Aerosol generating article comprising a capsule and a hollow tubular element with ventilation.

Abstract

An aerosol generating article (10) for generating an inhalable aerosol when heated comprises a hollow tubular element (101) and a capsule (102) attached inside the hollow tubular element (101) at the upstream end of the hollow tubular element (101). The capsule (102) contains an aerosol generating substrate. The hollow tubular element (101) is provided with a ventilation zone that allows outside air to enter the aerosol generating article (10). The ventilation zone is provided downstream of the downstream end of the capsule (102).

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. In particular, the present invention relates to an aerosol generating article comprising an aerosol generating substrate contained within a capsule, wherein the aerosol generating article further includes a ventilation zone. [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 the heat source, located within the heat source, around the heat source, 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 an aerosol.

[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.

[0004] The use of aerosol generating articles in combination with external heating systems is also known. For example, International Publication 2020 / 115151 describes the provision of one or more heating elements arranged around the aerosol generating article when the aerosol generating article is received in a cavity of an aerosol generating device. Alternatively, an inductively heatable aerosol generating article comprising an aerosol generating substrate and a susceptor disposed within the aerosol generating substrate is proposed in International Publication 2015 / 176898.

[0005] Certain types of aerosol-generating substrates containing nicotine and relatively high aerosol-forming material content, such as nicotine-containing gels and films, are known. These substrates are typically very stable during storage and, advantageously, provide very consistent delivery of nicotine to consumers upon heating. They also, advantageously, can generate aerosols at lower temperatures than other solid substrates. However, the use of this type of aerosol-generating substrate can also present problems. Relatively high aerosol-forming material content increases the risk of aerosol-forming material leakage from the substrate during storage and use. Leakage of aerosol-forming material from an aerosol-generating article is undesirable because it can leak into the heating chamber of an aerosol generator and contaminate the device. Leakage of aerosol-forming material or gel composition can also be potentially unpleasant for consumers.

[0006] Therefore, it is desirable to provide a novel aerosol generating article having an arrangement that provides improved retention of the aerosol generating substrate within the aerosol generating article during storage and use.

[0007] Furthermore, it is desirable to provide a novel aerosol generating article having an arrangement that maximizes the generation and delivery of aerosols from the aerosol generating substrate. [Overview of the project]

[0008] This disclosure relates to an aerosol generating article for generating an inhalable aerosol upon heating. The aerosol generating article may comprise a hollow tubular element. The aerosol generating article may comprise a capsule mounted within the hollow tubular element. The capsule may be located at the upstream end of the hollow tubular element. The capsule may include an aerosol generating substrate. The hollow tubular element may comprise a ventilation zone that allows external air to enter the aerosol generating article. The ventilation zone may be provided downstream of the downstream end of the capsule.

[0009] The present invention will be further described below with reference to the attached drawings. [Brief explanation of the drawing]

[0010] [Figure 1] A schematic side cross-sectional view of an aerosol generating article according to an embodiment of the present invention is shown. [Figure 2] This shows an enlarged schematic side cross-sectional view of a portion of an aerosol-generating article according to an embodiment of the present invention. [Figure 3] A schematic cross-sectional view along the longitudinal axis of a first aerosol generating article according to an embodiment of the present invention is shown. [Figure 4] A schematic cross-sectional view along the longitudinal axis of a second aerosol generating article according to an embodiment of the present invention is shown. [Figure 5] A schematic cross-sectional view along the longitudinal axis of a third aerosol generating article according to an embodiment of the present invention is shown. [Figure 6] This shows a schematic side cross-sectional view of an aerosol generation system according to an embodiment of the present invention. [Modes for carrying out the invention]

[0011] The aerosol generating article 10 shown in Figure 1 comprises a hollow tubular element 101 and a capsule 102 installed inside the hollow tubular element 101.

[0012] The hollow tubular element 101 is formed from cardboard and has a cylindrical shape extending from the upstream end to the downstream end. The hollow tubular element 101 has a constant outer diameter of about 7.2 mm and a constant inner diameter of about 6.7 mm. The hollow tubular element 101 therefore has a wall thickness of about 0.25 mm. The hollow tubular element 101 has a length of about 40 mm.

[0013] Capsule 102 has an outer wall formed from an impermeable polymer such as HPMC. Capsule 102 has an elongated capsule (spherical cylindrical) shape with a round cross-section. The capsule has an outer wall that defines an internal cavity containing a plurality of beads (not shown in Figure 1) of a solid aerosol generating substrate. The solid aerosol generating substrate contains nicotine and glycerin such as an aerosol former. The outer wall of the capsule is defined by a cylindrical wall and opposing hemispherical end walls at the upstream and downstream ends of capsule 102. Capsule 102 has a length of about 20 millimeters and an outer diameter of about 6.7 millimeters. Thus, the outer diameter of capsule 102 is similar to the inner diameter of the hollow tubular element 101 so that capsule 102 is held in place within the hollow tubular element 101 by friction fitting.

[0014] Capsule 102 has an internal volume of approximately 600 cubic millimeters and contains approximately 200 milligrams of solid aerosol-generating substrate. Therefore, the capsule contains approximately 0.33 milligrams / cubic millimeter of aerosol-generating substrate in its internal cavity.

[0015] Capsule 102 is provided with a plurality of capsule air intake ports 105 on the hemispherical upstream end wall of capsule 102 at its upstream end. Capsule 102 is also provided with a plurality of capsule air outlet ports 106 on the hemispherical downstream end wall of capsule 102 at its downstream end. The arrangement of the capsule air intake ports 105 and capsule air outlet ports 106 will be described in more detail below.

[0016] The hollow tubular element 101 comprises a ventilation zone that allows external air to enter the aerosol-generating article. The ventilation zone is provided downstream of the downstream end of the capsule 102. More specifically, the upstream end of the ventilation zone is aligned with the downstream end of the capsule 102.

[0017] The ventilation zone comprises 10 ventilation perforations 102 that extend through the hollow tubular element 101. The ventilation perforations 102 are evenly spaced apart from one another and are arranged on a line that surrounds the hollow tubular element 101. All of the ventilation perforations 102 are the same size. Each ventilation perforation 102 has a width of 100 micrometers and a length of 600 micrometers. The ventilation zone provides a ventilation level of at least 20 percent.

[0018] The aerosol-generating article 10 further comprises at least one stop 107 that protrudes from the inner surface of the hollow tubular element 101 and prevents the capsule 102 from moving further downstream than the at least one stop 107. In the aerosol-generating article 10 shown in FIG. 1, the at least one stop 107 comprises an annular flange that is attached to the inner surface of the hollow tubular element 101 and extends from the inner surface of the hollow tubular element 101. The inner diameter of the flange is smaller than the outer diameter of the capsule 102, thereby preventing the capsule from moving further downstream than the stop 107. The at least one stop 107 is located upstream of the ventilation zone.

[0019] The aerosol-generating article 10 further comprises an empty cavity 104 downstream of the capsule 102 and a downstream filter segment 108 downstream of the empty cavity 104. The empty cavity 104 extends from the downstream end of the capsule 102 to the upstream end of the downstream filter segment 108. The empty cavity 104 has a length of approximately 20 millimeters.

[0020] The downstream filter segment 108 extends from the downstream end of the empty cavity 104 to the downstream end of the aerosol-generating article. The downstream filter segment 108 is formed from cellulose acetate tow.

[0021] Figure 2 shows a portion of an alternative aerosol-generating article 10 according to the present invention. As shown in Figure 2, the hollow tubular element 101 comprises a plurality of flaps cut from the hollow tubular element 101. The flaps are removed from the hollow tubular element 101 at the downstream end of the flaps but attached to the hollow tubular element 101 at the upstream end. As can be seen in Figure 2, these flaps may be formed during manufacturing by angled through elements 201 that cut through the hollow tubular element 101 and fold the flaps inward.

[0022] In this embodiment, the holes in the hollow tubular element 101 formed by the through element 201 form ventilation holes 103 that allow ambient air to enter the aerosol generating article 10, and the material flaps form at least one stopper 107 to prevent the capsule 102 from moving further downstream.

[0023] Figure 3 shows a cross-sectional view of the aerosol-generating article 10 as seen along the longitudinal axis of the article at position "A" marked in Figure 1. As shown in Figure 3, the capsule 102 includes four capsule air outlets 106 arranged on a circle 301, with an additional capsule air outlet located at the center of the downstream end of the capsule 102. The aerosol-generating article 10 shown in Figure 3 further includes a ventilation zone containing four ventilation holes 103 through a hollow tubular element 101. Each capsule air outlet 106 is positioned to radially overlap with a ventilation hole 103. This radial overlap is demonstrated by a radial line 302 that clearly intersects both the capsule air outlets 106 and the ventilation holes 103.

[0024] Figure 4 shows a cross-sectional view of the aerosol-generating article 10 as seen along the longitudinal axis of the article at position "A" marked in Figure 1. The aerosol-generating article 10 shown in Figure 4 includes a ventilation zone containing eight ventilation holes 103 through a hollow tubular element 101. The angular diameter (θ) of the capsule air outlet C ) and the angular distance (θ) between adjacent ventilation holes S ) is shown. Capsule air outlet (θ C The angular diameter of the adjacent ventilation hole (θ) S) is greater than the angular distance therebetween.

[0025] Figure 5 shows a cross-sectional view of the further aerosol-generating article 10 along the longitudinal axis of the article at the position "A" marked in Figure 1. The aerosol-generating article 10 shown in Figure 5 includes a ventilation zone including 18 ventilation perforations 103 passing through a hollow tubular element 101. The angular diameter of the capsule air outlet (θ C ) is shown. The angular diameter of each ventilation perforation (θ S ) added to the angular distance between adjacent ventilation perforations (θ V ) is also shown. The angular diameter of the capsule air outlet (θ C ) is greater than the angular diameter of each ventilation perforation (θ S ) added to the angular distance between adjacent ventilation perforations (θ V ).

[0026] Figure 6 shows an aerosol generation system 20 according to the present invention. The system 20 comprises the aerosol-generating article 10 described above. The system 20 further comprises an aerosol generation device 30. The aerosol generation device 30 comprises a device housing 601. The housing 601 defines a heating chamber 602 for receiving the upstream end of the aerosol-generating article 20. The heating chamber 602 has an inner diameter substantially corresponding to the outer diameter of the aerosol-generating article 10. The heating chamber 602 has a length of about 30 millimeters.

[0027] The aerosol generation device 30 further comprises a heating element or heater 603 for heating the aerosol generation substrate when the aerosol-generating article 10 is received within the heating chamber 602. The heater 603 is an external heater surrounding the heating chamber 602. The heater 603 is a resistance heater, connected to a power source (not shown) and controlled using a control circuit (not shown).

[0028] The aerosol generation device 30 further comprises a plurality of device air inlets (not shown) 604 for allowing air to enter the heating chamber 602 of the device 30.

[0029] During use, the upstream end of the aerosol generating article 10 is inserted into the heating chamber 602 of the aerosol generating device 30. The heater 603 is activated, and the aerosol generating substrate is heated inside the capsule 102. The heated aerosol generating substrate generates vapor. When a pressure drop is applied to the downstream end of the aerosol generating article, ambient air is drawn into the capsule 102 through the device air intake 604 and the capsule air intake 105. Here, the air is accompanied by vapor before exiting the capsule 102 through the capsule air outlet 106. Here, the air mixes with the ambient air drawn out through the ventilation holes 103, which cools the vapor and promotes aerosol nucleation and condensation. The aerosol then passes through the downstream filter segment 108 and exits from the downstream end of the aerosol generating article.

[0030] According to a first aspect of the present invention, an aerosol generating article is provided for generating an inhalable aerosol upon heating, the article comprising a hollow tubular element and a capsule mounted inside the hollow tubular element at the upstream end of the hollow tubular element. The capsule contains an aerosol generating substrate. The hollow tubular element is provided with a ventilation zone that allows external air to enter the aerosol generating article. The ventilation zone is provided downstream of the downstream end of the capsule.

[0031] Providing an aerosol-generating substrate contained within a capsule offers a highly effective method for retaining the aerosol-generating substrate in a fixed position within an aerosol-generating article during storage and use. The configuration of the present invention may be particularly advantageous for aerosol-generating substrates having a relatively high aerosol-forming content. Encapsulating the aerosol-generating substrate within a capsule prevents leakage of the aerosol-forming material from the aerosol-generating substrate during storage or use. Furthermore, if the aerosol-generating substrate melts upon heating, the molten substrate can be effectively retained within the capsule. Therefore, leakage of the aerosol-forming material or aerosol-generating substrate from an aerosol-generating article during use can be substantially prevented, and as a result, the risk of contamination of the aerosol generator is advantageously minimized.

[0032] Placing capsules within hollow tubular elements is relatively simple, and therefore the amount of material required to manufacture aerosol-generating articles can be advantageously reduced compared to existing aerosol-generating articles with more complex structures. In particular, when an aerosol-generating substrate capable of generating aerosols at relatively low temperatures is used, it is possible to produce aerosol-generating articles according to the present invention with minimal filtration material downstream of the capsule.

[0033] By providing a ventilation zone downstream of the capsule's downstream end, ambient air can be drawn into the hollow tubular element. Providing ambient air can advantageously improve aerosol generation from the aerosol-generating substrate. While not wishing to be bound by theory, the cool ambient air provided by the ventilation zone can mix with the warmer air from the capsule. This mixing can advantageously facilitate aerosol nucleation, and the aerosol may then be delivered to the user through the downstream end of the aerosol-generating article. For example, if the aerosol-generating substrate contains an aerosol-forming agent such as nicotine and glycerin, heating the aerosol-generating substrate during use can generate free base nicotine vapor and volatile organic acid vapor. When these vapors are cooled by ambient air, acid droplets are formed that combine with volatile free base nicotine. In this way, nicotine can be delivered as a nicotine salt. Furthermore, the nicotine salt can bind to larger, condensed glycerin droplets to more readily adsorb nicotine. Therefore, the cooling effect of the ventilation zone can advantageously improve aerosol generation and delivery of aerosol-generating articles.

[0034] When in use, the aerosol generating article of the present invention may be used in conjunction with a corresponding aerosol generating device. The aerosol generating article may be placed in an aerosol generating device capable of heating at least a portion of the aerosol generating article containing the capsule. This may heat the aerosol generating substrate and generate vapor. These vapors exit the capsule and mix with ambient air provided by a ventilation zone, at which point the vapors may condense and nucleate to form an aerosol that can be delivered to the user.

[0035] As will be discussed in more detail below, additional components may or may not be provided downstream of the ventilation zone. The capsule may include at least one air intake and at least one air outlet, as will be discussed in more detail below.

[0036] As used herein, the term "aerosol-generating article" refers to an article that generates an inhalable aerosol by heating an aerosol-generating substrate and delivers it to a consumer. As used herein, the term "aerosol-generating substrate" means a substrate that has the ability to generate an aerosol by releasing volatile compounds upon heating.

[0037] 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.

[0038] As used herein, the term “longitudinal axis” refers to the direction corresponding to the main longitudinal axis of the aerosol generating article or aerosol generating device, extending between the upstream and downstream ends of the aerosol generating article or aerosol generating device. 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 or aerosol generating device with respect to the direction in which aerosols are moved through the aerosol generating article or aerosol generating device during use.

[0039] During use, air is drawn through the aerosol-generating article in the longitudinal direction. The terms “transverse direction” or “radial direction” refer to directions 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.

[0040] 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.

[0041] As used herein, the term “hollow tubular element” refers to a generally elongated element that defines a cavity 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.

[0042] In the context of the present invention, the hollow tubular element provides an unrestricted flow path. This means that the hollow tubular element provides a negligible level of drawdown resistance (RTD). The term “negligible level of RTD” is used to mean an RTD of less than 1 mmH2O per 10 millimeters of length of the hollow tubular element, preferably less than 0.4 mmH2O per 10 millimeters of length of the hollow tubular element, and more preferably less than 0.1 mmH2O per 10 millimeters of length of the hollow tubular element.

[0043] The hollow tubular element has a capsule containing an aerosol-generating substrate attached to its upstream end, as described above. Furthermore, the hollow tubular element defines an empty cavity downstream of the capsule, extending along part or all of the length of the hollow tubular element. In some embodiments, the empty cavity extends all the way from the capsule to the downstream end of the aerosol-generating article. Thus, in such embodiments, the aerosol-generating article can be formed by only two elements: the capsule and the hollow tubular element. Alternatively, one or more filter segments may be provided within the hollow tubular element at their downstream ends, as will be described in more detail below.

[0044] The empty cavity defined within the hollow tubular element downstream of the capsule preferably has a length of at least 10 millimeters, more preferably at least 12 millimeters, and more preferably at least 14 millimeters. The length of the empty cavity may be up to 40 millimeters, or up to 30 millimeters, or up to 25 millimeters. For example, the empty cavity may have a length of 10 to 40 millimeters, or 12 to 30 millimeters, or 14 to 25 millimeters.

[0045] Preferably, the hollow tubular element has a total length of at least 25 mm, more preferably at least 28 mm, more preferably at least 30 mm, more preferably at least 32 mm, and more preferably at least 34 mm. The length of the hollow tubular element may be less than 50 mm, or less than 48 mm, or less than 45 mm, or less than 42 mm, or less than 40 mm. For example, the total length of the hollow tubular element may be 25 mm to 50 mm, or 28 mm to 48 mm, or 30 mm to 45 mm, or 32 mm to 42 mm, or 34 mm to 40 mm.

[0046] The hollow tubular element may have an outer diameter of 5 to 12 millimeters, for example, 5 to 10 millimeters, or 6 to 8 millimeters. In a preferred embodiment, the hollow tubular element has an outer diameter of 7.2 millimeters plus or minus 10 percent.

[0047] Preferably, the inner diameter of the hollow tubular element is constant along the length of the hollow tubular element. The lumen or cavity of the hollow tubular segment may have any cross-sectional shape. The lumen of the hollow tubular segment may have a circular cross-sectional shape.

[0048] Preferably, the inner diameter of the hollow tubular element is at least 5 mm, more preferably at least 5.5 mm, more preferably at least 6 mm, and more preferably at least 6.5 mm. Preferably, the inner diameter of the hollow tubular element is less than 9 mm, more preferably less than 8.5 mm, more preferably less than 8 mm, and more preferably less than 7.5 mm. For example, the inner diameter may be 5 mm to 9 mm, or 5.5 mm to 8.5 mm, or 6 mm to 6 mm, or 6.5 mm to 7.5 mm. The inner diameter may be about 7 mm.

[0049] The hollow tubular element preferably has a wall thickness of at least 100 micrometers, more preferably at least 150 micrometers, more preferably at least 200 micrometers, more preferably at least 250 micrometers, and more preferably at least 500 micrometers. The wall thickness of the hollow tubular element may be less than 2 millimeters, preferably less than 1.5 millimeters, and even more preferably less than 1.25 mm. The wall thickness of the hollow tubular element may be less than 1 millimeter. For example, the wall thickness of the hollow tubular element may be 100 micrometers to 2 millimeters, or 150 micrometers to 1.5 millimeters, or 200 micrometers to 1.25 millimeters, or 250 micrometers to 1 millimeter, or 500 micrometers to 1 millimeter.

[0050] The hollow tubular segment may include a paper-based material. The hollow tubular segment may include at least one layer of paper. The paper may be very rigid paper. The paper may be crimped paper, such as crimped heat-resistant paper or crimped sulfuric acid paper. Advantageously, the crimped paper may form one or more airflow channels extending around the outside of the capsule. One or more airflow channels may be particularly advantageous in embodiments in which the capsule has at least one of an air intake and an air outlet on the cylindrical wall of the capsule.

[0051] Preferably, the hollow tubular element is formed from cardboard. The hollow tubular element may be a cardboard tube. Advantageously, cardboard is a cost-effective material that provides a balance between being deformable to provide ease of inserting articles into the aerosol generator and being rigid enough to provide proper engagement of articles with the inside of the device. Thus, cardboard tubes may provide adequate resistance to deformation or compression during use.

[0052] The hollow tubular segment may be a paper tube. The hollow tubular segment may be a tube formed from spirally wound paper. The hollow tubular segment may be formed from multiple layers of paper. The paper may have a basis weight of at least about 50 grams per square meter, at least about 60 grams per square meter, at least about 70 grams per square meter, or at least about 90 grams per square meter.

[0053] The hollow tubular segment may contain polymer materials. For example, the hollow tubular segment may contain a polymer film. The polymer film may contain a cellulose film. The hollow tubular segment may contain low-density polyethylene (LDPE) or polyhydroxyalkanoate (PHA) fibers. The hollow tube may contain cellulose acetate tow.

[0054] If the hollow tubular segment contains cellulose acetate tow, the cellulose acetate tow may have about 2 to about 4 deniers per filament and about 25 to about 40 total deniers.

[0055] The capsule may be mounted within a hollow tubular element such that a portion of the capsule extends from the upstream end of the hollow tubular element, thereby positioning at least one capsule air intake on the outside of the hollow tubular element. Preferably, at least 20 percent of the length of the capsule protrudes from the hollow tubular element, and more preferably at least 30 percent of the length of the capsule. Preferably, 50 percent or less of the length of the capsule protrudes from the hollow tubular element. Thus, the majority of the capsule is within the hollow tubular element so that the capsule can be held firmly in place. In such embodiments, the hollow tubular element may have at least one stopper, such as a flange or projection extending inward from the inner surface at the downstream end of the capsule, to prevent the capsule from being pushed further downstream into the hollow tubular element. For example, the hollow tubular element may have an annular flange extending from the inner surface. Providing at least one stopper will be described in more detail below.

[0056] The ventilation zone may have at least one ventilation hole.

[0057] At least one ventilation hole can, advantageously, allow ambient air to enter the hollow tubular element, thereby improving the aerosol generation described above.

[0058] The ventilation zone may be provided with multiple ventilation holes through a hollow tubular element.

[0059] Providing multiple ventilation holes can, advantageously, allow more ambient air to enter the hollow tubular element. Furthermore, providing multiple holes can provide a more uniform distribution of ambient air into the hollow tubular element. This can, advantageously, further improve aerosol generation.

[0060] The ventilation zone may have at least two ventilation holes. For example, the ventilation zone may have at least two, at least three, at least five, or at least ten ventilation holes passing through a hollow tubular element.

[0061] Providing a larger number of ventilation holes can, advantageously, improve aerosol generation.

[0062] The ventilation zone may be provided with 35 or fewer ventilation holes. For example, the ventilation zone may be provided with 30 or fewer, 25 or fewer, 20 or fewer, or 15 or fewer ventilation holes passing through a hollow tubular element.

[0063] This limitation on the number of ventilation holes is advantageous in that it can prevent the hollow tubular elements from being weakened by the ventilation zones. This is also advantageous in that it can prevent the draw resistance from being reduced to an unacceptable level.

[0064] The ventilation zone may have 2 to 35 ventilation holes. For example, the ventilation zone may have 3 to 30 ventilation holes, 5 to 25 ventilation holes, 5 to 20 ventilation holes, or 10 to 15 ventilation holes. The ventilation zone may have 5 to 15 ventilation holes.

[0065] Multiple ventilation holes may include at least one hole having a width of 200 micrometers or less.

[0066] For example, multiple ventilation holes may include at least one hole having a width of 175 micrometers or less, 150 micrometers or less, 125 micrometers or less, or 120 micrometers or less.

[0067] Multiple ventilation holes may comprise at least one hole having a width of 2 millimeters or less. For example, multiple ventilation holes may comprise at least one hole having a width of 1.5 millimeters or less, 1 millimeter or less, 500 micrometers or less, or 250 micrometers or less.

[0068] Multiple ventilation holes may comprise at least one hole having a width of at least 50 micrometers. For example, multiple ventilation holes may comprise at least one hole having a width of at least 65 micrometers, at least 80 micrometers, at least 90 micrometers, or at least 100 micrometers.

[0069] Multiple ventilation holes may comprise at least one hole having a length of at least 400 micrometers. For example, multiple ventilation holes may comprise at least one hole having a length of at least 425 micrometers, at least 450 micrometers, at least 475 micrometers, or at least 500 micrometers.

[0070] Multiple ventilation holes may comprise at least one hole having a length of 1 millimeter or less. For example, multiple ventilation holes may comprise at least one hole having a length of 950 micrometers or less, 900 micrometers or less, 850 micrometers or less, or 800 micrometers or less.

[0071] If the ventilation zone comprises multiple ventilation holes, each of the ventilation holes may have substantially the same dimensions. This is advantageous in that it can ensure a uniform supply of ambient air to the hollow tubular element.

[0072] Multiple ventilation holes may form a line of holes surrounding a hollow tubular element.

[0073] The ventilation zone may include a porous portion of a hollow tubular element.

[0074] This can prevent perforations from being visible on the outer surface of the aerosol-generating article. This is advantageous as it can improve the appearance of the aerosol-generating article. Furthermore, providing a porous portion of the hollow tubular element can eliminate the need for ventilation perforations, thus advantageously improving the strength of the hollow tubular element.

[0075] The porous portion of the hollow tubular element that forms the ventilation zone may have a lower basis weight than the portion of the hollow tubular element that does not form part of the ventilation zone.

[0076] The upstream end of the ventilation zone may be located at least 20 millimeters from the upstream end of the aerosol-generating article.

[0077] For example, the upstream end of the ventilation zone may be located at least about 25 millimeters from the upstream end of the aerosol-generating article.

[0078] The placement of the aforementioned ventilation zone ensures that when the aerosol-generating article is used with the aerosol generator, the ventilation zone is located outside the corresponding aerosol generator. This is advantageous because it ensures that the ventilation zone is not blocked by the aerosol generator during use, and that the ambient air entering the aerosol generator through the ventilation zone is not heated by the heater of the aerosol generator.

[0079] The upstream end of the ventilation zone may be located no more than 37 millimeters from the upstream end of the aerosol-generating article.

[0080] For example, the upstream end of the ventilation zone may be located within approximately 30 millimeters of the upstream end of the aerosol-generating article.

[0081] As outlined above, arranging ventilation zones may advantageously prevent the ventilation zones from being blocked by the user's mouth or lips during use of the aerosol-generating article.

[0082] The upstream end of the ventilation zone may be located approximately 20 to 37 millimeters, or approximately 25 to 30 millimeters, from the upstream end of the aerosol-generating article. The upstream end of the ventilation zone may be located at least approximately 27 millimeters from the upstream end of the aerosol-generating article.

[0083] The upstream end of the ventilation zone may be located no more than 10 millimeters from the downstream end of the capsule.

[0084] For example, the upstream end of the ventilation zone may be located 8 millimeters or less, 5 millimeters or less, 3 millimeters or less, or 1 millimeter or less from the downstream end of the capsule.

[0085] The upstream end of the ventilation zone may be aligned with the downstream end of the capsule in the longitudinal direction.

[0086] Placing the ventilation zone near the downstream end of the capsule can, advantageously, provide a rapid and abrupt temperature drop as soon as the vapor leaves the capsule. This can, advantageously, facilitate the efficient nucleation of aerosols from the vapor.

[0087] The ventilation level of the aerosol-generating article provided by the ventilation zone may be at least 20 percent.

[0088] Aerosol-generating articles may typically have a ventilation level of at least about 10 percent, preferably at least about 20 percent.

[0089] In a preferred embodiment, the aerosol-generating article has an air permeability level of at least about 20 percent, 25 percent, or 30 percent. More preferably, the aerosol-generating article has an air permeability level of at least about 35 percent.

[0090] Aerosol-generating articles preferably have a ventilation level of less than approximately 80 percent. More preferably, aerosol-generating articles have a ventilation level of less than approximately 60 percent or less than approximately 50 percent.

[0091] Aerosol-generating articles generally have a ventilation level of approximately 10 percent to 80 percent.

[0092] In some embodiments, the aerosol-generating article has an air permeability level of about 20 percent to about 80 percent, preferably about 20 percent to about 60 percent, and more preferably about 20 percent to about 50 percent. In another embodiment, the aerosol-generating article has an air permeability level of about 25 percent to about 80 percent, preferably about 25 percent to about 60 percent, and more preferably about 25 percent to about 50 percent. In yet another embodiment, the aerosol-generating article has an air permeability level of about 30 percent to about 80 percent, preferably about 30 percent to about 60 percent, and more preferably about 30 percent to about 50 percent.

[0093] In a particularly preferred embodiment, the aerosol-generating article has a permeability level of about 40 percent to about 50 percent. In some particularly preferred embodiments, the aerosol-generating article has a permeability level of about 45 percent.

[0094] The aerosol generating article may further include at least one stopper protruding from the inner surface of a hollow tubular element to prevent the capsule from moving further downstream than the at least one stopper.

[0095] Providing at least one stopper can, advantageously, help to hold the capsule in place within the hollow tubular element. In particular, at least one stopper can, advantageously, prevent the capsule from moving excessively downstream and prevent the capsule from blocking the ventilation zone and allowing ambient air to enter the hollow tubular element.

[0096] At least one stopper may be located upstream of the ventilation zone.

[0097] Placing at least one stopper upstream of the ventilation zone can, advantageously, further prevent the capsule from moving excessively downstream and blocking the ventilation zone.

[0098] At least one stopper may be of any type. At least one stopper may limit the inner diameter of a hollow tubular element at a certain point. The inner diameter of the hollow tubular element at at least one stopper may be smaller than the outer diameter of the capsule, thereby preventing the capsule from moving further downstream than at least one stopper.

[0099] At least one stopper may include an embossed portion of a hollow tubular element that extends into the interior of the hollow tubular element.

[0100] At least one stopper may include a thicker portion of the hollow tubular element, reducing the inner diameter of the hollow tubular element to prevent the capsule from moving further downstream than the thicker portion.

[0101] At least one stopper is located within a hollow tubular element and may be equipped with a flange attached to the hollow tubular element, which prevents the capsule from moving further downstream.

[0102] The hollow tubular element may have at least one flap, the flap being formed from a portion of the hollow tubular element partially removed from the rest of the hollow tubular element, the flap forming a gap between the flap and the rest of the hollow tubular element, the flap remaining attached to the rest of the hollow tubular element along a mounting line, the flap extending into the interior of the hollow tubular element such that at least one stop portion includes at least the flap, and at least one ventilation hole includes the gap between the flap and the rest of the hollow tubular element.

[0103] In other words, at least one ventilation hole can be formed by penetrating the hole in the hollow tubular element from the outside of the hollow tubular element to form a hole. In doing so, a portion of the hollow tubular element is pushed into the interior of the hollow tubular element. The penetration is carried out so that a portion of the hollow tubular element remains attached to the hollow tubular element along the attachment line, forming a flap. This flap, extending into the interior of the hollow tubular element, is at least one stopper.

[0104] By forming at least one stop in this manner, it is advantageous that both a ventilation zone and at least one stop are formed in a single process, thereby simplifying the manufacture of aerosol-generating articles.

[0105] The attachment wire may be located at the upstream end of the flap. Placing the attachment wire at the upstream end of the flap may, advantageously, mean that the flap acting as at least one stopper is located upstream of the ventilation perforation formed by the manufacture of the flap. As described above, this may, advantageously, prevent the capsule from blocking the ventilation perforation and, disadvantageously, prevent ambient air from entering the hollow tubular element.

[0106] The capsule may have an outer wall that defines an internal cavity containing an aerosol-generating substrate.

[0107] The capsule outer wall may be formed of any suitable material. Preferably, the capsule outer wall is formed of an impermeable material, and most preferably, an impermeable polymer material. This ensures that air does not pass through the capsule outer wall except through holes specifically provided for airflow during use. Therefore, the airflow through the capsule during use can be effectively controlled.

[0108] The capsule outer wall may contain polymeric or cellulosic materials. For example, the capsule outer wall may be made of one or more nicotine-compatible polymers, including medical-grade polymers such as ALTUGLAS® medical resin polymethyl methacrylate (PMMA), Chevron Phillips K-Resin® styrene-butadiene copolymer (SBC), Arkema specialty performance polymers Pebax®, Rilsan®, and Rilsan® Clear, DOW (Health+®) low-density polyethylene (LDPE), DOW® LDPE91003, DOW® LDPE91020 (MFI2.0; density 923), ExxonMobil® polypropylene (PP) PP1013H1, PP1014H1, and PP9074MED, and Trinseo CALIBRE® polycarbonate (PC) 2060-SERIES.

[0109] Alternatively, the capsule wall may be formed from one or more materials selected from polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), gelatin, and hydroxypropyl methylcellulose (HPMC).

[0110] In embodiments where the capsule wall is intended to be penetrated by a heating element or penetrating element within the aerosol generator, as described below, the capsule wall should be formed of a penetrating or fragile material. The upstream end wall of the capsule may optionally include one or more weak lines or weak regions positioned to facilitate the insertion of a heating element through the capsule wall during use.

[0111] The capsule is preferably spherical-cylindrical in shape, with the cylindrical portion defined by a cylindrical wall and rounded hemispherical end walls at each end of the cylindrical portion. This type of capsule is commonly used in the pharmaceutical industry. Alternatively, the capsule may be spherical or oval in shape.

[0112] The capsule is preferably a two-part capsule having two separate parts that fit together to close the capsule and hold its contents. The two separate parts may be fitted together by friction without adhesive. Alternatively, the two parts may be sealed together using adhesive.

[0113] The capsule preferably comprises a first component and a second component, the second component having a smaller diameter than the first component so that the end of the second component can be inserted into the open end of the first component to close the capsule.

[0114] In these embodiments, the outer diameters of the first and second parts of the capsule may be fitted such that only the second part of the capsule can be received within the hollow tubular element. The outer diameter of the first part of the capsule is fitted to be larger than the inner diameter of the hollow tubular element such that the first part of the capsule cannot be received within the hollow tubular element and remains outside of it. Preferably, the second part of the capsule is held within the hollow tubular element by friction fitting.

[0115] Alternatively, the capsule may be completely inserted into a hollow tubular element, and the outer diameters of the first and second parts of the capsule may be adapted such that the outer diameter of the second part is smaller than the inner diameter of the hollow tubular element. This provides space between the second part of the capsule and the wall of the hollow tubular element, allowing airflow around the second part of the capsule. Such an arrangement may be beneficial in embodiments where it is desirable to position the air outlet on the cylindrical wall of the capsule, as described below.

[0116] The internal cavity of the capsule has a volume of at least 250 cubic millimeters, corresponding to 0.25 millimeters. This corresponds to the internal volume, or capacity, of the capsule. Preferably, the internal cavity of the capsule has a volume of at least 400 cubic millimeters (0.4 milliliters), more preferably at least 500 cubic millimeters (0.5 milliliters), and more preferably at least 600 cubic millimeters (0.6 milliliters). The internal cavity of the capsule may be less than 2000 cubic millimeters (2 milliliters), or less than 1500 cubic millimeters (1.5 milliliters), or less than 1000 cubic millimeters (1 milliliter). For example, standard capsule sizes 000, 00, 0, 0, 1, 2, and 3 may be suitable.

[0117] The capsule preferably has a length of at least 10 mm, more preferably at least 12 mm, more preferably at least 15 mm, and more preferably at least 18 mm. The length of the capsule is preferably less than 30 mm, more preferably less than 28 mm, and even more preferably less than 25 mm. For example, the capsule may be 10 mm to 30 mm, or 12 mm to 28 mm, or 15 mm to 25 mm, or 18 mm to 25 mm. The capsule length may be about 20 mm.

[0118] Preferably, the capsule has a maximum diameter of at least 5 mm, more preferably at least 5.5 mm, more preferably at least 6 mm, and more preferably at least 6.5 mm. Preferably, the maximum diameter of the capsule is less than 9 mm, more preferably less than 8.5 mm, more preferably less than 8 mm, and more preferably less than 7.5 mm. For example, the maximum diameter of the capsule may be between 5 mm and 9 mm, or between 5.5 mm and 8.5 mm, or between 6 mm and 6 mm, or between 6.5 mm and 7.5 mm. The maximum diameter of the capsule may be about 7 mm.

[0119] The outer diameter of the capsule may be approximately the same as the inner diameter of the hollow tubular element.

[0120] In this way, air is substantially prevented from passing from the upstream end of the hollow tubular element to the downstream end of the hollow tubular element without passing through the capsule.

[0121] While we do not wish to be bound by theory, it is expected that once air leaves the capsule through at least one capsule air outlet and enters the interior of the hollow tubular element, the airflow through the aerosol-generating article will be significantly slowed. This is because the diameter of the hollow tubular element is larger than the diameter of at least one capsule air outlet. This slowing of the airflow also reduces the pressure, which may further facilitate the desirable nucleation of aerosols. Furthermore, the slowing of the airflow may also improve the cooling of the airflow by the ambient air entering through the ventilation zone. This may further favorably facilitate aerosol generation.

[0122] The internal cavity of the capsule preferably contains at least 50 milligrams of solid aerosol generating substrate, more preferably at least 100 milligrams of solid aerosol generating substrate, and more preferably at least 150 milligrams of solid aerosol generating substrate. The internal cavity may contain up to 1000 milligrams of solid aerosol generating substrate, or up to 750 milligrams of solid aerosol generating substrate, or up to 500 milligrams of solid aerosol generating substrate, or up to 250 milligrams of solid aerosol generating substrate. For example, the internal cavity of the capsule may contain 50 to 1000 milligrams of solid aerosol generating substrate, or 100 to 750 milligrams of solid aerosol generating substrate, or 150 to 500 milligrams of solid aerosol generating substrate, or 150 to 250 milligrams of solid aerosol generating substrate.

[0123] According to the present invention, the density of the solid aerosol generating substrate inside the capsule corresponds to at least 0.1 milligrams / cubic millimeter of the internal cavity. This corresponds to the total weight of the solid aerosol generating substrate divided by the total volume of the internal cavity. Preferably, the density of the solid aerosol generating substrate inside the capsule corresponds to at least 0.12 milligrams / cubic millimeter of the internal cavity, more preferably at least 0.15 milligrams / cubic millimeter of the internal cavity, more preferably at least 0.18 milligrams / cubic millimeter of the internal cavity, more preferably at least 0.2 milligrams / cubic millimeter, more preferably at least 0.22 milligrams / cubic millimeter, more preferably at least 0.25 milligrams / cubic millimeter, more preferably at least 0.28 milligrams / cubic millimeter, more preferably at least 0.3 milligrams / cubic millimeter, more preferably at least 0.32 milligrams / cubic millimeter, more preferably at least 0.35 milligrams / cubic millimeter, more preferably at least 0.38 milligrams / cubic millimeter, and more preferably at least 0.4 milligrams / cubic millimeter. Preferably, the density of the solid aerosol generating substrate inside the capsule corresponds to less than 2 milligrams / cubic millimeter of the internal cavity, more preferably less than 1.9 milligrams / cubic millimeter of the internal cavity, more preferably less than 1.8 milligrams / cubic millimeter, more preferably less than 1.7 milligrams / cubic millimeter, more preferably less than 1.6 milligrams / cubic millimeter, more preferably less than 1.5 milligrams / cubic millimeter, more preferably less than 1.4 milligrams / cubic millimeter, more preferably less than 1.3 milligrams / cubic millimeter, more preferably less than 1.2 milligrams / cubic millimeter, more preferably less than 1.1 milligrams / cubic millimeter, and more preferably less than 1 milligram / cubic millimeter.For example, the density of the solid aerosol generating substrate inside the capsule is 0.1 mg / m³ to 2 mg / m³ of the internal cavity, or 0.12 mg / m³ to 1.9 mg / m³ of the internal cavity, or 0.15 mg / m³ to 1.8 mg / m³ of the internal cavity, or 0.18 mg / m³ to 1.7 mg / m³ of the internal cavity, or 0.2 mg / m³ to 1.6 mg / m³ of the internal cavity, or 0.22 mg / m³ to 1.5 mg / m³ of the internal cavity, or 0.25 mg / m³ of the internal cavity This may correspond to a range of 1 / 30 millimeters to 1.4 milligrams / 30 millimeters for internal cavities, or 0.28 milligrams / 30 millimeters to 1.3 milligrams / 30 millimeters for internal cavities, or 0.3 milligrams / 30 millimeters to 1.2 milligrams / 30 millimeters for internal cavities, or 0.32 milligrams / 30 millimeters to 1.1 milligrams / 30 millimeters for internal cavities, or 0.35 milligrams / 30 millimeters to 1 milligram / 30 millimeter for internal cavities, or 0.38 milligrams / 30 millimeters to 1 milligram / 30 millimeter for internal cavities, or 0.4 milligrams / 30 millimeters to 1 milligram / 30 millimeter for internal cavities.

[0124] The filling ratio of the capsule with the solid aerosol generating substrate is preferably at least 50 percent, more preferably at least 60 percent, and more preferably at least 70 percent. A filling ratio of less than 90 percent is preferable. The filling ratio corresponds to the proportion of the internal cavity of the capsule occupied by the solid aerosol generating substrate. It may be advantageous to retain some empty space within the internal cavity to allow airflow through the internal cavity and to enable uniform heating of the solid aerosol generating substrate.

[0125] The capsule may be adapted so that one or more airflow paths are provided through the capsule during heating. This allows aerosols generated from the aerosol generating substrate to be drawn out through the aerosol generating article and delivered to the consumer. The capsule may be sealed and airtight in the initial stage so that when the aerosol generating article is inserted into the aerosol generating device, airflow paths are created, for example, through the insertion of an internal heating element or by penetrating elements that penetrate the outer wall of the capsule.

[0126] Alternatively, and more preferably, the capsule comprises at least one capsule air intake and at least one capsule air outlet within the outer wall of the capsule. The at least one capsule air intake and at least one capsule air outlet define one or more airflow paths through the internal cavity of the capsule. The at least one capsule air outlet is provided downstream of the at least one capsule air intake.

[0127] The capsule may include at least one capsule air intake located at the upstream end of the capsule and at least one capsule air outlet located at the downstream end of the capsule.

[0128] The capsule may have multiple capsule air intakes. For example, the capsule may have 2 to 6 air intakes.

[0129] The capsule may have multiple capsule air outlets. For example, the capsule may have 2 to 6 capsule air outlets. The number of capsule air outlets may be the same as or different from the number of capsule air intakes. Since the capsule air outlets need to allow aerosols generated inside the capsule to pass from the capsule into the hollow tubular element, it may be advantageous to provide more capsule air outlets than capsule air intakes.

[0130] The number and size of the capsule air intake and capsule air outlet may be adjusted to control the airflow through the capsule and the draw resistance (RTD) of the aerosol-generating article. In certain embodiments, the capsule provides the primary source of RTD within the article, and therefore the overall RTD of the aerosol-generating article is likely to be highly dependent on the RTD of the capsule.

[0131] Each capsule air intake and outlet is preferably in the form of a hole passing through the outer wall of the capsule. Each hole is preferably spherical, but other shapes may also be appropriate. The diameter of each hole must be large enough, for example, that the hole cannot be easily blocked by dust. However, the diameter of each hole should also be adapted according to the form and properties of the solid aerosol generating substrate so that the solid aerosol generating substrate is not lost from the internal cavity through the hole.

[0132] Preferably, each hole forming the air intake or air outlet has a diameter of at least 0.2 mm, more preferably at least 0.25 mm, more preferably at least 0.3 mm, more preferably at least 0.35 mm, more preferably at least 0.4 mm, and more preferably at least 0.5 mm. The diameter of each hole may be less than 2 mm, or less than 1.8 mm, or less than 1.6 mm, or less than 1.4 mm, or less than 1.2 mm, or less than 1 mm, or less than 0.9 mm, or less than 0.8 mm. For example, the diameter of each hole may be 0.2 mm to 2 mm, or 0.25 mm to 1.8 mm, or 0.3 mm to 1.6 mm, or 0.35 mm to 1.4 mm, or 0.4 mm to 1.2 mm, or 0.45 mm to 1 mm, or 0.5 mm to 0.9 mm, or 0.5 mm to 0.8 mm.

[0133] If multiple capsule air intakes or outlets are provided, each hole should be spaced sufficiently apart so that its presence does not adversely affect the structural integrity of the capsule. For example, it is preferable that the holes be spaced at least 1 millimeter apart from each other.

[0134] At least one capsule air outlet is preferably located at least 5 millimeters downstream of at least one air intake, more preferably at least 8 millimeters downstream of at least one air intake, and more preferably at least 10 millimeters downstream of at least one air intake. This spacing allows for maximizing the length of the airflow path through the capsule.

[0135] Preferably, at least one capsule air outlet is located at the downstream end of the capsule. If the capsule has a conventional capsule shape with an elongated cylindrical body and rounded end walls, it is preferable that at least one capsule air outlet is provided on the downstream end wall.

[0136] At least one capsule air intake may be located at the upstream end of the capsule. For example, if the capsule has the conventional capsule shape described above, at least one capsule air intake may be provided on the upstream end wall. However, in certain embodiments, it may be advantageous to position at least one capsule air intake at a specific distance downstream of the upstream end. For example, at least one capsule air intake may be provided at least 2 millimeters downstream of the upstream end of the capsule, or at least 3 millimeters downstream of the upstream end of the capsule, or at least 4 millimeters downstream of the upstream end of the capsule, or at least 5 millimeters downstream of the upstream end of the capsule. If multiple capsule air intakes are provided, all air intakes should be provided at least this distance from the upstream end, even when the position of the capsule air intakes along the length of the capsule changes.

[0137] In a preferred embodiment, the capsule comprises a cylindrical wall and rounded end walls at the upstream and downstream ends of the cylindrical wall (as in a conventional capsule shape), and at least one capsule air intake may be advantageously provided in the cylindrical wall downstream of the upstream end wall.

[0138] Positioning at least one capsule air intake away from the upstream end of the capsule may be particularly beneficial when the solid aerosol-generating substrate is in the form of a gel composition or any other type of substrate that melts or becomes more viscous upon heating. By positioning at least one capsule air intake away from the upstream end of the cavity where the molten substrate accumulates, the risk of the aerosol-generating substrate leaking from the capsule is minimized. The risk of the capsule air intake being blocked by the aerosol-generating substrate is also reduced.

[0139] At least one capsule air outlet may be provided with a plurality of air outlets located at the downstream end of the capsule, the plurality of air outlets arranged around a circle centered on the longitudinal axis of the capsule, the circle having a diameter smaller than the diameter of the aerosol-generating article.

[0140] Multiple capsule air outlets may be arranged in a circle such that each capsule air outlet radially overlaps with at least a portion of the ventilation hole.

[0141] As used herein, the term “radially overlapping” means that a plurality of capsule air outlets and a plurality of ventilation holes are arranged such that a line extending radially from the center of the aerosol generating article can intersect both the capsule air outlet and at least one ventilation hole.

[0142] Multiple capsule air outlets may further include a capsule air outlet located at the center of the circle.

[0143] This arrangement may mean that ambient air provided by at least one ventilation vent is directly supplied into the vapor pathway leaving the capsule through the capsule air outlet. This advantageously improves aerosol generation.

[0144] The aerosol generating article may have a corresponding ventilation hole for each capsule air outlet, and may also have an equal number of ventilation holes and capsule air outlets such that each capsule air outlet is radially aligned with the corresponding ventilation hole.

[0145] The arrangement of multiple capsule air outlets may be circular, such that each capsule air outlet radially overlaps with at least a portion of the ventilation hole, and each capsule air outlet radially overlaps with a portion of the ventilation hole of the same size. This may improve the consistency of aerosol generation because the vapor passing through each capsule air outlet should encounter an equal amount of ambient cooling air.

[0146] Capsule air outlet (θ) measured from the center of the circle C Each of the angular diameters of the adjacent ventilation holes (θ) S The angular distance between the points can be greater than θc. In other words, θc > θs.

[0147] This is advantageous because it can ensure that all capsule air outlets radially overlap with a portion of the ventilation perforation, regardless of the orientation in which the capsule is provided within the hollow tubular element. This is advantageous because it can simplify manufacturing, as the desired radial overlap can be achieved without the need to carefully control the orientation of the capsule during manufacturing.

[0148] Capsule air outlet (θ) measured from the center of the circle C Each of the angular diameters of the adjacent ventilation holes (θ) S Each ventilation hole (θ) is added to the angular distance between them V The angle may be greater than the diameter of θ. In other words, θc > θv + θs.

[0149] This, advantageously, ensures that the total radial overlap between each capsule air outlet and ventilation perforation remains constant, regardless of the orientation in which the capsule is provided within the hollow tubular element. This is advantageous because it simplifies manufacturing, as the desired radial overlap can be achieved without the need to carefully control the orientation of the capsule during manufacturing.

[0150] The aerosol generating article of the present invention comprises an aerosol generating substrate. The aerosol generating substrate may be a solid aerosol generating substrate contained within a capsule. The solid aerosol generating substrate may contain nicotine and an aerosol forming agent, but may take various different forms.

[0151] The aerosol generating substrate may contain at least 15 weight percent of aerosol forming material on a dry weight basis. Preferably, the aerosol generating substrate contains at least 20 weight percent of aerosol forming material on a dry weight basis. More preferably, the aerosol generating substrate contains at least 25 weight percent of aerosol forming material on a dry weight basis. More preferably, the aerosol generating substrate contains at least 30 weight percent of aerosol forming material on a dry weight basis. More preferably, the aerosol generating substrate contains at least 35 weight percent of aerosol forming material on a dry weight basis. More preferably, the aerosol generating substrate contains at least 40 weight percent of aerosol forming material on a dry weight basis. More preferably, the aerosol generating substrate contains at least 45 weight percent of aerosol forming material on a dry weight basis. More preferably, the aerosol generating substrate contains at least 50 weight percent of aerosol forming material on a dry weight basis.

[0152] The aerosol generating substrate preferably contains 80% by weight or less on a dry weight basis. The second aerosol generating substrate more preferably contains 75% by weight or less on a dry weight basis. The second aerosol generating substrate more preferably contains 70% by weight or less on a dry weight basis.

[0153] For example, the aerosol generating substrate may result in an aerosol-forming content of 15% to 80% by weight, or 20% to 80% by weight, or 25% to 80% by weight, or 30% to 75% by weight, or 35% to 75% by weight, or 40% to 70% by weight, or 45% to 70% by weight, or 50% to 70% by weight, on a dry weight basis.

[0154] In certain preferred embodiments, the water content of the aerosol-forming material of the aerosol-generating substrate may be 40% to 80% by weight, or 45% to 75% by weight, or 50% to 70% by weight, on a dry weight basis. In such embodiments, the aerosol-forming material content of the aerosol-generating substrate is therefore relatively high.

[0155] Suitable aerosol-forming materials for inclusion in aerosol-generating substrates 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 (such as glycerol mono-, di-, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dodecanediic acid and dimethyl tetradecanediic acid).

[0156] The aerosol generating substrate preferably contains glycerol as an aerosol forming body.

[0157] The aerosol generating substrate further comprises nicotine. As used herein in relation to the present invention, the term "nicotine" is used to describe nicotine, a nicotine base, or a nicotine salt. In embodiments in which the aerosol generating substrate comprises a nicotine base or a nicotine salt, the amounts of nicotine listed herein are, respectively, amounts of free base nicotine or amounts of protonated nicotine.

[0158] The aerosol generating substrate may contain natural or synthetic nicotine. The nicotine may contain one or more nicotine salts. One or more nicotine salts may be selected from a list consisting of nicotine lactate, nicotine citrate, nicotine pyruvate, nicotine beetartrate, nicotine benzoate, nicotine pectinate, nicotine alginate, and nicotine salicylate.

[0159] Nicotine may include tobacco extract.

[0160] The aerosol generating substrate preferably contains at least 0.5 weight percent of nicotine on a dry weight basis. More preferably, the aerosol generating substrate contains at least 1 weight percent of nicotine on a dry weight basis. Even more preferably, the aerosol generating substrate contains at least 2 weight percent of nicotine on a dry weight basis. In addition, or alternatively, the aerosol generating substrate preferably contains less than 10 weight percent of nicotine on a dry weight basis. More preferably, the aerosol generating substrate contains less than 8 weight percent of nicotine on a dry weight basis. More preferably, the aerosol generating substrate contains less than 6 weight percent of nicotine on a dry weight basis.

[0161] For example, the aerosol generating substrate may contain 0.5% to 10% by weight of nicotine, or 1% to 8% by weight of nicotine, or 2% to 6% by weight of nicotine, on a dry weight basis.

[0162] The aerosol generating substrate may contain one or more carboxylic acids. Advantageously, the inclusion of one or more carboxylic acids in the aerosol generating substrate allows for the production of nicotine salts.

[0163] One or more carboxylic acids include one or more of lactic acid and levulinic acid. Advantageously, the inventors have found that lactic acid and levulinic acid are particularly good carboxylic acids for producing nicotine salts.

[0164] The aerosol generating substrate preferably contains at least 0.5 weight percent of carboxylic acid on a dry weight basis. More preferably, the aerosol generating substrate contains at least 1 weight percent of carboxylic acid on a dry weight basis. More preferably, the aerosol generating substrate contains at least 2 weight percent of carboxylic acid on a dry weight basis.

[0165] In addition, or alternatively, the aerosol generating substrate preferably contains less than 15 weight percent of carboxylic acid on a dry weight basis. More preferably, the aerosol generating substrate preferably contains less than 10 weight percent of carboxylic acid on a dry weight basis. More preferably, the aerosol generating substrate preferably contains less than 5 weight percent of carboxylic acid on a dry weight basis. For example, the aerosol generating substrate may contain 0.5 to 15 weight percent of carboxylic acid, or 1 to 10 weight percent of carboxylic acid, or 2 to 5 weight percent of carboxylic acid.

[0166] In certain preferred embodiments, the aerosol-generating substrate is in the form of an aerosol-generating film comprising a cellulosic film-forming agent, nicotine, and an aerosol-forming agent. The aerosol-generating film may further contain a cellulosic reinforcing agent. The aerosol-generating film may further contain less than 30% by weight of water.

[0167] As used herein, the term “film” is used to describe a solid layered element having a thickness less than its width or length. A film may be self-supporting. In other words, a film may have cohesive and mechanical properties that allow it to be separated from a support surface, even if it is obtained by casting a film-forming formulation onto a support surface. Alternatively, a film may be placed on a support or sandwiched between other materials. This can enhance the mechanical stability of the film.

[0168] The solid aerosol generating substrate may be provided in any suitable form. The capsule preferably contains multiple particles of the solid aerosol generating substrate. For example, the capsule may contain multiple beads, pellets, granules, flakes, fragments, or flakes of the aerosol generating substrate.

[0169] In certain embodiments, the maximum size of each particle is preferably at least 0.05 mm, more preferably at least 0.1 mm, more preferably at least 0.15 mm, more preferably at least 0.2 mm, more preferably at least 0.25 mm, more preferably at least 0.5 mm, more preferably at least 0.75 mm, and more preferably at least 1 mm. The maximum size of each particle is preferably 10 mm or less, more preferably 9 mm or less, more preferably 8 mm or less, more preferably 6 mm or less, and more preferably 5 mm or less. Providing relatively large particles within these ranges may be preferable when holes are provided in the capsule wall for forming air intakes and outlets, as described below. Because the maximum size of the particles is relatively large, the particles are not lost through the holes in the capsule wall.

[0170] The maximum dimension of a particle corresponds to its maximum outer diameter. If the particle is substantially spherical, its maximum dimension corresponds to its diameter.

[0171] In these embodiments, the capsule preferably contains at least two particles of the aerosol-generating substrate, more preferably at least five particles, more preferably at least ten particles, more preferably at least 20 particles, and more preferably at least 30 particles. The capsule may contain up to 200 particles.

[0172] In other embodiments, the solid aerosol generating substrate may be in the form of a powder having more smaller particles. For example, in such embodiments, the powder may be formed from particles having a D50 particle size of 50 to 80 micrometers, 50 to 75 micrometers, 55 to 75 micrometers, 55 to 70 micrometers, or 60 to 70 micrometers.

[0173] As used herein in connection with the present invention, the term "D50 particle size" refers to the median particle size of a particulate material or powder. The D50 particle size is the particle size that divides the distribution in half, with half of the particles being larger than the D50 particle size and the other half being smaller than the D50 particle size. The particle size distribution can be determined by laser diffraction. For example, the particle size distribution can be determined by laser diffraction using a Malvern Mastersizer 3000 laser diffraction particle size analyzer, according to the manufacturer's instructions.

[0174] The powder may be formed from particles having a D95 particle size of 80 to 130 micrometers, 90 to 125 micrometers, 100 to 120 micrometers, or 110 to 120 micrometers.

[0175] As used herein in connection with the present invention, the term "D95 particle size" means a particle size in which 95 percent of the mass of particles have a particle size less than this value.

[0176] The powder may be formed from particles having a maximum diameter of 50 to 250 micrometers, 80 to 225 micrometers, or 100 to 125 micrometers.

[0177] In embodiments where the capsule contains multiple particles, the mass of each particle is preferably at least 0.05 micrograms, more preferably at least 0.1 micrograms, more preferably at least 0.2 micrograms, more preferably at least 0.3 micrograms, more preferably at least 0.4 micrograms, more preferably at least 0.5 micrograms, more preferably at least 0.6 micrograms, more preferably at least 0.7 micrograms, more preferably at least 0.8 micrograms, more preferably at least 0.9 micrograms, more preferably at least 1 microgram, more preferably at least 10 micrograms, more preferably at least 100 micrograms, more preferably at least 200 micrograms, more preferably at least 500 micrograms, and more preferably at least 1 milligram. The mass of each particle is preferably 600 milligrams or less, more preferably 500 milligrams or less, more preferably 400 milligrams or less, more preferably 300 milligrams or less, more preferably 200 milligrams or less, more preferably 100 milligrams or less, more preferably 50 milligrams or less, and more preferably 10 milligrams or less.

[0178] Alternatively, the solid aerosol generating substrate 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 layered element having a width and length substantially greater than its thickness.

[0179] One or more sheets as described herein may be crimped, folded, gathered, and pleated. One or more sheets may be cut into strands.

[0180] The aerosol-generating article according to the present invention may further comprise a downstream filter segment mounted within the hollow tubular element at the downstream end of the hollow tubular element. The downstream filter segment may extend to the downstream end of the hollow tubular element. The downstream end of the downstream filter segment may define the downstream end of the aerosol-generating article. Including the downstream filter segment within the hollow tubular element may be useful in providing the aerosol-generating article with a desired level of RTD (Ready-to-Dose).

[0181] The downstream filter segment is preferably located downstream of the capsule, and preferably there is a gap in the longitudinal direction between the capsule and the downstream filter segment so that a cavity is defined between them. The downstream filter segment is preferably located at least 5 millimeters downstream from the downstream end of the capsule, more preferably at least 8 millimeters downstream, more preferably at least 10 millimeters downstream, and more preferably at least 15 millimeters downstream. The downstream filter segment is preferably located less than 30 millimeters downstream from the downstream end of the capsule, and more preferably less than 25 millimeters downstream. The distance defined between the downstream end of the capsule and the downstream filter segment corresponds to the length of the cavity between the capsule and the downstream filter segment.

[0182] The downstream filter segment is preferably a solid plug, which may also be described as a "plain" plug and is non-tubular. Therefore, the filter segment is preferably substantially uniform in cross-sectional area.

[0183] The downstream filter segment is formed of a fibrous filter material. The fibrous filter material may be for filtering aerosols generated from the aerosol generating substrate. Suitable fibrous filter materials will be known to those skilled in the art. Particularly preferably, at least one downstream filter segment includes a cellulose acetate filter segment formed from cellulose acetate tow.

[0184] The downstream filter segment may optionally contain flavoring agents, which can be provided in any preferred form. For example, the downstream filter segment may comprise one or more capsules, beads, or granules of the flavoring agent, or threads or filaments filled with one or more flavoring agents.

[0185] The downstream filter segment preferably has a low particle filtration efficiency.

[0186] The downstream filter segment preferably has an outer diameter approximately equal to the inner diameter of the hollow tubular element, so that the downstream filter segment is held within the hollow tubular element by friction fitting.

[0187] Preferably, the outer diameter of the downstream filter segment is 5 mm to 12 mm, more preferably 6 mm to 10 mm, and more preferably 7 mm to 8 mm.

[0188] Unless otherwise specified, the draw resistance (RTD) of a component or aerosol-generating article shall be measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through the entire length of the component. The terms “pressure drop” or “draw resistance” of a component or article may also refer to “resistance to draw.” These terms generally refer to the fact that the measurement in accordance with ISO 6565-2015 is successfully performed under a test of a volumetric flow rate of 17.5 ml per second at the output or downstream end of the measured component, at a temperature of 22 degrees Celsius, a pressure of 101 kPa (approximately 760 Torr), and a relative humidity of 60%. The conditions for smoking and the specifications of the smoking machine are presented in ISO standard 3308 (ISO 3308:2000). The atmosphere for adjustment and testing is presented in ISO standard 3402 (ISO 3402:1999).

[0189] The draw-out resistance (RTD) of the downstream filter segment may be at least 0 mmH2O, or at least 3 mmH2O, or at least 6 mmH2O.

[0190] The RTD of the downstream filter segment may be 12 mmH2O or less, or 11 mmH2O or less, or 10 mmH2O or less.

[0191] As described above, the downstream filter segment may be formed from a fibrous material. The downstream filter segment may be formed from a porous material. The downstream filter segment may be formed from a biodegradable material. The downstream filter segment may be formed from a cellulose material such as cellulose acetate. For example, the downstream filter segment may be formed from a bundle of cellulose acetate fibers having 10 to 15 denier per filament. For example, the downstream filter segment may be formed from a relatively low-density cellulose acetate tow, such as cellulose acetate tow containing fibers of 12 denier per filament.

[0192] The downstream filter segment may be formed from a polylactic acid-based material. The downstream filter segment may be formed from a bioplastic material, preferably a starch-based bioplastic material. The downstream filter segment may be manufactured by injection molding or extrusion molding. Bioplastic materials are advantageous because they can provide a downstream filter segment structure that is easy and inexpensive to manufacture, with a specific complex cross-sectional profile that may have multiple relatively large airflow channels extending through the downstream filter segment material, providing suitable RTD properties.

[0193] The length of the downstream filter segment may be at least 5 millimeters, or at least 8 millimeters, or at least 10 millimeters. The length of the downstream filter segment may be less than 20 millimeters, or less than 15 millimeters, or less than 12 millimeters. For example, the length of the downstream filter segment may be between 5 millimeters and 20 millimeters, or between 8 millimeters and 15 millimeters, or between 8 millimeters and 12 millimeters, or between 10 millimeters and 12 millimeters.

[0194] In an alternative embodiment of the present invention, the downstream filter segment may be provided downstream of the hollow tubular element. The downstream filter segment may extend between the hollow tubular element and the downstream end of the aerosol-generating article. In such embodiments, the downstream filter segment may be connected to the hollow tubular element by a chipping wrapper.

[0195] The overall RTD of an aerosol-generating article may be at least 1 milliH2O. For example, the overall RTD of an aerosol-generating article may be at least 2 milliH2O, at least 3 milliH2O, at least 4 milliH2O, at least 5 milliH2O, at least 6 milliH2O, at least 7 milliH2O, at least 8 milliH2O, at least 9 milliH2O, at least 10 milliH2O, at least 15 milliH2O, at least 20 milliH2O, at least 30 milliH2O, at least 40 milliH2O, or at least 50 milliH2O.

[0196] The overall RTD of an aerosol-generating article may be 180 mmH2O or less. For example, the overall RTD of an aerosol-generating article may be 170 mmH2O or less, 160 mmH2O or less, 150 mmH2O or less, or 140 mmH2O or less.

[0197] The overall RTD of an aerosol-generating article may range from 1 mmH2O to 180 mmH2O. For example, the overall RTD of an aerosol-generating article may range from 5 mmH2O to 170 mmH2O, 10 mmH2O to 160 mmH2O, 20 mmH2O to 150 mmH2O, or 50 mmH2O to 140 mmH2O.

[0198] The aerosol-generating article according to the present invention may have an overall length of at least 40 millimeters, or at least 50 millimeters, or at least 60 millimeters.

[0199] The aerosol-generating article of the present invention may have a total length of 90 mm or less, 85 mm or less, or 80 mm or less.

[0200] In some embodiments, the total length of the aerosol-generating article is preferably 40 to 70 millimeters, more preferably 45 to 70 millimeters. In other embodiments, the total length of the aerosol-generating article is preferably 40 to 60 millimeters, more preferably 45 to 60 millimeters. In further embodiments, the total length of the aerosol-generating article is preferably 40 to 50 millimeters, more preferably 45 to 50 millimeters. In exemplary embodiments, the total length of the aerosol-generating article is about 45 millimeters.

[0201] The aerosol-generating article may have an outer diameter of at least 5 millimeters, at least 6 millimeters, or at least 7 millimeters.

[0202] The aerosol-generating article may have an outer diameter of approximately 12 mm or less, approximately 10 mm or less, or approximately 8 mm or less.

[0203] 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. In other embodiments, the aerosol-generating article has an outer diameter of less than 7 mm.

[0204] The outer diameter of an aerosol-generating article may be substantially constant along its entire length. Alternatively, different parts of the aerosol-generating article may have different outer diameters.

[0205] A second aspect of the present invention further provides an aerosol generating system comprising an aerosol generating article according to the first aspect of the present invention, an aerosol generating device comprising a heating chamber for receiving the aerosol generating article, and a heating element provided inside or around the heating chamber.

[0206] The aerosol generator may have an upstream end and a downstream end. The aerosol generator may have a main body. The main body or housing of the aerosol generator may define a heating chamber at the downstream end of the device for removably receiving an aerosol generating article. The aerosol generator includes a heating element or heater for heating the aerosol generating substrate when the aerosol generating article is received in the heating chamber.

[0207] The heating chamber may extend between an upstream end and a downstream end. The upstream end of the heating chamber may be a closed end, and the downstream end may be an open end. The aerosol generating article may be inserted into the heating chamber through the open end of the heating chamber. The heating chamber may be cylindrical in shape to accommodate the same shape as the aerosol generating article.

[0208] The expression "received within" may refer to the fact that a component or element is fully or partially received within another component or element. For example, the expression "an aerosol-generating article is received within a heating chamber" means that the aerosol-generating article is fully or partially received within the heating chamber of the aerosol-generating article. When an aerosol-generating article is received within a heating chamber, it may abut against the upstream end of the heating chamber. When an aerosol-generating article is received within a heating chamber, it may be substantially close to the upstream end of the heating chamber. The upstream end of the heating chamber may be defined by an end wall.

[0209] The length of the heating chamber may be 15 mm to 80 mm, or 20 mm to 70 mm, or 25 mm to 60 mm, or 25 mm to 50 mm.

[0210] The length of the heating chamber may be 25 mm to 29 mm, or 26 mm to 29 mm, or 27 mm to 28 mm.

[0211] When the aerosol-generating article is received into the heating chamber, it is preferable that the capsule be completely contained within the apparatus cavity in order to optimize the heating of the solid aerosol-generating substrate inside the capsule. Therefore, it is preferable that the length of the apparatus cavity be longer than the length of the capsule.

[0212] The diameter of the heating chamber may be 4 mm to 10 mm. The diameter of the heating chamber may be 5 mm to 9 mm. The diameter of the heating chamber may be 6 mm to 8 mm. The diameter of the heating chamber may be 6 mm to 7 mm.

[0213] The diameter of the heating chamber may be substantially the same as, or larger than, the diameter of the aerosol generating article. The diameter of the heating chamber may be the same as the diameter of the aerosol generating article in order to establish a tight fit with the aerosol generating article.

[0214] The heating chamber may be configured to establish a tight fit with the aerosol generating article received within the heating chamber. A tight fit may refer to a sliding fit. The aerosol generating device may include a peripheral wall. Such a peripheral wall may define the heating chamber. The peripheral wall defining the heating chamber may be configured to engage in a tight fit with the aerosol generating article received within the heating chamber such that, when received within the device, there is substantially no gap or empty space between the peripheral wall defining the heating chamber and the aerosol generating article.

[0215] Such a tight fit can establish an airtight fit or configuration between the heating chamber and the aerosol-generating article received therein.

[0216] In such an airtight configuration, there is virtually no gap or empty space between the surrounding walls defining the heating chamber and the aerosol-generating article through which air flows.

[0217] The tight fit with the aerosol-generating article may be established along the entire length of the heating chamber, or along a portion of the length of the heating chamber.

[0218] The aerosol generator may include an airflow channel extending between a channel inlet and a channel outlet. The airflow channel may be configured to establish fluid communication between the inside of the heating chamber and the outside of the aerosol generator. The airflow channel of the aerosol generator may be defined within the housing of the aerosol generator to enable fluid communication between the inside of the heating chamber and the outside of the aerosol generator. When an aerosol-generating article is received in the heating chamber, the airflow channel may be configured to provide air flowing into the article to deliver the generated aerosol to a user who draws it in from the downstream end of the article.

[0219] The airflow channels of the aerosol generator may be defined within or by the peripheral walls of the housing of the aerosol generator. In other words, the airflow channels of the aerosol generator may be defined within the thickness of the peripheral walls, by the inner surfaces of the peripheral walls, or a combination of both. The airflow channels may be partially defined by the inner surfaces of the peripheral walls, or partially defined within the thickness of the peripheral walls. The inner surfaces of the peripheral walls define the periphery of the device cavity.

[0220] The airflow channel of the aerosol generator may extend from an inlet located at the downstream end of the aerosol generator to an outlet located away from the downstream end of the device. The airflow channel may extend along a direction parallel to the longitudinal axis of the aerosol generator.

[0221] The heater may be any suitable type of heater. In this invention, the heater is preferably an external heater that heats the capsule and its contents from the outside. Such an external heater may surround the aerosol generating article when it is inserted into or received in an aerosol generating device.

[0222] Alternatively, the heater may be an elongated heating blade adapted to be inserted into the capsule to internally heat the capsule and its contents.

[0223] The heater may comprise at least one heating element. The at least one heating element can be any suitable type of heating element. In some embodiments, the device comprises only one heating element. In some embodiments, the device comprises multiple heating elements.

[0224] The heating element may be a resistance heating element.

[0225] Suitable materials for forming resistance heating elements include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilide), carbon, graphite, metals, metal alloys, and composite materials made of ceramic and metal materials. Such composite materials may contain doped ceramics or undoped ceramics. A suitable example of a doped ceramic is doped silicon carbide. Suitable examples of metals include titanium, zirconium, tantalum, and platinum group metals. Suitable examples of metal alloys include stainless steel, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel, iron, cobalt, stainless steel-based superalloys, Timetal®, and iron-manganese-aluminum alloys.

[0226] In some embodiments, the resistance heating element comprises one or more stamped portions of an electrically resistant material (such as stainless steel). Alternatively, at least one resistance heating element may include a heating wire or filament (e.g., Ni-Cr (nickel-chromium), platinum, tungsten, or alloy wire).

[0227] In some embodiments, the heating element includes an electrically insulated substrate, and at least one resistance heating element is provided on the electrically insulated substrate.

[0228] The electrically insulated substrate may include any suitable material. For example, the electrically insulated substrate may include one or more of paper, glass, ceramic, anodized metal, coated metal, and polyimide. The ceramic may include mica, alumina (Al2O3), or zirconia (ZrO2). The electrically insulated substrate preferably has a thermal conductivity of about 40 watts / meter Kelvin or less, preferably about 20 watts / meter Kelvin or less, and ideally about 2 watts / meter Kelvin or less.

[0229] The heater may comprise a heating element including a rigid, electrically insulated substrate having one or more conductive tracks or wires disposed on its surface. Depending on the size and shape of the electrically insulated substrate, it may be permissible to insert the heater directly into the aerosol generating substrate. If the electrically insulated substrate is not sufficiently rigid, the heating element may include further reinforcing means. Current may pass through one or more conductive tracks to heat the heating element and the aerosol generating substrate.

[0230] In some embodiments, the heater comprises an induction heating arrangement. The induction heating device may comprise an inductor coil and a power supply configured to supply a high-frequency oscillating current to the inductor coil. As used herein, a high-frequency oscillating current means an oscillating current having a frequency of about 500 kHz to about 30 MHz. The heater may advantageously comprise a DC / AC inverter for converting the DC current supplied by the DC power supply into an AC current. The inductor coil may be arranged to generate a high-frequency oscillating electromagnetic field upon receiving a high-frequency oscillating current from the power supply. The inductor coil may be positioned to generate a high-frequency oscillating electromagnetic field within the device cavity. In some embodiments, the inductor coil may substantially enclose the device cavity. The inductor coil may extend at least partially along the length of the device cavity.

[0231] The heater may include an induction heating element. The induction heating element may be a susceptor element. The susceptor element may be positioned such that when an aerosol generating article is received in the cavity of the aerosol generator, the oscillating electromagnetic field generated by the inductor coil induces a current within the susceptor element, thereby heating the susceptor element. In these embodiments, the aerosol generator is preferably capable of generating a fluctuating electromagnetic field having a magnetic field strength (H-field strength) of 1 to 5 kiloamperes / meter (kA / m), preferably 2 to 3 kA / m, for example, about 2.5 kA / m. The electrically operated aerosol generator is preferably capable of generating a fluctuating electromagnetic field having a frequency of 1 to 30 MHz, for example, 1 to 10 MHz, for example, 5 to 7 MHz.

[0232] In these embodiments, the susceptor element is preferably located in contact with a solid aerosol generating substrate. In some embodiments, the susceptor element is located inside the aerosol generator. In these embodiments, the susceptor element may be located inside a cavity. The aerosol generator may include only one susceptor element. The aerosol generator may include multiple susceptor elements. In some embodiments, the susceptor element is preferably arranged to heat the outer surface of the aerosol generating substrate.

[0233] A susceptor element may contain any appropriate susceptor element.

[0234] In some embodiments, the aerosol generator may comprise at least one resistance heating element and at least one induction heating element. In some embodiments, the aerosol generator may comprise a combination of a resistance heating element and an induction heating element.

[0235] During use, the heater can be controlled to operate within a specified operating temperature range below the maximum operating temperature. The operating temperature range within the heating chamber (or device cavity) is preferably about 150°C to about 300°C. The operating temperature range of the heater may be about 150°C to about 250°C.

[0236] The aerosol generator may be equipped with a power supply. The power supply may be a DC power supply. In some embodiments, the power supply is a battery. The power supply may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery (e.g., lithium cobalt, lithium iron phosphate, or lithium polymer battery). However, in some embodiments, the power supply may be another form of charge storage device, such as a capacitor. The power supply may require recharging and may have a capacity that allows for the storage of sufficient energy for one or more user operations, such as one or more aerosol generation experiences.

[0237] The aerosol generator may include a penetration device for penetrating the capsule when the aerosol generating article is inserted into the device cavity. As described above, penetration of the capsule may be necessary to establish one or more airflow paths through the capsule. [Examples]

[0238] A non-exclusive list of non-limiting embodiments is provided below. One or more features of these embodiments may be combined with one or more features of other embodiments, forms, or aspects described herein.

[0239] Example 1: An aerosol generating article for generating an inhalable aerosol when heated, wherein the article is A hollow tubular element, A capsule, which is attached to the upper end of a hollow tubular element and contains an aerosol generating substrate, comprises: An aerosol-generating article having a hollow tubular element that includes a ventilation zone allowing external air to enter the article, the ventilation zone being provided downstream of the downstream end of the capsule. Example 2: The aerosol-generating article according to Example 1, wherein the ventilation zone comprises at least one ventilation hole. Example 3: The aerosol generating article according to Example 2, wherein the ventilation zone comprises a plurality of ventilation holes passing through a hollow tubular element. Example 4: The aerosol generating article according to Example 3, wherein the ventilation zone comprises at least five ventilation holes through a hollow tubular element. Example 5: The aerosol generating article according to Example 3 or Example 4, wherein the ventilation zone is provided with 15 or fewer ventilation holes passing through a hollow tubular element. Example 6: An aerosol generating article according to any one of Examples 3 to 5, wherein the multiple ventilation holes each have at least one hole having a width of 200 micrometers or less. Example 7: An aerosol generating article according to any one of Examples 3 to 6, wherein the multiple ventilation holes each have at least one hole having a width of at least 50 micrometers. Example 8: An aerosol-generating article according to any one of Examples 3 to 7, wherein the multiple ventilation holes each comprise at least one hole having a length of at least 400 micrometers. Example 9: An aerosol generating article according to any one of Examples 3 to 8, wherein multiple ventilation holes are provided, each having at least one hole having a length of 1 millimeter or less. Example 10: An aerosol generating article according to any one of Examples 3 to 9, wherein multiple ventilation holes form a line of holes surrounding a hollow tubular element. Example 11: An aerosol generating article according to any one of Examples 3 to 10, further comprising at least one stop portion protruding from the inner surface of a hollow tubular element, thereby preventing the capsule from moving further downstream than the at least one stop portion. Example 12: The aerosol-generating article according to Example 11, wherein at least one stopper is located upstream of the ventilation zone. Example 13: The aerosol generating article according to Example 11 or Example 12, wherein at least one stopper comprises an embossed portion of a hollow tubular element extending into the interior of the hollow tubular element. Example 14: A hollow tubular element comprises at least one flap, the flap formed from a portion of the hollow tubular element partially removed from the rest of the hollow tubular element, and the flap remains attached to the rest of the hollow tubular element along the mounting line. At least one stopper is equipped with at least a flap, An aerosol-generating article according to any one of Examples 11 to 13, wherein at least one ventilation perforation extends internally or into the hollow tubular element, providing a gap between the flap and the rest of the hollow tubular element. Example 15: The aerosol-generating article according to Example 14, wherein the mounting wire is located at the upstream end of the flap. Example 16: The aerosol generating article according to any one of Examples 3 to 15, wherein the capsule comprises at least one capsule air intake located at the upstream end of the capsule and at least one capsule air outlet located at the downstream end of the capsule. Example 17: The aerosol generating article according to Example 16, wherein at least one capsule air outlet comprises a plurality of air outlets located at the downstream end of the capsule, the plurality of air outlets arranged around a circle centered on the longitudinal axis of the capsule, and the circle having a diameter smaller than the diameter of the aerosol generating article. Example 18: The aerosol generating article according to Example 17, wherein multiple capsule air outlets are arranged in a circle such that each capsule air outlet radially overlaps with at least a portion of the ventilation hole. Example 19: The aerosol generating article according to Example 18, wherein the angular diameter of each of the multiple capsule air outlets, measured from the center of the circle, is greater than the angular distance between adjacent ventilation holes in the ventilation zone. Example 20: The aerosol generating article according to Example 19, wherein the angular diameter of each of the multiple capsule air outlets, measured from the center of the circle, is greater than the angular diameter of each ventilation hole, which is added to the angular distance between adjacent ventilation holes in the ventilation zone. Example 21: An aerosol generating article according to any one of Examples 1 to 20, wherein the ventilation zone comprises a porous portion of a hollow tubular element. Example 22: An aerosol generating article according to any of Examples 1 to 21, wherein the outer diameter of the capsule is approximately the same as the inner diameter of the hollow tubular element. Example 23: An aerosol-generating article according to any one of Examples 1 to 22, wherein the upstream end of the ventilation zone is located at least 20 millimeters from the upstream end of the aerosol-generating article. Example 24: An aerosol-generating article according to any one of Examples 1 to 23, wherein the upstream end of the ventilation zone is located 37 millimeters or less from the upstream end of the aerosol-generating article. Example 25: An aerosol-generating article according to any of Examples 1 to 24, wherein the upstream end of the ventilation zone is located 8 millimeters or less from the downstream end of the capsule. Example 26: An aerosol-generating article according to any one of Examples 1 to 25, wherein the ventilation level of the aerosol-generating article provided by the ventilation zone is at least 20 percent. Example 27: Aerosol generation system, an aerosol generating article described in any one of Examples 1 to 26, An aerosol generating system comprising an aerosol generating device comprising a heating chamber for receiving an aerosol generating article, and a heating element provided inside or near the heating chamber.

[0240] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers representing amounts, quantities, percentages, etc., are understood to be modified in all cases by the term “approximately.” Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein. Thus, in this context, the figure A is understood as A ± 10%. In this context, the figure A may be considered to include a number that falls within the general standard error of the measurement of the characteristic that figure A modifies. In some cases as used in the appended claims, the figure A may deviate by the percentages listed above, provided that the amount of deviation does not substantially affect the basic and novel characteristics of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein.

Claims

1. An aerosol generating article for generating an inhalable aerosol when heated, wherein the article is A hollow tubular element, The upper end of the hollow tubular element is a capsule attached inside the hollow tubular element, which contains an aerosol generating substrate, and the capsule comprises the above-mentioned capsule, An aerosol-generating article wherein the hollow tubular element comprises a ventilation zone that allows external air to enter the aerosol-generating article, and the ventilation zone is provided downstream of the downstream end of the capsule.

2. The aerosol generating article according to claim 1, wherein the ventilation zone comprises at least one ventilation hole.

3. The aerosol generating article according to claim 2, wherein the ventilation zone comprises a plurality of ventilation holes passing through the hollow tubular element.

4. The aerosol generating article according to claim 3, wherein the ventilation zone comprises at least five ventilation holes passing through the hollow tubular element.

5. The aerosol generating article according to claim 3 or 4, wherein the ventilation zone comprises 15 or fewer ventilation holes passing through the hollow tubular element.

6. The aerosol generating article according to any one of claims 3 to 5, wherein the plurality of ventilation holes each comprise at least one hole having a width of 200 micrometers or less.

7. The aerosol generating article according to any one of claims 3 to 6, wherein the plurality of perforations comprises at least one perforation having a width of at least 50 micrometers.

8. The aerosol generating article according to any one of claims 3 to 7, wherein the plurality of ventilation holes each comprise at least one hole having a length of at least 400 micrometers.

9. The aerosol generating article according to any one of claims 3 to 8, wherein the plurality of ventilation holes each comprise at least one hole having a length of 1 millimeter or less.

10. The aerosol generating article according to any one of claims 3 to 9, wherein the plurality of ventilation holes form a first line of holes surrounding the hollow tubular element.

11. The aerosol generating article according to any one of claims 3 to 10, further comprising at least one stop portion protruding from the inner surface of the hollow tubular element, thereby preventing the capsule from moving further downstream than the at least one stop portion.

12. The aerosol generating article according to claim 11, wherein the at least one stopper is located upstream of the ventilation zone.

13. The hollow tubular element comprises at least one flap, and the at least one flap, formed from a portion of the hollow tubular element that has been partially removed from the rest of the hollow tubular element, forms a gap between the flap and the rest of the hollow tubular element, the flap remains attached to the rest of the hollow tubular element along the mounting line, and the flap is The at least one of the stopping parts includes the at least flap, The aerosol generating article according to claim 11 or 12, wherein the at least one ventilation hole extends inward or into the hollow tubular element such that it provides the gap between the flap and the rest of the hollow tubular element.

14. The aerosol generating article according to any one of claims 3 to 13, wherein the capsule comprises at least one capsule air intake located at the upstream end of the capsule and at least one capsule air outlet located at the downstream end of the capsule.

15. Aerosol generation system, an aerosol generating article according to any one of claims 1 to 14, An aerosol generating system comprising an aerosol generating device comprising a heating chamber for receiving the aerosol generating article, and a heating element provided inside or near the heating chamber.

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