Aerosol generating article having a predetermined insertion direction

Abstract

The present invention provides an aerosol-generating article that extends from the oral end to the distal end upstream of the oral end. [Solution] The aerosol generating article 10 includes a rod 12 of an aerosol generating base, a downstream section 14 located downstream of the rod of the aerosol generating base, and an upstream section 16 located upstream of the rod of the aerosol generating base. The downstream section includes a mouthpiece element 42 located downstream of the rod and aligned longitudinally with the rod, the mouthpiece element extending all the way to the oral end of the aerosol generating article. The upstream section includes an upstream element extending all the way to the distal end of the article. The diameter (D) of the aerosol generating article at the oral end ME ) is the diameter (D) of the aerosol-generating article at the distal end. DE ) is greater than the ratio (D) between the diameter of the aerosol-generating article at the oral end and the diameter of the aerosol-generating article at the distal end. ME / D DE ) is at least about 1.005.

Description

[Technical Field]

[0001] The present invention relates to an aerosol generating article comprising an aerosol generating substrate and adapted to generate an inhalable aerosol when heated. [Background technology]

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

[0003] Numerous prior art documents disclose aerosol generators for consuming aerosol-generating articles. Such devices include, for example, electrically heated aerosol generators in which aerosols are generated by heat transfer from one or more electric heater elements of the aerosol generator to an aerosol-generating substrate of a heated aerosol-generating article. For example, electrically heated aerosol generators have been proposed that include internal heater blades adapted to be inserted into an aerosol-generating substrate. Alternatively, an inductively exothermic aerosol-generating article comprising an aerosol-generating substrate and a susceptor disposed within the aerosol-generating substrate has been proposed by WO2015 / 176898.

[0004] Aerosol-generating articles in which the tobacco-containing substrate is heated rather than burned present several challenges not encountered with conventional smoking articles. Firstly, the tobacco-containing substrate is typically heated to significantly lower temperatures compared to the temperature reached by the pre-burning portion of a conventional cigarette. This can affect nicotine release from the tobacco-containing substrate and nicotine delivery to the consumer. Simultaneously, if the heating temperature is increased in an attempt to promote nicotine delivery, the resulting aerosol typically needs to be cooled more extensively and rapidly before reaching the consumer. However, technical solutions commonly used in conventional smoking articles to cool the mainstream smoke, such as providing a highly filtration-efficient segment at the mouth-end of the cigarette, may have undesirable effects in aerosol-generating articles in which the tobacco-containing substrate is heated rather than burned, as this can reduce nicotine delivery. Secondly, there is a general need for aerosol-generating articles that are generally easier to use and have improved practicality.

[0005] Furthermore, it is equally desirable to provide an aerosol-generating article that can be manufactured efficiently and quickly, preferably has a satisfactory RTD between articles, and exhibits small RTD variation.

[0006] Therefore, it would be desirable to provide a new and improved aerosol generating article adapted to achieve at least one of the desirable results described above. [Overview of the project]

[0007] This disclosure relates to an aerosol generating article comprising a rod of an aerosol generating substrate, the aerosol generating article extending from the oral end to the distal end upstream of the oral end. The aerosol generating article may have a downstream section located downstream of the rod of the aerosol generating substrate. The downstream section may have a mouthpiece segment located downstream of the rod and aligned longitudinally with the rod. The mouthpiece segment may extend all the way to the oral end of the aerosol generating article. The diameter (D) of the aerosol generating article at the oral end ME) is the diameter (D) of the aerosol-generating article at the distal end. DE ) may be greater than the ratio (D) between the diameter of the aerosol generating article at the distal end and the diameter of the aerosol generating article at the oral end. ME / D DE ) may be at least about 1.005.

[0008] According to the present invention, an aerosol generating article is provided that extends from the oral end to the distal end upstream of the oral end, the aerosol generating article comprising a rod of an aerosol generating substrate and a downstream section located downstream of the rod of the aerosol generating substrate. The downstream section includes a mouthpiece segment located downstream of the rod and aligned longitudinally with the rod, the mouthpiece segment extending all the way to the oral end of the aerosol generating article. The diameter (D) of the aerosol generating article at the oral end ME ) is the diameter (D) of the aerosol-generating article at the distal end. DE ) is greater than the ratio (D) between the diameter of the aerosol-generating article at the oral end and the diameter of the aerosol-generating article at the distal end. ME / D DE ) is at least about 1.005.

[0009] Providing a single such aerosol-generating article in which the outer diameter of the article is larger at one end than at the other has the advantage that it is easier for consumers to identify the end that is inserted into an aerosol generator to supply heat to the aerosol-generating substrate. This is particularly advantageous in embodiments in which, for example, the mouth end and distal end of an aerosol-generating article are visually nearly identical or both contain similar elements, making it otherwise difficult for consumers to distinguish between them. As an example, the present invention is particularly advantageous in these embodiments which include an upstream section located upstream of the rod of the aerosol-generating substrate, the upstream section including an upstream element containing a segment of filter material, and a downstream section located downstream of the aerosol-generating substrate, the downstream section including a mouthpiece segment that extends all the way to the mouth end of the article. In one such article design, it may otherwise be difficult for consumers to distinguish the mouth end—where the mouthpiece segment is provided—from the distal end—where the upstream element is provided. The present invention makes it possible for consumers to easily detect the decrease in diameter progressing toward the distal end that is inserted into the cavity of the device.

[0010] According to the present invention, an aerosol generating article is provided for generating an aerosol that can be inhaled when heated. The aerosol generating article comprises a rod of an aerosol generating substrate.

[0011] The term "aerosol-generating article" is used herein to mean an article in which an aerosol-generating substrate is heated to produce an inhalable aerosol that is delivered to the consumer. The term "aerosol-generating substrate" as used herein means a substrate having the ability to generate an aerosol by releasing volatile compounds upon heating.

[0012] Conventional cigarettes are ignited when the user lights a flame at one end of the cigarette and inhales air through the other end. The localized heat from the flame and the oxygen in the air drawn through the cigarette ignites the end of the cigarette, and the resulting combustion produces inhalable smoke. In contrast, in heated aerosol generating articles, the aerosol is generated by heating a flavor-generating substrate (such as tobacco). Known heated aerosol generating articles include, for example, electrically heated aerosol generating articles and aerosol generating articles in which an aerosol is generated by the transfer of heat from a combustible fuel element or heat source to a physically separated aerosol-forming material. For example, the aerosol generating article according to the present invention has a particular application in an aerosol generating system comprising an electrically heated aerosol generating device having an internal heater blade adapted to be inserted into a rod of an aerosol generating substrate. This type of aerosol generating article is described in the prior art, for example, EP0822670.

[0013] As used herein, the term "aerosol generator" refers to a device comprising a heater element that interacts with an aerosol-generating substrate of an aerosol-generating article to generate an aerosol.

[0014] As used herein in connection with the present invention, the term "rod" is used to refer to a generally cylindrical element having a substantially circular, oval, or elliptical cross-section.

[0015] As used herein, the term “longitudinal direction” refers to the direction corresponding to the longitudinal principal axis of the aerosol generating article, extending between the upstream and downstream ends of the aerosol generating article. As used herein, the terms “upstream” and “downstream” describe the relative position of an element (or part of an element) of the aerosol generating article with respect to the direction in which aerosols are transported through the aerosol generating article during use.

[0016] During use, air is drawn longitudinally through the aerosol-generating article. The term "transverse direction" refers to a direction perpendicular to the longitudinal axis. Any reference to the "cross section" of the aerosol-generating article or its components refers to the transverse section unless otherwise specified.

[0017] The term "length" refers to the dimensions of the components of an aerosol-generating article in the longitudinal direction. For example, it may be used to refer to the dimensions of a rod or an elongated tubular element in the longitudinal direction.

[0018] The aerosol generating substrate may be a solid aerosol generating substrate.

[0019] In a particular preferred embodiment, the aerosol-generating substrate comprises homogenized plant material, preferably homogenized tobacco material.

[0020] As used herein, the term “homogenized plant material” encompasses any plant material formed by the aggregation of plant particles. For example, a sheet or web of homogenized tobacco material for the aerosol-generating substrate of the present invention may be formed by aggregating plant material and, optionally, tobacco material particles obtained by grinding, crushing, or pulverizing one or more of tobacco leaf blades and tobacco leaf stems. The homogenized plant material may be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0021] Homogenized plant material can be provided in any preferred form. For example, homogenized plant material may be in the form of one or more sheets. As used herein in relation to the present invention, the term “sheet” refers to a thin layer element having a width and length considerably greater than its thickness.

[0022] Alternatively, or additionally, the homogenized plant material may be in the form of multiple pellets or granules.

[0023] Alternatively, or additionally, the homogenized plant material may be in the form of multiple strands, strips, or fragments. As used herein, the term “strand” refers to an elongated element of the material having a length substantially greater than its width and thickness. The term “strand” is considered to encompass strips, fragments, and any other homogenized plant material having a similar form. Strands of homogenized plant material may be formed from a sheet of homogenized plant material, for example, by cutting or shredding, or by other means, such as by extrusion.

[0024] In some embodiments, strands may be formed in situ within the aerosol-generating substrate as a result of splitting or cracking of a sheet of homogenized plant material during the formation of the aerosol-generating substrate, for example, as a result of crimping. The strands of homogenized plant material within the aerosol-generating substrate may be separated from each other. Alternatively, each strand of homogenized plant material within the aerosol-generating substrate may be at least partially connected to an adjacent strand(s) along the length of the strand. For example, adjacent strands may be connected by one or more fibers. This may occur, for example, when strands are formed as a result of splitting of a sheet of homogenized plant material during the manufacture of the aerosol-generating substrate as described above.

[0025] The aerosol generating substrate is preferably in the form of one or more sheets of homogenized plant material. In various embodiments of the present invention, one or more sheets of homogenized plant material may be produced by a casting process. In various embodiments of the present invention, one or more sheets of homogenized plant material may be produced by a papermaking process. Each of the one or more sheets described herein may individually have a thickness of 100 to 600 micrometers, preferably 150 to 300 micrometers, and most preferably 200 to 250 micrometers. Individual thicknesses refer to the thickness of individual sheets, and combined thickness refers to the total thickness of all sheets constituting the aerosol generating substrate. For example, if the aerosol generating substrate is formed from two individual sheets, the combined thickness is the thickness of the two individual sheets, or the sum of the measured thicknesses of the two sheets, and the two sheets are stacked within the aerosol generating substrate.

[0026] Each of the sheets described herein may individually have a basis weight of approximately 100 grams per square meter to approximately 300 grams per square meter.

[0027] Each of the sheets described herein may individually have a density of about 0.3 grams / cubic centimeter to about 1.3 grams / cubic centimeter, preferably about 0.7 grams / cubic centimeter to about 1.0 gram / cubic centimeter.

[0028] In embodiments of the present invention, the aerosol-generating substrate comprises one or more sheets of homogenized plant material, the sheets are preferably in the form of an aggregate of one or more sheets. As used herein, the term “aggregate” means that the sheets of homogenized plant material are spiraled substantially transversely to the cylindrical axis of a plug or rod, folded, or otherwise compressed or shrunk.

[0029] One or more sheets of homogenized plant material can be assembled transversely to their longitudinal axis and surrounded by a wrapper to form a continuous rod or plug.

[0030] One or more sheets of homogenized plant material may be advantageously crimped or similarly treated. As used herein, the term “crimped” means a sheet having multiple substantially parallel ridges or undulations. In addition to or otherwise than crimping, one or more sheets of homogenized plant material may be embossed, debossed, perforated, or otherwise deformed to provide texture on one or both sides of the sheet.

[0031] Preferably, each sheet of homogenized plant material can be crimped to have multiple ridges or undulations substantially parallel to the cylindrical axis of the plug. This process advantageously facilitates the assembly of the crimped sheets of homogenized plant material to form the plug. Preferably, one or more sheets of homogenized plant material can be assembled. Naturally, the crimped sheets of homogenized plant material may, by other means or additionally, have multiple substantially parallel ridges or undulations that form acute or obtuse angles with respect to the cylindrical axis of the plug. The sheets may be crimped to such an extent that the integrity of the sheet is interrupted at the multiple parallel ridges or undulations, causing separation of the material and resulting in the formation of fragments, strands, or shards of homogenized plant material.

[0032] Alternatively, one or more sheets of homogenized plant material may be cut into strands, as mentioned above. In such embodiments, the aerosol-generating substrate comprises several strands of homogenized plant material. The strands may be used to form a plug. Typically, the width of such strands is about 5 millimeters, or about 4 millimeters, or about 3 millimeters, or less than 2 millimeters. The length of the strands may be longer than about 5 millimeters, or between about 5 millimeters and about 15 millimeters, or between about 8 millimeters and about 12 millimeters, or about 12 millimeters. It is preferable that the strands are substantially the same length as each other. The length of the strands may be determined by a manufacturing process, thereby cutting the rods into shorter plugs, and the length of the strands corresponds to the length of the plugs. The strands are fragile and can break, especially during transport. In such cases, the length of some strands may be shorter than the length of the plugs.

[0033] It is preferable that the strands are aligned with the longitudinal axis and extend substantially along the length of the aerosol-generating substrate. Therefore, it is preferable that the strands are aligned substantially parallel to one another.

[0034] The homogenized plant material may contain up to about 95 weight percent of plant particles on a dry weight basis. Preferably, the homogenized plant material contains up to about 90 weight percent of plant particles on a dry weight basis, more preferably about 80 weight percent of plant particles, more preferably about 70 weight percent of plant particles, more preferably about 60 weight percent of plant particles, and more preferably about 50 weight percent of plant particles.

[0035] For example, homogenized plant material may contain, on a dry weight basis, approximately 2.5 to 95 percent by weight of plant particles, or approximately 5 to 90 percent by weight of plant particles, or approximately 10 to 80 percent by weight of plant particles, or approximately 15 to 70 percent by weight of plant particles, or approximately 20 to 60 percent by weight of plant particles, or approximately 30 to 50 percent by weight of plant particles.

[0036] In certain embodiments of the present invention, the homogenized plant material is a homogenized tobacco material containing tobacco particles. A sheet of homogenized tobacco material used in such embodiments of the present invention may have a tobacco content of at least about 40 weight percent on a dry weight basis, more preferably at at least about 50 weight percent on a dry weight basis, more preferably at at least about 70 weight percent on a dry weight basis, and most preferably at at least about 90 weight percent on a dry weight basis.

[0037] In relation to the present invention, the term “tobacco particles” refers to particles of any plant material of the Nicotiana species. The term “tobacco particles” encompasses crushed or powdered tobacco leaf lamina, crushed or powdered tobacco leaf stems, tobacco dust, tobacco fine powder, and other particulate tobacco by-products formed during the processing, handling, and shipping of tobacco. In preferred embodiments, tobacco particles are substantially all derived from tobacco leaf lamina. In contrast, isolated nicotine and nicotine salts, although compounds derived from tobacco, are not considered tobacco particles for the purposes of the present invention and are not included in the proportion of particulate plant material.

[0038] Tobacco particles can be prepared from one or more varieties of tobacco plants. Any type of tobacco can be used in the blend. Examples of types of tobacco materials that can be used include, but are not limited to, sun-dried tobacco, heat-dried tobacco, Burley tobacco, Maryland tobacco, Oriental tobacco, Virginia tobacco, and other specialty tobaccos.

[0039] Heat drying is a tobacco drying method particularly used for Virginia tobacco. During the heat drying process, heated air circulates through the densely packed tobacco. In the first stage, the tobacco leaves turn yellow and wither. In the second stage, the leaf laminas dry completely. In the third stage, the leaf stems dry completely.

[0040] Burley tobacco plays an important role in many tobacco blends. Burley tobacco possesses a distinctive flavor and aroma, and has the ability to absorb a large amount of casing.

[0041] Oriental tobacco is a type of tobacco with small leaves and high aromatic quality. However, Oriental tobacco has a milder flavor than, for example, Burley tobacco. Therefore, Oriental tobacco is generally used in relatively small proportions in tobacco blends.

[0042] Kasturi, Madura, and Jatim are usable subtypes of sun-dried tobacco. It is preferable to use Kasturi tobacco and heat-dried tobacco in the blend to produce tobacco particles. Therefore, tobacco particles in particulate plant material may include a blend of Kasturi tobacco and heat-dried tobacco.

[0043] Tobacco particles may have a nicotine content of at least about 2.5 weight percent based on dry weight. More preferably, tobacco particles may have a nicotine content of at least about 3 weight percent based on dry weight, even more preferably at least about 3.2 weight percent, even more preferably at least about 3.5 weight percent, and most preferably at least about 4 weight percent.

[0044] In certain other embodiments of the present invention, the homogenized plant material includes tobacco particles combined with non-tobacco plant-flavored particles. Preferably, the non-tobacco plant-flavored particles are selected from one or more of ginger particles, eucalyptus particles, clove particles, and star anise particles. Preferably, in such embodiments, the homogenized plant material contains at least about 2.5 weight percent of non-tobacco plant-flavored particles on a dry weight basis, with the remaining plant particles being tobacco particles. Preferably, the homogenized plant material contains at least about 4 weight percent of non-tobacco plant-flavored particles on a dry weight basis, more preferably at least about 6 weight percent of non-tobacco plant-flavored particles, more preferably at least about 8 weight percent of non-tobacco plant-flavored particles, and more preferably at least about 10 weight percent of non-tobacco plant-flavored particles. Preferably, the homogenized plant material contains up to about 20 weight percent of non-tobacco plant-flavored particles, more preferably up to about 18 weight percent of non-tobacco plant-flavored particles, and more preferably up to about 16 weight percent of non-tobacco plant-flavored particles.

[0045] The weight ratio of non-tobacco plant-flavored particles to tobacco particles in the particulate plant material forming the homogenized plant material may vary depending on the desired flavor characteristics and composition of the aerosol generated from the aerosol-generating substrate during use. Preferably, the homogenized plant material contains, on a dry weight basis, at least 1:30 weight ratio of non-tobacco plant-flavored particles to tobacco particles, more preferably at least 1:20 weight ratio of non-tobacco plant-flavored particles to tobacco particles, more preferably at least 1:10 weight ratio of non-tobacco plant-flavored particles to tobacco particles, and most preferably at least 1:5 weight ratio of non-tobacco plant-flavored particles to tobacco particles.

[0046] Alternatively, as another way of including tobacco particles in the homogenized plant material of the aerosol-generating substrate according to the present invention, or in addition thereto, the homogenized plant material may include cannabis particles. The term "cannabis particles" refers to particles of cannabis plants such as Cannabis sativa, Cannabis indica, and Cannabis ruderalis.

[0047] The homogenized plant material preferably contains 95% by weight or less of particulate plant material on a dry weight basis. Thus, the particulate plant material is typically combined with one or more other components to form the homogenized plant material.

[0048] Homogenized plant material may further contain a binder for altering the mechanical properties of particulate plant material, where the binder is included in the homogenized plant material during production as described herein. Suitable exogenous binders known to those skilled in the art include, but are not limited to, gums such as guar gum, xanthan gum, gum arabic, and locust bean gum; cellulose binders such as hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose, and ethyl cellulose; polysaccharides such as starch, organic acids such as alginic acid, conjugated base salts of organic acids such as sodium alginate, agar, and pectin, and combinations thereof. The binder preferably contains guar gum.

[0049] The binder may be present in an amount of about 1% to about 10% by weight, preferably about 2% to about 5% by weight, based on the dry weight of the homogenized plant material.

[0050] Alternatively, or additionally, the homogenized plant material may further contain one or more lipids to facilitate the diffusion of volatile components (e.g., aerosol-forming agents, gingerol, and nicotine), wherein the lipids are included in the homogenized plant material during the manufacturing process described herein. Suitable lipids for inclusion in the homogenized plant material include, but are not limited to, medium-chain triglycerides, cocoa butter, palm oil, kernel oil, mango oil, shea butter, soybean oil, cottonseed oil, coconut oil, hydrogenated coconut oil, candelilla wax, carnauba wax, shellac, sunflower wax, sunflower oil, rice bran, and RevelA, as well as combinations thereof.

[0051] Alternatively, or additionally, the homogenized plant material may further contain a pH adjuster.

[0052] Alternatively, or additionally, the homogenized plant material may further contain fibers to alter the mechanical properties of the homogenized plant material, wherein the fibers are included in the homogenized plant material during the manufacturing process described herein. Suitable exogenous fibers for inclusion in the homogenized plant material are known in the art and include, but are not limited to, cellulose fibers, soft wood fibers, hard wood fibers, jute fibers, and combinations thereof, as well as fibers formed from non-tobacco and non-ginger materials. Exogenous fibers derived from tobacco and / or ginger may also be added. Any fibers added to the homogenized plant material are not considered to form part of the “particulate plant material” as defined above. Before inclusion in the homogenized plant material, the fibers may be treated by suitable processes known in the art, including, but not limited to, mechanical pulping, purification, chemical pulping, bleaching, sulfate pulping, and combinations thereof. Typically, the fibers have a length greater than their width.

[0053] Preferred fibers are typically greater than 400 micrometers and have a length of 4 millimeters or less, preferably in the range of 0.7 millimeters to 4 millimeters. The fibers are preferably present in an amount of about 2% to about 15% by weight, most preferably about 4% by weight, based on the dry weight of the substrate.

[0054] Alternatively, or additionally, the homogenized plant material may further contain one or more aerosol-forming bodies. Upon volatilization, the aerosol-forming bodies can carry other vaporized compounds released from the aerosol-generating substrate upon heating, such as nicotine and flavoring agents in the aerosol. Suitable aerosol-forming bodies for inclusion in the homogenized plant material are known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, propylene glycol, 1,3-butanediol, and glycerol), esters of polyhydric alcohols (glycerol mono-, di-, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dodecanedioic acid and dimethyl tetradecanedioic acid).

[0055] Homogenized plant material may have an aerosol-forming content of approximately 5% to 30% by dry weight, such as approximately 10% to 25% by dry weight, or approximately 15% to 20% by dry weight.

[0056] For example, when intended for use in an aerosol generating article for an electrically operated aerosol generating system having a substrate that has a heating element, it is preferable that the aerosol-forming material content be about 5% to about 30% by weight on a dry weight basis. When intended for use in an aerosol generating article for an electrically operated aerosol generating system having a substrate that has a heating element, the aerosol-forming material is preferably glycerol.

[0057] In another embodiment, the homogenized plant material may have an aerosol-forming content of about 1% to about 5% by weight on a dry weight basis. For example, if the substrate is intended for use in an aerosol-generating article in which the aerosol-forming material is kept in a storage compartment separated from the substrate, the substrate may have an aerosol-forming content greater than 1% and less than about 5%. In such embodiments, the aerosol-forming material volatilizes upon heating, and the flow of the aerosol-forming material comes into contact with the aerosol-generating substrate to infuse flavor from the aerosol-generating substrate into the aerosol.

[0058] In another embodiment, the homogenized plant material may have an aerosol-forming content of about 30 to about 45 weight percent. This relatively high level of aerosol-forming is particularly suitable for aerosol-generating substrates intended to be heated at temperatures below 275 degrees Celsius. In such embodiments, the homogenized plant material preferably further comprises about 2 to about 10 weight percent of cellulose ether and about 5 to about 50 weight percent of additional cellulose on a dry weight basis. The use of a combination of cellulose ether and additional cellulose has been found to result in particularly effective aerosol delivery when used in aerosol-generating substrates having an aerosol-forming content of 30 to 45 weight percent.

[0059] Suitable cellulose ethers include, but are not limited to, methylcellulose, hydroxypropylmethylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, ethylhydroxyethylcellulose, and carboxymethylcellulose (CMC). In a particularly preferred embodiment, the cellulose ether is carboxymethylcellulose.

[0060] As used herein, the term “additional cellulose” encompasses any cellulose material incorporated into the homogenized plant material, which does not originate from the non-tobacco plant particles or tobacco particles provided to the homogenized plant material. Thus, additional cellulose is incorporated into the homogenized plant material as an individual and distinct source of cellulose to any cellulose essentially provided within the non-tobacco plant particles or tobacco particles, in addition to the non-tobacco plant material or tobacco material. The additional cellulose typically originates from a plant different from the non-tobacco plant particles or tobacco particles. Preferably, the additional cellulose is in the form of an inert cellulose material, which is sensorily inert and therefore does not substantially affect the functional properties of the aerosol generated from the aerosol-generating substrate. For example, the additional cellulose is preferably a tasteless and odorless material.

[0061] The additional cellulose may include cellulose powder, cellulose fibers, or a combination thereof.

[0062] The aerosol-forming material can act as a wetting agent in the aerosol-generating substrate.

[0063] The wrapper surrounding the rod of homogenized plant material may be a paper wrapper or a non-paper wrapper. Suitable paper wrappers for use in specific embodiments of the present invention are known in the art and include, but are not limited to, cigarette papers and filter plug wrappers. Suitable non-paper wrappers for use in specific embodiments of the present invention are known in the art and include, but are not limited to, sheets of homogenized tobacco material. In certain preferred embodiments, the wrapper may be formed from a laminated material comprising multiple layers. Preferably, the wrapper is formed from an aluminum co-laminate sheet. The use of an aluminum co-laminate sheet advantageously prevents combustion of the aerosol-generating substrate when the aerosol-generating substrate is to be ignited rather than heated in the intended manner.

[0064] In certain preferred embodiments of the present invention, the aerosol-generating substrate comprises a gel composition containing an alkaloid compound, or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound. In particularly preferred embodiments, the aerosol-generating substrate comprises a gel composition containing nicotine.

[0065] Preferably, the gel composition comprises an alkaloid compound, or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound, an aerosol-forming body, and at least one gelling agent. Preferably, at least one gelling agent forms a solid medium, glycerol is dispersed in the solid medium, and the alkaloid or cannabinoid is dispersed in the glycerol. The gel composition is preferably a stable gel phase.

[0066] Advantageously, a nicotine-containing stable gel composition provides a predictable compositional form during storage or during the transition from manufacture to consumer. The nicotine-containing stable gel composition substantially maintains its shape. The nicotine-containing stable gel composition substantially does not release the liquid phase during storage or during the transition from manufacture to consumer. The nicotine-containing stable gel composition may offer a simple consumable design. This consumable may not need to be designed to contain a liquid, and therefore a wider range of materials and container structures may be considered.

[0067] The gel compositions described herein may be combined with an aerosol generator to deliver nicotine aerosol to the lungs at inhalation rates or airflow rates within those of conventional smoking methods. The aerosol generator can continuously heat the gel composition. The consumer can take multiple inhalations or "smokes," each delivering an amount of nicotine aerosol. When heated, the gel composition can deliver a high nicotine / total particulate matter (TPM) aerosol to the consumer, preferably in a continuous manner.

[0068] The terms "stable gel phase" or "stable gel" refer to a gel that substantially maintains its shape and mass when exposed to various environmental conditions. A stable gel is substantially unable to release or absorb water (sweat) when exposed to standard temperature and pressure while the relative humidity is varied from approximately 10 percent to approximately 60 percent. For example, a stable gel can substantially maintain its shape and mass when exposed to standard temperature and pressure while the relative humidity is varied from approximately 10 percent to approximately 60 percent.

[0069] The gel composition may contain an alkaloid compound, or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound. The gel composition may contain one or more alkaloids. The gel composition may contain one or more cannabinoids. The gel composition may contain a combination of one or more alkaloids and one or more cannabinoids.

[0070] The term “alkaloid compound” refers to any one class of naturally occurring organic compounds containing one or more basic nitrogen atoms. Generally, alkaloids contain at least one nitrogen atom in an amine-type structure. This nitrogen atom or another nitrogen atom within the molecule of an alkaloid compound can be active as a base in acid-base reactions. Most alkaloid compounds have one or more of their nitrogen atoms as part of a cyclic system, such as a heterocycle. In nature, alkaloid compounds are found mainly in plants, and are particularly common in flowering plants of certain families. However, some alkaloid compounds are found in animal species and fungi. In this disclosure, the term “alkaloid compound” refers to both naturally occurring alkaloid compounds and synthetically produced alkaloid compounds.

[0071] The gel composition preferably contains an alkaloid compound selected from the group consisting of nicotine, anatabine, and combinations thereof.

[0072] Preferably, the gel composition contains nicotine.

[0073] The term "nicotine" refers to nicotine and nicotine derivatives (e.g., free base nicotine, nicotine salts, and similar substances).

[0074] The term “cannabinoid compound” means any one type of naturally occurring compound found in some cannabis plants, including Cannabis sativa, Cannabis indica, and Cannabis ruderalis. Cannabinoid compounds are particularly concentrated in female flower heads. Naturally occurring cannabinoid compounds in cannabis plants include cannabidiol (CBD) and tetrahydrocannabinol (THC). In this disclosure, the term “cannabinoid compound” is used to describe both naturally occurring and synthetically produced cannabinoid compounds.

[0075] The gel may contain cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabiersoin (CBE), cannabicitran (CBT), and combinations thereof.

[0076] The gel composition may preferably contain a cannabinoid compound selected from the group consisting of cannabidiol (CBD), THC (tetrahydrocannabinol), and combinations thereof.

[0077] The gel preferably contains cannabidiol (CBD).

[0078] The gel composition may contain nicotine and cannabidiol (CBD).

[0079] The gel composition may contain nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0080] The gel composition preferably contains about 0.5% to about 10% by weight of an alkaloid compound, or about 0.5% to about 10% by weight of a cannabinoid compound, or both alkaloid and cannabinoid compounds in a total amount of about 0.5% to about 10% by weight. The gel composition may contain about 0.5% to about 5% by weight of an alkaloid compound, or about 0.5% to about 5% by weight of a cannabinoid compound, or both alkaloid and cannabinoid compounds in a total amount of about 0.5% to about 5% by weight. The gel composition preferably contains about 1% to about 3% by weight of an alkaloid compound, or about 1% to about 3% by weight of a cannabinoid compound, or both alkaloid and cannabinoid compounds in a total amount of about 1% to about 3% by weight. The gel composition may preferably contain about 1.5% to about 2.5% by weight of an alkaloid compound, or about 1.5% to about 2.5% by weight of a cannabinoid compound, or both alkaloid and cannabinoid compounds in a total amount of about 1.5% to about 2.5% by weight. The gel composition may preferably contain about 2% by weight of an alkaloid compound, or about 2% by weight of a cannabinoid compound, or both alkaloid and cannabinoid compounds in a total amount of about 2% by weight. The alkaloid compound component of the gel formulation may be the most volatile component of the gel formulation. In some embodiments, water may be the most volatile component of the gel formulation, and the alkaloid compound component of the gel formulation may be the second most volatile component of the gel formulation. The cannabinoid compound component of the gel formulation may be the most volatile component of the gel formulation. In some embodiments, water may be the most volatile component of the gel formulation, and the alkaloid compound component of the gel formulation may be the second most volatile component of the gel formulation.

[0081] Preferably, nicotine is included in the gel composition. Nicotine may be added to the composition in free base form or salt form. The gel composition contains about 0.5% to about 10% by weight nicotine, or about 0.5% to about 5% by weight nicotine. Preferably, the gel composition contains about 1% to about 3% by weight nicotine, or about 1.5% to about 2.5% by weight nicotine, or about 2% by weight nicotine. The nicotine component of the gel formulation may be the most volatile component of the gel formulation. In some embodiments, water may be the most volatile component of the gel formulation, and the nicotine component of the gel formulation may be the second most volatile component of the gel formulation.

[0082] The gel composition contains an aerosol-forming body. Ideally, the aerosol-forming body is substantially resistant to thermal degradation at the operating temperature of the associated aerosol generator. Suitable aerosol-forming bodies include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids (such as dimethyl dodecanediol and dimethyl tetradecanediol). The polyhydric alcohol or a mixture thereof may be one or more of triethylene glycol, 1,3-butanediol, and glycerin (glycerol or propane-1,2,3-triol) or polyethylene glycol. The aerosol-forming body is preferably glycerol.

[0083] The gel composition contains the majority of the aerosol-forming material. The gel composition may contain a mixture of water and the aerosol-forming material, the aerosol-forming material forming the majority (by weight) of the gel composition. The aerosol-forming material may form at least about 50 weight percent of the gel composition. The aerosol-forming material may form at least about 60 weight percent, or at least about 65 weight percent, or at least about 70 weight percent of the gel composition. The aerosol-forming material may form about 70 to about 80 weight percent of the gel composition. The aerosol-forming material may form about 70 to about 75 weight percent of the gel composition.

[0084] The gel composition may consist mostly of glycerol. The gel composition may consist of a mixture of water and glycerol, with glycerol forming the majority (by weight) of the gel composition. Glycerol may form at least about 50 weight percent of the gel composition. Glycerol may form at least about 60 weight percent, or at least about 65 weight percent, or at least about 70 weight percent of the gel composition. Glycerol may form about 70 to about 80 weight percent of the gel composition. Glycerol may form about 70 to about 75 weight percent of the gel composition.

[0085] The gel composition preferably contains at least one gelling agent. The gel composition preferably contains gelling agents in a total amount ranging from about 0.4% to about 10% by weight. More preferably, the composition contains gelling agents in a range of about 0.5% to about 8% by weight. More preferably, the composition contains gelling agents in a range of about 1% to about 6% by weight. More preferably, the composition contains gelling agents in a range of about 2% to about 4% by weight. More preferably, the composition contains gelling agents in a range of about 2% to about 3% by weight.

[0086] The term "gelling agent" refers to a compound that, when added homogeneously to a mixture of 50% water and 50% glycerol in an amount of approximately 0.3% by weight, forms a solid culture medium or supporting matrix, leading to the formation of a gel. Examples of gelling agents, though not limited to them, include hydrogen-linked gelling agents and ion-linked gelling agents.

[0087] The gelling agent may contain one or more biopolymers. The biopolymers may be formed from polysaccharides.

[0088] Examples of biopolymers include gellan gum (natural gellan gum, low-acyl gellan gum, high-acyl gellan gum, and low-acyl gellan gum are preferred), xanthan gum, alginate (alginic acid), agar, and guar gum. It is preferable that the composition contains xanthan gum. The composition may contain two biopolymers. The composition may contain three biopolymers. The composition may contain two biopolymers in substantially equal weights. The composition may contain three biopolymers in substantially equal weights.

[0089] Preferably, the gel composition contains at least about 0.2 weight percent of a hydrogen-bonding crosslinking gelling agent. Alternatively or additionally, the gel composition preferably contains at least about 0.2 weight percent of an ion-crosslinking gelling agent. Most preferably, the gel composition contains at least about 0.2 weight percent of a hydrogen-bonding crosslinking gelling agent and at least about 0.2 weight percent of an ion-crosslinking gelling agent. The gel composition may contain about 0.5 to about 3 weight percent of a hydrogen-bonding crosslinking gelling agent and about 0.5 to about 3 weight percent of an ion-crosslinking gelling agent, or about 1 to about 2 weight percent of a hydrogen-bonding crosslinking gelling agent and about 1 to about 2 weight percent of an ion-crosslinking gelling agent. The hydrogen-bonding crosslinking gelling agent and the ion-crosslinking gelling agent may be present in substantially equal amounts in the gel composition.

[0090] The term "hydrogen bond crosslinking gelling agent" refers to a gelling agent that forms non-covalent or physical crosslinks via hydrogen bonds. Hydrogen bonds are not covalent bonds to hydrogen atoms, but rather a type of electrostatic dipole-dipole attraction between molecules. This results from the attraction between a hydrogen atom covalently bonded to an extremely electronegative atom, such as N, O, or F atoms, and another extremely electronegative atom.

[0091] The hydrogen bonding crosslinking gelling agent may contain one or more of galactomannan, gelatin, agarose, konjac gum, or agar. It is preferable that the hydrogen bonding crosslinking gelling agent contains agar.

[0092] The gel composition preferably contains a hydrogen bonding crosslinking gelling agent in an amount ranging from about 0.3% to about 5% by weight. Preferably, the composition contains a hydrogen bonding crosslinking gelling agent in an amount ranging from about 0.5% to about 3% by weight. Preferably, the composition contains a hydrogen bonding crosslinking gelling agent in an amount ranging from about 1% to about 2% by weight.

[0093] The gel composition may contain galactomannan in an amount ranging from about 0.2% to about 5% by weight. Preferably, the galactomannan may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the galactomannan may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the galactomannan may be in an amount ranging from about 1% to about 2% by weight.

[0094] The gel composition may contain gelatin in an amount ranging from about 0.2% to about 5% by weight. Preferably, the amount of gelatin may be in the range of about 0.5% to about 3% by weight. Preferably, the amount of gelatin may be in the range of about 0.5% to about 2% by weight. Preferably, the amount of gelatin may be in the range of about 1% to about 2% by weight.

[0095] The gel composition may contain agarose in an amount ranging from about 0.2% to about 5% by weight. Preferably, the agarose may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the agarose may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the agarose may be in an amount ranging from about 1% to about 2% by weight.

[0096] The gel composition may contain konjac gum in an amount ranging from about 0.2% to about 5% by weight. Preferably, the amount of konjac gum may be in the range of about 0.5% to about 3% by weight. Preferably, the amount of konjac gum may be in the range of about 0.5% to about 2% by weight. Preferably, the amount of konjac gum may be in the range of about 1% to about 2% by weight.

[0097] The gel composition may contain agar in an amount ranging from about 0.2% to about 5% by weight. Preferably, the agar may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the agar may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the agar may be in an amount ranging from about 1% to about 2% by weight.

[0098] The term "ionic crosslinking gelling agent" refers to a gelling agent that forms non-covalent or physical crosslinks via ionic bonding. Ionic crosslinking involves the association of polymer chains through non-covalent interactions. A crosslinking network is formed when polyvalent molecules with opposite charges are electrostatically attracted to each other, creating a crosslinked polymer network.

[0099] The ion-crosslinking gelling agent may include low-acylgellan, pectin, kappa-carrageenan, iota-carrageenan, or alginate. It is preferable that the ion-crosslinking gelling agent may include low-acylgellan.

[0100] The gel composition may contain an ion-crosslinking gelling agent in an amount ranging from about 0.3% to about 5% by weight. Preferably, the composition contains an ion-crosslinking gelling agent in an amount ranging from about 0.5% to about 3% by weight. Preferably, the composition contains an ion-crosslinking gelling agent in an amount ranging from about 1% to about 2% by weight.

[0101] The gel composition may contain low acylgelane in an amount ranging from about 0.2% to about 5% by weight. Preferably, the low acylgelane may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the low acylgelane may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the low acylgelane may be in an amount ranging from about 1% to about 2% by weight.

[0102] The gel composition may contain pectin in an amount ranging from about 0.2% to about 5% by weight. Preferably, the pectin may be in the range of about 0.5% to about 3% by weight. Preferably, the pectin may be in the range of about 0.5% to about 2% by weight. Preferably, the pectin may be in the range of about 1% to about 2% by weight.

[0103] The gel composition may contain kappacarrageenan in an amount ranging from about 0.2% to about 5% by weight. Preferably, the amount of kappacarrageenan may be in the range of about 0.5% to about 3% by weight. Preferably, the amount of kappacarrageenan may be in the range of about 0.5% to about 2% by weight. Preferably, the amount of kappacarrageenan may be in the range of about 1% to about 2% by weight.

[0104] The gel composition may contain ι-carrageenan in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the ι-carrageenan may be within the range of about 0.5 weight percent to about 3 weight percent. Preferably, the ι-carrageenan may be within the range of about 0.5 weight percent to about 2 weight percent. Preferably, the ι-carrageenan may be within the range of about 1 weight percent to about 2 weight percent.

[0105] The gel composition may contain alginate in the range of about 0.2 weight percent to about 5 weight percent. Preferably, the alginate may be within the range of about 0.5 weight percent to about 3 weight percent. Preferably, the alginate may be within the range of about 0.5 weight percent to about 2 weight percent. Preferably, the alginate may be within the range of about 1 weight percent to about 2 weight percent.

[0106] The gel composition may contain a hydrogen bond cross-linking gelling agent and an ionic cross-linking gelling agent in a ratio of about 3:1 to about 1:3. Preferably, the gel composition may contain a hydrogen bond cross-linking gelling agent and an ionic cross-linking gelling agent in a ratio of about 2:1 to about 1:2. Preferably, the gel composition may contain a hydrogen bond cross-linking gelling agent and an ionic cross-linking gelling agent in a ratio of about 1:1.

[0107] The gel composition may further contain a thickening agent. The thickening agent combined with the hydrogen bond cross-linking gelling agent and the ionic cross-linking gelling agent surprisingly seems to support the solid medium and maintain the gel composition even when the gel composition contains a high level of glycerol.

[0108] The term "thickening agent" refers to a compound that increases the viscosity without causing gel formation and keeps the mixture in a fluid state or remains fluid when uniformly added in an amount of 0.3 weight percent into a mixture of 50 weight percent water / 50 weight percent glycerin at 25°C. Preferably, the thickening agent has a viscosity of 0.1s when uniformly added in an amount of 0.3 weight percent into a mixture of 50 weight percent water / 50 weight percent glycerin at 25°C. -1This refers to a compound that, at a shear rate of 0.1°C, increases the viscosity to at least 50 cPs, preferably at least 200 cPs, preferably at least 500 cPs, preferably at least 1000 cPs, without causing gel formation, and causes the mixture to remain in a fluid state or stay fluid. Preferably, the thickener, when homogeneously added in an amount of 0.3 wt% to a mixture of 50 wt% water / 50 wt% glycerol at 25°C, causes a viscosity of 0.1°C without causing gel formation. -1 This refers to a compound that, at a shear rate, increases viscosity by at least 2 times, at least 5 times, at least 10 times, or at least 100 times compared to before addition, and which keeps the mixture fluid or preserved.

[0109] The viscosity values ​​listed herein can be measured using a Brookfield RVT viscometer, rotating a disk-type RV#2 spindle at a speed of 6 revolutions per minute (rpm) at 25°C.

[0110] The gel composition preferably contains a thickening agent in an amount ranging from about 0.2% to about 5% by weight. Preferably, the composition contains a thickening agent in an amount ranging from about 0.5% to about 3% by weight. Preferably, the composition contains a thickening agent in an amount ranging from about 0.5% to about 2% by weight. Preferably, the composition contains a thickening agent in an amount ranging from about 1% to about 2% by weight.

[0111] The thickener may contain one or more of the following: xanthan gum, carboxymethylcellulose, microcrystalline cellulose, methylcellulose, gum arabic, guar gum, lambda carrageenan, or starch. It is preferable that the thickener contains xanthan gum.

[0112] The gel composition may contain xanthan gum in an amount ranging from about 0.2% to about 5% by weight. Preferably, the xanthan gum may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the xanthan gum may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the xanthan gum may be in an amount ranging from about 1% to about 2% by weight.

[0113] The gel composition may contain carboxymethylcellulose in an amount ranging from about 0.2% to about 5% by weight. Preferably, the carboxymethylcellulose may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the carboxymethylcellulose may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the carboxymethylcellulose may be in an amount ranging from about 1% to about 2% by weight.

[0114] The gel composition may contain microcrystalline cellulose in an amount ranging from about 0.2% to about 5% by weight. Preferably, the microcrystalline cellulose may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the microcrystalline cellulose may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the microcrystalline cellulose may be in an amount ranging from about 1% to about 2% by weight.

[0115] The gel composition may contain methylcellulose in an amount ranging from about 0.2% to about 5% by weight. Preferably, the methylcellulose may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the methylcellulose may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the methylcellulose may be in an amount ranging from about 1% to about 2% by weight.

[0116] The gel composition may contain gum arabic in an amount ranging from about 0.2% to about 5% by weight. Preferably, the amount of gum arabic may be in the range of about 0.5% to about 3% by weight. Preferably, the amount of gum arabic may be in the range of about 0.5% to about 2% by weight. Preferably, the amount of gum arabic may be in the range of about 1% to about 2% by weight.

[0117] The gel composition may contain guar gum in an amount ranging from about 0.2% to about 5% by weight. Preferably, the amount of guar gum may be in the range of about 0.5% to about 3% by weight. Preferably, the amount of guar gum may be in the range of about 0.5% to about 2% by weight. Preferably, the amount of guar gum may be in the range of about 1% to about 2% by weight.

[0118] The gel composition may contain lambda carrageenan in an amount ranging from about 0.2% to about 5% by weight. Preferably, the lambda carrageenan may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the lambda carrageenan may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the lambda carrageenan may be in an amount ranging from about 1% to about 2% by weight.

[0119] The gel composition may contain starch in an amount ranging from about 0.2% to about 5% by weight. Preferably, the starch may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the starch may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the starch may be in an amount ranging from about 1% to about 2% by weight.

[0120] The gel composition may further contain divalent cations. Preferably, the divalent cations include calcium ions such as calcium lactate in the solution. Divalent cations (such as calcium ions) can assist in gel formation in compositions containing gelling agents, such as ion-crosslinking gelling agents. Ionic effects may assist in gel formation. Divalent cations may be present in the gel composition in the range of about 0.1 to about 1 weight percent, or about 0.5 weight percent.

[0121] The gel composition may further contain an acid. The acid may contain a carboxylic acid. The carboxylic acid may contain a ketone group. Preferably, the carboxylic acid may contain a ketone group having less than 10 carbon atoms, such as levulinic acid or lactic acid, or less than 6 carbon atoms or less than 4 carbonate atoms. Preferably, this carboxylic acid has three carbon atoms (such as lactic acid). Surprisingly, lactic acid improves the stability of the gel composition to a greater extent than similar carboxylic acids. The carboxylic acid may assist in gel formation. The carboxylic acid may reduce changes in the concentration of alkaloid compounds, or cannabinoid compounds, or both, in the gel composition during storage. The carboxylic acid may reduce changes in the nicotine concentration in the gel composition during storage.

[0122] The gel composition may contain a carboxylic acid in an amount ranging from about 0.1% to about 5% by weight. Preferably, the carboxylic acid may be in the range of about 0.5% to about 3% by weight. Preferably, the carboxylic acid may be in the range of about 0.5% to about 2% by weight. Preferably, the carboxylic acid may be in the range of about 1% to about 2% by weight.

[0123] The gel composition may contain lactic acid in an amount ranging from about 0.1% to about 5% by weight. Preferably, the lactic acid may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the lactic acid may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the lactic acid may be in an amount ranging from about 1% to about 2% by weight.

[0124] The gel composition may contain levulinic acid in an amount ranging from about 0.1% to about 5% by weight. Preferably, the levulinic acid may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the levulinic acid may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the levulinic acid may be in an amount ranging from about 1% to about 2% by weight.

[0125] The gel composition preferably contains some water. The gel composition is more stable when it contains some water. The gel composition preferably contains at least about 1 weight percent, or at least about 2 weight percent, or at least about 5 weight percent of water. The gel composition preferably contains at least about 10 weight percent, or at least about 15 weight percent of water.

[0126] The gel composition preferably contains about 8% to about 32% by weight of water. The gel composition preferably contains about 15% to about 25% by weight of water. The gel composition preferably contains about 18% to about 22% by weight of water. The gel composition preferably contains about 20% by weight of water.

[0127] Preferably, the aerosol generating substrate contains about 150 mg to about 350 mg of gel composition.

[0128] Preferably, the aerosol generating substrate comprises a porous medium filled with a gel composition. The advantage of a porous medium filled with a gel composition is that the gel composition is retained within the porous medium, which can aid in the manufacture, storage, or transport of the gel composition. This can help maintain the desired shape of the gel composition, particularly during manufacture, transport, or use.

[0129] The porous medium can be any suitable porous material capable of holding or retaining the gel composition. Ideally, the porous medium can allow the gel composition to move within it. In certain embodiments, the porous medium includes natural materials, synthetic or semi-synthetic materials, or combinations thereof. In certain embodiments, the porous medium includes sheet materials, foams, or fibers, such as loose fibers, or combinations thereof. In certain embodiments, the porous medium includes woven fabrics, nonwoven fabrics, or extruded materials, or combinations thereof. Preferably, the porous medium includes cotton, paper, viscose, PLA, or cellulose acetate, or combinations thereof. Preferably, the porous medium includes sheet materials, such as cotton or cellulose acetate. In a particularly preferred embodiment, the porous medium includes a sheet made from cotton fibers.

[0130] The porous medium used in the present invention may be crimped or shredded. In a preferred embodiment, the porous medium is crimped. In an alternative embodiment, the porous medium includes a shredded porous medium. The crimping or shredding process may be performed before or after loading the gel composition.

[0131] The crimping of sheet materials has the advantage of improving the structure and creating passages through it. These passages in the crimped sheet material facilitate gel loading, gel retention, and fluid passage through the crimped material. Therefore, there are advantages to using crimped sheet materials as porous media.

[0132] Shredding provides a high surface area-to-volume ratio to the medium, allowing it to easily absorb the gel.

[0133] In certain embodiments, the sheet material is a composite material. The sheet material is preferably porous. The sheet material can assist in the production of tubular elements containing gels. The sheet material can assist in the introduction of activators into tubular elements containing gels. The sheet material may help in stabilizing the structure of tubular elements containing gels. The sheet material can assist in the transport or storage of gels. The use of the sheet material allows, for example, to add structure to a porous medium by crimping the sheet material, or assists in such addition.

[0134] The porous medium can be thread. Thread may include, for example, cotton, paper, or acetate thread. Thread may also be loaded with gel, like any other porous medium. An advantage of using thread as a porous medium is that it can aid in ease of manufacture.

[0135] The threads may be loaded with gel by any known means. The threads may be simply coated with gel, or they may be impregnated with gel. In manufacturing, the threads may be impregnated with gel and stored ready for immediate use so that they can be included in the assembly of tubular elements.

[0136] The porous medium loaded with the gel composition is preferably provided within a tubular element that forms part of an aerosol-generating article. The term “tubular element” is used to describe a component suitable for use in an aerosol-generating article. Ideally, the tubular element has a longitudinal length greater than its width, but this is not necessarily required, as it may be part of a multi-component item where its longitudinal length is greater than its width. Typically, the tubular element is cylindrical, but this is not necessarily required. For example, the tubular element may have an elliptical, triangular, or rectangular polygonal, or irregular cross-section.

[0137] The tubular element preferably includes a first longitudinal passage. The tubular element is preferably formed from a wrapper defining the first longitudinal passage. The wrapper is preferably a water-resistant wrapper. This water resistance of the wrapper can be achieved by using a water-resistant material or by treating the material of the wrapper. This can be achieved by treating one or both sides of the wrapper. Being water-resistant can help not lose structure, hardness, or rigidity. This can also help prevent leakage of gel or liquid, especially when using a gel in a fluid structure.

[0138] Preferably, as described above, in embodiments in which the rod of the aerosol generating substrate includes a gel composition, the downstream section of the aerosol generating article comprises an aerosol cooling element having a length of less than 10 millimeters. It has been found that using a relatively short aerosol cooling element in combination with the gel composition optimizes the delivery of aerosols to consumers. More detailed information regarding the provision of aerosol cooling elements is provided below.

[0139] Embodiments of the present invention in which the aerosol-generating substrate rod contains the above-described gel composition preferably include an upstream element upstream of the aerosol-generating substrate rod. In this case, the upstream element advantageously prevents physical contact with the gel composition. The upstream element can also advantageously compensate for any potential reduction in RTD due to evaporation of the gel composition when the aerosol-generating substrate rod is heated during use, for example. Further details regarding the provision of one such upstream element are described below.

[0140] In some embodiments, the aerosol generating article according to the present invention has a susceptor positioned within a rod of the aerosol generating substrate and in thermal contact with the aerosol generating substrate. The susceptor is preferably elongated. More preferably, the elongated susceptor is positioned substantially longitudinally within the rod of the aerosol generating substrate.

[0141] As used herein, the term “susceptor” refers to a material capable of converting electromagnetic energy into heat. When located in a fluctuating electromagnetic field, induced eddy currents in the susceptor cause heating of the susceptor. The elongated susceptor is positioned in thermal contact with an aerosol-generating substrate, and the aerosol-generating substrate is heated by the susceptor.

[0142] When used to describe a susceptor, the term "elongated" means that the susceptor has a length dimension that is greater than its width dimension or thickness dimension, for example, a length dimension greater than twice its width dimension or thickness dimension.

[0143] The susceptors are arranged substantially longitudinally within the rod. This means that the length dimensions of the elongated susceptors are aligned approximately parallel to the longitudinal direction of the rod, for example, within ±10 degrees of parallel to the longitudinal direction of the rod. In a preferred embodiment, the elongated susceptors may be positioned radially centrally within the rod and extend along the longitudinal axis of the rod.

[0144] Preferably, the susceptor extends fully to the downstream end of the rod of the aerosol generating article. In some embodiments, the susceptor may extend fully to the upstream end of the rod of the aerosol generating article. In a particularly preferred embodiment, the susceptor has substantially the same length as the rod of the aerosol generating substrate and extends from the upstream end of the rod to the downstream end of the rod.

[0145] The susceptor is preferably in the form of a pin, rod, strip, or blade.

[0146] The susceptor is preferably in the range of approximately 5 mm to approximately 15 mm (for example, approximately 6 mm to approximately 12 mm, or approximately 8 mm to approximately 10 mm).

[0147] The ratio between the length of the susceptor and the total length of the aerosol-generating article substrate can be approximately 0.2 to 0.35.

[0148] Preferably, the ratio of the susceptor length to the total length of the aerosol-generating article substrate is at least about 0.22, more preferably at least about 0.24, and even more preferably at least about 0.26. Preferably, the ratio of the susceptor length to the total length of the aerosol-generating article substrate is less than about 0.34, more preferably less than about 0.32, and even more preferably less than about 0.3.

[0149] In some embodiments, the ratio of the susceptor length to the total length of the aerosol-generating article substrate is preferably about 0.22 to about 0.34, more preferably about 0.24 to about 0.34, and even more preferably about 0.26 to about 0.34. In other embodiments, the ratio of the susceptor length to the total length of the aerosol-generating article substrate is preferably about 0.22 to about 0.32, more preferably about 0.24 to about 0.32, and even more preferably about 0.26 to about 0.32. In further embodiments, the ratio of the susceptor length to the total length of the aerosol-generating article substrate is preferably about 0.22 to about 0.3, more preferably about 0.24 to about 0.3, and even more preferably about 0.26 to about 0.3.

[0150] In a particularly preferred embodiment, the ratio between the length of the susceptor and the total length of the aerosol-generating article substrate is about 0.27.

[0151] The susceptor preferably has a width of about 1 mm to about 5 mm.

[0152] The susceptor can generally have a thickness of about 0.01 mm to about 2 mm, for example, about 0.5 mm to about 2 mm. In some embodiments, the susceptor preferably has a thickness of about 10 micrometers to about 500 micrometers, more preferably about 10 micrometers to about 100 micrometers.

[0153] If the susceptor has a certain cross-section, for example a circular cross-section, it has a preferred width or diameter of about 1 mm to about 5 mm.

[0154] If the susceptor is in the form of a strip or blade, the strip or blade is preferably rectangular in shape with a width of about 2 mm to about 8 mm, more preferably about 3 mm to about 5 mm. As an example, a susceptor in the form of a strip or blade may have a width of about 4 mm.

[0155] If the susceptor is in the form of a strip or blade, the strip or blade is preferably rectangular in shape and thickness of about 0.03 mm to about 0.15 mm, more preferably about 0.05 mm to about 0.09 mm. As an example, a susceptor in the form of a strip or blade may have a thickness of about 0.07 mm.

[0156] In a preferred embodiment, the elongated susceptor (in the form of a strip or blade, preferably having a rectangular shape) has a thickness of about 55 micrometers to about 65 micrometers.

[0157] More preferably, the elongated susceptor has a thickness of about 57 micrometers to about 63 micrometers. Even more preferably, the elongated susceptor has a thickness of about 58 micrometers to about 62 micrometers. In a particularly preferred embodiment, the elongated susceptor has a thickness of about 60 micrometers.

[0158] While not wishing to be constrained by theory, the inventors believe that, as a whole, the selection of a given susceptor thickness is also influenced by constraints set by the selected length and width of the susceptor, as well as by constraints set by the geometric shape and dimensions of the rod of the aerosol generating substrate. As an example, the length of the susceptor is preferably selected to match the length of the rod of the aerosol generating substrate. The width of the susceptor should preferably be selected so as to prevent displacement of the susceptor within the substrate, while also allowing for easy insertion during manufacturing.

[0159] The inventors have found that susceptors having a thickness within the aforementioned range are advantageous in aerosol-generating articles provided to inductively supply heat during use, as they generate and distribute heat in a particularly effective and efficient manner throughout the aerosol-generating substrate. While not intended to be bound by theory, the inventors believe that one such susceptor is adapted to provide optimal heat generation and heat transfer due to its surface area and inductive force. In contrast, thinner susceptors are too easily deformed and may not maintain the desired shape and orientation within the rod of the aerosol-generating substrate during the manufacture of the aerosol-generating article, resulting in less homogeneous and finely tuned heat distribution during use. At the same time, thicker susceptors may be more difficult to cut to precise and consistent lengths, which may also affect how accurately the susceptors are provided longitudinally aligned within the rod of the aerosol-generating substrate, and thus the homogeneity of the heat distribution within the rod. These beneficial effects are particularly noticeable when the susceptor extends fully to the downstream end of the rod of the aerosol-generating article. This is thought to be because the downstream RTD can be essentially minimized because there is no aerosol-generating substrate in the rod located downstream of the susceptor, which could contribute to the RTD. This is achieved particularly effectively in some preferred embodiments, described in more detail below, in which the aerosol-generating article includes a downstream section containing a hollow intermediate section. One of these hollow intermediate sections does not substantially contribute to the overall RTD of the aerosol-generating article and does not directly contact the downstream end of the susceptor.

[0160] While not intended to be constrained by theory, the inventors believe that the downstream portion of the aerosol generating substrate rod can, to some extent, act as a filter for the upstream portion of the aerosol generating substrate rod. Therefore, the inventors believe it is desirable that the downstream portion of the aerosol generating substrate rod can also be heated uniformly, thereby actively counteracting any filtering effect that could potentially interfere with the release of volatile aerosol species, contribute to the overall generation and delivery of aerosols, and hinder the delivery of aerosols to consumers, as volatile aerosol species are released throughout the aerosol generating substrate.

[0161] The elongated susceptor is preferably the same length as or shorter than the aerosol-generating substrate.

[0162] The susceptor may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-generating substrate. Preferred susceptors include metals or carbon.

[0163] A preferred susceptor may include, or consist of, a ferromagnetic material, such as a ferromagnetic alloy, ferrite iron, or ferromagnetic steel or stainless steel. A preferred susceptor may also be aluminum or contain aluminum. A preferred susceptor may be formed from 400 series stainless steel, such as grade 410, or grade 420, or grade 430 stainless steel. Different materials dissipate different amounts of energy when positioned in an electromagnetic field having similar values ​​of frequency and magnetic field strength.

[0164] Thus, the parameters of the susceptor, such as the type of material, length, width, and thickness, may all be modified to provide desirable power dissipation within a known electromagnetic field. A preferred susceptor may be heated to a temperature above 250 degrees Celsius.

[0165] A suitable susceptor may include a nonmetallic core having a metal layer disposed on top of a nonmetallic core, for example, a metal track formed on the surface of a ceramic core. The susceptor may have a protective outer layer enclosing the susceptor, for example, a protective ceramic layer or a protective glass layer. The susceptor may also include a protective coating formed of glass, ceramic, or an inert metal formed on the core of the susceptor material.

[0166] The susceptor is positioned in thermal contact with the aerosol-generating substrate. As the temperature of the susceptor rises, the aerosol-generating substrate is heated, and an aerosol is formed. Preferably, the susceptor is positioned, for example, within the aerosol-generating substrate, in direct physical contact with the aerosol-generating substrate.

[0167] 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 arranged in physical contact with the second susceptor material. The second susceptor material preferably has a Curie temperature lower than 500 degrees Celsius. The first susceptor material is preferably used primarily to heat the susceptor when it is placed in a fluctuating electromagnetic field. Any suitable material may be used. For example, the first susceptor material may be aluminum or an iron-based material such as stainless steel. The second susceptor material is preferably used primarily 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 overall temperature of the susceptor during operation. Therefore, the Curie temperature of the second susceptor material should be below the ignition point of the aerosol generating substrate. Suitable materials for the second susceptor material may include nickel and certain nickel alloys.

[0168] The heating of the aerosol generating substrate and the temperature control of its heating can be separated by providing a susceptor having at least first and second susceptor materials, a second susceptor material having a Curie temperature and a first susceptor material not having a Curie temperature, or by providing first and second susceptor materials having different first and second Curie temperatures. The first susceptor material is preferably a magnetic material having a Curie temperature of over 500 degrees Celsius. From the viewpoint of heating efficiency, it is desirable that the Curie temperature of the first susceptor material exceeds any maximum temperature to which the susceptor can be heated. The second Curie temperature may be selected to be preferably lower than 400 degrees Celsius, preferably lower than 380 degrees Celsius, or lower than 360 degrees Celsius. The second susceptor material is preferably a magnetic material selected to have a second Curie temperature that is substantially the same as the desired maximum heating temperature. In other words, the second Curie temperature is preferably approximately the same as the temperature at which the susceptor should be heated to generate aerosols from the aerosol-generating substrate. The second Curie temperature may be, for example, in the range of 200 to 400 degrees Celsius, or in the range of 250 to 360 degrees Celsius. The second Curie temperature of the second susceptor material may be selected such that, when heated by a susceptor with a temperature equal to the second Curie temperature, the overall average temperature of the aerosol-generating substrate does not exceed 240 degrees Celsius.

[0169] As briefly described above, the aerosol generating article according to the present invention further comprises a downstream section located downstream of the rod of the aerosol generating substrate. As will become apparent from the following description of different embodiments of the aerosol generating article of the present invention, the downstream section may include one or more downstream elements.

[0170] According to the present invention, the downstream section of the aerosol generating article includes, in particular, a mouthpiece element located downstream of the rod of the aerosol generating substrate and aligned longitudinally with the rod of the aerosol generating substrate.

[0171] The mouthpiece element is preferably located at the downstream end or oral end of the aerosol-generating article and extends all the way to the oral end of the aerosol-generating article.

[0172] Preferably, the mouthpiece element comprises a mouthpiece filter segment of at least one fibrous filter material for filtering aerosols generated from an aerosol generating substrate. Suitable fibrous filter materials will be known to those skilled in the art. Particularly preferably, at least one mouthpiece filter segment comprises a cellulose acetate filter segment formed from cellulose acetate tow.

[0173] In certain preferred embodiments, the mouthpiece element consists of a single mouthpiece filter segment. In alternative embodiments, the mouthpiece element comprises two or more mouthpiece filter segments aligned axially with end-to-end contact with one another.

[0174] In certain embodiments of the present invention, the downstream section may have an oral end cavity at the downstream end of the mouthpiece element as described above. The oral end cavity may be defined by a hollow tubular element provided at the downstream end of the mouthpiece. Alternatively, the oral end cavity may be defined by an outer wrapper of the mouthpiece element, which extends downstream from the mouthpiece element.

[0175] The mouthpiece element may optionally contain flavoring agents that can be provided in any preferred form. For example, the mouthpiece element may contain one or more capsules, flavoring agent beads or granules, or one or more flavoring threads or filaments.

[0176] In the aerosol generating article according to the present invention, the mouthpiece element forms part of the downstream section and is therefore located downstream of the rod of the aerosol generating substrate.

[0177] In certain preferred embodiments, the downstream section of the aerosol generating article further comprises a support element located immediately downstream of the rod of the aerosol generating substrate. A mouthpiece element is preferably located downstream of the support element. Preferably, the downstream section further comprises an aerosol cooling element located immediately downstream of the support element. The mouthpiece element is preferably located downstream of both the support element and the aerosol cooling element. Particularly preferably, the mouthpiece element is located immediately downstream of the aerosol cooling element. As an example, the mouthpiece element may abut against the downstream end of the aerosol cooling element.

[0178] Preferably, the mouthpiece element has a low particle filtration efficiency.

[0179] Preferably, the mouthpiece is formed from segments of fibrous filter material.

[0180] The mouthpiece element is preferably surrounded by a plug wrap. Preferably, the mouthpiece element is not ventilated so that air does not enter the aerosol-generating article along the mouthpiece element.

[0181] The mouthpiece element is preferably connected by a chipping wrapper to one or more adjacent upstream components of the aerosol generating article. For example, the mouthpiece element may be connected by a band of chipping paper to the immediately adjacent aerosol cooling element.

[0182] Preferably, the mouthpiece element has an RTD of less than about 25 mmH2O. More preferably, the mouthpiece element has an RTD of less than about 20 mmH2O. Even more preferably, the mouthpiece element has an RTD of less than about 15 mmH2O.

[0183] A RTD value of approximately 10 mmH2O to approximately 15 mmH2O is particularly preferable, as it is expected that a mouthpiece element having one such RTD will contribute minimally to the overall RTD of the aerosol-generating article and therefore will not substantially filter the aerosol delivered to the consumer.

[0184] The mouthpiece element preferably has an outer diameter approximately equal to the outer diameter of the aerosol generating article. The mouthpiece element may have an outer diameter of about 5 mm to about 10 mm, or about 6 mm to about 8 mm. In a preferred embodiment, the mouthpiece element has an outer diameter of about 7.2 mm.

[0185] The mouthpiece element preferably has a length of at least about 5 mm, more preferably at least about 8 mm, and more preferably at least about 10 mm. Alternatively, or additionally, the mouthpiece element preferably has a length of less than about 25 mm, more preferably less than about 20 mm, and more preferably less than about 15 mm.

[0186] In some embodiments, the mouthpiece element preferably has a length of about 5 mm to about 25 mm, more preferably about 8 mm to about 25 mm, and even more preferably about 10 mm to about 25 mm. In other embodiments, the mouthpiece element preferably has a length of about 5 mm to about 10 mm, more preferably about 8 mm to about 20 mm, and even more preferably about 10 mm to about 20 mm. In further embodiments, the mouthpiece element preferably has a length of about 5 mm to about 15 mm, more preferably about 8 mm to about 15 mm, and even more preferably about 10 mm to about 15 mm.

[0187] For example, the mouthpiece element may have a length of about 5 mm to about 25 mm, or about 8 mm to about 20 mm, or about 10 mm to about 15 mm. In a preferred embodiment, the mouthpiece element has a length of about 12 mm.

[0188] In certain preferred embodiments of the present invention, the mouthpiece element has a length of at least 10 millimeters. In such embodiments, the mouthpiece element is therefore relatively longer than the mouthpiece elements provided in prior art articles. Providing a relatively long mouthpiece element in the aerosol generating article of the present invention may offer several benefits to consumers. The mouthpiece element is typically more elastic to deformation or better conformed to recover its initial shape after deformation than other elements that may be provided downstream of the rod of the aerosol generating substrate, such as aerosol cooling elements or support elements. Therefore, increasing the length of the mouthpiece element has been found to provide an improved grip by consumers and facilitate insertion of the aerosol generating article into a heating device. The additional use of longer mouthpieces may provide a higher level of filtration and removal of undesirable aerosol components such as phenol, thereby enabling the delivery of higher quality aerosols. Furthermore, the use of longer mouthpiece elements allows for the provision of more complex mouthpieces, as there is more space to incorporate mouthpiece components such as capsules, threads, and restrictors.

[0189] In a particularly preferred embodiment of the present invention, a mouthpiece having a length of at least 10 millimeters is combined with a relatively short aerosol cooling element, for example, an aerosol cooling element having a length of less than 10 millimeters. This combination has been found to provide a more rigid mouthpiece that reduces the risk of deformation of the aerosol cooling element during use and contributes to a more efficient smoking action by the consumer.

[0190] The ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate can be approximately 0.5 to approximately 1.5.

[0191] The ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate is preferably at least about 0.6, more preferably at least about 0.7, and even more preferably at least about 0.8. In a preferred embodiment, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate is less than about 1.4, more preferably less than about 1.3, and even more preferably less than about 1.2.

[0192] In some embodiments, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate is about 0.6 to about 1.4, preferably about 0.7 to about 1.4, and more preferably about 0.8 to about 1.4. In other embodiments, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate is about 0.6 to about 1.3, preferably about 0.7 to about 1.3, and more preferably about 0.8 to about 1.3. In further embodiments, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate is about 0.6 to about 1.2, preferably about 0.7 to about 1.2, and more preferably about 0.8 to about 1.2.

[0193] In a particularly preferred embodiment, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate is about 1.

[0194] The ratio between the length of the mouthpiece element and the total length of the aerosol-generating article substrate can be approximately 0.2 to approximately 0.35.

[0195] Preferably, the ratio of the length of the mouthpiece element to the total length of the aerosol-generating article substrate is at least about 0.22, more preferably at least about 0.24, and even more preferably at least about 0.26. Preferably, the ratio of the length of the mouthpiece element to the total length of the aerosol-generating article substrate is less than about 0.34, more preferably less than about 0.32, and even more preferably less than about 0.3.

[0196] In some embodiments, the ratio of the length of the mouthpiece element to the total length of the aerosol-generating article substrate is preferably about 0.22 to about 0.34, more preferably about 0.24 to about 0.34, and even more preferably about 0.26 to about 0.34. In other embodiments, the ratio of the length of the mouthpiece element to the total length of the aerosol-generating article substrate is preferably about 0.22 to about 0.32, more preferably about 0.24 to about 0.32, and even more preferably about 0.26 to about 0.32. In further embodiments, the ratio of the length of the mouthpiece element to the total length of the aerosol-generating article substrate is preferably about 0.22 to about 0.3, more preferably about 0.24 to about 0.3, and even more preferably about 0.26 to about 0.3.

[0197] In a particularly preferred embodiment, the ratio between the length of the mouthpiece element and the total length of the aerosol-generating article substrate is about 0.27.

[0198] The aerosol-generating article may have a length of approximately 35 mm to approximately 100 mm.

[0199] The total length of the aerosol generating article according to the present invention is preferably at least about 38 millimeters. More preferably, the total length of the aerosol generating article according to the present invention is at least about 40 millimeters. Even more preferably, the total length of the aerosol generating article according to the present invention is at least about 42 millimeters.

[0200] The total length of the aerosol generating article according to the present invention is preferably 70 millimeters or less. More preferably, the total length of the aerosol generating article according to the present invention is preferably 60 millimeters or less. Even more preferably, the total length of the aerosol generating article according to the present invention is preferably 50 millimeters or less.

[0201] In some embodiments, the total length of the aerosol generating article is preferably about 38 mm to about 70 mm, more preferably about 40 mm to about 70 mm, and even more preferably about 42 mm to about 70 mm. In other embodiments, the total length of the aerosol generating article is preferably about 38 mm to about 60 mm, more preferably about 40 mm to about 60 mm, and even more preferably about 42 mm to about 60 mm. In further embodiments, the total length of the aerosol generating article is preferably about 38 mm to about 50 mm, more preferably about 40 mm to about 50 mm, and even more preferably about 42 mm to about 50 mm. In an exemplary embodiment, the total length of the aerosol generating article is about 45 mm.

[0202] The aerosol-generating article has an outer diameter of at least 5 mm. Preferably, the aerosol-generating article has an outer diameter of at least 6 mm. More preferably, the aerosol-generating article has an outer diameter of at least 7 mm.

[0203] The aerosol generating article preferably has an outer diameter of about 12 mm or less. More preferably, the aerosol generating article has an outer diameter of about 10 mm or less. Even more preferably, the aerosol generating article has an outer diameter of about 8 mm or less.

[0204] In some embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 12 mm, preferably about 6 mm to about 12 mm, and more preferably about 7 mm to about 12 mm. In other embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 10 mm, preferably about 6 mm to about 10 mm, and more preferably about 7 mm to about 10 mm. In further embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 8 mm, preferably about 6 mm to about 8 mm, and more preferably about 7 mm to about 8 mm.

[0205] According to the present invention, the diameter (D) of the aerosol-generating article at the mouth end is ME ) is the diameter (D) of the aerosol-generating article at the distal end. DE ) is greater than the ratio (D) between the diameter of the aerosol-generating article at the oral end and the diameter of the aerosol-generating article at the distal end. ME / D DE ) is at least about 1.005.

[0206] Preferably, the ratio (D) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end. ME / D DE ) is (preferably) at least about 1.01. More preferably, the ratio (D) between the diameter of the aerosol generating article at the mouth end and the diameter of the aerosol generating article at the distal end is ME / D DE The ratio (D) between the diameter of the aerosol-generating article at the oral end and the diameter of the aerosol-generating article at the distal end is at least about 1.02. More preferably, the ratio (D) between the diameter of the aerosol-generating article at the oral end and the diameter of the aerosol-generating article at the distal end is at least about 1.02. ME / D DE ) is at least about 1.05.

[0207] The ratio (D) between the diameter of the aerosol-generating object at the oral end and the diameter of the aerosol-generating object at the distal end. ME / D DEThe ratio (D) between the diameter of the aerosol generating article at the mouth end and the diameter of the aerosol generating article at the distal end is preferably about 1.30 or less. ME / D DE The ratio (D) between the diameter of the aerosol generating article at the oral end and the diameter of the aerosol generating article at the distal end is approximately 1.25 or less. More preferably, the ratio (D) between the diameter of the aerosol generating article at the oral end and the diameter of the aerosol generating article at the distal end is approximately 1.25 or less. ME / D DE ) is about 1.20 or less. In a particularly preferred embodiment, the ratio (D) between the diameter of the aerosol generating article at the mouth end and the diameter of the aerosol generating article at the distal end is about 1.20 or less. ME / D DE ) is 1.15 or 1.10 or less.

[0208] In some preferred embodiments, the ratio (D) between the diameter of the aerosol-generating article at the oral end and the diameter of the aerosol-generating article at the distal end is ME / D DE The ratio is approximately 1.01 to 1.30, more preferably 1.02 to 1.30, and even more preferably 1.05 to 1.30.

[0209] In other embodiments, the ratio (D) between the diameter of the aerosol-generating article at the oral end and the diameter of the aerosol-generating article at the distal end is ME / D DE The ratio (D) is approximately 1.01 to 1.25, more preferably 1.02 to 1.25, and even more preferably 1.05 to 1.25. In further embodiments, the ratio (D) between the diameter of the aerosol generating article at the mouth end and the diameter of the aerosol generating article at the distal end is ME / D DE The ratio (D) is approximately 1.01 to 1.20, more preferably 1.02 to 1.20, and even more preferably 1.05 to 1.20. In further embodiments, the ratio (D) between the diameter of the aerosol generating article at the mouth end and the diameter of the aerosol generating article at the distal end is also specified. ME / D DE The ratio is approximately 1.01 to 1.15, more preferably 1.02 to 1.15, and even more preferably 1.05 to 1.15.

[0210] Diameter of the aerosol-generating article at the mouth end (D ME ) and the diameter of the aerosol-generating article at the distal end (D DE The difference between (D) and (D) may be at least about 25 micrometers. Preferably, the diameter of the aerosol-generating article at the mouth end (D) ME ) and the diameter of the aerosol-generating article at the distal end (D DE The difference between (D) and (D) is at least about 50 micromillimeters. More preferably, the diameter of the aerosol-generating article at the mouth end (D) ME ) and the diameter of the aerosol-generating article at the distal end (D DE The difference between (D) and (D) is at least about 100 micromillimeters. More preferably, the diameter (D) of the aerosol-generating article at the mouth end is at least about 100 micromillimeters. ME ) and the diameter of the aerosol-generating article at the distal end (D DE The difference between (D) and (D) is at least about 150 micromillimeters. In a particularly preferred embodiment, the diameter (D) of the aerosol-generating article at the mouth end is ME ) and the diameter of the aerosol-generating article at the distal end (D DE The difference between ) is at least about 200 micrometers, more preferably at least about 300 micrometers, and even more preferably at least about 500 micrometers.

[0211] Although not intended to be constrained by theory, the diameter (D) of the aerosol-generating article at the oral end. ME ) and the diameter of the aerosol-generating article at the distal end (D DE One such difference between the two is expected to be sufficient to establish interference between the mouth end of the aerosol-generating article and the access opening of the cavity of the heating device adapted to receive the aerosol-generating article during use, while at the same time ensuring that the distal end of the aerosol-generating article is easily and quickly received into the cavity.

[0212] As an example, the outer diameter of the article may be substantially constant over the distal portion of the article extending at least about 5 millimeters or at least about 10 millimeters from the distal end of the aerosol-generating article. Alternatively, the outer diameter of the article may gradually taper over the distal portion of the article extending at least about 5 millimeters or at least about 10 millimeters from the distal end.

[0213] As briefly mentioned earlier, in some preferred embodiments, the mouthpiece element is attached by a chipping wrapper to one or more adjacent upstream components of the aerosol generating article. For example, the mouthpiece element may be connected to the immediately adjacent aerosol cooling element by a band of chipping paper.

[0214] In certain embodiments, the aerosol generating article includes a first band of chipping paper that at least partially surrounds the mouthpiece element and adheres the mouthpiece element to a component of the aerosol generating article located immediately adjacent to and upstream of the mouthpiece element, and a second band of chipping paper that surrounds the first band of chipping paper. The combined thickness of the two or more bands of chipping paper is such that the diameter of the aerosol generating article at the mouth end is (D ME To effectively contribute to this, an effective and relatively convenient method can be provided that ensures the oral and distal ends of the aerosol-generating article have different diameters according to the present invention.

[0215] In some of these embodiments, the mouthpiece element is at least partially surrounded by two or more bands of chipping paper, but the upstream element at the distal end of the aerosol-generating article is not surrounded by chipping paper. This is advantageous because the diameter (D) of the aerosol-generating article at the oral end is smaller. ME ) and the diameter of the aerosol-generating article at the distal end (D DE This can help maximize the difference between ) and .

[0216] In other embodiments of these designs, the mouthpiece element is at least partially surrounded by two or more bands of chipping paper, while the upstream element at the distal end of the aerosol-generating article is surrounded by a single band of chipping paper. This can help control how the weight is distributed along the length of the aerosol-generating article.

[0217] In some embodiments, the downstream section may include an intermediate hollow section between the mouthpiece element and the rod of the aerosol generating substrate. The intermediate hollow section may include one or more of the support element and aerosol cooling element. One or more of the support element and aerosol cooling element may include a hollow tubular segment. In such embodiments, one or more of the support element and aerosol cooling element, including one or more hollow tubular segments, can therefore form the intermediate hollow section of the aerosol generating article.

[0218] As used herein, the term “hollow tubular segment” is used to mean a generally elongated element that defines a lumen or airflow passage along its longitudinal axis. In particular, the term “tubular” is used below with respect to a tubular element having a substantially cylindrical cross-section and defining at least one airflow conduit that establishes an uninterrupted fluid communication between the upstream and downstream ends of the tubular element. However, naturally, alternative shapes of tubular elements (e.g., alternative cross-sectional shapes) may be possible.

[0219] In the context of the present invention, the hollow tubular segment provides an unrestricted flow channel. This means that the hollow tubular segment provides a negligible level of drawdown resistance (RTD). Therefore, the flow channel should not contain any components that would obstruct the longitudinal airflow. Preferably, the flow channel is substantially empty.

[0220] When used to describe an aerosol cooling element or support element or other component of a downstream section, the term “elongated” means that the aerosol cooling element or support element or other component of a downstream section has a length dimension that is greater than its width dimension or diameter dimension, for example, twice or more its width dimension or diameter dimension.

[0221] 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 sulfuric acid paper), and polymer materials (such as low-density polyethylene (LDPE)). In a preferred embodiment, the support element is formed from cellulose acetate. Other suitable materials include polyhydroxyalkanoate (PHA) fibers.

[0222] The support element may comprise a first hollow tubular segment. In a preferred embodiment, the support element includes a hollow cellulose acetate tube.

[0223] The support elements are positioned substantially aligned with the rod. This means that the length dimension of the support elements is positioned substantially parallel to the longitudinal direction of the rod and the article, for example, within ±10 degrees of parallel to the longitudinal direction of the rod. In a preferred embodiment, the support elements extend along the longitudinal axis of the rod.

[0224] The support element preferably has an outer diameter that is approximately equal to the outer diameter of the rod of the aerosol generating substrate and the outer diameter of the aerosol generating article.

[0225] The support element may have an outer diameter of 5 mm to 12 mm, 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.

[0226] The peripheral wall of the support element may have a thickness of at least 1 millimeter, preferably at least about 1.5 millimeters, and more preferably at least about 2 millimeters.

[0227] The support element may have a length of approximately 5 mm to approximately 15 mm.

[0228] The support element is preferably at least about 6 millimeters in length, and more preferably at least about 7 millimeters in length.

[0229] In a preferred embodiment, the support element has a length of less than about 12 millimeters, more preferably less than about 10 millimeters.

[0230] In some embodiments, the support element has a length of about 5 mm to about 15 mm, preferably about 6 mm to about 15 mm, and more preferably about 7 mm to about 15 mm. In other embodiments, the support element has a length of about 5 mm to about 12 mm, preferably about 6 mm to about 12 mm, and more preferably about 7 mm to about 12 mm. In further embodiments, the support element has a length of about 5 mm to about 10 mm, preferably about 6 mm to about 10 mm, and more preferably about 7 mm to about 10 mm.

[0231] In a preferred embodiment, the support element has a length of about 8 millimeters.

[0232] Preferably, the total length of the intermediate hollow section is about 18 millimeters or less, more preferably about 17 millimeters or less, and more preferably 16 millimeters or less.

[0233] The ratio between the length of the support element and the length of the rod of the aerosol generating substrate can be approximately 0.25 to approximately 1.

[0234] Preferably, the ratio between the length of the support element and the length of the rod of the aerosol generating substrate is at least about 0.3, more preferably at least about 0.4, and even more preferably at least about 0.5. In a preferred embodiment, the ratio between the length of the support element and the length of the rod of the aerosol generating substrate is less than about 0.9, more preferably less than about 0.8, and even more preferably less than about 0.7.

[0235] In some embodiments, the ratio between the length of the support element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.9, preferably about 0.4 to about 0.9, and more preferably about 0.5 to about 0.9. In other embodiments, the ratio between the length of the support element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.8, preferably about 0.4 to about 0.8, and more preferably about 0.5 to about 0.8. In further embodiments, the ratio between the length of the support element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.7, preferably about 0.4 to about 0.7, and more preferably about 0.5 to about 0.7.

[0236] In a particularly preferred embodiment, the ratio between the length of the support element and the length of the rod of the aerosol generating substrate is about 0.66.

[0237] The ratio between the length of the support element and the total length of the aerosol-generating article substrate can be approximately 0.125 to approximately 0.375.

[0238] Preferably, the ratio between the length of the support element and the total length of the aerosol-generating article substrate is at least about 0.13, more preferably at least about 0.14, and even more preferably at least about 0.15. Preferably, the ratio between the length of the support element and the total length of the aerosol-generating article substrate is less than about 0.3, more preferably less than about 0.25, and even more preferably less than about 0.20.

[0239] In some embodiments, the ratio between the length of the support element and the total length of the aerosol-generating article substrate is preferably about 0.13 to about 0.3, more preferably about 0.14 to about 0.3, and even more preferably about 0.15 to about 0.3. In other embodiments, the ratio between the length of the support element and the total length of the aerosol-generating article substrate is preferably about 0.13 to about 0.25, more preferably about 0.14 to about 0.25, and even more preferably about 0.15 to about 0.25. In further embodiments, the ratio between the length of the support element and the total length of the aerosol-generating article substrate is preferably about 0.13 to about 0.2, more preferably about 0.14 to about 0.2, and even more preferably about 0.15 to about 0.2.

[0240] In a particularly preferred embodiment, the ratio between the length of the support element and the total length of the aerosol-generating article substrate is about 0.18.

[0241] In the aerosol-generating article according to the present invention, the support element preferably has an average radial hardness of at least about 80 percent, more preferably at least about 85 percent, and even more preferably at least about 90 percent. Therefore, the support element can provide the aerosol-generating article with a desired hardness level.

[0242] If desired, the radial hardness of the components of the downstream section of the aerosol generating article according to the present invention, such as the support element, may be further increased by surrounding the aerosol cooling element with a rigid plug wrap, such as a plug wrap having a basis weight of at least about 80 grams / square meter (gsm), at least about 100 gsm, or at least about 110 gsm.

[0243] As used herein, the term “radial hardness” refers to the resistance to compression in a direction transverse to the longitudinal axis of the support element. The radial hardness of an aerosol-generating article around a support element can be determined by applying a load across the article at the location of the support element in a direction transverse to the longitudinal axis of the article, and by measuring the average (mean) diameter of the article when it is compressed. Radial hardness is given by:

number

[0244] To determine the hardness of a portion of an aerosol article (such as a support element provided in the form of a hollow tube segment), the aerosol-generating articles should be aligned parallel to each other in a plane, and the same portion of each aerosol-generating article being tested should be subjected to a set load for a set duration. This test is performed using a known DD60A Densimeter apparatus (manufactured and commercially available by Heinr Borgwaldt GmbH (Germany)), which is fitted with a measuring head for aerosol-generating articles such as cigarettes, and also includes an aerosol-generating article container.

[0245] A load is applied using two load-applying cylindrical rods that extend across the diameter of all aerosol-generating articles at once. According to the standard test method for this device, the test should be conducted so that 20 contact points are created between the aerosol-generating articles and the load-applying cylindrical rods. In some cases, the hollow tube segment being tested may be long enough so that only 10 aerosol-generating articles are needed to form 20 contact points where each smoking article contacts both load-applying rods (as they are long enough to extend between both rods). In other cases, where the support elements are excessively short to achieve this, 20 aerosol-generating articles should be used to form 20 contact points, as will be further discussed below, with each aerosol-generating article contacting only one of the load-applying rods.

[0246] Two additional fixed cylindrical rods are positioned beneath the aerosol-generating article to support it and to counteract the load applied by each of the load-applying cylindrical rods.

[0247] The standard operating procedure for such a device involves applying an overall load of 2 kg for 20 seconds. After 20 seconds (while the load is still applied to the smoking article), the pressure on the load-applying cylindrical rod is determined and then used to calculate the hardness from the equation described above. The temperature is maintained within the range of 22 degrees Celsius ± 2 degrees. The above test is called the DD60A test. The standard method for measuring filter hardness is when the aerosol-generating article has not yet been consumed. Additional information regarding the measurement of mean radial hardness can be found, for example, in U.S. Patent Application No. 2016 / 0128378.

[0248] When inserting an aerosol generating article into an aerosol generator according to the present invention for heating the aerosol generating substrate, the user may need to apply some force to overcome the resistance of the aerosol generating article to the insertion of the aerosol generating substrate. This may damage one or both of the aerosol generating article and / or the aerosol generator. In addition, the application of force during insertion of the aerosol generating article into the aerosol generator may displace the aerosol generating substrate within the aerosol generating article. This may result in the heating element of the aerosol generator not being properly aligned with the susceptor provided within the aerosol generating substrate, potentially leading to uneven and inefficient heating of the aerosol generating substrate of the aerosol generating article. The support element is advantageously configured to resist the downstream movement of the aerosol generating substrate during insertion of the article into the aerosol generator.

[0249] Preferably, the hollow tubular segments of the support element are adapted to generate RTD of approximately 0 mmH2O (approximately 0 Pa) to approximately 20 mmH2O (approximately 100 Pa), more preferably approximately 0 mmH2O (approximately 0 Pa) to approximately 10 mmH2O (approximately 100 Pa). Therefore, the support element preferably does not contribute to the overall RTD of the aerosol-generating article.

[0250] The aerosol cooling element in the downstream section of the aerosol generating article according to the present invention preferably exists in the form of a second hollow tubular segment defining a cavity that extends all the way from the upstream end to the downstream end of the aerosol cooling element, and a ventilation zone is provided along the hollow tubular segment.

[0251] The inventors found that satisfactory cooling of the aerosol flow generated in conjunction with the heating of an aerosol generating substrate and drawn out through one of such aerosol cooling elements can be achieved by providing a ventilation zone along a hollow tubular segment. Furthermore, the inventors found that it may be possible to counteract the effects of increased aerosol dilution caused by the inflow of ventilation air into the article by locating the ventilation zone at a precisely defined location along the length of the aerosol cooling element, and preferably by utilizing a hollow tubular segment having a predetermined peripheral wall thickness or internal volume, as described in more detail below.

[0252] While not intended to be theoretically constrained, it is believed that as the aerosol moves toward the mouthpiece segment, the introduction of ventilation air rapidly reduces the temperature of the aerosol flow. This allows the ventilation air to enter the aerosol flow relatively close to the upstream end of the aerosol cooling element (i.e., close enough to the susceptor extending within the rod of the aerosol generating substrate, which is the heat source in use), achieving dramatic cooling of the aerosol flow, which is thought to have a favorable effect on the condensation and nucleation of aerosol particles. As a result, the overall ratio of the aerosol particle phase to the aerosol gas phase may be increased compared to existing non-ventilated aerosol generating articles.

[0253] Simultaneously, by maintaining a relatively low thickness in the peripheral walls of the hollow tubular elements—which is made possible by the aerosols initiating the nucleation process as soon as the aerosol components leave the rod of the aerosol-generating substrate—it is ensured that the overall internal volume of the hollow tubular elements and the cross-sectional area of ​​the hollow tubular segments are effectively maximized, while at the same time ensuring that the hollow tubular segments have the structural strength necessary to prevent the collapse of the aerosol-generating articles and provide some support to the rod of the aerosol-generating substrate, and that the RTD of the hollow tubular segments is minimized. The large cross-sectional area of ​​the cavity in the hollow tubular segments is understood to be associated with a reduced velocity of the aerosol flow moving along the aerosol-generating articles, and is further expected to work favorably for nucleation. Furthermore, by utilizing hollow tubular segments with relatively low thickness, it is possible to substantially prevent the diffusion of the venting air before it comes into contact with and mixes with the aerosol flow, and is further understood to work favorably for the nucleation phenomenon. In practice, it is possible to improve the cooling effect on the formation of new aerosol particles by providing more controllable and localized cooling of the flow of volatile seeds.

[0254] The aerosol cooling element preferably has an outer diameter that is approximately equal to the outer diameter of the rod of the aerosol generating substrate and the outer diameter of the aerosol generating article.

[0255] The aerosol cooling element may have an outer diameter of 5 mm to 12 mm, for example, 5 mm to 10 mm, or 6 mm to 8 mm. In a preferred embodiment, the aerosol cooling element has an outer diameter of 7.2 mm ± 10 percent.

[0256] Preferably, the second hollow tubular segment of the aerosol cooling element has an inner diameter of at least about 1.5 mm. More preferably, the second hollow tubular segment of the aerosol cooling element has an inner diameter of at least about 2 mm. Even more preferably, the second hollow tubular segment of the aerosol cooling element has an inner diameter of at least about 2.5 mm. In a particularly preferred embodiment, the second hollow tubular segment of the aerosol cooling element has an inner diameter of at least about 3 mm.

[0257] The peripheral wall of the second hollow tubular segment of the aerosol cooling element may have a thickness of less than about 2.5 millimeters, preferably less than 1.5 millimeters, more preferably less than about 1250 micrometers, and even more preferably less than about 1000 micrometers. In a particularly preferred embodiment, the peripheral wall of the second hollow tubular segment of the aerosol cooling element has a thickness of less than about 900 micrometers, preferably less than about 800 micrometers.

[0258] In one embodiment, the peripheral wall of the second hollow tubular segment of the aerosol cooling element has a thickness of approximately 2 millimeters.

[0259] The aerosol cooling element may have a length of 5 mm to 15 mm.

[0260] Preferably, the aerosol cooling element has a length of at least about 6 millimeters, and more preferably at least about 7 millimeters.

[0261] In a preferred embodiment, the aerosol cooling element has a length of less than about 12 millimeters, more preferably less than about 10 millimeters.

[0262] In some embodiments, the aerosol cooling element has a length of from about 5 millimeters to about 15 millimeters, preferably from about 6 millimeters to about 15 millimeters, more preferably from about 7 millimeters to about 15 millimeters. In other embodiments, the aerosol cooling element has a length of from about 5 millimeters to about 12 millimeters, preferably from about 6 millimeters to about 12 millimeters, more preferably from about 7 millimeters to about 12 millimeters. In further embodiments, the aerosol cooling element has a length of from about 5 millimeters to about 10 millimeters, preferably from about 6 millimeters to about 10 millimeters, more preferably from about 7 millimeters to about 10 millimeters.

[0263] In a particularly preferred embodiment of the present invention, the aerosol cooling element has a length of less than 10 millimeters. For example, in one particularly preferred embodiment, the aerosol cooling element has a length of 8 millimeters. In such embodiments, the aerosol cooling element thus has a relatively short length compared to the aerosol cooling elements of prior art aerosol generating articles. The reduction in the length of the aerosol cooling element is possible due to the optimization of the effect of the hollow tubular segment forming the aerosol cooling element in the cooling and nucleation of the aerosol. The reduction in the length of the aerosol cooling element advantageously reduces the risk of deformation of the aerosol generating article due to compression during use, since the aerosol cooling element is generally less resistant to deformation than a mouthpiece. Furthermore, the reduction in the length of the aerosol cooling element can provide a cost advantage to the manufacturer, since the cost of the hollow tubular segment is typically higher per unit length than the cost of other elements such as the mouthpiece element.

[0264] The ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate can be from about 0.25 to about 1.

[0265] Preferably, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is at least about 0.3, more preferably at least about 0.4, and even more preferably at least about 0.5. In a preferred embodiment, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is less than about 0.9, more preferably less than about 0.8, and even more preferably less than about 0.7.

[0266] In some embodiments, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.9, preferably about 0.4 to about 0.9, and more preferably about 0.5 to about 0.9. In other embodiments, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.8, preferably about 0.4 to about 0.8, and more preferably about 0.5 to about 0.8. In further embodiments, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.7, preferably about 0.4 to about 0.7, and more preferably about 0.5 to about 0.7.

[0267] In a particularly preferred embodiment, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is about 0.66.

[0268] The ratio between the length of the aerosol cooling element and the total length of the aerosol generating article substrate can be approximately 0.125 to approximately 0.375.

[0269] Preferably, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is at least about 0.13, more preferably at least about 0.14, and even more preferably at least about 0.15. Preferably, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is less than about 0.3, more preferably less than about 0.25, and even more preferably less than about 0.20.

[0270] In some embodiments, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is preferably about 0.13 to about 0.3, more preferably about 0.14 to about 0.3, and even more preferably about 0.15 to about 0.3. In other embodiments, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is preferably about 0.13 to about 0.25, more preferably about 0.14 to about 0.25, and even more preferably about 0.15 to about 0.25. In further embodiments, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is preferably about 0.13 to about 0.2, more preferably about 0.14 to about 0.2, and even more preferably about 0.15 to about 0.2.

[0271] In a particularly preferred embodiment, the ratio between the length of the aerosol cooling element and the total length of the aerosol generating article substrate is about 0.18.

[0272] The length of the mouthpiece element is preferably at least 1 millimeter greater than the length of the aerosol cooling element, more preferably at least 2 millimeters greater than the length of the aerosol cooling element, and more preferably at least 3 millimeters greater than the length of the aerosol cooling element. The reduction in the length of the aerosol cooling element as described above can advantageously allow for an increase in the length of other elements of the aerosol generating article, such as the mouthpiece element. The potential technical benefits of providing a relatively long mouthpiece element are described above.

[0273] In the aerosol-generating article according to the present invention, the aerosol cooling element preferably has an average radial hardness of at least about 80 percent, more preferably at least about 85 percent, and even more preferably at least about 90 percent. Therefore, the aerosol cooling element can provide the aerosol-generating article with a desired hardness level.

[0274] If desired, the radial hardness of the aerosol cooling element of the aerosol generating article according to the present invention may be further increased by surrounding the aerosol cooling element with a rigid plug wrap, such as a plug wrap having a basis weight of at least about 80 grams / square meter (gsm), at least about 100 gsm, or at least about 110 gsm.

[0275] The aerosol cooling element may be formed from any suitable material or combination of materials. For example, the aerosol cooling 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 sulfuric acid paper), and polymer materials (such as low-density polyethylene (LDPE)). Other suitable materials include polyhydroxyalkanoate (PHA) fibers.

[0276] In a preferred embodiment, the aerosol cooling element is formed from cellulose acetate.

[0277] The ventilation zone comprises multiple perforations passing through the peripheral wall of the aerosol cooling element. Preferably, the ventilation zone includes at least one row of perforations around the periphery. In some embodiments, the ventilation zone may include two rows of perforations around the periphery. For example, the perforations may be formed online during the manufacturing of the aerosol-generating article. Each of the peripheral rows of perforations preferably contains 8 to 30 perforations.

[0278] If the aerosol generating article includes a coupling plug for attaching an aerosol cooling element to one or more of the other components of the aerosol generating article, the ventilation zone preferably includes at least one corresponding row of perforations around the perimeter, provided through a portion of the coupling plug wrap. These may be formed online during the manufacture of the smoking article. The row or more of perforations around the perimeter, provided through a portion of the coupling plug wrap, are preferably substantially aligned with a row or more of perforations that penetrate the perimeter wall of the aerosol cooling element.

[0279] If the aerosol generating article includes a band of chipping paper for attaching an aerosol cooling element to the mouthpiece element of the aerosol generating article, and the band of chipping paper extends over a perimeter row or more of perforations in the peripheral wall of the aerosol cooling element, the ventilation zone preferably comprises at least one corresponding perimeter row of perforations provided through the band of chipping paper. These may be formed online during the manufacture of the smoking article. The perimeter row or more of perforations provided through the band of chipping paper are preferably substantially aligned with a row(s) of perforations penetrating the peripheral wall of the aerosol cooling element.

[0280] In some embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is at least about 1 millimeter. Preferably, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is at least about 2 millimeters. More preferably, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is at least about 3 millimeters.

[0281] In some embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is about 6 millimeters or less. Preferably, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is about 5 millimeters or less. More preferably, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is about 4 millimeters or less.

[0282] In some embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is about 1 mm to about 6 mm, preferably about 1 mm to about 5 mm, and more preferably about 1 mm to about 4 mm. In other embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is about 2 mm to about 6 mm, preferably about 2 mm to about 5 mm, and more preferably about 2 mm to about 4 mm. In further embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is about 3 mm to about 6 mm, preferably about 3 mm to about 5 mm, and more preferably about 3 mm to about 4 mm.

[0283] The distance between the ventilation zone and the mouth end of the aerosol-generating article is preferably at least about 10 millimeters. More preferably, the distance between the ventilation zone and the mouth end of the aerosol-generating article is preferably at least about 12 millimeters. Even more preferably, the distance between the ventilation zone and the mouth end of the aerosol-generating article is at least about 16 millimeters.

[0284] The distance between the ventilation zone and the mouth end of the aerosol-generating article is preferably about 26 millimeters or less. More preferably, the distance between the ventilation zone and the mouth end of the aerosol-generating article is about 24 millimeters or less. Even more preferably, the distance between the ventilation zone and the mouth end of the aerosol-generating article is about 22 millimeters or less. In a particularly preferred embodiment, the distance between the ventilation zone and the mouth end of the aerosol-generating article is about 20 millimeters or less.

[0285] In some embodiments, the distance between the ventilation zone and the mouth-side end of the aerosol-generating article is from about 10 millimeters to about 26 millimeters, preferably from about 10 millimeters to about 24 millimeters, more preferably from about 10 millimeters to about 22 millimeters, and even more preferably from about 10 millimeters to about 20 millimeters. In other embodiments, the distance between the ventilation zone and the mouth-side end of the aerosol-generating article is from about 12 millimeters to about 26 millimeters, preferably from about 12 millimeters to about 24 millimeters, more preferably from about 12 millimeters to about 22 millimeters, and even more preferably from about 12 millimeters to about 20 millimeters. In further embodiments, the distance between the ventilation zone and the mouth-side end of the aerosol-generating article is from about 14 millimeters to about 26 millimeters, preferably from about 14 millimeters to about 24 millimeters, more preferably from about 14 millimeters to about 22 millimeters, and even more preferably from about 14 millimeters to about 20 millimeters. In still further embodiments, the distance between the ventilation zone and the mouth-side end of the aerosol-generating article is from about 16 millimeters to about 26 millimeters, preferably from about 16 millimeters to about 24 millimeters, more preferably from about 16 millimeters to about 22 millimeters, and even more preferably from about 16 millimeters to about 20 millimeters.

[0286] The distance between the ventilation zone and the upstream end of the downstream section is preferably at least about 6 millimeters. The distance between the ventilation zone and the upstream end of the downstream section is more preferably at least about 8 millimeters. The distance between the ventilation zone and the upstream end of the downstream section is even more preferably at least about 10 millimeters.

[0287] The distance between the ventilation zone and the upstream end of the downstream section is preferably about 20 millimeters or less. The distance between the ventilation zone and the upstream end of the downstream section is more preferably about 18 millimeters or less. The distance between the ventilation zone and the upstream end of the downstream section is even more preferably about 16 millimeters or less.

[0288] In some embodiments, the distance between the ventilation zone and the upstream end of the downstream section is preferably about 6 mm to about 20 mm, more preferably about 8 mm to about 20 mm, and even more preferably about 10 mm to about 20 mm. In other embodiments, the distance between the ventilation zone and the upstream end of the downstream section is preferably about 6 mm to about 18 mm, more preferably about 8 mm to about 18 mm, and even more preferably about 10 mm to about 18 mm. In further embodiments, the distance between the ventilation zone and the upstream end of the downstream section is preferably about 6 mm to about 16 mm, more preferably about 8 mm to about 16 mm, and even more preferably about 10 mm to about 16 mm.

[0289] The distance between the ventilation zone and the downstream end of the susceptor is preferably at least about 6 millimeters. More preferably, the distance between the ventilation zone and the downstream end of the susceptor is at least about 8 millimeters. Even more preferably, the distance between the ventilation zone and the downstream end of the susceptor is at least about 10 millimeters.

[0290] The distance between the ventilation zone and the downstream end of the susceptor is preferably about 20 millimeters or less. More preferably, the distance between the ventilation zone and the downstream end of the susceptor is about 18 millimeters or less. Even more preferably, the distance between the ventilation zone and the downstream end of the susceptor is about 16 millimeters or less.

[0291] In some embodiments, the distance between the ventilation zone and the downstream end of the susceptor is preferably about 6 mm to about 20 mm, more preferably about 8 mm to about 20 mm, and even more preferably about 10 mm to about 20 mm. In other embodiments, the distance between the ventilation zone and the downstream end of the susceptor is preferably about 6 mm to about 18 mm, more preferably about 8 mm to about 18 mm, and even more preferably about 10 mm to about 18 mm. In further embodiments, the distance between the ventilation zone and the downstream end of the susceptor is preferably about 6 mm to about 16 mm, more preferably about 8 mm to about 16 mm, and even more preferably about 10 mm to about 16 mm.

[0292] The aerosol-generating article according to the present invention may have a ventilation level of at least about 5 percent.

[0293] The term "ventilation level" is used throughout this specification to mean the volume ratio of the airflow entering the aerosol-generating article through the ventilation zone (ventilation airflow) to the sum of the aerosol airflow and the ventilation airflow. A higher ventilation level results in greater dilution of the aerosol flow delivered to the consumer.

[0294] Aerosol-generating articles may typically have a ventilation level of at least about 10 percent, preferably at least about 15 percent, and more preferably at least about 20 percent.

[0295] In a preferred embodiment, the aerosol-generating article has an air permeability level of at least about 25 percent.

[0296] Aerosol-generating articles preferably have an air permeability level of less than approximately 60 percent.

[0297] The aerosol-generating article according to the present invention preferably has a ventilation level of about 45 percent or less. More preferably, the aerosol-generating article according to the present invention has a ventilation level of about 40 percent or less, and even more preferably about 35 percent or less.

[0298] In a particularly preferred embodiment, the aerosol-generating article has an air permeability level of about 30 percent.

[0299] In some embodiments, the aerosol-generating article has an air permeability level of about 20 percent to about 60 percent, preferably about 20 percent to about 45 percent, more preferably about 20 percent to about 40 percent. In other embodiments, the aerosol-generating article has an air permeability level of about 25 percent to about 60 percent, preferably about 25 percent to about 45 percent, more preferably about 25 percent to about 40 percent. In further embodiments, the aerosol-generating article has an air permeability level of about 30 percent to about 60 percent, preferably about 30 percent to about 45 percent, more preferably about 30 percent to about 40 percent.

[0300] In a particularly preferred embodiment, the aerosol-generating article has a permeability level of about 28 percent to about 42 percent. In some particularly preferred embodiments, the aerosol-generating article has a permeability level of about 30 percent.

[0301] While not wishing to be constrained by theory, the inventors found that the temperature reduction resulting from introducing colder outside air into the hollow tubular segment through a ventilation zone may have a favorable effect on the nucleation and growth of aerosol particles.

[0302] The formation of aerosols from gaseous mixtures containing various chemical species depends on the delicate interactions between nucleation, evaporation, condensation, and even fusion, which explain changes in vapor concentration, temperature, and velocity fields. The so-called classical nucleation theory is based on the assumption that some molecules in the gas phase are large enough to remain coherent for a long time with a sufficient probability (e.g., a 50 / 50 probability). These molecules represent a kind of critical threshold molecular cluster within transient molecular aggregates, meaning that smaller molecular clusters generally decompose into the gas phase somewhat more readily, while larger clusters generally grow more readily. These critical clusters are identified as the primary nucleation cores from which droplets are expected to grow due to the condensation of molecules from the vapor. The newly nucleated, untreated droplet is assumed to appear with a certain intrinsic diameter and then grow by several orders of magnitude. This can be facilitated and enhanced by the rapid cooling of the surrounding vapor, which induces condensation. In this regard, it is helpful to keep in mind that evaporation and condensation are two aspects of the same mechanism: the transfer of mass between liquid and gas. Evaporation involves net mass transfer from the liquid droplet phase to the gas phase, while condensation is net mass transfer from the gas phase to the liquid droplet phase. Due to evaporation (or condensation), the liquid droplet shrinks (or grows), but the number of droplets does not change.

[0303] In this scenario (and if the scenario is further complicated by fusion phenomena), the temperature and rate of cooling may play a crucial role in determining how the system responds. Generally, because the nucleation process is typically nonlinear, different cooling rates may lead to significantly different temperature behavior with respect to liquid phase (droplet) formation. While we do not wish to be bound by theory, we assume that cooling can result in a rapid increase in the number of droplet condensations, followed by a short, strong increase in this growth (nucleation burst). This nucleation burst is likely to be more pronounced at lower temperatures. Furthermore, faster cooling rates may favor the early initiation of nucleation. In contrast, a decrease in the cooling rate is likely to have a favorable effect on the final size that the aerosol droplets eventually reach.

[0304] Therefore, the rapid cooling induced by introducing outside air into the hollow tubular segment through the ventilation zone can be used to favor the advantageous nucleation and growth of aerosol droplets. However, at the same time, introducing outside air into the hollow tubular segment has the direct disadvantage of diluting the aerosol stream delivered to the consumer.

[0305] The inventors were surprised to find that the favorable effect of enhanced nucleation, facilitated by rapid cooling induced by the introduction of aeration air into the article, significantly counteracts the undesirable effect of dilution. Therefore, satisfactory values ​​of aerosol delivery are consistently achieved by the aerosol-generating article according to the present invention.

[0306] The inventors were surprised to find that the dilution effect on aerosols—which can be evaluated by measuring the effect on the delivery of aerosol-forming substances (such as glycerol) contained in the aerosol-generating substrate—is advantageously minimized when the permeability level is within the aforementioned range. In particular, permeability levels of 25 to 50 percent, and more preferably 28 to 42 percent, were found to lead to particularly satisfactory values ​​of glycerol delivery. At the same time, the degree of nucleation is enhanced, and consequently, the delivery of nicotine and aerosol-forming substances (e.g., glycerol) is enhanced.

[0307] This is particularly advantageous for “short” aerosol-generating articles, such as when the length of the rod of the aerosol-generating substrate is less than about 40 millimeters, preferably less than 25 millimeters, and even more preferably less than 20 millimeters, or when the total length of the aerosol-generating article is less than about 70 millimeters, preferably less than about 60 millimeters, and even more preferably less than 50 millimeters. As is understood, in such aerosol-generating articles, there is little time and space for aerosol formation and little time and space for the particulate phase of the aerosol to become available for delivery to the consumer.

[0308] Furthermore, since the vented hollow tubular segments do not substantially contribute to the overall RTD of the aerosol-generating article, the overall RTD of the article can be advantageously fine-tuned in the aerosol-generating article according to the present invention by adjusting the length and density of the rods of the aerosol-generating substrate, or optionally the length and density of the segments of the filter material forming part of the mouthpiece, or the length and density of the segments of the filter material provided upstream of the aerosol-generating substrate and susceptor. Thus, it is possible to manufacture aerosol-generating articles having a predetermined RTD consistently and with great precision, so that a satisfactory level of RTD can be provided to consumers even in the presence of venting.

[0309] In some embodiments, the intermediate hollow section includes both a support element comprising a first hollow tubular segment and an aerosol cooling element comprising a second hollow tubular segment, where the inner diameter (D) of the second hollow tubular segment is... STS ) is the inner diameter (D) of the first hollow tubular segment. FTS It is preferable that it be larger than ).

[0310] More specifically, the inner diameter (D) of the second hollow tubular segment. STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and (D) is preferably at least about 1.25. More preferably, the inner diameter (D) of the second hollow tubular segment is STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and the inner diameter of the second hollow tubular segment is preferably at least about 1.3. More preferably, the ratio between (D) and the inner diameter of the second hollow tubular segment is preferably at least about 1.3. STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and (D) is preferably at least about 1.4. In a particularly preferred embodiment, the inner diameter (D) of the second hollow tubular segment is STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between ) is at least about 1.5, more preferably at least about 1.6.

[0311] The inner diameter (D) of the second hollow tubular segment STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and (D) is preferably about 2.5 or less. More preferably, the inner diameter (D) of the second hollow tubular segment is STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and (D) is preferably about 2.25 or less. More preferably, the inner diameter (D) of the second hollow tubular segment is STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between ) and is preferably about 2 or less.

[0312] In some embodiments, the inner diameter (D) of the second hollow tubular segment STS) and the inner diameter (D FTS ) of the first hollow tubular segment is from about 1.25 to about 2.5. Preferably, the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is from about 1.3 to about 2.5. More preferably, the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is from about 1.4 to about 2.5. In a particularly preferred embodiment, the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is from about 1.5 to about 2.5.

[0313] In other embodiments, the ratio between the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is from about 1.25 to about 2.25. Preferably, the ratio between the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is from about 1.3 to about 2.25. More preferably, the ratio between the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is from about 1.4 to about 2.25. In a particularly preferred embodiment, the ratio between the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is from about 1.5 to about 2.25.

[0314] In a further embodiment, the ratio between the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is from about 1.25 to about 2. Preferably, the ratio between the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is from about 1.3 to about 2. More preferably, the inner diameter (D STS) and the ratio between the inner diameter (D FTS ) of the first hollow tubular segment is from about 1.4 to about 2. In a particularly preferred embodiment, the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment, the ratio is from about 1.5 to about 2.

[0315] In these embodiments where the article further comprises an elongated susceptor longitudinally disposed within the aerosol generating substrate, the ratio between the inner diameter (D FTS ) of the first hollow tubular segment and the width of the susceptor is preferably at least about 0.2. More preferably, the ratio between the inner diameter (D FTS ) of the first hollow tubular segment and the width of the susceptor is at least about 0.3. Even more preferably, the ratio between the inner diameter (D FTS ) of the first hollow tubular segment and the width of the susceptor is at least about 0.4.

[0316] In addition or alternatively, the ratio between the inner diameter (D STS ) of the second hollow tubular segment and the width of the susceptor is preferably at least about 0.2. More preferably, the ratio between the inner diameter (D STS ) of the second hollow tubular segment and the width of the susceptor is at least about 0.5. Even more preferably, the ratio between the inner diameter (D STS ) of the second hollow tubular segment and the width of the susceptor is at least about 0.8.

[0317] Preferably, the ratio between the volume of the cavity of the first hollow tubular segment and the volume of the cavity of the second hollow tubular segment is at least about 0.1. More preferably, the ratio between the volume of the cavity of the first hollow tubular segment and the volume of the cavity of the second hollow tubular segment is at least about 0.2. Even more preferably, the ratio between the volume of the cavity of the first hollow tubular segment and the volume of the cavity of the second hollow tubular segment is at least about 0.3.

[0318] Preferably, the ratio of the volume of the cavity in the first hollow tubular segment to the volume of the cavity in the second hollow tubular segment is about 0.9 or less. More preferably, the ratio of the volume of the cavity in the first hollow tubular segment to the volume of the cavity in the second hollow tubular segment is about 0.7 or less. Even more preferably, the ratio of the volume of the cavity in the first hollow tubular segment to the volume of the cavity in the second hollow tubular segment is about 0.5 or less.

[0319] In some embodiments, the aerosol generating article may further include additional cooling elements, such as downstream of the aerosol cooling element containing a hollow tubular segment, as described above, which define multiple longitudinally extending channels, such as by making a high surface area available for heat exchange. In other words, one such additional cooling element is adapted to function substantially as a heat exchanger. Multiple longitudinally extending channels may be defined by a sheet material that has been processed by crimping, assembling, or folding to form the channels. Multiple longitudinally extending channels may be defined by a single sheet that has been processed by crimping, assembling, or folding to form the multiple channels. The sheet may also be crimped before being crimped, assembling, or folded. Alternatively, multiple longitudinally extending channels may be defined by multiple sheets that have been processed by crimping, crimping, assembling, or folding to form the multiple channels. In some embodiments, a plurality of longitudinally extending channels may be defined by a plurality of sheets that are crimped, pleated, assembled, or folded, i.e., brought into an overlay arrangement and then defined by two or more sheets that are crimped, pleated, assembled, or folded as a single entity. As used herein, the term “sheet” means a thin, layered element having a width and length substantially greater than its thickness.

[0320] As used herein, the term “longitudinal direction” refers to the direction extending along or parallel to the cylindrical axis of the rod. As used herein, the term “crimped” means a sheet having multiple substantially parallel ridges or undulations. When an aerosol-generating article is assembled, it is preferable that the substantially parallel ridges or undulations extend longitudinally with respect to the rod. As used herein, the terms “assembled,” “crimped,” or “folded” mean that a sheet of material is spiraled, folded, or otherwise compressed or shrunk substantially transversely with respect to the cylindrical axis of the rod. The sheet may be crimped before being assembled, crimped, or folded. The sheet may be assembled, crimped, or folded without prior crimping.

[0321] One such additional cooling element may have a total surface area of ​​approximately 300 square millimeters per millimeter of length to approximately 1,000 square millimeters per millimeter of length.

[0322] The additional cooling element preferably provides low draw resistance to the passage of air through it. Preferably, the additional cooling element does not substantially affect the draw resistance of the aerosol-generating article. To achieve this, it is preferable that the longitudinal porosity is greater than 50 percent and that the airflow path through the additional cooling element is relatively unrestricted. The longitudinal porosity of the additional cooling element can be defined by the ratio of the cross-sectional area of ​​the material forming the additional cooling element to the internal cross-sectional area of ​​the aerosol-generating article at the location of the portion containing the additional cooling element.

[0323] The additional cooling element preferably includes a sheet material selected from the group consisting of metal foil, polymer sheets, and substantially non-porous paper or cardboard. In some embodiments, the aerosol cooling element may include 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. In a particularly preferred embodiment, the additional cooling element includes a sheet of PLA.

[0324] In other embodiments, the aerosol cooling element may alternatively be provided in one form of such cooling element comprising a plurality of longitudinally extending channels.

[0325] In a preferred embodiment, the aerosol generating article further comprises an upstream section located upstream of the rods of the aerosol generating substrate. The upstream section may comprise one or more upstream elements. In particular, the upstream section may comprise an upstream element positioned immediately upstream of the rods of the aerosol generating substrate.

[0326] The upstream element advantageously prevents direct physical contact with the upstream end of the aerosol-generating substrate. In particular, if the aerosol-generating substrate includes a susceptor element, the upstream element can prevent direct physical contact with the upstream end of the susceptor element. This helps prevent displacement or deformation of the susceptor element during handling or transport of the aerosol-generating article. This, in turn, helps to fix the shape and position of the susceptor element. Furthermore, the presence of the upstream element can be advantageous, for example, if the substrate contains particulate plant material, in which case it helps to prevent any loss of the substrate.

[0327] The upstream element may also provide an improved appearance to the upstream end of the aerosol-generating article. Furthermore, if desired, the upstream element may be used to provide information about the aerosol-generating article, such as the brand, flavor, content, or details of the aerosol generator in which the article is intended to be used.

[0328] The upstream element may be a porous plug element. A porous plug element is preferable as it does not alter the draw resistance of the aerosol-generating article. The upstream element preferably has a porosity of at least about 50 percent in the longitudinal direction of the aerosol-generating article. More preferably, the upstream element has a porosity of about 50 percent to about 90 percent in the longitudinal direction. The longitudinal porosity of the upstream element is defined by the ratio of the cross-sectional area of ​​the material forming the upstream element to the internal cross-sectional area of ​​the aerosol-generating article at the location of the upstream element.

[0329] The upstream element may be made of a porous material or may have multiple openings. This can be achieved, for example, by laser drilling. Preferably, the multiple openings are uniformly distributed across the entire cross-section of the upstream element.

[0330] The porosity or permeability of the upstream element can be advantageously varied to provide the desired overall draw resistance of the aerosol-generating article.

[0331] The RTD of the upstream element is preferably at least about 5 milliH2O. More preferably, the RTD of the upstream element is at least about 10 milliH2O. Even more preferably, the RTD of the upstream element is at least about 15 milliH2O. In a particularly preferred embodiment, the RTD of the upstream element is at least about 20 milliH2O.

[0332] The RTD of the upstream element is approximately 80 mmH2O or less. More preferably, the RTD of the upstream element is approximately 60 mmH2O or less. Even more preferably, the RTD of the upstream element is approximately 40 mmH2O or less.

[0333] In some embodiments, the RTD of the upstream element is about 5 mmH2O to about 80 mmH2O, preferably about 10 mmH2O to about 80 mmH2O, more preferably about 15 mmH2O to about 80 mmH2O, and even more preferably about 20 mmH2O to about 80 mmH2O. In other embodiments, the RTD of the upstream element is about 5 mmH2O to about 60 mmH2O, preferably about 10 mmH2O to about 60 mmH2O, more preferably about 15 mmH2O to about 60 mmH2O, and even more preferably about 20 mmH2O to about 60 mmH2O. In further embodiments, the RTD of the upstream element is about 5 mmH2O to about 40 mmH2O, preferably about 10 mmH2O to about 40 mmH2O, more preferably about 15 mmH2O to about 40 mmH2O, and even more preferably about 20 mmH2O to about 40 mmH2O.

[0334] In alternative embodiments, the upstream element may be formed from a material that is impermeable to air. In such embodiments, the aerosol generating article may be configured such that air flows into the rods of the aerosol generating substrate through a suitable ventilation means provided within the wrapper.

[0335] The upstream element may be made of any material suitable for use in an aerosol generating article. The upstream element may be made of the same material used for one of the other components of the aerosol generating article, such as a mouthpiece, cooling element, or support element. Suitable materials for the upstream element include filter materials, ceramics, polymer materials, cellulose acetate, cardboard, zeolite, or aerosol generating substrates. The upstream element is preferably formed from a cellulose acetate plug.

[0336] The upstream element is preferably made of a heat-resistant material. For example, the upstream element is preferably made of a material that can withstand temperatures up to 350 degrees Celsius. This ensures that the upstream element is not adversely affected by the heating means used to heat the aerosol generating substrate.

[0337] The upstream element preferably has a diameter approximately equal to the diameter of the aerosol-generating article.

[0338] The upstream element preferably has a length of about 1 mm to about 10 mm, more preferably about 3 mm to about 8 mm, and more preferably about 4 mm to about 6 mm. In a particularly preferred embodiment, the upstream element has a length of about 5 mm. The length of the upstream element can be advantageously varied to provide the desired overall length of the aerosol generating article. For example, if it is desirable to reduce the length of one of the other components of the aerosol generating article, the length of the upstream element can be increased to maintain the same overall length of the article.

[0339] The upstream element preferably has a substantially homogeneous structure. For example, the upstream element may have a substantially homogeneous texture and appearance. The upstream element may, for example, have a continuous, regular surface over its entire cross-section. The upstream element may, for example, not have recognizable symmetry.

[0340] The upstream element is preferably surrounded by a wrapper. The wrapper surrounding the upstream element is preferably a rigid plug wrap, for example, a plug wrap having a basis weight of at least about 80 grams / square meter (gsm), or at least about 100 gsm, or at least about 110 gsm. This provides structural rigidity to the upstream element.

[0341] In certain preferred embodiments of the present invention, as described above, the elements of the aerosol generating article are arranged such that the center of mass of the aerosol generating article is located at least about 60 percent along the length of the aerosol generating article from the downstream end. More preferably, the elements of the aerosol generating article are arranged such that the center of mass of the aerosol generating article is located at least about 62 percent along the length of the aerosol generating article from the downstream end, and more preferably, at least about 65 percent along the length of the aerosol generating article from the downstream end.

[0342] The center of mass is preferably about 70 percent or less along the length of the aerosol-generating article from the downstream end.

[0343] By providing an element arrangement that gives the center of mass closer to the upstream end than the downstream end, an aerosol-generating article with a weight imbalance having a heavier upstream end is created. This weight imbalance can advantageously provide tactile feedback to the consumer, allowing them to distinguish between the upstream and downstream ends and insert the correct end into the aerosol generator. This may be particularly beneficial when the upstream element is provided such that the upstream and downstream ends of the aerosol-generating article are visually similar to each other.

[0344] In embodiments of the aerosol generating article according to the present invention, both an aerosol cooling element and a support element are present, which are preferably wrapped together in a combined wrapper. The combined wrapper surrounds the aerosol cooling element and the support element, but does not surround further downstream elements such as a mouthpiece element.

[0345] In these embodiments, the aerosol cooling element and support element are assembled before being surrounded by the combined wrapper, and then further assembled with the mouthpiece segment.

[0346] From a manufacturing perspective, this is advantageous in that it allows for the assembly of shorter aerosol-generating articles.

[0347] Generally, dealing with individual elements whose length is smaller than their diameter can be challenging. For example, for an element with a diameter of 7 millimeters, a length of approximately 7 millimeters represents a desirable threshold where it remains constant. However, a 10-millimeter aerosol cooling element can be combined with pairs of 7-millimeter support elements on each side (and potentially with other elements such as rods of the aerosol generating substrate) to provide a 24-millimeter hollow segment, which can then be cut into two intermediate hollow sections of 12 millimeters each.

[0348] In a particularly preferred embodiment, the other components of the aerosol generating article are individually enclosed by their own wrappers. In other words, the upstream element, the rod of the aerosol generating substrate, the support element, and the aerosol cooling element are all individually wrapped. The support element and the aerosol cooling element are combined to form an intermediate hollow section. This is achieved by wrapping the support element and the aerosol cooling element in a combined wrapper. The upstream element, the rod of the aerosol generating substrate, and the intermediate hollow section are then combined with the outer wrapper. They are then combined with a mouthpiece element, which has its own wrapper, using chipping paper.

[0349] Preferably, at least one of the components of the aerosol-generating article is wrapped in a hydrophobic wrapper.

[0350] The term "hydrophobic" refers to a surface that exhibits water-repellent properties. One useful way to determine this is by measuring the water contact angle. The water contact angle is the angle conventionally measured through a liquid, where the liquid / vapor interface intersects with the solid surface. This quantifies the wettability of a solid surface by a liquid via Young's equation. Hydrophobicity or the water contact angle may also be determined using the TAPPI T558 test method, and the result is expressed as the interfacial contact angle and reported in degrees, which can range from approximately zero to approximately 180 degrees.

[0351] In a preferred embodiment, the hydrophobic wrapper includes a paper layer having a water contact angle of about 30 degrees or more, preferably about 35 degrees or more, or about 40 degrees or more, or about 45 degrees or more.

[0352] For example, the paper layer may contain PVOH (polyvinyl alcohol) or silicone. PVOH may be applied to the paper layer as a surface coating, or the paper layer may include a surface treatment containing PVOH or silicone.

[0353] In a particularly preferred embodiment, the aerosol generating article according to the present invention comprises, in a linear continuous arrangement, an upstream element, a rod of an aerosol generating substrate located immediately downstream of the upstream element, a support element located immediately downstream of the rod of the aerosol generating substrate, an aerosol cooling element located immediately downstream of the support element, a mouthpiece element located immediately downstream of the aerosol cooling element, and an outer wrapper surrounding the upstream element, the support element, the aerosol cooling element, and the mouthpiece element.

[0354] More specifically, the rod of the aerosol generating substrate may be in contact with the upstream element. The support element may be in contact with the rod of the aerosol generating substrate. The aerosol cooling element may be in contact with the support element. The mouthpiece element may be in contact with the aerosol cooling element.

[0355] The aerosol-generating article has a substantially cylindrical shape and an outer diameter of approximately 7.25 millimeters.

[0356] The upstream element has a length of approximately 5 mm, the rod of the aerosol generating article has a length of approximately 12 mm, the support element has a length of approximately 8 mm, and the mouthpiece element has a length of approximately 12 mm. Therefore, the total length of the aerosol generating article is approximately 45 mm.

[0357] The upstream element is in the form of a cellulose acetate plug encased in a rigid plug wrap.

[0358] The aerosol generating article comprises an elongated susceptor substantially positioned longitudinally within the rod of the aerosol generating substrate and in thermal contact with the aerosol generating substrate. The susceptor is in the form of a strip or blade and has a length substantially equal to the length of the rod of the aerosol generating substrate and a thickness of about 60 micrometers.

[0359] The support element is in the form of a hollow cellulose acetate tube with an inner diameter of approximately 1.9 mm. Therefore, the thickness of the peripheral wall of the support element is approximately 2.675 mm.

[0360] The aerosol cooling element is in the form of a finer, hollow cellulose acetate tube with an inner diameter of approximately 3.25 mm. Therefore, the thickness of the peripheral wall of the aerosol cooling element is approximately 2 mm.

[0361] The mouthpiece is in the form of low-density cellulose acetate filter segments.

[0362] The rod of the aerosol generating substrate includes at least one of the above-mentioned types of aerosol generating substrates, such as homogenized tobacco, a gel formulation, or a homogenized plant material containing particles of plants other than tobacco. The present invention will be further described below with reference to the attached drawings. [Brief explanation of the drawing]

[0363] [Figure 1] Figure 1 shows a schematic side cross-sectional view of an aerosol generating article according to the present invention. [Figure 2] Figure 2 shows a schematic side cross-sectional view of the aerosol generating article according to the present invention. [Modes for carrying out the invention]

[0364] In the following, the present invention will be further described with reference to the attached drawing Figure 1, which shows a schematic side cross-sectional view of the aerosol generating article according to the present invention.

[0365] The aerosol generating article 10 shown in Figure 1 comprises a rod 12 of an aerosol generating substrate 12 and a downstream section 14 located downstream of the rod 12 of the aerosol generating substrate. Furthermore, the aerosol generating article 10 includes an upstream section 16 located upstream of the rod 12 of the aerosol generating substrate. Thus, the aerosol generating article 10 may extend from an upstream or distal end 18 to a downstream or oral end 20.

[0366] The aerosol-generating article has a total length of 45 millimeters.

[0367] The downstream section 14 includes a support element 22 located immediately downstream of the rod 12 of the aerosol generating substrate, and the support element 22 is longitudinally aligned with the rod 12. In the embodiment of Figure 1, the upstream end of the support element 18 abuts against the downstream end of the rod 12 of the aerosol generating substrate. Furthermore, the downstream section 14 includes an aerosol cooling element 24 located immediately downstream of the support element 22, and the aerosol cooling element 24 is longitudinally aligned with the rod 12 and the support element 22. In the embodiment of Figure 1, the upstream end of the aerosol cooling element 24 abuts against the downstream end of the support element 22.

[0368] As will become clear from the following description, the support element 22 and the aerosol cooling element 24 together define the intermediate hollow section 50 of the aerosol generating article 10. Overall, the intermediate hollow section 50 does not contribute substantially to the overall RTD of the aerosol generating article. The RTD of the intermediate hollow section 26 as a whole is substantially 0 mmH2O.

[0369] The support element 22 may include a first hollow tubular segment 26. The first hollow tubular segment 26 is provided in the form of a hollow cylindrical tube made from cellulose acetate. The first hollow tubular segment 26 defines an internal cavity 28 that extends entirely from the upstream end 30 of the first hollow tubular segment 20 to the downstream end 32 of the first hollow tubular segment 20. The internal cavity 28 is substantially empty, and therefore substantially unrestricted airflow is possible along the internal cavity 28. The first hollow tubular segment 26, and consequently the support element 22, does not substantially contribute to the overall RTD of the aerosol generating article 10. More specifically, the RTD of the first hollow tubular segment 26 (which is substantially the RTD of the support element 22) is substantially 0 mmH2O.

[0370] The first hollow tubular segment 26 has a length of approximately 8 mm, an outer diameter of approximately 7.25 mm, and an inner diameter of approximately 1.9 mm (D FTS ) has. Therefore, the thickness of the peripheral wall of the first hollow tubular segment 26 is approximately 2.67 millimeters.

[0371] The aerosol cooling element 24 comprises a second hollow tubular segment 34. The second hollow tubular segment 34 is provided in the form of a hollow cylindrical tube made from cellulose acetate. The second hollow tubular segment 34 defines an internal cavity 36 that extends entirely from the upstream end 38 of the second hollow tubular segment 34 to the downstream end 40 of the second hollow tubular segment 34. The internal cavity 36 is substantially empty, and therefore substantially unrestricted airflow is possible along the internal cavity 36. The second hollow tubular segment 28, and consequently the aerosol cooling element 24, does not substantially contribute to the overall RTD of the aerosol generating article 10. More specifically, the RTD of the second hollow tubular segment 34 (which is essentially the RTD of the aerosol cooling element 24) is substantially 0 mmH2O.

[0372] The second hollow tubular segment 34 has a length of approximately 8 mm, an outer diameter of approximately 7.25 mm, and an inner diameter of approximately 3.25 mm (D STS) has. Therefore, the thickness of the peripheral wall of the second hollow tubular segment 34 is about 2 millimeters. Therefore, the inner diameter (D) of the first hollow tubular segment 26 is FTS ) and the inner diameter (D) of the second hollow tubular segment 34 STS The ratio between ) is approximately 0.75.

[0373] The aerosol-generating article 10 includes a ventilation zone 60 provided along the second hollow tubular segment 34. More specifically, the ventilation zone is provided approximately 2 millimeters from the upstream end of the second hollow tubular segment 34. The ventilation level of the aerosol-generating article 10 is approximately 25 percent.

[0374] In the embodiment shown in Figure 1, the downstream section 14 further comprises a mouthpiece element 42 located downstream of the intermediate hollow section 50. More specifically, the mouthpiece element 42 is positioned immediately downstream of the aerosol cooling element 24. As shown in the drawing of Figure 1, the upstream end of the mouthpiece element 42 abuts against the downstream end 40 of the aerosol cooling element 18.

[0375] The mouthpiece element 42 is provided in the form of a cylindrical plug made of low-density cellulose acetate.

[0376] The mouthpiece element 42 has a length of approximately 12 mm and an outer diameter of approximately 7.25 mm. The RTD of the mouthpiece element 42 is approximately 12 mm of H2O.

[0377] Rod 12 contains one of the aerosol-generating substrates of the type described above.

[0378] The rod 12 of the aerosol generating substrate has an outer diameter of approximately 7.25 millimeters and a length of approximately 12 millimeters.

[0379] The aerosol generating article 10 further comprises an elongated susceptor 44 within the rod 12 of the aerosol generating substrate. More specifically, the susceptor 44 is substantially longitudinally positioned within the aerosol generating substrate so as to be substantially parallel to the longitudinal direction of the rod 12. As shown in the drawing of Figure 1, the susceptor 44 is positioned radially centrally within the rod and effectively extends along the longitudinal axis of the rod 12.

[0380] The susceptor 44 extends along the entire length of the rod 12, from its upstream end to its downstream end. Substantially, the susceptor 44 has substantially the same length as the rod 12 of the aerosol generating substrate.

[0381] In the embodiment shown in Figure 1, the susceptor 44 is provided in the form of a strip, having a length of about 12 millimeters, a thickness of about 60 micrometers, and a width of about 4 millimeters. The upstream section 16 comprises an upstream element 46 located immediately upstream of the rod 12 of the aerosol generating substrate, the upstream element 46 being longitudinally aligned with the rod 12. In the embodiment shown in Figure 1, the downstream end of the upstream element 46 abuts against the upstream end of the rod 12 of the aerosol generating substrate. This advantageously prevents the susceptor 44 from detaching. Furthermore, this prevents consumers from accidentally coming into contact with the heated susceptor 44 after use.

[0382] The upstream element 46 is supplied in the form of a cylindrical plug of cellulose acetate surrounded by a rigid wrapper. The upstream element 46 has a length of approximately 5 millimeters. The RTD of the upstream element 46 is approximately 30 millimeters of H2O.

[0383] The aerosol generating article 110 in Figure 2 has substantially the same structure as the aerosol generating article 10 in Figure 1, and will be described below insofar as it differs from the aerosol generating article 10.

[0384] As shown in Figure 2, the aerosol generating article 110 comprises a rod 12 of the aerosol generating substrate 12 and a modified downstream section 114 located downstream of the rod 12 of the aerosol generating substrate. Furthermore, the aerosol generating article 10 comprises an upstream section 16 located upstream of the rod 12 of the aerosol generating substrate.

[0385] Similar to the downstream section 14 of the aerosol generating article 10, the modified downstream section 114 of the aerosol generating article 110 includes a support element 22 located immediately downstream of the rod 12 of the aerosol generating substrate, the support element 22 being longitudinally aligned with the rod 12, and the upstream end of the support element 22 abutting against the downstream end of the rod 12 of the aerosol generating substrate.

[0386] Furthermore, the downstream section 114 includes an aerosol cooling element 124 located immediately downstream of the support element 22, the aerosol cooling element 124 being longitudinally aligned with the rod 12 and the support element 22. More specifically, the upstream end of the aerosol cooling element 124 abuts against the downstream end of the support element 22.

[0387] In contrast to the downstream section 14 of the aerosol generating article 10, the aerosol cooling element 124 of the modified downstream section 114 comprises a plurality of longitudinally extending channels that provide low or substantially null resistance to the passage of air through the rod. More specifically, the aerosol cooling element 124 is preferably formed from a non-porous sheet material selected from the group including metal foil, polymer sheets, and substantially non-porous paper or cardboard. In particular, in the embodiment illustrated in Figure 2, the aerosol cooling element 124 is provided in the form of crimped sheets and sheet aggregates of polylactic acid (PLA). The aerosol cooling element 124 has a length of about 8 millimeters and an outer diameter of about 7.25 millimeters.

Claims

1. An aerosol generating article for generating an inhalable aerosol when heated, the article having an aerosol that extends from the mouth end to the distal end upstream from the mouth end, A rod of the aerosol generating substrate, A downstream section located downstream of the rod of the aerosol generating substrate, comprising a mouthpiece element positioned downstream of the rod and longitudinally aligned with the rod, wherein the mouthpiece element extends all the way to the mouth end of the aerosol generating article, The upstream section is located upstream of the rod of the aerosol generating substrate and includes an upstream element that extends all the way to the distal end of the article, The diameter (D) of the aerosol generating article at the mouth end. ME ) is the diameter (D) of the aerosol generating article at the distal end. DE ) is greater than the ratio (D) between the diameter of the aerosol generating article at the mouth end and the diameter of the aerosol generating article at the distal end. ME / D DE Aerosol-generating article in which the ratio is at least about 1.

005.

2. The ratio (D) between the diameter of the aerosol generating article at the mouth end and the diameter of the aerosol generating article at the distal end ME / D DE The aerosol-generating article according to claim 1, wherein the ratio is at least about 1.

05.

3. The diameter (D) of the aerosol generating article at the mouth end. ME ) and the diameter (D) of the aerosol generating article at the distal end. DE The aerosol-generating article according to claim 1 or 2, wherein the difference with ) is at least about 100 micrometers.

4. The aerosol generating article according to any one of claims 1 to 3, wherein the article further comprises an elongated susceptor arranged longitudinally within the rod of the aerosol generating substrate.

5. The aerosol generating article according to any one of claims 1 to 4, wherein the diameter of the upstream section is greater than the diameter of the rod of the aerosol generating substrate.

6. The aerosol generating article according to any one of claims 1 to 5, wherein the downstream section further includes a support element positioned immediately downstream of the rod of the aerosol generating substrate and aligned longitudinally with the rod of the aerosol generating substrate.

7. The aerosol generating article according to claim 6, wherein the downstream section further includes an aerosol cooling element positioned immediately downstream of the support element, the aerosol cooling element including a hollow tubular segment that defines a cavity extending from the upstream end of the hollow tubular segment to the downstream end of the hollow tubular segment.

8. The aerosol generating article according to claim 7, further comprising a ventilation zone along the hollow tubular segment.

9. The aerosol-generating article according to claim 8, wherein the article has an air permeability level of at least about 10 percent.

10. The aerosol generating article according to any one of claims 1 to 9, wherein the diameter of the article is substantially constant over the distal portion of the article extending at least about 5 millimeters from the distal end.

11. The aerosol generating article according to any one of claims 1 to 10, wherein the diameter of the article gradually tapers over the distal portion of the article extending at least about 5 millimeters from the distal end.

12. The aerosol generating article according to any one of claims 1 to 11, wherein the aerosol generating substrate comprises at least about 10 weight percent of an aerosol forming body on a dry weight basis.

13. The aerosol generating article according to any one of claims 1 to 12, wherein the aerosol generating article comprises a first band of chipping paper that at least partially surrounds the mouthpiece element and is attached immediately next to the mouthpiece, an upstream component of the aerosol generating article, and a second band of chipping paper that surrounds the first band of chipping paper.

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