Aerosol generating article with thick paper

Abstract

To provide an aerosol generating article with thick paper.SOLUTION: An aerosol generating article (10) includes an aerosol generating substrate (20), a filter element (22), and a first paper wrapper (30) and a second paper wrapper (40) circumscribing the aerosol forming substrate. The first paper wrapper has a thickness in a range from about 90 micrometers to about 160 micrometers. The second paper wrapper joins the aerosol forming substrate to a filter element.SELECTED DRAWING: Figure 1A

Description

[Technical Field]

[0001] The present disclosure relates to an aerosol-generating article having a thick wrapper. The thick wrapper and a second wrapper bond the aerosol-generating substrate to a filter element and surround the aerosol-generating substrate to form the aerosol-generating article.

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

[0003] The paper used to wrap the aerosol-generating substrate and form the aerosol-generating substrate element can absorb aerosol formers, water, and other liquid compounds found in mainstream smoke or aerosols passing through the aerosol-generating article, or moisture or water present in the vicinity of the paper. The absorbed liquids can stain or weaken the paper and adversely affect the appearance and structural integrity of the aerosol-generating article. Heated aerosol-generating articles are particularly susceptible to wetting and breakage due to the high amount of aerosol formers in the aerosol-generating substrates of these heated aerosol-generating articles. Heated aerosol-generating articles are particularly prone to expansion when aerosol components are absorbed by the wrapper, leading to difficult removal from the heating device.

[0004] A resistive heating blade may be inserted into the aerosol-generating substrate to heat the aerosol-generating substrate and release volatile compounds from the aerosol-generating substrate. The resistive heating blade may provide a localized heat source within the aerosol-generating substrate, which may be located along the central axis of the aerosol-generating substrate. Aerosol-generating substrates located around the periphery of the paper wrapper or its interface with the paper wrapper may not be sufficiently heated by a centrally located resistive heating blade, resulting in unused aerosol-generating substrates within the aerosol-generating substrate.

[0005] It would be desirable to provide an aerosol-generating article that is visually and mechanically stable, particularly in the case of heat-and-non-combustion aerosol-generating articles containing high amounts of liquid or aerosol formers, and it would also be desirable for the thick paper wrapper or layer not to affect the taste of the aerosol generated by the aerosol-generating article.

[0006] It would be desirable to provide an aerosol-generating article that reduces the amount of unused aerosol-generating substrate within the article.

[0007] It would also be desirable for the aerosol-generating substrate wrapper not to readily combust when in close proximity to a heating element, nor to adversely affect the heating of the heated non-combustion aerosol-generating substrate. Summary of the Invention [Problem to be solved by the invention]

[0008] SUMMARY OF THE INVENTION It may be an object of the present invention to at least partially address one or more of the desirable technical advantages set forth above. [Means for solving the problem]

[0009] According to the present disclosure, there is provided an aerosol-generating article including an aerosol-generating substrate, a filter element, and first and second paper wrappers surrounding the aerosol-forming substrate. The first paper wrapper has a thickness within the range of about 60 micrometers to about 160 micrometers. The first or second paper wrapper connects the aerosol-forming substrate to the filter element.

[0010] The aerosol-generating article preferably comprises an aerosol-generating substrate, a filter element, and first and second paper wrappers surrounding the aerosol-forming substrate. The first paper wrapper has a thickness in the range of about 90 micrometers to about 160 micrometers. The second paper wrapper connects the aerosol-forming substrate to the filter element.

[0011] The first paper wrapper may separate the second paper wrapper from the aerosol-generating substrate. The first paper wrapper may not extend beyond the aerosol-generating substrate. The first wrapper may extend the entire length of the aerosol-generating substrate. The second paper wrapper may connect the aerosol-generating substrate to the filter element. The first paper wrapper may extend the entire length of the aerosol-generating substrate. The second paper wrapper may extend less than about 50% of the length of the aerosol-generating substrate.

[0012] The second paper wrapper may separate the first paper wrapper from the aerosol-generating substrate. The second paper wrapper may not extend beyond the aerosol-generating substrate. The first paper wrapper may connect the aerosol-generating substrate to the filter element. The first paper wrapper may extend the entire length of the aerosol-generating substrate.

[0013] The first paper wrapper may have a paper thickness in the range of about 78 micrometers to about 160 micrometers. The first paper wrapper may have a paper thickness in the range of about 78 micrometers to about 140 micrometers. The first paper wrapper may have a paper thickness in the range of about 90 micrometers to about 140 micrometers. The first paper wrapper may have a paper thickness in the range of about 100 micrometers to about 140 micrometers. The first paper wrapper may have a paper thickness in the range of about 110 micrometers to about 140 micrometers. The first paper wrapper may have a paper thickness in the range of about 125 micrometers to about 140 micrometers. The first paper wrapper may have a paper thickness in the range of about 130 micrometers to about 140 micrometers.

[0014] The second paper wrapper may have a paper thickness less than the paper thickness of the first paper wrapper. The second paper wrapper may have a paper thickness in the range of about 10 micrometers to about 50 micrometers. The second paper wrapper may have a paper thickness in the range of about 10 micrometers to about 35 micrometers. The second paper wrapper may have a paper thickness in the range of about 15 micrometers to about 30 micrometers. The second paper wrapper may have a paper thickness in the range of about 20 micrometers to about 25 micrometers.

[0015] The aerosol-generating substrate may define a substantially cylindrical shape having a diameter within the range of about 6.8 mm to about 7.1 mm, or about 6.8 mm to about 7.0 mm. The first paper wrapper may have a ratio of paper thickness to diameter of the tobacco substrate within the range of about 1:120 to about 1:40. The first paper wrapper may have a ratio of paper thickness to diameter of the tobacco substrate within the range of about 1:100 to about 1:50. The first paper wrapper may have a ratio of paper thickness to diameter of the tobacco substrate within the range of about 1:70 to about 1:50. The first paper wrapper may have a ratio of paper thickness to diameter of the tobacco substrate within the range of about 1:60 to about 1:50.

[0016] The aerosol-generating substrate may comprise a homogenized tobacco material. The homogenized tobacco material may comprise, on a dry weight basis, about 1 percent to about 5 percent of a binder and about 5 percent to about 30 percent of an aerosol former. The aerosol-generating substrate may comprise an assembly of sheets of homogenized tobacco material, preferably crimped.

[0017] The aerosol-generating substrate may comprise a metal induction heating element.The aerosol-generating substrate may comprise a plurality of metal induction heating elements.

[0018] According to the present disclosure, there is provided an aerosol generating system comprising an aerosol-generating article as described herein and an aerosol generating device comprising a heating element configured to heat the aerosol-generating substrate.

[0019] The heating element may be a resistive heating blade element configured to be inserted into the aerosol-generating substrate, or the heating element may be an induction heating element configured to inductively heat a metallic induction heating element embedded within the aerosol-generating substrate.

[0020] Advantageously, aerosol-generating articles including a thick wrapper around an aerosol-generating substrate may provide visually and mechanically stable aerosol-generating articles, particularly in the case of heat-non-combustion aerosol-generating articles containing high amounts of liquid or aerosol former. As a result, swelling, visual staining, and physical weakening of the wrapper portion of the aerosol-generating article may be reduced, even when high amounts of humectant are included in the aerosol-generating substrate.

[0021] Advantageously, aerosol-generating substrate elements including thick wrappers may be formed on conventional aerosol-generating article-forming manufacturing equipment, which may improve the processability of the aerosol-generating substrate elements and reduce manufacturing costs.

[0022] Advantageously, an aerosol-generating substrate element including a thick wrapper may increase the amount of aerosol-generating substrate that is uniformly heated and consumed, thus reducing unused or wasted aerosol-generating substrate material.

[0023] Advantageously, aerosol-generating substrate elements including thick wrappers may utilize internal heating of the aerosol-generating substrate via induction or resistance heating elements embedded or inserted within the aerosol-generating substrate, and the thick paper wrapping the aerosol-generating substrate may not adversely affect the heating of the heated non-combustion aerosol-generating substrate.

[0024] A conventional cigarette is lit when a user applies a flame to one end of the cigarette and draws air through the other end. Localized heat provided by the flame and oxygen in the air drawn through the cigarette ignites the end of the cigarette, and the resulting combustion produces inhalable smoke. In contrast, in heated aerosol-generating articles, the aerosol is generated by heating a flavor-generating substrate (such as tobacco). Known heated aerosol-generating articles include, for example, electrically heated aerosol-generating articles and aerosol-generating articles in which the aerosol is generated by the transfer of heat from a combustible fuel element or heat source to a physically separated aerosol-forming substrate. For example, aerosol-generating articles according to the present disclosure find particular application in aerosol generation systems comprising an electrically heated aerosol generator having an internal heater blade adapted to be inserted into a rod of the aerosol-generating substrate. Aerosol-generating articles of this type have been described in the prior art, for example, in European Patent No. EP 0 822 670.

[0025] As used herein, the term "aerosol-generating device" refers to a device that includes a heater element that interacts with an aerosol-generating substrate of an aerosol-generating article to generate an aerosol.

[0026] As used herein, the term "aerosol-generating system" refers to the combination of an aerosol-generating device and an aerosol-generating article.

[0027] As used herein, the term "aerosol-generating article" refers to an article that includes an aerosol-generating substrate that is heated to generate and deliver to a consumer an inhalable aerosol.

[0028] The term "aerosol-generating substrate element" is used herein to mean an aerosol-generating substrate wrapped with a paper layer to form part of an aerosol-generating article.

[0029] The term "aerosol-generating substrate" refers to a material capable of generating or emitting an aerosol. The aerosol-generating substrate may be a solid, a paste, a gel, a slurry, a liquid, or may comprise any combination of solid, paste, gel, slurry, and liquid compounds. Preferably, the aerosol-generating substrate is a solid or gel composition. The aerosol-generating substrate may preferably comprise nicotine.

[0030] The term "mouthpiece" is used herein to refer to the portion of the aerosol-generating article that is designed to come into contact with the consumer's mouth. The mouthpiece can be the portion of the aerosol-generating article that may include a filter, or in some cases, the mouthpiece can be defined by the extent of the tipping wrapper.

[0031] The terms "upstream" and "downstream" refer to the relative positions of elements of an aerosol-generating article described in relation to the direction of the aerosol as it is withdrawn from the aerosol-generating substrate and through the mouthpiece.

[0032] The aerosol-generating article includes an aerosol-generating substrate, a filter element, and a first and second paper wrapper surrounding the aerosol-forming substrate. The first paper wrapper has a thickness within the range of about 60 micrometers to about 160 micrometers. The first or second paper wrapper connects the aerosol-forming substrate to the filter element.

[0033] The first paper wrapper may separate the second paper wrapper from the aerosol-generating substrate. The first paper wrapper may contact the aerosol-generating substrate. The first paper wrapper may contact the second paper wrapper. The second paper wrapper may not contact the aerosol-generating substrate. The first paper wrapper may surround the aerosol-forming substrate. The second paper wrapper may surround the first paper wrapper. The second paper wrapper may overlap only a portion of the first paper wrapper. The second paper wrapper may overlap less than about 50% or less than 25% of the downstream length of the aerosol-generating substrate. The second paper wrapper may connect the aerosol-generating substrate to a filter element. The second paper wrapper may be referred to as tipping paper. The first paper wrapper may define the upstream outer surface of the aerosol-generating article, and the second paper wrapper may define the downstream outer surface of the aerosol-generating article. The first paper wrapper may not extend beyond the ends or length of the aerosol-generating substrate. The first paper wrapper may extend the entire length of the aerosol-generating substrate.

[0034] In another embodiment, the second paper wrapper may separate the first paper wrapper from the aerosol-generating substrate. The second paper wrapper may contact the aerosol-generating substrate. The second paper wrapper may contact the first paper wrapper. The second paper wrapper may surround the aerosol-forming substrate. The first paper wrapper may surround the second paper wrapper. The first paper wrapper may overlap the entire length of the second paper wrapper. The first paper wrapper may overlap the entire length of the second paper wrapper or may be coextensive with the second paper wrapper. The first paper wrapper may connect the aerosol-generating substrate to the filter element. The first paper wrapper may define the entire outer surface of the aerosol-generating article. The second paper wrapper may not extend beyond the ends or length of the aerosol-generating substrate. The second paper wrapper may extend the entire length of the aerosol-generating substrate.

[0035] At least about 80%, or at least about 90%, or at least about 95% of the periphery of the aerosol-generating substrate may be surrounded by fewer than three layers of paper. Preferably, the fewer than three layers of paper do not extend beyond the length of the aerosol-generating substrate. Preferably, at least about 80%, or at least about 90%, or at least about 95% of the periphery of the aerosol-generating substrate is surrounded by fewer than three layers of paper that surround the aerosol-generating substrate substantially along the length of the aerosol-generating substrate.

[0036] The first and second paper wrappers completely surround the aerosol-generating substrate with very little overlap of the paper wrappers on each other. The overlap region forms two or more paper layers, e.g., two layers. The overlap region extends along the longitudinal length of the paper wrappers.

[0037] Three layers of paper wrappers may be present where a first paper wrapper overlaps itself. Three layers of paper wrappers may be present where a second paper wrapper overlaps itself. The overlaps of the first and second paper wrappers are preferably offset from one another. The overlaps of the first and second paper wrappers are preferably offset from one another by at least about 45 degrees around the circumference of the aerosol-generating substrate. The overlaps of the first and second paper wrappers are preferably offset from one another by at least about 90 degrees around the circumference of the aerosol-generating substrate. The overlaps of the first and second paper wrappers are preferably offset from one another by about 180 degrees around the circumference of the aerosol-generating substrate.

[0038] The overlap of each paper wrapper on its own paper wrapper may be about 20% or less around the circumference of the aerosol-generating substrate. The overlap may be about 15% or less around the circumference of the aerosol-generating substrate. The overlap may be about 10% or less around the circumference of the aerosol-generating substrate. Reducing the paper overlap or overlap may help prevent or minimize spaces or air pockets defined between the paper layers in the overlap area.

[0039] The first paper wrapper may have a paper thickness in the range of about 60 micrometers to about 160 micrometers. The first paper wrapper may have a paper thickness in the range of about 78 micrometers to about 160 micrometers. The first paper wrapper may have a paper thickness in the range of about 78 micrometers to about 140 micrometers. The first paper wrapper may have a paper thickness in the range of about 90 micrometers to about 160 micrometers. The first paper wrapper may have a paper thickness in the range of about 100 micrometers to about 140 micrometers. The first paper wrapper may have a paper thickness in the range of about 110 micrometers to about 160 micrometers. The first paper wrapper may have a paper thickness in the range of about 125 micrometers to about 140 micrometers. The first paper wrapper may have a paper thickness in the range of about 130 micrometers to about 160 micrometers.

[0040] The second paper wrapper may have a paper thickness in the range of about 10 micrometers to about 50 micrometers. The second paper wrapper may have a paper thickness in the range of about 10 micrometers to about 35 micrometers. The second paper wrapper may have a paper thickness in the range of about 15 micrometers to about 30 micrometers. The second paper wrapper may have a paper thickness in the range of about 20 micrometers to about 25 micrometers.

[0041] The aerosol-generating substrate may define a substantially cylindrical shape with a diameter in the range of about 6.8 mm to about 7.1 mm.The aerosol-generating substrate may define a substantially cylindrical shape with a diameter in the range of about 6.8 mm to about 7.0 mm.

[0042] The first paper wrapper may have a paper thickness to tobacco substrate diameter ratio in the range of about 1:120 to about 1:40. The first paper wrapper may have a paper thickness to tobacco substrate diameter ratio in the range of about 1:100 to about 1:50. The first paper wrapper may have a paper thickness to tobacco substrate diameter ratio in the range of about 1:75 to about 1:50. The first paper wrapper may have a paper thickness to tobacco substrate diameter ratio in the range of about 1:60 to about 1:50. Conventionally wrapped tobacco substrates may have a paper wrapper thickness to tobacco substrate diameter ratio of about 1:300.

[0043] The first paper wrapper may have a paper thickness to tobacco substrate element diameter ratio in the range of about 1:100 to about 1:40, or about 1:75 to about 1:50, or about 1:65 to about 1:50, or about 1:60 to about 1:50. Conventionally wrapped tobacco substrates may have a paper thickness to tobacco substrate element diameter ratio of about 1:300.

[0044] The first and second paper wrappers may surround the aerosol-generating substrate to define a substantially cylindrical aerosol-generating substrate. The aerosol-generating substrate may define a substantially cylindrical shape having a diameter within the range of about 6.8 mm to about 7.1 mm. The aerosol-generating substrate element surrounded by the first and second paper wrappers may define a substantially cylindrical shape having a diameter within the range of about 7.1 mm to about 7.3 mm.

[0045] The aerosol-generating article preferably comprises an aerosol-generating substrate, a filter element, a first paper wrapper surrounding the aerosol-forming substrate, and a second paper wrapper surrounding the first paper wrapper. The first paper wrapper has a thickness in the range of about 60 micrometers to about 160 micrometers. The second paper wrapper connects the aerosol-forming substrate to the filter element and has a thickness in the range of about 20 micrometers to about 40 micrometers. The first paper wrapper does not extend beyond the edge of the aerosol-generating substrate. The first paper wrapper surrounds the entire length of the aerosol-generating substrate. The first and second paper wrappers each overlap the circumference of the aerosol-generating substrate by less than 20%. The aerosol-generating substrate has a diameter in the range of about 6.8 mm to about 7.0 mm. The second paper wrapper preferably surrounds less than about 25% of the downstream length of the aerosol-generating substrate.

[0046] The aerosol-generating substrate element preferably comprises an aerosol-generating substrate having a diameter and a first paper wrapper having a thickness surrounding the aerosol-generating substrate, with at least 80% or at least 90% of the circumference of the aerosol-generating substrate being surrounded by fewer than three paper layers. The first paper wrapper preferably does not extend beyond the edge of the aerosol-generating substrate. The first paper wrapper preferably surrounds the entire length of the aerosol-generating substrate. The ratio of the thickness of the first paper wrapper to the diameter of the tobacco substrate is preferably within the range of about 1:120 to about 1:40, or about 1:100 to about 1:50, or about 1:75. The second paper wrapper preferably surrounds less than about 25% of the downstream length of the aerosol-generating substrate.

[0047] The aerosol-generating article includes an aerosol-generating substrate and a mouthpiece. The mouthpiece may include a filter. A tipping wrapper (either the first paper wrapper or, preferably, the second paper wrapper) may connect the filter to the aerosol-generating substrate. One or more intermediate sections may separate the aerosol-generating substrate and the mouthpiece.

[0048] The aerosol-generating substrate may be a solid composition. The composition may include a plant-based material. The aerosol-generating substrate may include tobacco, and preferably the tobacco contains volatile tobacco flavor compounds that are released from the aerosol-generating substrate upon heating. The aerosol-generating substrate may include a homogenized tobacco material, an aerosol former, and a binder.

[0049] The aerosol-generating substrate may comprise a homogenized tobacco material. The homogenized tobacco material may comprise, on a dry weight basis, about 1 percent to about 5 percent of a binder and about 5 percent to about 30 percent of an aerosol former. The aerosol-generating substrate may comprise an assembly of sheets of homogenized tobacco material, preferably crimped.

[0050] Nicotine may be present in the aerosol-generating substrate in the range of about 0.5 to about 10% by weight of nicotine, or about 0.5 to about 5% by weight of nicotine. Preferably, the aerosol-generating substrate contains about 1 to about 3% by weight of nicotine, or about 1.5 to about 2.5% by weight of nicotine, or about 2% by weight of nicotine.

[0051] The aerosol-generating substrate may comprise any suitable type(s) of tobacco material or tobacco substitute in any suitable form. The aerosol-generating substrate may comprise fully cured tobacco, Burley tobacco, Maryland tobacco, Oriental tobacco, specialty tobacco, homogenized tobacco, or reconstituted tobacco, or any combination thereof. The aerosol-generating substrate may be provided in the form of tobacco cut filler, tobacco lamina, processed tobacco materials such as volume-expanded or puffed tobacco, processed tobacco stems such as cut-rolled or cut-puffed stems, homogenized tobacco, reconstituted tobacco, cast leaf tobacco, or blends thereof, and the like. The term "tobacco cut filler" is used herein to refer to tobacco material primarily formed from the lamina portion of tobacco leaves. The term "tobacco cut filler" is used herein to refer to both a single species of the genus Nicotiana and two or more species of the genus Nicotiana that form a tobacco cut filler blend.

[0052] As used herein, the term "homogenized tobacco" refers to a material formed by agglomerating particulate tobacco. Homogenized tobacco may include reconstituted tobacco or cast leaf tobacco, or a mixture of both. The term "reconstituted tobacco" refers to a paper-like material that can be made from tobacco by-products such as tobacco fines, tobacco dust, tobacco stems, or a mixture of the foregoing. Reconstituted tobacco can be made by extracting soluble chemicals in tobacco by-products, processing the remaining tobacco fibers into a sheet, and then reapplying the extracted material in a concentrated form onto the sheet. The term "cast leaf tobacco" is used herein to refer to a product resulting from a process well known in the art, which involves casting a slurry containing ground tobacco particles and a binder (e.g., guar) onto a support surface (such as a belt conveyor), drying the slurry, and removing the dried sheet from the support surface. Exemplary methods for producing these types of aerosol-generating substrates are described in U.S. Patent Nos. 5,724,998, 5,584,306, 4,341,228, 5,584,306, and 6,216,706. The homogenized tobacco may be crimped, reeled, folded, or otherwise compressed into a sheet before being rolled to form a rod. For example, the homogenized tobacco material sheets used in the present invention may be crimped using a crimping unit of the type described in Swiss Patent No. 691156, which includes a pair of rotatable crimping rollers. It will be appreciated, however, that the homogenized tobacco material sheets used in the present invention may also be textured using other suitable machinery and processes that deform or perforate the homogenized tobacco material sheets.

[0053] Aerosol-generating substrates used in aerosol-generating articles typically contain a higher amount of aerosol former(s) than combustible smoking articles such as cigarettes. Humectants can also be referred to as "aerosol formers." Aerosol former is used to describe any suitable, well-known compound or mixture of compounds that facilitates aerosol formation during use and is substantially resistant to thermal decomposition at the operating temperatures of the aerosol-generating substrate. Suitable aerosol formers are well-known in the art and include, but are not limited to, polyhydric alcohols (e.g., propylene glycol, triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (e.g., glycerin monoacetate, diacetate, triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (e.g., dimethyl dodecanedioate, dimethyl tetradecanedioate). Preferred aerosol formers are polyhydric alcohols or mixtures thereof (e.g., propylene glycol, triethylene glycol, 1,3-butanediol), and most preferably glycerin or glycerin. The aerosol-generating substrate may comprise a single aerosol former, or alternatively, the aerosol-generating substrate may comprise a combination of two or more aerosol formers.

[0054] The aerosol-generating substrate may have a high amount of aerosol former. As used herein, a high amount of aerosol former means an aerosol former content of greater than about 10% by weight, or preferably greater than about 15% by weight, or more preferably greater than about 20% by weight. The aerosol-generating substrate may also have an aerosol former content of about 10% to about 30% by weight, about 15% to about 30% by weight, or about 20% to about 30% by weight. The aerosol-generating substrate may also have a glycerin content of about 10% to about 30% by weight, about 15% to about 30% by weight, or about 20% to about 30% by weight.

[0055] The aerosol-generating substrate may comprise at least about 1% by weight, or at least about 2% by weight, or at least about 5% by weight, or at least about 7% by weight, or at least about 10% by weight, or at least about 12% by weight, or at least about 15% by weight, or at least about 18% by weight of aerosol formers. The aerosol-generating substrate may comprise from about 1 to about 20% by weight, or from about 5 to about 20% by weight, or from about 10 to about 20% by weight of aerosol formers.

[0056] The aerosol-generating substrate may comprise at least about 1% by weight, or at least about 2% by weight, or at least about 5% by weight, or at least about 7% by weight, or at least about 10% by weight, or at least about 12% by weight, or at least about 15% by weight, or at least about 18% by weight of glycerin. The aerosol-generating substrate may comprise from about 1 to about 20% by weight, or from about 5 to about 20% by weight, or from about 10 to about 20% by weight of glycerin.

[0057] Preferably, the aerosol-generating article may be generally cylindrical, which allows for smooth flow of the aerosol. The aerosol-generating article may have an outer diameter of, for example, 7.1 mm to 7.3 mm, or 7.15 mm to 7.25 mm. The aerosol-generating article may have a length of, for example, 10 mm to 60 mm, 15 mm to 50 mm, or 20 mm to 45 mm.

[0058] The aerosol-generating substrate may include a flavoring agent. The plant material provides a flavoring agent that may impart flavor to the taste of the aerosol generated by the aerosol-generating article. A flavoring agent is any natural or artificial compound that affects the organoleptic qualities of the aerosol. Non-limiting examples of sources of flavoring agents include mint (such as peppermint and spearmint), coffee, tea, cinnamon, clove, cocoa, vanilla, eucalyptus, geranium, agave, and juniper, and combinations thereof.

[0059] The aerosol-generating substrate may contain an essential oil. The essential oil may provide a flavoring agent that may impart flavor to the taste of the aerosol generated by the aerosol-generating article. Suitable essential oils include, but are not limited to, eugenol, peppermint oil, and spearmint oil. A preferred essential oil is eugenol. The essential oil may be present in the aerosol-generating substrate in an amount of at least about 0.1% by weight, or at least about 0.5% by weight, or at least about 1% by weight. The essential oil may be present in the aerosol-generating substrate in a range of about 0.1% by weight to about 10% by weight, or about 0.1% by weight to about 5% by weight, or about 0.5% by weight to about 2% by weight.

[0060] The aerosol-generating substrate may comprise a homogenized tobacco material. The homogenized tobacco material may comprise, on a dry weight basis, tobacco material, about 1 percent to about 5 percent binder, and about 5 percent to about 30 percent aerosol former. Sheets of homogenized tobacco for use in the aerosol-generating articles of the present invention may be made by methods known in the art (e.g., the method disclosed in WO-A-201 2 / 1 64009 A2). In a preferred embodiment, sheets of homogenized tobacco material for use in the aerosol-generating article are formed by a casting process from a slurry containing particulate tobacco, guar gum, cellulose fibers, and glycerin.

[0061] The aerosol-generating substrate may comprise an assemblage of a sheet of homogenized tobacco material, which is preferably crimped. As used herein, the term "crimped" refers to a sheet having a plurality of substantially parallel ridges or corrugations. When the aerosol-generating article is assembled, the substantially parallel ridges or corrugations preferably extend along or parallel to the longitudinal axis of the aerosol-generating article.

[0062] The aerosol-generating system may comprise a heat source, an aerosol-generating substrate, at least one air inlet downstream of the aerosol-generating substrate, and an airflow path extending between the at least one air inlet and the mouth end of the article. The heat source may be integral with the aerosol-generating device, and the consumable aerosol-generating article may be releasably received within the aerosol-generating device.

[0063] The heat source may be a combustible heat source, a chemical heat source, an electrical heat source, a heat sink, or any combination thereof. The heat source may be an electrical heat source, which may preferably be shaped in the form of a blade that can be inserted into the aerosol-generating substrate. Alternatively, the heat source may be configured to surround the aerosol-generating substrate, and thus may be in the form of a hollow cylinder, or any other such suitable form.

[0064] Preferably, the heat source is configured to heat the aerosol-generating substrate directly without transmitting heat to the aerosol-generating substrate through at least one paper layer.

[0065] The aerosol-generating substrate may comprise an induction heating element or susceptor, or a plurality of induction heating elements or susceptors. The induction heating element or susceptor heats in the presence of an alternating or fluctuating electromagnetic field. When heating is by induction, the fluctuating electromagnetic field is transmitted through the aerosol-generating article to the induction heating element or susceptor, causing the susceptor or induction heating element to convert the fluctuating field into thermal energy, thereby heating the aerosol-generating substrate.

[0066] The induction heating element or susceptor may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-generating substrate. The induction heating element or susceptor may comprise metal or carbon. A preferred induction heating element or susceptor may comprise a ferromagnetic material (e.g., ferritic iron), or ferromagnetic steel or stainless steel. The induction heating element or susceptor may comprise aluminum. The induction heating element or susceptor 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 an electromagnetic field of similar frequency and field strength. The induction heating element or susceptor is preferably heated to a temperature above 250°C. However, the induction heating element or susceptor is preferably heated to less than 350°C to prevent combustion of materials in contact with the susceptor.

[0067] The aerosol-generating substrate may comprise a metallic induction heating element. The metallic induction heating element may comprise a plurality of metallic induction heating elements. The metallic induction heating element may comprise a metallic induction heating ring element.

[0068] This first paper wrapper may exhibit a range of permeability, including no permeability. The permeability of cigarette paper is determined using the international standard test method ISO 2965:2009, and the results are expressed in cubic centimeters per minute per square centimeter, referred to as "Colesta units." The permeability of the wrappers described herein may be within the range of about 1 to about 10 Coresta units, about 5 to about 20 Coresta units, or about 1 to about 5 Coresta units.

[0069] The first and second paper wrappers may each be separately formed from any cellulosic material such as paper, wood, fabric, natural as well as man-made fibers.

[0070] The first paper wrapper may comprise a laminate of a paper layer and a metal layer. The first paper wrapper may comprise a laminate of a paper layer and an aluminum layer. The laminate of the paper layer and the aluminum layer may have a uniform thickness within the range of about 78 micrometers to about 160 micrometers, or about 78 micrometers to about 140 micrometers, or about 100 micrometers to about 140 micrometers, or about 125 micrometers to about 140 micrometers. The laminate of the paper layer and the metal layer may not extend beyond the edges of the aerosol-generating substrate.

[0071] The resistance to withdrawal (RTD) of the aerosol-generating article after insertion into the aerosol-generating device is preferably from about 80 mmWG to about 140 mmWG, more preferably from about 100 mmWG to about 120 mmWG.

[0072] As used herein, resistance to withdrawal is expressed in pressure units "mmWG" or "millimeters of water column" and is measured in accordance with ISO 6565:2002. The resistance to withdrawal (RTD) of the rod of the aerosol-generating substrate is preferably from about 50 mmWG to about 80 mmWG. The RTD of the rod of the aerosol-generating substrate is preferably from about 5 mmWG to about 8 mmWG per millimeter of rod length.

[0073] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are provided to facilitate understanding of certain terms used frequently herein.

[0074] 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.

[0075] 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.

[0076] 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 should be understood that "consisting essentially of," "consisting of," and the like are encompassed by "comprising" and the like.

[0077] 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. [Brief explanation of the drawings]

[0078] [Figure 1A] FIG. 1A is a schematic cross-sectional view of an aerosol-generating article. [Figure 1B] FIG. 1B is a schematic cross-sectional view of another aerosol-generating article. [Figure 2] FIG. 2 is a schematic cross-sectional view of the aerosol-generating substrate element taken along line 2-2 of FIG. 1A. [Figure 3] FIG. 3 is a schematic cross-sectional view of the aerosol-generating substrate element taken along line 3-3 of FIG. [Figure 4] FIG. 4 is a schematic cross-sectional view of an aerosol generation system. [Figure 5]FIG. 5 is a schematic cross-sectional view of a heating blade inserted into an aerosol-generating substrate element. DETAILED DESCRIPTION OF THE INVENTION

[0079] The aerosol-generating articles depicted in Figures 1-5 illustrate one or more embodiments of the aerosol-generating articles, components of aerosol-generating articles, or aerosol-generating systems described above. The schematic diagrams are not necessarily to scale and are presented for illustrative purposes, not limitation. The drawings illustrate one or more embodiments described in the present disclosure. However, it should be understood that other embodiments not depicted in the drawings are within the scope and spirit of the present disclosure.

[0080] The aerosol-generating article includes an aerosol-generating substrate 20, a filter element 22, and a first paper wrapper 30 and a second paper wrapper 40 surrounding the aerosol-forming substrate 20. The first paper wrapper 30 has a thickness in the range of about 60 micrometers to about 160 micrometers. The first paper wrapper 30 or the second paper wrapper 40 connects the aerosol-forming substrate 20 to the filter element 22.

[0081] The aerosol-generating article preferably includes an aerosol-generating substrate 20, a filter element 22, and a first paper wrapper 30 and a second paper wrapper 40 surrounding the aerosol-forming substrate 20. The first paper wrapper 30 has a thickness in the range of about 90 micrometers to about 160 micrometers. The second paper wrapper 40 connects the aerosol-forming substrate 20 to the filter element 22.

[0082] 1A and 1B illustrate an aerosol-generating article 10. FIG. 1A illustrates a first paper wrapper 30 surrounding an aerosol-generating substrate 20 and a second paper wrapper 40 surrounding the first paper wrapper 30 and the filter element 22. The first paper wrapper 30 extends along the entire length of the aerosol-generating substrate 20. The second paper wrapper 40 connects the aerosol-generating substrate 20 to the filter element 22. The second paper wrapper 40 extends only over a downstream portion of the first paper wrapper 30.

[0083] 1B illustrates a second paper wrapper 40 surrounding the aerosol-generating substrate 20 and a first paper wrapper 30 surrounding the second paper wrapper 40 and the filter element 22. The first paper wrapper 30 joins the aerosol-generating substrate 20 to the filter element 22. The first paper wrapper 30 is coextensive with the second paper wrapper 40 along the entire length of the aerosol-generating substrate 20, from the distal end 13 to the proximal end 11.

[0084] The intermediate section 24 separates the filter element 22 from the aerosol-generating substrate element 12. The aerosol-generating substrate 12, intermediate section 24, and filter element 22 are aligned in order from the distal end 13 to the proximal end 11 to form a cylinder. A second paper wrapper 40 or a first paper wrapper 30 surrounds the aerosol-generating article 10 and joins the aerosol-generating substrate element 12 to the intermediate section 24 and the filter element 22.

[0085] The intermediate section 24 may comprise one or more of a hollow cellulose acetate tube or a polylactic acid filter segment. The filter element 22 may define a mouthpiece segment and may be formed from a cellulose acetate material. The aerosol-generating substrate element 12, intermediate section 24, and filter element 22 may be individually wrapped with paper layers and then bonded together with the second paper wrapper 40 or the first paper wrapper 30. In particular, the aerosol-generating substrate element 12 is wrapped with the second paper wrapper 40 or the first paper wrapper 30 as described herein.

[0086] The aerosol-generating article 10 has a mouth or proximal end 11 and an upstream distal end 13 located at the opposite end of the article from the mouth end 11. The aerosol-generating article 10 shown in Figures 1A and 1B is particularly suitable for use in an electrically operated aerosol-generating device that includes a heater for heating the aerosol-generating substrate element 12.

[0087] Figure 2 is a schematic cross-sectional view of the aerosol-generating substrate element 12 taken along line 2-2 in Figure 1A. Figure 3 is a schematic cross-sectional view of the aerosol-generating substrate element 12 taken along line 3-3 in Figure 2.

[0088] A first paper wrapper 30 surrounds the aerosol-generating substrate 20 to define a substantially cylindrically shaped aerosol-generating substrate element 12. A second paper wrapper surrounds the first paper wrapper 30 to define a substantially cylindrical shape.

[0089] The aerosol-generating substrate 20 defines a substantially cylindrical shape having a diameter 23 within the range of about 6.8 mm to about 7.1 mm. The aerosol-generating substrate element 12 defines a substantially cylindrical shape having a diameter 33 within the range of about 7.1 mm to about 7.3 mm, or about 7.15 mm to about 7.25 mm.

[0090] The first paper wrapper 30 has a thickness T in the range of about 60 micrometers to about 160 micrometers. The first paper wrapper 30 may preferably have a thickness in the range of about 78 micrometers to about 160 micrometers, or about 78 micrometers to about 140 micrometers, or about 100 micrometers to about 140 micrometers, or about 125 micrometers to about 140 micrometers.

[0091] The first paper wrapper 30 has a ratio of paper thickness T to tobacco substrate diameter 23 in the range of about 1:120 to about 1:40, or about 1:100 to about 1:50, or about 1:70 to about 1:50, or about 1:60 to about 1:50.

[0092] The first paper wrapper 30 surrounds the entire periphery of the aerosol-generating substrate 20 with a very small first overlap 100 on the paper wrapper of the first paper wrapper 30. The first overlap 100 area forms two or more paper layers. In FIG. 2, the first overlap 100 forms two paper layers. The first overlap 100 may be about 20% or less of the periphery of the aerosol-generating substrate 20. The first overlap 100 may be about 10% or less of the periphery of the aerosol-generating substrate 20. The first overlap 100 may be about 5% or less of the periphery of the aerosol-generating substrate 20. The first paper wrapper 30 may not extend beyond the ends 25, 26 of the aerosol-generating substrate 20. The first paper wrapper 30 surrounds the entire length of the aerosol-generating substrate 20 between the ends 25, 26 of the aerosol-generating substrate 20.

[0093] The second paper wrapper 40 surrounds the entire periphery of the first paper wrapper 30, with a very small second overlap 101 of the second paper wrapper 40 on the paper wrapper. The second overlap 101 area forms two or more paper layers. In FIG. 2, the second overlap 101 forms two paper layers. The second overlap 101 may be about 20% or less of the circumference of the aerosol-generating substrate 20. The second overlap 101 may be about 10% or less of the circumference of the aerosol-generating substrate 20. The second overlap 101 may be about 5% or less of the circumference of the aerosol-generating substrate 20. The second paper wrapper 40 may extend beyond the downstream end 26 of the aerosol-generating substrate 20. The second paper wrapper 40 surrounds only about the downstream 25% of the total length of the aerosol-generating substrate 20 between the ends 25 and 26 of the aerosol-generating substrate 20.

[0094] The first overlap 100 region is offset from the second overlap 101 region by at least about 45 degrees around the circumference of the aerosol-generating substrate 20 .

[0095] 2 illustrates that when the second paper wrapper 40 is superimposed on the first paper wrapper 30, each paper wrapper forms substantially a single turn or layer around the periphery of the aerosol-generating substrate 20. At least about 80%, or at least about 90%, or at least about 95% of the periphery of the aerosol-generating substrate 20 is surrounded by fewer than three paper layers or wrappers 30, 40. At least about 80%, or at least about 90%, or at least about 95% of the periphery of the aerosol-generating substrate 20 is surrounded by fewer than two paper layers or wrappers that do not extend beyond the length or ends 25, 26 of the aerosol-generating substrate 20. At least about 80%, or at least about 90%, or at least about 95% of the periphery of the aerosol-generating substrate 20 is surrounded by fewer than two paper layers or wrappers that enclose the aerosol-generating substrate 20 substantially along the length or entire length of the aerosol-generating substrate 20.

[0096] Figure 4 is a schematic cross-sectional view of an aerosol-generating system 201. Figure 5 is a schematic cross-sectional view of a heating blade 230 inserted into an aerosol-generating substrate element 12. The aerosol-generating article 10 may be used with an aerosol-generating device 200, as shown in Figures 4 and 5.

[0097] The aerosol-generating device 200 includes a housing 210 defining a receptacle 220 configured to receive the aerosol-generating article 10. The aerosol-generating device 200 also includes a heating blade element 230 configured to penetrate the aerosol-generating substrate element 12 of the aerosol-generating article 10. The heating blade element 230 may comprise 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 blade element 230.

[0098] The aerosol-generating article 10 is illustrated with an aerosol-generating substrate element 12, an intermediate section 24, and a filter element 22 arranged in order from the distal end 13 to the proximal end 11 to form a cylinder. The distal end 13 of the aerosol-generating article 10. The aerosol-generating substrate 12 has a length of approximately 12 millimeters. The aerosol-generating substrate 12 is cylindrical in shape and has a substantially circular cross-section. The aerosol-generating substrate 12 may comprise an assembly of a sheet of homogenized tobacco material. The sheet of homogenized tobacco material may contain approximately 10 weight percent glycerin on a dry basis. The intermediate section 24 may be a hollow cellulose acetate tube having a length of approximately 8 millimeters and a thickness of 1 millimeter. The mouthpiece segment or filter element 22 may comprise a plug of cellulose acetate tow with 8 denier per filament and have a length of approximately 7 millimeters.

[0099] 5 illustrates a heating blade element 230 disposed within the aerosol-generating substrate 12, 20. The heating blade element 230 may heat the aerosol-generating substrate 12 of the aerosol-generating article 10. Heating the aerosol-generating substrate 12 generates an aerosol containing nicotine in the aerosol-generating substrate 12, which may travel out of the aerosol-generating article 10 at the proximal end 11.

[0100] The heating blade element 230 may have a width 233 of about 5 mm. The aerosol-generating substrate 20 defines a substantially cylindrical shape with a diameter 23 within the range of about 6.8 mm to about 7.1 mm, or about 6.9 mm to about 7.0 mm. The aerosol-generating substrate element 12 defines a substantially cylindrical shape with a diameter 33 within the range of about 7.1 mm to about 7.3 mm, or about 7.15 mm to about 7.25 mm. The heating blade element 230 may be positioned within about 1 mm of the first paper wrapper 30.

[0101] In some embodiments, the heating mechanism may be induction, in which one or more metal induction heating elements emit wireless magnetic radiation that is absorbed by the heating element when the aerosol-generating article 10 is positioned within the receptacle 220 of the aerosol-generating device 200.

[0102] Once the aerosol-generating article 10 is releasably received within the aerosol-generating device 200 and on the heating blade element 230, the aerosol-generating device 200 is activated to heat the aerosol-generating substrate 12 to a temperature of approximately 375 degrees Celsius. When a user draws on the oral end 11 of the aerosol-generating article 10, volatile compounds released from the aerosol-generating substrate 12 are drawn downstream through the aerosol-generating article 10 and condense to form an aerosol that is drawn through the mouthpiece 11 of the aerosol-generating article 10 and into the user's mouth.

[0103] The above-described examples are not limiting, and other examples consistent with the above-described examples will be apparent to those skilled in the art.

Claims

1. An aerosol-generating article comprising: an aerosol-generating substrate; A filter element; an aerosol-generating article comprising a first paper wrapper and a second paper wrapper surrounding the aerosol-forming substrate, the first paper wrapper having a thickness in the range of about 90 micrometers to about 160 micrometers, and the second paper wrapper connecting the aerosol-forming substrate to a filter element.

2. 2. The aerosol-generating article of claim 1, wherein the first paper wrapper separates the second paper wrapper from the aerosol-generating substrate.

3. 2. The aerosol-generating article of claim 1, wherein the first paper wrapper extends the entire length of the aerosol-generating substrate.

4. 4. The aerosol-generating article of claim 1, wherein the first paper wrapper has a paper thickness in the range of about 100 micrometers to about 140 micrometers, or about 125 micrometers to about 140 micrometers.

5. 5. The aerosol-generating article of claim 1, wherein the second paper wrapper has a paper thickness in the range of from about 10 micrometers to about 50 micrometers, or from 10 micrometers to about 35 micrometers, or from about 15 micrometers to about 30 micrometers, or from about 20 micrometers to about 25 micrometers.

6. 6. An aerosol-generating article according to any preceding claim, wherein the first paper wrapper does not extend beyond the aerosol-generating substrate.

7. 7. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating substrate defines a substantially cylindrical shape having a diameter within the range of about 6.8 mm to about 7.1 mm.

8. 8. The aerosol-generating article of claim 1, wherein the first paper wrapper has a ratio of paper thickness to tobacco substrate diameter within the range of about 1:120 to about 1:40, or about 1:100 to about 1:

50.

9. 9. The aerosol-generating article of claim 1, wherein the aerosol-generating substrate comprises homogenized tobacco material.

10. 10. The aerosol-generating article of claim 9, wherein the homogenized tobacco material comprises tobacco material, from about 1 percent to about 5 percent of a binder, and from about 5 percent to about 30 percent of an aerosol former, on a dry weight basis.

11. 11. The aerosol-generating article according to claim 1, wherein the aerosol-generating substrate comprises a metal induction heating element.

12. 12. The aerosol-generating article according to claim 1, wherein the aerosol-generating substrate comprises a plurality of metal induction heating elements.

13. An aerosol generating system comprising: the aerosol-generating article according to any one of claims 1 to 12; and an aerosol generating device comprising a heating element configured to heat the aerosol-generating substrate.

14. 14. The aerosol generating system of claim 13, wherein the heating element is a resistive heating blade element configured to be inserted into the aerosol-generating substrate.

15. 14. The aerosol-generating system of claim 13, wherein the heating element is an induction heating element configured to inductively heat a metallic induction heating element embedded within the aerosol-generating substrate.

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