Tubular element including porous medium to be used in aerosol generating article

Abstract

To provide a tubular element to be used in an aerosol generating article and apparatus, the tubular element showing little or no leakage.SOLUTION: A tubular element includes a first long axial direction passage and a porous medium charged with gel (125). The gel includes an activator. At the tubular element, the porous medium charged with the gel is crimped to be used in an aerosol generating article or to be used in an aerosol generator. Preferably, various kinds of activator can be emitted from the tubular element to an aerosol, generated, or emitted, when the tubular element is heated.SELECTED DRAWING: Figure 30

Description

[Technical Field]

[0001] The present disclosure relates to a tubular element for use in an aerosol-generating article, the tubular element comprising a gel-loaded porous medium. [Background technology]

[0002] Nicotine-containing articles for use with aerosol-generating devices are known. The cartridges often contain a liquid, such as an e-liquid, that is heated by a coiled, electrically resistive filament to release an aerosol. The manufacture, transportation, and storage of such aerosol-generating articles containing liquids can be problematic and can lead to leakage of the liquid and its contents.

[0003] It would be desirable to provide a tubular element for use in aerosol-generating articles and devices, wherein the tubular element exhibits little or no leakage.

[0004] It is also desirable to provide a tubular element that includes a flow control system that efficiently delivers the aerosol generated from the tubular element when heated by an aerosol generating device. Summary of the Invention

[0005] In accordance with the present invention, there is provided a tubular element comprising a first longitudinal passage and further comprising a porous medium loaded with a gel, the gel comprising an active agent. In certain embodiments, the tubular element further comprises a wrapper.

[0006] The present invention provides a tubular element comprising a first longitudinal passage and further comprising a gel-loaded porous medium, the gel comprising an active agent, and the gel-loaded porous medium being crimped.

[0007] In some embodiments, the tubular element comprises a wrapper. In some embodiments, the tubular element comprises a wrapper, the wrapper comprising paper.

[0008] In certain embodiments, the gel-loaded porous medium completely fills the tubular element within the wrapper. Alternatively, in other certain embodiments, the porous medium only partially fills the tubular element.

[0009] In certain embodiments, the tubular element further comprises a second tubular element having a longitudinal side and a proximal end and a distal end, the second tubular element being longitudinally positioned within the first longitudinal passage formed by the wrapper.

[0010] In certain embodiments, the longitudinal side of the second tubular element comprises paper, or cardboard, or cellulose acetate.

[0011] In certain embodiments, the second tubular element comprises a gel-loaded porous medium, however, in alternative certain embodiments, the second tubular element comprises a gel.

[0012] In some particular embodiments, when the described first and second tubular elements and wrapper are present, the gel-loaded porous medium is positioned between the second tubular element and the wrapper that forms the first longitudinal channel.

[0013] In some alternative embodiments, when first and second tubular elements are present, the gel is positioned between the second tubular element and a wrapper that forms at least one longitudinal channel.

[0014] In combination with other features of certain embodiments, the tubular element comprises a longitudinal element longitudinally positioned within the first longitudinal channel.

[0015] In combination with other features of certain embodiments, the wrapper is rigid.Alternatively or additionally, in certain embodiments, the longitudinal side of the second tubular element is rigid.

[0016] In combination with other features of certain embodiments, the wrapper is water resistant.

[0017] In combination with other features of certain embodiments, the tubular element further comprises a susceptor.

[0018] In certain embodiments, the gel-loaded porous medium is crimped. The porous medium can be crimped before loading with the gel or after loading with the gel.

[0019] In certain embodiments, the gel-loaded porous medium is chopped. The porous medium can be chopped before loading with the gel or after loading with the gel.

[0020] According to the invention, there is provided a method for manufacturing a tubular element according to any one of the preceding claims, comprising the steps of: The method is - distributing a gel-loaded porous medium onto a web of wrapping material and distributing a second tubular element onto the gel-loaded porous medium on the web of wrapping material; - wrapping a web of wrapping material around the gel-loaded porous medium and the second tubular element to form a composite structure of the gel-loaded porous medium and the second tubular element.

[0021] In certain embodiments, the method of manufacturing the tubular element further comprises cutting the composite structure encasing the gel-loaded porous medium and the second tubular element to length.

[0022] In accordance with the present invention, there is provided a tubular element comprising a first longitudinal passageway and further comprising a gel-loaded thread, the gel including an active agent.

[0023] In certain embodiments, there is a single gel-loaded thread, however, in alternative embodiments, there are multiple gel-loaded threads, each of which may have the same gel or a different gel.

[0024] In certain embodiments, in combination with other features, the tubular element comprises threads loaded with gel, preferably loaded with the same gel. Alternatively, in other certain embodiments, the tubular element comprises different gels. In certain embodiments, the tubular element comprises threads loaded with gel, and two different gel-loaded threads are loaded with different gels. In certain embodiments, the tubular element comprises two or more gels.

[0025] In the manufacture of tubular elements, the gel, or porous medium, or threads may be dispensed simultaneously with or sequentially dispensed with other components. Preferably, the components are dispensed, but the components may be packed or rolled, or combined or positioned in any known manner to be positioned where desired.

[0026] In combination with other features, the tubular element includes a wrapper.

[0027] In combination with other features, in certain embodiments, the tubular element comprises a susceptor adjacent to at least one gel-loaded thread. The susceptor may be thin and elongated. Preferably, the susceptor is longitudinally positioned within the tubular element. Preferably, the susceptor is surrounded by the gel-loaded thread. In alternative embodiments, the susceptor is positioned between the inner surface of the wrapper and the gel-loaded thread. In certain embodiments, the wrapper comprises the susceptor. Alternatively, or in addition, the susceptor may be in the form of a powder, for example, a metal powder. The powder may be in the gel or within the wrapper, spaced between the gel and the wrapper, or a combination thereof.

[0028] In combination with other features, in certain embodiments the tubular element further comprises a second tubular element.

[0029] According to the invention, there is provided a method for manufacturing a tubular element, comprising the steps of: The tubular element - further comprising a gel-loaded thread having a first longitudinal passage, the gel including an active agent; The method is - placing material for the tubular element around a mandrel to form the tubular element; - dispensing the gel-loaded thread from the conduit within the mandrel so that the gel-loaded thread is within the tubular element.

[0030] The tubular elements may be cut to length. In certain embodiments, manufacturing the tubular elements further comprises cutting the tubular elements to length. The tubular elements may be cut to length.

[0031] The method of manufacturing may further include extruding the material of the tubular element around a mandrel to form the tubular element.

[0032] The method of manufacturing may further include the step of wrapping the tubular element in a wrapper.

[0033] According to the invention, there is provided a method for manufacturing a tubular element, comprising the steps of: The tubular element a wrapper forming a first longitudinal channel and further comprising a thread loaded with a gel, the gel including an active agent; The method is - distributing gel-loaded threads onto a web of packaging material; and - wrapping a web of packaging material around the gel-loaded thread to form a composite structure encasing the gel-loaded thread.

[0034] In certain embodiments, the method of manufacturing the tubular element further comprises cutting the composite structure of packaged gel-loaded thread to length.

[0035] According to the invention, there is provided a method for manufacturing a tubular element, comprising the steps of: The tubular element - Rappers and a gel-loaded thread, the gel comprising an active agent; and a second tubular element; The method is - distributing a gel-loaded thread onto a web of packaging material and distributing a second tubular element onto the gel-loaded thread on the web of packaging material; - wrapping a web of packaging material around the gel-loaded thread and the second tubular element to form a composite structure that wraps the gel-loaded thread and the second tubular element.

[0036] In certain embodiments, the method of manufacturing the tubular element further comprises cutting the composite structure encasing the gel-loaded thread and the second tubular element to length.

[0037] According to the invention, there is provided a method for manufacturing a tubular element, comprising the steps of: The tubular element - Threads and a wrapper; - further comprising a gel, the gel comprising an active agent; The method is - distributing threads onto a web of packaging material; - dispensing gel onto threads that are on a web of packaging material such that the gel impregnates or coats the threads and loads the threads with gel; - wrapping a packaging material around the gel-loaded thread to form a composite gel-loaded thread structure; - dividing the composite structure of gel-loaded threads into lengths.

[0038] According to the present invention there is provided a method of manufacturing a tubular element for use in an aerosol-generating article, comprising the steps of: The tubular element - Rappers and - a second tubular element extending along the length of the tubular element; - a gel-loaded thread located between the second tubular elements and extending along the hollow tubular element, the thread having an additive dispersed in the gel; a wrapper wrapped around the gel-loaded thread and the hollow tubular element; The method is - extruding the material of the hollow tubular element through a forming die and around a mandrel forming a hollow core within the hollow tubular element; - co-extruding the gel-loaded thread through a conduit into a forming die and around a hollow tubular element to form a composite core; - placing a composite core along a web of packaging material; - wrapping a wrapping material around the composite core to form a wrapped composite structure.

[0039] In certain embodiments, the method of manufacturing the tubular element further comprises dividing the composite structure into lengths.

[0040] The method of manufacturing the tubular element further includes distributing a plurality of threads.

[0041] In accordance with the present invention, there is provided a tubular element, the tubular element comprising a wrapper defining a first longitudinal passageway, the tubular element further comprising a gel, the gel comprising an active agent.

[0042] In certain embodiments, the gel completely fills the tubular element within the wrapper.

[0043] Alternatively, in certain embodiments, the gel may only partially fill the tubular element. For example, in certain embodiments, the gel is provided as a coating on the inner surface of the tubular element. An advantage of only partially filling the tubular element is that it leaves a fluid path, for example, for aerosol to flow into or out of the tubular element.

[0044] In combination with certain embodiments, the tubular element comprises a second tubular element.

[0045] In combination with certain embodiments, the tubular element includes a second tubular element having a longitudinal side and a proximal end and a distal end, the second tubular element being longitudinally positioned within the first longitudinal passage.

[0046] In combination with certain embodiments, the tubular element comprises a plurality of second tubular elements.

[0047] In certain embodiments, the tubular element comprises a plurality of second tubular elements arranged in parallel to extend along the longitudinal length of the tubular element. Optionally, gel is provided in all, some, or none of the plurality of second tubular elements. Furthermore, depending on the particular embodiment, if gel is present within the second tubular elements, the gel may completely fill each of the plurality of second tubular elements, or the gel may partially fill the second tubular elements.

[0048] In certain embodiments, the tubular element comprises a gel-loaded porous medium.

[0049] In combination with other features, in certain embodiments, one or more of the second tubular elements comprises a gel-loaded porous medium, where the gel-loaded porous medium is present, either completely filling each of the plurality of second tubular elements or partially filling the second tubular elements.

[0050] In certain embodiments, the gel-loaded porous medium is located between the second tubular element and the wrapper.

[0051] In certain embodiments, the longitudinal side of the second tubular element comprises paper, or cardboard, or cellulose acetate.

[0052] In certain embodiments, the second tubular element comprises a gel, preferably at least partially enclosed by the longitudinal side of the second tubular element.

[0053] In certain embodiments, the gel may be located between the second tubular element and the wrapper that forms the first longitudinal passageway.

[0054] In combination with certain embodiments, the tubular element has an outer diameter that is approximately equal to the outer diameter of the aerosol-generating article.

[0055] In certain embodiments, the tubular elements have an outer diameter of 5 millimeters to 12 millimeters, e.g., 5 millimeters to 10 millimeters, or 6 millimeters to 8 millimeters. Typically, the tubular elements have an outer diameter of 7.2 millimeters plus or minus 10%.

[0056] Typically, the tubular elements have a length of 5 to 15 mm, preferably the tubular elements have a length of 6 to 12 mm, preferably the tubular elements have a length of 7 to 10 mm, and preferably the tubular elements have a length of 8 mm.

[0057] In combination with certain embodiments, the gel is a mixture of materials that can release volatile compounds into an aerosol passing through the tubular element, preferably when the gel is heated. The provision of a gel can be advantageous for storage and transport or during use, as it can reduce the risk of leakage from the tubular element, the aerosol-generating article, or the aerosol-generating device.

[0058] Advantageously, the gel is solid at room temperature. In this context, "solid" means that the gel has a stable size and shape and does not flow. In this context, room temperature means 25 degrees Celsius.

[0059] The gel can include an aerosol former. Ideally, the aerosol former is substantially resistant to thermal decomposition at the operating temperatures of the tubing element. Suitable aerosol formers are well known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate and dimethyl tetradecanedioate). The polyhydric alcohol or mixture thereof can be one or more of triethylene glycol, 1,3-butanediol, and glycerin or polyethylene glycol.

[0060] Advantageously, the gel comprises, for example, a thermoreversible gel. This means that the gel becomes fluid when heated to the melting temperature and becomes a gel again at the gelling temperature. The gelling temperature can be above room temperature and above atmospheric pressure. Atmospheric pressure means a pressure of 1 atmosphere. The melting temperature can be higher than the gelling temperature. The melting temperature of a gel can be higher than 50 degrees Celsius, 60 degrees Celsius, or 70 degrees Celsius, and can be higher than 80 degrees Celsius. In this context, the melting temperature means the temperature at which the gel is no longer solid and begins to flow.

[0061] Alternatively, in certain embodiments, the gel is a non-melting gel that does not melt during use of the tubing element. In these embodiments, the gel may at least partially release the active agent at a temperature equal to or greater than the operating temperature of the tubing element during use, but below the melting temperature of the gel.

[0062] The gel preferably has a viscosity of 50,000 to 10 Pascals / second, preferably 10,000 to 1,000 Pascals / second, to provide the desired viscosity.

[0063] The gel preferably comprises a gelling agent, which is capable of forming a solid medium in which the aerosol former can be dispersed.

[0064] The gel may contain any suitable gelling agent. For example, the gelling agent may contain one or more biopolymers, such as two or three biopolymers. When the gel contains two or more biopolymers, the biopolymers are preferably present in substantially equal amounts by weight. The biopolymer may be formed from a polysaccharide. Suitable biopolymers for use as gelling agents include, for example, gellan gum (natural, low-acyl gellan gum, high-acyl gellan gum, with low-acyl gellan gum being preferred), xanthan gum, alginate (alginic acid), agar, guar gum, etc. Preferably, the gel contains agar.

[0065] The gel can include any suitable amount of gelling agent. For example, the gel may include from about 0.5 weight percent to about 7 weight percent of the gel. Preferably, the gel includes from about 1 weight percent to about 5 weight percent of the gelling agent, such as from about 1.5 weight percent to about 2.5 weight percent.

[0066] In some preferred embodiments, the gel comprises agar in the range of about 0.5 weight percent to about 7 weight percent, or in the range of about 1 weight percent to about 5 weight percent, or about 2 weight percent.

[0067] In some preferred embodiments, the gel comprises xanthan gum in the range of about 2 weight percent to about 5 weight percent, or in the range of about 2 weight percent to about 4 weight percent, or about 3 weight percent.

[0068] In some preferred embodiments, the gel comprises xanthan gum, gellan gum, and agar. The gel may comprise xanthan gum, low-acyl gellan gum, and agar. The gel may comprise xanthan gum, gellan gum, and agar in substantially equal weight amounts. The gel may comprise xanthan gum, low-acyl gellan gum, and agar in substantially equal weight amounts. The gel may comprise xanthan gum, low-acyl gellan gum, and agar in a range of about 1 weight percent to about 5 weight percent, or about 1 weight percent to about 4 weight percent, or about 2 weight percent (based on the total weight of xanthan gum, low-acyl gellan gum, and agar in the gel). The gel may comprise xanthan gum, low-acyl gellan gum, and agar in a range of about 1 weight percent to about 5 weight percent, or about 2 weight percent, where the xanthan gum, gellan gum, and agar are substantially equal in weight.

[0069] The gel may contain divalent cations. The divalent cations preferably include calcium ions, such as calcium lactate, in solution. Divalent cations (e.g., calcium ions) may aid in gel formation in compositions containing biopolymers (polysaccharides), such as gellan gum (native gellan gum, low-acyl gellan gum, high-acyl gellan gum), xanthan gum, alginate (alginic acid), agar, guar gum, and the like. Ionic effects may aid gel formation. Divalent cations may be present in the gel composition in a range of about 0.1 to about 1 weight percent, or about 0.5 weight percent. In some embodiments, the gel is free of divalent cations.

[0070] The gel may contain a carboxylic acid. The carboxylic acid may contain a ketone group. Preferably, the carboxylic acid contains a ketone group with fewer than 10 carbon atoms. Preferably, the carboxylic acid has five carbon atoms (such as levulinic acid). Levulinic acid may be added to neutralize the pH of the gel. This may also aid in gel formation with biopolymers (polysaccharides), such as gellan gum (low acyl gellan gum, high acyl gellan gum), xanthan gum, especially alginate (alginic acid), agar, guar gum, and the like. Levulin may also enhance the sensory profile of the gel formulation. In some embodiments, the gel does not contain a carboxylic acid.

[0071] In combination with certain embodiments, the gel comprises a gelling agent, hi certain embodiments, the gel comprises agar or agarose or sodium alginate or gellan gum, or a mixture thereof.

[0072] In certain embodiments, the gel comprises water, e.g., the gel is a hydrogel. Alternatively, in certain embodiments, the gel is non-aqueous.

[0073] Preferably, the gel contains an active agent. In combination with certain embodiments, the active agent includes nicotine (e.g., in powder or liquid form), or, for example, a tobacco product or another target compound for release in an aerosol. In certain embodiments, the nicotine is contained in the gel along with an aerosol former. Securing the nicotine within the gel at room temperature is desirable to prevent leakage.

[0074] In certain embodiments, the gel includes a solid tobacco material that releases flavor compounds when heated. According to certain embodiments, the solid tobacco material is one or more of a powder, granules, pellets, pieces, spaghetti, strips, or sheets, including one or more of plant materials such as herb leaves, tobacco leaves, tobacco stem fragments, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco.

[0075] Additionally or alternatively, there are embodiments in which the gel includes other flavors, such as menthol, which may be added either to the water or to the aerosol former prior to formation of the gel.

[0076] In embodiments in which agar is used as a gelling agent, the gel contains, for example, 0.5 to 5 weight percent, preferably 0.8 to 1 weight percent, agar. Preferably, the gel further contains 0.1 to 2 weight percent nicotine. Preferably, the gel further contains 30 to 90 weight percent (or 70 to 90 weight percent) glycerin. In certain embodiments, the remainder of the gel comprises water and flavorings.

[0077] Preferably, the gelling agent is agar, which has the property of melting at temperatures above 85°C and returning to a gel at around 40°C. This property makes agar suitable for high-temperature environments. The gel does not melt at 50°C, which is useful, for example, if the system is placed in a hot car in the sun. The phase change to a liquid at around 85°C means that the gel only needs to be heated to a relatively low temperature to induce aerosolization, which allows for low energy consumption. This can be beneficial when using only agarose, one of the components of agar, as a substitute for agar.

[0078] When gellan gum is used as the gelling agent, the gel typically contains 0.5 to 5 weight percent gellan gum. Preferably, the gel further contains 0.1 to 2 weight percent nicotine. Preferably, the gel contains 30 to 99.4 weight percent glycerin. In certain embodiments, the remainder of the gel contains water and flavorings.

[0079] In one example, the gel comprises 2 weight percent nicotine, 70 weight percent glycerol, 27 weight percent water, and 1 weight percent agar.

[0080] In another example, the gel comprises 65 weight percent glycerol, 20 weight percent water, 14.3 weight percent tobacco, and 0.7 weight percent agar.

[0081] Additionally or alternatively, in some particular embodiments, the tubular element comprises a gel-loaded porous medium. The gel-loaded porous medium is preferably located between the second tubular element and the wrapper that forms the first longitudinal passage. Alternatively, in some particular embodiments, the second tubular element comprises a gel-loaded porous medium. These embodiments do not necessarily exclude the gel or gel-loaded porous medium from additionally or alternatively being located elsewhere. In certain embodiments, the tubular element comprises a gel and a gel-loaded porous medium.

[0082] In conjunction with certain embodiments, the tubular element comprises a longitudinal element positioned longitudinally within the first longitudinal passage. In certain embodiments, the longitudinal element positioned longitudinally within the first longitudinal passage is a gel-loaded porous medium. In other certain embodiments, the longitudinal element may be a longitudinal element of any material that can, for example, occupy space within the tubular element, aid or assist in the passage of heat or material, or even aid in the hardness or rigidity of the structure.

[0083] In some embodiments, the wrapper is hard or rigid to aid in the structure of the tubular element. The gels used in the present invention are semi-solid, and are expected to be able to retain their shape, particularly during use. However, the present invention is not limited to solid gels. More fluid gels, even gels with viscosities higher than those of solid gels, can also be used in embodiments of the present invention. Therefore, it is beneficial, though not essential, that the wrapper itself be able to maintain the structure of the tubular element. Similarly, the longitudinal side of the second tubular element may be rigid or hard. Having the wrapper or the longitudinal side of the second tubular element, or both the wrapper and the longitudinal side of the second tubular element, being hard or rigid in nature may not only aid in the structure of the tubular element, but may also aid in manufacturing. The wrapper preferably has a thickness of about 50 to 150 micrometers.

[0084] In combination with other features, in certain embodiments, the wrapper is water-resistant. In certain embodiments, the longitudinal side of the second tubular element is water-resistant. This water-resistant property of either the wrapper or the longitudinal side of the second tubular element can be achieved by using a water-resistant material or by treating the material of the longitudinal side of the wrapper or the second tubular element. This can be achieved by treating one or both sides of the wrapper or the longitudinal side of the second tubular element. Being water-resistant can help prevent loss of structure, hardness, or rigidity. It can also help prevent leakage of gel or liquid, especially when using a fluidic gel structure.

[0085] In combination with certain embodiments, the tubular element includes a susceptor. The susceptor may be any heat-transfer material, such as metal threads, such as aluminum threads, or threads including aluminum or a metal powder, such as aluminum powder. Typically, the susceptor is longitudinally positioned within the tubular element. The susceptor may be located within, adjacent to, or near the gel, or within, adjacent to, or near the gel-loaded porous medium.

[0086] In combination with certain embodiments, the tubular element further comprises a thread, which may be of any natural or synthetic material, but is preferably cotton. The thread may be a vehicle for carrying an active ingredient, such as a flavoring agent. An example of a suitable flavoring agent for use in the present invention may be menthol. The thread may run longitudinally within the tubular element. Preferably, the thread may be located within, adjacent to, or near the gel, or within, adjacent to, or near the porous medium loaded with the gel.

[0087] In combination with certain embodiments, the tubular element further comprises a sheet material. In combination with certain embodiments, the gel-loaded porous medium comprises a sheet material. Providing the gel-loaded porous material as a sheet material may have manufacturing advantages, for example, it may be easier to pack the sheet materials together to obtain a suitable structure. The gel may be loaded into the sheet materials before they are packed together, or after they are packed together.

[0088] In accordance with the present invention, there is provided a tubular element, the tubular element comprising a wrapper forming a first longitudinal channel, the tubular element further comprising a gel-loaded porous medium, the gel-loaded porous medium further comprising an active agent.

[0089] In certain embodiments, the gel-loaded porous medium completely fills the tubular element within the wrapper. Alternatively, in other certain embodiments, the porous medium only partially fills the tubular element.

[0090] In certain embodiments, the tubular element further comprises a second tubular element having a longitudinal side and a proximal end and a distal end, the second tubular element being longitudinally positioned within the first longitudinal channel formed by the wrapper.

[0091] In certain embodiments, the longitudinal side of the second tubular element comprises paper, or cardboard, or cellulose acetate.

[0092] In certain embodiments, the second tubular element comprises a gel-loaded porous medium.

[0093] In some particular embodiments, when the described first and second tubular elements are present, the gel-loaded porous medium is positioned between the second tubular element and a wrapper that forms the first longitudinal channel.

[0094] In some alternative embodiments, when first and second tubular elements are present, the gel is positioned between the second tubular element and the wrapper that forms the first longitudinal channel.

[0095] According to the invention, there is provided a method for manufacturing a tubular element, comprising the steps of: The tubular element - comprising at least one longitudinal passage and further comprising a gel, the gel comprising an active agent; The method is - placing tubular element material around a mandrel forming the tubular element; - extruding the gel from the conduit within the mandrel so that the gel is within the tubular element.

[0096] The method may further include extruding the material of the tubular element around the mandrel to form the tubular element.

[0097] The method of manufacturing may further include the step of wrapping the tubular element in a wrapper.

[0098] According to the invention, there is provided a method for manufacturing a tubular element, comprising the steps of: The tubular element a wrapper forming a first longitudinal channel and further comprising a gel-loaded porous medium, the gel-loaded porous medium further comprising an active agent; The method is - dispensing a gel-loaded porous medium onto a web of wrapping material; - wrapping a packaging material around the gel-loaded porous medium.

[0099] According to the invention, there is provided a method for manufacturing a tubular element, comprising the steps of: The tubular element - a gel-loaded porous medium comprising a wrapper forming a first longitudinal channel, the tubular element further comprising: a gel-loaded porous medium, the gel-loaded porous medium further comprising an active agent; a second tubular element; The method is - distributing a gel-loaded porous medium onto a web of wrapping material and distributing a second tubular element onto the gel-loaded porous medium on the web of wrapping material; - wrapping a packaging material around the gel-loaded porous medium and the second tubular element.

[0100] In certain embodiments, the method of manufacturing the tubular elements further comprises cutting the wrapped tubular elements to length.

[0101] It is envisaged that the tubular elements of the present invention will be used in aerosol-generating articles. It is also envisaged that the aerosol-generating articles may be used in devices, such as aerosol-generating devices. The aerosol-generating devices may be used to hold and heat the aerosol-generating article to release a material. In particular, this may be to release a material from the tubular elements of the present invention.

[0102] According to the present invention, there is provided an aerosol-generating article for generating an aerosol, the aerosol-generating article comprising: - a fluid guide for permitting the movement of a fluid, the fluid guide having a proximal end and a distal end, the fluid guide having an inner longitudinal region and an outer longitudinal region separated by a barrier, the inner longitudinal region comprising an inner longitudinal passage between the distal and proximal ends, the outer region comprising a longitudinal passage communicating an external fluid through at least one aperture to the distal end of the fluid guide, whereby the external fluid can pass along the outer longitudinal passage to the distal end of the fluid guide; - a tubular element containing a gel, the gel containing an active agent, the tubular element having a proximal end and a distal end and positioned distal to the fluid guide.

[0103] In certain embodiments, the barrier separating the inner and outer longitudinal passages may be an impermeable barrier, for example, impermeable to fluids.

[0104] According to the present invention, there is provided an aerosol-generating article, comprising: - a fluid guide for permitting the movement of a fluid, the fluid guide having a proximal end and a distal end, the fluid guide having an inner longitudinal region and an outer longitudinal region separated by a barrier, the inner longitudinal region comprising an inner longitudinal passage between the distal and proximal ends, the outer region comprising an outer longitudinal passage communicating an external fluid to the distal end of the fluid guide through at least one aperture, whereby the external fluid can pass along the outer longitudinal passage to the distal end of the fluid guide; - a tubular element comprising a gel-loaded porous medium and further comprising an active agent, the tubular element having a proximal end and a distal end and positioned distal to the fluid guide.

[0105] In some embodiments, the distal end of the tubular element preferably comprises at least one aperture. An aperture at the distal end of the tubular element may allow fluid, such as air from outside the aerosol-generating article, to enter and pass through the tubular element, creating an aerosol. Fluid passing through the tubular element may pick up active agents or any other materials in the gel and pass them downstream (proximally) from the gel.

[0106] In certain embodiments, the aerosol-generating article may include a cavity located between the distal end of the fluid guide and the proximal end of the tubular element. Thus, the cavity may be at the upstream end of the inner longitudinal passage and the downstream end of the tubular element. The cavity allows fluid, e.g., ambient air, to travel through the outer longitudinal passage to the cavity and contact the gel within the tubular element. Fluid that contacts the tubular element can enter and pass through the tubular element, then return to the inner longitudinal passage and the proximal end of the fluid guide and the proximal end of the aerosol-generating article. When this fluid, e.g., ambient air, contacts the gel, it may capture an active agent or any other material in the gel or within the tubular element and pass it downstream along the inner longitudinal passage to the proximal end of the aerosol-generating article. To contact the gel, the ambient air may pass through the tubular element, through the gel, or through the surface of the gel, or a combination thereof.

[0107] In certain embodiments, the aerosol-generating article includes a wrapper. The wrapper may be made of any suitable material, for example, the wrapper may include paper. The wrapper preferably has an aperture corresponding to the aperture in the fluid guide. The corresponding aperture in the fluid guide and the wrapper may result from an aperture formed after packaging of the article.

[0108] In certain embodiments, the at least one aperture is located in the outer passage of the fluid guide.

[0109] Having at least one externally communicating aperture located in the outer passage of the fluid guide allows for a distance between the tubular element and the at least one externally communicating aperture, which helps to prevent leakage of the gel and its contents, but may also provide the desired aerosol draw.

[0110] In certain embodiments, the at least one aperture is located in a cavity between the fluid guide and the tubular element.

[0111] By having at least one aperture located in the outer passage of the fluid guide, the ambient fluid can easily reach the tubular element and mix in the cavity between the tubular element and the fluid guide.

[0112] In certain embodiments, the at least one aperture is located in a sidewall of the tubular element.

[0113] Having at least one aperture located in the sidewall of the tubular element allows the ambient fluid to travel in a substantially unidirectional manner when negative pressure is applied to the proximal end of the aerosol-generating article, and having at least one aperture located in the sidewall of the tubular element allows the ambient fluid to easily mix with the contents of the tubular element.

[0114] In certain embodiments, the outer longitudinal passage of the aerosol-generating article comprises one aperture or multiple apertures. An aperture may be any aperture, slit, hole, or passageway that allows a fluid, such as ambient air, to pass through and enter the aerosol-generating article. This allows fluid from outside the aerosol-generating article to be drawn into it. During use, this may be an external fluid, such as air, that is first drawn into the outer longitudinal passage of the aerosol-generating article through the aperture before being drawn into other parts of the aerosol-generating article. In certain embodiments, the apertures are evenly spaced around the circumference of the aerosol-generating article, e.g., 10 or 12 apertures. Evenly spaced apertures help ensure a smooth flow of fluid.

[0115] In combination with certain embodiments, the aerosol-generating article includes an end plug located at the distal end of the tubular element, the end plug having a high resistance to withdrawal. The end plug may be impermeable to fluids or may be substantially impermeable to fluids. The end plug is preferably located at the most distal end of the aerosol-generating article. By having the end plug have a high resistance to withdrawal, this advantageously urges fluids to enter through the aperture of the outer longitudinal passage when negative pressure is applied to the proximal end of the aerosol-generating article. In some embodiments, the end plug is fluid-impermeable.

[0116] In some embodiments, the tubular element comprises an end plug. Advantageously, this can facilitate manufacturing. The end plug of the tubular element will preferably be located at one end of the tubular element. Advantageously, this can facilitate manufacturing. In some embodiments, the tubular element comprises an end plug, and the end plug is fluid impermeable. If the tubular element comprises a fluid impermeable end plug, this prevents gels and other fluids from escaping the tubular element through the end plug of the tubular element.

[0117] In certain embodiments, the inner longitudinal passage of the inner region of the fluid guide includes a restrictor. In some embodiments, the restrictor is located at or near the proximal end of the fluid guide. In some embodiments, the restrictor is located at or near the downstream end of the fluid guide. However, if present, the restrictor may be positioned within a central region of the inner longitudinal passage or outer longitudinal passage of the fluid guide. The restrictor may also be positioned near or at the distal end of the inner longitudinal passage. The restrictor may be positioned at or near the upstream end of the inner longitudinal passage. More than one restrictor may be used in the inner or outer longitudinal passage of the fluid guide.

[0118] A restrictor for use with certain embodiments of the present invention may include an abrupt narrowing or gradual restriction, such as an aperture in a surface such as a wall. Alternatively, in certain other embodiments, the restrictor may include a gradual or smooth restriction, such as a sloping wall, or a funnel shape that narrows toward the opening, or a gradual, stepped restriction across the width of the passageway. A gradual or abrupt widening may be present on the downstream (proximal) side of the restrictor. Certain embodiments include a funnel shape on one or both sides of the restrictor. Thus, fluid flow from upstream to downstream (distal to proximal) may experience a gradual flow restriction, as both sides of the passageway narrow toward the restrictor opening, and then the passageway gradually widens from the restrictor opening. Typically, the restrictor opening has a restriction of 60 percent, 45 percent, or 30 percent from the maximum cross-sectional area of ​​the passageway. Thus, in the present invention, a restrictor may, in some embodiments, comprise a narrowing portion having an opening with a cross-sectional area that is, for example, only 60 percent, 45 percent, or 30 percent of the cross-sectional area of ​​the largest or widest portion of the inner longitudinal passageway. Typically, certain embodiments of the present invention reduce the cross-sectional diameter of a cylindrical passageway, for example, from 4 millimeters to 2.5 millimeters, or from 4 millimeters to 2.5 millimeters. By varying the different rates and amounts of width reduction, the positioning of the restrictors, the number of restrictors, and the gradient of reduction and widening, particular fluid flow characteristics can be achieved.

[0119] In combination with certain embodiments, the aerosol-generating article comprises a heating element, such as a susceptor, so that heat can be transferred to the gel within the tubular element, which, like the susceptor of the tubular element, may be of any suitable material, preferably a metal, such as or including aluminum.

[0120] According to the present invention, there is provided a method for producing an aerosol-generating article, the aerosol-generating article comprising:

[0121] - a fluid guide for permitting communication of a fluid, the fluid guide having a proximal end and a distal end, the fluid guide having an inner longitudinal region and an outer longitudinal region separated by a barrier, the inner longitudinal region comprising an inner longitudinal passage between the distal and proximal ends, the outer region comprising an outer longitudinal passage communicating fluid through at least one aperture to the distal end of the fluid guide, whereby fluid can pass along the outer longitudinal passage of the outer fluid control region to the distal end of the fluid guide; a tubing element containing a gel, the gel containing an active agent, the tubing element having a proximal end and a distal end; The method is - linearly disposing on a web of packaging material a tubular element provided with gel and a fluid guide; - wrapping the tubular element and the fluid guide and tightly sealing the wrapper around the tubular element and the fluid guide.

[0122] According to the present invention, there is provided an aerosol generating device comprising a container configured to receive the distal end of an aerosol-generating article as described herein.

[0123] The container of the device may be shaped and sized to allow a distal end or a portion of the distal end of the aerosol-generating article to fit snugly within the container and to retain the aerosol-generating article within the container during normal use.

[0124] Typically, the container includes a heating element, which may directly or indirectly heat the aerosol-generating article, the tubular element, or preferably the gel containing the active agent, or the porous medium loaded with the gel, or any combination thereof, to assist in the generation or release of the aerosol or the release of material into the aerosol. The aerosol may then pass to the proximal end of the aerosol-generating article. In certain embodiments, heating is achieved directly, indirectly via a heating element or susceptor, or a combination of both.

[0125] The heating means may be any known heating means. Typically, the heating means may be radiative or conductive or convective, or a combination thereof.

[0126] In combination with certain embodiments, the tubular element further comprises a thread. In certain embodiments, the thread is a natural or synthetic material, or the thread is a combination of natural and synthetic materials. The thread may comprise a semi-synthetic material. The thread may be made of fiber, or may comprise fiber, or may partially comprise fiber. The thread may be made of, for example, cotton, cellulose acetate, or paper. Composite threads may be used. The thread may aid in the manufacture of the tubular element containing the active agent. The thread may aid in the introduction of the active agent into the tubular element containing the active agent. The thread may help stabilize the structure of the tubular element containing the active agent.

[0127] In combination with certain embodiments, the tubular element comprises a gel-loaded porous medium. The porous medium can be used within the tubular element to create spaces within the tubular element. The porous medium can hold or retain the gel. This has the advantage of aiding in the transfer and storage of the gel and the manufacturing of tubular elements containing the gel. The gel in the gel-loaded porous medium can also contain an active agent or can hold or carry an active agent or other material.

[0128] The porous medium may be any suitable porous material capable of retaining or retaining a gel. Ideally, the porous medium allows the gel to move within. In certain embodiments, the gel-loaded porous medium comprises a natural, synthetic, or semi-synthetic material, or a combination thereof. In certain embodiments, the gel-loaded porous medium comprises a sheet material, a foam, or a fiber, e.g., loose fiber, or a combination thereof. In certain embodiments, the gel-loaded porous medium comprises a woven, nonwoven, or extruded material, or a combination thereof. Preferably, the gel-loaded porous medium comprises, for example, cotton, paper, viscose, PLA, or cellulose acetate, or a combination thereof. Preferably, the gel-loaded porous medium comprises a sheet material, e.g., cotton or cellulose acetate. An advantage of gel-loaded porous medium is that the gel is retained within the porous medium, which may aid in the manufacturing, storage, or transportation of the gel. This may help maintain the desired shape of the gel, particularly during manufacturing, transportation, or use. The porous media used in the present invention can be crimped or chopped. In certain embodiments, the porous media comprises crimped porous media. In alternative embodiments, the porous media comprises chopped porous media. The crimping or chopping process can occur before or after loading the gel.

[0129] The shredding provides the medium with a high surface area to volume ratio so that it can readily absorb the gel.

[0130] In certain embodiments, the sheet material is a composite material. Preferably, the sheet material is porous. The sheet material may aid in the manufacture of a tubular element containing a gel. The sheet material may aid in the introduction of an active agent into a tubular element containing a gel. The sheet material may help stabilize the structure of a tubular element containing a gel. The sheet material may aid in the transport or storage of the gel. The use of a sheet material allows or aids in adding structure to a porous medium, for example, by crimping the sheet material. Crimping the sheet material has the advantage of improving the structure and allowing passages through the structure. The passages through the crimped sheet material aid in gel loading, gel retention, and fluid passage through the crimped sheet material. Therefore, there are advantages to using a crimped sheet material as a porous medium.

[0131] The porous medium may be a thread. The thread may comprise, for example, cotton, paper, or acetate tow. The thread may also be loaded with a gel, like any other porous medium. An advantage of using a thread as a porous medium is that it may aid in ease of manufacture. The thread may be pre-loaded with gel before being used in the manufacture of a tubular element, or the thread may be loaded with gel during assembly of the tubular element.

[0132] The threads may be loaded with gel by any known means. They may be simply coated with gel or may be impregnated with gel. In manufacturing, the threads may be impregnated with gel and stored ready to use for inclusion in the assembly of tubular elements. In other processes, the threads undergo a loading process in the manufacture of gel-loaded tubular elements. Preferably, the gel includes an active agent, as do the gel-loaded porous media or the gel alone. The active agent is as described herein.

[0133] As used herein, the term "active agent" refers to an agent capable of activity, e.g., causing a chemical reaction or altering the aerosol produced. An active agent may be more than one agent.

[0134] As used herein, the term "aerosol-generating article" is used to describe an article that is capable of generating or emitting an aerosol.

[0135] As used herein, the term "aerosol-generating device" is a device used in conjunction with an aerosol-generating article to enable the generation or emission of an aerosol.

[0136] As used herein, the term "aerosol former" refers to any suitable known compound or mixture of compounds that, upon use, promotes enhancement of an initial aerosol received within a tubular element, which may result in, for example, a denser aerosol, a more stable aerosol, or both a denser and a more stable aerosol.

[0137] As used herein, the term "aerosol-generating material" is used to describe a material that is capable of generating or emitting an aerosol.

[0138] As used herein, the term "aperture" is used to describe any aperture, slit, hole, or opening.

[0139] As used herein, the term "cavity" is used to describe any void or space that is at least partially enclosed in a structure. For example, in the present invention, the cavity is the (in some embodiments) partially enclosed space between the fluid guide and the tubular element.

[0140] As used herein, the term "chamber" is used to describe an at least partially enclosed space or cavity.

[0141] For purposes of this disclosure, a "reduced" inner longitudinal cross-sectional area from a first position to a second position is used to indicate a decrease in the diameter of the inner longitudinal cross-sectional area from the first position to the second position. These are often referred to as "restrictors." Thus, as used herein, the term "restrictor" is used to describe a narrowing of a fluid passageway or a change in the cross-sectional area of ​​a fluid passageway.

[0142] As used herein, the term "crimped" means a material having multiple ridges or corrugations. It also includes the process of crimping a material.

[0143] The expression "cross-sectional area" is used to describe the cross-sectional area measured in a plane transverse to the longitudinal axis.

[0144] For purposes of this disclosure, as used herein, the term "diameter" or "width" refers to the largest transverse dimension of a tubular element, aerosol-generating article, or aerosol-generating device, a portion or component thereof, or any of a tubular element, aerosol-generating article, or aerosol-generating device. As an example, a "diameter" is the diameter of an object having a circular transverse cross-section, or the diagonal width of an object having a rectangular cross-section.

[0145] As used herein, the term "essential oil" is used to describe oils that have the characteristic odor and flavor of the plant from which they are obtained.

[0146] As used herein, the term "external fluid" is used to describe a fluid that originates from outside the aerosol-generating element, article, or device, such as ambient air.

[0147] As used herein, the term "flavorant" is used to describe a composition that affects the sensory properties of the aerosol.

[0148] As used herein, the term "fluid guide" is used to describe a device or component that can change the flow of a fluid. Preferably, this is to guide or direct the fluid flow path of the generated or emitted aerosol. The fluid guide can cause the fluid to mix. This can help increase the velocity of the fluid as it travels through the fluid guide, as the cross-sectional area of ​​the passage narrows, or can help slow the velocity of the fluid as it travels along the passage, as the cross-sectional area of ​​the passage widens.

[0149] As used herein, the term "collected" is used to describe a sheet that is rolled, folded, or otherwise compressed or contracted substantially transverse to the longitudinal axis of the aerosol-generating article or tubular element.

[0150] As used herein, the term "gel" is used to describe a solid, jelly-like, semi-rigid material or mixture of materials with a three-dimensional network that can hold other materials and release materials into an aerosol.

[0151] The term "leaf material" is used to refer to material from herbaceous plants. An "herb" is an aromatic plant, the leaves or other parts of which are used for medicinal, culinary, or aromatic purposes, and which can release flavor in the aerosol produced by the aerosol-generating article.

[0152] As used herein, the term "hydrophobic" refers to a surface that exhibits the property of repelling water. Hydrophobic properties can be expressed by the water contact angle, which is the angle, traditionally measured through a liquid, where a fluid interface meets a solid surface. It quantifies the wettability of a solid surface by a liquid via Young's equation.

[0153] As used herein, the term "impermeable" is used to describe an item, for example, a barrier, through which fluids do not substantially or readily pass.

[0154] As used herein, the term "induction heating" is used to describe heating an object by electromagnetic induction, whereby eddy currents (also known as Foucault currents) are generated within the object being heated, leading to resistive heating of the object.

[0155] As used herein, the term "longitudinal passage" is used to describe a passage or opening that allows a fluid or the like to flow along. Typically, air or a material, e.g., a generated aerosol carrying solid particles, flows along the longitudinal passage. Typically, a longitudinal passage has a longitudinal length that is greater than its width, but this is not necessarily the case. The term "longitudinal passage" also includes two or more longitudinal passages.

[0156] The term "longitudinal" is used to describe the direction between the proximal and distal ends of a tubular element, aerosol-generating article, or aerosol-generating device.

[0157] As used herein, the "longitudinal side" of, for example, a second tubular element is used to describe the longitudinal side or wall of the second tubular element, which in some embodiments is a unitary, e.g., cellulose acetate or gel-loaded porous medium that forms the tubular element. In alternative embodiments, the longitudinal side is a wrapper.

[0158] As used herein, the term "mandrel" is used to describe a shaft onto which another material is forged or shaped.

[0159] As used herein, the term "mint" is used to refer to plants of the Mentha genus.

[0160] The term "mouthpiece" is used herein to describe an element, component, or portion of an aerosol-generating article through which the aerosol exits the aerosol-generating article.

[0161] As used herein, the term "outer" with respect to a fluid guide is used to describe a portion of the fluid guide that is toward the longitudinal circumference of the fluid guide rather than toward the center of the cross-sectional portion of the fluid guide. Similarly, the term "inner" (with respect to a fluid guide) is used to describe a portion of the fluid guide that is at the center of the cross-sectional portion of the fluid guide rather than near the circumference of the fluid guide.

[0162] As used herein, the term "passageway" is used to describe a passageway that can allow access between.

[0163] As used herein, the term "plasticizer" is used to describe a substance, typically a solvent, that is added to create or promote plasticity or flexibility and reduce brittleness.

[0164] As used herein, the term "porous medium" is used to describe any medium that can retain, retain, or support a gel. Typically, porous media have passages within their structure that can be filled to retain or hold a fluid or semi-solid, e.g., retain a gel. Preferably, gel can also pass or transmit along and through the passages within the porous medium. As used herein, the term "gel-loaded porous medium" is used to describe a porous medium that includes a gel. Gel-loaded porous media can retain, retain, or support some amount of gel.

[0165] As used herein, the term "plug" is used to describe a component, segment, or element for use in an aerosol-generating article. As used herein, the term "end plug" is used to describe the distal-most component or plug of the aerosol-generating article, at the distal end of the aerosol-generating article. This end plug preferably has a high resistance to withdrawal (RTD).

[0166] The term "proton donating" means a group that can donate a hydrogen or a proton in a chemical reaction.

[0167] By the term "container" of an aerosol-generating device, this term is used to describe a chamber of the aerosol-generating device that can receive a portion of the aerosol-generating article, which is usually, but not necessarily, the distal end of the article.

[0168] As used herein, the term "resistance to draw" (RTD) is used to describe the resistance to a fluid, e.g., gas, being drawn through a material. As used herein, resistance to draw is expressed in units of pressure "mmWG" or "millimeters of water column" and is measured in accordance with ISO 6565:2002.

[0169] As used herein, the term "high resistance to withdrawal" (RTD) is used to describe the resistance to a fluid, e.g., gas, being drawn through a material, such as, for example, an end plug. As used herein, high resistance to withdrawal means greater than 200 "mmWG" or "millimeters of water column," measured according to ISO 6565:2002.

[0170] As used herein, the term "sheet material" is used to describe a generally planar, laminar element whose width and length are substantially greater than its thickness.

[0171] As used herein, the term "seal" refers to joining or "joining," for example, by joining the edges of wrappers to each other or to a fluid guide. This may be by the use of an adhesive or glue. However, the term seal also includes an interference fit joint. The seal need not create a fluid-tight seal or barrier.

[0172] As used herein, the term "shredded" is used to describe something that has been cut into fine pieces.

[0173] As used herein, the term "rigid" is used to describe an item that is sufficiently stiff or rigid enough to resist changes in shape, or that is sufficiently rigid enough to generally resist deformation in shape under normal use. This includes that it may be elastic so that it can generally return to its original shape when deformed. Similarly, as used herein, the term "rigid" describes an item that resists bending or losing shape and is able to generally maintain its shape, particularly under normal use.

[0174] As used herein, the term "susceptor" is used to describe a heating element that is any material capable of absorbing electromagnetic energy and converting it into heat. For example, in the present invention, the susceptor or heating element may assist in the transfer of thermal energy to the gel, heating the gel to aid in the release of material from the gel.

[0175] As used herein, the term "textured sheet" means a sheet that has been crimped, embossed, debossed, perforated, or otherwise modified.

[0176] As used herein, the term "gel-loaded thread" is used to describe a thread of porous media that holds, retains, or supports a gel, including, for example, being coated with or impregnated with a gel.

[0177] Throughout this specification, the term "tubular element" is used to describe a component suitable for use in an aerosol-generating article. Ideally, a tubular element may have a longer longitudinal length than it is wide, but this need not be the case, as it may be part of a multi-component item that ideally has a longer longitudinal length than it is wide. Typically, a tubular element is cylindrical, but this need not be the case. For example, a tubular element may have an oval, a polygonal such as a triangle or rectangle, or an irregular cross section. A tubular element need not be hollow.

[0178] The terms "upstream" and "downstream" are used to describe relative positions relative to the direction of the mainstream fluid as it is drawn into a tubular element, an aerosol-generating article, or an aerosol-generating device. In some embodiments, if the fluid enters the aerosol-generating article at its distal end and travels toward its proximal end, the distal end of the aerosol-generating article may be described as the upstream end of the aerosol-generating article, and the proximal end of the aerosol-generating article may also be described as the downstream end of the aerosol-generating article. Elements of the aerosol-generating article located between the proximal and distal ends may be described as being upstream of the proximal end, or alternatively, downstream of the distal end. However, in other embodiments of the present invention, if the fluid enters the aerosol-generating article from the side, first travels toward the distal end, turns, and then travels toward the proximal end of the aerosol-generating article, the distal end of the aerosol-generating article may be either upstream or downstream, depending on the respective reference points.

[0179] As used herein, the term "water-resistant" is used to describe a material, e.g., a wrapper, or the longitudinal side of a second tubular element, through which water cannot easily pass or is not easily damaged by water. A water-resistant material can withstand the penetration of water.

[0180] In certain embodiments, the tubular element includes an active agent. In certain embodiments, the gel includes an active agent. In certain embodiments, the active agent includes nicotine. In certain embodiments, the gel or tubular element including an active agent includes 0.2 to 5 weight percent of the active agent, for example, 1 to 2 weight percent of the active agent.

[0181] Typically, in certain embodiments, the tubing element will contain at least 150 mg of gel.

[0182] In certain embodiments, the active agent comprises a plasticizer.

[0183] In certain embodiments, the gel including the active agent includes an aerosol former, such as glycerol. In embodiments in which an aerosol former is present, typically, for example, the gel including the active agent includes 60 to 95 weight percent glycerol, e.g., 80 to 90 weight percent glycerol.

[0184] In certain embodiments, the gel including the active agent includes a gelling agent, such as, for example, alginate, gellan, guar, or a combination thereof. In embodiments including a gelling agent, the gel typically includes 0.5 to 10 weight percent gelling agent, e.g., 1 to 3 weight percent gelling agent.

[0185] In certain embodiments, the gel comprises water, in such embodiments, the gel typically comprises between 5 and 25 percent water by weight, such as between 10 and 15 percent water by weight.

[0186] In certain embodiments, the active agent includes a flavor or a medicinal substance, or a combination thereof. In certain examples, the active agent is nicotine in any form. The active agent can be active, e.g., capable of causing a chemical reaction or at least altering the aerosol generated.

[0187] The active agent may be a flavor. In certain embodiments, the active agent includes a flavor. The gel may include a flavor. Alternatively, or in addition, the flavor may be present in one or more other locations on the article. The flavor may impart a flavor that contributes to the taste of the fluid or aerosol generated by the article. A flavor is any natural or artificial compound that affects the sensory characteristics of the aerosol. Plants that can be used to provide flavors include, but are not limited to, plants belonging to the Lamiaceae family (e.g., mint), Umbelliferae family (e.g., anise, fennel), Lauraceae family (e.g., bay laurel, cinnamon, rosewood), Rutaceae family (e.g., citrus fruits), Myrtaceae family (e.g., anise myrtle), and Leguminosae family (e.g., licorice). Non-limiting examples of sources of flavors include mint (such as peppermint and pine sap), coffee, tea, cinnamon, cloves, ginger, cocoa, vanilla, eucalyptus, geranium, agave, and juniper, as well as combinations thereof.

[0188] Many flavoring agents are essential oils or mixtures of one or more essential oils. Suitable essential oils include, but are not limited to, eugenol, peppermint oil, and Dutch mentha oil. In many embodiments, the flavoring agent comprises menthol, eugenol, or a combination of menthol and eugenol. In many embodiments, the flavoring agent further comprises anethole, linalool, or a combination thereof. In certain embodiments, the flavoring agent comprises an herbal material. Leaf material includes herbal leaves or other herbal materials from herbal plants, including, but not limited to, mint (such as peppermint and spearmint), lemon balm, basil, cinnamon, lemon basil, coriander, lavender, sage, tea, thyme, and caraway. Suitable types of mint leaves may be harvested from plant varieties, including, but not limited to, peppermint, American mentha, Egyptian mint, bergamot mint, spearmint, curly mint, Kentucky kernel mint, long-leaved mint, morning glory, apple mint, and pineapple mint. In some embodiments, the flavoring agent may include a tobacco material.

[0189] In one particular example, in combination with other characteristics, the gel comprises approximately 2 weight percent nicotine, 70 weight percent glycerol, 27 weight percent water, and 1 weight percent agar, hi another example, the gel comprises 65 weight percent glycerol, 20 weight percent water, 14.3 weight percent solid powdered tobacco, and 0.7 weight percent agar.

[0190] In the present invention, the fluid guide may have two distinct regions, for example, an outer region with outer longitudinal passages and an inner region with inner longitudinal passages, such that the outer longitudinal passages run longitudinally near the circumference of the fluid guide and the inner fluid passages run longitudinally near the core or center of the cross section along the longitudinal axis.

[0191] In certain embodiments, ambient air preferably passes through apertures in the wrapper and the fluid guide toward the distal end of the aerosol-generating article, into the outer longitudinal passage (of the fluid guide), and into the area of ​​the tubular element comprising the gel containing the active agent. The fluid preferably contacts the gel containing the active agent to generate or release an aerosol of a mixed fluid comprising the fluid from outside the aerosol-generating article and a substance released from the gel containing the active agent. The fluid then travels along the inner longitudinal passage of the fluid guide toward the proximal end of the aerosol-generating article. The outer and inner longitudinal passages are likely to be separated by a barrier. The barrier may be impermeable to the fluid or may be resistant to fluid passing therethrough, thus urging the fluid toward the distal end. The outer longitudinal passage of the fluid guide preferably comprises an aperture that fluidly communicates with the exterior of the fluid guide, and preferably with the exterior of the article. It is also anticipated that the outer longitudinal passage will be blocked at its proximal end so that, during use, fluid received from outside the aerosol-generating article flows primarily toward the distal end of the fluid guide. The outer longitudinal passage of the fluid guide may have an aperture at or near its proximal end, but in that case, it will only be open at its distal end. In contrast, the inner longitudinal passage of the fluid guide is open at both its proximal and distal ends, but may have various flow restriction elements between its proximal and distal ends. The barrier separating the inner and outer longitudinal passages of the fluid guide forces fluid entering the outer longitudinal passage to move toward the distal end of the outer longitudinal passage and toward the tubular element, which preferably comprises a gel containing an active agent. This allows the fluid to contact the tubular element, which preferably comprises a gel containing an active agent.

[0192] The outer longitudinal passage of the fluid guide may be one passage or multiple passages. The outer longitudinal passage may be within the fluid guide, or may be one or more passages on the outer surface of the fluid guide, with the fluid guide forming a partial wall of the outer longitudinal passage and the wrapper forming another partial wall to the outer longitudinal passage. The outer longitudinal passage or the inner longitudinal passage of the fluid guide may comprise a porous material, such as a foam, particularly a reticulated foam, whereby the passage runs through the porous material. In certain embodiments, the fluid guide comprises a porous material, such as a foam. The porous material may allow the passage of fluid while still maintaining its shape. These materials are easy to shape, which may in turn aid in the manufacture of aerosol-generating articles.

[0193] In some embodiments, the outer longitudinal passage can extend substantially around the interior of the wrapper, hi some embodiments, the passage may not extend completely around the interior of the wrapper.

[0194] Various aspects or embodiments of the aerosol-generating article for use with the aerosol-generating device described herein may provide one or more advantages over currently available aerosol-generating articles or the aerosol-generating articles described above. For example, the aerosol-generating article, including the fluid guide and the inner and outer fluid passages of the fluid guide, preferably allows for efficient transmission of the aerosol generated from the tubular element comprising a gel containing an active agent. Furthermore, the gel containing the active agent is less likely to leak from the aerosol-generating article than a liquid element containing the active agent.

[0195] The aerosol-generating article may include a mouth end (proximal end) and a distal end. The distal end is preferably received by an aerosol-generating device having a heating element configured to heat the distal end of the aerosol-generating article. A tubular element, preferably comprising a gel containing an active agent, is preferably arranged proximate to the distal end of the aerosol-generating article. Thus, the aerosol-generating device can heat the tubular element, preferably comprising a gel containing an active agent, within the aerosol-generating article to generate an aerosol containing the active agent.

[0196] The aerosol-generating article or a portion of the aerosol-generating article, preferably including a tubular element with a gel containing an active agent, may be a single-use aerosol-generating article or a multiple-use aerosol-generating article. In some embodiments, a portion of the aerosol-generating article is reusable, and a portion is disposable after a single use. For example, the aerosol-generating article may include a mouthpiece, which may be reusable, and a single-use portion, which includes a tubular element with a gel and an active agent, further comprising, for example, nicotine. In embodiments including both a reusable portion and a single-use portion, the reusable portion may be detachable from the single-use portion.

[0197] In combination with certain embodiments, the aerosol-generating article comprises a wrapper. The aerosol-generating article has a proximal end that is an open end and a distal end that may be open or closed in different specific embodiments. A tubular element comprising a gel, preferably comprising an active agent, optionally including nicotine, is preferably arranged adjacent to the distal end of the aerosol-generating article. Application of negative pressure to the open proximal end releases material from the tubular element, preferably comprising a gel containing an active agent. The aerosol-generating article defines at least one aperture between the proximal and distal ends. The at least one aperture defines at least one fluid inlet, such that application of negative pressure to the open proximal end of the aerosol-generating article allows fluid, e.g., air, to enter the aerosol-generating article through the aperture. Fluid, e.g., ambient air, drawn into the aerosol-generating article through the aperture preferably flows along the outer longitudinal passage of the fluid guide toward the tubular element, preferably comprising a gel containing an active agent, adjacent the distal end of the aerosol-generating article. The fluid then flows through the inner longitudinal passage of the fluid guide from the distal end to the proximal end and out of the aerosol-generating article at the open proximal end.

[0198] By separating the aperture from the distal end of the aerosol-generating article, the aperture is separated from the tubular element containing the gel, reducing the likelihood of leakage of the gel through the aperture. Furthermore, by providing an airflow path, e.g., an outer longitudinal path, from the aperture to the tubular element containing the gel, fluid from the aperture can be directed toward the gel, with the fluid guide acting as an additional obstacle between the gel and the aperture. The advantage of this is to further reduce the likelihood of leakage of the tubular element through the aperture. Additionally, the inner longitudinal path of the fluid guide provides a path for fluid, e.g., air, and material or vapor generated or emitted from the tubular element to be drawn out of the aerosol-generating article through the open proximal end. The path provided by the inner longitudinal path of the fluid guide can have an inner longitudinal flow cross-sectional area that varies along the length of the inner longitudinal path to modify the flow of aerosol generated or emitted from the tubular element from the distal end of the aerosol-generating article to the open proximal end of the aerosol-generating article.

[0199] In combination with certain embodiments, the aerosol-generating article includes a fluid guide. The aerosol-generating article and the fluid guide, or portions thereof, can be formed as a single piece or separate pieces. The advantage of the fluid guide and the aerosol-generating article being integrally formed as a single piece is the ease of manufacturing only one piece, rather than manufacturing multiple pieces and then assembling these multiple pieces into the aerosol-generating article. However, if the aerosol-generating article is a multi-component structure that requires assembling multiple components together, this has the advantage that different components can be more easily changed without having to change the entire manufacturing process. Similarly, the fluid guide can be formed as a single piece or separate pieces for the same reason that it is easier to manufacture when integrally manufactured as one piece, but the components of the fluid guide can be more easily adapted when assembled. The fluid guide is arranged within the aerosol-generating article and has a proximal end, a distal end, and an internal longitudinal passage between the distal end and the proximal end.

[0200] The inner longitudinal passage of the fluid guide has an inner cross-sectional area.

[0201] Providing an opening or passageway angled relative to the longitudinal axis of the aerosol-generating article has the effect that, during use, the fluid is directed into the proximal-end cavity at an angle relative to the mainstream fluid flow. This advantageously optimizes fluid mixing and creates resistance to draw (RTD). Mixing can also increase turbulence in the generated aerosol and airflow through the proximal-end cavity. These effects on the flow dynamics of the mainstream-generated aerosol can enhance the benefits discussed above. A desired resistance to draw can be achieved by modifying the opening or passageway dynamics, for example, by making the passageway smaller or larger in cross-sectional area, by modifying the angle of the passageway walls, or a combination thereof. Such passageways, especially where there is a narrowing of the passageway, are known as restrictors or flow-restricting elements. According to the present invention, either or both of the outer and inner longitudinal passageways may have restrictors, although it is preferred that only the inner longitudinal passageway includes a restrictor. To aid in the following discussion, only the inner longitudinal passageway will be described when describing different embodiments and, consequently, the fluid flow direction and passageway orientation. However, restrictors can similarly be used in the outer longitudinal passages of the present invention, where fluid flow is generally in the opposite direction to the inner longitudinal fluid flow path. The general flow path in the outer longitudinal passage is proximal to distal, while in the inner longitudinal passage, the general flow direction during use is distal to proximal. Ventilated fluid passing through the aperture enters the aerosol-generating article and flows distally along the outer longitudinal passage. The fluid preferably contacts the tubular element, which preferably comprises a gel containing an active agent, to generate or release an aerosol containing the active agent or other contents of the tubular element.

[0202] To compensate for low RTD (resistance to draw), restrictors are provided in smoking articles and aerosol-generating articles. The restrictors may be embedded, for example, in plugs or tubes of filtering material. Furthermore, filter segments containing restrictors may be combined with other filter segments, which may optionally contain other additives such as absorbents or flavorants.

[0203] In the cross-sectional area of ​​the restrictor, each passage preferably extends along either the radius of the cross-sectional area or a line offset from the radius by an angle beta (β). A "radius" refers to any line extending from the center of the cross-sectional area to the edge of the cross-sectional area. The angle beta (β) is measured as the smallest angle between the intersection of the radii and the central axis of the passage. If the passage is not a straight line, the angle may be measured between the longitudinal axis of the filter and the exit of the passage.

[0204] When viewing the cross-sectional area in a downstream direction (from the distal end to the proximal end of the inner longitudinal passage), the angle beta (β) can be oriented clockwise or counterclockwise relative to the radius.

[0205] When the passages are offset from the radius, angle beta (β) is preferably less than 60 degrees, more preferably less than 45 degrees, and most preferably less than 15 degrees, and is either clockwise or counterclockwise. Mixing of any fluid emanating from the article and the ventilated fluid may be enhanced when angle beta (β) is offset from the radius. In some cases, all of the passages may be oriented in a clockwise or counterclockwise direction, or some of the passages may be oriented in a clockwise direction and some of the passages may be oriented in a counterclockwise direction.

[0206] The size of the openings or passages in the fluid guide is preferably between 1.0 square millimeters and 4.0 square millimeters (mm 2 ), more preferably 1.5 square millimeters to 3.5 square millimeters (mm 2) total open area. Preferably, the openings or passages of the inner longitudinal passage of the fluid guide are substantially circular, although other shapes of transverse cross section are possible. An advantage of the inner longitudinal passage of the fluid guide having a circular cross section is that it allows for a more uniform flow of fluid compared to passages of non-circular cross section. The shape of the passage can be varied to achieve the desired flow.

[0207] A single opening or passageway may be provided in the fluid guide. Alternatively, two or more openings or passageways may be provided in the fluid guide with gaps between them. For example, in some embodiments, a pair of substantially opposed passageways is provided. Having multiple passageways is advantageous to allow for increased control of fluid flow through the passageways. Having a single passageway is advantageous for ease of manufacturing.

[0208] In relation to inner and outer longitudinal passages having two or more openings or passages, the openings or passages may have the same or different opening areas relative to one another. Having equal opening areas of two or more passages all having the same area is advantageous for allowing uniform flow of fluid through all of the passages. However, having two or more passages with different opening areas is advantageous for creating turbulent flow of fluid as it passes through two or more passages.

[0209] The two or more passages may be provided at the same or different angles relative to the longitudinal axis. Having two or more passages with the same angle relative to the longitudinal axis is advantageous for enabling uniform flow of fluid through all passages. Generally, uniform flow of fluid is easier to predict and design. Having two or more passages at different angles relative to the longitudinal axis is advantageous for creating turbulent flow of fluid as it passes through the two or more passages. Generally, turbulent airflow can improve particle agglomeration and form aerosol droplets.

[0210] The two or more passages may be provided at the same angle or at different angles relative to the radius of the cross-sectional area of ​​the fluid guide. Having two or more passages at the same angle relative to the radius of the cross-sectional area of ​​the fluid guide is advantageous for allowing uniform flow of fluid through all of the passages. Having two or more passages at different angles relative to the radius of the cross-sectional area of ​​the fluid guide is advantageous for creating turbulent flow of fluid as it passes through the two or more passages.

[0211] With respect to the inner and outer longitudinal passages, when there are two or more passages, the passages may be positioned at substantially the same location along the length of the fluid guide or at different longitudinal locations relative to one another. Having two or more passages at the same location along the length of the fluid guide is advantageous for enabling uniform flow of fluid through all of the passages. Having two or more passages at different longitudinal locations relative to one another is advantageous for creating turbulent flow of fluid as the fluid passes through two or more passages.

[0212] In embodiments in which an aperture is provided upstream of the cavity, an outer longitudinal passage between the aperture and the cavity allows fluid to pass from the exterior of the aerosol-generating article through the cavity and the tubular element distally beyond the cavity. The cavity may be partially enclosed by the wrapper of the aerosol-generating article. In such embodiments, mixing of the fluid, e.g., ambient air, with the generated or emitted aerosol may occur, or may occur partially, before the aerosol passes through the restrictor.

[0213] If the fluid guide includes two or more restrictors of different sized cross-sectional areas, preferably the first upstream restrictor has the smallest cross-sectional area. Preferably, the first restrictor has a reduced outer diameter compared to the overall diameter of the inner longitudinal passage to form an annular passage between the distal and proximal sides.

[0214] In certain embodiments, the restrictor is substantially spherical. However, other shapes are also possible. The restrictor element may, for example, be substantially cylindrical or may be provided as a membrane. For example, the restrictor may be provided as a membrane that extends in a plane perpendicular to the longitudinal axis of the article.

[0215] In an alternative design, the restrictor may be an agglomerate of smaller particles (eg, granules held together by a binder).

[0216] In combination with certain embodiments, the cross-sectional area of ​​the inner longitudinal passage of the fluid guide is substantially constant from the distal end to the proximal end. This allows for smooth fluid flow. The inner diameter of the inner longitudinal passage of the fluid guide is typically in the range of 1 millimeter to 5 millimeters, typically about 2 millimeters. The inner longitudinal passage typically has an inner longitudinal cross-sectional area that is smaller than the cross-sectional area of ​​the cavity at the distal end of the fluid guide. In this way, the fluid guide presents a reduced inner longitudinal cross-sectional area for accelerating air entering the inner longitudinal passage at the distal end.

[0217] In combination with certain embodiments, the cross-sectional area of ​​the inner longitudinal passage varies from the distal end to the proximal end, thereby forcing the fluids to mix. For example, the cross-sectional area of ​​the inner longitudinal passage at the distal end may be larger than the cross-sectional area of ​​the inner longitudinal passage at the proximal end. When the cross-sectional area of ​​the inner longitudinal passage is larger at the distal end than at the proximal end, the diameter of the inner longitudinal passage at the proximal end is preferably 0.5 millimeters to 3 millimeters, e.g., about 1 millimeter, and the diameter of the inner longitudinal passage at the distal end is preferably 1 millimeter to 5 millimeters, e.g., approximately 2 millimeters.

[0218] In combination with certain embodiments, the fluid guide is preferably between 3 millimeters and 50 millimeters in length, preferably approximately 25 millimeters in length.

[0219] In combination with certain embodiments, the inner longitudinal passage of the fluid guide may have one or more portions disposed between the distal end and the proximal end that are adapted to modify the flow of fluid through the inner longitudinal passage from the distal end to the proximal end.

[0220] The inner longitudinal passage of the fluid guide may include a first portion between the proximal and distal ends configured to accelerate the fluid as it flows from the distal end toward the proximal end of the fluid guide. The first portion of the inner longitudinal passage may be configured in any suitable manner to accelerate the fluid as it flows through the inner longitudinal passage from the distal end toward the proximal end of the inner longitudinal passage. For example, the first portion of the inner longitudinal passage may include a restrictor defining a reduced inner longitudinal cross-sectional area that forces the fluid to accelerate in a substantially axial direction from the distal end toward the proximal end. The first portion of the inner longitudinal passage is preferably the first portion of the inner longitudinal passage in the distal-to-proximal direction.

[0221] In combination with certain embodiments, the inner longitudinal cross-sectional area of ​​the first portion of the inner longitudinal passage can decrease from a location near the distal end of the fluid guide to a location near the proximal end of the fluid guide to accelerate the fluid as it flows from the distal end to the proximal end. The inner longitudinal cross-sectional area of ​​the first portion can decrease from the distal end of the first portion to the proximal end of the first portion. Thus, the distal end of the first portion of the inner longitudinal passage (near the distal end of the fluid guide) can have a larger inner diameter than the proximal end of the first portion (near the proximal end of the fluid guide).

[0222] In combination with certain embodiments, the inner longitudinal cross-sectional area of ​​the first portion of the inner longitudinal passage may be constant from the distal end of the first portion to the proximal end of the first portion, and in such embodiments, the constant inner longitudinal cross-sectional area of ​​the first portion of the inner longitudinal passage may be smaller than the inner longitudinal cross-sectional area at the distal end of the inner longitudinal passage.

[0223] When the inner longitudinal passage of the fluid guide is reduced in diameter from the distal end to the proximal end, the reduction of the inner longitudinal passage typically comprises a gradual reduction in the cross-sectional area of ​​the inner longitudinal passage from the distal end to the proximal end of the fluid guide. The reduction in diameter of the inner longitudinal passage is preferably linear, e.g., frusto-conical, from the distal end to the proximal end of the first portion. A linear reduction in cross-sectional area, e.g., a frusto-conical shape, is advantageous for creating a smooth flow of fluid through the fluid guide.

[0224] Alternatively, the reduction is non-uniform. For example, in certain embodiments, the reduction in the inner longitudinal passage is stepped, where the cross-sectional area of ​​the inner longitudinal passage decreases in discrete increments or steps from the distal end to the proximal end. A non-uniform reduction in the cross-sectional area of ​​the inner longitudinal passage is advantageous for creating turbulent flow of the fluid as it passes along the fluid guide.

[0225] The inner longitudinal passage of the fluid guide may include a second portion between the proximal and distal ends configured to decelerate the fluid as it flows from the distal end toward the proximal end of the fluid guide. The second portion of the inner longitudinal passage may be configured in any suitable manner to decelerate the fluid as it flows through the inner longitudinal passage from the distal end toward the proximal end of the inner longitudinal passage. For example, the first portion of the inner longitudinal passage may include a guide defining an expanded inner longitudinal cross-sectional area that forces the fluid to decelerate substantially axially from the distal end toward the proximal end. The second portion of the inner longitudinal passage is preferably located after the first portion in the distal-to-proximal direction.

[0226] In combination with certain embodiments, the inner longitudinal cross-sectional area of ​​the first portion of the inner longitudinal passage can expand from a position near the distal end of the fluid guide to a position near the proximal end of the fluid guide to decelerate the fluid as it flows from the distal end toward the proximal end. The inner longitudinal cross-sectional area of ​​the first portion can expand from the distal end of the second portion of the fluid guide to the proximal end of the second portion. Thus, the distal end of the second portion of the inner longitudinal passage (closer to the distal end of the fluid guide) can have a smaller inner diameter than the proximal end of the second portion (closer to the proximal end of the fluid guide).

[0227] In combination with certain embodiments, the cross-sectional area of ​​the second portion of the inner longitudinal passage may be constant from the distal end of the second portion to the proximal end of the second portion, and in such embodiments, the area of ​​the constant cross-sectional area of ​​the second portion of the inner longitudinal passage may be greater than the area of ​​the cross-sectional area of ​​the second portion at the distal end of the inner longitudinal passage.

[0228] When the inner longitudinal passage of the fluid guide expands in cross-sectional area from the distal end to the proximal end, the expansion of the cross-sectional area of ​​the inner longitudinal passage typically comprises a gradual expansion in the cross-sectional area of ​​the inner longitudinal passage from the distal end to the proximal end of the second portion of the fluid guide. Preferably, the expansion in diameter of the inner longitudinal passage can be linear, e.g., frusto-conical, from the distal end to the proximal end of the second portion. A linear decrease in cross-sectional area, e.g., a frusto-conical shape, is advantageous for creating a smooth flow of fluid through the fluid guide.

[0229] Alternatively, the reduction is non-uniform. For example, in certain embodiments, the expansion of the inner longitudinal passage is stepped, with the cross-sectional area of ​​the inner longitudinal passage decreasing in discrete increments or steps from the distal end to the proximal end. A non-uniform reduction in the cross-sectional area of ​​the inner longitudinal passage is advantageous for creating turbulent flow of the fluid as it passes along the fluid guide.

[0230] The diameter of the proximal end of the inner longitudinal passage is typically between 0.5 millimeters and 3 millimeters, for example, 0.8 millimeters, 1 millimeter, or preferably 1.2 millimeters.

[0231] The diameter of the distal end of the inner longitudinal passage is typically between 1 millimeter and 5 millimeters, for example, 1.2 millimeters, 2 millimeters, or preferably 2.2 millimeters.

[0232] The ratio of the diameter of the proximal end of the inner longitudinal passage to the diameter of the distal end of the inner longitudinal passage is typically 1:4 to 3:4, or 2:5 to 3:5, or preferably 1:2.

[0233] The distance between the proximal and distal ends of the inner longitudinal passage may be any suitable distance, for example, the length of the inner longitudinal passage is typically between 3 mm and 15 mm, e.g., between 4 mm and 7 mm, or preferably between 5.2 mm and 5.8 mm.

[0234] In certain embodiments of the present invention, the fluid guide may be modular with two or more segments forming the fluid guide.

[0235] In combination with certain embodiments, the aerosol-generating article comprises at least one outer longitudinal passageway in communication with the aperture of the wrapper. In combination with certain embodiments, the passageway is at least partially formed by the wrapper, if present. The passageway directs fluid (e.g., ambient air) from the aperture toward the tubular element containing the active agent. In certain embodiments, the outer longitudinal passageway is formed in an outer portion of the fluid guide below the inner surface of the wrapper.

[0236] The aerosol-generating article may comprise two or more outer longitudinal passages. In certain embodiments, the aerosol-generating article comprises 2 to 20 outer longitudinal passages in the outer portion of the fluid guide. For example, the article may comprise 6 to 14 outer longitudinal passages, typically 10 to 12 passages. Different numbers of passages result in different aerosol flow dynamics.

[0237] Each outer longitudinal passage preferably communicates with at least one aperture through the wrapper. However, the aerosol-generating article may have one or more outer longitudinal passages that are not in direct communication with an aperture. Each outer longitudinal passage preferably communicates with at least one aperture through the outer wall of the fluid guide. If present, the apertures through the wrapper and the outer wall of the fluid guide are preferably aligned with each other and with the at least one outer longitudinal passage to enable efficient fluid flow along the inner and outer longitudinal passages of the aerosol-generating article toward the distal end of the aerosol-generating article.

[0238] Preferably, the outer longitudinal passageway and the wrapper have two or more apertures. For example, in combination with certain embodiments, the outer longitudinal passageway and the wrapper have 2 to 20 apertures. The number of apertures preferably equals the number of outer longitudinal passageways, with each aperture corresponding to a separate outer longitudinal passageway. The apertures are preferably evenly spaced and circumferentially arranged around the article to aid in uniform distribution of fluid.

[0239] In combination with certain embodiments, the sidewall of the outer longitudinal passage extends along at least a portion of the longitudinal length of the aerosol-generating article between the exterior of the fluid guide and the interior side of the wrapper, for example, in certain embodiments, the fluid guide has a longitudinal groove that, due to the presence of the wrapper, forms the outer longitudinal passage.

[0240] In combination with certain embodiments, the outer longitudinal passage extends completely around the interior of the wrapper. Alternatively, the outer longitudinal passage does not extend completely around the circumference of the fluid guide, such as less than 90 percent around the circumference of the fluid guide, less than 70 percent around the circumference of the fluid guide, or less than 50 percent around the circumference of the fluid guide. In certain embodiments, the outer longitudinal passage extends at least 5 percent around the circumference of the fluid guide.

[0241] In combination with certain embodiments, the distal end of the outer longitudinal passage is spaced apart from the distal end of the aerosol-generating article. Alternatively, in other certain embodiments, the distal end of the outer longitudinal passage is coincident with the distal end of the fluid guide. In combination with certain embodiments, the distal end of the outer longitudinal passage may be 2 to 20 millimeters from the distal end of the aerosol-generating article, for example, 10 to 12 millimeters from the distal end of the aerosol-generating article.

[0242] In combination with certain embodiments, the width of the outer longitudinal passage is, for example, between 0.5 millimeters and 2 millimeters, typically between 0.75 millimeters and 1.8 millimeters.

[0243] The distal end of the longitudinal passage may be positioned a distance from the distal end of the aerosol-generating article such that fluid entering the aperture of the outer longitudinal passage may contact the tubular element and be able to generate or release an aerosol from the gel. Aerosol generated or released in the tubular element may pass through the inner longitudinal passage of the fluid guide to the proximal end of the aerosol-generating article.

[0244] Preferably, at least 5 percent of the fluid flowing through the aerosol-generating article contacts the tubular element and gel, preferably containing the active agent, and more preferably, at least 25 percent of the air flowing through the article contacts the tubular element containing the active agent.

[0245] In certain embodiments, not all of the fluid contacts the tubular element, for example, at least 5 percent of the fluid flowing through the aerosol-generating article does not contact the tubular element, although in other certain embodiments this may be at least 10 percent of the fluid flowing through the aerosol-generating article.

[0246] In combination with certain embodiments, the distal end of the fluid guide is spaced apart from the distal end of the aerosol-generating article, for example, 2 to 20 millimeters from the distal end of the aerosol-generating article, for example, 7 to 17 millimeters, preferably 12 to 16 millimeters from the distal end of the aerosol-generating article.

[0247] Preferably, the aerosol-generating article is generally cylindrical, which facilitates smooth flow of the aerosol. The aerosol-generating article may have an outer diameter of, for example, 4 to 15 mm, 5 to 10 mm, or 6 to 8 mm. The aerosol-generating article may have a length of, for example, 10 to 60 mm, 15 to 50 mm, or 20 to 45 mm.

[0248] The resistance to draw (RTD) of an aerosol-generating article varies depending, among other factors, on the length and dimensions of the passageway, the size of the aperture, the dimensions of the narrowest cross-sectional area of ​​the internal passageway, and the materials used. In certain embodiments, the RTD of the aerosol-generating article is between 50 millimeters of water column and 140 millimeters of water column (mm H2O), between 60 millimeters of water column and 120 millimeters of water column (mm H2O), or between 80 millimeters of water column and 100 millimeters of water column (mm H2O). The RTD of an article refers to the static pressure difference between one or more apertures and the mouth end of the article across the internal longitudinal passageway under steady-state conditions with a volumetric flow rate of 17.5 milliliters / second at the mouth end. The RTD of a specimen can be measured using the method described in ISO standard 6565:2002.

[0249] Aerosol-generating articles according to the present invention preferably include apertures located along the outer longitudinal passageway. Thus, the apertures are located upstream of the restrictor. In certain embodiments, the apertures are provided as a row or rows of apertures through the wrapper, the fluid guide, or both the fluid guide and the wrapper, allowing fluid to be drawn into the aerosol-generating article. The fluid is drawn first through the apertures, then through the outer longitudinal passageway, and then toward the distal end of the aerosol-generating article, where it contacts the tubular element and preferably a gel, preferably containing an active agent, within the tubular element, and then along the inner longitudinal passageway and, if present in that embodiment, through the restrictor. The total internal fluid path from the aperture to the proximal end of the aerosol-generating article is preferably at least 9 millimeters. More preferably, it is at least 10 millimeters, providing optimal aerosol formation, particularly in terms of draw resistance and cooling effect.

[0250] By adjusting the number and size of the apertures, it is possible to tailor the amount of fluid admitted to the aerosol-generating article during withdrawal. For example, one or two rows of apertures can be formed through the wrapper to allow easy flow of fluid into the aerosol-generating article. In alternative specific embodiments, the wrapper has a fewer number of apertures, for example, two or four. The number of apertures and their size affect the flow of fluid into the aerosol-generating article. Aerosol-generating articles according to the present invention offer a wider range of design options, as different combinations of resistance to withdrawal (RTD) and fluid flow into the aerosol-generating article can result in different aerosol formation.

[0251] In certain embodiments, the aerosol-generating article comprises a plastic material, a metal material, a cellulosic material such as cellulose acetate, paper, cardboard, cotton, or a combination thereof.

[0252] In certain embodiments, the fluid guide comprises a plastic material, a metal material, a cellulosic material such as cellulose acetate, paper, cardboard, or a combination thereof.

[0253] In combination with certain embodiments, the wrapper comprises two or more materials. In certain embodiments, the wrapper, or a portion thereof, comprises a metal material, a plastic material, cardboard, paper, cotton, or a combination thereof. When the wrapper comprises cardboard or paper, the apertures can be formed by laser cutting.

[0254] The wrapper provides strength and structural rigidity for the aerosol-generating article. When paper or cardboard is used for the wrapper and a high degree of rigidity is desired, it preferably has a basis weight of greater than 60 grams per square meter. One such wrapper can provide high structural rigidity. The wrapper can resist external deformation of the aerosol-generating article where a restrictor, if present, is embedded within the aerosol-generating article, or in other locations, such as cavities (if present) where structural support is weak. In some embodiments, the wrapper of the tubular element comprises a metal layer. The metal layer can be used to concentrate externally applied energy to heat the tubular element; for example, the metal layer can act as a susceptor for an electromagnetic field or collect radiant energy provided by an external heat source. When an internal heat source is present, the metal layer can prevent heat from escaping from the tubular element through the wrapper and improve heating efficiency. It can also provide uniform distribution of heat along the circumference of the tubular element.

[0255] In certain embodiments, the aerosol-generating article includes a seal between the exterior of the fluid guide and the interior of the wrapper. The wrapper can then be securely attached to the fluid guide. It is not necessary to create a fluid-tight seal.

[0256] In certain embodiments, the aerosol-generating article includes a mouthpiece. The mouthpiece may include a fluid guide or a portion thereof and may form at least a proximal portion of the wrapper of the aerosol-generating article. The mouthpiece may be connected to the wrapper or to a distal portion of the wrapper in any suitable manner, such as by an interference fit, threaded engagement, or the like. The mouthpiece may be a portion of the aerosol-generating article that may include a filter, or in some cases, the mouthpiece may be defined by the extent of tipping paper, if present. In other embodiments, the mouthpiece may be defined as a portion of the aerosol-generating article that extends 40 millimeters from the mouth end of the aerosol-generating article, or that extends 30 millimeters from the mouth end of the aerosol-generating article.

[0257] A tubular element, preferably comprising a gel containing an active agent, may be positioned within the aerosol-generating article adjacent the distal end prior to final assembly of the aerosol-generating article.

[0258] When fully assembled, the aerosol-generating article defines a fluid pathway through which fluid can flow. When negative pressure is applied at the mouth end (proximal end) of the aerosol-generating article, fluid enters the aerosol-generating article through apertures in the wrapper (or fluid guide, or both), and then flows through the outer longitudinal passage toward the distal end of the aerosol-generating article. The aerosol may optionally be accompanied by aerosol generated by heating the tubular element containing the active agent. The fluid with the entrained aerosol may then flow through the inner longitudinal passage of the fluid guide and out the open mouth end of the aerosol-generating article.

[0259] Preferably, the aerosol-generating article is configured to be received by an aerosol-generating device, such that a heating element of the aerosol-generating device can heat the section of the aerosol-generating article comprising the tubular element. For example, the tubular element, preferably comprising a gel containing an active agent, may be at the distal end of the aerosol-generating article, where the tubular element is arranged at or near the distal end of the aerosol-generating article.

[0260] Preferably, the aerosol-generating article may be shaped and sized for use with a suitably correspondingly shaped and sized aerosol generating device comprising a container for receiving the aerosol-generating article and a heating element configured and positioned to heat a section of the aerosol-generating article comprising a tubular element, preferably comprising a gel containing an active agent.

[0261] The aerosol generating device may preferably include control electronics operably coupled to the heating element, the control electronics being configured to control heating of the heating element, and the control electronics may be internal to the housing.

[0262] The control electronics may be provided in any suitable form and may include, for example, a controller, or a memory and a controller. The controller may include one or more of an "Application Specific Integrated Circuit (ASIC)" state machine, a digital signal processor, a gate array, a microprocessor, or equivalent discrete or integrated logic circuitry. The control electronics may include a memory containing instructions that cause one or more components of the circuit to perform the function or aspect of the control electronics. The functionality attributed to the control electronics in this disclosure may be embodied as one or more of software, firmware, and hardware.

[0263] The electronic circuit may comprise a microprocessor, which may be a programmable microprocessor. The electronic circuit may be configured to regulate the power supply to the heating element. Power may be supplied to the heating element in the form of current pulses. The control electronics may be configured to monitor the electrical resistance of the heating element and control the power supply to the heating element in response to the electrical resistance of the heating element. In this manner, the control electronics may regulate the temperature of the resistive element.

[0264] The aerosol generating device may include a temperature sensor (such as a thermocouple) operably coupled to the control electronics to control the temperature of the heating element. The temperature sensor may be located in any suitable location. For example, the temperature sensor may be configured to be in contact with or in close proximity to the heating element. The sensor may send a signal regarding the sensed temperature to the control electronics, which may adjust the heating of the heating element to achieve the appropriate temperature at the sensor.

[0265] Whether or not the aerosol-generating device includes a temperature sensor, the device may be configured to heat a tubular element, preferably comprising a gel containing an active agent, arranged within the aerosol-generating article to a sufficient degree to generate an aerosol.

[0266] The control electronics may be operably coupled to a power source, which may be internal to the housing. The aerosol generating device may include any suitable power source. For example, the power source for the aerosol generating device may be a battery or a set of batteries. The battery or power unit may be rechargeable as well as removable and replaceable.

[0267] In combination with certain embodiments, the heating element comprises a resistive heating component, such as one or more resistive wires or other resistance elements. The resistive wires may be in contact with a thermally conductive material to distribute the generated heat over a larger area. Examples of suitable conductive materials include gold, aluminum, copper, zinc, nickel, silver, and combinations thereof. When the resistive wires are in contact with a thermally conductive material, it is preferred that both the resistive wires and the thermally conductive material are part of the heating element.

[0268] In combination with certain embodiments, the heating element comprises a cavity configured to receive and surround the distal end of the article. The heating element may comprise an elongate element configured to extend along a side of the housing of the article when the distal end of the article is received by the device.

[0269] Alternatively, heat may be applied externally to the tubular element using a heat jacket thermally bonded around the wrapper of the aerosol-generating article to insert a heating element into the aerosol-generating article, the jacket preferably being located on the portion of the aerosol-generating article that includes the tubular element.

[0270] In other particular embodiments, the heating element comprises induction heating.

[0271] In certain embodiments, the tubular element, preferably comprising a gel containing an active agent, is heated by induction heating.

[0272] The portion of the aerosol-generating article comprising the tubular element is preferably positioned within the aerosol-generating device such that one or more heating elements that generate electromagnetic radiation for inductive heating are adjacent to the portion of the aerosol-generating article comprising the tubular element. Accordingly, the heating elements of the aerosol-generating device, when positioned within the aerosol-generating device, are preferably adjacent to the gel within the aerosol-generating article.

[0273] In embodiments for use with induction heating, the aerosol-generating article preferably includes a susceptor. In embodiments for use with induction heating, the tubular element preferably includes a susceptor. In certain embodiments, the gel more preferably includes a susceptor. The susceptor is preferably in contact with or in close proximity to the gel. Thus, in such embodiments of the invention, heating the susceptor by radiation can facilitate heat transfer to the gel and aid in the release of material, such as an active agent, from the gel.

[0274] Additionally or alternatively, in combination with other features of the present invention, the gel-loaded porous medium includes a susceptor, which may thus be in contact with the gel-loaded porous medium, allowing for easy heating of the gel-loaded porous medium.

[0275] In certain embodiments, the gel within the tubular element may be initially separate from the aerosol received within the tubular element and may be released and entrained within the aerosol in response to rupture of a frangible partition. Optionally, in certain embodiments, multiple portions of gel may each be sealed behind a respective frangible partition, such that an appropriate number of frangible partitions must be ruptured to achieve a desired level of entrainment of active agent in the aerosol received in the tubular element during use.

[0276] In combination with certain embodiments, an aerosol generating device may be configured to receive two or more aerosol-generating articles described herein. For example, the aerosol generating device may include a container with an elongated heating element extending therethrough. One aerosol-generating article may be received in the container on one side of the heating element, and another aerosol-generating article may be received in the container on the other side of the heating element. Or, in another specific embodiment, the aerosol generating device includes two or more receivers. Thus, it can receive two or more aerosol-generating articles at once.

[0277] In combination with certain embodiments of the present invention, the wrapper or a portion of the wrapper is water-resistant or hydrophobic, providing a degree of waterproofness or resistance to moisture penetration. This may be the wrapper of the tubular element, the wrapper of the aerosol-generating article, or both the tubular element and the wrapper of the aerosol-generating article. It may also be the wrapper for any other portion of the aerosol-generating article, including the longitudinal side of the second tubular element within the first tubular element, or any other component of the aerosol-generating article. The wrapper may be naturally impermeable and thus resistant to water or moisture penetration. The wrapper may be multi-layered, having a barrier that prevents or reduces the passage of water or is at least resistant to water or moisture penetration. In combination with certain embodiments, the hydrophobic barrier or hydrophobic treatment of the wrapper may cover the entire area of ​​the wrapper. Alternatively, in other specific embodiments, the hydrophobic barrier or treatment of the wrapper is only for a portion of the wrapper, for example, it may be on one side of the wrapper (either the inside or outside of the wrapper) or both sides of the wrapper.

[0278] The hydrophobic region of the wrapper can be created by a process that includes applying a liquid composition containing a fatty acid halide to at least one surface of the wrapper and maintaining the surface at a temperature of 120° C. to 180° C. for approximately 5 minutes. The fatty acid halide reacts in situ with proton-donating groups of materials in the wrapper, resulting in the formation of fatty acid esters, thus imparting hydrophobic properties and resistance to moisture penetration.

[0279] It is contemplated that the hydrophobically treated wrapper can reduce or prevent water, moisture, or liquids from adsorbing to or permeating through the wrapper. Advantageously, the hydrophobically treated wrapper does not adversely affect the taste of the article.

[0280] In certain embodiments, the wrapper generally forms the outer portion of the aerosol-generating article during use. In certain embodiments, the wrapper comprises paper, homogenized paper, homogenized tobacco-impregnated paper, homogenized tobacco, wood pulp, hemp, flax, rice straw, espermum gracilis, eucalyptus, cotton, or the like. In certain embodiments, the substrate or paper forming the wrapper has a basis weight of the substrate or paper forming the wrapper in the range of 10 to 50 grams per square meter, e.g., 15 to 45 grams per square meter. In combination with certain embodiments, the thickness of the substrate or paper forming the wrapper is in the range of 10 to 100 micrometers, or preferably 30 to 70 micrometers.

[0281] In combination with certain embodiments, the hydrophobic group is covalently bonded to the inner surface of the wrapper. In other embodiments, the hydrophobic group is covalently bonded to the outer surface of the wrapper. It has been found that covalently bonding the hydrophobic group to only one side or surface of the wrapper imparts hydrophobic properties to the opposite side or surface of the wrapper. A hydrophobic wrapper or a hydrophobically treated wrapper can reduce or prevent fluids, such as liquid flavorants or liquid-releasing components, from staining, absorbing, or penetrating the wrapper.

[0282] In various specific embodiments, the wrapper, and particularly the region of the wrapper adjacent to the tubular element, preferably comprising the gel containing the active agent, is hydrophobic or has one or more hydrophobic regions. The hydrophobic wrapper or hydrophobically treated wrapper has a hydrophobicity of 40 g / m 2 Less than 35g / m 2 Less than 30g / m 2 Less than or equal to 25 g / m 2 It may have a Cobb water absorption (ISO 535:1991) value (at 60 seconds) of less than

[0283] In various specific embodiments, the wrapper, and particularly the region of the wrapper adjacent to the tubular element, preferably comprising a gel containing an active agent, has a water contact angle of at least 90 degrees, e.g., at least 95 degrees, at least 100 degrees, at least 110 degrees, at least 120 degrees, at least 130 degrees, at least 140 degrees, at least 150 degrees, at least 160 degrees, or at least 170 degrees. Hydrophobicity is determined using the TAPPI T558 om-97 test, with results presented as interfacial contact angles reported in degrees, which can range from approximately 0 degrees to approximately 180 degrees. If no contact angle is specified with the term hydrophobicity, the water contact angle is at least 90 degrees.

[0284] In combination with certain embodiments, the hydrophobic surface is uniformly present along the length of the wrapper; alternatively, in other certain embodiments, the hydrophobic surface is not uniformly present along the length of the wrapper.

[0285] The wrapper is preferably formed from any suitable cellulosic material, preferably a plant-derived cellulosic material. In many embodiments, the wrapper is formed from a material having pendant proton-donating groups. The proton-donating groups are preferably reactive hydrophilic groups, including, but not limited to, hydroxyl (-OH), amine (-NH), or sulfhydryl (-SH) groups.

[0286] Particularly suitable wrappers compatible with the present invention are described herein by way of example. Wrappers containing pendant hydroxyl groups include cellulosic materials such as paper, wood, textiles, natural and man-made fibers, etc. The wrapper may also contain one or more filler materials, such as calcium carbonate, carboxymethylcellulose, potassium citrate, sodium citrate, sodium acetate, or activated carbon.

[0287] The hydrophobic surface or region of the cellulosic material forming the wrapper can be formed with any suitable hydrophobic reagent or hydrophobic group. Preferably, the hydrophobic reagent is chemically bonded to the cellulosic material or to pendant proton-donating groups of the cellulosic material forming the wrapper. In many embodiments, the hydrophobic reagent is covalently bonded to the cellulosic material or to pendant proton-donating groups of the cellulosic material. For example, the hydrophobic group is covalently bonded to pendant hydroxyl groups of the cellulosic material forming the wrapper. The covalent bond between the structural component of the cellulosic material and the hydrophobic reagent can form hydrophobic groups that are more firmly attached to the paper material than simply disposing a coating of hydrophobic material on the cellulosic material forming the wrapper. By chemically bonding the hydrophobic reagent in situ at the molecular level, the permeability of the cellulosic material, e.g., paper, is better maintained than by applying a bulk layer of hydrophobic material to cover the surface, since a coating tends to cover or block the pores of the cellulosic material forming the continuous sheet, reducing permeability. Chemically bonding the hydrophobic group in situ to the paper can also reduce the amount of material needed to render the wrapper surface hydrophobic. As used herein, the term "in situ" refers to the location of a chemical reaction that occurs on or near the surface of the solid material that forms the wrapper, as distinguished from a reaction with dissolved cellulose in a solution. For example, the reaction occurs on or near the surface of the cellulosic material that forms the wrapper, including the heterogeneous structure of the cellulosic material. However, the term "in situ" does not require that the chemical reaction occur directly on the cellulosic material that forms the hydrophobic tubular region.

[0288] The hydrophobic reagent can include an acyl group or a fatty acid group. The acyl group or fatty acid group, or mixtures thereof, can be saturated or unsaturated. The fatty acid group (e.g., a fatty acid halide) in the reagent can react with pendant proton-donating groups, such as hydroxyl groups, of the cellulosic material to form ester bonds that covalently bond the fatty acid to the cellulosic material. Essentially, these reactions with the pendant hydroxyl groups can esterify the cellulosic material.

[0289] In one embodiment of the wrapper, the acyl or fatty acid group is C 12 -C 30 Alkyl (alkyl groups with 12 to 30 carbon atoms), C 14 -C 24 Contains alkyl (alkyl groups with 14 to 24 carbon atoms) or C 16 -C 20 Preferably, the alkyl group contains 16-20 carbon atoms. Those skilled in the art will understand that the term "fatty acid," as used herein, refers to a long-chain aliphatic, saturated or unsaturated fatty acid containing 12-30 carbon atoms, 14-24 carbon atoms, 16-20 carbon atoms, or more than 15, 16, 17, 18, 19, or 20 carbon atoms. In various embodiments, the hydrophobic reagent includes, for example, an acyl halide, a fatty acid chloride, such as palmitoyl chloride, stearoyl chloride, or behenoyl chloride, or a mixture thereof. The in situ reaction between the fatty acid chloride and the cellulosic material forming the continuous sheet results in a fatty acid ester of cellulose and hydrochloric acid.

[0290] Any suitable method can be utilized to chemically bond the hydrophobic reagent or group to the cellulosic material that forms the hydrophobic tubular region. The hydrophobic group is covalently bonded to the cellulosic material by diffusing a fatty acid halide onto its surface without the use of a solvent.

[0291] For example, a quantity of hydrophobic reagent, such as acyl halides, fatty acid halides, fatty acid chlorides, palmitoyl chloride, stearoyl chloride, behenoyl chloride, or mixtures thereof, is placed on the surface of wrapper paper at a controlled temperature without the use of a solvent (solventless process), so that, for example, 20-micrometer droplets of the reagent form regularly spaced circles on the surface. By controlling the vapor tension of the reagent, the reaction can be promoted by diffusion, resulting in the formation of ester bonds between the fatty acid and cellulose, while unreacted acid chlorides are continuously removed. Cellulose esterification is sometimes based on the reaction of alcohol groups or pendant hydroxyl groups of cellulose with acyl halides (e.g., acyl chlorides, including fatty acid chlorides). The temperature that can be used to heat the hydrophobic reagent depends on the chemical nature of the reagent; for example, for fatty acid halides, it ranges from 120°C to 180°C.

[0292] The hydrophobic reagent can be applied to the cellulosic material of the wrapper paper in any useful amount or basis weight. In many embodiments, the basis weight of the hydrophobic reagent is less than 3 grams per square meter, less than 2 grams per square meter, or less than 1 gram per square meter, or in the range of 0.1 to 3 grams per square meter, 0.1 to 2 grams per square meter, or 0.1 to 1 grams per square meter. The hydrophobic reagent can be applied or printed onto the surface of the wrapper paper to define a uniform or non-uniform pattern.

[0293] The hydrophobic tubular regions are preferably formed by reacting fatty acid ester groups or fatty acid groups with pendant hydroxyl groups on the cellulosic material of the wrapper paper to form a hydrophobic surface. The reacting step can be accomplished by applying a fatty acid halide (e.g., a chloride, etc.) that provides fatty acid ester groups or fatty acid groups that chemically bond with the pendant hydroxyl groups on the cellulosic material of the wrapper paper to form the hydrophobic surface. The applying step can be carried out by loading the fatty acid halide in liquid form onto a solid support, such as a brush, roller, or absorbent or non-absorbent pad, and then contacting the solid support with the paper surface. The fatty acid halide can also be applied by printing techniques (gravure printing, flexography, inkjet printing, heliography, etc.), by spraying, wetting, or immersing in a liquid containing the fatty acid halide. The applying step can arrange discrete islands of reagent that form uniform or non-uniform patterns of hydrophobic regions on the surface of the paper wrapper. The uniform or non-uniform pattern of hydrophobic regions on the wrapper paper can be formed of at least 100 discontinuous hydrophobic islands, at least 500 discontinuous hydrophobic islands, at least 1000 discontinuous hydrophobic islands, or at least 5000 discontinuous hydrophobic islands. The discontinuous hydrophobic islands can have any useful shape, such as, for example, circular, rectangular, or polygonal. The discontinuous hydrophobic islands can have any useful average lateral dimension. In many embodiments, the discontinuous hydrophobic islands can have an average lateral dimension in the range of 5 to 100 micrometers, or in the range of 5 to 50 micrometers. A gas flow can also be applied to the surface of the wrapper to aid in the diffusion of reagents applied to the surface.

[0294] In combination with certain embodiments, the hydrophobic wrapper can be produced by a process comprising applying a liquid composition containing an aliphatic acid halide (preferably a fatty acid halide) to at least one surface of a wrapper paper, optionally applying a gas stream to the surface of the wrapper to aid in the diffusion of the applied fatty acid halide, and maintaining the surface of the wrapper at a temperature of 120°C to 180°C for at least 5 minutes, wherein the fatty acid halide reacts in situ with hydroxyl groups of the cellulosic material in the wrapper paper, resulting in the formation of a fatty acid ester. Preferably, the wrapper paper is made of paper, and the fatty acid halide is stearoyl chloride, palmitoyl chloride, or a mixture of fatty acid chlorides having 16 to 20 carbon atoms in the acyl group. Thus, the hydrophobic wrapper paper produced by the process described herein above is distinguishable from materials produced by coating a surface with a preformed layer of a fatty acid ester of cellulose.

[0295] The hydrophobic wrapper can be produced by a process in which a liquid reagent composition is applied to at least one surface of the wrapper paper at a rate ranging from 0.1 to 3 grams per square meter, or from 0.1 to 2 grams per square meter, or from 0.1 to 1 grams per square meter, such that the liquid reagent applied at such rates renders the wrapper paper surface hydrophobic.

[0296] In many particular embodiments, the thickness of the wrapper paper allows the hydrophobic groups or reagents applied to one surface to spread to the opposite surface, effectively providing similar hydrophobicity to both surfaces. In one example, the wrapper paper is 43 micrometers thick, and both surfaces have been rendered hydrophobic by a gravure (printing) process using stearoyl chloride as the hydrophobic reagent on one surface.

[0297] In certain embodiments, the materials or methods that render the hydrophobic tubing region hydrophobic do not substantially affect the permeability of the wrapper in other regions. Preferably, the agents or methods that create the hydrophobic tubing region change the permeability of the wrapper in the treated region (compared to the untreated wrapper region) by less than 10 percent, or less than 5 percent, or less than 1 percent.

[0298] In many specific embodiments, the hydrophobic surface can be formed by printing the reagent along the length of the cellulosic material. Any useful printing method can be utilized, such as gravure printing, inkjet printing, and the like. Gravure printing is preferred. The reagent can include any useful hydrophobic group that can be chemically, e.g., covalently, attached to the wrapper, particularly the cellulosic material of the wrapper, or to pendant groups on the cellulosic material.

[0299] In combination with certain embodiments of the present invention, the aerosol-generating article comprises a susceptor. In combination with certain embodiments, the tubular element comprises a susceptor. The susceptor is preferably elongated and longitudinally disposed within the tubular element. The susceptor is preferably in thermal contact with the gel or gel-filled porous material. This aids in heat transfer from a heating element within the aerosol-generating device to the aerosol-generating article and through the aerosol-generating article, preferably through the tubular element, to the susceptor, and thus, if in close proximity to the susceptor, to the gel or gel-filled porous medium. When heating is by induction, a fluctuating electromagnetic field is transmitted through the aerosol-generating article, preferably through the tubular element, to the susceptor, which converts the fluctuating field into thermal energy and, consequently, heats the gel or gel-filled porous material in the vicinity. Typically, the susceptor has a thickness of 10 to 500 micrometers. In a preferred embodiment, the susceptor has a thickness of 10 to 100 micrometers. Alternatively, the susceptor may be in the form of a powder dispersed in a gel. Typically, the susceptor may be configured to dissipate energy between 1 watt and 8 watts, e.g., 1.5 watts to 6 watts, when used in conjunction with a specific inductor. The term configured means that the elongated susceptor may be constructed of a specific material and have specific dimensions that allow for energy dissipation between 1 watt and 8 watts when used in conjunction with a specific conductor that generates a varying magnetic field of a known frequency and known field strength.

[0300] According to a further aspect of the present invention, there is provided an aerosol generation system comprising an electrically operated aerosol generator having an inductor for generating an alternating or fluctuating electromagnetic field, and an aerosol-generating article including a susceptor as described and defined herein. The aerosol-generating article interfaces with the aerosol generator such that the fluctuating electromagnetic field generated by the inductor induces currents in the susceptor, thereby heating it. The electrically operated aerosol generator is preferably capable of generating a fluctuating electromagnetic field having a magnetic field strength (H-field strength) of 1 kiloampere / meter to 5 kiloampere / meter (kA / m), preferably 2 kiloampere / meter to 3 kiloampere / meter (kA / m), for example, 2.5 kiloampere / meter (kA / m). The electrically operated aerosol generator is preferably capable of generating a fluctuating electromagnetic field having a frequency of 1 megahertz (MHz) to 30 megahertz, for example, 1 megahertz to 10 megahertz, for example, 5 megahertz to 7 megahertz.

[0301] The elongated susceptor of the present invention is preferably part of a consumable item and therefore is used only once. The flavor of a series of aerosol-generating articles can be more consistent due to the fact that a fresh susceptor acts to heat each aerosol-generating article. Cleaning requirements for aerosol-generating devices are significantly easier in devices with reusable heating elements and can be accomplished without damaging the heat source. Furthermore, the absence of a heating element that requires penetration of the aerosol-forming substrate means that insertion and removal of an aerosol-generating article into and from the aerosol-generating device is less likely to cause inadvertent damage to either the aerosol-generating article or the aerosol-generating device. Thus, the overall aerosol-generating system is robust.

[0302] When the susceptor is positioned within the varying electromagnetic field, induced eddy currents in the susceptor cause it to heat up. Ideally, the susceptor is positioned in thermal contact with the gel or gel-loaded porous material of the tubular element, so that the gel or gel-loaded porous material, or both, are heated by the susceptor.

[0303] In combination with certain embodiments, the aerosol-generating article is designed to engage with an electrically operated aerosol-generating device that includes an induction heating source. The induction heating source, or inductor, generates a fluctuating electromagnetic field for heating a susceptor positioned within the field. In use, the aerosol-generating article engages with the aerosol-generating device such that the susceptor is positioned within the fluctuating electromagnetic field generated by the inductor.

[0304] The susceptor preferably has a length dimension that is greater than its width or thickness dimension (e.g., greater than twice its width or thickness dimension). Thus, the susceptor may be described as an elongated susceptor. Such a susceptor is disposed substantially longitudinally within the rod. This means that the length dimension of the elongated susceptor is disposed approximately parallel to the longitudinal axis of the aerosol-generating article, e.g., within ±10 degrees of the longitudinal axis relative to the longitudinal axis of the rod. In a preferred embodiment, the elongated susceptor element may be positioned at a radially central location within the aerosol-generating article, extending along the longitudinal axis of the aerosol-generating article.

[0305] The susceptor is preferably in the form of a pin, rod, strip, sheet, or blade. The length of the susceptor is preferably 5 to 15 millimeters, e.g., 6 to 12 millimeters, or 8 to 10 millimeters. Typically, the length of the susceptor is at least as long as the tubular element, and thus typically 20 to 120 percent of the longitudinal length of the tubular element, e.g., 50 to 120 percent of the longitudinal length of the tubular element, preferably 80 to 120 percent of the longitudinal length of the tubular element. The susceptor preferably has a width of 1 to 5 millimeters and may have a thickness of 0.01 to 2 millimeters, e.g., 0.5 to 2 millimeters. Preferred embodiments may have a thickness of 10 to 500 micrometers, with 10 to 100 micrometers being even more preferred. When the susceptor has a constant cross-section, e.g., a circular cross-section, it has a preferred width or diameter of 1 to 5 millimeters.

[0306] The susceptor can be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming substrate. In preferred embodiments, the susceptor comprises metal or carbon. Preferred susceptors may comprise ferromagnetic materials, such as ferritic iron, or ferromagnetic steel or stainless steel. In other specific embodiments, the susceptor comprises aluminum. Preferred susceptors may be formed from 400 series stainless steel, such as grade 410, grade 420, or grade 430 stainless steel. Different materials dissipate different amounts of energy when placed in electromagnetic fields with similar frequencies and field strengths. Thus, susceptor parameters, such as material type, length, width, and thickness, can all be modified to provide desired power dissipation within a known electromagnetic field.

[0307] The susceptor is preferably heated to a temperature above 250 degrees Celsius. However, the susceptor is preferably heated below 350 degrees Celsius to prevent burning of materials in contact with the susceptor. A suitable susceptor may comprise a non-metallic core having a metallic layer disposed thereon (e.g., a metallic track formed on the surface of a ceramic core).

[0308] The susceptor may have a protective outer layer, such as a protective ceramic layer or a protective glass layer, that encapsulates the elongated susceptor material. The susceptor may also include a protective coating formed of glass, ceramic, or an inert metal formed over a core of susceptor material.

[0309] The susceptor is preferably disposed in thermal contact with the aerosol-forming substrate, e.g., within a tubular element. Thus, when the susceptor is heated, the aerosol-forming substrate is heated, releasing material from the gel and forming an aerosol. The susceptor is preferably disposed in direct physical contact with the gel containing the active agent, e.g., within a tubular element, and the susceptor is preferably surrounded by the gel or a porous medium loaded with the gel.

[0310] In certain embodiments, the aerosol-generating article, or the tubular element, comprises a single susceptor. Alternatively, in other certain embodiments, the tubular element, or the aerosol-generating article, comprises two or more susceptors.

[0311] Any of the features described herein in relation to a particular embodiment, aspect, or example of a tubular element, aerosol-generating article, or aerosol-generating device may be equally applied to any embodiment of the tubular element, aerosol-generating article, or aerosol-generating device.

[0312] Reference will now be made to the drawings, which depict one or more aspects described in the present disclosure. However, it will be understood that other aspects not shown in the drawings are within the scope of the present disclosure. Like numbers used within the figures refer to like components, steps, and the like. However, it will be understood that the use of one number to refer to a component in a given figure is not intended to limit the same numbered component in another figure. Additionally, the use of different numbers to refer to components in different figures is not intended to indicate that the differently numbered components may not be identical or similar to other numbered components. The figures are presented by way of illustration and not by way of limitation. Schematic diagrams presented in the figures are not necessarily drawn to scale. [Brief explanation of the drawings]

[0313] [Figure 1] FIG. 1 is a schematic cross-sectional view of an aerosol generating device and a schematic side view of an aerosol-generating article that can be inserted into the aerosol generating device. [Figure 2] 2 is a schematic cross-sectional view of the aerosol generating device shown in FIG. 1 and a schematic side view of the article shown in FIG. 1 inserted into the aerosol generating device. [Figure 3a] FIG. 3a is a schematic cross-sectional view of various embodiments of aerosol-generating articles. [Figure 3b] FIG. 3b is a schematic cross-sectional view of various embodiments of aerosol-generating articles. [Figure 4] FIG. 4 is a schematic cross-sectional view of various embodiments of aerosol-generating articles. [Figure 5] FIG. 5 is a schematic cross-sectional view of various embodiments of aerosol-generating articles. [Figure 6] FIG. 6 is a schematic cross-sectional view of various embodiments of aerosol-generating articles. [Figure 7] FIG. 7 is a schematic side view of an aerosol-generating article. [Figure 8]FIG. 8 is a schematic perspective view of the embodiment of the aerosol-generating article shown in FIG. 7, with a section of the wrapper removed for illustrative purposes. [Figure 9] FIG. 9 is a schematic side view of an aerosol-generating article. [Figure 10] FIG. 10 is a schematic side view of the embodiment of the aerosol-generating article shown in FIG. 9 with a portion of the wrapper removed. [Figure 11] FIG. 11 is a schematic diagram of the fluid guide of the sample aerosol-generating article. [Figure 12] FIG. 12 is a schematic diagram of a sample aerosol-generating article into which the fluid guide illustrated in FIG. 11 has been inserted. [Figure 13] FIG. 13 shows a cross-sectional view sectioned along the length of the aerosol-generating article. [Figure 14] FIG. 14 shows a perspective view and two cross-sectional views of a tubular element for an aerosol-generating article. [Figure 15] FIG. 15 shows a perspective view and two cross-sectional views of a tubular element for an aerosol-generating article. [Figure 16] FIG. 16 shows a perspective view and two cross-sectional views of a tubular element for an aerosol-generating article. [Figure 17] FIG. 17 shows part of a manufacturing process for a tubular element for an aerosol-generating article. [Figure 18] FIG. 18 shows part of a further manufacturing process for a tubular element for an aerosol-generating article. [Figure 19] FIG. 19 shows part of an alternative manufacturing process for a tubular element for an aerosol-generating article. [Figure 20] FIG. 20 shows an aerosol generating system comprising an electrically heated aerosol generating device and an aerosol-generating article. [Figure 21] FIG. 21 shows a cross-sectional view of a further tubular element for an aerosol-generating article. [Figure 22] FIG. 22 shows a cross-sectional view of a further tubular element for an aerosol-generating article. [Figure 23]FIG. 23 shows a cross-sectional view of a further tubular element for an aerosol-generating article. [Figure 24] FIG. 24 shows a cross-section along the length of an aerosol-generating article. [Figure 25] FIG. 25 shows schematic cross-sectional views of various tubular elements. [Figure 26] FIG. 26 shows schematic cross-sectional views of various tubular elements. [Figure 27] FIG. 27 shows schematic cross-sectional views of various tubular elements. [Figure 28] FIG. 28 shows schematic cross-sectional views of various tubular elements. [Figure 29] FIG. 29 shows schematic cross-sectional views of various tubular elements. [Figure 30] FIG. 30 shows schematic cross-sectional views of various tubular elements. [Figure 31] FIG. 31 shows schematic cross-sectional views of various tubular elements. [Figure 32] FIG. 32 shows schematic cross-sectional views of various tubular elements. [Figure 33] FIG. 33 shows schematic cross-sectional views of various tubular elements. [Figure 34] FIG. 34 shows schematic cross-sectional views of various tubular elements. [Figure 35] FIG. 35 shows a perspective view of a schematic diagram of a tubular element with gel-loaded threads. [Figure 36] FIG. 36 shows a cross-sectional view (cut from proximal to distal) of the schematic diagram of the tubular element illustrated in FIG. [Figure 37] FIG. 37 shows a cross-sectional view of the tubular element illustrated in FIG. [Figure 38] FIG. 38 shows a cross section of a tubular element. [Figure 39] FIG. 39 shows a cross section of a tubular element. DETAILED DESCRIPTION OF THE INVENTION

[0314] Figures 1 and 2 show examples of aerosol-generating articles for use in aerosol-generating devices, suitable for use in conjunction with the tubular elements of the present invention.

[0315] 1-2 show examples of an aerosol-generating article 100 and an aerosol-generating device 200. The aerosol-generating article 100 has a proximal or mouth end 101 and a distal end 103. In FIG. 2, the distal end 103 of the aerosol-generating article 100 is received in a container 220 of the aerosol-generating device 200. The aerosol-generating device 200 includes a wrapper 110 defining the container 220 configured to receive the aerosol-generating article 100. The aerosol-generating device 200 also includes a heating element 230 forming a cavity 235 configured to receive the aerosol-generating article 100, preferably by an interference fit. The heating element 230 may include an electrical resistance heating component. Additionally, the device 200 includes a power source 240 and control electronics 250 that cooperate to control the heating of the heating element 230.

[0316] The heating element 230 may heat the distal end 103 of the aerosol-generating article 100, which contains a tubular element 500 (not shown). In this example, the tubular element 500 contains a gel 124 containing an active agent, the active agent comprising nicotine. Heating the aerosol-generating article 100 causes the tubular element 500, which contains the active agent-containing gel 124, to generate an active agent-containing aerosol that can exit the aerosol-generating article 100 at the proximal end 101. The aerosol-generating device 200 comprises a housing 210.

[0317] 1-2 do not show the exact heating mechanism.

[0318] Figures 1-6 show longitudinal cross-sectional cutaway views of the aerosol-generating article 100. In other words, Figures 1-6 show views of the aerosol-generating article 100 cut in half longitudinally. In the embodiment of Figures 1-6, the aerosol-generating article is tubular. If one were to view the entire end face of the aerosol-generating article 100 of Figures 1-6, either the proximal end 101 or the distal end 103 would be circular. The tubular element 500 used or shown in the embodiment of Figures 1-6 is also tubular. The tubular element 500 is a possible tubular component of the tubular aerosol-generating article 100 of the embodiment of Figures 1-6. If one were to view the entire end face of the tubular element 500 used or shown in the embodiment of Figures 1-6, whether at the proximal end or the distal end, the surface of the tubular element would be circular. Because Figures 1-6 are two-dimensional longitudinal cross-sectional cutaway views, the side curvature of the aerosol-generating article, particularly the tubular element 600, is not visible. The drawings are for illustrative purposes to explain the invention and may not be to scale. As shown in Figures 1-6, the tubular element 500 represents the tubular element 500 of the aerosol-generating article 100, however, the features of the aerosol-generating article 100 are optional to the embodiment of the tubular element 500 shown and should not be viewed as essential features of the tubular element 500.

[0319] In some examples, the heating mechanism may be by conductive heating, where heat is transferred from the heating element 230 of the aerosol-generating device 200 to the aerosol-generating article 100. This can be easily achieved when the aerosol-generating article 100 is positioned in the container 220 of the aerosol-generating device 200, so that the distal end 103 (preferably the end where the gel-containing tubular element 500 is located) and therefore the aerosol-generating article 100 is in contact with the heating element 230 of the aerosol-generating device 200. In particular examples, the heating element comprises a heating blade protruding from the aerosol-generating device 200 and adapted to penetrate into the aerosol-generating article 100 and be in direct contact with the gel 124 of the tubular element 500.

[0320] In this example, the heating mechanism is by induction, whereby a heating element emits radiative magnetic radiation that is absorbed by the tubular element when the aerosol-generating article 100 is positioned within the container 220 of the aerosol-generating device 200 .

[0321] Figures 3a and 3b illustrate one embodiment of an aerosol-generating article 100 including a wrapper 110 and a fluid guide 400. Figures 3a and 3b are longitudinal cross-sectional cutaway views of the aerosol-generating article 100. In other words, the views of Figures 3a and 3b are views of the aerosol-generating article 100 cut in half longitudinally. In the embodiment of Figures 3a and 3b, the aerosol-generating article is tubular. If one were to view the entire end face of the aerosol-generating article 100 of Figure 3a or 3b, either the proximal end 101 or the distal end 103 would be circular. The tubular element 500 of Figure 3a or 3b is also tubular. The tubular element 500 is a tubular component of the tubular aerosol-generating article 100 of the embodiment of Figures 3a and 3b. If one were to view the entire end face of the tubular element 500 of the embodiment of Figure 3a or 3b, whether the proximal end or the distal end, the surface of the tubular element would be circular. Because Figures 3a and 3b are two-dimensional longitudinal cross-sectional cutaway views, the side curvature of the aerosol-generating article, particularly the tubular element 600, cannot be seen. In Figure 3a, the proximal end of the tubular element 500 is not shown as a straight line. Figure 3b shows the proximal end of the tubular element 500 as a straight line across the width of the aerosol-generating article. The drawings are for illustrative purposes to explain the invention and may not be to scale. Although the tubular element 500 is shown in Figures 3a and 3b and shows a tubular element in an aerosol-generating article, features of the aerosol-generating article 100 are optional for embodiments showing the tubular element and should not be seen as required features of the tubular element 500.

[0322] The fluid guide 400 has a proximal end 401, a distal end 403, and an inner longitudinal passageway 430 extending from the distal end 403 to the proximal end 401. The inner longitudinal passageway 430 has a first portion 410 and a second portion 420. The first portion 410 defines a first portion of the passageway 430 extending from the distal end 413 of the first portion 410 to the proximal end 411 of the first portion 410. The second portion 420 defines a second portion of the flow passageway 430 extending from the distal end 423 of the second portion 420 to the proximal end 421 of the second portion 420. The first portion 410 of the flow path 430 has a compressed cross-sectional area moving from the distal end 413 to the proximal end 411 of the first portion 410 such that a fluid, such as air, accelerates through this first portion 410 of the inner longitudinal flow path 430 when a negative pressure is applied to the proximal end 101 of the aerosol-generating article 100. The cross-sectional area of ​​the first portion 410 of the inner longitudinal flow path 430 narrows from the distal end 413 to the proximal end 411 of the first portion 410. The second portion 420 of the inner longitudinal flow path 430 has a cross-sectional area that expands from the distal end 423 to the proximal end 421 of the second portion 420 of the fluid guide 400. In the second portion 420 of the inner longitudinal flow path 430, the fluid may decelerate.

[0323] The wrapper 110 defines open proximal and distal ends 101, 103 of the aerosol-generating article 100. A tubular element 500, containing a gel including an active agent (not shown), is disposed at the distal end 103 of the aerosol-generating article 100. The aerosol-generating article 100 includes an end plug 600 at its distal-most end 103. The end plug 600 is positioned distal to the tubular element 500. The end plug 600 comprises a material that is highly resistant to suction and thus urges fluid to enter the aerosol-generating article 100 through the opening 150 when negative pressure is applied to the proximal end 101 of the aerosol-generating article 100. The aerosol generated or emitted from the tubular element 500, which contains the active agent, upon heating, passes from the tubular element 500 into the cavity 140 of the aerosol-generating article downstream and is transported through the inner longitudinal passageway 430.

[0324] Openings 150 extend through the wrapper 110. At least one opening 150 communicates with an exterior longitudinal passageway 440 formed between the outer surface of the fluid guide 400 and the inner surface of the wrapper 110. A seal is formed between the fluid guide 400 and the wrapper 110 at a location between the opening 150 and the mouth end 101.

[0325] When negative pressure is applied to the proximal end 101 of the aerosol-generating article 100, fluid enters the opening 150, flows through the outer longitudinal passage 440 into the cavity 140, and into the tubular element 500 containing the gel containing the active agent, where the fluid entraps the aerosol when the tubular element 500 containing the gel containing the active agent is heated. The fluid then flows through the inner longitudinal passage 430 and out the proximal end 101 of the aerosol-generating article 100. As the fluid flows through the first portion 410 of the inner longitudinal passage 430, the fluid accelerates. As the fluid flows through the second portion of the inner longitudinal passage 430, the fluid decelerates. In the illustrated embodiment, the wrapper 110 defines a proximal cavity 130 between the proximal end 401 of the fluid guide 400 and the proximal end 101 of the article 100, which may help decelerate the fluid before exiting the mouth end 101.

[0326] FIG. 4 illustrates another embodiment of an aerosol-generating article 100 including a wrapper 110 and a fluid guide 400 .

[0327] The fluid guide 400 has a proximal end 401, a distal end 403, and an inner longitudinal passage 430 extending from the distal end 403 to the proximal end 401. The inner longitudinal passage 430 has a first portion 410, a second portion 420, and a third portion 435. The first portion 410 is between the second 420 and third 435 portions. The first portion 410 defines a first portion of the inner longitudinal passage 430 extending from the distal end 413 of the first portion 410 to the proximal end 411 of the first portion 410. The second portion 420 defines a second portion of the inner longitudinal passage 430 extending from the distal end 423 of the second portion 420 to the proximal end 421 of the second portion 420. The third portion 435 defines a third section of the inner longitudinal flow channel 430, extending from the third portion distal end 433 to the third portion proximal end 431. The third portion 435 has a substantially constant inner diameter from the proximal end 431 to the distal end 433. The first portion 410 of the inner longitudinal flow channel 430 has a compressed cross-sectional area that moves from the distal end 413 to the proximal end 411 of the first portion 410, such that fluid accelerates through this first portion 410 of the inner longitudinal flow channel 430 when negative pressure is applied to the proximal end 101 of the aerosol-generating article 100. The cross-sectional area of ​​the first portion 410 of the inner longitudinal flow channel 430 narrows from the distal end 413 to the proximal end 411 of the first portion 410. The second portion 420 of the inner longitudinal passage 430 has a cross-sectional area that expands from the distal end 423 to the proximal end 421 of the second portion 420 of the inner fluid passage 430. In the second portion 420 of the inner longitudinal passage 430, the fluid may decelerate as it travels in a distal-to-proximal direction.

[0328] Similar to the article 100 shown in Figure 3, the article shown in Figure 4 includes a wrapper 110 defining open proximal and distal ends 101, 103, with a high withdrawal resistance end plug 600. A tubular element 500 containing a gel containing an active agent is disposed at the distal end 103 of the aerosol-generating article. Upon heating, aerosol released from the active agent-containing gel enters a cavity 140 within the aerosol-generating article 110 and is transported through an internal longitudinal channel 430.

[0329] Although not shown in FIG. 4 , the aerosol-generating article 100 includes at least one opening (such as opening 150 shown in FIG. 3 ) extending through the wrapper 110 and communicating with an outer longitudinal passage 440 formed between the outer surface of the fluid guide 400 and the inner surface of the wrapper 110. A seal is formed between the fluid guide 400 and the wrapper 110 at a location between the opening and the proximal end 101. While the seal need not be fluid-tight, it is advantageous for the seal here to have a degree of resistance to elongation or impermeability that biases fluid entering the opening 150 along the outer longitudinal passage in a distal direction toward the tubular element 500. A third portion 435 of the fluid guide 400 extends the length of the fluid guide 400 and the outer longitudinal passage 440 to provide additional distance between the opening (not shown in FIG. 4 , but which may be located proximate the proximal end 401 of the inner longitudinal passage) and the tubular element 500 containing the active agent-containing gel, reducing leakage of the active agent-containing gel through the opening 150.

[0330] When negative pressure is applied at the proximal end 101 of the aerosol-generating article 100 shown in FIG. 4 , fluid enters the opening 150, flows through the outer longitudinal passage 440 into the cavity 140, and into the tubular element 500 containing the gel containing the active agent; when the gel containing the active agent is heated, the fluid may pick up material. The fluid then flows through the inner longitudinal passage 430 and out the proximal end 101 of the aerosol-generating article. As the fluid flows through the inner longitudinal passage 430, it flows through the third portion 435, the first portion 410, and then the second portion 420 of the aerosol-generating article 100. As the fluid flows through the first portion 410 of the inner longitudinal passage 430, it accelerates. As the fluid flows through the second portion 420 of the inner longitudinal passage 430, it decelerates. In certain alternative embodiments, the second portion 420 and third portion 435 of the inner longitudinal passage 430 are optional. In the illustrated embodiment, the wrapper defines a proximal cavity 130 between the proximal end 401 of the fluid guide 400 and the proximal end 101 of the article 100, which may help to slow the fluid before it exits the proximal end 101.

[0331] 5 and 6 show additional embodiments of the aerosol-generating article 100, including a wrapper 110, an end plug 600, a tubular element 500 containing a gel including an active agent, a proximal cavity 130, a cavity 140, and a fluid guide 400. The fluid guide 400 has a proximal end 401, a distal end 403, and an inner longitudinal passageway 430 extending from the distal end 403 to the proximal end 401. The inner longitudinal passageway 430 has a first portion 410 and a third portion 435. The first portion 410 defines the first portion 410 of the inner longitudinal passageway 430, extending from the distal end 413 of the first portion 410 to the proximal end 411 of the first portion 410. The third portion 435 defines the third portion of the inner longitudinal passageway 430, extending from the proximal end 433 of the third portion 435 to the distal end 431 of the third portion 435. The third portion 435 has a substantially constant inner diameter from the proximal end 433 to the distal end 431 .

[0332] 5 , the first portion 410 of the inner longitudinal channel 430 has a substantially constant inner diameter from the distal end 413 to the proximal end 411 of the first portion 410. The inner diameter of the inner longitudinal channel 430 at the first portion 410 is smaller than the inner diameter of the inner longitudinal channel 430 at the third portion 435. The limited inner diameter of the inner longitudinal channel 430 at the first portion 410 relative to the third portion 435 may cause the fluid to accelerate as it flows from the third portion 435 to the first portion 410.

[0333] 6, a first portion 410 of the fluid guide 400 includes multiple segments 410A, 410B, 410C with a stepped inner diameter. The most distal segment 410A has the largest inner diameter, and the most proximal segment 410B has the smallest inner diameter. As fluid flows through the inner longitudinal channel 430 from the first segment 410A to the second segment 410B and from the second segment 410B to the third segment 410C, the cross-sectional area of ​​the inner longitudinal channel 430 constricts at the steps, causing the fluid to accelerate.

[0334] The first portion 410 of Figures 5 and 6 provides an example of a structure that may be beneficial when the material used to form the first portion 410 is not easily moldable. For example, the first portion 410 or segments 410A, 410B, 410C of the first portion 410 may be formed from cellulose acetate taw. In contrast, the first portion 410 of the fluid guide 400 shown in Figures 3 and 4 provides an example of a structure that may be beneficial when the material used to form the first portion 410 is moldable, such as when the first portion is formed from, for example, polyetheretherketone (PEEK).

[0335] Similar to the aerosol-generating article 100 shown in Figures 3 and 4, the aerosol-generating article shown in Figures 5 and 6 includes a wrapper 110 defining an open proximal end 101 and a distal end 103 having an end plug 600, which has a high resistance to withdrawal. In these examples, a tubular element 500 containing a gel 124 comprising an active agent is disposed at the distal end 103 of the aerosol-generating article 100. Aerosol emitted from the tubular element 500 containing the gel 124 comprising an active agent, upon heating, enters the cavity 140 of the aerosol-generating article 100 and is transported through the inner longitudinal passageway 430.

[0336] 5 and 6, the aerosol-generating article 100 includes at least one opening (such as opening 150 shown in FIG. 3) extending through the wrapper 110 and communicating with an outer longitudinal passageway 440 formed between the outer surface of the fluid guide 400 and the inner surface of the wrapper 110. At a location between opening 150 and the proximal end 101, a seal is formed between the fluid guide 400 and the wrapper 110, which serves to bias fluid entering through opening 150 along the outer longitudinal passageway 440 toward the tubular element 500 or distally. In particular, the third portion 435 of the inner longitudinal channel 430 serves to extend the length of the fluid guide 400 and the outer longitudinal channel 440, providing additional distance between the openings 150 (not shown in Figures 5 and 6, but which may be located near the proximal end of the outer longitudinal channel 440) and the tubular element 500 containing the active agent-containing gel 124, so that leakage of the active agent-containing gel 124 through the openings 150 is unlikely.

[0337] When negative pressure is applied to the proximal end 101 of the aerosol-generating article 100 shown in Figures 5 and 6, fluid enters the opening 150, flows through the outer longitudinal channel 440 into the cavity 140, and into the tubular element 500 containing the gel 124 containing the active agent; the fluid may pick up material from the gel when the tubular element 500 is heated. The fluid then flows through the inner longitudinal channel 430 and out the proximal end 101. As the fluid flows through the inner longitudinal channel 430, it flows through the third portion 435 and then the first portion 410 of the aerosol-generating article 100. As the fluid flows into the first portion 410 of the inner longitudinal channel 430, the inner longitudinal channel 430 may accelerate because the inner diameter of the inner longitudinal channel 430 in the first portion 410 is smaller than that in the third portion 435. In the aerosol-generating article 100 shown in FIG. 6, the fluid may accelerate as it passes through each of the segments 410A, 410B, 410C of the first portion 410.

[0338] In the embodiment shown in Figures 4 and 5, the wrapper defines a cavity 130 between the proximal end 401 of the fluid guide 400 and the proximal end 101 of the aerosol-generating article 100 and may serve to slow down the fluid exiting the inner longitudinal flow channel 430 at the proximal end 401 of the fluid guide 400 before exiting the proximal end 101.

[0339] 7-8 illustrate an embodiment of an aerosol-generating article 100. The aerosol-generating article 100 includes a wrapper 110 and an opening 150 through the wrapper 110. The aerosol-generating article includes an end plug 600 that forms the distal end 103 of the aerosol-generating article 100. The end plug has a high resistance to withdrawal. A tubular element 500 containing a gel that includes an active agent is disposed at the proximal end of the end plug 600 of the aerosol-generating article 100. When heated, the tubular element 500 can form an aerosol that enters a cavity 140 proximal to the tubular element 500.

[0340] FIG. 7 shows a side view of the tubular aerosol-generating article 100. When looking at either the proximal end 101 or the distal end 103, the end face will be circular. FIG. 7 is a two-dimensional drawing, and therefore the curvature of the tubular aerosol-generating article is not visible. FIG. 8 is a partially cut-away perspective view of the same embodiment shown and described by FIG. 7. Although partially blocked, it can be seen that the distal end face is circular. Although partially cut-away, it can be seen that the proximal end 101 face is also circular. FIG. 8 also shows that the tubular element 500 has a tubular shape. FIG. 8 also shows that the end cap 600 for this embodiment also has a tubular shape.

[0341] At least one of the openings 150 communicates with at least one exterior longitudinal channel 440 formed between the fluid guide 400 and the wrapper 110 and between the sidewalls 450. The fluid guide 400 has a rim 460 that presses against the inner surface of the wrapper 110 to form a seal. The seal is formed between the proximal end 101 and the opening 150.

[0342] When negative pressure is applied to the proximal end 101, fluid, e.g., air, can enter the opening 150, flow through the outer longitudinal channel 440 into the cavity 140, and then flow through the tubular element 500 where material from the gel 124 is released into the fluid. The fluid then travels through the fluid guide 400, through the inner longitudinal channel 430, into the cavity 130 defined by the wrapper 110, and travels (exits) through the proximal end 101 of the aerosol-generating article 100. The inner longitudinal channel 430 of the fluid guide 400 can be configured in any suitable manner, such as the examples shown in Figures 3-6.

[0343] 9-10 show an embodiment of an aerosol-generating article 100 including a portion of the wrapper 110 and a mouthpiece 170 that forms the fluid guide 400 of the aerosol-generating article 100. The aerosol-generating article 100 includes a tubular element 500 that forms the distal end 103 of the aerosol-generating article 100 and is also formed by a portion of the wrapper 110. The tubular element 500 is configured to be received by the distal portion of the mouthpiece 170, such as by an interference fit. The tubular element 500, which includes a gel 124 that includes an active agent (not shown), may be disposed in the tubular element 500. The aerosol-generating article 100 includes an end plug 600 at the distal-most end 103. The end plug 600 has a high withdrawal resistance.

[0344] FIG. 9 shows a partial cutaway side view of the tubular aerosol-generating article 100. If one were to view the entire surface of either the proximal end 101 or the distal end 103, the end faces would be circular. FIG. 9 is a two-dimensional drawing, and therefore the curvature of the tubular aerosol-generating article is not visible. FIG. 10 is a partially cutaway perspective view of the same partial cutaway portion of the aerosol-generating article 100 as shown and described by FIG. 9. Although partially blocked, the distal end face can be seen to be circular. Although partially cut away, the proximal end 101 face can also be seen to be circular. FIG. 10 also shows that the tubular element 500 has a tubular shape. FIG. 10 also shows that the end cap 600 for this embodiment also has a tubular shape.

[0345] The fluid guide 400 includes an inner longitudinal channel 430 (not shown), which may include a portion that accelerates the fluid and a portion that decelerates the fluid. Because the wrapper 110 and the fluid guide 400 are formed from a single piece, a seal is formed between the wrapper 110 and the fluid guide 400. An opening 150 is formed in the wrapper 110 and communicates with an outer longitudinal channel 640 that is at least partially formed by the inner surface of the wrapper 110. A portion of the outer longitudinal channel 640 is generally formed between the inner surface of the wrapper 110 and the exterior of the fluid guide 400. The outer longitudinal channel 640 extends less than the entire distance around the article 100. In this embodiment, the outer longitudinal channel 640 extends approximately 50% of the distance around the circumference of the aerosol-generating article 100. The outer longitudinal channel 640 directs fluid, e.g., air, from the opening 150 to a tubular element 500 (not shown) near the distal end 103.

[0346] When negative pressure is applied at the proximal end 101, a fluid, e.g., ambient air, enters the aerosol-generating article 100 through the opening 150. The fluid flows through the outer longitudinal channel 640 toward the tubular element 500, which contains the gel 124, which includes an active agent, disposed at the distal end 103. The fluid then flows through the inner longitudinal channel 430 of the fluid guide 400, where the fluid is accelerated and optionally decelerated. The fluid, e.g., air, may then exit the proximal end 101 of the aerosol-generating article 100.

[0347] FIG. 11 is a diagram of a fluid guide 400 formed from polyetheretherketone (PEEK) material by computer numerical control (CNC) machining. The fluid guide 400 depicted in FIG. 11 has a length of 25 millimeters, an outer diameter at the proximal end of 6.64 millimeters, and an outer diameter at the distal end of 6.29 millimeters. The outer diameter at the distal end is the diameter of the distal end from the base of the sidewall. The fluid guide 400 has 12 outer longitudinal channels 640 formed around its outer surface, with each sidewall having a substantially semicircular cross-sectional area. The outer longitudinal channels 640 have a radius of 0.75 millimeters and a length of 20 millimeters. The fluid guide 400 has an inner longitudinal channel 430 (not shown) that includes three sections: a first section (fluid acceleration section), a second section (fluid deceleration section) downstream or proximal to the first section, and a third section upstream or distal to the first section. The third portion of the inner longitudinal channel 430 of the fluid guide 400 extends from the distal end 103 of the aerosol-generating article 100 and has an inner diameter at its distal end of 5.09 millimeters, tapering to a diameter of 4.83 millimeters at the proximal end of the first portion of the inner longitudinal channel 430. The length of the first portion of the inner longitudinal channel 430 is 15 millimeters. The first portion of the inner longitudinal channel 430 extends from the distal end to the proximal end of the proximal end of the third portion. The first portion of the inner longitudinal channel 430 has an inner diameter of 2 mm at its distal end, constricting to 1 mm at the proximal end. The length of the first portion of the inner longitudinal channel 430 is 5.5 millimeters. The second portion of the inner longitudinal channel 430 extends from the distal end at the proximal end of the first portion to the proximal end at the proximal end of the article. The second portion of the inner longitudinal channel 430 has an inner diameter of 1 mm at its distal end, the same as the inner diameter of the first portion at its proximal end. The inner diameter of the second portion increases at a decreasing rate (i.e., in a curve) to a proximal end having an inner diameter of 5 mm. The length of the second portion is 4.5 mm. Thus, fluid drawn through the internal channel of the fluid guide from the distal end to the proximal end encounters a chamber having a substantially constant inner diameter (third portion), a converging section (first portion) configured to accelerate the fluid, and an expanding section (second portion) configured to decelerate the fluid.It has been found that by providing such an internal longitudinal flow path 430 for the aerosol emitted from the heated tubular element 500 (not shown), the aerosol volume and droplet size can be controlled to produce a satisfactory aerosol emission. Figure 11 is a side view of the tubular shaped fluid guide 400. Figure 11 is a two-dimensional drawing, and therefore, in this embodiment, the curvature of the tubular shape of the fluid guide 400 is not visible. If one were to look at the end face of the fluid guide 400 in this embodiment, the face would be circular.

[0348] FIG. 12 is a diagram of an assembled aerosol-generating article 100. The aerosol-generating article 100 includes a wrapper 110 into which the fluid guide 400 of FIG. 11 is inserted. The wrapper illustrated in FIG. 12 is a generally cylindrical paper tube having a length of 45 millimeters. One end of the wrapper 110 is distal, providing a distal end of the wrapper for holding a tubular element 500 (not shown). The outer proximal portion of the fluid guide 400 above the outer longitudinal flow passage has a diameter of 6.64 millimeters. This diameter is substantially the same as the inner diameter of the wrapper so that an interference fit seal is formed between the outer proximal portion of the fluid guide 400 and the interior of the wrapper 110. The outer distal portion of the fluid guide 400, which extends the length of the outer longitudinal flow passage, may have a diameter slightly smaller than the diameter of the outer proximal portion of the fluid guide 400 so that the fluid guide 400 can be easily inserted into the wrapper 110 up to the outer proximal portion where the interference fit is formed. FIG. 12 is a side view of the aerosol-generating article 100. 12 is a two-dimensional drawing, and therefore does not show the curvature of the tubular shape of the aerosol-generating article 100 in this embodiment. If one were to look at the end face of the aerosol-generating article 100 in this embodiment, the face would be circular.

[0349] Figure 13 shows an aerosol-generating article 100 manufactured with a tubular element 500 containing a gel 124, as further illustrated in Figures 14, 15, and 16. Figure 13 is a longitudinal cross-sectional cutaway view of the aerosol-generating article 100. Figure 13 is a two-dimensional drawing, and therefore the curvature of the tubular shape of the fluid guide 100 and its components, such as, for example, the tubular element 500 in this embodiment, are not visible. If one were to view the entire end face of the aerosol-generating article 100 in this embodiment, the face would be circular. Similarly, if one were to view the entire end face of the tubular element 500, the face in this embodiment would be circular.

[0350] The aerosol-generating article 100 of Figure 13 comprises four elements arranged in coaxial alignment: a high resistance to withdrawal (RTD) end plug 600 at the distal end 103, a tubular element 500 containing gel 124, a fluid guide 400, and a mouthpiece 170 at the proximal end 101. These four elements are arranged consecutively and surrounded by a wrapper 110 to form the aerosol-generating article 100. (In a similar but alternative embodiment, there is a cavity 140 between the fluid guide 400 and the tubular element 500.) The aerosol-generating article 100 has a proximal or mouth end 101 and a distal end 103 located at the opposite end of the aerosol-generating article 100 from the proximal end 101. The tubular element 500 used in the aerosol-generating article 100 of Figure 13 may or may not include a wrapper (not shown in Figure 13).

[0351] In use, when negative pressure is applied to the proximal end 101, fluid, e.g., air, is drawn through the aerosol-generating article 100 via opening 150 (not shown, but similar to that described for the example of Figures 1-10).

[0352] The end plug 600 is located at the distal-most end 103 of the aerosol-generating article 100 .

[0353] In this example, tubular element 500 is located immediately downstream of and adjacent to end plug 600 .

[0354] In FIG. 9, the distal end portion of the outer wrapper 110 of the aerosol-generating article 100 is surrounded by a strip of tipping paper (not shown).

[0355] As further shown in Figures 14, 15, and 16, tubing element 500 is a cellulose acetate tube 122 that includes a gel 124 in its core, e.g., the core is filled with gel 124. In this example, gel 124 includes an active agent, which is nicotine and an aerosol former. Other examples similar to this example include different active agents or none at all. Not all components of the tubing elements shown in Figures 14, 15, and 16 are necessarily shown or labeled.

[0356] Figure 14 shows a perspective view of tubular element 500, Figure 15 shows a cross-section coplanar with the central axis of tubular element 500, and Figure 16 shows a cross-section perpendicular to the central axis. Figure 16 shows an end view of tubular element 500.

[0357] The tubular element 500 is disposed within the aerosol-generating article 100 ( FIG. 13 ) at the distal end 103 of the aerosol-generating article 100 such that the tubular element 500 is penetrated by the heating element of the aerosol-generating device 200, which in this example can penetrate the end plug 600 (at the distal-most end 103 of the aerosol-generating article 100) and contact the tubular element 500 containing the gel 124. Thus, the heating element is in contact with or in close proximity to the gel 124.

[0358] Gel 124 contains an active agent, e.g., air, that is released into the fluid and flows from opening 150 along an outer longitudinal passage (not shown) of fluid guide 400 to tubular element 500 near distal end 103, and then via inner longitudinal passage 430 (not shown) to proximal end 101. In this illustrated example, the active agent is nicotine. Optionally, gel 124 further contains a flavor, e.g., menthol.

[0359] The tubular element 500 may further include a plasticizer.

[0360] The fluid guide 400 is located immediately downstream of the tubular element 500 and abuts the tubular element 500. (In a similar but alternative specific example, e.g., FIG. 24 , there is a cavity between the fluid guide 400 and the tubular element 500, so that the fluid guide does not contact the tubular element.) In use, material released from the tubular element 500, including the gel 124, passes along the fluid guide 400 towards the proximal end 101 of the aerosol-generating article 100.

[0361] In the example of Figure 13, mouthpiece 170 is located immediately downstream of and abuts fluid guide 400. In the example of Figure 13, mouthpiece 170 includes a conventional cellulose acetate tow filter with low filtration efficiency.

[0362] To assemble the aerosol-generating article 100, the four elements described above are aligned and tightly wrapped within an outer wrapper 110. In Figure 13, the outer wrapper is conventional cigarette paper.

[0363] The tubular element 500 may be formed by an extrusion process, for example, as shown in Figure 17. The longitudinal side of the cellulose acetate 122 of the tubular element 500 may be formed by extruding the cellulose acetate material along a die 184 and around a mandrel 180 that projects rearward relative to the direction of travel T of the extruded cellulose acetate material. The rearward projecting portion of the mandrel 180 is a pin-shaped, cylindrical member having an outer diameter of 3 to 7 millimeters and a length of 55 to 100 millimeters (not drawn to scale to aid in illustration).

[0364] In this example, the cellulose acetate material 122 is thermoset by exposure to steam S at a pressure greater than 1 bar.

[0365] The mandrel 180 is provided with a conduit 182 along which the gel 124 is extruded into a core of set cellulose acetate material 122 which in this example forms the longitudinal side of the tubular element 500. In other examples, the cellulose acetate material 122 is thermoset prior to extruding the gel 124 into the core of the cellulose acetate material 122.

[0366] The composite cylindrical rod is cut to length to form the individual tubular elements 500 .

[0367] The composite cylindrical rod is formed by a hot extrusion process in this example. The composite cylindrical rod is cooled or subjected to a cooling process before being processed to length. Alternatively, in other examples, the composite cylindrical rod may be formed by a cold extrusion process.

[0368] In the illustrated tubular element 500 of this example, the cellulose acetate 122 is shown as the longitudinal side of the tubular element 500 having a core, the core being filled with a gel 124. However, alternatively in other examples, the longitudinal side of the cellulose acetate 122 may have any shape with a core (or multiple cores) for receiving the gel 124 extending generally along the tubular rod. In alternative particular examples, the core is filled with a gel-filled porous medium 125.

[0369] In this example, the longitudinal sides of the cellulose acetate 122 of the tubular element have a minimum thickness of 0.6 millimeters.

[0370] In the manufacturing process illustrated in Figure 17, the gel 124 is continuously extruded.

[0371] In an alternative example, as shown in Figure 18, the gel 124 can be extruded in bursts separated by gaps 128 as shown in Figure 18. In an alternative specific example, the gel-filled porous media 125 is extruded in bursts with separating gaps in the core of the tubular rod.

[0372] The gel 124 may be heated above room temperature before being poured into the mandrel 180. The mandrel 180 may be thermally conductive (e.g., a metal mandrel), and some externally applied heat (e.g., from steam S) may be applied to the thermosetting cellulose acetate. This may transfer thermal energy to the gel, heating the gel and thereby reducing its viscosity and facilitating its extrusion.

[0373] 19, the mandrel 180 is configured to reduce heating of the gel 124 prior to extrusion. In some of these examples, the mandrel 180 is formed from a substantially insulating material. Alternatively, or additionally, the mandrel 180 is cooled, for example, by having a liquid-cooled jacket 186 (e.g., a water-cooled jacket) with a circulating layer of chilled liquid that forms a thermal barrier between externally applied heat (e.g., steam S) and the gel 124. Maintaining the gel 124 at a low temperature can facilitate molding the gel 124 into the longitudinal side of the cellulose acetate 122 of the tubular element 500.

[0374] In this example, the tubular element 500 is formed by cutting the gap 128 in the composite rod, which helps prevent contamination of the cutting machine with the gel 124, thereby improving cutting performance. In this example, the composite rod is cooled by resting for a period of time to reach a temperature suitable for cutting before cutting. After cutting, the cut length is trimmed in some examples to form the tubular element, within the gap 128, and having hollow ends when cut before assembly into the aerosol-generating article 100. In this example, the bursts of gel 124 are 60 millimeters long and separated by a 10 millimeter gap. In other examples, the hollow ends are not trimmed at both ends to form a cavity 140 between the gel 124 and the fluid guide 400.

[0375] Alternatively, for the illustrated examples herein, in certain instances, the gel 124 may be extruded at room temperature, and alternatively, in certain instances, the cellulose acetate is replaced with another material, such as polylactic acid.

[0376] In FIG. 19, the mandrel has a cylindrical shape to aid in the production of tubular shaped tubular elements.

[0377] FIG. 20 shows a portion of an aerosol generating device 200 having an aerosol-generating article 100 partially inserted therein, as described above and illustrated in FIG.

[0378] The aerosol-generating device 200 includes a heating element 230. As shown in Figure 20, the heating element 230 is mounted within the aerosol-generating article 100 receiving chamber of the aerosol-generating device 200. In use, the aerosol-generating article 100 is inserted into the aerosol-generating article receiving chamber of the aerosol-generating device 200 such that the heating element 230 is inserted into the tubular element 500 of the aerosol-generating article 100 via the end plug 600, as shown in Figure 20. In Figure 20, the heating element 230 of the aerosol-generating device 200 is a heater blade.

[0379] The aerosol-generating device 200 includes a power source and electronics capable of activating the heating element 230. Such activation may be manual or may occur automatically in response to negative pressure applied at the proximal end of the aerosol-generating article 100, which is inserted into the aerosol-generating-article-receiving chamber of the aerosol-generating device 200. A plurality of openings are provided in the aerosol-generating device to allow air to flow through the aerosol-generating article 100; the direction of fluid, e.g., air, flow in the aerosol-generating device 200 is indicated by arrows in FIG. 20 . The fluid can then enter the aerosol-generating article 100 through openings 150, not shown.

[0380] When the internal heating element 230 is inserted into the tubular element 500 of the aerosol-generating article 100 and activated, the tubular element 500, which contains the active agent-containing gel 124, is heated by the heating element 230 of the aerosol-generating device 200 to a temperature of 375 degrees Celsius. At this temperature, material from the tubular element 500 of the aerosol-generating article 100 leaves the gel. When negative pressure is applied to the proximal end 101 of the aerosol-generating article 100, this material from the tubular element 500 is drawn downstream through the aerosol-generating article 100, specifically, through the fluid guide 400, towards the proximal end and out of the proximal end 101 of the aerosol-generating article 100.

[0381] As the aerosol passes downstream through the aerosol-generating article 100, the temperature of the aerosol decreases due to the transfer of thermal energy from the aerosol to the fluid guide 400. In this example, when the aerosol enters the fluid guide 400, the temperature of the aerosol is approximately 150° C. Due to cooling within the fluid guide 400, the temperature of the aerosol is 40° C. when it exits the fluid guide 400. This leads to the formation of aerosol droplets.

[0382] 20, the tubular element 500 comprises cellulose acetate forming the longitudinal side 122 of a cylindrical rod, with the gel 124 in the core or central portion of the tubular element 500. In another particular example, the longitudinal side of the tubular element 500 can be cardboard, crimped paper such as crimped heat-resistant paper or crimped parchment paper, or a polymeric material such as, for example, low-density polyethylene (LDPE).

[0383] 14, 15, and 16, the tubular element 500 has a single core with a single gel 124 that fills the core and is surrounded by cellulose acetate along the longitudinal side of the tubular element 500. However, in alternative specific examples, the tubular element 500 comprises two or more cores. In certain embodiments, the tubular element includes multiple gels 124. Not all components of the tubular element 500 in FIGS. 14, 15, and 16 are necessarily shown or labeled.

[0384] As shown in the example of Figure 21, tubular element 500 includes a plurality of gels 524A, 524B extending along the axial length of the core of tubular element 500, as shown in cross section in Figure 21. In this embodiment, tubular element 500 includes longitudinal sides 522, 622, 722 of cellulose acetate. Not all components of tubular element 500 are necessarily shown or labeled in the embodiment of Figure 21.

[0385] Multiple gels 524A, 524B may be extruded into the cellulose acetate 522 through separate conduits in a mandrel (not shown) that forms the core of the tubular element 500. The use of gels 124 with different volatilities may facilitate optimization of the delivery of the active agent.

[0386] In the example shown in FIG. 22, tubular element 500 includes a cellulose acetate longitudinal side 622, and tubular element 500 additionally includes a plurality of cores 624A, 624B, 624C, as shown in cross section in FIG.

[0387] Not all components of tubular element 500 are necessarily shown or labeled in this FIG. 22 embodiment.

[0388] In this particular example, multiple cores are provided with different gels 624A, 624B, 624C, which have different active agents, e.g., different nicotine and flavoring agents, as shown in Figure 22. The use of gels with different volatilities can facilitate optimization of active ingredient delivery, particularly over the heating cycle of the aerosol generating device.

[0389] In another particular example (not shown), each of the multiple cores 624A, 624B, 624C is provided with the same gel 124 (not shown). The use of multiple cores helps optimize airflow performance through the tubular element 500.

[0390] The multiple cores may be formed by use of a mandrel (not shown) having a corresponding number of rearwardly extending protrusions relative to the direction of advancement T of the extruded cellulose acetate material. The gel may be extruded through respective conduits within the multiple rearwardly extending mandrel protrusions.

[0391] 14, 15, and 16, the tubular element 500 comprises a core of cellulose acetate 122 filled with gel 124 on the longitudinal sides. However, alternatively, in certain instances, in combination with other features, the core of the tubular element 500 is only partially filled with gel 124 across a cross section perpendicular to the axial length. Advantageously, this promotes axial airflow through the length of the tubular element 500. For example, as shown in FIG. 23, a gel 724 may be provided as a coating on the interior surface of the longitudinal side of the tubular element 500.

[0392] In this illustrated example, the embodiment of Figure 23, tubular element 500 has a hollow conduit 726 extending axially along its length by use of a mandrel (not shown) having a central rod that extends further downstream from where gel 724 is extruded into the tube during manufacture, forming a hollow conduit within the extruded gel 724. Not all components of tubular element 500 are necessarily shown or labeled in the embodiment of Figure 23.

[0393] Although Figure 20 shows the aerosol-generating article 100 used with a blade-like heating element 230 of an aerosol-generating device 200, the tubular element 500 may alternatively be used with other aerosol-generating articles 100 that are heated differently.

[0394] For example, Figure 24 shows a cutaway view of an example of an aerosol-generating article 100 suitable for induction heating and heating with a blade-like heating element. Figure 24 shows an example of an aerosol-generating article 100 suitable for use with the tubular elements of the present invention. Figure 24 is a cross-sectional cutaway view of a tubular aerosol-generating article and its components, such as tubular element 500, and does not show the curvature of the tubular shape. Not all components of tubular element 500 are necessarily shown or labeled in this Figure 24.

[0395] 24, the aerosol-generating article 100 includes, in proximal to distal order at its proximal end 101, a mouthpiece 170, a fluid guide 400, a cavity 700, a tubular element 500, and an end plug 600. In this example, the tubular element 500 includes a gel 824 containing an active agent and further includes a susceptor (both not shown). The susceptor in this example is a single aluminum strip centrally located along the longitudinal axis of the tubular element 500. When the distal end 103 of the aerosol-generating article 100 is inserted into an aerosol-generating device 200 (not shown), a portion of the aerosol-generating article 100 including the tubular element 500 is positioned adjacent to an induction heating element 230 (not shown) of the aerosol-generating device 200 (not shown). Electromagnetic radiation generated by the induction heating element 230 is absorbed by the susceptor and assists in heating the gel 824 within the tubular element 500, which then assists in the release of material from the gel 824, e.g., an active agent, which is entrained in the passing aerosol, when negative pressure is applied to the proximal end 101 of the aerosol-generating article 100. Fluid, e.g., air, enters the outer longitudinal passage 834 through opening 150 (not shown), travels to the cavity 700, and then to the tubular element 500, where it mixes with the gel 824 and entrains the active agent, before returning to the cavity and then exiting at the proximal end 101 via the inner longitudinal passage (not shown) of the fluid guide 400. In this example, the longitudinal side 822 of the tubular element 500 comprises paper. The aerosol-generating article includes an outer wrapper 850. The aerosol-generating article 100 shown and described in Figure 24 can be used in conjunction with an aerosol-generating device 200 as shown and described in Figures 1-2. The aerosol-generating article 100 of Figure 16 is preferably heated by induction from the aerosol-generating device 200.

[0396] The tubular element 500 may have many different combinations of, among other things, gel 124, gel-loaded porous medium 125, active agent, inner longitudinal element, voids, filler material (preferably porous), and wrapper. A desired aerosol can be created by the particular combination and arrangement of its components.

[0397] example: 25 shows an example where a tubular element 500 comprises a wrapper 110, a second tubular element 115, the second tubular element 115 including a gel 124, the second tubular element 115 including a paper wrapper, the second tubular element 115 being centrally located along the longitudinal axis of the tubular element 500, and a porous filler material 132 located between the second tubular element 115 and the wrapper 110. The porous filler material 132 helps to center the second tubular element within the tubular element 500. The gel 124 in this example is located within a central portion of the second tubular element 115.

[0398] 26 shows an example where a tubular element 500 includes a wrapper 110 and a second tubular element 115 including a gel 124, the second tubular element including a paper wrapper, the second tubular element being centrally disposed along the longitudinal axis of the tubular element 500, and the gel 124 disposed between the second tubular element 115 and the wrapper 110. The gel located between the second tubular element 115 and the wrapper 110 helps to center the second tubular element 115 within the tubular element 500. The gel 124 in this example is located within a central portion of the second tubular element 115 as well as between the second tubular element 115 and the wrapper 110.

[0399] FIG. 27 shows an example in which a tubular element 500 includes a wrapper 110, an inner longitudinal element including a gel-filled porous medium 125, the inner longitudinal element being centrally located along the longitudinal axis of the tubular element 500, and a gel 124 located between the inner longitudinal element including the gel-filled porous medium 125 and the wrapper 110. The gel 124 may help to keep the inner longitudinal element including the gel-filled porous medium 124 centered within the tubular element 500. In this example, the inner longitudinal element has a cross-sectional shape in its longitudinal cross section such that a portion of the inner longitudinal element contacts the inner surface of the wrapper 110. Other examples may use inner longitudinal elements of other shapes and sizes, and therefore may not necessarily contact the inner surface away from the wrapper 110. Certain other examples may also use inner longitudinal elements of different materials.

[0400] 28 shows an example where a tubular element 500 includes a wrapper 110, a second tubular element 115 including a gel 124, the second tubular element 115 including a paper wrapper, the second tubular element 115 being centrally disposed along the longitudinal axis of the tubular element 500, and a gel-filled porous medium 124 disposed between the second tubular element 115 and the wrapper 110. In this example, the gel-filled porous medium 124 helps to center the second tubular element 115 within the tubular element 500.

[0401] 29 shows an example where a tubular element 500 includes a wrapper 110, a gel-filled porous medium 125, and a gel 124, with the gel-filled porous medium 125 adjacent to the inner surface of the wrapper 110 and surrounding the gel 124. In this example, there is both the gel 124 and the gel-filled porous medium 125. The gel-filled porous medium 125 coats the inner surface of the wrapper, although the shape of the gel-filled porous medium 125 may be formed first and then enveloped by the wrapper 110. In this example, the gel-filled porous medium 125 surrounds the gel 124, which is held centrally along the longitudinal axis of the tubular element 500. The gel-filled porous medium may help hold the gel 125 along a central position.

[0402] 30 shows an example where a tubular element 500 includes a wrapper 110 and a second tubular element 115 including a gel-filled porous medium 125, the second tubular element 115 including a paper wrapper, the second tubular element 115 being centrally disposed along the longitudinal axis of the tubular element 500, and a porous filler material 132 disposed between the second tubular element 115 and the wrapper 110. The porous filler material 132 helps to center the second tubular element within the tubular element 500. The gel-filled porous medium 125 in this example is located within a central portion of the second tubular element 115. In this example, the paper wrapper of the second tubular element 115 surrounds the gel-filled porous medium.

[0403] 31 shows an example where a tubular element 500 includes a wrapper 110 and a second tubular element 115 including a gel-filled porous medium 125, the second tubular element 115 being centrally disposed along the longitudinal axis of the tubular element 500, the second tubular element 115 further including a paper wrapper, and the gel-filled porous medium 125 located between the second tubular element 115 and the wrapper 110. In this example, the gel-filled porous medium 125 is in two locations within the second tubular element 115, between the second tubular element and the wrapper 110. These may have the same or different porous media, gels, or active agents.

[0404] 32 shows an example where a tubular element 500 includes a wrapper 110, a porous filler material 132, a second tubular element 115 centrally disposed along the longitudinal axis of the tubular element 500, the second tubular element 115 further including a paper wrapper, and a gel-filled porous medium 125 disposed between the second tubular element 115 and the wrapper 110. The gel-filled porous medium may help to keep the second tubular element 115 centered along the longitudinal axis of the tubular element 500. In this example, the gel-filled porous medium 125 is adjacent to the inner surface of the wrapper 110. The gel-filled porous medium 125 coats the inner surface of the wrapper 110.

[0405] 33 shows an example where a tubular element 500 includes a wrapper 110, a second tubular element 115 including a gel-filled porous medium 125, the second tubular element 115 being centered along the longitudinal axis of the tubular element 500, the second tubular element 115 further including a paper wrapper, and a gel 124 located between the second tubular element 115 and the wrapper 110. In this example, the gel 124 may help to center the second tubular element 115 along the longitudinal axis of the tubular element 500. In this example, the gel 124 is adjacent to the inner surface of the wrapper 110. In this example, the gel-filled porous medium 124 is centrally located within the second tubular element 115, surrounded by the paper wrapper of the second tubular element 115.

[0406] 34 shows an example in which a tubular element 500 includes a wrapper 110, an inner longitudinal element including a gel-filled porous medium 125, where the inner longitudinal element including the gel-filled porous medium 125 is cylindrical and centrally disposed along the longitudinal axis of the tubular element 500, and a gel 124 located between the inner longitudinal element including the gel-filled porous medium 125 and the wrapper 110. The gel 124 may help to center the inner longitudinal element including the gel-filled porous medium 124 within the tubular element 500. In this example, the inner longitudinal element is cylindrical in shape in its longitudinal cross-section and is held away from the inner surface of the wrapper 110 by the gel 124. Other examples may use inner longitudinal elements of other shapes and sizes and materials.

[0407] 35, 36, and 37 show a tubular element 500 comprising a gel-loaded thread 125. In this example, the gel-loaded thread 125 runs longitudinally, substantially parallel to the longitudinal axis of the tubular element 500. In this example, there is a second tubular element 304 centrally positioned within the tubular element 500, comprising an inner wrapper 115. The second tubular element 304 is also longitudinally positioned within the tubular element 500. The gel-loaded thread 125 is positioned between the second tubular element 304 and the inner surface of the wrapper 110. In the embodiment shown in FIGS. 35, 36, and 37, the gel-loaded thread runs substantially the entire longitudinal length of the tubular element.

[0408] 38 also illustrates a tubular element 500 with a gel-loaded thread 125. In this example, there are three second tubular elements 304, and the gel-loaded thread 125 is positioned between the three second tubular elements and between the second tubular elements and the inner surface of the wrapper 110.

[0409] 39 illustrates a tubular element with gel-loaded threads 125, where the tubular element 500 includes two or more gels 124. The gel-loaded threads 125 are evenly divided, in this embodiment, between gel-loaded threads 125A of one type of gel 124 and gel-loaded threads 125B of another type of gel 124.

[0410] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are intended to facilitate understanding of certain terms used frequently herein.

[0411] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include embodiments having plural referents unless the content clearly dictates otherwise.

[0412] As used in this specification and the appended claims, the term "or" is generally used in its sense including "and / or" unless the context clearly dictates otherwise.

[0413] As used herein, the words "have," "having," "include," "including," "comprise," "comprising," and the like are used in their open-ended sense and generally mean "including, but not limited to." It will be understood that "consisting essentially of," "consisting of," and the like are encompassed by "comprising" and the like.

[0414] The words "preferred" and "preferably" refer to embodiments of the invention that may offer certain advantages, under particular circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Moreover, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the present disclosure, including the claims.

[0415] Any directions referred to herein, such as "up," "down," "left," "right," "upper," "lower," and other directions or orientations, are described herein for clarity and brevity and are not intended to limit the actual device or system. The devices and systems described herein may be used in numerous directions and orientations.

[0416] The above illustrated embodiments are not limiting, and other embodiments consistent with those described above will be apparent to those skilled in the art. [Example]

[0417] 1. A tubular element comprising a first longitudinal passage and further comprising a gel-loaded porous medium, the gel including an active agent. 2. The tubular element of example 1, wherein the tubular element comprises a wrapper. 3. The tubular element of example 1 or 2, wherein the tubular element comprises a second tubular element, the second tubular element being longitudinally positioned within the first longitudinal passage. 4. The tubular element of Example 3, wherein the second tubular element comprises a gel-loaded porous medium. 5. The tubular element of any one of Examples 3 or 4, wherein the gel-loaded porous medium is positioned between the second tubular element and the wrapper forming the first longitudinal passage. 6. The tubular element of any one of Examples 3, 4 or 5, wherein a gel is positioned between the second tubular element and the wrapper that forms the first longitudinal passage. 7. The tubular element of example 1, comprising a longitudinal element positioned longitudinally within the first longitudinal passage. 8. The tubular element of any one of Examples 2 to 7, wherein the wrapper is rigid. 9. The tubular element of any one of Examples 2-8, wherein the wrapper is water resistant. 10. The tubular element of any one of Examples 3 to 9, wherein the longitudinal side of the second tubular element is rigid. 11. The tubular element of any of Examples 1-10, further comprising a susceptor to assist in heat transfer. 12. The tubular element of any of Examples 1-11, wherein the gel-loaded porous medium is crimped. 13. The tubular element of any of Examples 1-12, wherein the gel-loaded porous medium is chopped. 14. An article comprising a tubular element according to any one of Examples 1 to 13. 15. A method for producing a tubular element according to any of Examples 1 to 14, comprising: The method is distributing a gel-loaded porous medium onto a web of wrapping material and distributing a second tubular element onto the gel-loaded porous medium on the web of wrapping material; and wrapping the web of wrapping material around the gel-loaded porous medium and the second tubular element to form a composite structure of the gel-loaded porous medium and the second tubular element.

Claims

1. A tubular element, the tubular element comprising a first longitudinal passage, further comprising a gel-loaded porous medium, the gel comprising an active agent, and the gel-loaded porous medium being crimped.

2. The tubular element of claim 1 , wherein the porous medium comprises a sheet material.

3. 3. The tubular element of claim 1 or 2, wherein the porous medium comprises cellulose acetate, cotton, viscose, polylactic acid, combinations thereof.

4. A tubular element according to any one of claims 1 to 3, wherein the porous medium comprises threads.

5. The tubular element of any of claims 1 to 4, wherein the porous medium comprises a woven material, a nonwoven material, an extruded material, or any combination thereof.

6. A tubular element according to any preceding claim, further comprising a susceptor.

7. A tubular element according to any preceding claim, wherein the tubular element further comprises a wrapper.

8. The tubular element of claim 7 wherein the wrapper comprises paper.

9. 9. The tubular element of claim 8, wherein the wrapper is hydrophobic.

10. 10. The tubular element of claim 9, wherein the wrapper comprises hydrophobic groups covalently bonded to at least one surface of the wrapper.

11. The tubular element of claim 4 , wherein the susceptor is positioned longitudinally with the tubular element.

12. The tubular element of claim 11 , wherein the tubular element comprises a second tubular element.

13. A tubular element according to any preceding claim, wherein the second tubular element comprises a wrapper.

14. An article comprising a tubular element according to any one of claims 1 to 13.

15. The method is dispensing a gel-loaded porous medium onto a web of wrapping material and dispensing a second tubular element onto the gel-loaded porous medium on said web of wrapping material; 15. A method of manufacturing a tubular element according to any one of claims 1 to 14, comprising wrapping the web of wrapping material around the gel-loaded porous medium and the second tubular element to form a composite structure of the gel-loaded porous medium and the second tubular element.

Images