Aerosol-generating items

Abstract

An aerosol-forming substrate is provided that includes an elongated susceptor. The aerosol-generating article (10) comprises a plurality of elements assembled in the form of a rod having an oral end (70) and a distal end (80) upstream from the oral end. The plurality of elements comprises an aerosol-forming substrate (20) having an elongated susceptor (25) longitudinally disposed within the aerosol-forming substrate. A plug element (90) is located within the rod upstream of and adjacent to the aerosol-forming substrate. The plug element (90) thereby prevents direct physical contact with the distal end of the elongated susceptor (25) longitudinally disposed within the aerosol-forming substrate (20).

Description

[Technical Field]

[0001] The present invention relates to an aerosol-generating article comprising an aerosol-forming substrate and an elongated susceptor disposed within the aerosol-forming substrate. In particular, the present invention relates to an inductively heatable aerosol-generating article. [Background technology]

[0002] Inductively heatable aerosol-generating articles comprising an aerosol-forming substrate and an elongated susceptor disposed within the aerosol-forming substrate are known from the prior art. For example, International Patent Publication WO 2015 / 176898 discloses an aerosol-generating article having an elongated susceptor disposed within an aerosol-forming substrate plug. The aerosol-generating article comprises a plurality of rod-shaped elements and is adapted for use in an electrically operated aerosol generating device comprising an inductor for generating heat within the elongated susceptor. The location of the elongated susceptor may depend on the manufacturing method of the aerosol-forming substrate comprising the susceptor. However, the elongated susceptor typically extends at least to the distal end of the aerosol-forming substrate plug. This exposed location of at least the end of the susceptor may alter the consistency of the article, as the susceptor's position may change during handling or transport of the article.

[0003] Therefore, it would be desirable to have an aerosol-generating article that includes an aerosol-forming substrate and an elongated susceptor disposed within the aerosol-forming substrate that improves the consistency of the article. Summary of the Invention

[0004] According to the present invention, there is provided an aerosol-generating article comprising a plurality of elements assembled in the form of a rod having an oral end and a distal end upstream from the oral end. The plurality of elements comprises an aerosol-forming substrate having an elongated susceptor longitudinally disposed within the aerosol-forming substrate. A plug element is located within the rod upstream of and adjacent to the aerosol-forming substrate. The plug element prevents direct physical contact with the distal end of the elongated susceptor longitudinally disposed within the aerosol-forming substrate.

[0005] The plug element prevents direct contact with the distal end of the susceptor, and thus can prevent displacement or deformation of the susceptor during handling or transport of the article. Susceptors, which are typically metal components and relatively heavy, tend to fall off the aerosol-forming substrate as the article is transported. Therefore, the plug element also prevents the susceptor from falling off the aerosol-generating article, for example, if the susceptor becomes dislodged during transport of the article. A further advantage of the plug element protecting the distal end of the aerosol-forming substrate can be for aesthetic or branding reasons. The plug element can be used to cover the distal end of the article, which can provide a visually appealing appearance to the distal end of the article. It can also provide information on the article, such as the brand, contents, flavor, or electronically operated devices used with the article.

[0006] The plug element can fix the shape and position of the susceptor within the aerosol-forming substrate, thus improving or ensuring consistency from article to article. In addition, the plug element may also preferably improve the aesthetic appearance of the article and provide an easy way to provide further information about the article to the user.

[0007] As used herein, the terms "upstream" and "downstream" are used to describe the relative positions of elements or portions of elements of an aerosol-generating article in relation to the direction in which a user draws on the aerosol-generating article during use. The aerosol-generating article is in the form of a rod that includes two ends: an oral end (i.e., the proximal end, through which the aerosol exits the aerosol-generating article and is delivered to the user) and a distal end. In use, a user can draw on the oral end. The distal end may also be referred to as the upstream end and is upstream of the oral end.

[0008] The aerosol-generating article is preferably a smoking article that generates an aerosol.More preferably, the aerosol-generating article is a smoking article that generates a nicotine-containing aerosol.

[0009] The plug element may be a porous element. Preferably, a porous plug element does not alter the withdrawal resistance of the aerosol-generating article. Preferably, the plug element has a porosity of at least 50 percent along the longitudinal axis of the rod. Preferably, the plug element has a porosity of between 50 percent and 90 percent. The porosity of the plug element along its longitudinal axis is defined as the ratio of the cross-sectional area of ​​the material forming the plug element to the internal cross-sectional area of ​​the aerosol-generating article at the location of the plug element. This definition of porosity also applies, as appropriate, to any other element of the aerosol-generating article.

[0010] The plug element may be made of a porous material or may include a plurality of openings, which may be achieved, for example, by laser drilling.

[0011] The permeability of the plug element may allow the user to draw air through the rod via the plug element.

[0012] Preferably, the plurality of openings are uniformly distributed across the cross section of the plug element.

[0013] The size of the openings of the plurality of openings is preferably such that the distal end of the aerosol-forming substrate cannot be seen from above.

[0014] The porosity or permeability of the plug element may be varied to accommodate control of the resistance to withdrawal through the aerosol-generating article.

[0015] The resistance to withdrawal (RTD) of the plug element may be between 20 mmWG and 40 mmWG, preferably between 25 mmWG and 35 mmWG (millimeter water gauge). Preferably, the RTD of the plug element does not exceed 30 mmWG. Preferably, the resistance to withdrawal (RTD) of the plug element is between 1 and 5 mmWG per millimeter of plug element length, for example 2.5 mmWG per millimeter of plug element length. The plug element may have the same RTD as an element made of an aerosol-forming substrate comprising an elongated susceptor.

[0016] Alternatively, the plug element may be airtight and formed of a material that is impermeable to air. In such an embodiment, the article may be configured so that air flows into the rod through the sidewall, for example, through holes defined in the cigarette paper or wrapper material.

[0017] The plug element can be made of any material suitable for use in an aerosol-generating article for an inductively heatable aerosol-generating device. For example, the plug element can be made of the same material as used in the article, such as a conventional mouthpiece filter, an aerosol cooling element, or a support element. Exemplary materials are filter material, ceramic, polymeric material, cellulose acetate, cardboard, a non-inductively heatable metal, zeolite, or an aerosol-forming substrate.

[0018] The plug element is preferably made of a heat-resistant material, which in this context means that the plug element can withstand temperatures up to about 350° C., thereby ensuring that the plug element is preferably not affected by the heated susceptor or the heated aerosol-forming substrate.

[0019] Preferably, the plug element does not change its consistency, geometry or optical properties upon use of the article.

[0020] Preferably, during use of the article the plug element does not generate additional material to the generated aerosol.

[0021] The plug element has a diameter approximately equal to the diameter of the aerosol-generating article. Preferably, the plug element has a diameter of 5 mm to 10 mm. Preferably, the diameter of the plug is greater than 5 mm, for example, 6 mm to 8 mm. The plug element has a length that can be defined as the dimension along the longitudinal axis of the aerosol-generating article. The length of the plug element can be 1 mm to 10 mm, for example, 4 mm to 8 mm or 5 mm to 7 mm. Preferably, the plug element is substantially cylindrical. Preferably, the plug element is smaller than 8 mm. Preferably, the plug element has a length of at least 2 mm, preferably at least 3 mm, or at least 5 mm, to facilitate assembly of the aerosol-generating article.

[0022] In principle, whenever a value is stated throughout this specification, it is understood that the value is expressly disclosed, but it is also understood that the value may not be strictly a particular value due to technical considerations.

[0023] The plug elements may be separate elements. The above-mentioned minimum size for the length of the plug elements facilitates or enables the use of conventional combiners to assemble multiple elements into a rod shape.

[0024] The plug element may have a homogeneous structure. The plug element may be homogeneous, for example, in texture and appearance. The plug element may have, for example, a continuous, regular surface across its cross-section, or may have no discernible symmetry, for example. Preferably, at least the distal end of the plug element has a homogeneous structure. A homogeneous distal end of the plug element favors consistency of the plug element across the cross-section of the article.

[0025] The plug element may have an inner surface defining a recess, preferably located at least at the proximal end of the plug element. The recess is oriented toward the aerosol-forming substrate. The recess is positioned within the plug element such that the plug element does not contact, or only contacts over a limited area, an elongated susceptor disposed within the aerosol-forming substrate. The recess may be positioned centrally within the plug element such that a central portion of the proximal end of the plug element does not contact the elongated susceptor. The inner surface of the recess may have, for example, a concave shape, e.g., a dome-shaped shape. The diameter of the recess in the radial direction of the rod is preferably greater than the radial extension of the elongated susceptor.

[0026] Providing a recess in the plug element so that it does not physically contact the susceptor, and generally limiting the contact area between the plug element and the aerosol-forming substrate, may prevent excessive heating of the plug element (particularly those portions of the plug element that contact the susceptor), thereby reducing the risk of overheating or charring of the plug element and may also broaden the choice of materials suitable for manufacturing the plug element.

[0027] The aerosol-forming substrate may be a solid aerosol-forming substrate. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavor compounds that are released from the substrate upon heating. Alternatively, the aerosol-forming substrate may comprise a non-tobacco material. The aerosol-forming substrate may further comprise an aerosol former. Examples of suitable aerosol formers are glycerin and propylene glycol.

[0028] When the aerosol-forming substrate is a solid aerosol-forming substrate, the solid aerosol-forming substrate may comprise, for example, one or more of powder, granules, pellets, shreds, spaghetti strands, strips, or sheets, including one or more of herb leaves, tobacco leaves, tobacco stem fragments, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco. The solid aerosol-forming substrate may be in a loose form, or may be provided with a suitable container or cartridge. For example, the aerosol-forming material of the solid aerosol-forming substrate may be contained within a paper or other wrapper and have the form of a plug. When the aerosol-forming substrate is in the form of a wrapped plug, the entire plug, including any wrapper, is considered to be the aerosol-forming substrate.

[0029] Optionally, the solid aerosol-forming substrate may contain additional tobacco or non-tobacco volatile flavor compounds that are released upon heating of the solid aerosol-forming substrate. The solid aerosol-forming substrate may also contain capsules, for example containing additional tobacco or non-tobacco volatile flavor compounds, which may dissolve during heating of the solid aerosol-forming substrate.

[0030] The aerosol-forming substrate may comprise one or more sheets of homogenized tobacco material collected into a rod, surrounded by a wrapper, and cut to provide individual plugs of aerosol-forming substrate. Preferably, the aerosol-forming substrate comprises an aggregate of crimped sheets of homogenized tobacco material.

[0031] The aerosol-forming tobacco substrate is preferably a crimped tobacco sheet comprising tobacco material, fiber, binder, and aerosol former. The tobacco sheet is preferably a cast leaf. Cast leaf is a form of reconstituted tobacco formed from a slurry containing tobacco particles, fiber particles, aerosol former, binder, and, for example, flavors.

[0032] The wrapper may be any non-tobacco material suitable for encasing the elements of the aerosol-generating article in the form of a rod, and the wrapper holds the elements within the aerosol-generating article when the article is assembled into a rod.

[0033] The aerosol-forming substrate may be substantially cylindrical in shape. The aerosol-forming substrate may be substantially elongated. The aerosol-forming substrate may also have a length and a circumference substantially perpendicular to the length.

[0034] Furthermore, the length of the aerosol-forming substrate may be 10 millimeters. Alternatively, the length of the aerosol-forming substrate may be 12 millimeters. Furthermore, the diameter of the aerosol-forming substrate may be between 5 millimeters and 12 millimeters.

[0035] As used herein, the term "susceptor" refers to a material capable of converting electromagnetic energy into heat. When placed in a fluctuating electromagnetic field, eddy currents induced within the susceptor cause the susceptor to heat. The elongated susceptor is in thermal contact with the aerosol-forming substrate, causing the aerosol-forming substrate to be heated by the susceptor. The susceptor has a length dimension that is greater than its width or thickness, e.g., a length dimension that is twice its width or thickness. Thus, the susceptor may be described as an elongated susceptor. The susceptor is substantially longitudinally aligned within the rod. This means that the length dimension of the elongated susceptor is approximately parallel to the longitudinal axis of the rod, e.g., within ±10 degrees of parallel to the longitudinal axis of the rod. In a preferred embodiment, the elongated susceptor may be positioned radially centrally within the rod and extend along the longitudinal axis of the rod.

[0036] The susceptor is preferably in the form of a pin, rod, strip, or blade. The susceptor preferably has a length of 5 to 15 mm, e.g., 6 to 12 mm, or 8 to 10 mm. The susceptor preferably has a width of 1 to 5 mm and a thickness of 0.01 to 2 mm, e.g., 0.5 to 2 mm. In a preferred embodiment, the susceptor may have a thickness of 10 to 500 micrometers, more preferably 10 to 100 micrometers. When the susceptor has a constant cross-section, e.g., a circular cross-section, it preferably has a width or diameter of 1 to 5 mm. When the susceptor is in the form of a strip or blade, the width of the strip or blade is preferably 2 to 8 mm, more preferably 3 to 5 mm, e.g., 4 mm, and the thickness is preferably 0.03 to 0.15 mm, more preferably 0.05 to 0.09 mm, e.g., 0.07 mm, and is preferably rectangular.

[0037] The elongated susceptor preferably has a length that is the same as or shorter than the length of the aerosol-forming substrate.The elongated susceptor preferably has the same length as the aerosol-forming substrate.

[0038] The susceptor can be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming substrate. Preferred susceptors include metal or carbon. Preferred susceptors can include or consist of a ferromagnetic material, such as a ferromagnetic alloy, ferritic iron, or ferromagnetic steel or stainless steel. Suitable susceptors can be aluminum or include aluminum. Preferred susceptors can 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 having similar values ​​of frequency and field strength. Thus, any of the susceptor parameters, such as material type, length, width, and thickness, can be varied to provide a desired power distribution within a known electromagnetic field.

[0039] Preferred susceptors may be heated to temperatures in excess of 250°C. Suitable susceptors may include a non-metallic core having disposed thereon a metallic layer, e.g., a metal band formed on the surface of the ceramic core. The susceptor may have a protective outer layer, e.g., a protective ceramic layer or a protective glass layer, encapsulating the susceptor. The susceptor may include a protective coating formed of glass, ceramic, or an inert metal formed over a core of susceptor material.

[0040] The susceptor is arranged in thermal contact with the aerosol-forming substrate, such that as the temperature of the susceptor increases, the aerosol-forming substrate is heated and an aerosol is formed. Preferably, the susceptor is arranged in direct physical contact with the aerosol-forming substrate, for example, within the aerosol-forming substrate.

[0041] The susceptor may be a multi-material susceptor and may include a first susceptor material and a second susceptor material. The first susceptor material is laminated in close physical contact with the second susceptor material. The second susceptor material preferably has a Curie temperature below 500°C. The first susceptor material is preferably primarily used to heat the susceptor when it is placed in an oscillating electromagnetic field. Any suitable material may be used. For example, the first susceptor material may be aluminum or a ferrous material such as stainless steel. The second susceptor material is preferably primarily used to indicate when the susceptor has reached a specific temperature (the Curie temperature of the second susceptor material). The Curie temperature of the second susceptor material can be used to regulate the temperature of the entire susceptor during operation. Therefore, the Curie temperature of the second susceptor material must be below the ignition point of the aerosol-forming substrate. Suitable materials for the second susceptor material may include nickel and certain nickel alloys.

[0042] The heating of the aerosol-forming substrate and the temperature control of the heating can be separated by providing a susceptor having at least first and second susceptor materials, with the first susceptor material having no Curie temperature and the second susceptor material having a Curie temperature, or by providing first and second susceptor materials having different Curie temperatures. The first susceptor material is preferably a magnetic material having a Curie temperature greater than 500°C. From the standpoint of heating efficiency, it is desirable that the Curie temperature of the first susceptor material exceed any maximum temperature to which the susceptor can be heated. The second Curie temperature can be selected to be lower than 400°C, preferably lower than 380°C, or even lower than 360°C. The second susceptor material is preferably a magnetic material selected to have a second Curie temperature substantially equal to the desired maximum heating temperature. That is, the second Curie temperature is preferably approximately equal to the temperature to which the susceptor must be heated to generate an aerosol from the aerosol-forming substrate. The second Curie temperature may be, for example, in the range of 200° C. to 400° C., or 250° C. to 360° C. The second Curie temperature of the second susceptor material may be selected such that the overall average temperature of the aerosol-forming substrate does not exceed 240° C. when heated by a susceptor having a temperature equal to the second Curie temperature, for example.

[0043] The aerosol-generating article may be substantially cylindrical in shape. The aerosol-generating article may be substantially elongated. The aerosol-generating article may also have a length and a circumference that are substantially perpendicular to the length.

[0044] The overall length of the aerosol-generating article may be between 30 mm and 100 mm. In a preferred embodiment, the overall length of the aerosol-generating article is between 40 mm and 55 mm, for example between 47 and 53 mm.

[0045] The outer diameter of the aerosol-generating article may be between 5 mm and 12 mm, for example between 6 mm and 8 mm. In one preferred embodiment, the aerosol-generating article has an outer diameter of 7.2 mm ± 10 percent.

[0046] The aerosol-generating article may comprise a mouthpiece element, which may be located at the mouth end or downstream end of the aerosol-generating article.

[0047] The mouthpiece element may include at least one filter segment. The filter segment may be a cellulose acetate filter plug made of cellulose acetate tow. The filter segment may have low or very low particle filtration efficiency. The filter segment may be longitudinally spaced from the aerosol-forming substrate. The filter segment is 7 millimeters long in one embodiment, but may have a length between 5 millimeters and 14 millimeters.

[0048] The mouthpiece element is the downstream final portion of the aerosol-generating article that the user contacts to direct the aerosol generated by the aerosol-generating article through the mouthpiece element to the user, thus positioning the mouthpiece element downstream of the aerosol-forming substrate.

[0049] Preferably, the mouthpiece element has an outer diameter approximately equal to the outer diameter of the aerosol-generating article. The mouthpiece element may have an outer diameter of 5 millimeters to 10 millimeters, for example, 6 millimeters to 8 millimeters. In a preferred embodiment, the mouthpiece element has an outer diameter of 7.2 mm ± 10 percent. The mouthpiece element may have a length of 5 millimeters to 25 millimeters, preferably a length of 10 millimeters to 17 millimeters. In a preferred embodiment, the mouthpiece element has a length of 12 mm to 14 mm. In a preferred embodiment, the mouthpiece element has a length of 7 mm.

[0050] The aerosol-generating article may be located immediately downstream of the aerosol-forming substrate and may comprise a support element which may be adjacent to the aerosol-forming substrate.

[0051] The support element may be formed from any suitable material or combination of materials. For example, the support element may be formed from one or more materials selected from the group consisting of cellulose acetate, cardboard, crimped paper (such as crimped heat-resistant paper or crimped parchment paper), and polymeric materials (such as low-density polyethylene (LDPE)). In a preferred embodiment, the support element is formed from cellulose acetate.

[0052] The support element may comprise a hollow tubular element. In a preferred embodiment, the support element comprises a hollow cellulose acetate tube.

[0053] Preferably, the support element has an outer diameter approximately equal to the outer diameter of the aerosol-generating article.

[0054] The support element can have an outer diameter of 5 millimeters to 12 millimeters, for example, 5 mm to 10 mm or 6 mm to 8 mm. In a preferred embodiment, the support element has an outer diameter of 7.2 mm ±10 percent. The support element can have a length of 5 millimeters to 15 millimeters. In a preferred embodiment, the support element has a length of 8 mm.

[0055] The aerosol-generating article may comprise an aerosol-cooling element. The aerosol-cooling element may be located downstream of the aerosol-forming substrate, for example the aerosol-cooling element may be located immediately downstream of and adjacent to the support element.

[0056] The aerosol cooling element may be located between the support element and a mouthpiece element located at the extreme downstream end of the aerosol-generating article.

[0057] As used herein, the term "aerosol cooling element" is used to describe an element having a large surface area and low draw resistance. In use, an aerosol formed by volatile compounds released from an aerosol-forming substrate is drawn through the aerosol cooling element before being conveyed to the mouth end of the aerosol-generating article. In contrast to filters with high draw resistance (e.g., filters formed from fiber bundles), aerosol cooling elements have low draw resistance. Chambers and recesses within the aerosol-generating article, such as expansion chambers and support elements, are also not considered to be aerosol cooling elements.

[0058] The aerosol cooling element preferably has a longitudinal porosity of greater than 50 percent. The airflow path through the aerosol cooling element is preferably relatively unrestricted. The aerosol cooling element may be a sheet assembly or a crimped sheet assembly. The aerosol cooling element may comprise a sheet material selected from the group consisting of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), and aluminum foil, or any combination thereof.

[0059] In a preferred embodiment, the aerosol cooling element comprises an assembly of sheets of biodegradable material, for example, an assembly of sheets of non-porous paper or a biodegradable polymeric material such as polylactic acid or Mater-Bi® grades (a commercially available family of starch-based copolyesters).

[0060] The aerosol cooling element preferably comprises an assembly of PLA sheets, more preferably an assembly of crimped PLA sheets. The aerosol cooling element may be formed from a sheet having a thickness of 10 micrometers to 250 micrometers (e.g., 50 micrometers). The aerosol cooling element may be formed from a sheet having a width of 150 millimeters to 250 millimeters. The aerosol cooling element may have a specific surface area of ​​300 square millimeters to 1000 square millimeters per millimeter of length and 10 square millimeters to 100 square millimeters per millimeter of weight. In some embodiments, the aerosol cooling element may be formed from a sheet of material having a specific surface area of ​​about 35 square millimeters per millimeter of weight. The aerosol cooling element may have an outer diameter of 5 millimeters to 10 millimeters, e.g., 7 millimeters.

[0061] In some preferred embodiments, the length of the aerosol cooling element is between 10 and 15 millimeters. Preferably, the length of the aerosol cooling element is between 10 and 14 millimeters, for example 13 millimeters.

[0062] In an alternative embodiment, the length of the aerosol cooling element is between 15 mm and 25 mm. Preferably, the length of the aerosol cooling element is between 16 mm and 20 mm, for example 18 mm.

[0063] As the aerosol passes through the aerosol cooling element, its temperature decreases due to the transfer of thermal energy to the aerosol cooling element. Additionally, water droplets condensing from the aerosol may adsorb onto the material of the aerosol cooling element. Depending on the type of material forming the aerosol cooling element, the water content of the aerosol may be reduced by 0 to 90 percent. For example, when the aerosol cooling element contains polylactic acid, the water content is not significantly reduced. For example, when a starch-based material (e.g., Mater-Bi) is used to form the aerosol cooling element, the water reduction may be approximately 40 percent. Therefore, the water content in the aerosol can be determined by the material selected for the aerosol cooling element.

[0064] For example, aerosols formed by heating tobacco-derived aerosol-forming substrates typically contain phenolic compounds. Aerosol cooling elements can reduce phenol and cresol levels by 90 to 95 percent.

[0065] Generally available electronic heating devices are designed to use aerosol-generating articles of predetermined dimensions, particularly predetermined standard lengths. To enable an aerosol-generating article to be used with these standard heating devices, the overall length of the aerosol-generating article should be a standard length. Typically, this standard length is 45 millimeters. Furthermore, it is preferable that the dimensions and arrangement of the aerosol-forming substrate contained within the aerosol-generating article and heated by the heating element of the heating device remain unchanged.

[0066] Therefore, when a plug element is added to an aerosol-generating device, the length of the article is increased by the length of the plug element. Therefore, the length of the plug element should not exceed 8 mm so that the overall length of the aerosol-generating article is not excessively extended. Preferably, an aerosol-generating article having a standard length of 45 mm will have a length of 47 mm to 53 mm when provided with a plug element.

[0067] However, the length of the article may be kept constant by compensating for the added length of the plug element through shortening of another element or segment of the article (preferably the aerosol cooling element), provided that doing so preferably does not change the properties of the article.

[0068] Experiments have shown that aerosol cooling elements having lengths shorter than the standard 18 millimeter aerosol cooling element can achieve the desired aerosol cooling or phenolic compound reduction in a standard length aerosol-generating article. In particular, comparable cooling or different smoke chemistry has been found for shorter aerosol cooling elements made of polylactic acid.

[0069] Thus, the additional length of the plug element is compensated for by a shortening of the aerosol cooling element. The shortening of the aerosol cooling element, or a further shortening of the aerosol cooling element, can also be achieved by providing a hollow tube.

[0070] Some materials used in aerosol-generating articles are also more cost-sensitive than others. For example, materials used in aerosol cooling elements, particularly crimped polylactic acid sheets, are expensive. Thus, in aerosol-generating articles, the length of the aerosol cooling element may be reduced compared to such elements in standard aerosol-generating articles for electronic devices. Typically, the standard length of an aerosol cooling element is 18 millimeters. To maintain the overall length of the aerosol-generating article at a predetermined length (e.g., 45 millimeters), the length of the mouthpiece element may be increased to compensate for the shorter length of the aerosol cooling element.

[0071] It has been surprisingly found that the aerosol cooling element can be shortened to a certain extent without adversely affecting the chemistry of the smoke. It has also been surprisingly found that this can be done without changing the transport of smoke constituents through the mouthpiece if the difference in length is compensated for within the mouthpiece. In particular, when a hollow tube is used to compensate for the overall length, no change in smoke constituents due to the mouthpiece has been detected. It has been found that shortening the aerosol cooling element by just a few millimeters can result in significant cost savings. Preferably, the extension of the mouthpiece is achieved by providing a hollow tube. A hollow tube (e.g., a cardboard tube) can be manufactured at very low cost, and as a result, cost savings can be achieved by partially "replacing" the aerosol cooling element in the tobacco portion of the aerosol-generating article with a hollow tube in the mouthpiece portion of the aerosol-generating article.

[0072] Thus, the mouthpiece element may comprise a hollow tube.

[0073] When present, the hollow tube is preferably located at the downstream end of the mouthpiece element, and thus the downstream end of the aerosol-generating article, thereby imparting the effect of a recessed filter to the aerosol-generating article, thereby providing a customer with a tactile sensation when using an electronic smoking system that is equivalent to the tactile sensation provided by a recessed filter when smoking a conventional cigarette.

[0074] The hollow tube of the mouthpiece element may be made of cardboard. The hollow tube may also be made of a different material (e.g., paper or thin plastic sheet material). Preferably, the hollow tube has stability that allows for handling of the aerosol-generating article.

[0075] The length of the hollow tube may be between 3 mm and 8 mm, and preferably is 5 mm.

[0076] The lengths of the hollow tubes described above, particularly cardboard tube lengths, have been found to allow for good manufacturing of the tubes and good handling of the tubes during assembly of the mouthpiece element and the aerosol-generating article.

[0077] The wall thickness of the hollow tube is preferably 100 micrometers to 300 micrometers, for example 200 micrometers. When inserting the aerosol-generating article into the electronic heating device, the consumer typically holds the aerosol-generating article by its proximal end or pushes the aerosol-generating article by its proximal end. The hollow tube is preferably the most proximal segment of the aerosol-generating article, and thus the aerosol-generating article is typically pushed by the hollow tube. The above-mentioned wall thicknesses have been found to meet the stability requirements for hollow tubes, particularly cardboard tubes, when the aerosol-generating article is inserted into the electronic heating device.

[0078] The aerosol-generating article according to the present invention preferably comprises a plug element, an aerosol-forming substrate including a susceptor, a support element, an aerosol-cooling element, and a mouthpiece element. The mouthpiece element comprises at least one filter element and may optionally comprise a hollow tube. In such an aerosol-generating article, the support element is disposed downstream of the aerosol-forming substrate, and the aerosol-cooling element is disposed downstream of the support element.

[0079] In an aerosol-generating article according to the present invention, comprising a mouthpiece element comprising a filter segment and a hollow tube, the hollow tube is preferably located at the distal end of the rod. The mouthpiece element can be extended in length, particularly by adding or extending the hollow tube, to compensate for the shortened length of the aerosol cooling element so that the overall length of the aerosol-generating article remains the predetermined overall length. Preferably, the overall length of the article is 45 millimeters, and the length of the tobacco element aerosol cooling element is at most 15 millimeters. The length of the mouthpiece element, preferably the length of the hollow tube, is adapted according to the length of the aerosol cooling element so that the overall length of the aerosol-generating article remains the predetermined overall length.

[0080] The possibility of having a shortened aerosol cooling element, the supplementation of such a shortened aerosol cooling element by providing an additional hollow tube in the mouthpiece element, its advantages and specific features are described in detail in European Patent Application No. 15173224.5, the contents of which, with respect to the aforementioned supplementation of length, are incorporated herein by reference.

[0081] Preferably, the aerosol-generating article comprises five to six elements or segments.

[0082] The elements of the aerosol-forming article, such as the aerosol-forming substrate, the plug element, and any other elements of the aerosol-generating article (such as the support element, the aerosol cooling element, and the mouthpiece element), are surrounded by an outer wrapper. The outer wrapper may be formed from any suitable material or combination of materials. The outer wrapper is preferably cigarette paper.

[0083] The invention will be further described with reference to embodiments, which are illustrated by the following drawings, in which: [Brief explanation of the drawings]

[0084] [Figure 1] FIG. 1 is a schematic cross-sectional view of an embodiment of an aerosol-generating article with a plug element. [Figure 2] FIG. 2 is a schematic cross-sectional view of another embodiment of an aerosol-generating article with a recessed filter. [Figure 3] FIG. 3 shows a close-up of the recessed plug element. [Figure 4] FIG. 4 shows another embodiment of a plug element. DETAILED DESCRIPTION OF THE INVENTION

[0085] FIG. 1 illustrates an aerosol-generating article 10. The aerosol-generating article 10 includes five coaxially aligned elements: a plug element 90, an aerosol-forming substrate 20, a support element 30, an aerosol-cooling element 40, and a mouthpiece 50. Each of these five elements is substantially cylindrical and has substantially the same diameter. These five elements are arranged in series and surrounded by an outer wrapper 60 to form a cylindrical rod. A blade-shaped susceptor 25 is located within and in contact with the aerosol-forming substrate. The susceptor 25 has a length approximately the same as the length of the aerosol-forming substrate and is located along the radial center axis of the aerosol-forming substrate.

[0086] The susceptor 25 is a ferritic iron material having a length of 10 mm, a width of 3 mm, and a thickness of 1 mm. One or both ends of the susceptor may be sharpened or pointed to facilitate insertion into the aerosol-forming substrate.

[0087] The aerosol-generating article 10 has a proximal or oral end 70 that a user inserts into their mouth during use, with a distal end 80 located at the opposite end of the aerosol-generating article 10 from the oral end 70. The assembled aerosol-generating article 10 has an overall length of about 47 mm to 53 mm and a diameter of about 7.2 mm.

[0088] During use, air is drawn by a user through the aerosol-generating article from the distal end 80 to the oral end 70. The distal end 80 of the aerosol-generating article may also be described as the upstream end of the aerosol-generating article 10, and the oral end 70 of the aerosol-generating article 10 may also be described as the downstream end of the aerosol-generating article 10. Elements of the aerosol-generating article 10 located between the oral end 70 and the distal end 80 may be described as being upstream of the oral end 70, or alternatively, downstream of the distal end 80.

[0089] The plug element 90 is located at the distal-most or upstream end 80 of the aerosol-generating article 10. In Figure 1, the plug element is shown as a hollow tube, for example, a hollow cellulose acetate tube. The inner diameter of the hollow tube is the same as or slightly smaller than the width of the susceptor 25 to prevent the susceptor from becoming dislodged from the distal end of the aerosol-forming substrate 20.

[0090] The aerosol-forming substrate 20 is located immediately downstream of the plug element 90 within the aerosol-generating article 10. In Figure 1, the aerosol-forming substrate 20 comprises an assembly of a crimped, homogenized sheet of tobacco material surrounded by a wrapper. The crimped sheet of homogenized tobacco material contains glycerin as an aerosol former.

[0091] The support element 30 is located immediately downstream of and adjacent to the aerosol-forming substrate 20. In Figure 1, the support element 30 is a hollow cellulose acetate tube. The support element 30 positions the aerosol-forming substrate 20 within the aerosol-generating article 10. In this manner, the support element 30 helps prevent the aerosol-forming substrate 20 from being pushed downstream within the aerosol-generating article 10 toward the aerosol-cooling element 40, for example, when the article is inserted into a device. The support element 30 also serves as a spacer to space the aerosol-cooling element 40 of the aerosol-generating article 10 from the aerosol-forming substrate 20.

[0092] The aerosol cooling element 40 is located immediately downstream of and adjacent to the support element 30. In use, volatile material emitted from the aerosol-forming substrate 20 passes along the aerosol cooling element 40 toward the mouth end 70 of the aerosol-generating article 10. The volatile material may cool within the aerosol cooling element 40 to form an aerosol that is inhaled by the user. In Figure 1, the aerosol cooling element comprises an assembly of crimped sheets of polylactic acid surrounded by a wrapper 90. The assembly of crimped sheets of polylactic acid defines a plurality of longitudinal channels extending along the length of the aerosol cooling element 40.

[0093] Mouthpiece 50 is located immediately downstream of and adjacent to aerosol cooling element 40. In Figure 1, mouthpiece 50 includes a conventional cellulose acetate tow filter with low filtration efficiency.

[0094] To assemble the aerosol-generating article 10, the five cylindrical elements described above are aligned and tightly wrapped within an outer wrapper 60. In Figure 1, the outer wrapper is conventional cigarette paper.

[0095] Once the article is manufactured, the four elements, excluding the plug element 90, may be assembled. The susceptor 25 is then inserted into the distal end 80 of the assembly so that it penetrates the aerosol-forming substrate 20. The plug element 80 is then aligned with the assembly, after which the five elements are wrapped in the wrapper 60 to form the complete aerosol-generating article 10. As an alternative to assembly, the susceptor 25 is inserted into the aerosol-forming substrate 20 before assembling the elements to form the rod.

[0096] The aerosol-generating article 10 of FIG. 1 is designed to engage an electrically operated aerosol-generating device that includes an induction coil (or inductor) for smoking or consumption by a user.

[0097] 2 illustrates an aerosol-generating article 1 comprising six elements, with the same reference numerals used for the same or similar elements. The plug element 91, the aerosol-forming substrate 20, the support element in the form of a hollow cellulose acetate tube 30, the aerosol cooling element 40, the mouthpiece filter 50, and the cardboard tube 56 are arranged consecutively and coaxially side by side and are assembled with cigarette paper and tipping paper (not shown) to form a rod. The cardboard tube 56 is located at the mouth end 70 of the aerosol-generating article 1, and the plug element 91 is located at the distal end 80 of the aerosol-generating article 1.

[0098] The rod, when assembled, has a length 15 of, for example, 45 millimeters and an outer diameter of about 7.2 millimeters.

[0099] The plug element 91 is a porous plug, for example a plug of open-pore heat-resistant material, and has a length 95 of 3 to 5 mm.

[0100] The aerosol-forming substrate 20 may comprise a bundle of crimped cast leaf tobacco wrapped in filter paper (not shown) to form a plug. The cast leaf tobacco contains additives, including glycerin as an aerosol-forming additive. The length 25 of the aerosol-forming substrate is 12 millimeters. The susceptor 25 is approximately 10 mm long and is pointed at its proximal end.

[0101] A hollow acetate tube 30 is located immediately downstream of and adjacent to the aerosol-forming substrate 20. The length 35 of the acetate tube 30 is 8 mm.

[0102] The aerosol cooling element 40 has a length 45 between 10 mm and 13 mm and an outer diameter of approximately 7.12 mm. The aerosol cooling element 40 is preferably formed from a sheet of polylactic acid having a thickness of 50 mm ± 2 mm. The polylactic acid sheet is crimped and assembled to define a plurality of channels extending along the length of the aerosol cooling element 40. The total surface area of ​​the aerosol cooling element may be between 300 and 1000 square millimeters per mm of length of the aerosol cooling element 40, or between approximately 10 and 100 square millimeters per mg of weight of the aerosol cooling element 40.

[0103] The length 45 of the aerosol cooling element 40 is 5 mm to 8 mm shorter than conventional aerosol cooling elements for aerosol-generating articles having a standard length of 45 mm. Conventional aerosol cooling elements for aerosol-generating articles of such standard length, particularly aerosol cooling elements made from polylactic acid sheets, have a length of 18 mm.

[0104] Mouthpiece filter 50, located downstream of aerosol cooling element 40, may be a conventional mouthpiece filter formed from cellulose acetate and has a length 55 of 7 millimeters.

[0105] The cardboard tube 56 is the most downstream element of the aerosol-generating article 1 and has a length 57 of 3 to 5 millimeters. The cardboard tube, together with the plug element 80, compensates for the shorter aerosol-cooling element 50, so that the total length of the aerosol-generating article is 45 mm. The cardboard tube 56 also provides a recessed mouth end 70 of the aerosol-generating article, which mimics the use of a conventional cigarette with a recessed mouth end.

[0106] The reduced length of the aerosol cooling element 40 can compensate for the additional length 95 of the plug element 91 alone. A cardboard tube 56 can optionally be provided.

[0107] 3, plug element 92 has a recess 920 with an open end facing the aerosol-forming substrate 20. Recess 920 is dome-shaped and has a maximum depth 921 that is 25 to 50 percent of the length 95 of the plug element. If the plug element has a length 95 of 5 mm, then depth 921 of recess 920 is approximately 1 to 2.5 mm. The material of plug element 92 is a heat-resistant material that can withstand temperatures of approximately 350°C. The plug element is preferably porous to allow air to pass through plug element 92.

[0108] 4 illustrates an embodiment of a plug element 93 having an opening 930 longitudinally disposed within the plug element for air to pass through the plug element. The plug element material may otherwise be airtight. The opening 930 has an irregular star-shaped cross section, which may serve marking purposes and may enhance the aesthetic appeal of the aerosol-generating article.

Claims

1. 1. An aerosol-generating article comprising a plurality of elements assembled in the form of a rod having a mouth end and a distal end upstream from the mouth end, wherein the plurality of elements comprises an aerosol-forming substrate having an elongated susceptor longitudinally disposed within the aerosol-forming substrate, and a plug element is located within the rod upstream of and adjacent to the aerosol-forming substrate, the plug element preventing direct physical contact with the distal end of the elongated susceptor longitudinally disposed within the aerosol-forming substrate.

2. 2. The aerosol-generating article of claim 1, wherein the plug element has a resistance to withdrawal (RTD) of between 20 mmWG and 40 mmWG.

3. 3. The aerosol-generating article according to claim 1, wherein the plug element comprises a plurality of openings.

4. 4. The aerosol-generating article of claim 1, wherein the plug element is made of a ceramic, a polymeric material, cellulose acetate, cardboard, a non-inductively heatable metal, a zeolite, or an aerosol-forming substrate.

5. 10. The aerosol-generating article of claim 1, wherein the plug element is airtight.

6. 6. An aerosol-generating article according to any one of claims 1 to 5, wherein at least the distal end of the plug element has a homogeneous structure.

7. 7. The aerosol-generating article of claim 1, wherein the plug element has an inner surface defining a recess, the recess being disposed within the plug element such that a proximal end of the plug element does not contact the elongated susceptor disposed within the aerosol-forming substrate.

8. 8. The aerosol-generating article of claim 7, wherein the inner surface of the cavity has a concave shape.

9. An aerosol-generating article according to any one of claims 1 to 8, wherein the plug element is made of a heat-resistant material.

10. An aerosol-generating article according to any one of claims 1 to 9, wherein the plug element is a separate element.

11. 11. An aerosol-generating article according to any one of claims 1 to 10, wherein the plug element has a length of between 1 millimetre and 10 millimetres.

12. 10. An aerosol-generating article according to any one of claims 1 to 9, wherein the plug element is a coating applied to the distal end of the aerosol-generating substrate.

13. 13. An aerosol-generating article according to any one of claims 1 to 12, wherein the aerosol-forming substrate comprises an assembly of sheets of homogenised tobacco material.

14. 14. An aerosol-generating article according to any one of claims 1 to 13, wherein the plurality of elements further comprises a support element, an aerosol cooling element, and a mouthpiece element comprising a filter segment and a hollow tube, the aerosol cooling element of the tobacco element having a length of up to 15 millimeters, and the length of the mouthpiece element is adapted according to the length of the aerosol cooling element so as to maintain a predetermined overall length of the aerosol-generating article.

15. 15. The aerosol-generating article of claim 14, wherein the hollow tube of the mouthpiece element is positioned at the distal end of the rod, and the length of the hollow tube is adapted to the length of the aerosol cooling element so that the overall length of the aerosol-generating article is maintained at a predetermined overall length.

Images