Aerosol generation article including mouthpiece having upstream recess

Abstract

To provide an aerosol generation article including a mouthpiece having a recess in an upstream side.SOLUTION: An aerosol generation article 10 includes: an aerosol generation base substance 12; and a mouthpiece 14 aligned with the aerosol generation base substance in an axial direction, the mouthpiece including an additive segment of a filtration material including one or more easy-to-break capsules 22. Each of the easy-to-break capsule includes an outside shell and an inner core storing the additive. The additive segment of the filtration material defines an upstream recess 26 in a part between the aerosol generation base substance of the filtration material and the additive segment of the filtration material on the downstream from the aerosol generation base substance through a gap. The upstream recess is substantially not filled. A wrapper 16 surrounds the additive segment of the filtration material and the upstream recess.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to an aerosol-generating article having a mouthpiece with an upstream recess. [Background technology]

[0002] Filter cigarettes typically comprise a cylindrical rod of cut tobacco filler surrounded by a paper wrapper and a cylindrical filter axially aligned end-to-end with the wrapped tobacco rod. The cylindrical filter typically includes a filtration material surrounded by a paper plug wrap. Traditionally, the wrapped tobacco rod and filter are joined by a strip of tipping wrapper, usually made of an opaque paper material, that surrounds the entire length of the filter and an adjacent portion of the wrapped tobacco rod. Smoking articles have also been proposed that have a recess at the mouth end of their filter section.

[0003] Many smoking articles in which tobacco is heated rather than burned have been proposed in the art. In heated smoking articles, an aerosol is generated by heating an aerosol-generating substrate (such as tobacco). Known heated smoking articles include, for example, smoking articles in which an aerosol is generated by electrical heating or by the transfer of heat from a combustible fuel element or heat source to the aerosol-forming substrate. During smoking, volatile compounds are released from the aerosol-forming substrate by heat transfer from the heat source and are entrained in the air drawn through the smoking article. As the released compounds cool, they condense to form an aerosol, which is inhaled by the consumer. Smoking articles are also known in which a nicotine-containing aerosol is generated from tobacco material, tobacco extract, or other nicotine sources without combustion, and in some cases without heat, for example, by a chemical reaction.

[0004] It is known to incorporate one or more frangible capsules containing additives into the mouthpiece of an aerosol-generating article, where the one or more frangible capsules are intended to be broken by the consumer by applying a compressive force to the mouthpiece. When the one or more capsules are broken, the additives contained therein are released into the mouthpiece and can be entrained in the smoke or aerosol passing through the mouthpiece. The consumer may choose to break one or more capsules to release the additives into the mouthpiece before, during, or after smoking. For example, it has been proposed to incorporate one or more frangible capsules containing additional flavorants into the mouthpiece of a smoking article so that the flavorants can be released into mainstream smoke to provide the consumer with a modified sensory experience.

[0005] A frangible capsule is typically formed with an inner core containing an additive and an outer frangible shell. When a consumer applies force, the outer shell cracks and separates, releasing the inner core from the capsule. The rupture of the outer shell typically produces an audible sound, indicating to the consumer that the capsule has ruptured and the additive has been released.

[0006] During smoking of a smoking article incorporating a breakable capsule, the smoke drawn from the aerosol-generating substrate through the mouthpiece typically comes into contact with the capsule within the mouthpiece. It has been found that the capsule can be adversely affected by the heat and moisture of the smoke. Specifically, the outer shell of the capsule softens as a result of contact with the smoke, which can make it difficult for the consumer to break the capsule to release the additive. It can also be difficult to tell the consumer whether the capsule has broken, as the outer shell softens too much to produce an audible sound upon breaking. The same problem can occur in heated aerosol-generating articles as a result of the aerosol passing through the mouthpiece coming into contact with the capsule.

[0007] It would be desirable to provide aerosol-generating articles that incorporate novel mouthpiece arrangements that provide a more reliable and consistent means for releasing additives, such as flavorants, into the mouthpiece during smoking. In particular, it would be desirable to provide such aerosol-generating articles with mouthpiece arrangements that reduce degradation of capsules within the mouthpiece as a result of contact with mainstream smoke or aerosols generated during use. It would also be desirable to provide such aerosol-generating articles that can be rapidly manufactured using existing equipment and methods without requiring significant modifications. Summary of the Invention

[0008] According to the present invention, there is provided an aerosol-generating article comprising an aerosol-generating substrate and a mouthpiece axially aligned with the aerosol-generating substrate, the mouthpiece comprising an additive segment of filtration material including one or more frangible capsules, each frangible capsule including an outer shell and an inner core containing an additive. The additive segment of the filtration material defines an upstream recess between the aerosol-generating substrate and the additive segment of the filtration material, downstream from the aerosol-generating substrate via a gap, the upstream recess being substantially unfilled. The aerosol-generating article further comprises a wrapper surrounding the additive segment of filtration material and the upstream recess.

[0009] As used herein, the term "aerosol-generating substrate" describes a substrate capable of releasing volatile compounds upon heating (including combustion) to form an aerosol. The aerosol generated from an aerosol-generating substrate may be visible or invisible and may include vapor (e.g., gaseous fine particles of a substance that is normally liquid or solid at room temperature) as well as gases and droplets of condensed vapor. As used herein, the term "aerosol" encompasses the aerosol generated upon heating of a substrate in a heated aerosol-generating article and the smoke generated upon combustion of a substrate in a combustible smoking article.

[0010] As used herein, the terms "upstream" and "downstream" describe the relative positions of elements or portions of elements of an aerosol-generating article with respect to the direction in which a user draws on the aerosol-generating article during use. The aerosol-generating articles described herein comprise a downstream end and an opposite upstream end. In use, a consumer draws on the downstream end of the aerosol-generating article. The downstream end, also described as the mouth end, is downstream of the upstream end, which may also be described as the distal end.

[0011] As used herein, the term "substantially unfilled" describes a cavity that is substantially free of solid or liquid material. Preferably, less than 5 percent of the upstream cavity contains solid or liquid material. More preferably, less than 2 percent of the upstream cavity contains solid or liquid material. Most preferably, the upstream cavity is completely unfilled, such that the upstream cavity contains no solid or liquid material. Thus, the aerosol passes through the upstream cavity substantially unrestrictedly.

[0012] The aerosol-generating article according to the present invention comprises a mouthpiece incorporating an upstream cavity between the aerosol-generating substrate and an additive segment containing one or more capsules. The provision of the upstream cavity advantageously improves the stability of the one or more capsules by significantly reducing the adverse effects of the aerosol on the capsules. This is due to the fact that the aerosol must pass through the upstream cavity before reaching the additive segment, which means that the aerosol is cooled when it comes into contact with the one or more capsules. There is also usually some condensation within the upstream cavity, which means that the water content of the aerosol is reduced before it reaches the additive segment.

[0013] Thus, as a result of the upstream recess, the aerosol is significantly cooled and has a lower water content by the time it reaches the one or more capsules in the additive segment than if the aerosol were to enter the additive segment directly from the aerosol-generating substrate. Accordingly, the aerosol has less of an effect on the outer shell of the one or more capsules. In particular, it has been found that softening of the outer shell during use of the aerosol-generating article is reduced, preferably minimized, such that the one or more capsules in the additive segment are more reliably ruptured when a consumer applies a compressive force. Furthermore, because the one or more capsules retain the ability to produce an audible sound upon rupture, consumers may be able to more reliably detect the rupture of the one or more capsules during use.

[0014] The novel mouthpiece arrangement of the present invention can be easily incorporated into aerosol-generating articles without significantly affecting manufacturing equipment and techniques. The mouthpiece components themselves do not need to be significantly modified, and equipment for assembling the mouthpiece components can be easily adjusted to accommodate the novel arrangement with the upstream recess without significantly affecting the speed of the assembly process.

[0015] The upstream recess preferably has a length of at least about 3 millimeters, more preferably at least about 4 millimeters, and most preferably at least about 5 millimeters. This ensures that the upstream recess provides sufficient space for the aerosol to cool and dry to the desired extent before reaching the additive segment. The upstream recess preferably has a length of less than about 30 millimeters, and more preferably less than about 25 millimeters. However, in certain embodiments, such as those in which the upstream recess is defined by a plug wrap as described below, the upstream recess preferably has a length of less than about 10 millimeters, and more preferably less than about 7 millimeters. The "length" of the upstream recess refers to the dimension of the upstream recess in the longitudinal direction of the aerosol-generating article.

[0016] Preferably, the length of the upstream recess corresponds to at least about 15 percent of the total length of the mouthpiece, and more preferably to at least about 20 percent of the total length of the mouthpiece.

[0017] Preferably, the cross-sectional area of ​​the upstream recess corresponds to at least about 30 percent of the cross-sectional area of ​​the mouthpiece, and more preferably to at least about 50 percent of the cross-sectional area of ​​the mouthpiece.

[0018] In some embodiments of the invention, the upstream recess extends from the downstream end of the aerosol-generating substrate to the upstream end of the additive segment, and in such embodiments, no intervening material is required between the downstream end of the aerosol-generating substrate and the upstream end of the additive segment.

[0019] In an alternative embodiment, the mouthpiece includes one or more intermediate segments of filtration material between the aerosol-generating substrate and the additive filter segment. For example, the intermediate segment of filtration material may be provided adjacent to the aerosol-generating substrate such that an upstream recess is provided between the intermediate segment of filtration material and the additive segment. Alternatively, or additionally, the intermediate segment of filtration material may be provided adjacent to the additive segment. The wrapper of the aerosol-generating article according to the present invention preferably surrounds any intermediate segment of filtration material provided between the aerosol-generating substrate and the additive segment.

[0020] The provision of one or more intermediate segments of filtration material may advantageously provide further cooling and drying of the aerosol before it reaches the additive segment, thereby further reducing the impact of the aerosol on the one or more capsules.

[0021] The upstream recess in the mouthpiece of an aerosol-generating article according to the present invention may be defined by any suitable means.

[0022] In certain preferred embodiments of the present invention, the wrapper surrounding the additive segment and the upstream depression is a plug wrap, and the plug wrap defines the upstream depression. Thus, the plug wrap extends upstream of the additive segment to define the upstream depression. In such embodiments, the plug wrap preferably has a basis weight of at least about 50 grams per square meter, and more preferably at least about 70 grams per square meter. This provides a relatively stiff plug wrap that helps maintain the structural rigidity of the upstream depression and prevent collapse of the upstream depression during manufacture or use. For example, the plug wrap may have a basis weight of about 50 grams per square meter to about 120 grams per square meter, or about 70 grams per square meter to about 110 grams per square meter.

[0023] Using plug wrap to define the upstream recess may simplify the manufacturing process as no additional components need to be incorporated into the mouthpiece.

[0024] In embodiments in which the plug wrap defines the upstream recess, the length of the upstream recess is typically limited to maintain the structural integrity of the mouthpiece. Moreover, in such embodiments, the upstream recess does not significantly contribute to the RTD of the mouthpiece. Therefore, the desired level of RTD must be provided by the additive segment and any other mouthpiece components downstream of the upstream recess. Therefore, in such embodiments, the upstream recess preferably has a length of 7 millimeters or less, for example, from about 5 millimeters to about 7 millimeters.

[0025] In these embodiments, the length of the upstream recess preferably represents less than about 25 percent of the overall length of the mouthpiece, and more preferably less than about 20 percent of the overall length of the mouthpiece. Thus, the length of the upstream recess in these embodiments is preferably between about 15 percent and about 25 percent of the overall length of the mouthpiece.

[0026] In an alternative preferred embodiment, the mouthpiece comprises a hollow tube segment between the substrate and the filter segment, the hollow tube segment defining the upstream recess. Using a hollow tube segment to define the upstream recess may advantageously make the upstream recess more resistant to collapse or deformation during manufacture and subsequent use of the aerosol-generating article. In some cases, the hollow tube segment may further contribute to the overall RTD of the mouthpiece.

[0027] The hollow tube segment may be formed from any suitable material. For example, the hollow tube segment may be formed from an annular segment of filtration material (such as cellulose acetate) having a hollow core extending from the upstream end of the annular segment of filtration material to the downstream end of the annular segment of filtration material. Such a segment may be referred to as a hollow acetate tube.

[0028] The filtration material of the annular segments preferably comprises fibers having a density of from about 2.1 denier per filament (dpf) to about 12 dpf, more preferably from about 3.0 denier per filament (dpf) to about 10 dpf. The filtration material of the annular segments preferably comprises fibers having a density of from about 30,000 total denier (td) to about 50,000 td, more preferably from 35,000 total denier (td) to about 45,000 td.

[0029] In one preferred embodiment, the filtration material of the annular segment comprises approximately 40,000 td fibers. The hollow tube segment preferably includes one or more plasticizers. Suitable plasticizers include triacetin, triethyl citrate, and triethylene glycol diacetate. The plasticizer is preferably present in the annular segment in an amount of about 8 to about 25 weight percent, more preferably about 10 to about 22 weight percent. This may help the hollow tube segment maintain structural rigidity within the mouthpiece.

[0030] When the hollow tube is a segment of annular filtration material, such as hollow acetate tubing, the wall thickness of the hollow tube segment is preferably at least about 0.3 millimeters, and more preferably at least about 0.5 millimeters. Alternatively or additionally, the wall thickness of the hollow tube segment in such embodiments is less than about 1.2 millimeters, and more preferably less than about 1.1 millimeters. In some preferred embodiments, the wall thickness of the hollow tube segment is between about 0.5 millimeters and about 1.1 millimeters.

[0031] In some other preferred embodiments, the hollow tube segment is formed from a paper material. More preferably, the hollow tube segment is formed from multiple overlapping paper layers, such as multiple parallel wound paper layers or multiple spirally wound paper layers. Forming the hollow tube segment from multiple overlapping paper layers can help improve resistance to collapse or deformation.

[0032] Preferably, each hollow tube segment includes at least two paper layers. Alternatively, or additionally, each hollow tube segment includes fewer than 11 paper layers.

[0033] Preferably, at least one paper layer is made from paper having a basis weight of at least about 100 grams per square meter.

[0034] Preferably, the hollow tube segments are formed from paper layers, and the wall thickness of the hollow tube segments is at least about 100 micrometers. More preferably, the wall thickness of the hollow tube segments is at least about 200 micrometers. Alternatively, or additionally, the wall thickness of the hollow tube segments in these embodiments is less than about 300 micrometers. Preferably, the wall thickness of the hollow tube segments is less than about 270 micrometers. In some preferred embodiments, the wall thickness of the hollow tube segments is between about 100 micrometers and about 300 micrometers, with between 200 micrometers and 270 micrometers being preferred.

[0035] As noted above, when the upstream recess is defined by a hollow pipe segment, the length of the upstream recess may be significantly greater than when the upstream recess is defined by a plug wrap. For example, the upstream recess may be up to 30 millimeters long, or up to 25 millimeters long. This reduces the risk of collapse of the upstream recess due to the structural rigidity provided by the hollow pipe segment.

[0036] In such embodiments, the length of the upstream recess can be up to about 85 percent of the overall length of the mouthpiece, or up to about 70 percent of the overall length of the mouthpiece. Thus, the length of the upstream recess in these embodiments is preferably between about 15 percent and about 85 percent of the overall length of the mouthpiece.

[0037] The additive segment of the mouthpiece of the aerosol-generating article according to the present invention comprises a segment of filtering material housing one or more frangible capsules. The additive segment preferably has a length of at least about 8 millimeters, more preferably at least about 10 millimeters, and most preferably about 12 millimeters. The additive segment preferably has a length of less than about 16 millimeters, more preferably less than about 14 millimeters.

[0038] In some embodiments of the present invention, for example, when the upstream recess is defined by a plug wrap, the length of the additive segment may be greater than the length of the upstream recess, for example, the length of the additive segment may be at least about 1.5 times the length of the upstream recess, and more preferably at least twice the length of the upstream recess.

[0039] In other embodiments of the invention, for example, when the upstream recess is defined by a hollow tube segment, the length of the additive segment may be less than or substantially the same as the length of the upstream recess, for example, the length of the additive segment may be about 0.25 to about 1 times the length of the upstream recess.

[0040] The length of the additive segment preferably represents at least about 20 percent, and more preferably at least about 30 percent, of the total length of the mouthpiece, and preferably represents less than about 85 percent, and more preferably less than about 60 percent, of the total length of the mouthpiece.

[0041] The additive segment preferably comprises a plug of fibrous filtration material such as cellulose acetate tow or paper. The filter plasticizer may be applied to the fibrous filtration material in a conventional manner by spraying onto the separated fibers.

[0042] The additive segment may comprise a single frangible capsule. For example, in one preferred embodiment, the additive segment comprises a single frangible capsule within a plug of cellulose acetate tow. When a single frangible capsule is provided, the frangible capsule is preferably substantially spherical with a diameter of about 2 millimeters to about 5 millimeters. The single capsule is preferably provided approximately centrally along the length of the additive segment.

[0043] Alternatively, the additive segment may comprise a plurality of frangible capsules dispersed throughout the segment, which may all contain the same additive, or the frangible capsules may contain two or more different additives.

[0044] The additive contained in one or more frangible capsules may include at least one flavoring agent including at least one of menthol, linalool, thymol, eucalyptus, methyl salicylate, and combinations thereof. Additionally or alternatively, the at least one flavoring agent may include at least one of lemon oil, peppermint oil, parsley oil, mushroom extract, green tea extract, oolong tea extract, mugwort extract, apple extract, persimmon extract, ginger extract, and combinations thereof. Suitable flavoring agents are described in U.S. Patent No. 6,426,089 (B1).

[0045] The at least one flavoring agent may include a diluent, which may include at least one of palm oil and medium chain triglycerides.

[0046] Many natural flavors are available by extraction from natural sources or by chemical synthesis if the compound's structure is known. Flavors can be extracted from plant or animal parts by physical means, enzymes, or water or organic solvents, and therefore include any extracts, essences, hydrolysates, distillates, or anhydrous forms thereof. 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 flavoring sources include mints such as peppermint and spearmint, coffee, tea, cinnamon, cloves, ginger, cocoa, vanilla, chocolate, eucalyptus, geranium, agave, juniper, lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway. The term "mint" is used to refer to plants of the genus Mentha. Suitable types of mint leaves can be obtained from plant varieties including, but not limited to, peppermint, American mint, Egyptian mint, bergamot mint, spearmint, curly mint, Kentucky kernel mint, long-leaved mint, morning glory, apple mint, and pineapple mint.

[0047] The additive contained within the one or more frangible capsules may provide one or more sensory effects other than a taste sensation, such as a cooling or warming sensation, a tingling sensation, a numbing sensation, a buzz, increased salivation, a cough suppressant, and combinations thereof. These sensory effects may be provided by one or more flavoring agents, including those flavorings described above. Additionally, or in addition, the additive may include at least one non-flavoring material that provides one or more of these sensory effects without providing a taste sensation. For example, suitable compounds that produce a cooling effect and can be used as active ingredients include, but are not limited to, carboxamide compounds such as the Wilkinson-Sword (WS) compounds WS-3 (N-ethyl-p-menthane-3-carboxamide), WS-23 (2-isopropyl-N,2,3-trimethylbutyramide), WS-5 [ethyl 3-(p-menthane-3-carboxamide)acetate], WS-27 (N-ethyl-2,2-diisopropylbutanamide), WS-14 [N-([ethoxycarbonyl]methyl)-p-menthane-3-carboxamide], and WS-116 (N-(1,1-dimethyl-2-hydroxyethyl)-2,2-diethylbutanamide). A suitable compound that provides an antitussive effect is benzonatate.

[0048] Preferably, the one or more frangible capsules are provided at least about 2 millimeters, and more preferably at least about 4 millimeters, from the upstream end of the additive segment. This maximizes separation of the one or more capsules from the aerosol-generating substrate, which in turn maximizes reduction in the temperature and moisture content of the aerosol before it reaches the capsules. Furthermore, locating the one or more capsules away from the upstream end of the additive segment ensures that the additive, after being released from the one or more capsules, is dispersed throughout the additive segment and does not leak into the upstream cavity.

[0049] Preferably, the one or more frangible capsules in the additive segment are provided at least about 5 mm from the downstream end of the aerosol-generating substrate, more preferably at least about 8 mm from the downstream end of the aerosol-generating substrate, and most preferably at least about 10 mm from the downstream end of the aerosol-generating substrate. For example, the one or more frangible capsules in the additive segment may be provided at a distance of about 5 mm to about 12 mm from the downstream end of the aerosol-generating substrate.

[0050] The mouthpiece of an aerosol-generating article according to the present invention may comprise only an additive segment downstream of the upstream recess. Alternatively, the mouthpiece may further comprise a downstream segment of filtration material downstream of the additive segment. The downstream segment of filtration material is preferably in end-to-end abutting relationship with the additive segment.

[0051] If present, the downstream segment of the filtration material preferably includes one or more additional frangible capsules, which may be the same as or different from the one or more frangible capsules in the additive segment.

[0052] Alternatively, or in addition to providing one or more additional frangible capsules within the downstream segment of filtration material, the downstream segment of filtration material may optionally incorporate a downstream recess. The downstream recess preferably provides an oral end recess in the mouthpiece. If present, the recess may have a length of about 3 millimeters to about 8 millimeters, and most preferably has a length of about 5 millimeters.

[0053] The downstream segment of filtration material preferably has a length of at least about 8 millimeters, more preferably at least about 9 millimeters, and most preferably about 10 millimeters. The downstream segment preferably has a length of less than about 14 millimeters, and more preferably less than about 12 millimeters. The length of the downstream segment of filtration material may be approximately equal to the length of the additive segment. Alternatively, the additive segment may be at least about 1 millimeter or at least about 2 millimeters longer than the downstream segment of filtration material. Alternatively, the additive segment may be at least 1 millimeter shorter or at least 2 millimeters longer than the downstream segment of filtration material.

[0054] The downstream segment of filtration material may be formed of the same filtration material as the additive segment or a different filtration material. In one preferred embodiment, both the additive segment and the downstream segment of filtration material are formed of a plug of cellulose acetate tow.

[0055] The downstream segment of filtration material can be selected to provide the required resistance to draw (RTD). Preferably, the downstream segment of filtration material has an RTD of at least about 5 mm WG (water gauge). Preferably, the downstream segment of filtration material has an RTD of less than about 120 mm WG, and more preferably, an RTD of less than about 80 mm WG. RTD is measured in accordance with ISO 6565:2002.

[0056] The mouthpiece of the aerosol-generating article according to the present invention preferably further comprises one or more ventilation zones provided on the additive segment. The one or more ventilation zones are preferably provided upstream of one or more capsules within the additive segment. The provision of an upper ventilation zone introduces cool air into the aerosol upstream of the one or more capsules. This advantageously provides an additional cooling effect on the aerosol, further minimizing the impact of the aerosol on the friability of the outer shell. Furthermore, the air introduced into the mouthpiece through the one or more ventilation zones dilutes the aerosol, thereby reducing its water content. This further minimizes the impact of the aerosol on the outer shell.

[0057] Preferably, one or more ventilation zones are provided at least about 1 millimeter upstream of one or more capsules in the additive segment, and more preferably at least about 2 millimeters upstream of one or more capsules, to ensure that cool air is introduced into the mouthpiece sufficiently upstream of the one or more capsules to be entrained in the aerosol.

[0058] Preferably, one or more ventilation zones are provided at least about 2 millimeters from the upstream end of the additive segment, and more preferably at least about 3 millimeters from the upstream end of the additive segment.

[0059] The additive segment preferably has a level of breathability of from about 20 percent to about 80 percent as measured in accordance with ISO 9512:2002.

[0060] One or more ventilation zones may be provided by a circumferential row of perforations in the wrapper or wrappers surrounding the additive segment. For example, an online laser drilling process may be used to create the necessary ventilation zones in the wrapper.

[0061] As described above, instead of or in addition to one or more ventilation zones provided on the additive segment, the mouthpiece may include one or more ventilation zones provided on the upstream cavity. By providing one or more ventilation zones on the upstream cavity, air is introduced into the upstream cavity during smoking. This advantageously increases the turbulence of the aerosol within the upstream cavity, increasing the residence time of the aerosol within the cavity. As a result, it takes the aerosol more time to reach one or more frangible capsules within the additive segment.

[0062] As described above, the mouthpiece of the aerosol-generating article according to the present invention includes a wrapper surrounding the upstream cavity and the additive segment. The wrapper is preferably a plug wrap that surrounds the additive cavity and surrounds or defines the upstream cavity. As described above, the plug wrap defines the upstream cavity, and the plug wrap is preferably a stiff plug wrap having a relatively high basis weight, as described above. When a downstream segment of filtration material is provided downstream of the additive segment, the plug wrap preferably surrounds the downstream segment of filtration material to combine the mouthpiece components. Similarly, when one or more intermediate segments of filtration material are provided between the aerosol-generating substrate and the additive segment, the plug wrap preferably surrounds the intermediate segment of filtration material to combine all of the mouthpiece components.

[0063] Preferably, the wrapper does not extend around any portion of the aerosol-generating substrate. Preferably, the wrapper extends between the downstream end of the aerosol-generating substrate and the downstream end of the mouthpiece. Utilizing a wrapper that does not extend around any portion of the aerosol-generating substrate advantageously simplifies the construction of the aerosol-generating article by allowing the mouthpiece to be formed separately from the aerosol-generating substrate and then attached during manufacturing. Furthermore, utilizing a wrapper that does not extend around any portion of the aerosol-generating substrate allows the mouthpiece and aerosol-generating substrate to be constructed with the same outer diameter, thereby facilitating the connection of the mouthpiece and aerosol-generating substrate together (e.g., using a tipping wrapper).

[0064] To connect the mouthpiece to the aerosol-generating substrate, the aerosol-generating article according to the present invention may include a tipping wrapper surrounding the mouthpiece and at least a portion of the aerosol-generating substrate. The tipping wrapper may comprise paper having a basis weight of less than about 70 grams per cubic meter, preferably less than about 40 grams per cubic meter. Preferably, the tipping wrapper has a basis weight of more than about 20 grams per cubic meter.

[0065] The mouthpiece of the aerosol-generating article according to the present invention preferably has a total length, measured between the downstream end of the aerosol-generating substrate and the mouth end of the aerosol-generating article, of about 20 millimeters to about 35 millimeters. For example, the mouthpiece may have a total length of about 27 millimeters.

[0066] The aerosol-generating substrate of the aerosol-generating article according to the present invention preferably comprises a wrapped tobacco rod that can be combusted to form smoke. Alternatively, the aerosol-generating substrate may be a source of tobacco material, tobacco extract, or other nicotine source that can be heated to produce an aerosol without being combusted.

[0067] The aerosol-generating substrate may have a length of from about 45 millimeters to about 65 millimeters. For example, the aerosol-generating substrate may have a length of about 56 millimeters.

[0068] An aerosol-generating article according to the present invention may be a filter cigarette or other smoking article having an aerosol-generating substrate therein, the aerosol-generating substrate comprising tobacco material that is combusted to form smoke. Thus, in any of the above-described embodiments, the aerosol-generating substrate may comprise a tobacco rod.

[0069] Alternatively, an aerosol-generating article according to the present invention may be an article in which the tobacco material therein is heated rather than combusted to form an aerosol. In one type of heated aerosol-generating article, the tobacco material is heated by one or more electrical heating elements to generate the aerosol. In another type of heated aerosol-generating article, the aerosol is generated by transferring heat from a combustible or chemical heat source to physically separated tobacco material (which may be located within, around, or downstream from the heat source). The present invention further encompasses aerosol-generating articles in which a nicotine-containing aerosol is generated from tobacco material, tobacco extract, or other nicotine source without combustion, and in some cases without heating, for example, by a chemical reaction.

[0070] The aerosol-generating article may have an overall length, measured between the upstream end of the aerosol-generating article and the mouth end of the aerosol-generating article, of between about 40 millimeters and about 90 millimeters. For example, the aerosol-generating article may have an overall length of about 83 millimeters.

[0071] The aerosol-generating article may have an outer diameter of about 4 millimeters to about 9 millimeters (including any tipping wrapper that may be present). For example, the aerosol-generating article may have an outer diameter of about 7.8 millimeters. In other preferred embodiments, the aerosol-generating article may have a diameter of less than about 7.1 millimeters, or less than about 6 millimeters. The present invention finds particular application in mouthpieces for "thin" or "slim" aerosol-generating articles having a diameter of less than about 7.1 millimeters. In such aerosol-generating articles, degradation of the capsule within the mouthpiece as a result of contact with aerosols during use can be particularly problematic.

[0072] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which: [Brief explanation of the drawings]

[0073] [Figure 1] FIG. 1 shows a perspective view of an aerosol-generating article according to the present invention.

[0074] [Figure 2] FIG. 2 shows a longitudinal cross-section of the aerosol-generating article of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0075] 1 and 2 illustrate an aerosol-generating article 10 according to the present invention. The aerosol-generating article 10 comprises a wrapped rod 12 of tobacco cut filler attached at one end to an axially aligned mouthpiece 14. A strip 16 of tipping paper surrounds the mouthpiece 14 and a portion of the wrapped rod 12, holding the two components of the aerosol-generating article 10 together.

[0076] As shown in Figure 2, mouthpiece 14 includes a first filter segment 18 and a second filter segment 20. First filter segment 18 is provided at the oral end of mouthpiece 14 and includes a wrapped plug of cellulose acetate tow containing a centrally located capsule 22. First filter segment 18 has a length of 10 millimeters. Second filter segment 20 is provided upstream of first filter segment 18, with the downstream end of second filter segment 20 abutting the upstream end of first filter segment 18. Second filter segment 20 includes a wrapped plug of cellulose acetate tow containing a centrally located capsule 24.

[0077] Each of the capsules 22, 24 includes an inner core of flavor additive and a frangible outer shell.

[0078] 2, the second filter segment 20 is longitudinally spaced from the wrapped tobacco rod 12, and an upstream recess 26 is provided between the second filter segment 20 and the wrapped tobacco rod 12. The upstream recess 26 is unfilled and has a length of 5 millimeters.

[0079] The upstream recess 26 is defined by a combined plug wrap 28 that surrounds the first filter segment 18 and the second filter segment 20 and extends 5 millimeters upstream of the second filter segment 20. Thus, the combined plug wrap 28 does not extend onto the wrapped tobacco rod 12. As shown in FIG. 2 , the tipping wrap 16 lies over the combined plug wrap 28 and connects the mouthpiece 14 and the wrapped tobacco rod 12.

[0080] The combined plug wrap 28 is formed from a sheet of paper material having a basis weight of at least 70 grams per square meter so that the combined plug wrap 28 has a relatively high stiffness.

[0081] The aerosol-generating article 10 further comprises a ventilation zone 30 at a location along the second filter segment 20, upstream of the capsule 24. The ventilation zone 30 comprises an array of perforations extending through the tipping wrap 16 and the combined plug wrap 28.

[0082] During smoking of the aerosol-generating article 10, mainstream smoke generated from the tobacco in the wrapped rod 12 passes through the second filter segment 20 and into the upstream recess 26 before contacting the capsule 24. The smoke continues downstream and passes through the first filter segment 18, which is in contact with the capsule 22. As the mainstream smoke passes through the upstream recess 26, it cools, thereby minimizing the impact of the mainstream smoke on the capsules 22, 24. The capsules 22, 24 retain their crushability during smoking and can still be broken by the consumer after smoking, producing an audible sound.

Claims

1. An aerosol-generating article comprising: an aerosol-generating substrate; a mouthpiece axially aligned with the aerosol-generating substrate, the mouthpiece comprising an additive segment of filtration material including one or more frangible capsules, each frangible capsule comprising an outer shell and an inner core containing an additive, the additive segment of filtration material defining an upstream recess between the aerosol-generating substrate and the additive segment of filtration material, downstream from the aerosol-generating substrate via a gap, the upstream recess being substantially unfilled; a wrapper surrounding the additive segment of the filtration material and the upstream recess.

2. 2. The aerosol-generating article of claim 1, wherein the upstream recess has a length of at least 3 millimeters.

3. 3. The aerosol-generating article of claim 1, wherein the wrapper is a plug wrap and the upstream recess is defined by the plug wrap.

4. 4. The aerosol-generating article of claim 3, wherein the plug wrap is formed from a sheet material having a basis weight of at least 50 grams per square meter.

5. 5. The aerosol-generating article of claim 3, wherein the length of the upstream recess corresponds to 25 percent or less of the overall length of the mouthpiece.

6. 3. The aerosol-generating article of claim 1, wherein the mouthpiece includes a hollow tube segment between the segment of first filtration material and the aerosol-generating substrate, the hollow tube segment defining the upstream recess.

7. 7. The aerosol-generating article of claim 6, wherein the length of the upstream recess defined by the hollow tube segment is at most 30 millimeters.

8. 8. An aerosol-generating article according to claim 1, wherein the upstream recess extends from the downstream end of the aerosol-generating substrate to the upstream end of the additive segment.

9. 9. The aerosol-generating article of claim 1, wherein the mouthpiece further comprises a downstream segment of filtration material downstream of the additive segment.

10. 10. The aerosol-generating article of claim 9, wherein the downstream segment of the filtration material comprises one or more additional frangible capsules, each additional frangible capsule comprising an outer shell and an inner core containing an additive.

11. 11. The aerosol-generating article of claim 1, wherein the mouthpiece comprises one or more ventilation zones around the additive segment of the filtration material.

12. 12. The aerosol-generating article of claim 11, wherein the one or more ventilation zones are provided upstream of the one or more frangible capsules within the additive segment of the filtration material.

13. 13. The aerosol-generating article of claim 12, wherein the one or more ventilation zones are provided at least 2 millimeters upstream of the one or more frangible capsules within the additive segment of the filtration material.

14. 14. An aerosol-generating article according to any preceding claim, wherein the additive segment of the filtration material comprises a single frangible capsule having a maximum width of between 2 millimeters and 5 millimeters.

15. 15. The aerosol-generating article of any one of claims 1 to 14, wherein the aerosol-generating substrate is a tobacco rod, and the aerosol-generating article further comprises a tipping wrapper securing the mouthpiece in axial alignment with the tobacco rod.

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