Aerosol-generating article comprising aerosol-cooling element with elongated protrusion

Abstract

To provide an aerosol-generating article adapted to produce an aerosol upon heating.SOLUTION: An aerosol-generating article (10) comprises a rod of an aerosol-generating substrate (12) and an aerosol-cooling element (16) positioned downstream of the rod of aerosol-generating substrate (12). The aerosol-cooling element (16) comprises a hollow tubular segment (8) comprising a peripheral wall (24). The hollow tubular segment (8) extends along a longitudinal axis and has a downstream end in fluid communication with an upstream end. The hollow tubular segment (8) comprises at least one elongated protrusion (26) extending from the peripheral wall (24) into the interior of the hollow tubular segment (8). The at least one elongated protrusion (26) extends along the longitudinal axis from an upstream position on the peripheral wall (24) to a downstream position on the peripheral wall (24) downstream of the upstream position. The aerosol-generating article (10) further comprises a wrapper (18) circumscribing the rod of aerosol-generating substrate (12) and the first aerosol-cooling element (16).SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present disclosure relates to a cooling element for use in an aerosol-generating article comprising an aerosol-generating substrate and adapted to generate an inhalable aerosol upon heating, and an aerosol-generating article comprising such an aerosol cooling element.

Background Art

[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, the aerosol is generated by transferring heat from a heat source to a physically separated aerosol-generating substrate or material, which may be in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and entrained in the air drawn through the aerosol-generating article. The released compounds condense as they cool 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 an aerosol is generated by heat transfer from one or more electrical heater elements of the aerosol-generating device to the aerosol-generating substrate of the heated aerosol-generating article.

[0004] Substrates for heated aerosol generating articles have heretofore typically been produced using randomly oriented fragments, strands, or shreds of tobacco material. More recently, alternative substrates for aerosol generating articles that are heated rather than burned, such as rods formed from sheets of collected tobacco material, have been disclosed. By way of example, the rod disclosed in International Patent Application No. WO-A-2012 / 164009 has an axial porosity that allows air to be drawn through the rod. As a further alternative, International Patent Application No. WO-A-2011 / 101164 discloses a rod for a heated aerosol generating article formed from strands of homogenized tobacco material, which may be formed by casting, rolling, calendaring, or extruding a mixture comprising particulate tobacco and at least one aerosol former to form a sheet of homogenized tobacco material. In another embodiment, the rod of WO-A-2011 / 101164 may be formed from strands of homogenized tobacco material obtained by extruding a mixture comprising particulate tobacco and at least one aerosol former to form a continuous length of homogenized tobacco material.

[0005] Substrates for heated aerosol generating articles typically further comprise an aerosol former, i.e., a compound or mixture of compounds that facilitates the formation of an aerosol during use and is preferably substantially resistant to thermal decomposition at the use temperature of the aerosol generating article. Examples of suitable aerosol formers include, but are not limited to, polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate or triacetate, etc.), and aliphatic esters of monocarboxylic, dicarboxylic or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.).

[0006] It is also common for aerosol-generating articles for generating inhalable aerosols upon heating to include one or more additional elements assembled with the substrate within the same wrapper. Examples of such additional elements include mouthpiece filter segments, support elements adapted to impart structural strength to the aerosol-generating article.

[0007] It has also been proposed to include in an aerosol-generating article for generating inhalable aerosols upon heating a cooling element adapted to advantageously act on the cooling of the aerosol before it reaches the mouthpiece. As an example, WO2013 / 120565 discloses an aerosol-generating article, an aerosol-forming substrate, and an aerosol cooling element located downstream of the aerosol-forming substrate within a rod. In one embodiment, the aerosol cooling element comprises a crimped sheet of polylactic acid (PLA) that is assembled to define a plurality of channels extending in the longitudinal axis. As the aerosol flow is drawn through the aerosol cooling element, heat can be transferred from the aerosol to the PLA sheet.

[0008] When aerosol-generating articles of the above type are used, especially under hot and humid climatic conditions such as the climatic conditions frequently encountered in countries characterized by tropical climates, the temperature reached by the mouthpiece of the article can be a high temperature in the range of 42 degrees Celsius to 45 degrees Celsius. Since sensitive tissues such as the lips, mouth, tongue, and mucous membranes can generally come into direct contact with the surface of the mouthpiece during use, these temperatures can be associated with a feeling of discomfort or mild pain for some consumers. Without wishing to be bound by theory, this is understood to be because thermoreceptors that respond to an increase in skin temperature respond most at approximately 45 degrees Celsius. In contrast, when the skin temperature is between about 30 degrees Celsius and about 36 degrees Celsius, the thermoreceptors are spontaneously activated, but generally there is no perception of warmth (neutral thermal region). Furthermore, the skin also contains heat-sensitive receptors known as nociceptors, which produce a sensation accompanied by pain when the skin temperature rises above 45 degrees Celsius. This is because the fact that nociceptors respond to temperature signals to the central nervous system that tissue damage may be imminent and the affected area should be quickly removed from the heat source.

[0009] Therefore, it is desirable to provide a novel and improved aerosol cooling element for an aerosol-generating article adapted to optimize the cooling of the aerosol delivered to the consumer. It is also desirable to provide a novel and improved aerosol cooling element for an aerosol-generating article adapted to optimize the cooling of the surface of the mouth-side end of the article that can come into contact with the sensitive tissues of the consumer during use. At the same time, it would be desirable to provide one such aerosol-generating article that can be manufactured efficiently and quickly without the need for major modifications to existing equipment and devices. Summary of the Invention

[0010] The present disclosure relates to an aerosol cooling element configured for use in an aerosol-generating article. The aerosol cooling element may comprise a hollow tubular segment including a peripheral wall. The hollow tubular segment may extend along a longitudinal axis and may have a downstream end in fluid communication with an upstream end. The hollow tubular segment may comprise at least one elongate protrusion extending from the peripheral wall into the interior of the hollow tubular segment. The at least one elongate protrusion may extend longitudinally from an upstream position on the peripheral wall to a downstream position on the peripheral wall downstream of the upstream position.

[0011] According to a first aspect of the present disclosure, there is provided an aerosol cooling element configured for use in an aerosol-generating article. The aerosol cooling element comprises a hollow tubular segment including a peripheral wall. The hollow tubular segment extends along a longitudinal axis and has a downstream end in fluid communication with an upstream end. The hollow tubular segment comprises at least one elongate protrusion extending from the peripheral wall into the interior of the hollow tubular segment. The at least one elongate protrusion extends longitudinally from an upstream position on the peripheral wall to a downstream position on the peripheral wall downstream of the upstream position.

[0012] The term "aerosol-generating article" is used herein in relation to the present invention to describe an article in which an aerosol-generating substrate is heated to generate an aerosol for delivery to a consumer. In use, the substrate has the ability to release volatile compounds upon heating to generate an aerosol.

[0013] Conventional cigarettes are ignited when a user applies a flame to one end of the cigarette and draws air through the other end. The localized heat brought about by the flame and the oxygen in the air drawn through the cigarette ignites the end of the cigarette, and the resulting combustion generates 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 an aerosol forming material physically separated therefrom. For example, the aerosol generating article according to the present invention has a specific application in an aerosol generating system comprising an electrically heated aerosol generating device having an internal heater blade adapted to be inserted into a rod of an aerosol generating substrate. This type of aerosol generating article is described in the prior art, for example, in EP0822670.

[0014] As used herein, the term "aerosol generating device" refers to a device comprising a heater element that interacts with an aerosol generating substrate of an aerosol generating article to generate an aerosol.

[0015] During use, the volatile compounds are released from the aerosol generating substrate by heat transfer and are mixed into the air drawn through the aerosol generating article. The released compounds condense as they cool to form an aerosol, which is inhaled by the consumer.

[0016] As used herein, the term "tubular element" means an elongated element that defines a lumen or air flow passage along its longitudinal axis. In the context of this specification, the term "tubular" is intended to encompass any tubular element having a substantially cylindrical cross-section that defines at least one air flow conduit establishing fluid communication between an upstream end of the tubular element and a downstream end of the tubular element. As used herein in connection with the present invention, the term "hollow" is used to describe a tubular element that defines an empty internal space such as a chamber or cavity.

[0017] As used herein, the term "longitudinal direction" refers to the direction corresponding to the major longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. As used herein, the terms "upstream" and "downstream" describe the relative position of an element (or portion of an element) of the aerosol-generating article with respect to the direction in which the aerosol is conveyed through the aerosol-generating article during use. During use, air is drawn longitudinally through the aerosol-generating article. The term "transverse direction" refers to a direction perpendicular to the longitudinal axis. Any reference to a "cross-section" of the aerosol-generating article or a component of the aerosol-generating article refers to a transverse cross-section, unless otherwise specified.

[0018] The term "length" means the maximum dimension of a component of the aerosol-generating article in the longitudinal direction. For example, it may be used to mean the dimension of a rod or tubular element in the longitudinal direction. In particular, in the context of the present invention, the term "length of the tubular element" is used to indicate the maximum distance between the upstream and downstream ends of the tubular element.

[0019] The term "peripheral wall" refers to the wall that defines the outer perimeter of a hollow tubular segment. The term "peripheral" refers to an element or feature located at such a perimeter.

[0020] The term "elongated protrusion" refers to a protrusion or projection that is long relative to its width and thickness. For example, the elongated protrusion may include a flattened surface. The height, circumferential and radial positions of the elongated protrusion are with respect to the base of the elongated protrusion. The elongated protrusion is connected at its base to the inner surface of the peripheral wall of the hollow tubular segment. The base of the elongated protrusion refers to a portion of the elongated protrusion that is connected to the inner surface of the peripheral wall of the hollow tubular segment. The base of the elongated protrusion defines the longitudinal or axial position, circumferential position and radial position of the elongated protrusion. For example, the radial position of the upstream position of the elongated protrusion refers to the radial position of the upstream position of the base of the elongated protrusion.

[0021] As used herein, the term "radial position" refers to the direction along the radius from the center of an object that is a hollow tubular element, an aerosol cooling element, or an aerosol generating article. In other words, a particular radial position of an elongate protrusion, or a portion of the elongate protrusion, refers to the position and distance of the elongate protrusion or portion thereof relative to the central axis of the hollow tubular segment.

[0022] As used herein, the term "circumferential position" refers to the direction following the circumference defined with respect to the center (or central axis) of an object that is a hollow tubular element, an aerosol cooling element, or an aerosol generating article. In other words, a particular circumferential position of an elongate protrusion, or a portion of the elongate protrusion, refers to the position and distance of the elongate protrusion, or portion thereof, along the circumference defined with respect to the central axis of the hollow tubular segment.

[0023] As used herein, the term "peripheral wall thickness of a tubular element" is used to mean the minimum distance measured between the outer surface and the inner surface of the wall of the tubular element. In practice, the distance at a given location is measured along a direction that is locally substantially perpendicular to the opposing sides of the wall of the tubular element. For a substantially cylindrical tubular element, i.e., a tubular element having a substantially circular cross-section, the peripheral wall thickness is evaluated as the distance between the outer surface and the inner surface of the peripheral wall measured substantially along the radial direction of the tubular element.

[0024] As used throughout this specification, the expression "air-impermeable material" is used to mean a material that does not allow the passage of fluids, particularly air and smoke, through the gaps or pores in the material. When the tubular support element is formed of a material that is impermeable to air and aerosol particles, the air and aerosol particles drawn through the support element are forced to flow through the air flow conduit but cannot flow across the wall of the support element.

[0025] In contrast, the term "porous" as used herein is used to refer to a material that provides a plurality of pores or openings that allow the passage of air through the material.

[0026] As used herein, the term "homogenized tobacco material" encompasses any tobacco material formed by the aggregation of tobacco material particles. A sheet or web of homogenized tobacco material is formed by aggregating particulate tobacco obtained by grinding one or both of the leaf blade of a tobacco leaf and the stem of a tobacco leaf, or by powdering in other ways. In addition, the homogenized tobacco material may include one or more of a small amount of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during the processing, handling, and shipping of tobacco. The sheet of homogenized tobacco material may be produced by casting, extrusion, a papermaking process, or any other suitable process known in the art.

[0027] In the aerosol-generating article according to the present invention, the aerosol cooling element is adapted to lower the temperature of the aerosol flowing through the article, while homogenizing the aerosol flow and finely controlling the way in which the aerosol flow is delivered to the consumer's mouth.

[0028] More specifically, it has been found that the structure and characteristics of the aerosol cooling element are such that they consistently reduce the temperature of the gas flow within the article below a threshold value that may be associated with discomfort or a feeling of pain for the consumer. Without wishing to be bound by theory, it is of course the case that in the aerosol cooling element and the aerosol generating article according to the invention, heat from the aerosol flowing through the article is advantageously dissipated as the material of the aerosol cooling element is heated by conduction and convection. At the same time, at least one elongated protrusion extending within the interior of the aerosol cooling element increases the internal surface area of the aerosol cooling element. An increase in the internal surface area of the aerosol cooling element means that there is a larger surface area for heat transfer to occur between the aerosol flow and the material of the aerosol cooling element. Thus, the temperature of the flowing aerosol is reduced and overheating of the outer surface of the article that may come into contact with the consumer's lips during use is advantageously prevented, particularly when the article is used under hot and humid weather conditions.

[0029] In addition to enhancing the heat transfer of the aerosol cooling element with the flowing aerosol, at least one elongated protrusion enters the aerosol cooling element and partially blocks and distributes the heated aerosol flowing through the aerosol cooling element. At least one elongated protrusion generates turbulence in the flowing aerosol, which promotes the mixing of the aerosol with the cold air already present in the aerosol cooling element. Thus, such an effect further improves the cooling function of the aerosol cooling element.

[0030] Furthermore, the aerosol cooling element and the aerosol generating article according to the invention can be manufactured in a continuous process, and their manufacture can advantageously be carried out at high speed and incorporated into existing production lines for the manufacture of heated aerosol generating articles without the need for extensive modification of the manufacturing equipment.

[0031] The aerosol cooling element may be made of a material having a relatively high heat capacity. As a result, the aerosol cooling element has the ability to absorb thermal energy carried by the aerosol flowing through the article without causing a significant increase in the temperature of the aerosol cooling element. By way of example, the aerosol cooling element may be made of a cellulose-based compound containing a thermoplastic paper compound. As another example, the aerosol cooling element may be made of polylactic acid (PLA) or polyhydroxyalkanoic acid (PHA).

[0032] At least one elongated protrusion may be made of the same material as the remainder of the aerosol cooling element. By way of example, at least one elongated protrusion may be made of a cellulose-based compound containing a thermoplastic paper compound. As another example, at least one elongated protrusion may be made of polylactic acid (PLA) or polyhydroxyalkanoic acid (PHA). At least one elongated protrusion may be made by injection molding or other extrusion molding techniques.

[0033] The length of the aerosol cooling element can be from about 5 millimeters to about 35 millimeters. In some embodiments, the length of the aerosol cooling element is from about 5 millimeters to about 25 millimeters, or from about 5 millimeters to about 20 millimeters, or from about 5 millimeters to about 19 millimeters.

[0034] The length of the aerosol cooling element is preferably at least about 8 millimeters. The length of the aerosol cooling element is more preferably at least about 9 millimeters. The length of the aerosol cooling element is preferably about 30 millimeters or less, or from about 8 millimeters to about 25 millimeters, or from about 8 millimeters to about 20 millimeters, or from about 8 millimeters to about 19 millimeters. The length of the aerosol cooling element is more preferably about 25 millimeters or less. The length of the aerosol cooling element is even more preferably about 20 millimeters or less. In particularly preferred embodiments, the length of the aerosol cooling element is 19 millimeters or less.

[0035] In a preferred embodiment, the length of the aerosol cooling element is from about 8 millimeters to about 30 millimeters, or from about 8 millimeters to about 25 millimeters, or from about 8 millimeters to about 20 millimeters, or from about 8 millimeters to about 19 millimeters, and more preferably from about 9 millimeters to about 30 millimeters, or from about 9 millimeters to about 25 millimeters, or from about 9 millimeters to about 20 millimeters, or from about 9 millimeters to about 19 millimeters.

[0036] The thickness of the peripheral wall of the hollow tubular segment is preferably at least about 0.2 millimeters. More preferably, the thickness of the peripheral wall of the hollow tubular segment is at least about 0.5 millimeters. Even more preferably, the thickness of the peripheral wall of the hollow tubular segment is at least about 1 millimeter. The thickness of the peripheral wall of the hollow tubular segment is preferably 3.5 millimeters or less. More preferably, the thickness of the peripheral wall of the hollow tubular segment is 3 millimeters or less. Even more preferably, the thickness of the peripheral wall of the hollow tubular segment is about 2.5 millimeters or less.

[0037] In some embodiments, the thickness of the peripheral wall of the hollow tubular segment is from about 0.2 millimeters to about 3.5 millimeters, or from about 0.2 millimeters to about 3 millimeters, or from about 0.2 millimeters to about 2.5 millimeters. In other embodiments, the thickness of the peripheral wall of the hollow tubular segment is from about 0.5 millimeters to about 3.5 millimeters, or from about 0.5 millimeters to about 3 millimeters, or from about 0.5 millimeters to about 2.5 millimeters. In further embodiments, the thickness of the peripheral wall of the hollow tubular segment is from about 1 millimeter to about 3.5 millimeters, or from about 1 millimeter to about 3 millimeters, or from about 1 millimeter to about 2.5 millimeters.

[0038] In some preferred embodiments, the thickness of the peripheral wall of the hollow tubular segment is from about 0.2 millimeters to about 3.5 millimeters, more preferably from about 0.5 millimeters to about 3 millimeters, and even more preferably from about 1 millimeter to about 2.5 millimeters.

[0039] Preferably, the outer diameter of the hollow tubular segment is at least about 3 millimeters. More preferably, the outer diameter of the hollow tubular segment is at least about 4 millimeters. Even more preferably, the outer diameter of the hollow tubular segment is at least about 5 millimeters. Preferably, the outer diameter of the hollow tubular segment is about 13 millimeters or less. More preferably, the outer diameter of the hollow tubular segment is about 10 millimeters or less. Even more preferably, the outer diameter of the hollow tubular segment is about 8 millimeters or less.

[0040] In some embodiments, the outer diameter of the hollow tubular segment is from about 3 millimeters to about 13 millimeters, or from about 3 millimeters to about 10 millimeters, or from about 3 millimeters to about 8 millimeters. In other embodiments, the outer diameter of the hollow tubular segment is from about 4 millimeters to about 13 millimeters, or from about 4 millimeters to about 10 millimeters, or from about 4 millimeters to about 8 millimeters. In further embodiments, the outer diameter of the hollow tubular segment is from about 5 millimeters to about 13 millimeters, or from about 5 millimeters to about 10 millimeters, or from about 5 millimeters to about 8 millimeters.

[0041] In preferred embodiments, the outer diameter of the hollow tubular segment is from about 3 millimeters to about 13 millimeters, more preferably from about 4 millimeters to about 10 millimeters, and even more preferably from about 5 millimeters to about 8 millimeters. In some embodiments, the outer diameter of the hollow tubular segment is from about 4 millimeters to about 8 millimeters.

[0042] The inner diameter of the hollow tubular segment is preferably at least about 2 millimeters. More preferably, the inner diameter of the hollow tubular segment is at least about 3 millimeters. Even more preferably, the inner diameter of the hollow tubular segment is at least about 4 millimeters. The inner diameter of the hollow tubular segment is preferably about 10 millimeters or less. More preferably, the inner diameter of the hollow tubular segment is about 7.5 millimeters or less. Even more preferably, the inner diameter of the hollow tubular segment is about 6 millimeters or less.

[0043] In some embodiments, the inner diameter of the hollow tubular segment is from about 2 millimeters to about 10 millimeters, or from about 2 millimeters to about 7.5 millimeters, or from about 2 millimeters to about 6 millimeters. In other embodiments, the inner diameter of the hollow tubular segment is from about 3 millimeters to about 10 millimeters, or from about 3 millimeters to about 7.5 millimeters, or from about 3 millimeters to about 6 millimeters. In further embodiments, the inner diameter of the hollow tubular segment is from about 4 millimeters to about 10 millimeters, or from about 4 millimeters to about 7.5 millimeters, or from about 4 millimeters to about 6 millimeters.

[0044] In a preferred embodiment, the inner diameter of the hollow tubular segment is from about 2 millimeters to about 10 millimeters, more preferably from about 3 millimeters to about 7.5 millimeters, and even more preferably from about 4 millimeters to about 6 millimeters. In some embodiments, the inner diameter of the hollow tubular segment is from about 3 millimeters to about 7.5 millimeters.

[0045] In some preferred embodiments, at least one elongated protrusion extends radially along the central axis of the hollow tubular segment from the peripheral wall. By extending along the radial direction of the hollow tubular segment of the aerosol cooling element, at least one elongated protrusion impedes and obstructs the incoming flowing aerosol as much as possible in order to promote the turbulent flow in the flowing aerosol. As described above, the turbulent flow assists the cooling effect provided by the aerosol cooling element.

[0046] In some preferred embodiments, the height of at least one elongated protrusion varies between an upstream position and a downstream position. Such "height of at least one elongated protrusion" refers to the perpendicular distance from the inner surface of the peripheral wall of the hollow tubular segment along which the elongated protrusion extends. In such embodiments, at least one elongated protrusion may have any profile such that at a particular portion of the protrusion, the protrusion may extend further into the interior of the hollow tubular segment than at other portions of the protrusion.

[0047] In some preferred embodiments, the height of at least one elongated protrusion decreases between one of an upstream position and a downstream position and the other.

[0048] In some preferred embodiments, the ratio of the maximum height of at least one elongated protrusion to the inner diameter of the aerosol cooling element is at least 0.1. It is more preferable that the ratio of the maximum height of at least one elongated protrusion to the inner diameter of the aerosol cooling element is at least 0.25. It is even more preferable that the ratio of the maximum height of at least one elongated protrusion to the inner diameter of the aerosol cooling element is at least 0.33 (1 / 3). The term "maximum height" refers to the height of a portion of at least one elongated protrusion that has a greater height than any other portion of the at least one elongated protrusion.

[0049] In some preferred embodiments, the ratio of the maximum height of at least one elongated protrusion to the inner diameter of the aerosol cooling element is 0.75 or less. It is more preferable that the ratio of the maximum height of at least one elongated protrusion to the inner diameter of the aerosol cooling element is 0.6 or less. It is even more preferable that the ratio of the maximum height of at least one elongated protrusion to the inner diameter of the aerosol cooling element is 0.5 or less.

[0050] In some preferred embodiments, the ratio of the maximum height of at least one elongated protrusion to the inner diameter of the aerosol cooling element is from 0.1 to 0.75. More preferably, the ratio of the maximum height of at least one elongated protrusion to the inner diameter of the aerosol cooling element is from 0.25 to 0.6. Even more preferably, the ratio of the maximum height of at least one elongated protrusion to the inner diameter of the aerosol cooling element is from 0.33 (1 / 3) to 0.5.

[0051] At least one elongated protrusion may have a fin-like profile, a tapered profile, a curved profile, or a wavy profile when viewed from the side.

[0052] In some preferred embodiments, at least one elongated protrusion comprises (or is) a deflector fin configured to change the direction of the aerosol flow from the upstream end to the downstream end of the hollow tubular segment. "Fin" refers to a flattened, thin, protruding surface.

[0053] In preferred embodiments, at least one elongated protrusion comprises a plurality of deflector fins. In such preferred embodiments, the plurality of deflector fins comprises at least two deflector fins. More preferably, the plurality of deflector fins comprises at least four deflector fins. Even more preferably, the plurality of deflector fins comprises at least six deflector fins.

[0054] In some preferred embodiments, the deflector fin comprises first and second opposing surfaces, and the angle formed between a reference surface, which is parallel to the longitudinal axis and bisects the internal volume of the hollow tubular segment, and the first surface of the deflector fin at the upstream position is different from the angle formed between the reference surface and the first surface of the deflector fin at the downstream position.

[0055] In some preferred embodiments, the deflection fins are twisted along the length of the hollow tubular segment. The term "twisted" refers to the fact that the profile of the deflection fin is bent or curled around a reference point or reference line along the length of the deflection fin. When the deflection fins extend along the length of the aerosol cooling element, they can take on a helical or spiral form or shape. Such helical or spiral shapes are optimal for imparting turbulence into the flowing aerosol, which in turn enhances the cooling effect provided by the aerosol cooling element. The term "helical" refers to an element having a helical or spiral profile or shape.

[0056] In some preferred embodiments, the radial or circumferential position of at least one elongated protrusion or a portion thereof varies between its upstream and downstream positions. In such embodiments, at least one elongated protrusion may not follow a straight line when viewed from above or from below. In such embodiments, the base of at least one elongated protrusion may follow a curved profile, a wavy profile, or any other profile resulting from being parallel to the longitudinal axis of the hollow tubular segment of the aerosol cooling element along the inner surface of the peripheral wall.

[0057] In some preferred embodiments, the height of at least one elongated protrusion is less than the radius of the hollow tubular segment. Such radius of the hollow tubular segment preferably refers to the inner diameter of the hollow tubular segment, which is half of the inner diameter of the hollow tubular segment described above.

[0058] In some preferred embodiments, the upstream position is located between the upstream end of the hollow tubular segment and the midpoint of the hollow tubular segment, and the downstream position is located between the midpoint of the hollow tubular segment and the downstream end of the hollow tubular segment. The midpoint of the hollow tubular segment refers to the center of the hollow tubular segment at an intermediate position between the upstream end and the downstream end of the hollow tubular segment.

[0059] In some preferred embodiments, the upstream position is located at 1 / 4 of the length of the aerosol cooling element in a direction away from the upstream end. In some other preferred embodiments, the upstream position is located at 1 / 3 of the length of the aerosol cooling element in a direction away from the upstream end. In some other preferred embodiments, the upstream position is located at 1 / 2 of the length of the aerosol cooling element in a direction away from the upstream end.

[0060] In some preferred embodiments, the downstream position is located at 1 / 4 of the length of the aerosol cooling element in a direction away from the downstream end. In some other preferred embodiments, the downstream position is located at 1 / 3 of the length of the aerosol cooling element in a direction away from the downstream end. In some other preferred embodiments, the downstream position is located at 1 / 2 of the length of the aerosol cooling element in a direction away from the downstream end.

[0061] In some preferred embodiments, at least one elongated protrusion extends in the longitudinal axis direction from the upstream end of the hollow tubular segment to the downstream end of the hollow tubular segment.

[0062] In some preferred embodiments, the length of at least one elongated protrusion is from about 8 mm to about 30 mm. More preferably, the length of at least one elongated protrusion is from about 9 mm to about 19 mm. Even more preferably, at least one elongated protrusion is from about 10 mm to about 15 mm.

[0063] In some preferred embodiments, the ratio of the length of at least one elongated protrusion to the length of the aerosol cooling element is at least 0.25. More preferably, the ratio of the length of at least one elongated protrusion to the length of the aerosol cooling element is at least 0.33 (1 / 3). Even more preferably, the ratio of the length of at least one elongated protrusion to the length of the aerosol cooling element is at least 0.5.

[0064] In some preferred embodiments, the ratio of the length of at least one elongated protrusion to the length of the aerosol cooling element is 1 or less. More preferably, the ratio of the length of at least one elongated protrusion to the length of the aerosol cooling element is 0.75 or less. Even more preferably, the ratio of the length of at least one elongated protrusion to the length of the aerosol cooling element is 0.5 or less.

[0065] In some preferred embodiments, the ratio of the length of at least one elongated protrusion to the length of the aerosol cooling element is 0.25 to 1. More preferably, the ratio of the length of at least one elongated protrusion to the length of the aerosol cooling element is 0.25 to 0.75.

[0066] In some preferred embodiments, the thickness of at least one elongated protrusion is about 0.1 mm to about 1 mm. More preferably, the thickness of at least one elongated protrusion is about 0.25 mm to about 0.75 mm. Even more preferably, the thickness of at least one elongated protrusion is about 0.4 mm to about 0.6 mm.

[0067] In some preferred embodiments, the thickness of at least one elongated protrusion is about 0.1 mm. More preferably, the thickness of at least one elongated protrusion is about 0.25 mm. Even more preferably, the thickness of at least one elongated protrusion is about 0.4 mm. In some preferred embodiments, the thickness of at least one elongated protrusion is about 0.6 mm. More preferably, the thickness of at least one elongated protrusion is about 0.75 mm. Even more preferably, the thickness of at least one elongated protrusion is about 1 mm.

[0068] Preferably, the thickness of at least one elongated protrusion is less than 20 percent of the length of at least one elongated protrusion. More preferably, the thickness of at least one elongated protrusion is less than 10 percent of the length of at least one elongated protrusion. Even more preferably, the thickness of at least one elongated protrusion is less than 5 percent of the length of at least one elongated protrusion.

[0069] In some preferred embodiments, at least one elongated protrusion includes a plurality of elongated protrusions radially distributed on the peripheral wall. In such preferred embodiments, the plurality of elongated protrusions are evenly (or uniformly) distributed on the peripheral wall in such a manner that the elongated protrusions are equally spaced from each other.

[0070] In some preferred embodiments, at least one elongated protrusion includes a plurality of elongated protrusions. The plurality of elongated protrusions preferably includes at least two elongated protrusions. More preferably, the plurality of elongated protrusions includes at least four elongated protrusions. Even more preferably, the plurality of elongated protrusions includes at least six elongated protrusions.

[0071] In some preferred embodiments, at least one elongated protrusion includes a plurality of elongated protrusions axially distributed at the same radial or circumferential position on the peripheral wall.

[0072] In some preferred embodiments, the plurality of elongated protrusions are evenly (or uniformly) distributed on the peripheral wall. This means that the plurality of elongated protrusions are evenly (or uniformly) spaced from each other on the peripheral wall. In other embodiments, the plurality of elongated protrusions are spaced from each other by various distances.

[0073] In some preferred embodiments, the elongated protrusions have substantially the same shape as each other.

[0074] The present invention relates to an aerosol generating article for generating an aerosol upon heating. The aerosol generating article comprises a rod of an aerosol generating substrate. The aerosol generating article may comprise a first aerosol cooling element according to a first aspect of the present disclosure, positioned downstream of the rod of the aerosol generating substrate, as described above.

[0075] According to a second aspect of the present disclosure, there is provided an aerosol generating article for generating an aerosol upon heating. The aerosol generating article comprises a rod of an aerosol generating substrate. The aerosol generating article comprises a first aerosol cooling element according to the first aspect of the present disclosure, positioned downstream of the rod of the aerosol generating substrate, as described above.

[0076] In some embodiments, the aerosol generating article may further comprise a hollow tubular support element positioned immediately downstream of the rod of the aerosol generating substrate.

[0077] In some embodiments, the aerosol generating article may further comprise a second aerosol cooling element downstream of the hollow tubular support element, the first aerosol cooling element being positioned downstream of the second aerosol cooling element and extending throughout to the downstream end of the aerosol generating article.

[0078] In a preferred embodiment, the cavity defined by the first aerosol cooling element defines a mouth-side end cavity at the downstream end of the aerosol generating article.

[0079] As briefly described above, the aerosol-generating article may comprise additional components between the hollow tubular support element and the aerosol cooling element. In some embodiments, the additional component is adapted to initiate cooling of the gas stream entering from the aerosol-generating substrate so as to promote condensation of the compound released from the substrate that condenses to form the aerosol, a further aerosol cooling element (also referred to herein as a "secondary" or "second" aerosol cooling element). In some embodiments, the secondary aerosol cooling element may be in the form of an assembly sheet of a polymeric material such as polylactic acid (PLA) that defines a plurality of longitudinally extending channels, optionally a curled sheet. In practice, the PLA sheet may be "curled" to form substantially parallel ridges or corrugations. The curled PLA sheet is then assembled, incorporated, pleated, folded, or otherwise compressed or contracted substantially transversely to the longitudinal axis so that the substantially parallel ridges or corrugations extend in the longitudinal direction. Without wishing to be bound by theory, one of these curled sheets of assembled polymeric material may act substantially as a heat exchanger.

[0080] The length of the further aerosol cooling element is preferably at least about 4 millimeters. The length of the further aerosol cooling element is more preferably at least about 6 millimeters. The length of the further aerosol cooling element is even more preferably at least about 9 millimeters. The length of the further aerosol cooling element is preferably about 25 millimeters or less. The length of the further aerosol cooling element is more preferably about 20 millimeters or less. The length of the further aerosol cooling element is even more preferably about 15 millimeters or less.

[0081] In some embodiments, the length of the additional aerosol cooling element is from about 4 millimeters to about 25 millimeters, or from about 4 millimeters to about 20 millimeters, or from about 4 millimeters to about 15 millimeters. In other embodiments, the length of the additional aerosol cooling element is from about 6 millimeters to about 25 millimeters, or from about 6 millimeters to about 20 millimeters, or from about 6 millimeters to about 15 millimeters. In further embodiments, the length of the additional aerosol cooling element is from about 9 millimeters to about 25 millimeters, or from about 9 millimeters to about 20 millimeters, or from about 9 millimeters to about 15 millimeters.

[0082] In some preferred embodiments, the length of the additional aerosol cooling element is from about 4 millimeters to about 25 millimeters, more preferably from about 6 millimeters to about 20 millimeters, and even more preferably from about 9 millimeters to about 15 millimeters.

[0083] Briefly described above, the aerosol generating article according to the present invention incorporates a rod of the aerosol generating substrate and a hollow tubular support element positioned immediately downstream of the rod of the aerosol generating substrate. Further, the aerosol generating article of the present invention may further comprise an aerosol cooling element downstream of the hollow tubular support element.

[0084] In contrast to existing aerosol generating articles, in the article according to the present invention, the aerosol cooling element can extend throughout to the downstream end of the aerosol generating article. In other words, the aerosol cooling element may define the mouth-side end portion of the article and may be inhaled by the consumer during use.

[0085] The overall length of the aerosol generating article is preferably at least about 35 millimeters. More preferably, the overall length of the aerosol generating article is at least about 40 millimeters. Even more preferably, the overall length of the aerosol generating article is at least about 45 millimeters. Additionally, or alternatively, the overall length of the aerosol generating article is preferably about 100 millimeters or less. More preferably, the overall length of the aerosol generating article is about 80 millimeters or less. Even more preferably, the overall length of the aerosol generating article is about 75 millimeters or less. Most preferably, the overall length of the aerosol generating article is about 70 millimeters or less.

[0086] In some embodiments, the overall length of the aerosol generating article is from about 35 millimeters to about 100 millimeters, or from about 35 millimeters to about 80 millimeters, or from about 35 millimeters to about 75 millimeters, or from about 35 millimeters to about 70 millimeters. In other embodiments, the overall length of the aerosol generating article is from about 40 millimeters to about 100 millimeters, or from about 40 millimeters to about 80 millimeters, or from about 40 millimeters to about 75 millimeters, or from about 40 millimeters to about 70 millimeters. In further embodiments, the overall length of the aerosol generating article is from about 45 millimeters to about 100 millimeters, or from about 45 millimeters to about 80 millimeters, or from about 45 millimeters to about 75 millimeters, or from about 45 millimeters to about 70 millimeters.

[0087] In particularly preferred embodiments, the overall length of the aerosol generating article is from about 35 millimeters to about 80 millimeters, more preferably from about 40 millimeters to about 75 millimeters, and even more preferably from about 45 millimeters to about 70 millimeters.

[0088] The aerosol generating article according to the present invention comprises an aerosol generating substrate which can be provided in the form of a rod surrounded by a wrapper.

[0089] The rod of the aerosol generation substrate preferably has an outer diameter substantially equal to the outer diameter of the aerosol generation article.

[0090] The rod of the aerosol generation substrate preferably has an outer diameter of at least 5 millimeters. The rod of the aerosol generation substrate can have an outer diameter of about 5 millimeters to about 12 millimeters, for example, about 5 millimeters to about 10 millimeters, or about 5 millimeters to about 8 millimeters, or about 6 millimeters to about 12 millimeters, or about 6 millimeters to 10 millimeters, or about 6 millimeters to about 8 millimeters. In a preferred embodiment, the rod of the aerosol generation substrate has an outer diameter of 7.2 millimeters.

[0091] The rod of the aerosol generation substrate may have a length of about 5 millimeters to about 100 mm. The rod of the aerosol generation substrate preferably has a length of at least about 5 millimeters, more preferably at least about 7 millimeters. Additionally, or alternatively, the rod of the aerosol generation substrate preferably has a length of less than about 100 millimeters, more preferably less than about 80 millimeters, even more preferably less than about 65 millimeters, and most preferably less than about 50 millimeters. In a particularly preferred embodiment, the rod of the aerosol generation substrate has a length of about 35 millimeters or less, more preferably a length of 25 millimeters or less, and even more preferably a length of about 20 millimeters or less. In one embodiment, the rod of the aerosol generation substrate may have a length of about 10 millimeters. In a preferred embodiment, the rod of the aerosol generation substrate has a length of about 12 millimeters.

[0092] In some embodiments, the rod of the aerosol generating substrate has a length of from about 5 millimeters to about 80 millimeters, or from about 5 millimeters to about 65 millimeters, or from about 5 millimeters to about 50 millimeters. In other embodiments, the rod of the aerosol generating substrate has a length of from about 7 millimeters to about 100 millimeters, or from about 7 millimeters to about 80 millimeters, or from about 7 millimeters to about 65 millimeters, or from about 7 millimeters to about 50 millimeters. In further embodiments, the rod of the aerosol generating substrate has a length of from about 10 millimeters to about 100 millimeters, or from about 10 millimeters to about 80 millimeters, or from about 10 millimeters to about 65 millimeters, or from about 10 millimeters to about 50 millimeters.

[0093] The rod of the aerosol generating substrate preferably has a substantially uniform cross-section along the length of the rod. The rod of the aerosol generating substrate particularly preferably has a substantially circular cross-section.

[0094] In a preferred embodiment, the aerosol generating substrate comprises an assembly of one or more sheets of homogenized tobacco material. The one or more sheets of homogenized tobacco material are preferably textured. As used herein, the term "textured sheet" means a sheet that has been crimped, embossed, debossed, perforated, or otherwise deformed. The textured sheets of homogenized tobacco material used in the present invention may include a plurality of spaced depressions, protrusions, perforations, or combinations thereof. According to a particularly preferred embodiment of the present invention, the rod of the aerosol generating substrate comprises an assembly of crimped sheets of homogenized tobacco material surrounded by a wrapper.

[0095] As used herein, the term "crimped sheet" is intended to be synonymous with the term "creased sheet" and means a sheet having a plurality of substantially parallel ridges or corrugations. A crimped sheet of homogenized tobacco material preferably has a plurality of ridges or corrugations that are substantially parallel to the cylindrical axis of the rod according to the present invention. This advantageously facilitates the assembly of crimped sheets of homogenized tobacco material for forming a rod. However, of course, the crimped sheets of homogenized tobacco material used in the present invention alternatively or additionally have a plurality of substantially parallel ridges or corrugations that are disposed at an acute or obtuse angle to the cylindrical axis of the rod. In certain embodiments, the sheet of homogenized tobacco material used in the rod of the article of the present invention may be substantially evenly textured over substantially its entire surface. For example, a crimped sheet of homogenized tobacco material used in the manufacture of a rod for use in an aerosol-generating article according to the present invention may include a plurality of substantially parallel ridges or corrugations that are substantially uniformly spaced across the width of the sheet.

[0096] The sheet or web 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 60 weight percent on a dry weight basis, even more preferably at least about 70 weight percent on a dry basis, and most preferably at least about 90 weight percent on a dry weight basis.

[0097] A sheet or web of homogenized tobacco material for use in an aerosol-generating substrate may include one or more endogenous binders (i.e., tobacco endogenous binders), one or more exogenous binders (i.e., tobacco exogenous binders), or combinations thereof, to assist in agglomerating particulate tobacco. Alternatively, or additionally, a sheet of homogenized tobacco material for use in an aerosol-generating substrate may include tobacco fibers and non-tobacco fibers, aerosol formers, humectants, plasticizers, flavorants, fillers, aqueous and non-aqueous solvents, and other additives including but not limited to combinations thereof.

[0098] Suitable exogenous binders for inclusion in a sheet or web of homogenized tobacco material for use in an aerosol-generating substrate are well known in the art and include gums (such as guar gum, xanthan gum, gum arabic, and locust bean gum, etc.), cellulose-based binders (such as hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose, and ethyl cellulose, etc.), polysaccharides (such as starch, organic acids (such as alginic acid), conjugate base salts of organic acids (such as sodium alginate), agar, pectin, etc.), and combinations thereof, but are not limited thereto.

[0099] Suitable non-tobacco fibers for inclusion in a sheet or web of homogenized tobacco material for use in an aerosol-generating substrate are known in the art and include cellulose fibers, coniferous fibers, hardwood fibers, jute fibers, and combinations thereof, but are not limited thereto. Prior to inclusion in a sheet of homogenized tobacco material for use in an aerosol-generating substrate, the non-tobacco fibers may be treated by suitable processes well known in the art, which processes include but are not limited to mechanical pulping, refining, chemical pulping, bleaching, sulfite pulping, and combinations thereof.

[0100] The sheet or web of homogenized tobacco material preferably contains an aerosol former. As used herein, the term "aerosol former" describes any suitable known compound or mixture of compounds that facilitates the formation of an aerosol upon use and is substantially resistant to thermal decomposition at the operating temperature of the aerosol-generating article.

[0101] Suitable aerosol formers are known in the art and include, but are not limited to, polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3 - butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, triacetate, etc.), and aliphatic esters of monocarboxylic, dicarboxylic or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.).

[0102] Preferred aerosol formers are polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3 - butanediol, and most preferably glycerin, or mixtures thereof.

[0103] The sheet or web of homogenized tobacco material may contain a single aerosol former. Alternatively, the sheet or web of homogenized tobacco material may contain a combination of two or more aerosol formers.

[0104] The sheet or web of homogenized tobacco material has an aerosol former content of more than 10 percent on a dry weight basis. Preferably, the sheet or web of homogenized tobacco material has an aerosol former content of more than 12 percent on a dry weight basis. More preferably, the sheet or web of homogenized tobacco material has an aerosol former content of more than 14 percent on a dry weight basis. Even more preferably, the sheet or web of homogenized tobacco material has an aerosol former content of more than 16 percent on a dry weight basis.

[0105] The sheet of homogenized tobacco material may have an aerosol former content of approximately 10 percent to approximately 30 percent on a dry weight basis. The sheet or web of homogenized tobacco material preferably has an aerosol former content of less than 25 percent on a dry weight basis.

[0106] In a preferred embodiment, the sheet of homogenized tobacco material has an aerosol former content of approximately 20 percent on a dry weight basis.

[0107] The sheet or web of homogenized tobacco for use in the aerosol generating article of the present invention may be produced by methods well known in the art (for example, the method disclosed in International Patent Application No. WO-A-2012 / 164009 (A2)). In a preferred embodiment, the sheet of homogenized tobacco material for use in the aerosol generating article is formed from a slurry containing particulate tobacco, guar gum, cellulose fibers, and glycerin by a casting process.

[0108] Alternative arrangements of the homogenized tobacco material in the rod for use in the aerosol generating article are well known to those skilled in the art and may include, for example, multiple stacked sheets of homogenized tobacco material, multiple elongated tubular elements formed by winding strips of homogenized tobacco material around the longitudinal axis.

[0109] As a further alternative, the rod of the aerosol generating substrate may include a material having nicotine from a non-tobacco source, such as a sheet of absorbent non-tobacco material loaded with nicotine (for example, in the form of a nicotine salt) and an aerosol former. Examples of such rods are described in International Application No. WO-A-2015 / 052652. Additionally, or alternatively, the rod of the aerosol generating substrate may include a non-tobacco plant material, such as a fragrant non-tobacco plant material.

[0110] In the rod of the aerosol generation substrate of the article according to the present invention, it is preferable that the aerosol generation substrate is surrounded by a wrapper. The wrapper may be formed of a porous or non-porous sheet material. The wrapper may be formed of any suitable material or combination of materials. Preferably, the wrapper is a paper wrapper.

[0111] As described above, the tubular support element can be provided at a position downstream of the rod of the aerosol generation substrate. The tubular support element includes a cylindrical peripheral wall and defines an air flow conduit that extends in the longitudinal axis direction from the upstream end of the tubular support element to the downstream end of the tubular support element. Thus, the tubular support element establishes fluid communication between the rod of the aerosol generation substrate and one or more components of the article located further downstream.

[0112] More specifically, the tubular support element is aligned with the rod in the longitudinal axis direction and is disposed immediately downstream of the rod. In the context of the present invention, the expression "immediately downstream of the rod" means that the tubular support element and the rod are in contact with each other or are very close to each other, such that when the article is received for use in an aerosol generating device adapted to heat the aerosol generation substrate (e.g., one including a heating element inserted into the rod), the tubular support element effectively provides support for the rod in a state where there is little or no deformation of the aerosol generating article, or little or no displacement of the rod, or both of these states. Thus, in practice, the expression "immediately downstream of the rod" as used herein in connection with the present invention indicates that the minimum longitudinal axis distance between the downstream end surface of the rod and the upstream end surface of the peripheral wall of the tubular support element is less than 1 millimeter, preferably less than 0.5 millimeter, and even more preferably less than 0.25 millimeter. In a particularly preferred embodiment, the upstream end surface of the peripheral wall of the tubular support element is in direct contact with the downstream end surface of the rod of the aerosol generation substrate.

[0113] Accordingly, the tubular support element can effectively maintain the rod of the aerosol generating substrate at a predetermined distance from the downstream end of the aerosol generating article. Further, the tubular support element imparts structural strength to the aerosol generating article so that the aerosol generating article can be conveniently inserted into the aerosol generating device for easy handling and use by the consumer.

[0114] The tubular support element may be made of a porous material or an air-impermeable material. Suitable examples of the porous material include, but are not limited to, cellulose acetate and several other porous polymer materials known to those skilled in the art. Suitable examples of the air-impermeable material include, but are not limited to, non-porous polymer materials, which are particularly preferred for bioplastics.

[0115] In a preferred embodiment, the tubular support element is a hollow tube of cellulose acetate.

[0116] During use, a thermal gradient is established along the air flow conduit of the tubular support element. In fact, the temperature difference is provided such that the temperature of the volatilized aerosol component entering the tubular support element at the downstream end of the rod of the aerosol generating substrate is generally greater than the temperature of the volatilized aerosol component exiting the tubular support element at the downstream end of the tubular support element. However, this is generally not sufficient to sufficiently cool the volatilized aerosol component.

[0117] The thickness of the cylindrical peripheral wall of the hollow tubular support element is preferably 2 millimeters or less. The thickness of the cylindrical peripheral wall is more preferably 1.5 millimeters or less. The thickness of the cylindrical peripheral wall is even more preferably 1 millimeter or less.

[0118] The thickness of the cylindrical peripheral wall of the hollow tubular support element is at least 0.2 millimeters. The thickness of the cylindrical peripheral wall is more preferably at least 0.4 millimeters. The thickness of the cylindrical peripheral wall is even more preferably at least 0.6 millimeters.

[0119] In some embodiments, the thickness of the cylindrical peripheral wall of the hollow tubular support element is preferably from about 0.2 millimeters to about 2 millimeters, more preferably from about 0.4 millimeters to about 1.5 millimeters, and even more preferably from about 0.6 millimeters to about 1 millimeter.

[0120] Thus, at the upstream end, the cylindrical peripheral wall presents an end surface adapted to abut against the peripheral portion of the rod of the aerosol-generating substrate. In some embodiments, the upstream end surface of the peripheral wall may have a substantially flat profile. Thus, the upstream end surface of the peripheral wall can substantially contact the entire downstream end surface of the rod. In an alternative embodiment, the upstream end surface of the peripheral wall has a non-flat profile, such as an inclined profile or a curved profile, such that the peripheral wall contacts the rod only at its outermost peripheral edge, while some space is provided between the downstream end surface of the rod and the end surface of the peripheral wall at the inner periphery of the peripheral wall.

[0121] The length of the hollow tubular support element is preferably at least about 10 millimeters. The length of the hollow tubular support element is more preferably at least about 15 millimeters. The length of the hollow tubular support element is even more preferably at least about 20 millimeters.

[0122] The length of the hollow tubular support element is preferably about 60 millimeters or less. The length of the hollow tubular support element is more preferably about 50 millimeters or less. The length of the hollow tubular support element is even more preferably about 40 millimeters or less.

[0123] In some embodiments, the length of the hollow tubular support element is from about 10 millimeters to about 60 millimeters, or from about 10 millimeters to about 50 millimeters, or from about 10 millimeters to about 40 millimeters. In other embodiments, the length of the hollow tubular support element is from about 15 millimeters to about 60 millimeters, or from about 15 millimeters to about 50 millimeters, or from about 15 millimeters to about 40 millimeters. In further embodiments, the length of the hollow tubular support element is from about 20 millimeters to about 60 millimeters, or from about 20 millimeters to about 50 millimeters, or from about 20 millimeters to about 40 millimeters.

[0124] In some preferred embodiments, the length of the hollow tubular support element is from about 10 millimeters to about 60 millimeters, more preferably from about 15 millimeters to about 50 millimeters, and even more preferably from about 20 millimeters to about 40 millimeters.

[0125] Briefly described above, the aerosol generating article according to the present invention comprises a rod and an aerosol cooling element aligned in the longitudinal axis direction with the hollow tubular support element and located downstream of the hollow tubular support element.

[0126] In some embodiments, the aerosol cooling element is positioned immediately downstream of the hollow tubular support element. As used herein in connection with the present invention, the expression "immediately downstream of the hollow tubular support element" means that the aerosol cooling elements are in contact with each other or are very close to each other. In practice, the expression "immediately downstream of the hollow tubular support element" is used to indicate that the minimum longitudinal distance between the downstream end surface of the hollow tubular support element and the upstream end surface of the peripheral wall of the aerosol cooling element is less than 1 millimeter, preferably less than 0.5 millimeter, and even more preferably less than 0.25 millimeter. In a particularly preferred embodiment, the upstream end surface of the aerosol cooling element is in direct contact with the downstream end surface of the peripheral wall of the hollow tubular support element.

[0127] In other embodiments, the aerosol-generating article may comprise one or more additional components between the hollow tubular support element and the aerosol cooling element.

[0128] By way of example, the aerosol-generating article may include a plug of filter material having the ability to remove particulate components, gaseous components, or combinations thereof. Suitable filter materials are well known in the art and include, but are not limited to, fibrous filter materials such as cellulose acetate tow, viscose fibers, polyhydroxyalkanoate (PHA) fibers, polylactic acid (PLA) fibers and paper, adsorbents such as activated alumina, zeolites, molecular sieves and silica gel, and combinations thereof. Additionally, the plug of filter material may further include one or more aerosol modifiers. Suitable aerosol modifiers are known in the art and include, but are not limited to, flavorants such as menthol. The length of the plug of filter material can be from about 4 millimeters to about 25 millimeters. The length of the plug of filter material is preferably at least about 6 millimeters, more preferably at least about 8 millimeters. The length of the plug of filter material is preferably about 25 millimeters or less, more preferably about 20 millimeters or less, even more preferably about 15 millimeters or less. In a particularly preferred embodiment, the length of the plug of filter material is about 10 millimeters or less. In an exemplary embodiment, the length of the plug of filter material is about 5 millimeters. In another exemplary embodiment, the length of the mouthpiece is about 7 millimeters.

[0129] The components of the aerosol generating article according to the present invention may be individually enclosed by such wrappers. The wrapper may be formed of a porous or non-porous sheet material. The wrapper may be formed of any suitable material or combination of materials. The wrapper is preferably a paper wrapper. However, two or more components may be enclosed by the same wrapper. Further, the rod and other components of the aerosol generating substrate are typically assembled within a single wrapper. For example, in one embodiment, the aerosol generating article is in a linear continuous arrangement and includes a rod of the aerosol generating substrate as described above, a tubular support element, an aerosol cooling element, and an outer wrapper surrounding the rod, the support element, and the aerosol cooling element. In another embodiment, the aerosol generating article is in a linear continuous arrangement and includes a rod of the aerosol generating substrate as described above, a tubular support element, a secondary aerosol cooling element, an aerosol cooling element, and an outer wrapper surrounding the rod, the support element, and the aerosol cooling element.

[0130] In some embodiments, the aerosol generating article comprises a ventilation zone at a position along the aerosol cooling element. The aerosol generating article preferably comprises a ventilation zone at a position along the length of the aerosol cooling element.

[0131] In some embodiments, the ventilation zone is provided at a position along the cavity of the hollow tubular segment. Thus, a fluid communication is established between the external environment and the cavity such that when the consumer inhales the aerosol generating article, some ambient air is drawn into the cavity through ventilation holes formed through the peripheral wall of the hollow tubular segment. This is advantageous in that it can advantageously act to lower the temperature of the aerosol by mixing the ambient air with the incoming flow of aerosol, and to cause condensation or growth, or both, of the aerosol particles. At the same time, the flow of ambient air through the peripheral wall of the aerosol cooling element can further facilitate maintaining the temperature of the peripheral wall below a desired threshold.

[0132] In a particularly preferred embodiment, the ventilation zone comprises a plurality of holes extending through the peripheral wall such that an inclined air duct connecting the external environment to the cavity of the hollow tubular segment is formed. This can particularly facilitate maintaining the temperature of the peripheral wall of the aerosol cooling element below a desired threshold value.

[0133] The aerosol generating article described above can be used in an electrically operated aerosol generating device as part of an aerosol generation system according to the present disclosure or another aspect of the present invention. One such aerosol generation system comprises the aerosol generating article described above and an electrically operated aerosol generating device, the electrically operated aerosol generating device comprising a heating element and an elongated heating chamber configured to receive the aerosol generating article, whereby the rod of the aerosol generating substrate is heated within the heating chamber. The heating element preferably comprises a heater blade or heater pin adapted to be inserted into the rod of the aerosol generating substrate when the aerosol generating article is received within the heating chamber.

[0134] Here, the present invention will be further described with reference to the drawings.

Brief Description of the Drawings

[0135]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Best Mode for Carrying Out the Invention

[0136] The aerosol cooling element 16 shown in FIG. 1 has a thickness of about 0.5 millimeters and includes a hollow tubular segment 8 having a peripheral wall 24 that defines a cavity 28. Further, the hollow tubular segment 8 includes a plurality of elongated protrusions 26 that extend from the peripheral wall 24 into the interior of the hollow tubular segment 22. Each of the elongated protrusions 26 extends from the upstream end of the hollow tubular segment 8 to the downstream end of the hollow tubular segment 8 into the interior of the hollow tubular segment 23.

[0137] As shown in FIG. 1, the plurality of elongated protrusions 26 includes four deflection fins. The four deflection fins 26 are evenly distributed radially within the interior of the aerosol cooling element. This means that the deflection fins 26 are radially spaced evenly from each other. The deflection fins 26 are twisted between the upstream end of the hollow tubular segment 8 and the downstream end of the hollow tubular segment 8 as shown in FIG. 2. As shown in FIG. 2, the circumferential position of the elongated protrusions 26 varies along the length of the aerosol cooling element. As shown in FIG. 2, the circumferential position of the elongated protrusions at the midpoint of the aerosol cooling element is different from the circumferential position of the elongated protrusions at the downstream end of the aerosol cooling element as indicated by the dotted line by the cross-section of the deflection fins.

[0138] The aerosol generating article 10 shown in FIG. 4 includes a rod 12 of an aerosol generating substrate, a tubular support element 14, and an aerosol cooling element 16 according to a first embodiment of the present invention. These three elements are arranged sequentially and coaxially aligned and surrounded by a wrapper 18 to form the aerosol generating article 10. The aerosol generating article 10 has a mouth-side end or downstream end 20 and an upstream end 22 located at the end of the article opposite the mouth-side end 20. The aerosol generating article 10 shown in FIG. 4 is particularly suitable for use in an electrically operated aerosol generating device that includes a heater for heating the rod of the aerosol generating substrate.

[0139] The rod 12 of the aerosol generating substrate has a length of approximately 12 millimeters and a diameter of approximately 7 millimeters. The rod 12 is of cylindrical shape and has a substantially circular cross-section.

[0140] The tubular support element 14 is provided as a hollow tube of cellulose acetate. The tubular support element 14 has a length of approximately 8 millimeters. The outer diameter of the tubular support element 14 is approximately 7 millimeters. The peripheral wall of the tubular support element 14 has a thickness of about 1.85 millimeters.

[0141] Figure 5 shows a part of an electrically operated aerosol generating system 200 that utilizes a heater blade 210 to heat the rod 12 of the aerosol generating substrate of the aerosol generating article 10 shown in Figure 4. The heater blade 210 is installed in an aerosol generating article chamber within the housing of an electrically operated aerosol generating device 212. The aerosol generating device 212 defines a plurality of air holes 214 to enable air to flow to the aerosol generating article 10 as indicated by the arrows in Figure 5. The aerosol generating device 212 is equipped with a power source and electronic components, which are not shown in Figure 5.

[0142] The aerosol generating article 10 shown in Figure 4 is designed to engage with the aerosol generating device 212 shown in Figure 5 for consumption.

[0143] The user inserts the aerosol generating article 10 into the aerosol generating device 212, whereby the heater blade 210 is inserted into the rod 12 of the aerosol generating substrate. The aerosol cooling element 16 protrudes outward from the mouth-side end of the device 212. When the aerosol generating article 10 engages with the aerosol generating device 212, the user sucks on the aerosol cooling element 16 that defines the mouthpiece of the aerosol generating article 10, and the rod 12 of the aerosol generating substrate is heated by the heater blade 210 to a temperature sufficient to generate aerosol from the rod 12 of the aerosol generating substrate. The aerosol is drawn through the aerosol cooling element 16 and into the user's mouth.

[0144] Of course, the aerosol generating article 10 shown in FIG. 4 may also be suitable for use with other types of aerosol generating devices.

Claims

1. An aerosol generating article for generating an aerosol upon heating, the aerosol generating article comprising: a rod of an aerosol generating substrate; a first aerosol cooling element positioned downstream of the rod of the aerosol generating substrate, the aerosol cooling element comprising a hollow tubular segment including a peripheral wall, the hollow tubular segment extending along a longitudinal axis and having an upstream end and a downstream end in fluid communication, the hollow tubular segment including at least one elongated protrusion extending from the peripheral wall into the interior of the hollow tubular segment, the at least one elongated protrusion extending longitudinally from an upstream position on the peripheral wall to a downstream position on the peripheral wall at the upstream position, the first aerosol cooling element; a wrapper surrounding the rod of the aerosol generating substrate and the first aerosol cooling element.

2. The aerosol generating article according to claim 1, wherein the at least one elongated protrusion extends radially from the peripheral wall towards the central axis of the hollow tubular segment.

3. The aerosol generating article according to claim 1 or 2, wherein the height of the at least one elongated protrusion varies between the upstream position and the downstream position.

4. The aerosol generating article according to claim 3, wherein the height of the at least one elongated protrusion decreases between one of the upstream position and the downstream position and the other.

5. The aerosol generating article according to any one of claims 1 to 4, wherein the at least one elongated protrusion is a deflector fin configured to change the direction of flow of an aerosol flowing from the upstream end to the downstream end of the hollow tubular segment.

6. The aerosol generating article according to claim 5, wherein the deflector fin includes first and second opposing surfaces, a reference surface parallel to the longitudinal axis and bisecting the internal volume of the hollow tubular segment, and an angle formed between the reference surface and the first surface of the deflector fin at the upstream position is different from an angle formed between the reference surface and the first surface of the deflector fin at the downstream position.

7. The aerosol generating article according to claim 5, wherein the deflector fin is twisted along the length of the hollow tubular segment.

8. The aerosol generating article according to any one of claims 1 to 7, wherein the circumferential position of the at least one elongated protrusion varies between its upstream position and its downstream position.

9. The aerosol generating article according to any one of claims 1 to 8, wherein the height of the at least one elongated protrusion is less than the radius of the hollow tubular segment.

10. The aerosol generating article according to any one of claims 1 to 9, wherein the upstream position is located between the upstream end of the hollow tubular segment and the midpoint of the hollow tubular segment, and the downstream position is located between the midpoint of the hollow tubular segment and the downstream end of the hollow tubular segment.

11. The aerosol generating article according to any one of claims 1 to 9, wherein the at least one elongated protrusion extends in the longitudinal direction from the upstream end of the hollow tubular segment to the downstream end of the hollow tubular segment.

12. The aerosol generating article according to any one of claims 1 to 11, wherein the length of the aerosol generating article is from about 8 mm to about 30 mm.

13. The aerosol generating article according to any one of claims 1 to 12, wherein the thickness of the at least one elongated protrusion is from about 0.1 mm to about 1 mm.

14. The aerosol generating article according to any one of claims 1 to 13, wherein the at least one elongated protrusion includes a plurality of elongated protrusions radially distributed on the peripheral wall.

Images