned downstream of the aerosol-generating article. A tubular element may be positioned between the matrix element and the mouthpiece element. Preferably, the mouthpiece element is positioned immediately downstream of the tubular element.

[0044] The upstream end of the matrix element may define the upstream end of the aerosol-generating article. The upstream end of the tubular element may be adjacent to the downstream end of the matrix element. The upstream end of the mouthpiece element may be adjacent to the downstream end of the tubular element. The downstream end of the mouthpiece element may define the downstream end of the aerosol-generating article.

[0045] The mouthpiece element may include at least one mouthpiece filter segment of fibrous filter material for filtering aerosols generated from an aerosol-forming matrix. Suitable fibrous filter materials are 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.

[0046] Preferably, the mouthpiece element has a low particle filtration efficiency.

[0047] 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.

[0048] The mouthpiece element is preferably connected to one or more adjacent upstream components of the aerosol-generating article by means of a tipping package.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] The aerosol-generating article may include a ventilation zone located along the tubular element. Preferably, the ventilation zone is located along the first tubular portion.

[0053] Advantageously, the ventilation zone can provide desired cooling for the aerosol flow generated during the heating of the aerosol-forming matrix and drawn through the tubular element.

[0054] The ventilation zone may include a plurality of ventilation holes or perforations through the peripheral wall of the first tubular portion. Preferably, the ventilation zone includes at least one row of circumferential perforations. In some instances, the ventilation zone may include two rows of circumferential perforations. Preferably, each row of circumferential perforations includes 8 to 30 perforations.

[0055] Aerosol-generating products can have a ventilation level of at least about 5%.

[0056] The term "ventilation level" is used herein to refer to the volume ratio of the airflow (ventilation flow) permitted to enter the aerosol-generating article via a ventilated area to the sum of the aerosol flow and the ventilation flow. The higher the ventilation level, the higher the dilution of the aerosol stream delivered to the consumer.

[0057] 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 30%.

[0058] Preferably, the matrix element is positioned immediately upstream of the tubular element. Preferably, the matrix element is adjacent to the upstream end of the tubular element.

[0059] Preferably, the matrix element is defined by a rod package.

[0060] Preferably, the matrix element has an outer diameter approximately equal to the outer diameter of the aerosol-generating 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.

[0061] 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.

[0062] 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.

[0063] The aerosol forming matrix can be a solid aerosol forming matrix. The aerosol forming matrix can also be an aerosol forming matrix strip.

[0064] The aerosol forming matrix preferably includes an aerosol forming agent.

[0065] Aerosol forming agents can be any suitable known compound or mixture of compounds that facilitates the formation of a dense and stable aerosol during use. Aerosol forming agents facilitate the thermal degradation of the aerosol at temperatures typically applied during the 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.

[0066] 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.

[0067] The aerosol forming matrix may include 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 forming matrix.

[0068] The aerosol forming matrix may include an aerosol forming agent of 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, based on the dry weight of the aerosol forming matrix.

[0069] The aerosol forming matrix may include an aerosol forming agent in the dry weight of the aerosol forming matrix at a concentration between about 5% and about 30% by weight, between about 5% and about 25% by weight, or between about 5% and about 20% by weight.

[0070] The aerosol forming matrix may include an aerosol forming agent at a dry weight of between about 10% and about 30% by weight, between about 10% and about 25% by weight, or between about 10% and about 20% by weight.

[0071] The aerosol forming matrix may include an aerosol forming agent in a dry weight of about 12% to about 30% by weight, about 12% to about 25% by weight, or about 12% to about 20% by weight.

[0072] The aerosol-forming matrix can contain tobacco.

[0073] The aerosol forming matrix may include multiple tobacco material strips. The aerosol forming matrix may include multiple homogenized tobacco material strips.

[0074] As used herein with reference to the invention, the term "strip" refers to an element whose length is substantially greater than its width and thickness.

[0075] As used herein with reference to the present invention, the term "homogenized tobacco material" is used to describe materials formed by agglomerating particulate tobacco material.

[0076] Homogenized tobacco strips can be formed from homogenized tobacco sheets, for example, by cutting or shredding. Homogenized tobacco strips can also be formed by other methods, such as extrusion.

[0077] The tobacco material 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.

[0078] 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.

[0079] The tobacco material 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.

[0080] The tobacco material 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.

[0081] The tobacco material 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.

[0082] The tobacco strip may have a width smaller than the inner diameter of the cavity defined by the first tubular portion. The tobacco strip may have a width substantially the same as the inner diameter of the cavity defined by the first tubular portion. The ratio of the width of the tobacco strip to the inner diameter of the cavity defined by the first tubular portion may be at least 0.5, at least 0.55, at least 0.6, at least 0.65, at least 0.7, at least 0.75, at least 0.8, at least 0.85, at least 0.9, or at least 0.95.

[0083] Preferably, the tobacco strip has a width greater than the inner diameter of the second tubular portion. Advantageously, providing a second tubular portion smaller than the tobacco strip facilitates holding the tobacco strip within the matrix element through the second tubular portion. The ratio of the inner diameter of the second tubular portion to the width of the tobacco strip may be less than 0.95, less than 0.9, less than 0.85, less than 0.8, less than 0.75, less than 0.7, less than 0.65, less than 0.6, less than 0.55, or less than 0.5.

[0084] The tobacco strips may have a length of at least about 10 millimeters.

[0085] Tobacco strips may have a length of about 40 millimeters or less.

[0086] The tobacco material strips can have a length between approximately 10 mm and approximately 40 mm.

[0087] At least about 20% by weight of a plurality of tobacco material strips, based on dry weight, may extend along the entire length of the matrix element. At least about 20% by weight of a plurality of tobacco material strips, based on dry weight, may have a length substantially the same as the length of the matrix element.

[0088] Multiple tobacco material strips, comprising less than or equal to about 60% by weight on a dry weight basis, may extend along the entire length of the matrix element. These multiple tobacco material strips, comprising less than or equal to about 60% by weight on a dry weight basis, may have a length substantially the same as the length of the matrix element.

[0089] Multiple tobacco material strips, ranging from approximately 20% to 60% by dry weight, may extend along the entire length of the matrix element. These multiple tobacco material strips, ranging from approximately 20% to 60% by dry weight, may have a length substantially the same as the length of the matrix element.

[0090] The dimensions of components of the aerosol forming matrix (such as multiple tobacco material strips) can affect the heat distribution within the aerosol forming matrix. Additionally, the dimensions of these components can influence the raw material demand (RTD) of the product.

[0091] The aerosol forming matrix may include multiple tobacco material pellets or particles. The aerosol forming matrix may include multiple homogenized tobacco material pellets or particles.

[0092] The aerosol forming matrix may include one or more tobacco material sheets.

[0093] The aerosol forming matrix may include one or more homogenized tobacco material sheets.

[0094] 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.

[0095] As used herein with reference to the present invention, 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 constituting the aerosol forming matrix. For example, if the aerosol forming 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 forming matrix, the measured thickness of the two tobacco material sheets.

[0096] 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.

[0097] 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.

[0098] 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.

[0099] 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.

[0100] One or more tobacco material sheets may each have a length substantially the same as the length of the aerosol-forming matrix.

[0101] One or more tobacco material sheets may have been rolled, folded, gathered, and pleated in one or more of the following ways:

[0102] The curling, folding, agglomeration, or pleating of one or more tobacco material sheets can cause the separation of one or more tobacco material sheets to form tobacco material strips. For example, one or more tobacco material sheets may be curled to such an extent that the integrity of one or more tobacco material sheets is disrupted at multiple parallel ridges or corrugations, thereby causing the separation of the material and resulting in the formation of tobacco material strips.

[0103] The matrix element may include a capsule, wherein the aerosol-forming matrix is ​​contained within the capsule.

[0104] The capsule may include a first fragile portion at the upstream end of the capsule and a second fragile portion at the downstream end of the capsule. Advantageously, the first and second fragile portions facilitate puncturing the capsule before using the aerosol-generated article.

[0105] The sac may have an outer diameter smaller than the inner diameter of the lumen defined by the first tubular portion. The sac may have an outer diameter substantially the same as the inner diameter of the lumen defined by the first tubular portion. The ratio of the outer diameter of the sac to the inner diameter of the lumen defined by the first tubular portion may be at least 0.5, at least 0.55, at least 0.6, at least 0.65, at least 0.7, at least 0.75, at least 0.8, at least 0.85, at least 0.9, or at least 0.95.

[0106] Preferably, the capsule has an outer diameter larger than the inner diameter of the second tubular portion. Advantageously, providing a second tubular portion smaller than the capsule facilitates holding the capsule in a desired position within the aerosol-generating article via the second tubular portion. The ratio of the inner diameter of the second tubular portion to the outer diameter of the capsule may be less than 0.95, less than 0.9, less than 0.85, less than 0.8, less than 0.75, less than 0.7, less than 0.65, less than 0.6, less than 0.55, or less than 0.5.

[0107] 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 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.

[0108] The capsule may contain pharmaceutically active particles such as nicotine granules. As used herein, the term "nicotine" may refer to nicotine and nicotine derivatives, such as free nicotine bases, nicotine salts, etc.

[0109] The capsule may contain one or more nicotine salts.

[0110] Pharmaceutically active particles may have a median aerodynamic diameter of about 5 micrometers or less, or about 4 micrometers or less.

[0111] Pharmaceutically active particles may have a median aerodynamic diameter of at least about 0.5 micrometers or at least about 1 micrometer.

[0112] Pharmaceutically active particles may have a median aerodynamic diameter between approximately 0.5 micrometers and approximately 4 micrometers.

[0113] The capsule may contain enough nicotine particles to provide at least 2 inhalations or "puffs", at least 5 inhalations or "puffs", or at least 10 inhalations or "puffs".

[0114] 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.

[0115] The capsule may hold or contain at least about 5 mg of nicotine particles or at least about 10 mg of nicotine particles.

[0116] The capsule may hold or contain less than or equal to about 900 mg of nicotine particles, less than or equal to about 300 mg of nicotine particles, or less than or equal to about 150 mg of nicotine particles.

[0117] The capsule may contain flavor particles.

[0118] The matrix element may include a receptor element. Preferably, the receptor element is disposed within the aerosol forming matrix.

[0119] The term "receptor" is used in this article to refer 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.

[0120] Preferably, the receptor element is arranged in thermal contact with the aerosol forming matrix. Therefore, when the receptor element heats up, the aerosol forming matrix is ​​heated by the receptor element to generate aerosols. The receptor element can be arranged in direct physical contact with the aerosol forming matrix.

[0121] The receptor element can be a slender receptor element.

[0122] The term "slender" is used in this document to describe components of aerosol-generated articles whose length is greater than their width and thickness.

[0123] Elongated receptor elements can be arranged substantially longitudinally within the aerosol-forming matrix. In other words, the longitudinal axis of the elongated receptor element can be approximately parallel to the longitudinal axis of the matrix element. For example, the longitudinal axis of the elongated receptor element can be within ±10 degrees of the longitudinal axis of the matrix element. The elongated receptor element can be located at the radial center within the aerosol-forming matrix and extend along the longitudinal axis of the matrix element.

[0124] The receptor element can extend from the downstream end of the aerosol forming matrix toward the upstream end of the aerosol forming matrix.

[0125] The receptor element can extend from the upstream end of the aerosol forming matrix toward the downstream end of the aerosol forming matrix.

[0126] The receptor element can extend from the upstream end of the aerosol-forming matrix to the downstream end of the aerosol-forming matrix. In other words, the receptor element can extend along the entire length of the aerosol-forming matrix.

[0127] The length of the receptor element can be substantially the same as the length of the matrix element.

[0128] The receptor element can extend partially along the length of the matrix element.

[0129] The receptor element can be spaced apart from the downstream end of the matrix element.

[0130] The receptor element can be spaced apart from the upstream end of the matrix element.

[0131] The receptor element can be spaced apart from both the downstream and upstream ends of the matrix element.

[0132] The length of the receptor element can be smaller than the length of the matrix element.

[0133] The receptor element can be completely encapsulated within the aerosol-forming matrix. In other words, the aerosol-forming matrix can completely surround the receptor element.

[0134] Receptor elements can take the form of needles, strips, strips, or blades.

[0135] The receptor element may have a length of at least about 5 mm, at least about 6 mm, or at least about 8 mm. The receptor element 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.

[0136] 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.

[0137] The receptor element 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.

[0138] The receptor element 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.

[0139] The receptor element may have a width of at least about 1 mm.

[0140] The sensor element may have a width of less than or equal to about 5 millimeters.

[0141] The sensor element may have a width between approximately 1 mm and approximately 5 mm.

[0142] The receptor element may have a width smaller than the inner diameter of the cavity defined by the first tubular portion. The receptor element may have a width substantially the same as the inner diameter of the cavity defined by the first tubular portion. The ratio of the width of the receptor element to the inner diameter of the cavity defined by the first tubular portion may be at least 0.5, at least 0.55, at least 0.6, at least 0.65, at least 0.7, at least 0.75, at least 0.8, at least 0.85, at least 0.9, or at least 0.95.

[0143] Preferably, the receptor element has a width greater than the inner diameter of the second tubular portion. Advantageously, providing a second tubular portion smaller than the receptor element facilitates holding the receptor element within the matrix element through the second tubular portion. The ratio of the inner diameter of the second tubular portion to the width of the receptor element may be less than 0.95, less than 0.9, less than 0.85, less than 0.8, less than 0.75, less than 0.7, less than 0.65, less than 0.6, less than 0.55, or less than 0.5.

[0144] The sensor element may have a thickness of at least about 0.01 mm or at least about 0.5 mm.

[0145] The sensor element may have a thickness of less than or equal to about 2 mm, less than or equal to about 500 micrometers, or less than or equal to about 100 micrometers.

[0146] The sensor element 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.

[0147] The sensor element may have a thickness between about 0.5 mm and about 2 mm.

[0148] The receptor element may have a substantially circular cross-section.

[0149] The receptor element may have a substantially constant cross section along the length of the receptor element.

[0150] If the receptor element is in the form of a strip or blade, the strip or blade 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 element in the form of a strip or blade may have a width of about 4 mm.

[0151] If the receptor element is in the form of a strip or 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 element in the form of a strip or blade may have a thickness of about 0.07 mm or about 0.06 mm.

[0152] The sensor element 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 sensor element may contain metal or carbon.

[0153] The sensor element may contain or be composed of ferromagnetic materials, such as ferromagnetic alloys, ferritic iron, ferromagnetic steel, or stainless steel. Suitable sensor elements may be aluminum or contain aluminum. The sensor may 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.

[0154] Therefore, parameters such as material type, length, width, and thickness of the sensor element can all be modified to provide the desired power dissipation within a known electromagnetic field. During use, the sensor element can be heated to temperatures exceeding 250 degrees Celsius.

[0155] Suitable receptor elements may include a non-metallic core having a metallic layer disposed on the non-metallic core, such as metallic traces formed on the surface of a ceramic core. The receptor element may have an outer protective layer, such as a ceramic or glass protective layer encapsulating the receptor material. The receptor element may include a protective coating formed of glass, ceramic, or an inert metal on the core of the receptor material.

[0156] The receptor element can be a multi-material receptor element, and may include a first receptor material and a second receptor material.

[0157] Aerosol-generating articles may include an upstream section located upstream of a matrix element. The upstream section may include one or more upstream elements. In some instances, the upstream section may include an upstream element disposed immediately upstream of 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 element.

[0158] 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.

[0159] 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.

[0160] The upstream element may have a length between about 2 mm and about 10 mm, or 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.

[0161] The aerosol generating article may also include packaging that defines at least one component of the aerosol generating article. The packaging may define at least a portion of the tubular element and at least one additional 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. 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.

[0162] The packaging material can be an outer packaging material. The packaging material can be the outermost packaging material. The outer surface of the packaging material can form at least a portion of the outer surface of the aerosol-generating article. The packaging material can be porous or equipped with ventilation devices.

[0163] Preferably, the packaging material is formed of paper. The packaging material may have a gram weight of at least 20 g / m², at least 40 g / m², at least 60 g / m², at least 80 g / m², at least 100 g / m², at least 120 g / m², at least 140 g / m², at least 160 g / m², or at least 180 g / m². The packaging material may have a gram weight of less than 200 g / m², less than 180 g / m², less than 160 g / m², less than 140 g / m², less than 120 g / m², less than 100 g / m², less than 80 g / m², less than 60 g / m², or less than 40 g / m². The packaging material may have a gram weight between 20 g / m² and 200 g / m², or between 50 g / m² and 100 g / m².

[0164] 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.

[0165] Example 1: An aerosol-generating article, the aerosol-generating article comprising a plurality of elements assembled in the form of strips, the plurality of elements comprising:

[0166] Including matrix elements of aerosol-forming matrices; and

[0167] A tubular element, the tubular element comprising:

[0168] A first tubular portion, the first tubular portion defining a cavity extending from a first end of the first tubular portion to a second end of the first tubular portion;

[0169] A second tubular portion, at least partially positioned within the cavity defined by the first tubular portion, the second tubular portion forming an air inlet in fluid communication with the cavity; and

[0170] The folded portion extends between the first end of the first tubular portion and the second tubular portion.

[0171] Example 2: An aerosol-generated article according to Example 1, wherein the first end is the upstream end of the first tubular portion, and wherein the folded portion extends between the upstream end of the first tubular portion and the downstream end of the second tubular portion.

[0172] Example 3: An aerosol-generated article according to Example 2, wherein the downstream end of the second tubular portion is positioned within the cavity.

[0173] Example 4: An aerosol-generated article according to Example 2 or 3, wherein the upstream end of the second tubular portion is positioned outside the cavity.

[0174] Example 5: An aerosol-generating article according to any one of Examples 2 to 4, wherein the upstream end of the second tubular portion is flush with the upstream end of the first tubular portion.

[0175] Example 6: An aerosol-generated article according to any of the preceding examples, wherein the second tubular portion is completely positioned within the cavity.

[0176] Example 7: An aerosol-generated article according to any of the preceding examples, wherein the angle between the folded portion and the inner surface of the first tubular portion is less than 90 degrees.

[0177] Example 8: An aerosol-generated article according to any of the preceding examples, wherein the angle between the folded portion and the outer surface of the second tubular portion is less than 90 degrees.

[0178] Example 9: An aerosol-generating article according to any of the preceding examples, wherein the first tubular portion has a first length, wherein the second tubular portion has a second length, and wherein the second length is less than the first length.

[0179] Example 10: The aerosol-generated article according to Example 9 has a second length that is less than 50%, less than 40%, less than 30%, less than 20%, or less than 10% of the first length.

[0180] Example 11: An aerosol-generating article according to any of the foregoing examples further includes at least one airflow orifice extending through the folded portion.

[0181] Example 12: An aerosol-generated article according to Example 11, wherein the at least one airflow orifice comprises a plurality of airflow orifices.

[0182] Example 13: An aerosol-generated article according to Example 12, wherein the airflow orifices are arranged symmetrically around the folded portion.

[0183] Example 14: An aerosol-generated article according to any of the preceding examples, wherein the tubular element is formed from at least one of paper and cardboard.

[0184] Example 15: An aerosol-generated article according to any of the preceding examples, wherein the tubular element is formed of a material with a basis weight between 100 g / m² and 700 g / m², preferably between 100 g / m² and 400 g / m².

[0185] Example 16: An aerosol-generating article according to any of the preceding examples, wherein the tubular element has a length between 10 mm and 30 mm, preferably between 15 mm and 25 mm, and preferably between 15 mm and 20 mm.

[0186] Example 17: An aerosol-generated article according to any of the preceding examples, wherein the tubular element is positioned adjacent to the matrix element.

[0187] Example 18: An aerosol-generated article according to any of the preceding examples, wherein the plurality of elements further includes a mouthpiece element.

[0188] Example 19: An aerosol-generating article according to Example 18, wherein the tubular element is positioned between the matrix element and the mouthpiece element.

[0189] Example 20: An aerosol generating article according to Example 19, wherein the upstream end of the matrix element defines the upstream end of the aerosol generating article, wherein the upstream end of the tubular element is adjacent to the downstream end of the matrix element, wherein the upstream end of the mouthpiece element is adjacent to the downstream end of the tubular element, and wherein the downstream end of the mouthpiece element defines the downstream end of the aerosol generating article.

[0190] Example 21: An aerosol-generating article according to any of the foregoing examples further includes a ventilation zone along the location of the tubular element.

[0191] Example 22: An aerosol generating article according to any of the foregoing examples, wherein the aerosol forming matrix is ​​an aerosol forming matrix strip, and wherein the matrix element further includes a receptor element disposed within the aerosol forming matrix strip.

[0192] Example 23: An aerosol-generating article according to Example 22, wherein the receptor element is an elongated receptor arranged longitudinally within the aerosol-forming matrix.

[0193] Example 24: An aerosol generating article according to any one of Examples 1 to 21, wherein the matrix element further includes a capsule, and wherein the aerosol forming matrix is ​​contained within the capsule.

[0194] Example 25: An aerosol-generating article according to Example 24, wherein the upstream end of the tubular element is adjacent to the downstream end of the capsule.

[0195] Example 26: An aerosol-generated article according to Example 24 or 25, wherein the capsule includes a first fragile portion at an upstream end of the capsule and a second fragile portion at a downstream end of the capsule. Attached Figure Description

[0196] The examples will now be described further with reference to the accompanying drawings, in which:

[0197] Figure 1 A cross-sectional view of an aerosol-generated article according to a first example of the present disclosure is shown;

[0198] Figure 2 It shows Figure 1 A cross-sectional view of a tubular element of an aerosol-generated product;

[0199] Figure 3 It shows Figure 2 A perspective view of the tubular element in the image;

[0200] Figures 4 to 13 It shows the method for forming Figure 2 and Figure 3 Exemplary methods and apparatus for tubular elements;

[0201] Figure 14 A cross-sectional view of an aerosol-generated article according to a second example of the present disclosure is shown;

[0202] Figure 15 It shows Figure 14 A cross-sectional view of a tubular element of an aerosol-generating article; and

[0203] Figure 16 It shows Figure 15 A perspective view of a tubular element. Detailed Implementation

[0204] Figure 1A cross-sectional view of an aerosol generating article 10 according to a first embodiment of the present disclosure is shown. The aerosol generating article 10 includes a plurality of elements assembled in the form of strips and axially aligned along the longitudinal direction 12 of the aerosol generating article 10.

[0205] Multiple components include an upstream component 14, a matrix component 16, a tubular component 18, and a mouthpiece component 20. An aerosol generating article 10 extends from an upstream end 15 to a downstream end 17. The aerosol generating article 10 has an overall length between approximately 60 mm and approximately 80 mm.

[0206] The tubular element 18 is located immediately downstream of the matrix element 16, and the tubular element 18 is longitudinally aligned with the matrix element 16. Figure 1 In one example, the upstream end of the tubular element 18 is adjacent to the downstream end of the matrix element 16. Figure 2 and Figure 3 The tubular element 18 is shown in more detail.

[0207] The tubular element 18 includes a first tubular portion 22 and a second tubular portion 24 connected to the first tubular portion 22 via a folded portion 26 having an annular shape. The folded portion 26 extends between an upstream end 28 of the first tubular portion 22 and a downstream end 30 of the second tubular portion 24. The folded portion 26 has a linear cross-sectional shape that forms an angle of less than 90 degrees with respect to the inner surface of the first tubular portion 22 and the outer surface of the second tubular portion 24. Due to this arrangement, the downstream end 30 of the second tubular portion 24 is positioned within the first tubular portion 22. The tubular element 18 is formed as a single integral element such that the first tubular portion 22, the second tubular portion 24, and the folded portion 26 are formed from a continuous material as a single piece.

[0208] The first tubular portion 22 defines a cavity 32 extending from an upstream end 28 to a downstream end 34 of the first tubular portion 22. The cavity 32 is substantially empty, thus allowing substantially unrestricted airflow through it. Therefore, the first tubular portion 22 substantially does not affect the overall suction resistance (RTD) of the aerosol generating article 10. In other words, the RTD of the first tubular portion 22 is substantially 0 mmHg. The first tubular portion 22 serves as an aerosol cooling element for the aerosol generating article 10.

[0209] The second tubular portion 24 defines an airflow passage 36 extending from its upstream end 38 to its downstream end 30. The airflow passage 36 is substantially empty, thus allowing substantially unrestricted airflow. Therefore, the second tubular portion 24 substantially does not affect the overall RTD of the aerosol-generating article 10. In other words, the RTD of the second tubular portion 24 is substantially 0 mmHg. The second tubular portion 24 serves as a support element to prevent the matrix element 16 from moving toward the downstream end 17 of the aerosol-generating article 10. To support this function, the inner diameter 40 of the second tubular portion 24 is smaller than the inner diameter 42 of the first tubular portion 22 and smaller than the outer diameter of the matrix element 16. Figures 1 to 3 In the specific example shown, the inner diameter of the first tubular portion 22 is between about 6.5 mm and about 7.5 mm, and the inner diameter of the second tubular portion 24 is between about 2.25 mm and about 2.75 mm.

[0210] The tubular element 18 has a length between approximately 10 mm and approximately 20 mm. If the second tubular portion 24 is fully positioned within the cavity 32 defined by the first tubular portion 22, the first tubular portion 22 has a similar length and can define the entire length of the tubular element 18. The second tubular portion 24 has a length less than 50% of the length of the first tubular portion 22.

[0211] The aerosol generating article 10 also includes a ventilation zone 44 disposed along a first tubular portion 22 of the tubular element 18. The ventilation zone 44 includes a ring of circumferential ventilation holes extending through the wall of the first tubular portion 22. Air can be drawn through the ventilation holes and through the first tubular portion 22 to achieve cooling of the aerosol stream generated when the matrix element 16 is heated. The ventilation level of the aerosol generating article 10 is approximately 25%.

[0212] The mouthpiece element 20 is positioned immediately downstream of the first tubular portion 22 of the tubular element 18. The upstream end of the mouthpiece element 20 is adjacent to the downstream end 34 of the first tubular portion 22 of the tubular element 18. The mouthpiece element 20 is provided in the form of a low-density cellulose acetate cylindrical rod. The mouthpiece element 20 has a length of approximately 12 mm and an outer diameter of approximately 7.1 mm. A mouthpiece filter segment package 46 surrounds the mouthpiece element 20.

[0213] Matrix element 16 includes an aerosol forming matrix 48 of one of the types described above. Matrix element 16 is in the form of a strip including the aerosol forming matrix 48. The aerosol forming matrix 48 can substantially define the structure and dimensions of matrix element 16. Matrix rod package 50 surrounds matrix element 16. Matrix element 16 has an outer diameter of approximately 7.1 mm and a length of approximately 12 mm.

[0214] The aerosol generating article 10 also includes an elongated receptor element 52 within a matrix element 16. The receptor element 52 is arranged substantially longitudinally within the aerosol generating matrix 48 and extends substantially parallel to the longitudinal direction 12. The receptor element 52 is located at a radial center position within the matrix element 16 and extends substantially along the longitudinal axis of the matrix element 16. The receptor element 52 extends from an upstream end to a downstream end of the matrix element 16. In fact, the receptor element 52 has substantially the same length as the matrix element 16. Figure 1 In one example, the receptor element 52 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. The inner diameter 40 of the second tubular portion 24 is smaller than the width of the receptor element 52 to hold the receptor element 52 in the matrix element 16.

[0215] Upstream element 14 is located immediately upstream of matrix element 16, and upstream element 14 is longitudinally aligned with matrix element 16. Figure 1 In this example, the downstream end of the upstream element 14 is adjacent to the upstream end of the matrix element 16. This advantageously prevents displacement of the receptor element 52 and ensures that the consumer does not accidentally come into contact with the heated receptor element 52 after use. The upstream element 14 is provided in the form of a cellulose acetate cylindrical rod defined by the upstream rod package 54. The upstream element 14 has a length of approximately 5 mm.

[0216] The aerosol generating article 10 also includes an outer packaging 56 defining the upstream element 14, the matrix element 16, and the tubular element 18, and a tip package 58 defining a portion of the mouthpiece element 20 and the tubular element 18.

[0217] Figures 4 to 13 Exemplary methods and apparatus for forming tubular element 18 are shown. The method begins with a tubular precursor or tubular body 100 comprising a simple cardboard tube. Figure 4 In the first step illustrated in the three figures, a first folding force is applied to a first end 102 of the tubular body 100 using a flanging mandrel 104 to form a flanged tube 106 including a first tubular portion 22 and an annular flanged portion 108. The first tubular portion 22 defines a cavity 32 extending from an upstream end or first end 28 of the first tubular portion 22 to a downstream end or second end 34 of the first tubular portion 22. The flanged portion 108 extends from the first end 28 of the first tubular portion 22 toward the longitudinal axis of the tubular body 100. To facilitate folding of the tubular body 100 to form the flanged tube 106, the flanging mandrel 106 rotates about its longitudinal axis during the application of the first folding force to the first end 102 of the tubular body 100.

[0218] Figures 5 to 8An exemplary first mandrel or inner mandrel 200 and a second mandrel or outer mandrel 300 are shown that can be used to convert the flanged tube 106 into a tubular element 18.

[0219] The inner axis 200 is shown in perspective and section views, respectively. Figure 5 and Figure 6 As shown in the diagram, the inner shaft 200 has a generally cylindrical shape and includes a first cylindrical portion 202 defining a first cylindrical outer surface 204 and a second cylindrical portion 206 defining a second cylindrical outer surface 208. The inner shaft 200 also defines a recessed chamfered outer surface 210 extending between the first cylindrical outer surface 204 and the second cylindrical outer surface 208. The first cylindrical outer surface 204, the second cylindrical outer surface 208, and the recessed chamfered outer surface 210 together form the inner shaft forming surface.

[0220] The outer mandrel 300 is shown in perspective view and cross-sectional view, respectively. Figure 7 and Figure 8 As shown in the diagram, the outer mandrel 300 has a generally tubular shape and includes a recess 302 defining a first cylindrical inner surface 304 and a second cylindrical inner surface 308. The outer mandrel 300 also defines a truncated conical inner surface 310 extending between the first cylindrical inner surface 304 and the second cylindrical inner surface 308. The first cylindrical inner surface 304, the second cylindrical inner surface 308, and the truncated conical inner surface 310 together form the outer mandrel forming surface. The recess 302 is shaped such that the shape of the outer mandrel forming surface is complementary to that of the inner mandrel forming surface.

[0221] Figures 9 to 13 An exemplary method for converting a flanged tube 106 into a tubular element 18 using an inner mandrel 200 and an outer mandrel 300 is shown. Figure 9 In the first step shown, the flanged portion 108 of the flanged tube 106 is inserted into the recess 302 of the outer mandrel 300, and the inner mandrel 200 is inserted into the cavity 32 defined by the first tubular portion 22. Figure 10 In the second step shown, the inner shaft 200 and outer shaft 300 advance toward each other until the edge of the second cylindrical portion 206 and the edge of the truncated conical surface 310 engages the flanged portion 108 of the flanged tube 106. Figure 11 In the third step shown, the inner shaft 200 and outer shaft 300 further advance toward each other to apply a second folding force to the flanged portion 108 of the flanged tube 106. The second folding force forms the second tubular portion 24 by compressing a portion of the flanged portion 108 between the second cylindrical outer surface 208 and the second cylindrical inner surface 308. Figure 12In the fourth step shown, the inner core shaft 200 and outer core shaft 300 further advance toward each other to apply a third folding force to the remainder of the flange portion 108. The third folding force forms the folded portion 26 by compressing the remainder of the flange portion 108 between the concave chamfered outer surface 210 and the truncated conical inner surface 310, which positions the downstream end 30 of the second tubular portion 24 within the cavity 32 defined by the first tubular portion 22. Finally, in Figure 13 In the fifth step shown, the inner core shaft 200 and the outer core shaft 300 are pulled out of each other to allow removal of the finished tubular element 18.

[0222] To facilitate the folding of the flanged tube 106 to form a tubular element 18, at least one of the inner shaft 200 and the outer shaft 300 rotates about its longitudinal axis during the application of the second folding force and the third folding force.

[0223] The technician will understand that, depending on the length of the second columnar portion 206 and the length of the flange portion 108, the application of the third folding force can occur before the application of the second folding force, or the application of the second folding force and the third folding force can occur simultaneously.

[0224] Figure 14 A cross-sectional view of an aerosol generating article 400 according to a second embodiment of the present disclosure is shown. The aerosol generating article 400 is an inhaler article, such as a dry powder inhaler. The aerosol generating article 400 includes an outer body 402 having a partially closed upstream end 404 and a partially closed downstream end 406. An upstream opening 408 is formed in the upstream end 404 of the outer body 402, and a downstream opening 410 is formed in the downstream end 406 of the outer body 402. The upstream opening 408 serves as an air inlet, and the downstream opening 410 serves as an air outlet. An airflow path extends between the upstream opening 408 and the downstream opening 410 and through an inner cavity 407 of the outer body 402. The upstream portion of the inner cavity 407 of the outer body 402 near the upstream end 404 accommodates a matrix segment 416 in the form of a bladder containing nicotine particles.

[0225] The partially closed upstream end 404 of the outer body 402 prevents the bladder from falling out of the upstream end 404 of the outer body 102. The diameter of the bladder is larger than the diameter of the upstream opening 408 and therefore cannot pass through the upstream opening 408. A tubular element 418 is disposed within the inner cavity 407 and positioned downstream of the bladder. The tubular element 418 is fixed to the inner surface of the outer body 402 and acts as a retainer for limiting downstream movement of the bladder to hold the bladder in the upstream portion of the inner cavity 407.

[0226] The tubular element 418 is shown in cross-sectional and perspective views, respectively. Figure 15 and 16 The tubular element 418 is shown in more detail below, along with the reference. Figures 1 to 3 The tubular element 18 described herein is similar, and therefore the same reference numerals are used to denote the same parts.

[0227] The tubular element 418 differs from the tubular element 18 in that it adds multiple airflow orifices 420 extending through the folded portion 26. The multiple airflow orifices 420 are arranged symmetrically around the second tubular portion 24.

[0228] The second tubular portion 24 is adjacent to the downstream end of the bladder, and the inner diameter 40 of the second tubular portion 24 is smaller than the outer diameter of the bladder, thereby preventing the bladder from moving toward the downstream end 406 of the outer body 402. The inner diameter 42 of the first tubular portion 22 is larger than the inner diameter 40 of the second tubular portion, thus allowing substantially unrestricted airflow through the cavity 32.

[0229] Tubular element 418 can be used with reference Figures 4 to 14 The substantially the same method described for forming the tubular element 18 is used. Multiple airflow orifices 420 may be formed in the tubular body 100 prior to folding to form the flanged tube 106. Alternatively, the airflow orifices 420 may be formed in the folded portion 26 after the tubular element 18 has been formed. The airflow orifices 420 may be formed using any suitable process. For example, the airflow orifices 420 may be formed using laser perforation.

[0230] In use, the consumer uses an external piercing tool to pierce the cyst via the upstream opening 408. The piercing tool is pushed through the upstream opening 408 and into the cyst to create a hole in the cyst through which the nicotine particles can exit the cyst. Significant downstream movement of the cyst is restricted by a tubular element 418. The upstream end 38 of the second tubular portion 24 abuts the cyst during piercing and holds the cyst in place to allow for easier piercing.

[0231] When a consumer inhales or inhales at the downstream end 406 of the aerosol-generating article 400, air is drawn in through the upstream opening 408 and through the upstream portion of the receiving sac within the inner cavity 407 of the outer body 402. Nicotine particles leave the sac and are entrained in the airflow passing through the outer body 402. The airflow carrying nicotine particles passes through the cavity 32 of the tubular element 418. The expansion of the cross-section of the airflow path as air is transferred from the second tubular portion 24 to the first tubular portion 22, along with the airflow through the multiple airflow orifices 420, can induce a vortex effect that facilitates the mixing of nicotine particles with the airflow before it is drawn into the consumer's mouth via the downstream opening 410.

[0232] The smaller outer diameter of the second tubular portion 24 compared to the first tubular portion 22 defines an annular space 426 between the outer surface of the second tubular portion 24 and the inner surface of the outer body 402. The annular space 426 defines a groove or recess that collects excess nicotine particles released from the capsule but not entrained in the airflow when inhaled by a consumer on the aerosol-generating article 400. The annular space 426 also collects nicotine particles released from the capsule as the aerosol-generating article 400 moves between consumer inhalations. The annular space 426 created by the tubular element 418 acts as a barrier reducing the likelihood of nicotine particle leakage from the aerosol-generating article 400 between consumer inhalations or between uses of the aerosol-generating article 400.

Claims

1. An aerosol generating article, said aerosol generating article comprising a plurality of elements assembled in the form of strips, said plurality of elements comprising: Including matrix elements for aerosol-forming matrices; as well as A tubular element, wherein the tubular element is an integral element, the integral element comprising: A first tubular portion, the first tubular portion defining a cavity extending from a first end of the first tubular portion to a second end of the first tubular portion; A second tubular portion, at least partially positioned within the cavity defined by the first tubular portion, the second tubular portion forming an air inlet in fluid communication with the cavity; and The folded portion extends between the first end of the first tubular portion and the second tubular portion.

2. The aerosol generating article according to claim 1, wherein the first end is the upstream end of the first tubular portion, and wherein the folded portion extends between the upstream end of the first tubular portion and the downstream end of the second tubular portion.

3. The aerosol generating article according to claim 2, wherein the downstream end of the second tubular portion is positioned within the cavity.

4. The aerosol generating article according to claim 3, wherein the distance in the longitudinal direction between the upstream end of the first tubular portion and the downstream end of the second tubular portion is an overlap length, and wherein the overlap length is between 0.5 mm and 3 mm, between 0.75 mm and 1.5 mm, or between 0.9 mm and 1.1 mm.

5. The aerosol generating article according to claim 2, 3 or 4, wherein the upstream end of the second tubular portion is positioned outside the cavity.

6. The aerosol generating article according to any one of claims 2 to 5, wherein the upstream end of the second tubular portion is flush with the upstream end of the first tubular portion.

7. The aerosol generating article according to any of the preceding claims, wherein the second tubular portion is completely positioned within the cavity.

8. The aerosol-generating article according to any of the preceding claims, wherein the angle between the folded portion and the inner surface of the first tubular portion is less than 90 degrees.

9. The aerosol-generating article according to any of the preceding claims, wherein the angle between the folded portion and the outer surface of the second tubular portion is less than 90 degrees.

10. The aerosol generating article according to any of the preceding claims, wherein the first tubular portion has a first length, wherein the second tubular portion has a second length, and wherein the second length is less than the first length, optionally wherein the second length is less than 50%, less than 40%, less than 30%, less than 20%, or less than 10% of the first length.

11. The aerosol generating article according to any of the preceding claims further includes at least one airflow orifice extending through the folded portion.

12. The aerosol generating article according to any of the preceding claims, wherein the tubular element is formed of at least one of paper and cardboard.

13. The aerosol generating article according to any of the preceding claims, wherein the tubular element is formed of a material with a basis weight between 100 g / m² and 700 g / m², preferably between 100 g / m² and 400 g / m².

14. The aerosol generating article according to any of the preceding claims, wherein the tubular element has a length between 10 mm and 40 mm, preferably between 10 mm and 30 mm, and preferably between 10 mm and 20 mm.

15. The aerosol generating article according to any of the preceding claims further includes a ventilation zone along the location of the tubular element.

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