Tubular component for an aerosol-generating article and a method of manufacture

Abstract

A tubular component for an aerosol-generating article for use in a non-combustible aerosol-provision system is disclosed. The tubular component has a longitudinal axis and is configured to filter an aerosol generated by the aerosol-generating article. The tubular component comprises a tubular body of filtration material defining a cavity, an outer layer that encircles the body of filtration material, and an inner layer within the cavity lining the body of filtration material. The inner layer is formed from a nonwoven sheet-like material. An article for use in a non-combustible aerosol provision system that includes an aerosol-generating device, a system comprising a non-combustible aerosol generating device, and a method of manufacturing tubular components are also disclosed.

Description

[0001] Tubular Component for an Aerosol-Generating Article and a Method of Manufacture

[0002] The present invention relates to a tubular component for an aerosol-generating article for use in a non-combustible aerosol provision system. The invention also relates to an aerosol-generating article for use in a non-combustible aerosol provision system that includes the article comprising a tubular component according to the invention, and an aerosol-generating device. A system comprising an aerosol-generating device and the aerosol-generating article of the invention is also provided. A method of manufacturing tubular components for use in an aerosol-generating article forming part of a non- combustible aerosol-provision system is also disclosed.

[0003] Background

[0004] Certain tobacco industry products produce an aerosol which is inhaled by a user during use. For example, tobacco heating devices heat an aerosol generating substrate such as tobacco to form an aerosol by heating, but not burning, the substrate. Such tobacco industry products commonly include mouthpieces through which the aerosol passes to reach the user’s mouth. Summary

[0005] In accordance with some embodiments described herein, there is provided a tubular component for an aerosol-generating article for use in a non-combustible aerosolprovision system, the tubular component having a longitudinal axis and being configured to filter an aerosol generated by said aerosol-generating article, the tubular component comprising a tubular body of filtration material defining a cavity, an outer layer that encircles the body of filtration material, and an inner layer within the cavity lining said body of filtration material, wherein the inner layer is formed from a nonwoven sheet-like material. The nonwoven sheet-like material may comprise cellulose or paper.

[0006] The inner and outer layers may each be coaxial with the longitudinal axis.

[0007] The tubular body of filtration material may comprise non-woven sheet-like material. For example, the tubular body of filtration material may comprise paper. The paper may be crimped and / or can be formed from strips that extend in a direction along the longitudinal axis. Alternatively, the paper may be corrugated.

[0008] The outer layer and the body of material can be attached to each other with adhesive.

[0009] The inner layer and the body of filtration material can be attached to each other with adhesive.

[0010] The outer layer may comprise paper.

[0011] The body of filtration material may have a thickness in the radial direction greater than the corresponding thickness of the inner and outer layers. According to another aspect of the invention, there is also provided an article for use in a non-combustible aerosol provision system that includes an aerosol-generating device, and the article comprising a tubular component according to the invention.

[0012] The article may comprise a segment formed from aerosol-generating material and a cooling element located downstream of said segment formed from aerosol-generating material. The tubular component can be located between the segment formed from aerosol-generating material and the cooling element.

[0013] The tubular component may abut the segment formed from aerosol generating material at one end and the cooling element at the opposite end.

[0014] The cooling element may comprise a hollow tubular member. The thickness of the wall of the cooling element in a radial direction maybe less than the corresponding thickness of the wall of the tubular component.

[0015] According to an aspect of the invention, there is provided a system comprising a noncombustible aerosol generating device, the aerosol generating device comprising a heating element, and an aerosol-generating article according to the invention. According to another aspect of the invention, there is provided a method of manufacturing tubular components having a longitudinal axis, each tubular component being for use in an aerosol-generating article forming part of a non-combustible aerosol-provision system, wherein the method comprises: forming a tube about said longitudinal axis from a first continuous web of non-woven sheet-like material, applying a body of material to an outer surface of said tube as said tube is being conveyed in a longitudinal direction and such that the tube is surrounded by said body of material, wrapping said tube to which the body of material has been applied with a second continuous web of non-woven sheet-like material, and cutting said rod at spaced intervals along the longitudinal axis to form a plurality of tubular components each comprising a body of material encircled by an outer layer formed from the first continuous web of material and lined by an inner layer formed from the second continuous web of material.

[0016] The method may comprise supplying the first continuous web of material from a first bobbin, and second continuous web of material from a second bobbin.

[0017] The method may comprise supplying the first and second continuous webs of material from a single bobbin, the method comprising slitting the material prior to forming the tube from said first continuous web of material and prior to wrapping the tube to which the body of material has been applied with said second continuous web of material.

[0018] Brief Description of the Drawings

[0019] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a side-on cross-sectional view of an aerosol-generating article for use with a non-combustible aerosol provision device, according to an embodiment of the invention;

[0020] Figure 2 shows a cross-section through a hollow tubular component of the aerosolgenerating article of Figure 1, taken along line A- A, according to a first embodiment of the invention; and

[0021] Figure 3 shows a method of manufacturing a rod which is cut at spaced intervals along its length to form a plurality of tubular components according to the invention.

[0022] Figure 4 is a simplified cross-sectional view of a non-combustible aerosol provision system comprising an aerosol provision device with an aerosol-generating article, as shown in Figure 1, inserted into it; and Figure 5 is a simplified schematic of the components of the aerosol provision device shown in Figure 4.

[0023] Detailed Description As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

[0024] According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned to facilitate delivery of at least one substance to a user.

[0025] In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

[0026] In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0027] In some embodiments, the non-combustible aerosol provision system is an aerosol- generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system. In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product. Typically, the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device, and a consumable for use with the non- combustible aerosol provision device.

[0028] An embodiment of the disclosure relates to a component that forms part of a consumable comprising aerosol-generating material and which is configured to be used with a non-combustible aerosol provision device. The consumable is sometimes referred to as an article throughout the disclosure. The disclosure also relates to a consumable or article comprising the component, and to a system comprising the device and the article.

[0029] The terms ‘upstream’ and ‘downstream’ used herein are relative terms defined in relation to the direction of mainstream aerosol drawn through an article in use. Reference to the ‘distal end’ (D) refers to an upstream end of the device, whereas ‘proximal end’ (P) refers to the downstream end of the device.

[0030] In some embodiments, the non-combustible aerosol provision system, particularly the non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

[0031] In some embodiments, the non-combustible aerosol provision device comprises an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and / or an aerosol-modifying agent. In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol-modifying agent.

[0032] The consumable comprises a substance to be delivered. The substance to be delivered is an aerosol-generating material. As appropriate, the material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and / or one or more other functional materials.

[0033] In some embodiments, the substance to be delivered comprises an active substance.

[0034] The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical. In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12. As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint maybe chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

[0035] In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

[0036] In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

[0037] In some embodiments, the substance to be delivered comprises a flavour. As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang- ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They maybe imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

[0038] In some embodiments, the flavour comprises menthol, spearmint and / or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and / or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis. In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

[0039] An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. An aerosol-generating material may be in the form of a solid, liquid or gel which may or may not contain an active substance and / or flavourants. The aerosol-generating material is incorporated into an article for use in the aerosol-generating system.

[0040] As used herein, the term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and / or tobacco extract. A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and / or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, in particular a heating element, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, comprise, a material heatable by electrical conduction, or a susceptor.

[0041] An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosolmodifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent. The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent maybe in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

[0042] An aerosol-generating device is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. The aerosol generating device comprises a heater configured to subject the aerosol-generating material to heat energy to release one or more volatiles from the aerosol-generating material to form an aerosol. The filamentary tow material described herein can comprise cellulose acetate fibre tow. The filamentary tow can also be formed using other materials used to form fibres, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(i-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, cotton, aliphatic polyester materials and polysaccharide polymers or a combination thereof. The filamentary tow may be plasticised with a suitable plasticiser for the tow, such as triacetin where the material is cellulose acetate tow, or the tow may be non-plasticised. The tow can have any suitable specification, such as fibres having a Y shaped or other cross section such as ‘X’ shaped, filamentary denier values between

[0043] 2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per filament and total denier values of 5,000 to 50,000, for example between 10,000 and 40,000.

[0044] In the figures described herein, like reference numerals are used to illustrate equivalent features or components.

[0045] Figure 1 is a longitudinal cross-sectional view of an aerosol-generating article 1 that forms part of an aerosol delivery system 15 that includes an aerosol delivery device 100 (see Figures 4 and 5).

[0046] The article 1 has an upstream or distal end ‘D’ and a downstream or proximal end ‘P’ and a longitudinal axis X-X. The proximal end P comprises a mouthpiece 2, which may comprise cellulose acetate filter material and can contain capsule 3 containing an aerosol-modifying agent or liquid flavourant. In alternate embodiments, the mouthpiece 2 may be a hollow tubular element and / or the capsule 3 may be omitted.

[0047] An aerosol-generating section 4 is connected to the mouthpiece 2. In the present example, the aerosol generating section 4 comprises a rod of aerosol-generating material 5. The aerosol-generating material 5 may comprise a plurality of strands or strips of aerosol-generating material 5 and is circumscribed by a wrapper 6 that can include one or more layers. The wrapper 6, or one of the layers of the wrapper 6, may be aluminium foil. In other embodiments, the wrapper 6 can be made of one or more paper layers optionally comprising a barrier coating to make the material of the wrapper 6 substantially moisture impermeable. The aerosol-generating section 4 includes a cooling element 7, positioned downstream of the aerosol-generating material 5 and in abutting relation to the mouthpiece 2. The cooling element 7 comprises a hollow channel 8, having an internal diameter of between about 1 mm and about 4 mm, for example between about 2 mm and about 4 mm. In the present example, the hollow channel 8 has an internal diameter of about 3 mm. The hollow channel 8 extends along the full length of the cooling element 7. The hollow channel 8 provides a space into which aerosol drawn into the cooling element 7 from the rod of aerosol generating material 5 expands and cools down. The cooling element 7 can be configured to provide a temperature differential of at least 40 degrees Celsius between a heated volatilised component entering a first, upstream end (D) of the cooling element 7 and a heated volatilised component exiting a second, downstream end (P) of the cooling element 7. Ventilation is provided directly into the cooling element 7 via at least one row of perforations 9 extending through the outer wall.

[0048] The cooling element 7 has a wall thickness in a radial direction. The wall thickness of the cooling element 7, for a given outer diameter, defines the internal diameter for the channel 8 surrounded by the walls of the cooling element 7. The cooling element 7 has a wall thickness of at least about 1.5 mm and up to about 2 mm. In the present example, the cooling element 7 has a wall thickness of about 2 mm.

[0049] The cooling element 7 may be formed from filamentary tow. The wall material of the cooling element 7 can be relatively non-porous, such that at least 90% of the aerosol generated by the aerosol generating material 5 passes longitudinally through the channel 8 of the cooling element 7 rather than through the wall material of the cooling element 7. For instance, at least 92% or at least 95% of the aerosol generated by the aerosol generating material 3 passes longitudinally through the hollow channel 8. As shown in Figure 1, the article 1 may comprise a plug 10 at the distal end D. In this embodiment, the heating element is inserted into the aerosol-generating material 5 through the plug 10. In the embodiment of Figure 1, the plug 10 is tubular, although it may also be a cylindrical solid element. In embodiments of the invention, a tubular component 11 is positioned between the aerosol generating material 5 and the cooling element 7. The tubular component 11 is hollow and comprises a body of material 12 that is encircled by an outer layer 13 which maybe plug wrap or other wrapping material. The tubular component 11 has a radial wall thickness that is greater relative to the radial wall-thickness of the cooling element . For example, the wall thickness of the tubular component 11 can be in the order of 3.5 to 4mm. The tubular component 11 is also shorter that the cooling element 7 and may have a typical length of around 7mm.

[0050] The body of material 12 can be formed from non-woven sheet-like material such as cellulose, paper or other fibrous material or tow. If paper is used, it may be crimped and / or formed from strips, or the paper may have a corrugated or other irregular shaped profile.

[0051] A nonwoven sheet-like material or fibrous tow typically comprises a plurality of fibers therein. In some embodiments, filter materials according to the disclosure (either in the form of a nonwoven sheet or a fibrous tow) may be formed of alternative or recycled fiber materials. Such alternative fibers materials may beneficially provide increased biodegradability and / or reduced plasticity when compared to the types of fiber inputs used in conventional cigarette filters, e.g., such as cellulose acetate. In some embodiments, the body of material prepared according to the present disclosure may comprise a plurality of fibers selected from the group consisting of regenerated cellulose, hemp, sisal, kenaf, esparto, jute, flax, wood, reconstituted tobacco, and combinations thereof. As used herein, the term “fiber” is defined as a basic element of textiles. It should be noted that the body of material of the present disclosure may include any of the noted fiber inputs individually or in combination with one or more other fiber inputs. Fibers are often in the form of a rope- or string -like element. As used herein, the term “fiber” is intended to include fibers, filaments, continuous filaments, staple fibers, and the like. In some embodiments, the body of material as described herein may comprise regenerated cellulose, such as regenerated cellulose fibers, in particular. It should be noted that the body of material may comprise solely regenerated cellulose fibers or the regenerated cellulose fibers may be combined with one or more other fiber inputs as described herein. Regenerated cellulose fibers are typically prepared by extracting non- cellulosic compounds from wood, contacting the extracted wood with caustic soda, followed by carbon disulfide and then by sodium hydroxide, giving a viscous solution. The solution is subsequently forced through spinneret heads to create viscous threads of regenerated fibers. Exemplary methods for the preparation of regenerated cellulose are provided in U.S. Pat. No. 4,237,274 to Leoni et al; U.S. Pat. No. 4,268,666 to Baldini et al; U.S. Pat. No. 4,252,766 to Baldini et al.; U.S. Pat. No. 4,388,256 to Ishida et al.;

[0052] U.S. Pat. No. 4,535,028 to Yokogi et al.; U.S. Pat. No. 5,441,689 to Laity; U.S. Pat. No. 5,997,790 to Vos et al.; and U.S. Pat. No. 8,177,938 to Sumnicht, which are incorporated herein by reference. The way in which the regenerated cellulose is made is not limiting, and can include, for example, both the rayon and the TEN CEL processes. Various suppliers of regenerated cellulose are known, including Lenzing (Austria), Cordenka (Germany), Aditya Birla (India), and Daicel (Japan). Examples of regenerated cellulose fibers include, but are not limited to, rayon, viscose, viscose rayon, lyocell, and the like.

[0053] In addition to the outer layer 13, the tubular component 11 also comprises an inner layer 14 that lines the body of material 12, as shown in the cross-sectional view through the tubular component 11 of Figure 2 according to an embodiment of the invention, taken along the line A-A of Figure 1.

[0054] The inner layer 14 may be formed from the same material as the outer layer 13 and both layers may be coaxial with each other and with the longitudinal axis of the tubular component. The inner layer may also be formed from a non-woven sheet like material such as paper or cellulose, similar to the body of material between the inner and outer layers. At least one of the outer and inner layers 13, 14 maybe formed from paper.

[0055] Due to its increased wall thickness relative to the wall thickness of the cooling element 7, the tubular component 11 is a structural element of the aerosol-generating article 1 and provides the aerosol-generating article 1 with improved rigidity that makes it more able to withstand the axial compressive forces and bending moments that arise during manufacture and whilst the article 1 is in use. Further, as the tubular component 11 is hollow, it doesn’t impede the flow of aerosol therethrough compared to the flow through a solid cylindrical filter element. The increased wall thickness also makes the tubular component 11 more resilient and able to withstand moisture ingress for longer without collapsing or buckling.

[0056] Tipping paper (not shown) may be wrapped around the full length of the mouthpiece 2 and the aerosol-generating section, over the wrapper 4, to connect the mouthpiece 2 to the aerosol-generating section, including the tubular component 11.

[0057] The aerosol-generating article of Figure 1 forms part of a non-combustible aerosol provision system 15. Figure 4 shows a simplified view of a device 16 with the aerosol generating article 1 received in the device 16. As shown, the non-combustible aerosol provision device 16 has a housing 17 comprising a recess or opening 18 in which is received the aerosol-generating article i and in which a heater 19 is inserted into the aerosol generating material of the article 1.

[0058] As shown in Figure 5, within the housing 17 there is an electrical energy supply 20, for example a rechargeable lithium-ion battery. A controller 21 is connected to the heater 19, the electrical energy supply 20, and a user interface 22, for example a button or display. The controller 21 controls the power supplied to the heater 19 to regulate its temperature. Typically, the aerosol-forming substrate 5 is heated to a temperature of between 250 and 450 degrees centigrade.

[0059] A method of manufacturing the tubular element 11 shown in Figure 2 and incorporated into the aerosol-generating article of Figure 1 will now be described in more detail with reference to Figure 3. Figure 3 shows a method of manufacturing a rod which is subsequently cut at spaced intervals along its length to form a plurality of tubular components 11 according to the invention. A tubular component 11 is then incorporated into an aerosol-generating article 1 using a smoking article manufacturing apparatus.

[0060] Apparatus for combining different types of tubular elements to form a smoking article or consumable are well-known in the art and will not be described further. The tubular component 11 according to the invention is manufactured by forming a continuous rod which is then cut at spaced intervals to form individual tubular components 11. To form the continuous rod, which comprises a body of material 12 encircled by an outer layer 13 and lined with an inner layer 14, a sheet or continuous web of material is first formed into a tubular shape about a longitudinal axis X-X. This can be achieved by wrapping the web about a cylindrical mandrel as the web is being advanced in a longitudinal direction (the direction indicated by arrow B in Figure 3) towards a filter rod forming machine. The tubular structure thus formed forms the inner layer 14 of the tubular component. After formation of the tubular structure, and as the tubular structure continues to advance in a longitudinal direction in the direction of arrow B, a body of material 12 is applied to the outer surface of the tubular structure forming the inner layer 14 so that tubular structure is surrounded by the body of material 12. Optionally, an adhesive may be applied to the outer surface of the tubular structure forming the inner layer 14 so that the body of material 12 bonds to the outer surface during application thereto. As the tubular structure that forms the inner layer 14, together with the body of material 12 applied thereto advances further in the longitudinal direction, it passes through a constriction 25 that compresses the body of material 12 and forms it into a rod-like shape of the required diameter about the tubular structure forming the inner layer 14.

[0061] After the tubular structure and body of material 12 has passed through the constriction 25, a continuous web of material forming the outer layer 13 is wrapped around the outside of the body of material 12. Optionally, an adhesive maybe applied to the inner surface of the continuous web of material forming the outer layer 13 so that it bonds to the outer surface of the body of material 12 as it wraps around the body of material 12.

[0062] The above method provides a continuous tubular rod comprising a body of material 12 encircled by a continuous web of material forming the outer layer 13 and lined by another continuous web of material forming the inner layer 14. The rod continues to advance in a longitudinal direction (in the direction of arrow B) and passes hrough a cutting unit (not shown) that cuts the rod into individual tubular components 11 by severing the rod at right angles to the longitudinal axis X-X at repeated intervals along the length of the rod.

[0063] The first continuous web of material that forms the inner layer can be supplied from bobbin or reel, and the second continuous web of material that forms the outer layer can be supplied from a different bobbin or reel. Alternatively, the first and second continuous webs of material can be formed from a single bobbin or reel of material in which case, the method further comprises the step of slitting the material into two separate webs so that one web is used to form the tubular structure or inner layer 14, and the other is used to wrap the tubular structure to which the body of material 12 has been applied. The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only and are not exhaustive and / or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised, and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

Claims1. A tubular component for an aerosol-generating article for use in a noncombustible aerosol-provision system, the tubular component having a longitudinal axis and being configured to filter an aerosol generated by said aerosol-generating article, the tubular component comprising a tubular body of filtration material defining a cavity, an outer layer that encircles the body of filtration material, and an inner layer within the cavity lining said body of filtration material, wherein the inner layer is formed from a nonwoven sheet-like material.

2. A tubular component according to claim 1, wherein the nonwoven sheet-like material comprises cellulose or paper.

3. A tubular component according to claim 1, wherein the inner and outer layers are each coaxial with the longitudinal axis.

4. A tubular component according to any of claims 1 to 3, wherein the tubular body of filtration material comprises non-woven sheet-like material.

5. A tubular component according to claim 4, wherein the tubular body of material comprises paper.

6. A tubular component according to claim 5, wherein the paper is crimped.

7. A tubular component according to claims 5 or 6, wherein the paper is formed from strips that extend in a direction along the longitudinal axis.

8. A tubular component according to claim 4, wherein the paper is corrugated. . A tubular component according to any of claims 1 to 7, wherein the outer layer and the body of material are attached to each other with adhesive.

10. A tubular component according to any of claims 1 to 8, wherein the inner layer and the body of filtration material are attached to each other with adhesive.

11. A tubular component according to any preceding claim, wherein the outer layer comprises paper.

12. A tubular component according to any preceding claim, wherein the body of filtration material has a thickness in the radial direction greater than the corresponding thickness of the inner and outer layers.

13. A tubular component according to any preceding claim, wherein the tubular body of filtration material comprises a regenerated cellulose material.

14. An article for use in a non-combustible aerosol provision system that includes an aerosol-generating device, the article comprising a tubular component according to any of claims 1 to 13.

15. An article according to claim 14, comprising a segment formed from aerosolgenerating material and a cooling element located downstream of said segment formed from aerosol-generating material, wherein the tubular component is located between the segment formed from aerosol-generating material and the cooling element.

16. An article according to claim 14, wherein the tubular component abuts the segment formed from aerosol generating material at one end and the cooling element at the opposite end.

17. An article according to claim 14 or 15, wherein the cooling element comprises a hollow tubular member, wherein the thickness of the wall of the cooling element in a radial direction is less than the corresponding thickness of the wall of the tubular component.

18. A system comprising a non-combustible aerosol generating device, the aerosol generating device comprising a heating element, and an aerosol-generating article according to any of claims 14 to 17.

19. A method of manufacturing tubular components having a longitudinal axis, each tubular component being for use in an aerosol-generating article forming part of a non-combustible aerosol-provision system, wherein the method comprises: forming a tube about said longitudinal axis from a first continuous web of non-woven sheet-like material, applying a body of material to an outer surface of said tube as said tube is being conveyed in a longitudinal direction and such that the tube is surrounded by said body of material,wrapping said tube to which the body of material has been applied with a second continuous web of non-woven sheet-like material, and cutting said rod at spaced intervals along the longitudinal axis to form a plurality of tubular components each comprising a body of material encircled by an outer layer formed from the first continuous web of material and lined by an inner layer formed from the second continuous web of material.

20. A method according to claim 19, comprising supplying the first continuous web of material from a first bobbin, and second continuous web of material from a second bobbin.

21. A method according to claims 19, comprising supplying the first and second continuous webs of material from a single bobbin, the method comprising slitting the material prior to forming the tube from said first continuous web of material and prior to wrapping the tube to which the body of material has been applied with said second continuous web of material.

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