Aerosol-generating rod with multiple aerosol-generating segments

Abstract

The aerosol-generating rod 10 for generating an inhalable aerosol upon heating comprises a first aerosol-generating segment 12 including a first aerosol-generating substrate, the first aerosol-generating substrate including tobacco material and an aerosol former, a second aerosol-generating segment 14 located upstream of the first aerosol-generating segment, and a wrapper (22) surrounding at least the first and second aerosol-generating segments. The second aerosol-generating segment 14 includes a plug of porous substrate. At least a core portion 24 of the plug includes an aerosol-generating medium or flavorant, or both. A peripheral portion 26 of the plug 18 surrounding the core portion 24 is substantially free of aerosol-generating medium or flavorant. The aerosol-generating rod provides sufficient aerosol delivery at low temperatures to combat the "cold puff" or "empty puff" effect.

Description

[Technical field]

[0001] The present invention relates to an aerosol-generating article comprising an aerosol-generating substrate and adapted to generate an inhalable aerosol upon heating. [Background technology]

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

[0003] Numerous prior art documents disclose aerosol generating devices for consuming aerosol-generating articles. Such devices include, for example, electrically heated aerosol generating devices, in which the aerosol is generated by heat transfer from one or more electric heater elements of the aerosol generating device to an aerosol-generating substrate of the heated aerosol-generating article. For example, an electrically heated aerosol generating device has been proposed, which includes an internal heater blade adapted to be inserted into the aerosol-generating substrate. As an alternative, WO2015 / 176898 proposes an inductively heated aerosol-generating article, which includes an aerosol-generating substrate and a susceptor disposed within the aerosol-generating substrate. A further alternative is described in WO2020 / 115151, which discloses an aerosol-generating article used in combination with an external heating system comprising one or more heating elements disposed around the outer surface of the aerosol-generating article. For example, the external heating element may be provided in the form of a flexible heating foil on a dielectric substrate, such as polyimide. Summary of the Invention [Problem to be solved by the invention]

[0004] Aerosol-generating articles in which the tobacco-containing substrate is heated rather than combusted present several challenges not faced with conventional smoking articles.

[0005] First, the tobacco-containing substrate is typically heated to a significantly lower temperature than that reached by the combustion front of a conventional cigarette. This can affect the nicotine release from the tobacco-containing substrate and the nicotine delivery to the consumer. At the same time, when the heating temperature is increased in an attempt to enhance nicotine delivery, the aerosol generated typically needs to be cooled more extensively and more quickly before it reaches the consumer.

[0006] Second, it typically takes time to heat a tobacco-containing aerosol-generating substrate to one of those temperatures required for aerosol formation, which may delay aerosol delivery to the consumer. When a user first draws on the article, the aerosol that reaches the user may be relatively low in flavor or nicotine content, or both, often referred to as the "cold puff" or "empty puff" effect.

[0007] For example, one such delay may be detectable in aerosol-generating rods and articles in which the aerosol-generating substrate comprises homogenized tobacco material, as the aerosol former and nicotine may not be particularly readily available for release, particularly when using cast leaf homogenized tobacco material prepared from a slurry containing the aerosol former, as opposed to one in which the aerosol former is applied (e.g., sprayed) onto a formed sheet.

[0008] It has been proposed to address this by providing two or more independent heating zones within the device in which the aerosol-generating rod or article is heated, which allows different heating profiles to be implemented for different parts of the aerosol-generating substrate, which may help combat the "cold puff" effect.

[0009] However, it would be desirable to provide new and improved aerosol-generating rods or articles adapted to address the initial "cold puff" or "empty puff" effect. For example, it would be desirable to provide new and improved aerosol-generating rods or articles that can more quickly provide a satisfactory aerosol delivery to the user and that generally allow finer adjustment of the aerosol delivery during use.

[0010] It would be particularly desirable to provide such new and improved aerosol generating rods or articles which are capable of generating satisfactory aerosol delivery to the user at lower temperatures while still heating the tobacco-containing substrate for normal consumption.

[0011] It would be desirable to provide such an aerosol-generating rod or article that could be efficiently and rapidly manufactured without requiring extensive modifications of existing equipment. [Means for solving the problem]

[0012] The present disclosure relates to an aerosol-generating rod for generating an inhalable aerosol upon heating. The aerosol-generating rod may comprise a first aerosol-generating segment. The first aerosol-generating segment may comprise a first aerosol-generating substrate. The first aerosol-generating substrate may comprise a tobacco material and an aerosol former. The aerosol-generating rod may comprise a second aerosol-generating segment. The second aerosol-generating segment may be located upstream of the first aerosol-generating segment. The second aerosol-generating segment may comprise a plug of a porous substrate. At least a core portion of the plug may comprise an aerosol-generating medium or a flavourant, or both.

[0013] The present disclosure also relates to an aerosol generating article comprising the aerosol generating rod described above, as well as an aerosol generating system comprising a heating device and one such aerosol generating article.

[0014] According to the present invention there is provided an aerosol-generating rod for producing an inhalable aerosol upon heating, the aerosol-generating rod comprising a first aerosol-generating segment including a first aerosol-generating substrate, the first aerosol-generating substrate including a tobacco material and an aerosol former, and a second aerosol-generating segment located upstream of the first aerosol-generating segment, the second aerosol-generating segment including a plug of porous substrate, at least a core portion of the plug including an aerosol-generating medium or flavourant, or both.

[0015] According to the present invention there is also provided an aerosol generating article comprising an aerosol generating rod as described above, and an aerosol generating system comprising a heating device and one such aerosol generating article.

[0016] The aerosol-generating rod according to the invention thus provides a novel configuration of an aerosol-generating medium, characterized by the combination of two separate aerosol-generating segments in a specific mutual arrangement. The inventors have found that by combining two segments containing different aerosol-generating substrates essentially adapted to release volatile species on heating according to different release profiles, it is advantageously possible to avoid the initial delay in aerosol generation and delivery that is often found in existing aerosol-generating articles.

[0017] The invention will now be further described with reference to the drawings of the accompanying drawings, in which: [Brief description of the drawings]

[0018] [Figure 1A] 1 shows a schematic perspective view of an aerosol-generating rod according to the present invention with the wrapper removed; [Figure 1B] 1 shows a schematic perspective view of an aerosol-generating rod according to the present invention with the wrapper removed; [Figure 1C] FIG. 2 shows a further schematic perspective view of the aerosol-generating rod of FIGS. 1A and 1B. [Diagram 2] 1A, 1B and 1C show schematic cross-sectional side views of an aerosol-generating article comprising the aerosol-generating rod of FIG. [Diagram 3] 3 shows qualitatively how aerosol delivery changes over time during use of the aerosol-generating article of FIG. 2. [Figure 4A] 3 shows a schematic perspective view of an aerosol generating system comprising an aerosol generating device and the aerosol generating article of FIG. 2. [Figure 4B] 3 shows a schematic perspective view of an aerosol generating system comprising an aerosol generating device and the aerosol generating article of FIG. 2. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] FIG. 3 qualitatively illustrates how the aerosol delivery from each of the segments containing a homogenized tobacco substrate and a plug of a porous substrate loaded with an aerosol-generating medium or flavorant changes over time. As shown by line A in FIG. 3, at the beginning of heating of a rod containing both a homogenized tobacco substrate and a segment containing a plug of a loaded porous substrate, aerosol is rapidly released from the aerosol-generating medium or flavorant in the loaded porous substrate plug. Aerosol delivery from the loaded porous substrate reaches a maximum value and then decreases almost as rapidly. Because the content of aerosol species in the loaded porous substrate decreases relatively quickly, aerosol emission from the aerosol-generating medium or flavorant stops after a relatively short time. On the other hand, the aerosol emission from the segment containing a homogenized tobacco substrate, represented by line B, is not very high at first, and it is only after the aerosol emission from the aerosol-generating medium or flavorant begins to decrease that the amount of aerosol emission from the first aerosol-generating segment reaches a comparable level. By the time aerosol emission from the loaded porous substrate has nearly ceased, aerosol emission from the segment containing homogenized tobacco substrate will more than double in intensity, only to decrease smoothly over a long period covering the remainder of the use cycle of the rod or article.

[0020] At any time during the use of the aerosol-generating rod or article according to the invention, the consumer receives in effect the sum of the flow of aerosol species emitted from the aerosol-generating medium or flavoring provided in the second aerosol-generating segment and the flow of aerosol species emitted from the substrate of the first aerosol-generating segment. The dotted line C in FIG. 3 illustrates this effect during the initial part of the use cycle of the rod or article. As can be seen from the graph, the emission of aerosol from the second aerosol-generating segment makes up for the initial delay in the aerosol emission from the first aerosol-generating segment until the latter substantially takes over. This is perceived by the consumer as an overall more rapid, homogenous and consistent aerosol delivery throughout the use cycle of the rod or article, as compared to existing aerosol-generating rods or articles.

[0021] Advantageously, fine tuning of the transition from one aerosol source to the other is possible through selection of a particular aerosol-generating medium or flavorant for the second aerosol-generation segment, such as by selectively selecting a tobacco-containing substrate for the first aerosol-generation segment and adjusting the aerosol former content of the second aerosol-generation segment.

[0022] The inventors have found that the "cold puff" or "empty puff" effect is particularly realized when the tobacco-containing substrate of the first aerosol-generation segment comprises a homogenized tobacco material incorporating an aerosol former. Without wishing to be bound by theory, it is hypothesized that this is because the aerosol-generating medium or flavorants in the upstream second aerosol-generation segment are more readily available, and the nicotine and aerosol formers are present in the tobacco-containing substrate of the first aerosol-generation segment.

[0023] This effect may be enhanced by selecting an aerosol-generating medium or flavourant in the second aerosol-generation segment that is adapted to release aerosol species as the tobacco-containing substrate in the first aerosol-generation segment is heated to a temperature T2 that is lower than the temperature T1 at which the aerosol species may begin to be released. In particular, as discussed in more detail below, the aerosol-generating medium or flavourant in the first aerosol-generation segment may be selected such that the difference between the release temperatures T1 and T2 is greater than a predetermined value to enhance this effect.

[0024] Additionally or alternatively, when an aerosol-generating article comprising a rod according to the present invention is used in a device with a separate heating zone, heat (e.g., heat generated by induction) can be supplied more rapidly and at a higher temperature upstream to a second segment, such that a first burst-like release of aerosol can be provided to the consumer, while the temperature of the bulk of the tobacco-containing substrate in the first segment continues to rise more gradually. Thus, once aerosol emanating from the tobacco-containing substrate begins to be released at a satisfactory rate and with the desired flavor and nicotine content, this flow provides a sustained release of aerosol for the remainder of the use cycle.

[0025] As previously discussed, the present invention provides aerosol-generating rods for generating an inhalable aerosol upon heating, as well as aerosol-generating articles comprising the rods, and systems comprising aerosol-generating devices and aerosol-generating articles.

[0026] As used herein, the term "aerosol-generating article" refers to an article in which an aerosol-generating substrate is heated to generate an inhalable aerosol for delivery to a consumer. As used herein, the term "aerosol-generating substrate" refers to a substrate that has the ability to release volatile compounds upon heating to generate an aerosol.

[0027] A conventional cigarette is lit when a user applies a flame to one end of the cigarette and draws air through the other end. Localized heat provided by the flame and oxygen in the air drawn through the cigarette ignites the end of the cigarette and the resulting combustion produces inhalable smoke. In contrast, in heated aerosol-generating articles, the aerosol is generated by heating a flavor-generating substrate (such as tobacco). Known heated aerosol-generating articles include, for example, electrically heated aerosol-generating articles and aerosol-generating articles in which the aerosol is generated by the transfer of heat from a combustible fuel element or heat source to a physically separated aerosol-forming material. For example, the aerosol-generating article according to the present invention finds particular application in aerosol-generating systems comprising an electrically heated aerosol generator having an internal heater blade adapted to be inserted into a rod of aerosol-generating substrate. Aerosol-generating articles of this type are described in the prior art, for example in EP0822670.

[0028] As used herein, the term "aerosol-generating device" refers to a device that includes a heater element that interacts with an aerosol-generating substrate of an aerosol-generating article to generate an aerosol.

[0029] As used herein in connection with the present invention, the term "rod" is used to denote a generally elongated element, preferably a cylindrical element of substantially circular, oval or elliptical cross section.

[0030] The term "longitudinal" as used herein refers to a direction corresponding to a major longitudinal axis of the aerosol-generating article extending between the upstream and downstream ends of the aerosol-generating article. The terms "upstream" and "downstream" as used herein describe the relative positions of an element (or part of an element) of the aerosol-generating article with respect to the direction in which aerosol is transported through the aerosol-generating article during use.

[0031] In use, air is drawn longitudinally through the aerosol-generating article. The term "transverse" refers to a direction perpendicular to the longitudinal axis. Any reference to a "cross section" of an aerosol-generating article or a component of an aerosol-generating article refers to a transverse cross section, unless otherwise specified.

[0032] The term "length" refers to the dimension of a component of an aerosol-generating article in a longitudinal direction. For example, it may be used to refer to the dimension of a rod or elongated tubular element in a longitudinal direction.

[0033] The aerosol-generating article may further comprise a downstream section at a location downstream of the aerosol-generating rod. As will become apparent from the following description of embodiments of the aerosol-generating article of the present invention, the downstream section may comprise one or more downstream elements.

[0034] The downstream section may include a hollow section between the mouth end of the aerosol-generating article and the aerosol-generating rod. The hollow section may comprise a hollow tubular element.

[0035] As used herein, terms such as "hollow tubular segment" and "hollow tubular element" are used to mean a generally elongated element that defines a lumen or airflow passage along its longitudinal axis. In particular, the term "tubular" is used hereinafter with reference to an element or segment that has a substantially cylindrical cross-section and defines at least one airflow conduit that establishes uninterrupted fluid communication between an upstream end of the tubular element or segment and a downstream end of the tubular element or segment. However, it will be appreciated that alternative shapes (e.g., alternative cross-sectional shapes) of the tubular element or segment may be possible.

[0036] In the context of the present invention, a hollow tubular segment or hollow tubular element provides an unrestricted flow path. This means that the hollow tubular segment or hollow tubular element provides a negligible level of resistance to withdrawal (RTD). The term "negligible level of RTD" is used to describe an RTD of less than 1 mmH2O per 10 millimeters of length of a hollow tubular segment or hollow tubular element, preferably less than 0.4 mmH2O per 10 millimeters of length of a hollow tubular segment or hollow tubular element, more preferably less than 0.1 mmH2O per 10 millimeters of length of a hollow tubular segment or hollow tubular element.

[0037] Thus, the flow channels should not include any components that would impede the longitudinal air flow. Preferably, the flow channels are substantially empty.

[0038] As used herein, a "hollow tubular segment" or "hollow tubular element" may also be referred to as a "hollow tube" or "hollow tube segment."

[0039] The aerosol-generating article may further comprise an upstream section at a location upstream of the aerosol-generating rod. The upstream section may comprise one or more upstream elements. The upstream section may include an upstream element disposed immediately upstream of the aerosol-generating rod.

[0040] The aerosol-generating rod according to the present invention may be substantially cylindrical and may have an outer diameter of at least about 4 millimeters. More preferably, the aerosol-generating rod has an outer diameter of at least about 5 millimeters. Even more preferably, the aerosol-generating rod has an outer diameter of at least about 6 millimeters.

[0041] Preferably, the aerosol-generating rod has an outer diameter of about 12 millimeters or less. More preferably, the element comprising the aerosol-generating rod has an outer diameter of about 11 millimeters or less. Even more preferably, the aerosol-generating rod has an outer diameter of about 8 millimeters or less.

[0042] The aerosol-generating rod may have an outer diameter of about 4 mm to about 12 mm, preferably about 5 mm to about 12 mm, more preferably about 6 mm to about 12 mm. In other embodiments, the aerosol-generating rod has an outer diameter of about 4 mm to about 11 mm, preferably about 5 mm to about 11 mm, more preferably about 6 mm to about 11 mm. In further embodiments, the aerosol-generating rod has an outer diameter of about 4 mm to about 8 mm, preferably about 5 mm to about 8 mm, more preferably about 6 mm to about 8 mm.

[0043] It has generally been observed that the smaller the diameter of the rod-shaped element comprising the aerosol-generating substrate, the lower the temperature required to raise the core temperature of the rod-shaped element, and a sufficient amount of volatile species is released from the aerosol-generating substrate to form the desired amount of aerosol. At the same time, without wishing to be bound by theory, it is understood that the smaller the diameter of the rod-shaped element, the faster the heat supplied to the aerosol-generating rod can penetrate its entire volume. Nevertheless, if the diameter of the rod-shaped element is too small, the amount of available aerosol-forming substrate is reduced, and the volume-to-surface ratio of the aerosol-generating substrate becomes less favorable.

[0044] Aerosol-generating rod diameters falling within the ranges described herein are particularly advantageous in terms of the balance between energy consumption and aerosol delivery. This advantage is particularly realized when an aerosol-generating article comprising an aerosol-generating rod with a diameter described herein is used in combination with an external heater disposed around the outer surface of the aerosol-generating rod or article. It has been observed that under these operating conditions, less thermal energy is required to achieve a sufficiently high temperature at the core of the aerosol-generating rod or at the core of the article comprising the rod. Thus, when operating at a lower temperature, the desired target temperature at the core of the aerosol-generating rod can be achieved within a desirably reduced time frame and with less energy consumption.

[0045] The overall length of the aerosol-generating rod may be at least about 8 millimeters. Preferably, the overall length of the aerosol-generating rod is at least about 9 millimeters. More preferably, the overall length of the aerosol-generating rod is at least about 10 millimeters.

[0046] Preferably, the total length of the aerosol-generating rod is about 27 millimeters or less. More preferably, the total length of the aerosol-generating rod is about 23 millimeters or less. Even more preferably, the total length of the aerosol-generating rod is about 19 millimeters or less.

[0047] In some embodiments, the total length of the aerosol-generating rod is from about 8 mm to about 27 mm, preferably from about 9 mm to about 27 mm, more preferably from about 10 mm to about 27 mm. In other embodiments, the total length of the aerosol-generating rod is from about 8 mm to about 23 mm, preferably from about 9 mm to about 23 mm, more preferably from about 10 mm to about 23 mm. In further embodiments, the total length of the aerosol-generating rod is from about 8 mm to about 19 mm, preferably from about 9 mm to about 19 mm, more preferably from about 10 mm to about 19 mm.

[0048] The components of the aerosol-generating rod described in more detail may be surrounded by a wrapper, which may be a paper wrapper or a non-paper wrapper. One such wrapper may also attach two or more components of the aerosol-generating rod to one another.

[0049] Suitable paper wrappers for use in certain embodiments of the present invention are known in the art and include, but are not limited to, cigarette paper and filter plug wrap. Suitable non-paper wrappers for use in certain embodiments of the present invention are known in the art and include, but are not limited to, sheets of homogenized tobacco material.

[0050] In certain embodiments, the wrapper is non-porous.The aerosol-generating rod preferably comprises a non-porous wrapper surrounding at least the first and second aerosol-generating segments.

[0051] In certain embodiments, the wrapper may comprise a metal foil. In certain preferred embodiments, the wrapper may be formed from a laminate material comprising multiple layers. Preferably, the wrapper is formed from an aluminum co-laminate sheet. The use of an aluminum-containing co-laminate sheet advantageously prevents combustion of the aerosol-generating substrate if the aerosol-generating substrate is to be ignited rather than heated in the intended manner.

[0052] As briefly described above, an aerosol-generating rod according to the present invention comprises a first aerosol-generating segment which includes a first aerosol-generating substrate, the first aerosol-generating substrate comprising a tobacco material and an aerosol former.

[0053] The outer diameter of the first aerosol-generation segment is substantially the same as the outer diameter of the rod.

[0054] The first aerosol-generation segment may have a length of at least about 5 millimeters. Preferably, the first aerosol-generation segment has a length of at least about 7 millimeters. More preferably, the first aerosol-generation segment has a length of at least about 8 millimeters.

[0055] The first aerosol-generation segment may have a length of up to about 25 millimeters. Preferably, the first aerosol-generation segment has a length of about 20 millimeters or less. More preferably, the first aerosol-generation segment has a length of about 13 millimeters or less.

[0056] In some embodiments, the first aerosol-generation segment has a length of about 5 millimeters to about 25 millimeters, preferably about 7 millimeters to about 25 millimeters, and more preferably about 8 millimeters to about 25 millimeters. In other embodiments, the first aerosol-generation segment has a length of about 5 millimeters to about 20 millimeters, preferably about 7 millimeters to about 20 millimeters, and more preferably about 8 millimeters to about 20 millimeters. In further embodiments, the first aerosol-generation segment has a length of about 5 millimeters to about 13 millimeters, preferably about 7 millimeters to about 13 millimeters, and more preferably about 8 millimeters to about 13 millimeters.

[0057] The first aerosol-generating substrate is a solid aerosol-generating substrate comprising tobacco plant material. The term "tobacco plant material" is used herein to mean material that forms part of any plant member of the genus Nicotiana.

[0058] In a particularly preferred embodiment, the first aerosol-generating substrate comprises homogenized tobacco material.

[0059] Homogenized tobacco material is an example of a "homogenized plant material." As used herein, the term "homogenized plant material" encompasses any plant material formed by agglomeration of plant particles. For example, a sheet or web of homogenized tobacco material for an aerosol-generating substrate of the present invention may be formed by agglomerating particles of tobacco material obtained by grinding, crushing, or comminuting one or more of tobacco lamina and tobacco stems. Homogenized plant material, such as homogenized tobacco material, may be produced by casting, extrusion, a papermaking process, or any other suitable process known in the art.

[0060] The homogenized tobacco material can be provided in any suitable form. For example, the homogenized tobacco material may be in the form of one or more sheets. As used herein with respect to the present invention, the term "sheet" describes a layered element having a width and length substantially greater than its thickness.

[0061] The homogenized tobacco material may be in the form of a plurality of pellets or granules.

[0062] The homogenized tobacco material may be in the form of multiple strands, strips, or pieces. As used herein, the term "strand" describes an elongated element of material having a width and length substantially greater than its width and thickness. The term "strand" should be considered to encompass strips, pieces, and any other homogenized tobacco material having a similar form. Strands of homogenized tobacco material may be formed from a sheet of homogenized tobacco material, for example, by cutting or chopping, or by other methods, such as extrusion methods.

[0063] In some embodiments, the strands may be formed in situ within the first aerosol-generating substrate as a result of splitting or breaking of the sheet of homogenized tobacco material during formation of the first aerosol-generating substrate, for example as a result of crimping. The strands of homogenized tobacco material within the aerosol-generating substrate may be separated from one another. Each strand of homogenized tobacco material within the first aerosol-generating substrate may be at least partially connected to an adjacent strand or strands along the length of the strand. For example, adjacent strands may be connected by one or more fibers. This may occur, for example, when strands are formed due to splitting of a sheet of homogenized tobacco material during manufacture of the first aerosol-generating substrate, as described above.

[0064] The first aerosol-generating substrate is preferably in the form of one or more sheets of homogenized tobacco material. In various embodiments of the invention, the one or more sheets of homogenized tobacco material may be produced by a casting process. In various embodiments of the invention, the one or more sheets of homogenized tobacco material may be produced by a papermaking process. The one or more sheets described herein may each individually have a thickness of from 100 micrometers to 600 micrometers, preferably from 150 micrometers to 300 micrometers, and most preferably from 200 micrometers to 250 micrometers. Individual thickness refers to the thickness of an individual sheet, and combined thickness refers to the total thickness of all sheets that make up the aerosol-generating substrate. For example, if the first aerosol-generating substrate is formed from two individual sheets, the combined thickness is the thickness of the two individual sheets, or the sum of the measured thicknesses of the two sheets, the two sheets being stacked within the aerosol-generating substrate.

[0065] One or more of the sheets described herein may each individually have a weight of about 100 g / m 2 ~about 300g / m 2 The sheet may have a basis weight of 100 g.

[0066] One or more of the sheets described herein may each individually have a density of about 0.3 g / cm 3 ~Approx. 1.3g / cm 3 and may have a density of about 0.7 g / cm 3 ~Approx. 1.0g / cm 3 It is preferred that the density of the granular material is 0.01 to 0.05.

[0067] In embodiments of the invention in which the first aerosol-generating substrate comprises one or more sheets of homogenized tobacco material, the sheets are preferably in the form of an assembly of one or more sheets. As used herein, the term "assembly" means that the sheet of homogenized tobacco material is spiraled, folded, or otherwise compressed or pinched in a direction substantially transverse to the cylindrical axis of the plug or rod.

[0068] One or more sheets of homogenized tobacco material may be gathered transversely to their longitudinal axis and surrounded by a wrapper to form a continuous rod or plug.

[0069] One or more sheets of homogenized tobacco material may be advantageously crimped or similarly treated. As used herein, the term "crimped" refers to a sheet having a plurality of substantially parallel ridges or corrugations. Alternatively, or in addition to being crimped, one or more sheets of homogenized tobacco material may be embossed, debossed, perforated, or otherwise deformed to provide texture to one or both sides of the sheet.

[0070] Preferably, each sheet of homogenized tobacco material may be crimped to have a plurality of ridges or corrugations substantially parallel to the cylindrical axis of the plug. This process advantageously facilitates assembling the crimped sheets of homogenized tobacco material to form the plug. Preferably, one or more sheets of homogenized tobacco material may be assembled. It will be appreciated that the crimped sheets of homogenized tobacco material may have a plurality of substantially parallel ridges or corrugations that form acute or obtuse angles with respect to the cylindrical axis of the plug. The sheet may be crimped to an extent that the integrity of the sheet is disturbed at the plurality of parallel ridges or corrugations, causing separation of the material and resulting in the formation of pieces, strands, or strips of homogenized tobacco material.

[0071] One or more sheets of homogenized tobacco material may be cut into strands as mentioned above. In such an embodiment, the aerosol-generating substrate comprises a plurality of strands of homogenized tobacco material. The strands may be used to form plugs. Typically, such strands have a width of about 5 millimeters, or about 4 millimeters, or about 3 millimeters, or about 2 millimeters, or less. The length of the strands may be greater than about 5 millimeters, may be between about 5 millimeters and about 15 millimeters, may be between about 8 millimeters and about 12 millimeters, or may be about 12 millimeters. It is preferred that the strands have substantially the same length as each other. The length of the strands may be determined by the manufacturing process whereby the rod is cut into shorter plugs, the length of the strands corresponding to the length of the plugs. The strands are fragile and may break, especially during transition. In such cases, the length of some of the strands may be shorter than the length of the plugs.

[0072] The strands preferably extend substantially longitudinally along the length of the first aerosol-generating substrate, aligned with the longitudinal axis, and thus preferably are aligned substantially parallel to one another.

[0073] The homogenized tobacco material may comprise up to about 95 weight percent plant particles on a dry weight basis. Preferably, the homogenized tobacco material comprises up to about 90 weight percent plant particles on a dry weight basis, more preferably comprises up to about 80 weight percent plant particles, more preferably comprises up to about 70 weight percent plant particles, more preferably comprises up to about 60 weight percent plant particles, and more preferably comprises up to about 50 weight percent plant particles.

[0074] For example, the homogenized tobacco material may contain, on a dry weight basis, from about 2.5 weight percent to about 95 weight percent plant particles, or from about 5 weight percent to about 90 weight percent plant particles, or from about 10 weight percent to about 80 weight percent plant particles, or from about 15 weight percent to about 70 weight percent plant particles, or from about 20 weight percent to about 60 weight percent plant particles, or from about 30 weight percent to about 50 weight percent plant particles.

[0075] Sheets of homogenized tobacco material used in the present invention may have a tobacco content of at least about 40 weight percent on a dry weight basis, more preferably at least about 50 weight percent on a dry weight basis, more preferably at least about 70 weight percent on a dry weight basis, and most preferably at least about 90 weight percent on a dry weight basis.

[0076] In the context of the present invention, the term "tobacco particles" refers to particles of any plant member of the Nicotiana species. The term "tobacco particles" encompasses ground or powdered tobacco lamina, ground or powdered tobacco stems, tobacco dust, tobacco fines, and other particulate tobacco by-products formed during tobacco processing, handling, and shipping. In a preferred embodiment, the tobacco particles are substantially entirely derived from tobacco lamina. In contrast, isolated nicotine and nicotine salts, although compounds derived from tobacco, are not considered tobacco particles for purposes of the present invention and are not included in the percentage of particulate plant material.

[0077] The tobacco particles may be prepared from one or more tobacco plant varieties. Any type of tobacco may be used in the blend. Examples of types of tobacco that may be used include, but are not limited to, sun-cured tobacco, flue-cured tobacco, burley tobacco, Maryland tobacco, Orient tobacco, Virginia tobacco, and other specialty tobaccos.

[0078] Flame-curing is a tobacco curing method used specifically with Virginia tobacco. During the flue-curing process, heated air is circulated through tightly packed tobacco. During the first stage, the tobacco leaves turn yellow and wither. During the second stage, the leaf lamina dries completely. During the third stage, the leaf stem dries completely.

[0079] Burley tobacco plays an important role in many tobacco blends. It has a unique flavor and aroma, and the ability to absorb large amounts of casing.

[0080] Orient is a type of tobacco that has small leaves and high aromatic qualities. However, Orient tobacco has a milder flavor than, for example, Burley. Thus, Orient tobacco is generally used in relatively small proportions in tobacco blends.

[0081] Kasturi, Madura, and Jatim are subtypes of sun-cured tobacco that may be used. Preferably, Kasturi and flue-cured tobaccos are used in a blend to produce tobacco particles. Thus, the tobacco particles in the particulate plant material may comprise a blend of Kasturi and flue-cured tobaccos.

[0082] The tobacco particles may have a nicotine content of at least about 2.5 weight percent based on dry weight. More preferably, the tobacco particles may have a nicotine content of at least about 3 weight percent based on dry weight, even more preferably at least about 3.2 weight percent, even more preferably at least about 3.5 weight percent, and most preferably at least about 4 weight percent.

[0083] In certain other embodiments of the present invention, the homogenized tobacco material may include tobacco particles in combination with non-tobacco plant flavor particles. Preferably, the non-tobacco plant flavor particles are selected from one or more of ginger particles, eucalyptus particles, clove particles, and star anise particles. Preferably, in such embodiments, the homogenized tobacco material includes at least about 2.5 weight percent of non-tobacco plant flavor particles on a dry weight basis, with the remaining plant particles being tobacco particles. Preferably, the homogenized tobacco material includes at least about 4 weight percent of non-tobacco plant flavor particles on a dry weight basis, more preferably at least about 6 weight percent of non-tobacco plant flavor particles, more preferably at least about 8 weight percent of non-tobacco plant flavor particles, more preferably at least about 10 weight percent of non-tobacco plant flavor particles. Preferably, the homogenized tobacco material includes up to about 20 weight percent of non-tobacco plant flavor particles, more preferably up to about 18 weight percent of non-tobacco plant flavor particles, more preferably up to about 16 weight percent of non-tobacco plant flavor particles.

[0084] The weight ratio of non-tobacco plant flavour particles and tobacco particles in the particulate plant material forming the homogenized tobacco material can vary depending on the desired flavour characteristics and composition of the aerosol generated from the aerosol-generating substrate during use. Preferably, the homogenized tobacco material comprises, on a dry weight basis, at least a 1:30 weight ratio of non-tobacco plant flavour particles to tobacco particles, more preferably at least a 1:20 weight ratio of non-tobacco plant flavour particles to tobacco particles, more preferably at least a 1:10 weight ratio of non-tobacco plant flavour particles to tobacco particles, and most preferably at least a 1:5 weight ratio of non-tobacco plant flavour particles to tobacco particles.

[0085] The homogenized tobacco material preferably comprises no more than 95 weight percent particulate plant material on a dry weight basis. Accordingly, the particulate plant material is typically combined with one or more other ingredients to form the homogenized tobacco material.

[0086] The homogenized tobacco material may further comprise a binder for modifying the mechanical properties of the particulate plant material, where the binder is included in the homogenized tobacco material during manufacture as described herein.Suitable extrinsic binders known to those skilled in the art are known in the art and include, but are not limited to, gums such as guar gum, xanthan gum, gum arabic and locust bean gum, cellulose binders such as hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose and ethyl cellulose, polysaccharides such as starch, organic acids such as alginic acid, sodium alginate, conjugate base salts of organic acids such as agar and pectin, and combinations thereof.Preferably, the binder comprises guar gum.

[0087] The binder may be present in an amount of about 1 weight percent to about 10 weight percent, based on the dry weight of the homogenized tobacco material, preferably in an amount of about 2 weight percent to about 5 weight percent, based on the dry weight of the homogenized tobacco material.

[0088] The homogenized tobacco material may further include one or more lipids to enhance the diffusion rate of volatile components (e.g., aerosol formers, gingerols, and nicotine), where the lipids are included in the homogenized tobacco material during manufacture as described herein. Suitable lipids for inclusion within the homogenized tobacco material include, but are not limited to, medium chain triglycerides, cocoa butter, palm oil, palm kernel oil, mango oil, shea butter, soybean oil, cottonseed oil, coconut oil, hydrogenated coconut oil, candellila wax, carnauba wax, shellac, sunflower wax, sunflower oil, rice bran, and Revel A, and combinations thereof.

[0089] The homogenized tobacco material may further include a pH modifier.

[0090] The homogenized tobacco material may further include fibers to alter the mechanical properties of the homogenized tobacco material, and the fibers are included in the homogenized tobacco material during manufacture as described herein. Suitable exogenous fibers for inclusion in the homogenized tobacco material are known in the art and include fibers formed from non-tobacco materials and ginger materials, including, but not limited to, cellulose fibers, soft wood fibers, hard wood fibers, jute fibers, and combinations thereof. Exogenous fibers derived from tobacco and / or ginger may also be added. Any fibers added to the homogenized tobacco material are not considered to form part of the "particulate plant material" defined above. Prior to inclusion within the homogenized tobacco material, the fibers may be treated by any suitable process known in the art, including, but not limited to, mechanical pulping, refining, chemical pulping, bleaching, sulfate pulping, and combinations thereof. Typically, the fibers have a length greater than their width.

[0091] Suitable fibers are typically greater than 400 micrometers and have a length of 4 millimeters or less, with lengths in the range of 0.7 millimeters to 4 millimeters being preferred. The fibers are preferably present in an amount of about 2 weight percent to about 15 weight percent, most preferably about 4 weight percent, based on the dry weight of the substrate.

[0092] In the context of the present invention, the first aerosol-generating substrate further comprises one or more aerosol formers. Upon volatilization, the aerosol formers can carry other vaporized compounds, such as nicotine and flavorants in the aerosol, which are released from the first aerosol-generating substrate upon heating. Aerosol formers suitable for inclusion in the first aerosol-generating substrate are known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, propylene glycol, 1,3-butanediol and glycerol), esters of polyhydric alcohols (such as glycerol mono-, di- or triacetate), and aliphatic esters of mono-, di- or polycarboxylic acids (such as dimethyl dodecanedioate and tetradecanedioate).

[0093] In some embodiments, the first aerosol-generating substrate may include two or more of homogenized tobacco material, tobacco cast leaves, and reconstituted tobacco.

[0094] As an example, the first aerosol-generating substrate may include a sheet of homogenized tobacco material produced from a blend of high-quality tobacco leaf materials, with the aerosol former being intimately combined with the tobacco leaf material prior to forming the sheet from the resulting mixture. Such homogenized tobacco material may be tobacco cast leaf, or reconstituted tobacco, or a combination of both. The tobacco cast leaf or reconstituted tobacco, or both, may be, for example, standard cast leaf or standard reconstituted tobacco, including but not limited to, recovered tobacco particles formed from tobacco particles, with the standard cast leaf or standard reconstituted tobacco being impregnated with the aerosol former after being formed into a sheet.

[0095] The inventors have found that these tobacco materials may have different aerosol delivery profiles when heated under the same conditions for the same period of time. In particular, standard tobacco cast leaf may tend to release aerosol species more quickly and at a lower temperature compared to standard reconstituted tobacco. Standard reconstituted tobacco may then tend to release aerosol species more quickly and at a lower temperature compared to the homogenized tobacco material described above. Thus, by adjusting the relative proportions of these different tobacco materials in the first aerosol-generating substrate, it is advantageously possible to fine-tune the timing and intensity of aerosol delivery from the first aerosol-generating segment during use.

[0096] The first aerosol-generating substrate may have an aerosol former content of from about 5 weight percent to about 30 weight percent on a dry weight basis.

[0097] Preferably, the first aerosol-generating substrate has an aerosol former content of at least about 10 weight percent on a dry weight basis, more preferably at least about 15 weight percent on a dry weight basis.

[0098] The first aerosol-generating substrate preferably has an aerosol former content of about 25 weight percent or less on a dry weight basis, more preferably about 20 weight percent or less on a dry weight basis.

[0099] In some embodiments, the first aerosol-generating substrate has an aerosol former content of from 5 to 25 percent by weight on a dry weight basis, preferably from 10 to 25 percent by weight on a dry weight basis, more preferably from 15 to 25 percent by weight on a dry weight basis. In other embodiments, the first aerosol-generating substrate has an aerosol former content of from 5 to 20 percent by weight on a dry weight basis, preferably from 10 to 20 percent by weight on a dry weight basis, more preferably from 15 to 20 percent by weight on a dry weight basis.

[0100] In other embodiments, the first aerosol-generating substrate may have an aerosol former content of about 30 percent to about 45 percent by weight. This relatively high level of aerosol former is particularly suitable for first aerosol-generating substrates intended to be heated at temperatures below 275 degrees Celsius. In such embodiments, the first aerosol-generating substrate preferably further comprises a homogenized tobacco material comprising about 2 percent to about 10 percent by weight, on a dry weight basis, of a cellulose ether, and about 5 percent to about 50 percent by weight, on a dry weight basis, of additional cellulose. The use of a combination of cellulose ether and additional cellulose has been found to provide particularly effective aerosol delivery when used in an aerosol-generating substrate having an aerosol former content of 30 percent to 45 percent by weight.

[0101] Suitable cellulose ethers include, but are not limited to, methyl cellulose, hydroxypropyl methyl cellulose, ethyl cellulose, hydroxyl ethyl cellulose, hydroxyl propyl cellulose, ethyl hydroxyl ethyl cellulose and carboxymethyl cellulose (CMC). In a particularly preferred embodiment, the cellulose ether is carboxymethyl cellulose.

[0102] As used herein, the term "additional cellulose" encompasses any cellulose material incorporated into the homogenized tobacco material that is not derived from non-tobacco plant particles or tobacco particles provided in the homogenized tobacco material. Thus, the additional cellulose is incorporated into the homogenized tobacco material as an individual and separate cellulose source to any cellulose essentially provided within the non-tobacco plant particles or tobacco particles, in addition to the non-tobacco plant materials or tobacco materials. The additional cellulose is typically derived from a plant different from the non-tobacco plant particles or tobacco particles. Preferably, the additional cellulose is in the form of an inert cellulose material, which is sensorily inert and therefore does not substantially affect the sensory properties of the aerosol generated from the aerosol-generating substrate. For example, the additional cellulose is preferably a tasteless and odorless material.

[0103] The additional cellulose may include cellulose powder, cellulose fibers, or a combination thereof.

[0104] The aerosol former may act as a wetting agent in the aerosol-generating substrate.

[0105] As briefly described above, an aerosol-generating rod according to the present invention further comprises a second aerosol-generating segment located upstream of the first aerosol-generating segment.

[0106] The second aerosol-generation segment includes a plug of a porous substrate.

[0107] The term "porous substrate" is used herein to describe a material that provides a plurality of pores or openings that allow the passage of air through the material. The porous substrate can be any suitable porous material that is capable of holding or retaining the aerosol-generating medium or flavor, particularly when these are provided in liquid or gel form, as described below.

[0108] An advantage of a porous substrate loaded with an aerosol-generating medium or flavor is that the aerosol-generating medium or flavor is retained within the porous medium, which may aid in the manufacture, storage, or transportation of the gel composition. This is particularly effective when the aerosol-generating medium or flavor is in the form of a gel, since the use of a porous substrate may aid in preserving and maintaining the gel in a desired core location, particularly during use, but also during manufacture and transportation.

[0109] In certain embodiments, the porous substrate comprises natural, synthetic, or semi-synthetic materials, or a combination thereof. In certain embodiments, the porous substrate comprises a sheet material, a foam, or a fiber, such as loose fiber, or a combination thereof. In certain embodiments, the porous substrate comprises a woven, nonwoven, or extruded material, or a combination thereof. The porous substrate preferably comprises cotton, paper, viscose, PLA, or cellulose acetate, or a combination thereof. In some embodiments, the porous substrate may comprise an assembly of sheet materials, for example, made of cotton or cellulose acetate.

[0110] At least a core portion of the plug contains an aerosol-generating medium or a flavorant, or both.

[0111] Preferably, the peripheral portion of the plug surrounding the core portion is substantially free of aerosol-generating medium or flavourant. In a preferred embodiment, the peripheral portion of the plug extends all the way from the peripheral surface of the plug to the outer periphery of the core portion. In other words, the core portion of the plug contains either the aerosol-generating medium or flavourant, or both, and the remainder of the plug is substantially free of the aerosol-generating medium or flavourant.

[0112] The cross-sectional area of ​​the core portion may be at least about 30 percent of the cross-sectional area of ​​the second segment. Preferably, the cross-sectional area of ​​the core portion is at least about 40 percent of the cross-sectional area of ​​the second segment. More preferably, the cross-sectional area of ​​the core portion is at least about 50 percent of the cross-sectional area of ​​the second segment. Even more preferably, the cross-sectional area of ​​the core portion is at least about 60 percent of the cross-sectional area of ​​the second segment.

[0113] Preferably, the cross-sectional area of ​​the core portion is about 90 percent or less than the cross-sectional area of ​​the second segment. More preferably, the cross-sectional area of ​​the core portion is about 85 percent or less than the cross-sectional area of ​​the second segment. Even more preferably, the cross-sectional area of ​​the core portion is about 80 percent or less than the cross-sectional area of ​​the second segment.

[0114] In some embodiments, the cross-sectional area of ​​the core portion is about 30 percent to about 90 percent of the cross-sectional area of ​​the second segment, preferably about 40 percent to about 90 percent of the cross-sectional area of ​​the second segment, and more preferably about 50 percent to about 90 percent of the cross-sectional area of ​​the second segment. In other embodiments, the cross-sectional area of ​​the core portion is about 30 percent to about 85 percent of the cross-sectional area of ​​the second segment, preferably about 40 percent to about 85 percent of the cross-sectional area of ​​the second segment, and more preferably about 50 percent to about 85 percent of the cross-sectional area of ​​the second segment. In further embodiments, the cross-sectional area of ​​the core portion is about 30 percent to about 80 percent of the cross-sectional area of ​​the second segment, preferably about 40 percent to about 80 percent of the cross-sectional area of ​​the second segment, and more preferably about 50 percent to about 80 percent of the cross-sectional area of ​​the second segment.

[0115] The outer diameter of the second aerosol-generation segment is substantially the same as the outer diameter of the rod.

[0116] The aerosol-generation segment may have a length of at least about 2 millimeters. Preferably, the second aerosol-generation segment has a length of at least about 3 millimeters. More preferably, the second aerosol-generation segment has a length of at least about 4 millimeters.

[0117] The second aerosol-generation segment may have a length of up to about 10 millimeters. Preferably, the second aerosol-generation segment has a length of about 7 millimeters or less. More preferably, the second aerosol-generation segment has a length of about 5 millimeters or less.

[0118] In some embodiments, the second aerosol-generation segment has a length of about 2 millimeters to about 10 millimeters, preferably about 3 millimeters to about 10 millimeters, more preferably about 4 millimeters to about 10 millimeters. In other embodiments, the second aerosol-generation segment has a length of about 2 millimeters to about 17 millimeters, preferably about 3 millimeters to about 7 millimeters, more preferably about 4 millimeters to about 7 millimeters. In further embodiments, the second aerosol-generation segment has a length of about 2 millimeters to about 5 millimeters, preferably about 3 millimeters to about 5 millimeters, more preferably about 4 millimeters to about 5 millimeters.

[0119] In an aerosol-generating rod according to the present invention, the ratio of the length of the second aerosol-generation segment to the length of the first aerosol-generation segment is at least about 0.15. Preferably, the ratio of the length of the second aerosol-generation segment to the length of the first aerosol-generation segment is at least about 0.2. More preferably, the ratio of the length of the second aerosol-generation segment to the length of the first aerosol-generation segment is at least about 0.3.

[0120] Preferably, the ratio of the length of the second aerosol-generation segment to the length of the first aerosol-generation segment is about 0.5 or less. More preferably, the ratio of the length of the second aerosol-generation segment to the length of the first aerosol-generation segment is about 0.45 or less. Even more preferably, the ratio of the length of the second aerosol-generation segment to the length of the first aerosol-generation segment is about 0.4 or less.

[0121] In some embodiments, the ratio of the length of the second aerosol-generation segment to the length of the first aerosol-generation segment is about 0.15 to about 0.5, preferably about 0.2 to 0.5, more preferably about 0.3 to about 0.5. In other embodiments, the ratio of the length of the second aerosol-generation segment to the length of the first aerosol-generation segment is about 0.15 to about 0.45, preferably about 0.2 to 0.45, more preferably about 0.3 to about 0.45. In further embodiments, the ratio of the length of the second aerosol-generation segment to the length of the first aerosol-generation segment is about 0.15 to about 0.4, preferably about 0.2 to 0.4, more preferably about 0.3 to about 0.4.

[0122] The aerosol-generating medium or flavourant in the second aerosol-generation segment is preferably adapted to release volatile species as the tobacco material in the first aerosol-generation segment is heated to a second temperature (T2) that is less than the first temperature (T1) at which the tobacco material in the first aerosol-generation segment begins to release volatile species.

[0123] The difference (T1-T2) between the first temperature (T1) at which the tobacco material in the first aerosol-generation segment begins to release volatile species and the second temperature (T2) at which the aerosol-generating medium or flavorant in the second aerosol-generation segment begins to release volatile species is at least about 15 degrees Celsius. Preferably, the difference (T1-T2) between the first temperature (T1) at which the tobacco material in the first aerosol-generation segment begins to release volatile species and the second temperature (T2) at which the aerosol-generating medium or flavorant in the second aerosol-generation segment begins to release volatile species is at least about 20 degrees Celsius. More preferably, the difference (T1-T2) between the first temperature (T1) at which the tobacco material in the first aerosol-generation segment begins to release volatile species and the second temperature (T2) at which the aerosol-generating medium or flavorant in the second aerosol-generation segment begins to release volatile species is at least about 30 degrees Celsius.

[0124] The difference (T1-T2) between the first temperature (T1) at which the tobacco material in the first aerosol-generation segment begins to release volatile species and the second temperature (T2) at which the aerosol-generating medium or flavourant in the second aerosol-generation segment begins to release volatile species may be less than about 80 degrees Celsius. Preferably, the difference (T1-T2) between the first temperature (T1) at which the tobacco material in the first aerosol-generation segment begins to release volatile species and the second temperature (T2) at which the aerosol-generating medium or flavourant in the second aerosol-generation segment begins to release volatile species is less than about 70 degrees Celsius. More preferably, the difference (T1-T2) between the first temperature (T1) at which the tobacco material in the first aerosol-generation segment begins to release volatile species and the second temperature (T2) at which the aerosol-generating medium or flavourant in the second aerosol-generation segment begins to release volatile species is less than about 60 degrees Celsius.

[0125] In some embodiments, the difference (T1-T2) between the first temperature (T1) at which the tobacco material in the first aerosol-generation segment begins to release volatile species and the second temperature (T2) at which the aerosol-generating medium or flavorant in the second aerosol-generation segment begins to release volatile species is between about 15 degrees Celsius and about 80 degrees Celsius, preferably between about 20 degrees Celsius and about 80 degrees Celsius, and more preferably between about 30 degrees Celsius and about 80 degrees Celsius. In other embodiments, the difference (T1-T2) between the first temperature (T1) at which the tobacco material in the first aerosol-generation segment begins to release volatile species and the second temperature (T2) at which the aerosol-generating medium or flavorant in the second aerosol-generation segment begins to release volatile species is between about 15 degrees Celsius and about 80 degrees Celsius, preferably between about 20 degrees Celsius and about 70 degrees Celsius, and more preferably between about 30 degrees Celsius and about 70 degrees Celsius. In a further embodiment, the difference (T1-T2) between a first temperature (T1) at which the tobacco material in the first aerosol-generation segment begins to release volatile species and a second temperature (T2) at which the aerosol-generating medium or flavorant in the second aerosol-generation segment begins to release volatile species is between about 15 degrees Celsius and about 60 degrees Celsius, preferably between about 20 degrees Celsius and about 60 degrees Celsius, and more preferably between about 30 degrees Celsius and about 60 degrees Celsius.

[0126] By combining the aerosol-generating medium or flavourant, or both, in the second aerosol-generation segment with the tobacco material in the first aerosol-generation segment having the above-mentioned relationship, it may be advantageously possible to effectively counter the "cold puff" effect. In addition, it may be possible to achieve a smooth transition during use from an ascent phase, in which the second aerosol-generation segment is the primary source of aerosol species delivered to the consumer, to a plateau phase, in which the first aerosol-generation segment becomes and remains the primary source of aerosol-generating species delivered to the consumer.

[0127] The aerosol-generating medium or flavour may be adapted to release a volatile species upon heating to a temperature of at least about 50 degrees Celsius. Preferably, the aerosol-generating medium or flavour is adapted to release a volatile species upon heating to a temperature of at least about 60 degrees Celsius. More preferably, the aerosol-generating medium or flavour is adapted to release a volatile species upon heating to a temperature of at least about 70 degrees Celsius. Even more preferably, the aerosol-generating medium or flavour is adapted to release a volatile species upon heating to a temperature of at least about 80 degrees Celsius.

[0128] The aerosol-generating medium or flavour may be adapted to release a volatile species upon heating to a temperature of less than about 140 degrees Celsius. Preferably, the aerosol-generating medium or flavour is adapted to release a volatile species upon heating to a temperature of less than about 130 degrees Celsius. More preferably, the aerosol-generating medium or flavour is adapted to release a volatile species upon heating to a temperature of less than about 110 degrees Celsius.

[0129] In some embodiments, the aerosol-generating medium or flavor is adapted to release a volatile species upon heating to between about 60 degrees Celsius and about 140 degrees Celsius, preferably between about 70 degrees Celsius and about 140 degrees Celsius, and more preferably between about 80 degrees Celsius and about 140 degrees Celsius. In other embodiments, the aerosol-generating medium or flavor is adapted to release a volatile species upon heating to between about 60 degrees Celsius and about 130 degrees Celsius, preferably between about 70 degrees Celsius and about 130 degrees Celsius, and more preferably between about 80 degrees Celsius and about 130 degrees Celsius. In further embodiments, the aerosol-generating medium or flavor is adapted to release a volatile species upon heating to between about 60 degrees Celsius and about 110 degrees Celsius, preferably between about 70 degrees Celsius and about 110 degrees Celsius, and more preferably between about 80 degrees Celsius and about 110 degrees Celsius.

[0130] The inventors have found that by providing a second aerosol-generating segment that includes an aerosol-generating medium or flavor adapted to release volatile species within the above-mentioned temperature range, it is advantageously possible to achieve a good compensation of the first "cold puff" effect. Without wishing to be bound by theory, it is understood that this is because their volatilization temperatures are sufficiently far from the volatilization temperatures of the species contained in the tobacco material of the first aerosol-generating substrate. It is further understood that when the rod begins to heat, it is relatively easy to quickly and effectively heat the aerosol-generating medium or flavor in the core portion of the plug of the second aerosol-generating segment, and therefore aerosol generation and delivery to the consumer can begin very quickly.

[0131] In some embodiments, the aerosol-generating medium comprises a liquid or gel that impregnates the porous substrate.

[0132] In certain preferred embodiments, the aerosol-generating medium comprises a gel containing an alkaloid compound, an aerosol former, and at least one gelling agent.

[0133] The term "alkaloid compound" refers to any one of a class of naturally occurring organic compounds that contain one or more basic nitrogen atoms. Generally, alkaloids contain at least one nitrogen atom in an amine-type structure. This nitrogen atom or another nitrogen atom in the molecule of an alkaloid compound can be active as a base in an acid-base reaction. Most alkaloid compounds have one or more of their nitrogen atoms as part of a ring system, such as a heterocycle. In nature, alkaloid compounds are found primarily in plants, and are particularly common in certain families of flowering plants. However, some alkaloid compounds are found in animal species and fungi. In this disclosure, the term "alkaloid compound" refers to both naturally occurring and synthetically produced alkaloid compounds.

[0134] The aerosol generating medium may preferably include an alkaloid compound selected from the group consisting of nicotine, anatabine, and combinations thereof.

[0135] The aerosol generating medium preferably comprises nicotine.

[0136] The term "nicotine" refers to nicotine and nicotine derivatives, such as free base nicotine, nicotine salts, and the like.

[0137] The aerosol-generating medium preferably contains about 0.5 weight percent to about 10 weight percent of the alkaloid compound. The aerosol-generating medium may contain about 0.5 weight percent to about 5 weight percent of the alkaloid compound. The aerosol-generating medium preferably contains about 1 weight percent to about 3 weight percent of the alkaloid compound. The aerosol-generating medium may preferably contain about 1.5 weight percent to about 2.5 weight percent of the alkaloid compound. The aerosol-generating medium may preferably contain about 2 weight percent of the alkaloid compound.

[0138] The alkaloid compound component of the aerosol-generating medium may be the most volatile component of the aerosol-generating medium. In some embodiments, the aerosol-generating medium may comprise water, which may be the most volatile component of the aerosol-generating medium, and the alkaloid compound component of the aerosol-generating medium may be the second most volatile component of the aerosol-generating medium.

[0139] Nicotine is preferably included in the aerosol generating medium. Nicotine may be added to the aerosol generating medium in free base form or in salt form.

[0140] The aerosol-generating medium comprises from about 0.5 weight percent to about 10 weight percent nicotine, or from about 0.5 weight percent to about 5 weight percent nicotine. Preferably, the aerosol-generating medium comprises from about 1 weight percent to about 3 weight percent nicotine, or from about 1.5 weight percent to about 2.5 weight percent nicotine, or about 2 weight percent nicotine.

[0141] As briefly described above, the aerosol generating medium preferably further comprises an aerosol former. Ideally, the aerosol former is substantially resistant to thermal degradation at the operating temperature of the associated aerosol generating device. Suitable aerosol formers include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.). The polyhydric alcohol or mixtures thereof may be one or more of triethylene glycol, 1,3-butanediol, and glycerin (glycerol or propane-1,2,3-triol) or polyethylene glycol. The aerosol former is preferably glycerol.

[0142] The aerosol-generating medium may be in the form of a gel.

[0143] The gel may preferably include an alkaloid compound selected from the group consisting of nicotine, anatabine, and combinations thereof.

[0144] Preferably, the gel contains nicotine.

[0145] The term "nicotine" refers to nicotine and nicotine derivatives, such as free base nicotine, nicotine salts, and the like.

[0146] The gel preferably contains about 0.5 weight percent to about 10 weight percent of the alkaloid compound. The gel may contain about 0.5 weight percent to about 5 weight percent of the alkaloid compound. The gel preferably contains about 1 weight percent to about 3 weight percent of the alkaloid compound. The gel may preferably contain about 1.5 weight percent to about 2.5 weight percent of the alkaloid compound. The gel may preferably contain about 2 weight percent of the alkaloid compound.

[0147] The alkaloid compound component of the gel may be the most volatile component of the gel, in some embodiments, the gel may include water, which may be the most volatile component of the gel, and the alkaloid compound component of the gel may be the second most volatile component of the gel.

[0148] Preferably, nicotine is included in the gel. Nicotine may be added to the gel composition in its free base form or in its salt form.

[0149] The gel comprises from about 0.5 weight percent to about 10 weight percent nicotine, or from about 0.5 weight percent to about 5 weight percent nicotine. Preferably, the gel comprises from about 1 weight percent to about 3 weight percent nicotine, or from about 1.5 weight percent to about 2.5 weight percent nicotine, or about 2 weight percent nicotine.

[0150] As briefly described above, the gel preferably further comprises an aerosol former. Ideally, the aerosol former is substantially resistant to thermal degradation at the operating temperature of the associated aerosol generating device. Suitable aerosol formers include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.). The polyhydric alcohol or mixtures thereof may be one or more of triethylene glycol, 1,3-butanediol, and glycerin (glycerol or propane-1,2,3-triol) or polyethylene glycol. The aerosol former is preferably glycerol.

[0151] The gel may comprise a majority of the aerosol former. The gel may comprise a mixture of water and aerosol former, with the aerosol former forming a majority (by weight) of the gel. The aerosol former may form at least about 50 percent by weight of the gel. The aerosol former may form at least about 60 percent by weight, or at least about 65 percent by weight, or at least about 70 percent by weight of the gel. The aerosol former may form between about 70 percent by weight and about 80 percent by weight of the gel. The aerosol former may form between about 70 percent by weight and about 75 percent by weight of the gel.

[0152] The gel may comprise a majority of glycerol. The gel may comprise a mixture of water and glycerol, with glycerol forming a majority (by weight) of the gel. The glycerol may form at least about 50 percent by weight of the gel. The glycerol may form at least about 60 percent by weight, or at least about 65 percent by weight, or at least about 70 percent by weight of the gel. The glycerol may form about 70 percent to about 80 percent by weight of the gel. The glycerol may form about 70 percent to about 75 percent by weight of the gel.

[0153] Preferably, the gel further comprises at least one gelling agent. Preferably, the gel composition comprises a total amount of gelling agents in the range of about 0.4 weight percent to about 10 weight percent. More preferably, the gel comprises a gelling agent in the range of about 0.5 weight percent to about 8 weight percent. More preferably, the gel comprises a gelling agent in the range of about 1 weight percent to about 6 weight percent. More preferably, the gel comprises a gelling agent in the range of about 2 weight percent to about 4 weight percent. More preferably, the gel comprises a gelling agent in the range of about 2 weight percent to about 3 weight percent.

[0154] The term "gelling agent" refers to a compound that, when homogeneously added in an amount of about 0.3 weight percent to a 50 weight percent water / 50 weight percent glycerol mixture, leads to the formation of a solid medium or support matrix leading to a gel. Gelling agents include, but are not limited to, hydrogen bond cross-linking gelling agents and ionic cross-linking gelling agents.

[0155] The gelling agent may comprise one or more biopolymers. The biopolymers may be formed from polysaccharides.

[0156] Biopolymers include, for example, gellan gum (preferably native gellan gum, low acyl gellan gum, high acyl gellan gum, low acyl gellan gum), xanthan gum, alginate (alginic acid), agar, guar gum, etc. It may be preferred that the composition comprises xanthan gum. The composition may comprise two biopolymers. The composition may comprise three biopolymers. The composition may comprise two biopolymers in substantially equal amounts by weight. The composition may comprise three biopolymers in substantially equal amounts by weight.

[0157] Preferably, the gel comprises at least about 0.2 weight percent of the hydrogen bond crosslinked gelling agent. The gel preferably comprises at least about 0.2 weight percent of the ionic crosslinked gelling agent. Most preferably, the gel comprises at least about 0.2 weight percent of the hydrogen bond crosslinked gelling agent and at least about 0.2 weight percent of the ionic crosslinked gelling agent. The gel may comprise from about 0.5 weight percent to about 3 weight percent of the hydrogen bond crosslinked gelling agent and from about 0.5 weight percent to about 3 weight percent of the ionic crosslinked gelling agent, or from about 1 weight percent to about 2 weight percent of the hydrogen bond crosslinked gelling agent and from about 1 weight percent to about 2 weight percent of the ionic crosslinked gelling agent. The hydrogen bond crosslinked gelling agent and the ionic crosslinked gelling agent may be present in the gel in substantially equal amounts by weight.

[0158] The term "hydrogen bond cross-linking gelator" refers to a gelator that forms non-covalent or physical cross-links via hydrogen bonds. Hydrogen bonds are not covalent bonds to hydrogen atoms, but are a type of electrostatic dipole-dipole attraction between molecules. It results from the attraction between a hydrogen atom covalently bonded to an extremely electronegative atom, such as an N, O, or F atom, and another extremely electronegative atom.

[0159] The hydrogen-bond cross-linking gelling agent may comprise one or more of galactomannan, gelatin, agarose, or konjac gum, or agar. It may be preferred that the hydrogen-bond cross-linking gelling agent comprises agar.

[0160] The gel preferably contains the hydrogen-bond cross-linking gelling agent in the range of about 0.3 weight percent to about 5 weight percent. Preferably, the gel contains the hydrogen-bond cross-linking gelling agent in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the gel contains the hydrogen-bond cross-linking gelling agent in the range of about 1 weight percent to about 2 weight percent.

[0161] The gel may contain galactomannan in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the galactomannan may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the galactomannan may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the galactomannan may be in the range of about 1 weight percent to about 2 weight percent.

[0162] The gel may contain gelatin in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the gelatin may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the gelatin may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the gelatin may be in the range of about 1 weight percent to about 2 weight percent.

[0163] The gel may contain agarose in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the agarose may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the agarose may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the agarose may be in the range of about 1 weight percent to about 2 weight percent.

[0164] The gel may contain konjac gum in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the konjac gum may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the konjac gum may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the konjac gum may be in the range of about 1 weight percent to about 2 weight percent.

[0165] The gel may contain agar in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the agar may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the agar may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the agar may be in the range of about 1 weight percent to about 2 weight percent.

[0166] The term "ionically cross-linking gelator" refers to a gelator that forms non-covalent or physical cross-links through ionic bonds. Ionic cross-linking involves the association of polymer chains through non-covalent interactions. A cross-linked network is formed when multivalent molecules with opposite charges are electrostatically attracted to each other, giving rise to a cross-linked polymer network.

[0167] The ionic cross-linking gelling agent may include low acyl gellan, pectin, kappa carrageenan, iota carrageenan or alginate. Preferably, the ionic cross-linking gelling agent may include low acyl gellan.

[0168] The gel may contain an ionically cross-linking gelling agent in the range of about 0.3 weight percent to about 5 weight percent. Preferably, the gel contains an ionically cross-linking gelling agent in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the gel contains an ionically cross-linking gelling agent in the range of about 1 weight percent to about 2 weight percent.

[0169] The gel may contain low acyl gellan in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the low acyl gellan may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the low acyl gellan may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the low acyl gellan may be in the range of about 1 weight percent to about 2 weight percent.

[0170] The gel may contain pectin in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the pectin may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the pectin may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the pectin may be in the range of about 1 weight percent to about 2 weight percent.

[0171] The gel may include kappa carrageenan in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the kappa carrageenan may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the kappa carrageenan may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the kappa carrageenan may be in the range of about 1 weight percent to about 2 weight percent.

[0172] The gel may contain iota carrageenan in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the iota carrageenan may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the iota carrageenan may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the iota carrageenan may be in the range of about 1 weight percent to about 2 weight percent.

[0173] The gel may contain alginate in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the alginate may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the alginate may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the alginate may be in the range of about 1 weight percent to about 2 weight percent.

[0174] The gel may contain a hydrogen-bond cross-linking gelling agent and an ionic cross-linking gelling agent in a ratio of about 3:1 to about 1:3. Preferably, the gel may contain a hydrogen-bond cross-linking gelling agent and an ionic cross-linking gelling agent in a ratio of about 2:1 to about 1:2. Preferably, the gel may contain a hydrogen-bond cross-linking gelling agent and an ionic cross-linking gelling agent in a ratio of about 1:1.

[0175] The gel may further comprise a thickening agent. The thickening agent in combination with the hydrogen bond crosslinking gelling agent and the ionic crosslinking gelling agent surprisingly appears to support a solid medium and maintain the gel composition even when the gel composition contains high levels of glycerol.

[0176] The term "thickening agent" refers to a compound that, when uniformly added in an amount of 0.3 weight percent into a 50 weight percent water / 50 weight percent glycerol mixture at 25° C., increases the viscosity without resulting in the formation of a gel, and the mixture remains in a fluid state or remains fluid. Preferably, the thickening agent, when uniformly added in an amount of 0.3 weight percent into a 50 weight percent water / 50 weight percent glycerol mixture at 25° C., increases the viscosity by 0.1 s without resulting in the formation of a gel. -1 Preferably, the thickener is a compound that, when homogeneously added in an amount of 0.3 weight percent to a 50 weight percent water / 50 weight percent glycerol mixture at 25° C., increases the viscosity by 0.1 s without causing the formation of a gel, preferably increases the viscosity by at least 50 cPs, preferably increases the viscosity by at least 200 cPs, preferably increases the viscosity by at least 500 cPs, preferably increases the viscosity by at least 1000 cPs, and the mixture remains in a fluid state or remains fluid, at a shear rate of 0.1 s without causing the formation of a gel. -1 "fluid" refers to a compound that increases the viscosity of a mixture at a shear rate of at least 2 times, at least 5 times, at least 10 times, or at least 100 times greater than before its addition and that causes the mixture to remain in a fluid state or to remain fluid.

[0177] The viscosity values ​​listed herein may be measured using a Brookfield RVT viscometer with a disk type RV#2 spindle rotating at 25° C. and a speed of 6 revolutions per minute (rpm).

[0178] The gel preferably comprises a thickening agent in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the gel comprises a thickening agent in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the gel comprises a thickening agent in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the gel comprises a thickening agent in the range of about 1 weight percent to about 2 weight percent.

[0179] The thickening agent may include one or more of xanthan gum, carboxymethylcellulose, microcrystalline cellulose, methylcellulose, gum arabic, guar gum, lambda carrageenan, or starch. Preferably, the thickening agent may include xanthan gum.

[0180] The gel may contain xanthan gum in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the xanthan gum may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the xanthan gum may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the xanthan gum may be in the range of about 1 weight percent to about 2 weight percent.

[0181] The gel may include carboxymethylcellulose in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the carboxymethylcellulose may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the carboxymethylcellulose may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the carboxymethylcellulose may be in the range of about 1 weight percent to about 2 weight percent.

[0182] The gel may contain microcrystalline cellulose in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the microcrystalline cellulose may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the microcrystalline cellulose may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the microcrystalline cellulose may be in the range of about 1 weight percent to about 2 weight percent.

[0183] The gel may contain methylcellulose in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the methylcellulose may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the methylcellulose may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the methylcellulose may be in the range of about 1 weight percent to about 2 weight percent.

[0184] The gel may include gum arabic in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the gum arabic may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the gum arabic may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the gum arabic may be in the range of about 1 weight percent to about 2 weight percent.

[0185] The gel may contain guar gum in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the guar gum may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the guar gum may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the guar gum may be in the range of about 1 weight percent to about 2 weight percent.

[0186] The gel may include lambda carrageenan in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the lambda carrageenan may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the lambda carrageenan may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the lambda carrageenan may be in the range of about 1 weight percent to about 2 weight percent.

[0187] The gel may include starch in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the starch may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the starch may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the starch may be in the range of about 1 weight percent to about 2 weight percent.

[0188] The gel may further comprise a divalent cation. Preferably, the divalent cation comprises calcium ions, such as calcium lactate in solution. The divalent cation (such as calcium ions) may aid in gel formation in compositions that include a gelling agent, such as an ionically cross-linking gelling agent. Ionic effects may aid in gel formation. The divalent cation may be present in the gel composition in a range of about 0.1 to about 1 weight percent, or about 0.5 to about 1 weight percent.

[0189] The gel may further comprise an acid. The acid may comprise a carboxylic acid. The carboxylic acid may comprise a ketone group. Preferably, the carboxylic acid may comprise a ketone group having less than about 10 carbon atoms, such as levulinic acid or lactic acid, or less than about 6 carbon atoms or less than about 4 carbon atoms. Preferably, the carboxylic acid has three carbon atoms (such as lactic acid). Lactic acid surprisingly improves the stability of the gel over similar carboxylic acids. The carboxylic acid may aid in gel formation. The carboxylic acid may reduce the change in the concentration of alkaloid compounds in the gel during storage. The carboxylic acid may reduce the change in the concentration of nicotine in the gel during storage.

[0190] The gel may include a carboxylic acid in the range of about 0.1 weight percent to about 5 weight percent. Preferably, the carboxylic acid may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the carboxylic acid may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the carboxylic acid may be in the range of about 1 weight percent to about 2 weight percent.

[0191] The gel may include lactic acid in the range of about 0.1 weight percent to about 5 weight percent. Preferably, the lactic acid may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the lactic acid may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the lactic acid may be in the range of about 1 weight percent to about 2 weight percent.

[0192] The gel may include levulinic acid in the range of about 0.1 weight percent to about 5 weight percent. Preferably, the levulinic acid may be in the range of about 0.5 weight percent to about 3 weight percent. Preferably, the levulinic acid may be in the range of about 0.5 weight percent to about 2 weight percent. Preferably, the levulinic acid may be in the range of about 1 weight percent to about 2 weight percent.

[0193] The gel preferably contains some water. If the gel contains some water, the gel is more stable. The gel preferably contains at least about 1 weight percent water, or at least about 2 weight percent water, or at least about 5 weight percent water. The gel preferably contains at least about 10 weight percent water, or at least about 15 weight percent water.

[0194] The gel preferably contains about 8 weight percent to about 32 weight percent water. The gel preferably contains about 15 weight percent to about 25 weight percent water. The gel preferably contains about 18 weight percent to about 22 weight percent water. The gel preferably contains about 20 weight percent water.

[0195] In a preferred embodiment, the aerosol-generating rod further comprises a non-aerosol-generating segment downstream of the first aerosol-generating segment, the non-aerosol-generating segment comprising a plug of porous substrate, the plug of porous substrate being substantially free of the aerosol-generating compound.

[0196] Advantageously, the non-aerosol-generating segment may support the first aerosol-generating segment and help prevent any of the tobacco material contained in the first aerosol-generating segment from becoming dislodged. Additionally, the non-aerosol-generating segment contributes to the overall structural strength of the rod, facilitating its handling, particularly during manufacture.

[0197] Preferably, the plugs of porous substrate in the non-aerosol-generating segments do not contribute substantially to the overall RTD of the rod.

[0198] The outer diameter of the non-aerosol-generating segment is substantially the same as the outer diameter of the rod.

[0199] The non-aerosol-generating segment may have a length of at least about 2 millimeters. Preferably, the non-aerosol-generating segment has a length of at least about 3 millimeters. More preferably, the non-aerosol-generating segment has a length of at least about 4 millimeters.

[0200] The non-aerosol-generating segments may have a length of up to about 10 millimeters. Preferably, the non-aerosol-generating segments have a length of about 7 millimeters or less. More preferably, the non-aerosol-generating segments have a length of about 5 millimeters or less.

[0201] In some embodiments, the non-aerosol-generating segments have a length of about 2 millimeters to about 10 millimeters, preferably about 3 millimeters to about 10 millimeters, and more preferably about 4 millimeters to about 10 millimeters. In other embodiments, the non-aerosol-generating segments have a length of about 2 millimeters to about 17 millimeters, preferably about 3 millimeters to about 7 millimeters, and more preferably about 4 millimeters to about 7 millimeters. In further embodiments, the non-aerosol-generating segments have a length of about 2 millimeters to about 5 millimeters, preferably about 3 millimeters to about 5 millimeters, and more preferably about 4 millimeters to about 5 millimeters.

[0202] As is already apparent from the above description, the aerosol-generating rod according to the invention is used in the manufacture of an aerosol-generating article, such as an aerosol-generating article for producing an inhalable aerosol on heating.

[0203] An aerosol-generating article according to the invention may comprise an aerosol-generating rod as described above and may further comprise a downstream section at a position downstream of the aerosol-generating rod. Additionally or alternatively, an aerosol-generating article according to the invention may comprise an upstream section at a position upstream of the aerosol-generating rod.

[0204] The downstream section may include one or more downstream elements.

[0205] The downstream section may include a support element disposed in alignment with and downstream of the aerosol-generation rod, in particular the support element may be located immediately downstream of the aerosol-generation rod and may abut the aerosol-generation rod.

[0206] The support element may be formed from any suitable material or combination of materials. For example, the support element may be formed from one or more materials selected from the group consisting of cellulose acetate, cardboard, crimped paper (such as crimped heat-resistant paper or crimped parchment paper), and polymeric materials (such as low-density polyethylene (LDPE)). In a preferred embodiment, the support element is formed from cellulose acetate. Other suitable materials include polyhydroxyalkanoate (PHA) fibers.

[0207] The support element may comprise a hollow tubular segment. In a preferred embodiment, the support element comprises a hollow cellulose acetate tube.

[0208] The support element is disposed substantially in alignment with the aerosol-generating rod, meaning that the length dimension of the support element is disposed approximately parallel to the longitudinal direction of the rod and article, for example within ±10 degrees of parallel to the longitudinal direction of the rod. In a preferred embodiment, the support element extends along the longitudinal axis of the rod.

[0209] The support element preferably has an outer diameter approximately equal to the outer diameter of the aerosol-generating rod.

[0210] The peripheral wall of the support element may have a thickness of at least 1 millimeter, preferably at least about 1.5 millimeters, and more preferably at least about 2 millimeters.

[0211] The support elements may have a length of about 5 millimeters to about 15 millimeters. Preferably, the support elements have a length of at least about 6 millimeters, and more preferably at least about 7 millimeters. In preferred embodiments, the support elements have a length of less than about 12 millimeters, and more preferably less than about 10 millimeters.

[0212] In some embodiments, the support element has a length of about 5 millimeters to about 15 millimeters, preferably about 6 millimeters to about 15 millimeters, and more preferably about 7 millimeters to about 15 millimeters. In other embodiments, the support element has a length of about 5 millimeters to about 12 millimeters, preferably about 6 millimeters to about 12 millimeters, and more preferably about 7 millimeters to about 12 millimeters. In further embodiments, the support element has a length of about 5 millimeters to about 10 millimeters, preferably about 6 millimeters to about 10 millimeters, and more preferably about 7 millimeters to about 10 millimeters.

[0213] In a preferred embodiment, the support element has a length of about 8 millimeters.

[0214] Preferably, the hollow tubular segment of the support element is adapted to generate an RTD of approximately 0 millimeters of H2O (about 0 Pa) to approximately 20 millimeters of H2O (about 100 Pa), more preferably approximately 0 millimeters of H2O (about 0 Pa) to approximately 10 millimeters of H2O (about 100 Pa). Thus, the support element preferably does not contribute to the overall RTD of the aerosol-generating article.

[0215] In certain preferred embodiments, the downstream section of the aerosol-generating article comprises a mouthpiece element positioned downstream of and longitudinally aligned with the aerosol-generating rod.

[0216] The mouthpiece element is preferably located at the downstream or mouth end of the aerosol-generating article and extends all the way to the mouth end of the aerosol-generating article.

[0217] Preferably, the mouthpiece element comprises at least one mouthpiece filter segment of fibrous filtration material for filtering the aerosol generated from the aerosol-generating substrate. Suitable fibrous filtration materials will be known to those skilled in the art. It is particularly preferred that the at least one mouthpiece filter segment comprises a cellulose acetate filter segment formed from cellulose acetate tow.

[0218] In certain preferred embodiments, the mouthpiece element comprises a single mouthpiece filter segment, hi alternative embodiments, the mouthpiece element comprises two or more mouthpiece filter segments axially aligned in abutting end-to-end relationship with one another.

[0219] In certain embodiments of the invention, the downstream section may comprise an oral end recess at a downstream end downstream of the mouthpiece element as described above. The oral end cavity may be defined by a hollow tubular element provided at the downstream end of the mouthpiece. The oral end cavity may be defined by an outer wrapper of the mouthpiece element, the outer wrapper extending in a downstream direction from the mouthpiece element.

[0220] The mouthpiece element may optionally include a flavorant, which may be provided in any suitable form, for example, the mouthpiece element may include one or more capsules, beads or granules of flavorant, or one or more flavor-loaded threads or filaments.

[0221] In certain preferred embodiments, the downstream section of the aerosol-generating article further comprises both a support element located immediately downstream of the aerosol-generating rod, and a mouthpiece element located downstream of the support element.

[0222] Preferably, the mouthpiece element has a low particle filtration efficiency.

[0223] Preferably, the mouthpiece is formed from a segment of fibrous filtration material.

[0224] The mouthpiece element is preferably surrounded by a plug wrap. The mouthpiece element is preferably non-ventilated so that air does not enter the aerosol-generating article along the mouthpiece element.

[0225] The mouthpiece element is preferably connected to one or more of the adjacent upstream components of the aerosol-generating article by a leading wrapper.

[0226] Preferably, the mouthpiece elements have an RTD of less than about 25 millimeters HO. More preferably, the mouthpiece elements have an RTD of less than about 20 millimeters HO. Even more preferably, the mouthpiece elements have an RTD of less than about 15 millimeters HO.

[0227] RTD values ​​of about 10 millimeters HO to about 15 millimeters HO are particularly preferred, as a mouthpiece element having one such RTD is expected to contribute minimally to the overall RTD of the aerosol-generating article and therefore provide substantially no filtering effect on the aerosol delivered to the consumer.

[0228] The mouthpiece element preferably has an outer diameter approximately equal to the outer diameter of the aerosol-generating article.

[0229] The mouthpiece element preferably has a length of at least about 5 millimeters, more preferably at least about 8 millimeters, more preferably at least about 10 millimeters. The mouthpiece element may preferably have a length of less than about 25 millimeters, more preferably less than about 20 millimeters, more preferably less than about 15 millimeters.

[0230] In some embodiments, the mouthpiece element preferably has a length of about 5 millimeters to about 25 millimeters, more preferably about 8 millimeters to about 25 millimeters, and even more preferably about 10 millimeters to about 25 millimeters. In other embodiments, the mouthpiece element preferably has a length of about 5 millimeters to about 10 millimeters, more preferably about 8 millimeters to about 20 millimeters, and even more preferably about 10 millimeters to about 20 millimeters. In further embodiments, the mouthpiece element preferably has a length of about 5 millimeters to about 15 millimeters, more preferably about 8 millimeters to about 15 millimeters, and even more preferably about 10 millimeters to about 15 millimeters.

[0231] For example, the mouthpiece element may have a length of about 5 millimeters to about 25 millimeters, or about 8 millimeters to about 20 millimeters, or about 10 millimeters to about 15 millimeters. In a preferred embodiment, the mouthpiece element has a length of approximately 12 millimeters.

[0232] In a particularly preferred embodiment, the downstream section further comprises an aerosol cooling element located downstream of the support element, and the mouthpiece element is located downstream of both the support element and the aerosol cooling element. Particularly preferably, the mouthpiece element is located immediately downstream of the aerosol cooling element. As an example, the mouthpiece element may abut the downstream end of the aerosol cooling element.

[0233] The aerosol cooling element may define multiple longitudinally extending channels, for example to create a high surface area available for heat exchange. The multiple longitudinally extending channels may be defined by a sheet material that is pleated, assembled, or folded to form the channels. The multiple longitudinally extending channels may be defined by a single sheet that is pleated, assembled, or folded to form the channels. The sheet may also be crimped before being pleated, assembled, or folded. The multiple longitudinally extending channels may be defined by multiple sheets that are crimped, pleated, assembled, or folded to form the channels. In some embodiments, the multiple longitudinally extending channels may be defined by multiple sheets that are crimped, pleated, assembled, or folded, i.e., two or more sheets that are brought into an overlay arrangement and then crimped, pleated, assembled, or folded as one.

[0234] One such additional aerosol cooling element may have a total surface area of ​​about 300 square millimeters per millimeter of length to about 1000 square millimeters per millimeter of length.

[0235] One such aerosol cooling element preferably provides a low draw resistance to the passage of air through the additional cooling element. Preferably, the aerosol cooling element does not substantially affect the draw resistance of the aerosol-generating article. The aerosol cooling element preferably comprises a sheet material selected from the group consisting of metal foil, polymer sheet, and substantially non-porous paper or cardboard. In some embodiments, the aerosol cooling element may comprise a sheet material selected from the group consisting of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA) and aluminum foil. In a particularly preferred embodiment, the additional cooling element comprises a sheet of PLA.

[0236] The aerosol-generating article further comprises an upstream section at a location upstream of the aerosol-generating element. The upstream section may comprise one or more upstream elements. In some embodiments, the upstream section may comprise an upstream element disposed immediately upstream of the aerosol-generating element.

[0237] The upstream element may provide an improved appearance to the upstream end of the aerosol-generating article. Additionally, if desired, the upstream element may be used to provide information about the aerosol-generating article, such as information about the brand, flavor, content, or details of the aerosol-generating device with which the article is intended to be used.

[0238] The upstream element may be a porous plug element. Preferably, the porous plug element does not alter the resistance to withdrawal of the aerosol-generating article. Preferably, the upstream element has a porosity of at least about 50 percent in the longitudinal direction of the aerosol-generating article. More preferably, the upstream element has a porosity of between about 50 percent and about 90 percent in the longitudinal direction. The longitudinal porosity of the upstream element is defined by the ratio of the cross-sectional area of ​​the material forming the upstream element to the internal cross-sectional area of ​​the aerosol-generating article at the location of the upstream element.

[0239] The upstream element may be made of a porous material or may comprise a plurality of openings, which may be achieved, for example, by laser drilling, and which are preferably homogeneously distributed across the cross section of the upstream element.

[0240] The porosity or permeability of the upstream element may be advantageously varied to provide a desired overall withdrawal resistance of the aerosol-generating article.

[0241] It is preferred that the RTD of the upstream element is at least about 5 millimeters of H2O. More preferably, the RTD of the upstream element is at least about 10 millimeters of H2O. Even more preferably, the RTD of the upstream element is at least about 15 millimeters of H2O. In a particularly preferred embodiment, the RTD of the upstream element is at least about 20 millimeters of H2O.

[0242] The RTD of the upstream element is preferably less than or equal to about 80 millimeters of H2O. More preferably, the RTD of the upstream element is less than or equal to about 60 millimeters of H2O. Even more preferably, the RTD of the upstream element is less than or equal to about 40 millimeters of H2O.

[0243] In some embodiments, the RTD of the upstream element is about 5 millimeters H2O to about 80 millimeters H2O, preferably about 10 millimeters H2O to about 80 millimeters H2O, more preferably about 15 millimeters H2O to about 80 millimeters H2O, and even more preferably about 20 millimeters H2O to about 80 millimeters H2O. In other embodiments, the RTD of the upstream element is about 5 millimeters H2O to about 60 millimeters H2O, preferably about 10 millimeters H2O to about 60 millimeters H2O, more preferably about 15 millimeters H2O to about 60 millimeters H2O, and even more preferably about 20 millimeters H2O to about 60 millimeters H2O. In further embodiments, the RTD of the upstream element is about 5 millimeters H2O to about 40 millimeters H2O, preferably about 10 millimeters H2O to about 40 millimeters H2O, more preferably about 15 millimeters H2O to about 40 millimeters H2O, and even more preferably about 20 millimeters H2O to about 40 millimeters H2O.

[0244] In alternative embodiments, the upstream element may be formed from a material that is impermeable to air. In such embodiments, the aerosol-generating article may be configured to allow air to flow into the aerosol-generating rod via suitable vent means provided in the wrapper.

[0245] The upstream element may be made of any material suitable for use in an aerosol-generating article. The upstream element may be made of the same material as that used in one of the other components of the aerosol-generating article, such as the mouthpiece, cooling element, or support element. Suitable materials for the upstream element include filter material, ceramic, polymeric material, cellulose acetate, cardboard, zeolite, or an aerosol-generating substrate. The upstream element is preferably formed from a plug of cellulose acetate.

[0246] The upstream element is preferably formed from a heat resistant material, for example, the upstream element is preferably formed from a material that can withstand temperatures up to 350 degrees Celsius, thereby ensuring that the upstream element is not adversely affected by the heating means for heating the aerosol-generating substrate.

[0247] The upstream element preferably has a diameter approximately equal to the diameter of the aerosol-generating article.

[0248] Preferably, the upstream element has a length of about 1 millimeter to about 10 millimeters, more preferably about 3 millimeters to about 8 millimeters, and even more preferably about 4 millimeters to about 6 millimeters. In a particularly preferred embodiment, the upstream element has a length of about 5 millimeters. The length of the upstream element may be advantageously varied to provide a desired overall length of the aerosol-generating article. For example, if it is desired to reduce the length of one of the other components of the aerosol-generating article, the length of the upstream element may be increased to maintain the same overall length of the article.

[0249] The upstream element preferably has a substantially homogeneous structure. For example, the upstream element may be substantially homogeneous in texture and appearance. The upstream element may, for example, have a continuous regular surface over its entire cross section. The upstream element may, for example, have no discernible symmetry.

[0250] The upstream element is preferably surrounded by a wrapper that is preferably a stiff plug wrap, such as a plug wrap having a basis weight of at least about 80 grams per square meter (gsm), or at least about 100 gsm, or at least about 110 gsm, which provides structural rigidity to the upstream element.

[0251] The aerosol-generating article may have a length of from about 35 millimeters to about 100 millimeters.

[0252] The aerosol-generating article may have a length of from about 35 millimeters to about 100 millimeters.

[0253] Preferably, the overall length of an aerosol-generating article according to the invention is at least about 38 millimeters. More preferably, the overall length of an aerosol-generating article according to the invention is at least about 40 millimeters. Even more preferably, the overall length of an aerosol-generating article according to the invention is at least about 42 millimeters.

[0254] Preferably, the overall length of an aerosol-generating article according to the invention is 70 mm or less. More preferably, the overall length of an aerosol-generating article according to the invention is 60 mm or less. Even more preferably, the overall length of an aerosol-generating article according to the invention is 50 mm or less.

[0255] In some embodiments, the total length of the aerosol-generating article is preferably between about 38 millimeters and about 70 millimeters, more preferably between about 40 millimeters and about 70 millimeters, and even more preferably between about 42 millimeters and about 70 millimeters. In other embodiments, the total length of the aerosol-generating article is preferably between about 38 millimeters and about 60 millimeters, more preferably between about 40 millimeters and about 60 millimeters, and even more preferably between about 42 millimeters and about 60 millimeters. In further embodiments, the total length of the aerosol-generating article is preferably between about 38 millimeters and about 50 millimeters, more preferably between about 40 millimeters and about 50 millimeters, and even more preferably between about 42 millimeters and about 50 millimeters. In an exemplary embodiment, the total length of the aerosol-generating article is about 45 millimeters.

[0256] The aerosol-generating article has an outer diameter of at least 5 millimeters. Preferably, the aerosol-generating article has an outer diameter of at least 6 millimeters. More preferably, the aerosol-generating article has an outer diameter of at least 7 millimeters.

[0257] Preferably, the aerosol-generating article has an outer diameter of about 12 millimeters or less. More preferably, the aerosol-generating article has an outer diameter of about 10 millimeters or less. Even more preferably, the aerosol-generating article has an outer diameter of about 8 millimeters or less.

[0258] In some embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 12 mm, preferably about 6 mm to about 12 mm, more preferably about 7 mm to about 12 mm. In other embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 10 mm, preferably about 6 mm to about 10 mm, more preferably about 7 mm to about 10 mm. In further embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 8 mm, preferably about 6 mm to about 8 mm, more preferably about 7 mm to about 8 mm.

[0259] In a particularly preferred embodiment, an aerosol-generating article according to the invention comprises, in a linear continuous arrangement, an upstream element, an aerosol-generating rod located immediately downstream of the upstream element, a support element located immediately downstream of the aerosol-generating element, a mouthpiece element located immediately downstream of the support element, and an outer wrapper surrounding the upstream element, aerosol-generating element, support element and mouthpiece element.

[0260] More particularly, the aerosol generation rod may abut the upstream element. The support element may abut the aerosol generation rod. The aerosol cooling element may abut the support element. The mouthpiece element may abut the aerosol cooling element.

[0261] The aerosol-generating article has a substantially cylindrical shape and an outer diameter of about 7.25 millimeters.

[0262] The upstream element has a length of about 9 millimeters, the aerosol-generating element has a length of about 12 millimeters, the support element has a length of about 18 millimeters, and the mouthpiece element has a length of about 8 millimeters. Thus, the overall length of the aerosol-generating article is about 47 millimeters.

[0263] The upstream element is in the form of a plug of cellulose acetate encased in stiff plug wrap.

[0264] The aerosol-generating rod comprises, in a linear sequential arrangement, a second aerosol-generating segment comprising a plug of porous substrate and the aerosol-generating gel described above provided in a core portion of the plug, a first aerosol-generating segment comprising an assembly of sheets of homogenized tobacco material, and a non-aerosol-generating segment comprising a plug of porous substrate.

[0265] The mouthpiece is in the form of a low density cellulose acetate filter segment.

[0266] The aerosol-generating rod and article according to the invention may be used in an aerosol-generating device comprising a heater for heating the rod or article. The present invention therefore also relates to an aerosol-generating system comprising one such aerosol-generating device, e.g. an electrically heated aerosol-generating device, and an aerosol-generating article comprising the aerosol-generating rod described above. Examples of suitable aerosol-generating devices are known to those skilled in the art. In general, suitable aerosol-generating devices comprise a heating chamber for receiving at least the first and second aerosol-generating segments, and a heater adapted to heat the first and second aerosol-generating segments when received in the chamber.

[0267] This includes, but is not limited to, aerosol generators that include one or more induction heaters disposed about the exterior surface of a tubular susceptor element that defines a heating chamber, although aerosol generators with other types of external heater elements may also be suitable.

[0268] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of any other example, embodiment, or aspect described herein.

[0269] Example 1. 1. An aerosol-generating rod for producing an inhalable aerosol upon heating, the aerosol-generating rod comprising: a first aerosol-generating segment comprising a first aerosol-generating substrate, the first aerosol-generating substrate comprising a tobacco material and an aerosol former; and a second aerosol-generating segment located upstream of the first aerosol-generating segment, the second aerosol-generating segment comprising a plug of porous substrate, at least a core portion of the plug comprising an aerosol-generating medium or a flavourant, or both. Example 2. An aerosol-generating rod according to Example 1, wherein the peripheral portion of the plug is substantially free of aerosol-generating medium or flavouring agent. Example 3. An aerosol-generating rod according to Example 1 or 2, comprising a non-aerosol-generation segment downstream of the first aerosol-generation segment, the non-aerosol-generation segment comprising a plug of porous substrate. Example 4. An aerosol-generating rod according to any one of Examples 1 to 3, comprising a non-porous wrapper surrounding at least a first aerosol-generating segment and a second aerosol-generating segment. Example 5. An aerosol-generating rod according to Example 4, wherein the non-porous wrapper comprises a metal foil. Example 6. An aerosol-generating rod according to any one of Examples 1 to 5, wherein the first aerosol-generating substrate comprises one or more of homogenized tobacco material, cast tobacco leaf, and reconstituted tobacco. Example 7. An aerosol-generating rod according to any one of Examples 1 to 6, wherein the first aerosol-generating substrate further comprises non-tobacco plant material. Example 8. An aerosol-generating rod according to any one of Examples 1 to 7, wherein the aerosol-generating medium comprises a liquid or gel impregnating the porous substrate. Example 9. An aerosol-generating rod according to any one of Examples 1 to 8, wherein the aerosol-generating medium comprises a gel containing an alkaloid compound, an aerosol former, and at least one gelling agent. Example 10. An aerosol-generating rod according to any one of Examples 1 to 9, wherein the length of the first aerosol-generating segment is between 5 millimeters and 25 millimeters. Example 11. An aerosol-generating rod according to any one of Examples 1 to 10, wherein the length of the second aerosol-generating segment is between 2 millimeters and 10 millimeters. Example 12. An aerosol-generating rod according to any one of Examples 1 to 11, wherein the ratio between the length of the first aerosol-generating segment and the length of the second segment is between 0.15 and 0.5. Example 13. The aerosol-generating rod according to any one of Examples 1-12, wherein the cross-sectional area of ​​the core portion is at least 50 percent of the cross-sectional area of ​​the second segment. Example 14. An aerosol-generating article comprising an aerosol-generating rod according to any one of Examples 1 to 13. Example 15. An aerosol generating system comprising a heating device and an aerosol generating article according to Example 14.

[0270] The aerosol-generating rod 10 shown in Figure 1 comprises a first aerosol-generation segment 12 and a second aerosol-generation segment 14 located upstream of the first aerosol-generation segment 12. In addition, the aerosol-generation segment 10 comprises a non-aerosol-generation segment 16 located downstream of the first aerosol-generation segment 12.

[0271] The first aerosol-generation segment 12, the second aerosol-generation segment 14, and the non-aerosol-generation segment 16 are arranged in linear succession. The first aerosol-generation segment 12 is located immediately downstream of the second aerosol-generation segment 14, and the non-aerosol-generation segment 16 is located immediately downstream of the first aerosol-generation segment 12. Even more specifically, the upstream end of the first aerosol-generation segment 12 abuts the downstream end of the second aerosol-generation segment 14, and the upstream end of the non-aerosol-generation segment 16 abuts the downstream end of the first aerosol-generation segment 12. Thus, the aerosol-generation rod 10 extends from an upstream or distal end 18 to a downstream or oral end 20. The arrows in FIG. 1C indicate the intended direction of airflow through the rod 10 during use.

[0272] The first aerosol-generating segment has a length of about 12 millimeters. The aerosol-generating segment 14 has a length of about 5 millimeters. The non-aerosol-generating segment 16 has a length of about 3 millimeters. Thus, the aerosol-generating rod has a total length of about 20 millimeters.

[0273] The aerosol-generating rod 10 further comprises a wrapper 22 that surrounds the first aerosol-generating segment 12, the second aerosol-generating segment 14, and the non-aerosol-generating segment 16. In the embodiment of Figures 1A, 1B, and 1C, the wrapper is non-porous and formed of a metal foil.

[0274] The aerosol-generating rod has a diameter of about 7.25 millimeters.

[0275] The first aerosol-generating segment 12 includes a first aerosol-generating substrate 22 that includes tobacco material and an aerosol former. More specifically, the first aerosol-generating substrate includes an assemblage of a sheet of homogenized tobacco material.

[0276] The second aerosol-generation segment 14 includes a plug 18 of porous substrate. A core portion 24 of the plug 18 includes the aerosol-generation medium. A peripheral portion 26 of the plug surrounding the core portion 18 is substantially free of the aerosol-generation medium. The cross-sectional area of ​​the core portion 24 is approximately 60 percent of the cross-sectional area of ​​the second aerosol-generation segment 14.

[0277] The aerosol-generating article 50 shown in Figure 2 comprises the rod 10 described above, a hollow cellulose acetate tube 52, a spacer element 54, and a mouthpiece filter 56. These four elements are arranged in contiguous and coaxial alignment and surrounded by a wrapper 58 to form the aerosol-generating article 50. The aerosol-generating article 50 has an oral end 60 and a distal end 62 located at the opposite end of the article relative to the oral end 60. The aerosol-generating article 10 shown in Figure 2 is particularly suitable for use in an electrically operated aerosol generating device that includes a heater for heating the rod 10.

[0278] Figures 4A and 4B show a schematic representation of an electrically operated aerosol generating apparatus 200, with some elements removed in Figure 4A. The aerosol generating apparatus 200 utilizes an external inductor coil 210 and susceptor sleeve 212 pair to heat the rod 10 of the aerosol-generating article 50 described above. The inductor coil 210 is mounted around the susceptor sleeve 212 and defines a cylindrical chamber for receiving the aerosol-generating article 50, as shown diagrammatically in Figure 4B.

[0279] The aerosol generating device 200 is powered by a battery 214, controlled by electronic circuitry 216, and has an on / off button 218.

[0280] Of course, the aerosol-generating rod 10 and aerosol-generating article 50 described above may be suitable for use with other types of aerosol generating devices.

[0281] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like should be understood in all cases as being modified by the term "about." Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is understood as A ± 10% of A. Within this context, the number A may be considered to include numerical values ​​that are within the general standard error for the measurement of the property that the number A modifies. The number A may, in some instances used in the appended claims, deviate by the percentages recited above, provided that the amount by which A deviates does not materially affect the basic and novel properties of the claimed invention. Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. An aerosol-generating article (50) having an aerosol-generating rod (10) for generating an inhalable aerosol upon heating, said aerosol-generating rod (10) comprising: a first aerosol-generation segment (12) comprising a first aerosol-generating substrate, said first aerosol-generating substrate comprising a tobacco material and an aerosol former; a second aerosol-generation segment (14) located upstream of said aerosol-generation segment; a wrapper (22) surrounding at least the first aerosol-generation segment and the second aerosol-generation segment; The second aerosol-generating segment comprises a plug (18) of porous substrate comprising a material selected from the group consisting of cotton, paper, viscose, polylactic acid (PLA), cellulose acetate, and combinations thereof, and at least a core portion (24) of the plug (18) comprises an aerosol-generating medium or a flavorant, or both.

2. 2. The aerosol-generating article (50) of claim 1, wherein the plug (18) of the second aerosol-generation segment (14) is free of tobacco material and non-tobacco plant material.

3. 3. The aerosol-generating article of claim 1, further comprising a non-aerosol-generating segment (16) downstream of the first aerosol-generating segment (12), the non-aerosol-generating segment (16) comprising a plug of porous substrate.

4. 4. The aerosol-generating article of claim 1, wherein the wrapper (22) surrounds at least the first aerosol-generating segment (12) and the second aerosol-generating segment (14) is non-porous.

5. 5. The aerosol-generating article of claim 4, wherein the non-porous wrapper (22) comprises a metal foil.

6. The aerosol-generating article of any one of claims 1 to 5, wherein the first aerosol-generating substrate comprises one or more of homogenized tobacco material, tobacco cast leaf, and reconstituted tobacco.

7. The aerosol-generating article of any one of claims 1 to 6, wherein the first aerosol-generating substrate further comprises a non-tobacco plant material.

8. 8. The aerosol-generating article of claim 1, wherein the aerosol-generating medium comprises a liquid or gel that impregnates the porous substrate.

9. The aerosol-generating article of any one of claims 1 to 8, wherein the aerosol-generating medium comprises a gel containing an alkaloid compound, an aerosol former, and at least one gelling agent.

10. An aerosol-generating article according to any one of the preceding claims, wherein the first aerosol-generating segment (12) has a length of between 5 millimetres and 25 millimetres.

11. An aerosol-generating article according to any one of the preceding claims, wherein the second aerosol-generating segment (14) has a length of between 2 millimetres and 10 millimetres.

12. 12. An aerosol-generating article according to any one of the preceding claims, wherein the ratio between the length of the second aerosol-generation segment (14) and the length of the first aerosol-generation segment (12) is between 0.15 and 0.

5.

13. 13. An aerosol-generating article according to any one of the preceding claims, wherein the cross-sectional area of ​​the core portion (24) is at least 50 percent of the cross-sectional area of ​​the second segment (14).

14. 14. An aerosol-generating article according to any one of the preceding claims, wherein a peripheral portion (26) of the plug (18) surrounding the core portion (24) is substantially free of aerosol-generating medium or flavourants.

15. An aerosol generating system comprising a heating device (200) and an aerosol generating article (50) according to any one of claims 1 to 14.

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